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 The 1st micro PLC
with a can-do attitude

Stand-alone PLC Unit Expansion Modules

The new BRX Micro PLCs are determined to get it done!

The new BRX PLC family incorporates many high-level features in a small,
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Comparison

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with 10 built-in discrete I/O (28) 24VDC Inputs

$38.00 Built-in $433.00 $85.00
BX-08ND3 6ES7 221-1BH30-0XB0 FC6A-N08B1
(28 DC IN on PLC unit)
(8-pt DC IN module + 20 DC IN on PLC unit) (16-pt DC IN module + 14 DC IN on PLC unit) (8-pt DC IN module + 20 DC IN on PLC unit)

The BRX PLC family offers: (20) 24VDC Outputs

$45.00 Built-in $433.00 $125.00
BX-08TD1 6ES7 222-1BH30-0XB0 FC6A-T08K1

• Advanced motion control

(20 DC OUT on PLC unit)
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Built-in $149.00
• Robust data logging
(4) Analog Inputs
(4 Analog IN on PLC unit) 2080-IF4
$330.00 $320.00
6ES7 234-4HE30-0XB0 FC6A-L06A1

• Onboard serial and (2) Analog Outputs Built-in

(2 Analog OUT on PLC unit)
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2080-OF2
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Ethernet ports
Total System Price $556.00 $880.00 $2,010.00 $1,020.50
• Discrete, high-speed and
analog I/O All prices are U.S. published prices. AutomationDirect prices as of 2/20/2017. Allen-Bradley, Siemens and IDEC prices taken from www.radwell.com 1/27/2017.

• Expansion capabilities
• Interchangeable
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• Free programming
software (with simulator)
• Integrated video help
• Free technical support Research, price, buy at:
• Much, much more...
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Order Today, Ships Today!

* See our Web site for details and restrictions. © Copyright 2017 AutomationDirect, Cumming, GA USA. All rights reserved. 1-800-633-0405 the #1 value in automation

input #1 at www.controleng.com/information
When things
just work,
work gets done.

Kepware’s industrial connectivity software provides

secure and reliable data from the shop floor to the top
floor, so you can focus on productivity.

Learn more at kepware.com/CE

input #2 at www.controleng.com/information
 JULY 2017

Vol. 64
Number 7

Features
30 Controller embeds programming efficiency
Cover Story: PLC programming: Selecting the right controller and
accompanying programming software adds efficiency to the controller
8,10, 30, 34
COVER IMAGES COURTESY: From top, AutomationDirect, p. 30; CFE EDU
programming process.
PLC training; PLC tutorial from Automation Primer with related coverage, p. 34;
EZAutomation PLC, p.10.
34 PLC programming tips, benefits for engineers
Cover story: Get help for programmable logic controller (PLC) program-
ming from Control Engineering editorial advisory board member Frank
Lamb, covering ladder logic and scanning, binary-coded decimals, and
reusable codes.

36 Safety over industrial communication

networks
Industrial Ethernet is becoming easier to use for industrial safety
applications. Standards, trends, and technologies are helping with
industrial Ethernet-based safety systems.

38 Industrial fail-safe, node-to-node

communication
CIP Safety, for functional safety applications on EtherNet/IP and De-
viceNet networks, provides fail-safe communication between nodes. 36
40 Safety layer on top of networks
Safety network: PI North America, the organization for Profinet and
Profibus, explains use of the ProfiSafe safety network on top of
industrial Ethernet, Profinet, and device-level Profibus networks.

42 Thermal management requirements

for edge computing
Edge computing requires several variables to be considered and
an advanced climate control solution.

44 Transfer switches: Which configuration

is right for your system? 42
When it comes to picking the right transfer switch for a facility,
engineers need to consider many aspects such as system installation, CONTROL ENGINEERING (ISSN 0010-8049, Vol. 64, No. 7, GST #123397457) is pub-
operation modes, and switching mechanisms to help prevent down- lished 12x per year, Monthly by CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak
time in the event of a power outage. Brook, IL 60523. Jim Langhenry, Group Publisher /Co-Founder; Steve Rourke CEO/COO/
Co-Founder. CONTROL ENGINEERING copyright 2017 by CFE Media, LLC. All rights reserved.
CONTROL ENGINEERING is a registered trademark of CFE Media, LLC used under license.
Periodicals postage paid at Oak Brook, IL 60523 and additional mailing offices. Circulation
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57 Digital Edition Exclusives 60523. E-mail: customerservice@cfemedia.com. Postmaster: send address changes to
CONTROL ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Pub-
 Specifying enclosures for machine vision systems lications Mail Agreement No. 40685520. Return undeliverable Canadian addresses
to: 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Email: customerservice@
 IT/OT convergence needs conflict resolution from both sides cfemedia.com. Rates for nonqualified subscriptions, including all issues: USA, $150/yr;
 Link online: Digitalization trends in the automotive industry Canada/Mexico, $180/yr (includes 7% GST, GST#123397457); International air delivery
$325/yr. Except for special issues where price changes are indicated, single copies are
 Link online: Industrie 4.0 and smart services available for $30.00 US and $35.00 foreign. Please address all subscription mail to CON-
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USA. CFE Media, LLC does not assume and hereby disclaims any liability to any person for
any loss or damage caused by errors or omissions in the material contained herein, regard-
less of whether such errors result from negligence, accident or any other cause whatsoever.

2 | JULY 2017 CONTROL ENGINEERING www.controleng.com

 Simplify Your Work

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 JULY 2017 Safety lifecycle model

LOPA
PHA SRS
Conceptual Apply Non-SIS SIS Define
Process Hazard Develop Safety
Process Protection Layers to Required? Target
Analysis & Risk Requirement
Design Prevent Identified SIL
Assessment Specification
Hazards or Reduce Risk

Vol. 64 SPECIFICATIONS
Number 7

?
SIL CALCS
SIS Installation, SIS Start-up,
Perform SIS
Perform SIS Commissioning, Operation, Maintenance, Changes
Conceptual
Detail Design & Pre-Startup Periodic Functional
Design and Verify
SAT Testing
it Meets SRS

DESIGN INSTALL O&M

P1
Inside Process
Appears after page 46; Also, see the Digital Edition:
www.controleng.com/DigitalEdition

P1 Determine safety integrity level

for a process application
Safety instrumented systems (SIS) are installed in process plants
to mitigate process hazards and they must be assigned a target
safety integrity level (SIL) during the process to determine what
needs to be done next.

P6 Three ways to increase efficiency 18

at a spirit manufacturing plant
Manufacturers at a spirit manufacturing plant can increase produc-

Products
tion and efficiency by setting realistic expectations, simplify their
model, and asking for a third-party’s input with an overall equipment
effectiveness (OEE) analysis.
59 Permanent magnet motor with
integrated speed control; Motor series
Departments for positioning, velocity control;
RIGHT: IoT edge device;
8 Think Again BELOW: Piezo stages for 3-D position-
Ease of use: Programmable controllers ing accuracy; BELOW, RIGHT: Integrated
10 New Products for Engineers hybrid servomotor; Permanent
Chlorine analysis sensor systems; Rugged rack-style PLC magnet motor

12 Research
In-house system integrators

Control Engineering international

14 Expansion in instrumentation with software, technology updates
16 Industrie 4.0 optimizes safety

Technology Update
18 PC-based controls: Expanding plant-floor architectures
from the edge to IIoT 60 Power supply series; Extensometer for safety ap-
20 The benefits of robotics process automation plications; BELOW, RIGHT: Miniaturized MEMS accelerom-
64 Back to Basics eter; HMI for machine components; BELOW, LEFT: Real-time
Seven ways to integrate worker health and safety SCADA for IT, OT applications

News
22 Robots for logistics and transportation; manufacturer expands

23 Cybersecurity workforce education; process instrumentation growth

24 GE leader led the largest company acquistion; online headlines

25 Video use in data collection is increasing, survey says

www.controleng.com CONTROL ENGINEERING JULY 2017 | 5

 More resources posted daily at:
JULY
www.controleng.com

IIoT New Products Control Systems Process Manufacturing Discrete Manufacturing System Integration Networking & Security Info Management Education & Training

The impact of robotics technology On-demand

on urbanization webcasts:
There’s a lot more to read Couldn’t catch a recent
online. Go to webcast? See it on-
www.controleng.com/news demand at Webcasts
to read Control Engineering’s www.controleng.com/webcasts.
exclusive Web content.  June 13: Leave My Things Alone –
Getting Ready for IIoT
 Digitization trends to leave large
footprint on automotive industry  June 8: IIoT Webcast Two: Sensing
 Benefits of equipment life and control at the edge: Microcon-
optimization programs troller kits

 Real-world HMI design considerations for improved safety  May 25: Cloud ERP Streamlines
Operations in an Era of IIoT Data
 Conference focuses on IIoT for process, oil and gas industries.
 April 13: IIoT Webcast One: Get your
head into the cloud.
Control Engineering provides unique automation research: See more on the HMI
software and hardware survey in this issue. Read other research summaries and Oil & Gas Engineering
sign up to download the full reports at www.controleng.com/ce-research. June issue
Oil & Gas Engineer-
ing provides industry-
NEWSLETTER: PROCESS INSTRUMENTATION & SENSORS
specific solutions de-
Hydrocarbon chemistry signed to maximize

transforms a century, uptime and increase

productivity through
and still going the use of industry
best practices and
Keep up with the latest industry news
new innovations,
by subscribing to Control Engineering’s
increase efficiency
16 newsletters at from the wellhead
www.controleng.com/newsletters: to the refinery by
implementing automation and monitor-
 Control Engineering Salary and
ing strategies, and maintain and improve
Career Survey, 2017
safety for workers and the work environ-
 Technology drives performance of presence ment. Read the digital edition at
sensor range and accuracy www.oilandgaseng.com.
 Temperature manufacturing facilities opened in Indiana, Michigan.
Digital Edition
Point, click, watch
The tablet and digital
GAMS 2016: Robotics: editions of this publica-
Rise of the Machines tion have unique content
The 2016 Global Automation and for our digital subscribers.
Manufacturing Summit (GAMS), This month has digital
presented by CFE Media, will exclusives on: Specifying
bring together experts from all enclosures for machine MAY17 AC Branding Snipe - New Size (CE).qxp_Layout 1 4/13/17 11:34 AM Page 1

areas of the Industrial Internet of Things (lloT) to look at not just the current vision systems; Why IT/
state of lloT but also at the potential benefits of deployment for the manu- OT convergence needs
conflict resolution from
www.controleng.com thinkallied.com

facturing industry.
www.youtube.com/user/controlengineeringtv. both sides.

6 | JULY 2017 CONTROL ENGINEERING www.controleng.com

 Your Source for
Automation
& Control
Over 3.5 million automation, electromechanical,
cabling, and interconnect products
from 300+ manufacturers.

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thinkallied.com •1.800.433.5700

© Allied Electronics, Inc 2017.

input #4 at www.controleng.com/information
THINK AGAIN programming
1111 W. 22nd St. Suite 250, Oak Brook, IL 60523
630-571-4070, Fax 630-214-4504

Content Specialists/Editorial

Ease of use: Mark T. Hoske, Content Manager

847-830-3215, MHoske@CFEMedia.com
Jack Smith, Content Manager

Programmable controllers
630-907-1622, JSmith@CFEMedia.com
Kevin Parker, Senior Contributing Editor, IIoT, OGE
630-890-9682, KParker@CFEMedia.com
Emily Guenther, Associate Content Manager
Standard programming has abstracted into configuration, wizards 630-571-4070 x2220, eguenther@cfemedia.com
Amanda Pelliccione, Director of Research
are more intelligent, and libraries of code are embedded into intuitive 978-302-3463, APelliccione@CFEMedia.com

P
Joy Chang, Digital Project Manager
objects. Controllers touts modularity, flexibility, and connectivity. 630-571-4070 x2225, JChang@CFEMedia.com
Chris Vavra, Production Editor
630-571-4070 x2219, CVavra@CFEMedia.com
Programming someday may consist encapsulated code inside object that can then Contributing Content Specialists
entirely of humans talking to computers, but be grouped into larger objects. The latest ver- Frank J. Bartos, P.E., braunbart@sbcglobal.net
since humans often misunderstand humans, sion was demonstrated in about four min- Peter Welander, PWelander@CFEMedia.com
this may take awhile. For now, many simple utes, producing results without programming. Vance VanDoren, Ph.D., P.E., controleng@msn.com
Suzanne Gill, Control Engineering Europe
programs or common goals can be achieved In addition, Kodosky said, the new platform suzanne.gill@imlgroup.co.uk
through the use of abstraction, wizards, librar- refreshes a 30-year-old code base that will Ekaterina Kosareva, Control Engineering Russia
ekaterina.kosareva@fsmedia.ru
ies of objects, and other intuitive tools, avoid- enable NI programmers to innovate more
Wojciech Stasiak, Control Engineering Poland
ing programming for simple functions. This quickly (CE, June, p.28). wojciech.stasiak@trademedia.us
comes as programmable controller hard- Another industrial control platform, Igni- Lukáš Smelík, Control Engineering Czech Republic
lukas.smelik@trademedia.us
ware—whether in something that looks like tion, has rapidly expanded, according to
Aileen Jin, Control Engineering China
a traditional programmable logic controller Inductive Automation’s founder and CEO, aileenjin@cechina.cn
(PLC) or another form factor—becomes more Steve Hechtman, at the 2016 Ignition con- Publication Services
powerful, more economical, and easier to inte- ference in September. One reason for dou- Jim Langhenry, Co-Founder/Publisher, CFE Media
grate. This seems to apply for devices using ble-digit annual growth, Hechtman said, is 630-571-4070, x2203; JLanghenry@CFEMedia.com
Steve Rourke, Co-Founder, CFE Media
standards, such as IEC 61131-3 programming having industrial software that empowers cus- 630-571-4070, x2204, SRourke@CFEMedia.com
languages, IT-familiar languages, or both. tomers to swiftly turn great ideas into real- Trudy Kelly, Executive Assistant,
ity by removing technological and economic 630-571-4070, x2205, TKelly@CFEMedia.com

Easier productivity obstacles. The software is said to install in Elena Moeller-Younger, Marketing Manager
773-815-3795, EMYounger@CFEMedia.com
With programming, ease-of-use conven- four minutes, is scalable from a Raspberry Pi Kristen Nimmo, Marketing Manager
tions help those with less formal comput- board-level controller to enterprise servers, is 630-571-4070, x2215, KNimmo@CFEMedia.com
er education increase industrial productivity, more intuitive, and has a fixed (simpler, eco- Brian Gross, Marketing Consultant, Global SI Database
630-571-4070, x2217, BGross@CFEMedia.com
even as with shortages of those with appro- nomical) pricing structure.
Michael Smith, Creative Director
priate skills in science, technology, engineer- 630-779-8910, MSmith@CFEMedia.com
ing, and math (STEM) fields. Smarter software Automation benefits Paul Brouch, Director of Operations
630-571-4070, x2208, PBrouch@CFEMedia.com
makes contextualized help, documentation, These examples, while significant, are
Michael Rotz, Print Production Manager
and training available when and where need- not unique. For more on these topics in this 717-766-0211 x4207, Fax: 717-506-7238
ed, avoiding online searches, help desk calls, issue, see pages 10, 18, 30, and 34, as you think mike.rotz@frycomm.com

or, worse, paging through a paper manual. again about how programmable controllers Maria Bartell, Account Director, Infogroup Targeting Solutions
847-378-2275, maria.bartell@infogroup.com
The progression is natural. Jeff Kodosky, a are adapting for ease of use, greater flexibility, Rick Ellis, Audience Management Director
National Instruments (NI) founder and busi- modularity, easier upgrades, greater safety and 303-246-1250, REllis@CFEMedia.com

ness and technology fellow, and father of NI security, with wider and simpler interconnec- Letters to the editor: Please e-mail us your opinions to
MHoske@CFEMedia.com or fax 630-214-4504. Letters should
LabVIEW software, noted at 2017 NIWeek tions to legacy and IT systems. The benefits of include name, company, and address, and may be edited.
that when engineers draw something, it usu- optimal automation and controls have become Information: For a Media Kit or Editorial Calendar,
email Trudy Kelly at TKelly@CFEMedia.com.
ally includes boxes and arrows. Software that the mantra of Industrial Internet of Things
Marketing consultants: See ad index.
uses those conventions naturally is more intu- (IIoT) and Industrie 4.0 platforms. Custom reprints, electronic: Brett Petillo
itive. For years, the NI software platform has As we’ve said for years, don’t wait until it’s Wright’s Media, 281-419-5725, bpetillo@wrightsmedia.com
too late to integrate automation, controls, and
MORE instrumentation. Evaluate new technologies’ Editorial Advisory Board www.controleng.com/EAB
ADVICE capabilities, redesign processes, and imple-
Doug Bell, president, InterConnecting Automation,
www.interconnectingautomation.com

GO ONLINE ment opportunities to augment better deci- David Bishop, president and a founder
Matrix Technologies, www.matrixti.com
www.controleng.com keyword: Controller sions, higher productivity, and more. ce Daniel E. Capano, president, Diversified Technical Services Inc.
of Stamford, CT, www.linkedin.com/in/daniel-capano-7b886bb0
Webcasts on IIoT: www.controleng.com/webcasts
Frank Lamb, founder and owner
Research on IIoT: www.controleng.com/ce-research Automation Consulting LLC, www.automationllc.com
PLC training: www.controleng.com/cfe-edu Joe Martin, president and founder
Martin Control Systems, www.martincsi.com
Digital edition: click the headline for more info Mark T. Hoske, Content Manager
Rick Pierro, president and co-founder
online, photos, and links. MHoske@CFEMedia.com Superior Controls, www.superiorcontrols.com
Mark Voigtmann, partner, automation practice lead
Faegre Baker Daniels, www.FaegreBD.com
8 | JULY 2017 CONTROL ENGINEERING www.controleng.com
 Cabinet Confidence
Powerful output means system reliability
Phoenix Contact’s expertise and commitment to innovation across a wide range
of industries enable you to build your control cabinet with confidence. QUINT Power
supplies are the most powerful and flexible choice for your industrial environment.
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Call 1-800-322-3225 or visit: www.phoenixcontact.com/confidence_quint4

© PHOENIX CONTACT 2017

input #5 at www.controleng.com/information
PRODUCTS New Products for Engineers

Chlorine analysis sensor systems

Endress+Hauser’s chlorine analysis systems are designed to elimi-
nate the need for costly reagents and accompanying required mainte-
nance. It’s panel-mounted and includes a chlorine sensor, pH probe in
an integrated flow assembly, sensor cables, and a transmitter.

E
Endress+Hauser’s chlorine analysis systems are
designed to eliminate the need for costly reagents and accompa-
nying required maintenance. They are designed for applications
where water is disinfected using chlorine such as, industrial
water, power, and wastewater. Each turnkey system is panel-
mounted with an amperometric free chlorine sensor and a pH
compensated measurement ensures accurate N,N-diethyl-P-phen-
ylenediamine (DPD) verification, and a separate ¼-in. sample
valve allows a DPD verification test for residual chlorine to be per-
formed without interrupting system measurement. The indepen-
dent DPD verification test capability also ensures compliance with
EPA requirements. A built-in needle valve in the flow assembly
probe mounted in an integrated flow assembly, sensor cables, provides flow control between 30 and 120 L/hour, and an induc-
and an Endress+Hauser Liquiline transmitter. An integral flow tive low-flow alarm switch indicates when flow is too low for
switch mounted in the flow assembly monitors for proper sys- proper measurement. ce
tem flow, and provides an alarm at the transmitter if flow is Endress+Hauser
interrupted. A lead-free regulator sets system pressure to 15 psi. www.us.endress.com
System tubing is ⅜-in. stainless steel and all components are Input #200 at www.controleng.com/information
installed on a 20 x 20-in. stainless steel panel prepared with ⅜-
in. ID mounting holes for secure mounting to a vertical sur- MORE
face. Stainless steel inlet and outlet shut off valves, with ½-in. PRODUCTS
female National Pipe Thread (NPT) fittings, allow for system GO ONLINE
isolation during routine sensor maintenance. The pH- More New Products for Engineers: www.controleng.com/NP4E.

Rugged rack-style PLC

The EZAutomation EZLogix programmable logic controller
is a low-cost, rugged, modular rack-styled PLC ready for
Industrial Internet of Things (IIoT) applications. Ladder logic,
advanced function blocks, and a built-in simulator are just
a few features that come with free programming software.

E
EZLogix from EZAutomation, a U.S. manufac-
turer and online distributor, is a rugged rack-style, din-rail
mounted programmable logic controller (PLC) said to offer
high-performance specifications at extremely cost-effective
price points. It includes free software and manuals with sim-
ple ladder logic programming, advanced function blocks, a
database networks, so valuable data can be shared reliably and
securely to improve plant productivity and efficiency.
Data collection is integrated, up to 64 GB. Break point lad-
der debugging is included along with automatic input/output
(I/O) point configuration, automatic proportional-integral-
derivative (PID) tuning, and a wide variety of digital and ana-
built-in simulator to test logic where no additional hardware is log I/O.
needed, and a built-in data logger. Integrated communications include USB, Ethernet,
The controllers are said to be ready for Industrial Inter- RS232/422/485, and micro USB. For a typical 50-60 I/O
net of Things (IIoT) applications. With an integrated mes- mid-sized machine PLC, with CPU, power supply, modular
sage queuing telemetry transport (MQTT) protocol, direct I/Os, and software, total cost is less than one-tenth that of
connectivity to external devices (such as sensors, resistance another industry offering.
temperature detectors (RTDs), analog inputs, etc.), and easy- The EZLogix is offered with free same-day shipping and
to-setup secure communication with other networks (such as free U.S.-based technical support from 6 a.m. to midnight and
Modbus TCP/IP), the EZLogix is designed to be a PLC, and is made in EZAutomation’s Iowa plant. ce
a low-cost edge-gateway computer/controller. The EZLogix EZAutomation
line is designed to be a “bridge” between existing operational EZAutomation.net
technology within a plant, such as factory machines and plant Input #201 at www.controleng.com/information

10 | JULY 2017 CONTROL ENGINEERING www.controleng.com

 LEAP™ for Operations Increases Operational

More Integrated. Productivity and Throughput.

Now, use LEAP project methodology to optimize,

More Synergies. simplfy, and run operations efficiently. Once an

Less Work.
automation project is implemented, continue to
use LEAP principles to squeeze more out of what
you have and avoid major capital expansions.

For more information, please visit

www.honeywellprocess.com/LEAPforOperations
Connected Industrial © 2017 Honeywell International Inc.

input #6 at www.controleng.com/information
Connected Plant
 IIoT, Industrie 4.0
integration process
Nearly 100%
1%
Perhaps 75%
Little or
3% none

research
21% 29%

2016 SYSTEM INTEGRATION STUDY

46%

In-house system
integrators Perhaps 50% Perhaps 25%

F
Figure 1: Three-quarters of facili-
Four out of 10 respondents to the report automation system integration
Control Engineering 2016 System Inte- to be highly effective in their projects, ties are less than 25% of the way
gration Study perform all system inte- compared to 47% moderately effective, through the integration process of
gration projects in-house, as opposed 2% somewhat ineffective, and 3% not IIoT and/or Industrie 4.0. Source:
to providing services to third parties or effective. Control Engineering 2016 Industrial
hiring system integrators. Below are five 4. Most recent project: Looking at Internet of Things & Industrie 4.0
findings from this study as they relate to their most recently completed system inte- Study
in-house system integrators: gration project, 62% of respondents indi-
1. System integration projects: On cated an on-time delivery, and 67% were
average, eight in-house system integra-
tion projects are performed per year;
the average project size is $231,162.
able to adhere to the budget initially set-
tled upon.
5. Challenges: These system integra-
85% of system integra-
tors outsource up to 10 projects
2. Devices integrated: The top devic- tors are challenged with finding/hiring each year. Source: Control Engi-
es these companies integrate in-house engineering talent for system integration neering 2016 System Integration
are programmable logic controllers or (50%) and for industry experience (41%), Study
programmable automation controllers frequent changes to regulations/codes and
(72%) and human machine interface standards (33%), and a lack of communi-
hardware or equipment, operator inter- cation (33%). ce
face, control panels, alarms, annuncia-
tors, data acquisition equipment, or
data recorders or plotters (67%).
View more information online at
www.controleng.com/2016SystemIntegration.
46% of end users have
earned their Bachelor’s degree,
3. Project effectiveness: Forty-eight Amanda Pelliccione is the research director and 20% have earned their Mas-
percent of in-house system integrators at CFE Media, apelliccione@cfemedia.com.
ter’s. Source: Control Engineering
2017 Career & Salary Survey
Measuring project success
In-house system integration projects

Increased productivity levels 63% 35% of survey respon-

dents report spending $40,000 or
Completed on time 61%
more on HMI software and hard-
Completed on budget 57% ware in the past year. Source: Con-
trol Engineering 2017 HMI Software
Operator adoption 41% & Hardware Study
Return on investment 41%

Quality of information flow 35%

More research
Control Engineering covers sev-
Figure 2: Six in 10 in-house system integrators consider a project successful if the proj- eral research topics each year. All
ect was completed on time and on budget, and resulted in increased productivity. Source: reports are available at
Control Engineering www.controleng.com/ce-research.
www.controleng.com/ce-research FOR MORE RESEARCH INFORMATION

12 | JULY 2017 CONTROL ENGINEERING www.controleng.com

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 CONTROL ENGINEERING international

Expansion in instrumentation
with software, technology updates
Market update: Honeywell expands process automation and instrumentation products and channels
to continue to augment growth in the next three years, according to Control Engineering China.

W With the slowdown in global economic

growth, the growth rate of major new projects in the
process automation market has decreased in recent
years. To continue growth, various process automa-
tion manufacturers, including Honeywell Process
Solutions (HPS), have made strategic adjustments.

Vision in instruments
continuously make investments to increase more
target markets, and realize the increase from $5 bil-
lion at present to $10 billion in 2020,” said Arora.
With broader lines and more product introduc-
tions, watch for more software and products based
on IIoT.
HPS attaches an increasing amount of impor-
tance to offering services for small and medi-
At a recent conference, Asheesh Arora, vice um-sized clients. In particular, with a continuous
president of HPS global channel marketing, said increase of product lines, channel partners become
HPS would see breakthrough growth within three more important. Arora said that HPS owns more
years. In 2016, the sales volume of flow measure- than 200 channel partners in Asia-Pacific region,
ment and control business reached $650 million, including more than 50 channel partners in China.
MORE fifth in the instrument field. By 2020, he said, HPS In 2016, the channel business performance was
ADVICE expects to achieve sales of $1 billion in its flow mea- better than the overall market. With year-on-year
KEY CONCEPTS surement and control business, and rank among the growth of 16% globally, channel business reached
Honeywell Process Solution top three, globally, in the instrument field. $248 million, and the Asia-Pacific region realized
outlines growth plans. Arora said HPS determined five ways to lever- 14% growth. With strong growth in the second half
Flow measurement and control, in- age and promote growth in 2016: follow areas of of the year, personnel in the Asia-Pacific channel
strumentation, channels, and products
are growth areas.
growth, implement breakthrough strategies, expand business manager team increased 50%.
Full support for the natural gas
the channel network, focus on large project oppor- Honeywell will provide the personnel support,
supply chain is offered with Elster tunities, and introduce new products. In 2017, HPS tools, and software to “help distributors provide
acquisition, integration. will increase investment to continuously promote products for Chinese customers and carry out rela-
GO ONLINE implementation. For 2015 HPS revenue, the ser- tionship management. Therefore, we expect that
www.controleng.com/international vice business accounted for 39%, project business China’s channel business may surpass USA, and
www.cechina.cn accounted for 33%, products accounted for 17%, China will become the largest market globally in
CONSIDER THIS and Industrial Internet of Things (IIoT) accounted the next three years,” Arora suggested.
How do your supplier growth plans for 11%. By 2020, HPS expects the proportion of its
support your anticipated expansion? products business to increase to 30%, and project New growth: value chain
business will be 16%, and IIoT With the completion of Elster’s business inte-
will be about the same. gration, HPS has been able to provide service for
As some manufactur- the entire natural gas supply chain. Arora said he
ers plan a shift from being believes the natural gas industry has a rather long
mostly product providers to supply chain: upstream, midstream, and down-
overall solution providers, HPS stream. Even with different HPS products and solu-
seems to emphasize break- tions, the demand for Big Data is a common thread
through performance growth through the existing and future industrial environ-
from product sales, with an ment, to make factories more intelligent. “We will
increase in the product propor- further make more investments in the natural gas
tion from 17% to 30%. field, provide a safer, more effective and reliable
Honeywell has prepared for solution to industrial applications of customers, and
growth in product innovations. stimulate the growth.” Arora expects breakthrough
Asheesh Arora, vice president of Honeywell In 2015, Honeywell completed growth within three years. ce
Process Solutions (HPS) global channel marketing, its biggest acquisition to date,
expects significant growth for the company in the next $5.1 billion for the gas heating, Stone Shi is executive editor-in-chief, Control Engi-
three years, driven by product innovation and channel control, and metering system neering China; edited by Mark T. Hoske, content man-
expansion. Courtesy: Control Engineering China, HPS company Elster. “We will ager, Control Engineering, mhoske@cfemedia.com.

14 | JULY 2017 CONTROL ENGINEERING www.controleng.com

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from work created and shared by Google and used according to terms described in the Creative Commons 3.0 Attribution License.
 CONTROL ENGINEERING international

Industrie 4.0 optimizes safety

I
Control Engineering Europe: Industrie 4.0 efforts include human interactions and safety.
Control, Instrumentation and Automation in the Process and Manufacturing Industries

June 2017
Industrie 4.0 is set to redefine the current robot, to slow down to a safe speed, allowing the
www.controlengeurope.com
working environment as a highly adaptable work- individual time to move away from the hazard.
Welcome to the future of space that can respond to changing customer This type of feature also is beneficial when
Industrial
Ethernet requirements almost instantly. Based on informa- equipment has to be moved, for example, previously
diagnostics
tion generated and stored, individual production a machine would need to have all its guards in place
lines can help to transform operations. and be completely switched off before any action
Automation use is primarily associated with could be taken. With the desire to avoid switching
Putting big data
into context
Identifying your industrial
Industrie 4.0. Even so, one of the main beliefs of off machines to avoid additional warm-up times
Industrie 4.0 is that people are the key players. Con- and quality issues with first-off components, this is
cyber security gaps
Special CC-Link IE
supplement: Enabling
Industry 4.0 with Open

nectivity between humans and machine, with the a major advantage in the dynamic production envi-
Gigabit Ethernet

CEE_June_2017_3.indd 1 09/06/2017 14:52

integration of IT, is fundamental. ronments associated with Industrie 4.0.

In a traditional production environment, with Many Industrie 4.0-compatible technologies
lines or cells frequently geared to the manufacture have additional safety features integrated, rather

‘
of one product, the safety of those working in the than having to be added afterwards. One example
facility is generally straightforward to monitor. A is Industrie 4.0 compatible drives that can be used
Many Industrie risk assessment of all aspects of the operation— to create a machine protocol with a unique number,
from individual components through to operator highlighting immediately a potential safety issue if a
4.0-compatible “touch points” with equipment—will create a guide, different protocol is used.
which, in theory, should remain valid until the use
technologies of that line changes or alterations are made to the Safety networks, risk assessments
equipment within it. Immediate hazards can be Safety networks are common in Industrie 4.0
have additional minimized and risks to operator safety averted, as environments. These include openSafety, Sercos,
long as correct procedures are followed. and Profinet (to name a few) with all common bus
safety features systems now having a safety version. All have been
Safety challenges in reconfiguration designed as an advance on older wire-based sys-
built into them, An Industrie 4.0 plant can present different and tems for powering down and enable a greater flow
rather than a more intricate set of challenges. Reconfiguration of information to ensure uptime is maximized and
of production areas at short notice, involving the that equipment only powers down as a last resort.
having to be rapid changes of tooling and the physical movement An alternative is a safety zone module that
of equipment, can pose safety challenges, while the checks wires and negates the need to invest in a sep-

’
added later. sheer number of configurations achievable to meet arate safety bus system in certain applications.
potential requirements may entail a separate risk Sound health and safety practices are
assessment for each. Safety of personnel and data needed; a risk assessment of every scenario likely to
under a secure network cannot be ignored if com- be encountered (effectively, any machine configu-
pliance with local, national, and international regu- ration which can be selected) must be undertaken,
lations is to be maintained. with operatives receiving the necessary training to
Technologies can help. Industrie 4.0 offers the work effectively in this more dynamic environment.
MORE opportunity to increase safety further with the abil- No effort should be spared in protecting personnel
ADVICE ity to gather data in real time and then act upon it no matter the manufacturing processes adopted.
KEY CONCEPTS before a potential hazard becomes a real one. While individual system components may be
Industrie 4.0 includes automation, A range of devices can be fitted onto equipment considered to be “safe,” the story may differ when
people, and safety. capable of detecting and reporting operator behav- considering components’ use in combination. In an
Flexible reconfiguration can pose a ior that may pose a risk to safety. Among the most Industrie 4.0 environment, there may be an added
safety challenge.
common forms are intelligent cameras which gather requirement to program alternative routes for
Risk assessments are key.
digital images or footage and pass these to a central autonomous or robotic equipment that experiences
GO ONLINE control point, automatically highlighting any abnor- an obstacle on its route around the facility. By work-
www.controleng.com/international
www.controlengeurope.com
mal behaviors, such as restricted-area entry. ing with component suppliers and safety-qualified
Many systems designers also opt to equip engineers, achieving a Industrie 4.0 compliant pro-
CONSIDER THIS machines with safety sensing devices that immedi- duction environment is practical. ce
How is safety related to your auto-
mation efforts? ately can detect if a human operator has moved into
This was from a June 5 Control an unsafe area or positioned themselves too close Andrew Minturn is product manager at Bosch
Engineering Europe article, “How to some plant equipment. A default response is to Rexroth. Edited by Mark T. Hoske, content manager,
Industrie 4.0 can optimise safety.” power down the machine or, with a collaborative Control Engineering, mhoske@cfemedia.com.

16 | JULY 2017 CONTROL ENGINEERING www.controleng.com

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Introduction to IIoT and Introduction to PLCs Critical Power: Generators

Industrie 4.0 and System Design

Lighting: LED Codes Electrical Systems: Impacts of Climate and

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Critical Power: Hospitals Data Centers Safety First: Arc Flash 101

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 TECHNOLOGY UPDATE on the edge

PC-based controls: Expanding plant-

floor architectures from the edge to IIoT
Edge devices facilitate data processing at the plant level, increasing security and
using Industrial Internet of Things (IIoT) standards.

MORE
ADVICE
KEY CONCEPTS
How smart edge devices facilitate
data processing at the plant level.
C Cloud computing is a hot topic in fac-
tory automation circles, and while Industrial Inter-
net of Things (IIoT) technologies can offer many
benefits, not every company is fully onboard with
moving operations to the cloud. This could be due
to security concerns, corporate policies for data
access, resource availability, among other reasons.
Edge computing, conversely, takes the data pro-
accomplishes its primary task—data analysis
based on preset goals or parameters. These tasks
are carried out directly on the device, with the
option to move the data vertically to the cloud
or to other company databases for filling dash-
boards used by business and facilities managers.
Data can be transmitted at the edge and/
or to the cloud using recognized IoT and IIoT
Security measures for industrial cessing concept enabled by cloud service providers standards, such as object linking and embed-
Ethernet systems and edge devices.
and moves it back down to the plant level, closer to ding for process control unified architecture
How PC-based control technology
the devices that create the data. This can alleviate (OPC UA), message queuing telemetry transport
benefits facilities.
some of the security concerns, as the data never (MQTT), and advanced message queuing proto-
GO ONLINE leaves the facility, but also can serve as a step- col (AMQP). This creates a seamless migration
For related links about edge
computing, including a recent web- ping stone into a future cloud solution as business path for future upgrades, and PC-based control
cast, read this article online. In the needs grow and change. systems are best-suited for these kinds of appli-
digital edition, click on the headline or cations because of inherent openness to IT stan-
search the headline for Smart edge devices for data processing dards for hardware, software, and networking.
www.controleng.com and
“Smart” edge devices facilitate data processing Another important point to consider with PC-
www.controleng.com/webcasts.
at the plant level. Several tasks must be accom- based control is scalability in hardware. Controls
CONSIDER THIS plished before a device can be considered a smart engineers can start with small processors for very
Are built-in security features
in industrial Ethernet systems and edge device. The first task centers on data collec- basic commands and protocol translation, then
communication protocols enough to tion from the industrial process. Once data has migrate to powerful multi-core industrial PCs
protect data processing? been acquired and stored, the edge device then and embedded PCs for advanced data process-
ing and analytics at the edge. The more powerful
industrial PCs also can pull double duty as com-
plete machine or line controllers.
PC-based control architectures make it
possible for the same hardware platform to
be deployed everywhere on the manufactur-
ing floor. For example, this type of automation
hardware can serve as the programmable logic
controller (PLC), motion controller, robot con-
troller and/or as an IoT gateway device, and
much more. Thinking higher level, the hard-
ware components used to power the cloud are
typically data center-level servers run by a large
IT companies, or smaller servers that are pur-
chased by a large end-user and run on-site as a
private cloud application.
Using an intelligent edge device, such as a PC-
based controller, can help users filter out impor-
tant data from huge masses of raw data, whether
this data stays in the facility or is sent to the cloud.
As part of a cloud services solution, smart edge
Smart edge devices facilitate data processing at the plant level, enabling trans- devices can reduce the associated expenses, regard-
mission of process data to and from the cloud. Courtesy: Beckhoff Automation less of whether cloud service fees are based on the

18 | JULY 2017 CONTROL ENGINEERING www.controleng.com

 Your Global Automation Partner

volume of data transmitted or the number EtherCAT does not require the use of
of messages sent to the cloud. switches, there is little danger of out-
PC-based control technology makes side frames being inserted into the
it possible to implement plant floor- control system in the first place, but
to-cloud communication architectures if so, those frames would be destroyed
that do not need expensive managed automatically.
switches from a third-party IT ven- For vertical integration, OPC UA
dor. Machine builders and manufactur- provides built-in session encryption,
ers can access some pre-integrated IoT message signing, sequenced packets (to
and cloud-connected technologies. The block replay attacks), authentication,
hardware involved is part of the stan- and more. MQTT and AMQP offer
dard industrial PC and I/O hardware similar security and encryption mea-
offering. sures for cloud communication. Further
All the programming or configu- protections can be implemented with

WARNING
ration to establish the IoT connectiv- standard IT infrastructure planning

‘
ity is conducted in the for firewalls, provid-
same universal platform ing ample security for
used to program a PLC, Future smart public cloud systems. Not suitable for repairing
motion control, robot- If preferred, end users
ics, safety, and human- devices must find can consider a private flimsy connectors
machine interface. While a balance between cloud running entirely (or your reputation).
this won’t make a motion within the enterprise IT
control programmer an delivering high- system. When the right
instant “IoT expert,” it technology components
facilitates highly efficient performance and are in place, users can Rugged, reliable industrial
programming among spe- feel confident that data
cialized programmers and
offering a compact is encrypted and pro- automation products from Turck

’
teams. This way, advanced footprint. tected from intrusion. are built to perform in the toughest
analytics and filtering can In the future, smart
be handled at the machine devices must find a bal- conditions, and our engineered
in a programming environment that’s very ance between delivering high-performance solutions are customized to meet
familiar across engineering teams. and offering a compact footprint. Despite
the ultra-compact size, CPU options your application challenges.
Security for smart edge devices are available up to a quad-core proces- Cheap knock-offs can’t compare.
The combination of a high-perfor- sor, so this interprocess communica-
mance industrial Ethernet system such tion (IPC) can be an overall machine Turck works!
as EtherCAT and a vertical communica- controller and/or an IoT gateway to
tion protocol such as OPC UA provides push data to cloud services. IPCs can
a variety of built-in security measures integrate industrial Ethernet protocols
that do not require programming to such as EtherCAT and cloud commu-
implement. At the plant floor and nication standards such as OPC UA
machine to machine level, EtherCAT and MQTT with ease.
has integrated security features that With the appropriate PC-based control
block unwanted intrusion from out- software, the IPC hardware becomes what-
side sources, and it does not require ever it is programmed to be. Advanced
the use of IP addresses. By default, IoT and Industrie 4.0 concepts are chang-
EtherCAT slave devices “destroy” ing by the minute, and it is this kind
non-EtherCAT frames. This includes of flexibility and adaptability in hard-
injected malware or viruses, since they ware and software that will help machine
Overmolded Deutsch Connectors
are not part of the control process. These builders and end-users stay ahead in the
Designed for longevity in demanding
unexpected “bad” frames of data are industry. ce
environments where shock, vibration, cold,
not forwarded by EtherCAT, so they
moisture and oils can affect performance.
are immediately stopped without losing Eric Reiner is industrial PC market spe-
important process data. EtherCAT also cialist, Beckhoff Automation. Edited by
preserves data tunneled through stan- Emily Guenther, associate content man-
dard TCP/IP devices that are connected ager, Control Engineering, CFE Media,
as part of the system architecture. Since eguenther@cfemedia.com. input #9 at www.controleng.com/information

Call 1-800-544-7769
www.controleng.com CONTROL ENGINEERING JULY 2017 | 19 or visit info.turck.us/connectivity
 TECHNOLOGY UPDATE intelligent robots

The benefits of robotics

process automation
Process automation enhances business development with a vast return on investment (ROI).

I
In automation’s 60-year history, busi- complicated medical procedures. Automation
ness executives and workers often hesitated to can be applied to every business when the right
implement new technology before they sup- automation experts critically looks at an organi-
ported its benefits. Robotics process automa- zation’s practices.
tion (RPA) is the use of software with artificial Customer-facing businesses setting them-
intelligence (AI) and machine learning capabil- selves apart with personal touches and big smiles
ities to accomplish repeatable tasks, previously should not shy away from automation as a busi-
requiring human interaction. Though there are ness enhancement. In fact, the opposite is true.
jobs in nearly every industry that in time will no Automation implementation on the back-end
longer require human interaction due to automa- processes can free up valuable time for employ-
tion, keeping RPA at arm’s length is a rejection of ees to spend on more meaningful customer inter-
progress for businesses that want to develop and actions – not less.

‘
cultivate a competitive edge.
Business development, automation
While there might be routine maintenance, Automation technology is ever-changing. But
an update to automation technology will only need
automation expenses are controlled by the desire to change when processes or the business needs
to expand the business and employ additional change. Unlike other business efficiency tools,

’
it doesn’t require numerous software updates,
automation capabilities to realize greater benefits. renewals, or pricey upgrades. While there might
be routine maintenance, automation expenses are
Automation benefits controlled by the desire to expand the business
Like any new technology or process, automa- and employ additional automation capabilities to
tion implementation does require upfront costs. realize greater benefits.
But the use of automation can result in increased Automation is a sign of growth. It is a sign of
return on investment (ROI) because automation efficiency and an investment that will pay off for
reduces labor costs, allowing employees to focus years to come. Business owners frightened of RPA
on more business-critical tasks instead of focus- and what it stands for in regards to the future of
ing on repeatable processes. According to Infor- the business should think of it as a natural step in
mation Services Group, automation’s returns have expanding and keeping up with the needs of an
garnered double-digit productivity improvements ever-growing clientele.
over outsourcing, and cost reductions between While there are growing pains and staff
MORE 14% and 28% have been realized. realignments associated with many RPA imple-
ADVICE Automation can also streamline regulatory mentations, current employees can use this oppor-
compliance that imposes fines by virtually elimi- tunity to learn about automation and expand
KEY CONCEPTS
The benefits of robotics process nating human error. With the correct automation skillsets. Also, if an automation plan is inclusive,
automation (RPA). solution, the cost savings reverberate throughout employees can contribute meaningful insights
The challenges of implementing an organization and the ROI impacts multiple into the best ways for the automation to func-
process automation. budget lines. tion and hence, support a more efficient RPA
How to maximize ROI with RPA. Automation can be complicated, but the implementation.
GO ONLINE beauty of this technology is its ability to easily scale If experts with a vast understanding of automa-
For related links on automa- from simple to complex. The key to understand- tion implementation and rethinking processes are
tion, read this article online. In the ing what type of automation can work for a par- put to use, automation can open the door to a new
digital edition, click on the headline or
ticular application is to rediscover every aspect world in business development. ce
search the headline for
www.controleng.com. of each process then realistically think through
what can be streamlined or eliminated in each Deanna M. Murray is a content specialist at
CONSIDER THIS
What industries would benefit the action. Keep in mind that many current every- Disys. Edited by Emily Guenther, associate con-
most and receive the most ROI from day processes exist because of automation— tent manager, Control Engineering, CFE Media,
process automation? from simple automated stamp machines to eguenther@cfemedia.com.

20 | JULY 2017 CONTROL ENGINEERING www.controleng.com

CALLING ALL SYSTEM INTEGRATORS...

2018 call for

System Integrator
of the Year entries
Entries are due August 18, 2017

Control Engineering and Plant Engineering’s annual

2018 System Integrator
of the Year Awards

Questions?
Contact Bailey Rice
Director of Business
and Market Development
Who should enter? CFE Media
If you’re a system integrator with demonstrable industry success, Control brice@cfemedia.com
Engineering and Plant Engineering urge you to enter the 2018 System (630) 571-4070 x 2206
Integrator of the Year competition. Past System Integrator of the Year win-
ners—Class of 2017, Class of 2016, and Class of 2015—are not eligible to
enter the 2018 System Integrator of the Year program. 2017 System Integrators of the Year 15 | 2016 SI Giants 29

What’s in it for the winners?

The chosen System Integrator of the Year winners will receive worldwide
recognition from Control Engineering and Plant Engineering. The winners
also will be featured as the cover story of the Global System Integrator
Report, distributed in December 2017.

How will the competition be judged? Finding the right recipe

Control Engineering and Plant Engineering’s panel of judges will conscien- People, processes are
tiously evaluate all entries. Three general criteria will be considered for the crucial to SI success story
23

selection of the System Integrator of the Year:

• Business skills
• Technical competence A supplement to CONTROL ENGINEERING
and PLANT ENGINEERING magazines

• Customer satisfaction

Tell us how you measure up in these three areas.

Get the application: www.controleng.com/SIYApplication
INDUSTRY NEWS and events

Robot use in logistics and transportation

industries expected to grow
The robotics market serving logistics presents challenges for automation, which Custom packaging
and transportation companies is primed is easiest and cheapest to implement where Whether it’s a big sale or a bulk dis-
for rapid growth over the next five years. there are easy and repetitive tasks. But new count, many items need custom pack-
Currently, around 80% of warehouses technology is overcoming these logistical aging before they hit retailers’ shelves.
are operated manually, meaning they obstacles in a few distinct ways. This is very difficult for a robot since it
have no automation support. means working with different sizes and
That’s about to change in a big way. Container loading and unloading shapes of products, but also because it
In 2016, the logistics robotic market Much of the goods consumed in requires work to be completed around
had a global market revenue of $1.9 bil- America were at some point shipped in humans as opposed to inside of a work-
lion. In 2021, a recent study predicts a standard container from overseas. Typ- cell. This is where collaborative robots,
market revenue for the global sector to ically, these products aren’t palletized, designed to work safely around humans,
reach $22.4 billion. In the same amount meaning they’re stacked from floor to have played a role in logistics.
of time, robot unit shipments will grow ceiling. The variation in products sizes Collaborative robots (cobots) have
from 40,000 to 620,000 annually. and shapes has made automation of load- no sharp edges and shut down when
Amazon is known for automated distri- ing and unloading difficult until recently. they bump into something. In logistics
bution centers, but other logistics compa- 3-D laser vision, coupled with robotic applications, some cobots even can be
nies are turning to robotics for the safety, software, can view different products in trained to do tasks by letting a human
efficiency, and accuracy they provide. a container, determine the optimal load- guide their arms once to learn the
ing or unloading sequence, and carry motion. This decreases inefficient pro-
Robotics applications in logistics out this function with a high level of gramming time and speeds of the cus-
and transportation accuracy. tom packaging process.
Distribution networks, across the entire Robots are quickly making their way
global supply chain, require a high vol- Stationary piece picking into the logistics and transportation sec-
ume of varied and complicated tasks. This In the warehouse, items are always tor. They’re providing safety, efficiency,
being sorted. Often, it’s simply a matter and accuracy in a wide variety of appli-
of moving a product from one box to cations, mostly involving work in the
another. Historically, piece picking has distribution center.
been difficult because robots weren’t sure
which items they were picking. Indus- This article originally appeared on the
trial robot arms, enabled by vision sys- Robotics Industries’ Association (RIA)
tems that can recognize which product Robotics Online Blog. The RIA is a part
is which, are able to handle this process of the Association for Advancing Automa-
in a stationary workcell. These robots tion (A3), a CFE Media content partner.
boost efficiency and accuracy in the Edited by Hannah Cox, content specialist,
warehouse. CFE Media, hcox@cfemedia.com.

Manufacturer relocates, expands

A
manufacturer of custom universal joints and mechanical power transmission prod-
ucts, Belden Universal, announced its plans to move into a 40,000-sq-ft factory in
Hillside, Ill., in close proximity to Belden’s current headquarters in Broadview. Relo-
cation will proceed in staged phases this fall and is expected to conclude by late 2017.
The constructed factory will accommodate manufacturing technologies, Lean equip-
ment layout and automated workflow for increased efficiency and better overall customer
experience. Ergonomic design throughout the building will further enhance employee pro-
ductivity and job satisfaction.
Robots with increased intelligence and “We are extremely proud to move into our new building in the very near future. The
speed can help in palletizing or package larger, modern facility will allow us to continue delivering highly innovative products and
transfer and other motion control applica- quality service to our customers and provide an improved work environment to our employ-
tions. This Fanuc Robot moved boxes at the ees,” says Perry Sainati, president of Belden Universal.
2016 Pack Expo. Courtesy: Mark T. Hoske, Edited from a Belden Universal press release by CFE Media.
Control Engineering

22 | JULY 2017 CONTROL ENGINEERING www.controleng.com

 Digital edition? Click on headlines for more details.
See news daily at www.controleng.com/news

Groups to collaborate
on cybersecurity workforce education

A
RC Advisory Group and SANS Institute a major challenge for ARC clients. Cyberse- ARC and SANS plan to collaborate to pro-
have agreed to collaborate to further curity is also constraining broader adoption vide enhanced cybersecurity content at the
develop and nurture the global cyber- of emerging technologies that can improve 2018 ARC Industry Forum.
security community. The two organizations performance, reliability, and safety,” said Sid Edited from an ARC Advisory Group press
will work together to support cybersecurity Snitkin, vice president at ARC Advisory Group. release by CFE Media.
workforce education and development for
industry, energy, utilities, government, aca-
demia, and infrastructure. They also will help
address the pressing need to develop and
propagate new cybersecurity solutions for
the emerging smart cities, smart transporta-
tion, and Industrial Internet of Things (IIoT)
initiatives. This includes performing joint
research to provide a better understanding of
the current state of cybersecurity awareness
and preparedness.
ARC and SANS aim to foster an expanded
and more aware security community through
joint workshops and other activities at the
2018 ARC Industry Forum in Orlando, FL and
upcoming SANS events, including the 2018
ICS Security Summit.
“By equipping the workforce with the
cyber-awareness and technical training
needed to help safeguard today’s connected
and converged systems, we increase the
effectiveness of our security operations,” said
Doug Wylie, director at SANS Institute.
“Managing the security of industrial
facilities, infrastructure, and smart cities is

Process growth
The 2016 U.S. process instrumentation
and automation (PI&A) market, valued at
$11.7 billion, is projected to grow 3.6% by
2021 to a total of $14 billion according to
the Measurement, Control & Automation
Association (MCAA). The group’s 2017
annual market forecast report projects
growth concentrated in five industries:
Chemicals, electric utilities, oil refining,
food and beverage, and pharmaceuticals
with a cumulative market gain of $2.28 bil-
lion over the forecast period.
The report projects the chemicals
industry market gain will be largest, about
$850 million; the other four are projected
to add over $1 billion in market gain during
that time. Oil and gas spending, expected
to be essentially flat in 2017, is expected to
increase through 2021. See more online.
Edited from an MCAA press release.

CONTROL ENGINEERING JULY 2017 | 23 input #10 at www.controleng.com/information

INDUSTRY NEWS and events

Flannery named CEO of GE

GE announced that John Flannery, cur-
rent president and CEO of GE Health-
care, has been named CEO of the company
by the GE Board of Directors effective
and Chile. In 2002, Mr. Flannery became
the president and CEO of GE Equity. In
2005, he moved to Asia where he was
responsible for the Asia Pacific region for
‘ Flannery led the acquisition

of Alstom, the largest industrial

Aug. 1, 2017, and Chairman and CEO GE Capital. In 2009, he moved to India to acquisition in company

’
effective January 1, 2018. lead the country for GE. During his time
Flannery began his career at GE Capi- in India, Mr. Flannery upgraded the lead- history.
tal in 1987 where he focused on evaluat- ership team, built the culture, and focused
ing risk for leveraged buy-outs. In 1997, on the industrial side of the business, focus on technology leadership in core
he moved to Argentina and led GE’s where he increased industrial sales by 50 imaging, created digital platforms and
Equity business in Latin America and the percent in 2011. solutions, expanded life sciences through
overall GE Capital business for Argentina In 2013, he was tapped to lead business bioprocess solutions, and added key tech-
development at GE Corporate where he nology to its cell therapy systems business.
focused on capital allocation for the com- He also launched Sustainable Healthcare
pany and led the acquisition of Alstom, Solutions, which is focused on bringing
the largest industrial acquisition in the disruptive technologies to healthcare pro-
company’s history. viders across emerging markets.
Since joining GE Healthcare in 2014, Jeff Immelt, who was named CEO in
Flannery expanded the division with a 2001, changed the company into a digi-
tal industrial portfolio aligned to key
John Flannery, the president and CEO of markets—power, aviation, transportation,
GE Healthcare, has been named the CEO health care, and oil and gas. He will retire
of GE effective Aug. 1, 2017, taking over from the company on Dec. 31, 2017.
for Jeff Immelt, who has been running the Edited from a GE press release by CFE
company since 2001. Courtesy: GE Media.

Headlines
Medical power supplies online
Very compact and efficient 40 and 65 Watt models in metal Industry events
package or open frame are certified to ES 60601-1 3rd edition At www.controleng.com, industry events
for 2ƒ×ƒMOPP. include:
 Process Expo 2017, Chicago, Sept. 19-22
www.myprocessexpo.com

 Pack Expo and Healthcare Packaging Expo,

Las Vegas, Sept. 25-27
www.packexpolasvegas.com

 Fabtech, Chicago, Nov. 6-9

www.fabtechexpo.com/about

 A3 Business Forum, Orlando, Jan. 17-19, 2018

https://a3.a3automate.org/a3/businessforum

TPP40 & TPP65 Series  ARC Industry Forum 2018, Orlando, Feb. 12-15
www.arcweb.com/events/rc-industry-forum-orlando
• Low leakage current (< 75µA) within the limits for BF applications
• Low EMC emission according IEC 60601-1-2 4rd edition Top five Control Engineering articles
June 12-18: Most visited articles included NEC
• Risk management process to ISO 14971 incl. risk management file changes, control system automation errors, Sal-
• Acceptability of electronic assemblies according IPC-A-610 Level 3 ary and Career Survey, networking to improve a
• Design and manufacturing according ISO 13485 management system superconducting magnets, and integrator advice.
• 5-year product warranty May PMI ticks up slightly as
manufacturing remains solid
Collaborative robots in the laboratory
Cyber espionage the cause for most
companies security breaches
Six questions about reliability vision
Reliable. Available. Now. www.tracopower.com companies need to answer

input #11 at www.controleng.com/information

24 | JULY 2017 CONTROL ENGINEERING
 Digital edition? Click on headlines for more details.
See news daily at www.controleng.com/news

Video use in data collection rising, according to survey

A
survey conducted by HBM shows that video use is acceler-  The most common reason for using video in data collection
ating in data collection. Almost half of the respondents (47%) is to gain additional input analyzing unexpected deviations (73%).
already use video in data recording. In addition, 54% of the Other common reasons are decision finding (50%) and visualization
respondents expect video use within their organization to increase of results to management (41%).
in the next year.  Regular video (such as webcams) most commonly is used for
Video cameras already are used in many industrial test and data collection. In the survey, 80% of respondents use this type.
measurement applications in addition to data collection with tradi- High-speed video is used by over one-third of the respondents

‘
tional tactile sensors. However, (36%), often in combination with
until now, there has been very Video supports traditional sensor data traditional video.
little information on the level and  Video in data collection is
nature of this use. and is becoming a valuable source of likely to increase substantially

’
“Based on the study there in the next several years. This is
is no longer any question that additional information. indicated by both sides; by those
recording video data in parallel already using video today and by
to tactile sensors or digital bus signals is becoming more and more those who do not. In total, 54% of all the respondents expect video
attractive to users,” said Christof Salcher, product manager instru- use in data collection within their organization to increase. Among
mentation at HBM. “Video supports traditional sensor data and is non-users that amounts to 37%.
becoming a valuable source of additional information, making the  Use brings more use. Those already using video are more prone
room for interpretation even narrower in testing.” The survey’s to increase their usage within the next years (76%). Of those 50
findings include: respondents expecting to increase their use of video in data, a majority
 Video is most commonly used in structural durability, fatigue (69%), predicts a substantial growth of 10-50%. None of those already
testing (48%). Machine monitoring or general lab testing (30%) and using video expect the video usage to decrease in the next year.
mobile data acquisition or road load data acquisitions (28%) are Edited from a Control Engineering Europe article by Chris Vavra, pro-
also relatively common areas of application. duction editor, Control Engineering, CFE Media, cvavra@cfemedia.com.
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input #12 at www.controleng.com/information
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input #13 at www.controleng.com/information
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Redundant Power Supply Concepts

Important Contribution to Uptime
Anja Moldehn | Phoenix Contact Electronics GmbH, Germany
Mike Garrick | Phoenix Contact USA

To ensure business success in the industrial sector, machines and systems

around the world require a high degree of reliability. Less downtime
results in higher profits, and control cabinets that operate continuously
are a key to keeping factories efficient. For this reason, many engineers
are implementing redundant power supply concepts combined with
redundancy modules.

Power supplies are configured redundantly anywhere that

downtimes would have a negative impact. For example, for a
device with a rated current of 20 A, the power supply system
would consist of two power supplies, each with 20 A on the out-
put side, connected in parallel. If one of the power supply units
develops an internal fault or if the primary power supply fails,
the second unit automatically takes over and supplies the load
current. This means that the power supplies must be dimen-
sioned so that one power supply unit can cover the complete
power demand of the connected devices in all operating states.

To minimize the risk of a failure, the user should consider all potential fault sources. This paper demonstrates
several examples of potential failures and offers suitable solutions for each situation.
Examples in the paper include:
• Fault in one phase of the primary power supply • Break in the cable between the power supply
• Short circuit or break in the cable to the power unit and the redundancy module
supply or failure of one power supply unit • Break in the cable between the redundancy
• Short circuit between the power supply and module and the load
the redundancy module • Excessive load current caused either by a faulty
• Internal defect in the redundancy module load or subsequent increase through other devices

In sensitive applications, a redundant configuration of the automation solution ensures high system reliability.
Depending on the application, operators can choose between solutions without decoupling or with
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input #14 at www.controleng.com/information
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on Your Terms
Jim Wilmot | Controls Product Manager, Siemens

Underperforming automation systems can Some vendors

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input #15 at www.controleng.com/information
 advertisement

How to Balance Cable Properties with

Thermal Performance in Industrial Applications
Alex Terpe | Product Management, Lapp Group

Control cables increasingly have to withstand temperature extremes in applications such as food
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ce201707_whitePprHLF_lapp.indd 1 input #16 at www.controleng.com/information 6/14/2017 12:10:13 PM

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 COVER STORY programming for PLCs

Controller embeds
programming efficiency
Selecting the right controller and accompanying programming software adds efficiency
to the controller programming process.

A
programmable logic controller (PLC) parameters to some or all the items below CPU
or other controller is selected based configuration.
on its application, but choice should
take into consideration the capabili- Table: Top-down configuration steps
ties of the accompanying controller
1. CPU configuration
programming software platform, as this will have a
great effect on quick and efficient coding. 2. I/O configuration
It’s possible to start up the development plat- 3. Module configuration
form, create a new project, and start writing
4. Device configuration
ladder code from scratch with just about any con-
troller programming software package, but this 5. I/O mappings
method requires configuration-on-the-fly and is 6. Memory configuration
not as efficient as other methods. However, some
controller programming software platforms have
built-in efficiencies. By design, these platforms Configuring the controller in the proper
lead the developer along the right path, reducing order helps everything below it fall into place,
the effort needed to complete a program. simplifying and automating some software
One approach combines two methods for development. Configuring a CPU as a Modbus
more efficient programming: top-down config- RTU client only, for example, affects the items
uration and device-centric concepts (Figure 1). below by only exposing the appropriate param-
Top-down configuration provides a clear path eter options, simplifying subsequent steps.
for the programmer by showing what is and
isn’t needed when configuring a PLC project, all Device-centric concepts
based on menu-driven selections. Device-centric The development efficiencies realized by an
concepts let devices handle common functions orderly configuration lead directly to device-
“behind the scenes,” freeing the programmer centric concepts. With these concepts, ladder
MORE from these tasks. code talks to a device in the middle, not directly
ADVICE Examples and explanations of top-down con- to the hardware itself (Figure 2). A device is sim-
figuration and device-centric programming can ilar to a printer driver on a PC, where the driver
KEY CONCEPTS improve programming efficiency. (device) handles all the low-level details so a pro-
PLC architecture can ease program-
ming.
grammer can send data to a printer, without wor-
Top-down configuration and device-
Top-down configuration rying about printer programming.
centric programming help with PLC For some controllers, configuration is sim- A programmer likely thinks of a device as a
programming. plified using a top-down method (see Table). In sensor, encoder, I/O module, variable frequency
Various devices can be programmed the table, the order of the tasks is by precedence, drive (VFD), EtherNet/IP module, remote rack,
similarly. with each item in the list depending on the item or a similar piece of hardware. In a device-cen-
GO ONLINE or items above it. For example, everything below tric controller, the devices are instead pieces of
See more details and links to other CPU configuration depends on how the CPU code between the program and the hardware.
programming advice by clicking on is configured. Serial port, port type, Ethernet Using this concept, the device is configured, and
the headline in the digital edition or
searching on the headline at
input/output (I/O) master options and server it handles the details for control of the hardware
www.controleng.com. options such as Modbus/TCP and EtherNet/IP by the controller, such as establishing commu-
explicit messaging are configuration selections nication protocols, handshaking, and defining
CONSIDER THIS
Would decreased programming and typically available during CPU configuration. memory requirements. Much of the hardware
less configuration help with your next (EtherNet/IP is an industrial Ethernet protocol details are handled via configuration of each
project? from ODVA.) These selections add necessary device, not with controller programming.

30 | JULY 2017 CONTROL ENGINEERING www.controleng.com

 Figure 1: Some control-
lers, such as Automation-
Direct’s Do-more BRX
Micro PLC family, provide
top-down configuration
and a device-centric
approach for more effi-
cient programming. All
figures courtesy:
AutomationDirect

After configuration
Once a device is configured, the program
instruction talks to the device, not directly to
the hardware. The instruction uses the defined
‘ If the controller lacks on-board high-
speed inputs, a high-speed counter
memory, handshaking bits, and memory flags
created during configuration of the device. The
module can be used to count encoder

’
instruction also can talk directly to and from
memory using bits and integers to make logic
quadrature pulses.
decisions. The instruction also can perform
math functions and place the floating-point steps, which require selecting features and fill-
result back in memory, for example. ing in a few blanks.
A device, such as a serial port, talks directly to A typical application, like a box diverter,
memory as well. As data flows to or from a serial contains several pieces of hardware that must
port, the device handles buffering and status flags be controlled. The application may include an
in memory. The device handling the behind-the- encoder to synchronize the diverter gate to differ-
scenes details is what makes the programming ent box lengths, a motor controlled by a VFD, and
device-centric, with everything revolving around a barcode reader to scan a conveyed box to deter-
the device. mine its destination. Input and outputs also will be
A server can be thought of as a device as well. needed to monitor sensors for box detection, and to
It runs in the background, talks directly to the control pneumatic actuators, such as a lift.
hardware, and moves data between the hardware As this box diverter application demon-
and memory. Modbus TCP is an example of a strates, it’s not unusual to have several differ-
server. It functions for the most part outside ent pieces of automation hardware connected
of the controller program, but can be accessed to a PLC, with each hardware component and
by it. its required connections defining the devices.
However, in this instance, a controller with a
Put efficiency into action with devices top-down configuration and device-centric con-
Regardless of the complexity of the hardware cepts is quickly configured, with much of this
selected, the device provides a clean, uniform effort performed automatically.
interface between the hardware and controller If the controller lacks on-board high-speed
program. Each device is set up the same way, for inputs, a high-speed counter module can be
example a Modbus/RTU or a general-purpose used to count encoder quadrature pulses. This
serial port, by following top-down configuration module is not a part of the CPU configuration,

www.controleng.com CONTROL ENGINEERING JULY 2017 | 31

 COVER STORY programming for PLCs

but it is automatically dis-

covered in the second
step, I/O configuration.
The third step, mod-
‘ Newer, advanced

controllers are simplifying

ule configuration, will
then autofill the needed programming by enforcing
parameters with default
values for the discovered a more top-down approach
module. Any edits to the
configuration required
can be made here dur- and using device-centric
ing this step. The PLC

’
will automatically handle concepts.
the I/O mapping for the
added module, and create
the needed image register There are thousands of uses for PID loops,
addresses. so there is no one-size-fits-all solution. Some
The controller’s Eth- controllers have limited options, but others have
ernet port communicates improved PID instructions to increase efficiency
to the VFD. Starting at by providing independent, modular, interchange-
Figure 2: Using a device- the top of the configuration list, the Ethernet I/O able, and run-time configurable methods to meet
centric approach, where the Master is enabled as part of the CPU configura- application needs.
device handles the low-level tion step. This creates an entry in the I/O con- Part of this improved efficiency is the result
details of the hardware inter- figuration, allowing IP configuration and other of breaking down the PID loop into smaller piec-
faces, can simplify program- communication options. Nothing more is typi- es. Instead of embedding all the PID parameters,
ming. AutomationDirect’s cally needed for this device’s configuration since such as filters, scaling, ramp-soak tables and
Do-more Designer controller the other parameters, like I/O mapping, all are alarm handlers, in one PID instruction, sepa-
programming software plat- done automatically. rate instructions are used to access the param-
form has a device-centric The controller’s serial port is used to communi- eters individually to simplify customization of
approach. cate with the barcode scanner using simple ASCII these control algorithms. These instructions also
text strings. The port is recognized during the can include trend views for display to help with
CPU configuration step where a general-purpose understanding of the control loop response, and
serial port is configured, including settings such as to assist with initial tuning and troubleshooting.
baud rate and hardware protocols such as RS-232. Motion control instructions can follow a sim-
I/O and module configuration are not needed, ilar path, broken down into different levels of
and the device configuration is created automat- instruction complexity. Simple motion instruc-
ically, providing a pre-configured interface with tions allow quick application of basic move com-
access to system resources. The memory config- mands with minimal required configuration.
uration step automatically allocates memory for Intermediate-level motion instructions pro-
the device. vide more user-defined parameters. Advanced
Multi-point discrete input and output mod- instructions enable selection or creation of cus-
ules are used to monitor and control the sensors tom move profiles, often through a simple con-
and pneumatics. These modules are configured figuration process.
in a similar fashion. Some of these devices are Newer, advanced controllers are simplifying
easy to set up and some more complicated, but programming by enforcing a more top-down
all use the same methodology. Configuration approach and using device-centric concepts.
starts at the top of the table list and works down- With proper configuration, much of the device
ward, filling in only the parameters not automat- interface between the controller software pro-
ically defined in prior steps. gram and the hardware happens automatically
and efficiently without the need to write code.
Efficient instructions Quicker configuration leads to fast program-
As shown in Figure 2, a top-down and ming, and this is enhanced with the wider vari-
device-centric controller programming platform ety of available instructions. ce
is quickly configured. Controllers with this type
of programming software typically also provide Bill Dehner is technical marketing engineer at
more efficient instructions, such as proportional- AutomationDirect; edited by Mark T. Hoske, con-
integral-derivative (PID) loop and motion con- tent manager, Control Engineering, CFE Media,
trol blocks. mhoske@cfemedia.com.

32 | JULY 2017 CONTROL ENGINEERING www.controleng.com

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 COVER STORY programming for PLCs

PLC programming tips,

benefits for engineers
Get help for programmable logic controller (PLC) programming, covering common topics
in ladder logic.

L
adder logic and programmable logic con- in the program or make repetitive calls to the same
troller (PLC) scanning, binary coded deci- routines. All of this has an effect on the total scan
mals, and reusable codes are among PLC time. There is usually documentation available indi-
programming tips offered by Control Engi- cating the execution time for different instructions,
neering editorial advisory board member but there’s no point in trying to add up all of the
Frank Lamb, the founder of Automation Consulting code to make an estimate on length. It simply is
Services Inc., a Control Engineering content partner. available for reference.
Featured below are tips on PLC programming from Scan time can take as long as 80 ms. If the scan
three different viewpoints. time is longer than about 50 ms (for a machine
control project) then the user should seek a more
Ladder logic, PLC scanning powerful processor or ways to make the code more
Almost all PLCs worldwide handle scanning efficient. Beyond 50 ms, the effect on output reac-
in the same way. First, the CPU reads the physi- tion for a machine control project can be noticeable;
cal inputs into a memory table, usually called the for a process control project this may not matter.
“input table.” This table is then used as the program
is evaluated. There are different types of registers Binary-coded decimals and PLCs
that are used in different platforms; these registers Binary-coded decimals (BCDs) are a class of
are updated as the logic is processed left to right on binary encodings (usually represented by four or
each rung and top to bottom within each routine. eight bits). Humans need to add up those individ-
MORE This includes updating an output table, which will ual bits in our registers to convert them to base 10
ADVICE later be used to drive the physical devices con- because that’s the way we’re programmed to think.
nected to the PLC. Back in the days before touchscreens, 7-segment
KEY CONCEPTS
There are different types of regis- The program might call different subrou- displays and thumbwheel switches were used as a
ters for PLC scanning that are updated tines for different purposes, and it can be impor- numerical interface between humans and PLCs.
to an output table, which will be used tant in what order routines are called. Depending Even before the PLC, these devices were the only
to drive physical devices connected on where memory registers and output tables are graphical way to interface with circuits numerically.
to the PLC.
updated, the physical outputs could be delayed by Users could move plugs around like in the days of
Binary-coded decimals (BCDs) are
a class of binary encodings repre-
up to two scans. In either case, the program mean- ENIAC (the first electronic general purpose com-
sented by four or eight bits. ders through the different routines as they are called puter), but it was a lot easier to view and adjust
Many platforms allow reusable before returning to wherever they were called from decimal numbers with these devices. The problem
code to create powerful programs and eventually ends up at the end of the original was, they were very input/output (I/O) intensive.
quickly, but each has its own method. cyclic routine. Most programs use an initial cyclic Each thumbwheel segment required four inputs (+
GO ONLINE routine that is used to call all of the other routines. power), while each 7-segment display required four
Visit cfeedu.cfemedia.com for Some programs, however, run on a period- outputs (+2 power connections). Still, it was easier
“Introduction to PLCs,” a five-part ic basis instead of a continuous program. This is to interface with signed or unsigned integers in dec-
comprehensive series on PLC pro-
gramming and its history by Control
uncommon, though. Most programs use a contin- imals than use pushbuttons and pilot lights.
Engineering editorial advisory board uous program configuration that runs as fast as it A common complaint is the math; every data
member Doug Bell. can. After executing all of the code, evaluating the type has to be explicitly declared on the platform,
Read the full versions of these logic, and updating all of the tables (except for the and converted if data types are not equivalent. Not
stories online at input tables, which were written at the beginning of only that, but the standard timer and counter data
www.controleng.com with additional the scan), the resulting output table or register con- types incorporate BCD into their data structures.
images and other articles by Frank
Lamb about PLC programming. tents are written to the physical outputs. This is because the structures go all the way back
How long does this take? That depends on the to when people had to deal with things like these
CONSIDER THIS
What other programming methods
platform (speed of the processor), how much code thumbwheels and seven-segment displays. In fact,
can be used for PLCs and what ben- there is in the program, and the types of instruc- the timer setpoints are still entered as “S5T#3S”
efits do they provide for engineers? tions used. Sometimes programmers will use loops for a 3-second setpoint. The timer uses three BCD

34 | JULY 2017 CONTROL ENGINEERING www.controleng.com

 Binary code Decimal BCD code
number Reusable
ABCD B5 B4 B3 B2 B1 EN code block EN 0
0 0 0 0 0 0 0 0 0 0
0 0 0 1 1 0 0 0 0 1
0 0 1 0 2 0 0 0 1 0 Variable 1 Word1 in Word1 out Variable 3
0 0 1 1 3 0 0 0 1 1
0 1 0 0 4 0 0 1 0 0
0 1 0 1 5 0 0 1 0 1 Constant Word2 in Bit1 out Variable 4
0 1 1 0 6 0 0 1 1 0
0 1 1 1 7 0 0 1 1 1
Variable 2 Bit1 in
1 0 0 0 8 0 1 0 0 0
1 0 0 1 9 0 1 0 0 1
1 0 1 0 10 1 0 0 0 0
1 0 1 1 11 1 0 0 0 1
1 1 0 0 12 1 0 0 1 0 61131 for programming languages has existed since Reusable code for
1 1 0 1 13 1 0 0 1 1 1993 or so, and other PLCs leveraged that early on. programmable logic con-
1 1 1 0 14 1 0 1 0 0 An important difference between the older, register- trollers (PLCs) provides
1 1 1 1 15 1 0 1 0 1 only based systems and more modern ones is the users with flexibility and
ability to build re-usable code blocks. Supporting allows structures to be
Binary-coded decimal (BCD) is a class of binary platforms must have three features: built that can be exported
encodings of decimal numbers where each decimal from one application to
is represented by a fixed number of bits, usually 1. Local vs. global variables. Re-usable code another.
four or eight, which goes against the way humans must have variables that apply to each instance of
compute data. This disconnect can cause problems the code; ideally only formatting the data once for
for programmable logic controller (PLC) users. the original code. What this means is that a list of
Graphics courtesy: Frank Lamb, Automation Primer tags or symbols should not have to be re-named for
each instance or call. Duplicating a subroutine sev-
digits (12-bits) and two extra bits for the time base. eral times and iterating the addresses inside of it,
This is also true for the counters, meaning that though it saves time, isn’t really re-usable code.
they only count from -999 to +999.
Each four-digit section can only carry bit val- 2. UDTs. Creating UDTs allows structures to
ues from 0000 to 1001; for the next value, rather be built that can be exported from one application
than indexing to 1010, (“10” in signed or unsigned to another. They allow components to be described
decimal or “A” in hexadecimal), the next bit gets using generic terms such as “Speed,” “Start,” and
bumped to the next section of bits. This means that “Reject.” UDTs don’t require tag-based systems, but
the last six combinations of bits (A-F) are effectively they do require an advanced use of symbols.
wasted—not possible in the BCD structure.
The BCD structure or base also is still usable 3. Protectable self-contained blocks. It is
in many of the newer touchscreens, but most pro- important that the code be contained in a block that
grammers tend to choose an integer base to express allows variables to be passed in and out, and pro-
decimal numbers. BCD is sort of like DOS; engi- tected so that users can’t change a specific instance
neering schools still touch on it, but people really of it. This requires a password or software key.
don’t know where it comes from. Referring to old
thumbwheels and seven-segment displays may help These are just some requirements. Other features
clear up some of the mystery and “why” of BCD. like being able to write code in other IEC-compliant
PLC languages also help make platforms much more
Advantages of reusable code for PLCs powerful and “rapid code development” friendly.
Many programmers base their knowledge and Regardless of whether the platform uses subroutines
abilities on experiences with Allen-Bradley prod- with local variables or customizable instructions,
ucts from Rockwell Automation since much of the reusable code is a critical part of creating powerful
installed base in manufacturing consists of A-B programs quickly. Many platforms allow reusable
PLCs. Rockwell Automation’s ControlLogix family code, and each has its own methods. ce
was a huge jump in PLC capabilities with enhance-
ments such as being tag-based, allowing the use Frank Lamb, a Control Engineering Editorial
of user-defined data types (UDTs), and add-on Advisory Board member, is the founder of Automa-
instructions (AOIs). Tags could also be local to each tion Consulting Services Inc. This material originally
program, allowing them to be duplicated for re-use. appeared on the Automation Primer blog. Automa-
Those capabilities, except for being tag-based, tion Primer is a CFE Media content partner. Edited
already existed years before that on other platforms. by Chris Vavra, production editor, Control Engi-
International Electrotechnical Commission (IEC) neering, CFE Media, cvavra@cfemedia.com.

www.controleng.com CONTROL ENGINEERING JULY 2017 | 35

 SAFETY networks

Safety over industrial

communication networks
Industrial Ethernet is becoming easier to use for industrial safety applications. Standards, trends,
and technologies are helping with industrial Ethernet-based safety systems.

I
mplementation of an industrial safety net- recommended in IEC 61784-3. However, this
work using Ethernet can be simpler with was accompanied by the important recom-
more standard configuration tools that are mendation that the safety data channel not
easier to program and use, reducing cost and exceed 1% of the maximum failure probability
complexity. of the target safety integrity level (SIL) safety
rating for which the safety profile is designed.
Standards for safety-rated protocols This enables safety protocol containers to be
The majority of the standards for transmit- “tunneled” inside the fieldbus system, consid-
ting safety-rated protocols via Ethernet have erably simplifying the hardware and software
been around for more than 15 years. The major for safety systems. Most devices for EtherCAT
specifications that define the requirements of functional safety over EtherCAT (FSoE) are
MORE
modern digital safety systems are contained in rated for SIL3.
ADVICE the following standards, International Electro-
KEY CONCEPTS technical Commission (IEC) 61508 Functional Trends for FSoE
The requirements for modern digital Safety of Electrical/Electronic/Programmable The trends for FSoE have been the acceptance
safety systems. Safety-Related Systems and IEC 61784-3 Indus- of safety logic controllers and safety input/output
Standards for transmitting safety- trial Communication Networks - Profiles - Part (I/O) devices from multiple vendors. There are
rated protocols.
3: Functional Safety Fieldbuses - General rules 27 companies making products that complement
Advanced technology for safety
programming tools. and profile definitions. (Safety-over-EtherCAT a FSoE system. This falls in line with the multi-
protocol is referred to as functional safety com- vendor acceptance of EtherCAT in general, which
GO ONLINE
For related links, read this article
munication profile [FSCP 12] in the IEC 61784- has 200 master controller vendors, 105 I/O ven-
online. In the digital edition, click on 3 specification.) The first digital safety systems dors, and 160 drive vendors.
the headline or search the headline at were dedicated controllers with separate, pro- Additionally, the availability of servo drives
www.controleng.com. Also search prietary communication buses. This was a step with safe motion functions onboard has stream-
“SIL3” for more safety coverage and forward for safety implementation, but required lined automation design for vendors and users
search “safety” in the New Products
for Engineers Database, additional hardware, programming software, of motion control products because the motion
www.controleng.com/NP4E. licenses, and an additional fieldbus for the controller can issue safety function commands
CONSIDER THIS
machine designer and end users. directly to drives for safe stop, safe torque, and
Since safety systems could be The availability of fast and efficient indus- safe position (see Table). In addition, there is no
networked instead of hard wired, trial Ethernet systems such as EtherCAT made longer a need to power down the drives, which
what savings have you realized? it possible to use the “black channel” approach was always a point of debate when considering
whether a freewheeling flywheel, for example,
Table: Safety function commands for drives actually established the safest conditions follow-
ing an E-stop button push.
Safe torque off (STO): Shuts off power to the motor without disconnecting
power to the drive. STO is used for emergency stop situations and to prevent The benefits of advanced technologies
unexpected motor movements. Configuration tools for FSoE have become
more standardized over time. Users no longer
Safe stop: Uses a controlled ramp-down (deceleration) to safely stop the have to maintain separate safety programming
motor, and then activates the STO function. tools or licenses for each vendor’s products.
Safe position: This function transfers the safe position actual values of the Configuration and programming tools are avail-
drive to the higher-level controller. This function can be used to implement a able for free from multiple EtherCAT hardware
reliable range positional travel for specific axes. If the safe position is out of and software vendors, and these can configure
range the axis will STO to prevent motion. any vendor’s FSoE devices, eliminating the need
for additional programming tools, training for

36 | JULY 2017 CONTROL ENGINEERING www.controleng.com

 Through next-genera-
tion communication pro-
tocols such as EtherCAT,
modern safety concepts
still can be connected with
legacy fieldbus systems.
Courtesy: Beckhoff Auto-
mation

‘ Users no
longer have
to maintain
separate safety
programming
additional software platforms and program- safety technology in more places as a result of
ming languages, and the need to purchase and these savings. ce tools or licenses
maintain additional licenses. This enables the
FSoE user to easily implement a SIL3-based Joey Stubbs is a North American representative for each vendor’s

’
safety system while reducing cost and com- at EtherCAT Technology Group. Edited by Emily
plexity. In addition to the budgetary bene- Guenther, associate content manager, Control Engi-
products.
fits, users also will be able to implement more neering, CFE Media, eguenther@cfemedia.com.

input #17 at www.controleng.com/information

 SAFETY networks

Industrial fail-safe,
node-to-node communication
CIP Safety, for functional safety applications on EtherNet/IP and DeviceNet networks,
provides fail-safe communication between nodes.

F
or safety applications, nodes may be safe- ments. The combination of fast-responding local
ty I/O blocks, safety interlock switches, safety cells and the inter-cell routing of safety data
safety light curtains, and safety program- allows users to create significant safety applica-
mable logic controllers (PLCs) in safety tions with fast response times.
applications up to Safety Integrity Level
(SIL) 3, pursuant to International Electrotechni- Protocol for control, safety, energy, more
cal Commission (IEC) 61508 standards and as CIP, an object-based protocol, encompasses

‘
certified by TÜV Rheinland. Since 2005 Common a comprehensive suite of messages and services
To better meet Industrial Protocol (CIP) Safety devices have been for the collection of industrial automation appli-
working in the field. CIP Safety has been adopted cations—control, safety, energy, synchronization
application by Sercos International as the only safety proto- and motion, information and network manage-
col for Sercos III networks, in addition to use in ment—and allows users to integrate these appli-
needs, users EtherNet/IP (the ODVA Ethernet protocol) and cations with enterprise-level Ethernet networks
DeviceNet (ODVA device communication). and the internet. EtherNet/IP—the adaptation of
also can design The capability eases integration and increases CIP on standard Ethernet technology Institute of
flexibility, because with CIP’s safety application Electrical and Electronic Engineers (IEEE) 802.3:
a network coverage, applications can mix safety devices and Standard for Ethernet combined with the trans-
standard devices on the same network or wire. mission control protocol (TCP)/internet proto-
architecture with Single channel (non-redundant) hardware can be col (IP) suite)—provides users with the network
used for the data link communication interface tools to deploy industrial automation applications
or without because the safety application layer extensions do while enabling internet and enterprise connectiv-

’
not rely on the integrity of the underlying stan- ity, resulting in data anytime and anywhere.
a safety PLC. dard CIP services and data link layers. This same Because CIP Safety devices have CIP function-
partitioning of functionality allows standard rout- ality, CIP Safety is connected through a CIP object:
ers to route safety data. the safety validator object. This object is the inter-
face between link layer connections and safety
Data integrity at the end device application objects, and it ensures the integrity of
Because the end device is responsible for safety data transfers. CIP Safety does not prevent
ensuring the integrity of the data, routing safety communication errors from occurring. Instead,
MORE messages is possible. The end device will detect the safety validator object detects communica-
ADVICE the failure and take appropriate action if an error tion errors and allows devices to take appropriate
KEY CONCEPTS
occurs in data transmission or in the intermedi- actions while ensuring transmission integrity.
CIP’s safety application coverage ate router. Without gateways, but by incorporating CIP Safety uses safety cyclic redundancy
The benefits of CIP safety on safety functionality into each device, safety devic- checks (CRCs), data cross-checking, and time-
EtherNet/IP es from multiple manufacturers can communi- stamps to ensure the integrity of the safety
CIP safety technology requirements. cate across EtherNet/IP or DeviceNet networks. information. These measures detect the possi-
GO ONLINE To better meet application needs, users also can ble corruption and/or delay of safety data that is
For related links about CIP safety, design a network architecture with or without a transmitted. In addition, the use of end-to-end
read this article online. In the digital safety PLC. safety CRCs eliminates certification require-
edition, click on the headline or This routing capability allows the creation ments for intermediate devices, allowing the
search the headline for
www.controleng.com. Also search
of CIP Safety cells with quick reaction times on safety protocol to be independent of the net-
ODVA and Sercos. one network, such as DeviceNet, to be inter- work technology. While individual link CRCs
connected with other cells via other networks, are not relied on for safety, they still provide an
CONSIDER THIS
In addition to networked motion such as EtherNet/IP. Only the safety data that additional level of protection and noise immu-
applications, how is safety technology is needed is routed to the required cell, which nity by allowing data retransmission for tran-
growing to address safety concerns? reduces the individual bandwidth require- sient errors at the local link.

38 | JULY 2017 CONTROL ENGINEERING www.controleng.com

 ‘
With networked motion applications grow-
ing as a critical area for safety technology, ODVA,
the organization that manages the CIP Safe-
The resulting CIP Safety services for
ty technology, expanded application cover- safe motion include support for drives on
age of CIP Safety to include safe motion. Using

’
the safety functions defined in IEC 61800-5-2: EtherNet/IP and Sercos III.
(Adjustable Speed Electrical Power Drive System
– Part 5-2: Safety Requirements – Functional as
a framework, ODVA defined the requirements the CIP Network specifications comply with
to use safe motion in systems deploying CIP those specifications. Products built to CIP
Safety, allowing users to deploy networked motion Safety are required to hold a Declaration of Con-
control systems using EtherNet/IP and Sercos III formity from ODVA to demonstrate to the indus-
in applications requiring safe motion functions, try that the device has been successfully exercised
such as safe torque off and safety limited posi- against tests designed to help ensure compliance
tions. The resulting CIP Safety services for safe with the specification and with interoperability
motion include support for drives on EtherNet/ with other products. Due to demand, ODVA has
IP and Sercos III. Devices that succeed in meeting expanded the number of test service providers it
the requirements for ODVA’s CIP Safety confor- has authorized to test CIP Safety devices. Vendors
mance test and are certified by an authorized com- can now submit products to multiple labs in Ger-
petent body for full compliance with IEC 61508 many and in the United States to receive a Decla-
will receive a Declaration of Conformity from ration of Conformity for CIP Safety. ce
ODVA indicating compliance with the CIP Safety
specification. Katherine Voss is ODVA’s president and executive
ODVA’s conformance testing process pro- director. Edited by Emily Guenther, associate con-
vides the general industry with the vendor- tent manager, Control Engineering, CFE Media,
independent assurance that products built to eguenther@cfemedia.com.

sponsored by:

2017 HMI Software & Hardware

Turning research into insights makes for better business decisions

This study was conducted by Control Engineering to acquire information related

to the buying and specifying habits of automation engineering professionals for
human-machine interface (HMI) software and hardware. Respondents to the
Control Engineering 2017 HMI Software & Hardware study unveiled five key
findings regarding what end users expect and how they purchase or
specify human-machine interface (HMI) software and hardware.

According to the study, the top situations in which end users purchase
new HMI software and/or hardware are an automation upgrade (28%), a
new installation (20%), and an operations/engineering upgrade (11%). In
addition; over the past 12 months, the average respondent’s company
was estimated to have been spent $127,000 on HMI software and
hardware; and an average of $123,000 is expected to be spent in the
next year on these products.

Access the 2017 HMI Software & Hardware report with additional
findings and insights. www.controleng.com/2017HMIReport
 SAFETY networks

Safety layer for networks

PI North America, the organization for Profinet and Profibus, explains use of the ProfiSafe safety
network on top of industrial Ethernet, Profinet, and device-level Profibus networks.

N
etworked safety for PI North America transmitted data between certified devices
involves using ProfiSafe, an addition- and controllers and includes safety checks.
al software layer used on top of Profi-
net (industrial Ethernet) and Profibus  Operates without interference, avoiding
(device-level) networks. impact on connected standard bus proto-
cols and automation systems.
According to PI North America, ProfiSafe:
 Can be used for safety applications up to
 Adds functional safety to an existing auto- SIL3 according to IEC 61508/IEC 62061,
mation network, running on the same or Category 4 according to EN 954-1, or
cables. PL “e” according to ISO 13849-1.

 Compared to wired circuits, requires less To implement ProfiSafe, one must first assess
engineering, less cable, faster commission- risks, determine a mitigation strategy (includ-
ing, and easier maintenance. ing controls, guarding, signage, etc.), use a Pro-
fiSafe controller and input and output devices,
 Has been available since 2001 with nearly 7 and finally, reassess periodically. ProfiSafe also
million ProfiSafe devices in operation in 2016. can integrate AS-i Safety at Work, said Michael
Bowne, PI North America, executive director,
 Can be used with wireless (such as WLAN citing ProfiSafe training materials. ce
and Bluetooth) and with open Ethernet
backbones. Edited by Mark T. Hoske, content manager,
CFE Media, Control Engineering,
 Works by reducing error probabilities in mhoske@cfemedia.com.

Which technology or service do you buy or specify that use,

connect with, or support mobility, Ethernet, or wireless technologies?
MORE
ADVICE Control systems 78%
Wired or wireless networking
KEY CONCEPTS I/O and systems 64%
A safety network has been available to
use with Profinet and Profibus.
HMIs, SCADA, historian, etc. 62%
PCs, IPCs, mobile devices,
ProfiSafe safety network is more embedded, etc. 50%
flexible and less costly than hardwired Motors, drives, and actuators 49%
safety. Process/discrete sensors, vision
Use of ProfiSafe has been carefully systems, power supplies 42%
documented and help is available from Power distribution systems, power
39%
protection, enclosure systems
the PI North America organization.
Pumps, valves, positioners 38%
GO ONLINE Analytical instruments, test,
See an application story about how or calibration equipment 36%
ProfiSafe was used with the Boeing 787 Safety for process or machine systems 31%
Dreamliner, as integrated by Advanced
Integration Technology (AIT). Motion control systems and robotics 30%
Design, analytics, PLM, ERP, MES,
Link to more from PI North America. batch, scheduling, SCM, IoT 17%
http://us.profinet.com/technology/profinet/
CONSIDER THIS
If you’re hardwiring safety, have Controllers, networking equipment, and operator interface software are the most used tech-
you considered savings available by nologies to support mobility, Ethernet, or wireless technologies. Safety devices were used by 31% of
implementing a safety network? respondents for networking. Courtesy: Control Engineering 2016 Mobility, Ethernet, Wireless Report

40 | JULY 2017 CONTROL ENGINEERING www.controleng.com

WEBCAST SERIES

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sustain productivity in today’s, and tomorrow’s, cyber-physical world.

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Thursday, August 24, 2017
Connecting complex machinery and equipment to operations and enterprise systems enables machine learning, predictive maintenance
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It’s a fact that predictive maintenance and services has, out of the box, proven to be the most significant Industrial Internet of Things
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Register for the IIoT series today at www.controleng.com/lloT

 ENCLOSURES for automation

Thermal management
requirements for
edge computing
Edge computing requires several variables to be considered and an
advanced climate control solution.

E
dge computing houses data processing  Have options for scalability at the rack level
capability at or near the “edge” of a net- and at the edge data center as a whole.
work facility. Usually servers are con-
tained in a micro data center, with as few Evaluating the variables in edge
as one or two enclosures. Data which is computing
mission-critical, such as a component malfunc- Heat dissipation and the inherent heat problems
tion or a software defect, is captured and available in edge computing require modular climate control
in real-time on-site. Edge computing is valuable in systems. An energy-efficient and advanced climate
capturing bandwidth-intensive and latency-sensi- control and cooling concept for edge computing
tive data for analysis, lowering operating costs and takes these variables into account:
improving energy efficiency. Lower-priority data
can be sent to the cloud or to a remote data center.  Temperature
Companies are recognizing the importance  Humidity
of incorporating edge computing into their pro-  The velocity and pressure of airflows
cesses. However, a basic rack-mounted enclo-  Heat losses of the installed components.
sure is still a challenge. In edge computing, server
rack density and small footprints are key compo- Consider these fundamental criteria and vari-
nents to provide the near-user computing data. ants in the design phase:
However, power consumption of a server rack is
MORE converted to heat which is deadly to IT systems.  What type of liquid cooling package (LCP)
ADVICE And the smaller the space, the more the temper- cooling system should be installed? Whether
KEY CONCEPTS ature rises. Thus, thermal safety is a paramount or not a water- or refrigerant-based system is
Requirements to consider for edge priority. used can depend on the environment and the
computing availability of a water supply.
Defining edge computing and its Checklist requirements for edge cooling  Will the amount of racks and enclosures
benefits To determine the correct cooling solution for an require hot and cold aisles? Cold aisle con-
How to protect equipment with edge computing microcenter, and prepare a plan tainment usually requires a raised floor.
proper thermal management.
that allows for correct sizing of the center, assess the  What average temperatures should be main-
GO ONLINE distinct obstacles for edge computing. tained in the racks? It is still widely accepted
For related links about edge Of all the concerns for an edge data center, cool- that racks should be maintained at a cooler
computing, read this article online.
In the digital edition, click on the ing capacity consistently rates as a primary focus. A temperature, no more than 68 ° to 72 °F. The
headline requirements checklist includes: setpoint temperature required depends in
or search the headline for part on the heat output calculations for the
www.controleng.com  Select a climate control system that is rack enclosure. With densely-populated edge
Read more online about protecting well-matched to the heat output of the edge centers, additional cooling power may be
equipment with thermal manage-
ment and the criteria to consider in
data center needed to offset the higher heat loads.
edge computing.  Provide adequate airflow to each server rack  What is the volumetric flow rate of cooled
 Assure operational reliability of the air required? Calculating the airflow
CONSIDER THIS
What benefits would more efficient cooling and redundancy system requirement for each center depends on the
enclosure cooling offer beyond  Maintain constant acceptable levels of rack requirements to design an efficient air-
energy savings? temperature and humidity flow strategy.

42 | JULY 2017 CONTROL ENGINEERING www.controleng.com

  What are the ambient conditions? Tempera-
ture extremes in either direction will affect
the energy required to maintain an accept-
able environment for the racks. The degree to
which ambient temperature may assist or hin-
der cooling may depend on the efficiency of
the system and the density of the racks.
 Where will the airflow be directed? Direct-
ing the cooler airflow to the front of the racks
is desirable, but how will the heated air be
discharged?
 Do load fluctuations exist and what impact
do these have on the cooling response times? cooling these systems is greater. The power den- Closed-loop cooling ensures
If the operation of the data center will see sity of these server racks has increased from 2-8 edge data centers are pro-
variations in energy use, a selected cooling kW per enclosure to more than 100 kW. tected from environments
system should be adaptable to the variations Providing a liquid cooling package (LCP) for that have uncontrolled and
in power needs. an enclosure (suite-based or rack-based) can effi- fluctuating temperatures.
 Should the system be scalable for future ciently dissipate heat from IT racks. Applications See this article online for a
expansion? Having a system that can adapt to may include aisle containment or closed-loop diagram showing thermal flow
baying or can support additional rack cooling cooling of single- or dual-IT-rack enclosures. inside an enclosure. Courtesy:
over the existing needs will eliminate costs if LCPs are a reliable, cost-effective cooling Rittal
additional computing power is needed. means to provide cooling capacity of 3 kW, up
to as high as 60 kW. LCP devices support IT-
Cooling the edge computing microcenter can compatible cooling and can achieving up to 50%
be approached most effectively via a liquid cool- energy savings using intelligent control, free
ing system, either inline-based, rack-based, or a cooling, and additional fans that keep a steady
combination of both. There are two heat transfer volumetric flow and a constant cooling output.
media (water and refrigerant) that can work with In IT data centers confined in small spaces,
these systems. Water offers exceptional cooling such as edge computing, heat build-up is rapid,
properties, well-suited to the high heat output of and an LCP matched to the enclosure can pro-
an edge system. vide efficient closed-loop cooling. With high-
Refrigerant-based cooling is well-suited to performance EC fan technology, refrigerant
small or medium edge enclosures, especially when cooled air is targeted to the racks. Servers are
a water supply is not readily available. Refrigerant cooled independently from the ambient air, eas-
cooling often operates with a smaller footprint, ily adapted to one enclosure or a modular series.
efficient in microcenters. In both cases, energy Certain LCPs are designed for a bayed enclo-
efficiency is a consideration. The energy-efficient, sure suite. Hot air from the room or hot aisle at
IT climate control system considers: the rear of the device is efficiently chilled by the
high-capacity variable speed compressor and the
 Dimensioning of the cooling systems to match refrigerated air is directed back into the room
the actual power requirements or cold aisle after cooling. Other attributes of an
 Separation of cooling for server racks and LCP may include air path control, small foot-
room air conditioning by partitioning of aisles print, a design that augments fan life, redundant
 Use of energy-efficient components, such fan design, and efficient cool-air flows.
as electronically commutated (EC) fans that With the ever-increasing densities and
include power regulation of the cooling demands for more capacity, the protection of vital
compressors IT data from edge applications to large legacy data
 Keeping the cooling water and room tempera- centers requires the reliability and selection of
tures as high as possible thermal management products. Energy efficient
 Controlling all subsystems and continu- design lowers operating costs, while IT compo-
ous adaptation to the actual cooling power nents work at capacity. ce
requirements.
Hans Baumann is a product manager at Rittal
Liquid cooling for thermal management Corp. Edited by Emily Guenther, associate con-
As data centers concentrate high-power tent manager, Control Engineering, CFE Media,
servers in smaller footprints, the challenge of eguenther@cfemedia.com.

www.controleng.com CONTROL ENGINEERING JULY 2017 | 43

 POWER QUALITY electrical distribution

Transfer switches:
Which configuration is best?
When it comes to picking the right transfer switch for a facility, engineers need to consider many
aspects such as system installation, operation modes, and switching mechanisms to help prevent
downtime in the event of a power outage.

M
any commercial and industrial ate hazards or interfere with rescue or firefighting
facilities require continuous uptime operations if electrical power is unavailable. Power
to maintain business continuity in transfers between normal and emergency sources
the event of a power outage. For must be complete within 60 seconds.
this reason, these facilities rely on
electrical distribution equipment such as trans- Critical operations power systems (COPS)
fer switches to safely transition electrical power These systems supply, distribute, and control
between normal and emergency power sources. electricity in designated control areas when a normal
Not all transfer switches are alike, however. The power source fails. These include HVAC, fire alarm,
sheer number of available options and configura- security, communication, signaling, and other ser-
tion modes can be daunting for an engineer while vices that the authority having jurisdiction (some-
designing a system. Because of that, engineers need times a government agency) has deemed important
to understand the configurations available to deter- to national security, the economy, or public health
mine what is correct for the application’s needs and safety.
when implementing transfer switch technology.
Optional standby systems
Common system installation types Operational standby systems are not required
Engineers first need to understand their sys- to function automatically during power failures.
tem installation type to determine the best transfer They supply power to loads with no direct impact
switch. The National Electrical Code (NEC) defines on health or life safety. These systems are most com-
four categories for transfer switches: emergency sys- mon in commercial buildings, farms, and residences.
tems, legally-required systems, critical operations
power systems, and optional standby systems. Understanding transition types
There are two basic ways transfer switches can
MORE Emergency systems transition loads between normal and emergency
ADVICE Emergency systems supply, automatically dis- power sources: open or closed. The specific func-
KEY CONCEPTS tribute, and control electricity used by systems tions performed by a given load and the impor-
Engineers need to understand essential to life safety during fires and similar disas- tance of those functions to safety or security play an
what is correct for their unique needs ters. They include fire detectors, alarms, emergency important role in determining which kind of transi-
when implementing transfer switch lights, elevators, public safety communication sys- tion is required.
technology.
tems, and ventilation systems. They are often found
Factors engineers need to consider
in hotels, theaters, arenas, and hospitals. And they Open transition
include system installation, transition
types, switching mechanisms, and are regulated by a municipal, state, federal, or other An open transition is a “break before make”
operation modes. government agency. They require the transfer of transfer, meaning the transfer switch breaks its
Picking the right transfer switch power from the normal to emergency power source connection to one power source before making a
technology will keep a facility up and to be completed within 10 seconds. connection to the other. For some time between
running in the event of an outage or disconnection and connection, neither the normal
power loss.
Legally required systems power source nor the emergency source is provid-
GO ONLINE Like emergency systems, legally-required sys- ing electricity to downstream loads. There are two
Read this article online at
tems are government-regulated, but they are kinds of open transition: open delayed and open
www.controleng.com for more stories
about transfer switches. designed to automatically supply power to a select- in-phase.
ed set of regulated tools that are not classified as
CONSIDER THIS
What other factors should be emergency systems. These systems serve functions Open delayed transition
considered when selecting a transfer such as critical heating, refrigeration, communi- In an open delayed transition, the transfer
switch for a facility? cation, ventilation, and lighting that could cre- switch pauses in-between disconnecting from one

44 | JULY 2017 CONTROL ENGINEERING www.controleng.com

power source and connecting to the other. That
delay typically lasts either a specific, pre-set amount
of time, or however long it takes the load voltage to
drop below a pre-specified level.

Open in-phase transition

With open in-phase transitions, an automatic
controller uses built-in intelligence to execute an
open transition at the precise moment it expects the
normal and emergency power sources to be syn-
chronized in phase, voltage, and frequency. If syn-
chronization doesn’t occur within that time span,
some transfer switches have the ability to default
automatically to a delayed transition that serves as
a failsafe.

Closed transition
A closed transition is a “make before break” so the power contacts are not self-protecting. Transfer switches can
transfer, meaning the transfer switch makes a con- be configured in multiple
nection to the new power source before breaking Molded case switching mechanisms ways to meet specific
its connection to the old one. Because there is no Molded case switching mechanisms are used application needs.
gap between disconnection and connection, down- routinely for closing and interrupting a circuit Courtesy: Eaton
stream loads receive continuous power throughout under both normal and abnormal conditions.
the transfer process. They are capable of supporting a mechanically
Switches configured for closed transitions usu- operated, over-center toggle or a motor operator.
ally transfer power automatically as soon as both When configured for use in a transfer switch, a
power sources are closely synchronized in phase, pair of molded case switches are operated through
voltage, and frequency. The overlap period during an interlocking mechanical linkage, which can be
which both sources are simultaneously connected, driven manually or automatically. These mecha-
or “paralleled,” usually lasts no more than 100 ms to nisms provide a compact, cost-effective and ser-
comply with local utility interconnect requirements. vice entrance-rated solution, as they eliminate the

‘
need for additional upstream protective devices.
Switching mechanisms
The switching mechanism is the part of a Power case mechanisms
High interrupt
transfer switch that is physically responsible for Power case mechanisms are larger, faster, and
carrying the rated electrical current and shift- more powerful than molded case mechanisms.
rating also
ing the load connection from one power source The two-step stored energy technology they use
to another. Low-voltage switching mechanism can be operated mechanically and electrically,
makes power
technology comes in two basic varieties: contac- and some models feature integral overcurrent
tor type and circuit breaker type. Circuit breaker protection similar to what typically is found in
case mechanisms
switching mechanisms can be further divided into molded case designs. Their high interrupt rating
two sub-types: molded case and power case. also makes power case mechanisms a good fit for
a good fit for
applications vulnerable to large fault currents.
Contractor switching mechanisms
applications
Contractor switching mechanisms are the most Operation modes
common and affordable. These mechanisms often Power transfers involve two processes: initiation
vulnerable
are constructed as a double-throw switch where an and operation. Initiation is what starts the transfer,
electrical operator opens one set of power contacts while operation is what completes it. Most trans-
to large fault

’
while closing a second set. In an open transition fer switches can support multiple operation modes
design, a mechanical interlock often is employed to through the addition of configurable options.
currents.
prevent simultaneous closure of both contact sets.
In a closed transition design, the mechanical inter- Manual mode
lock is absent. Contactor switching mechanisms are In manual, initiation and operation are per-
designed to support all three transition types: open formed manually, usually by pushing a button
delayed, open in-phase, and closed. These mecha- or moving a handle, giving the operator max-
nisms don’t include integral overcurrent protection, imum control of the transfer. An advantage

www.controleng.com CONTROL ENGINEERING JULY 2017 | 45

POWER QUALITY electrical distribution

‘ For repairs, a
technician can
of manual operation is, with molded case or
power case designs, transfers can occur under
load as a failsafe if the automatic controller sus-
tains damage or becomes inoperable.
Bypass isolation mode
Bypass isolation mode allows users to service
transfer switches safely without compromising
availability. Traditional transfer switches feature one
bypass power switching mechanism, but bypass isolation trans-
Non-automatic mode fer switches include dual-switching mechanisms
...to ensure that In non-automatic mode, the operator man- that provide redundancy for critical applications.
ually initiates a transfer by pressing a button or The primary switching mechanism handles day-
critical loads rotating a switch that causes an internal elec- to-day distribution of electrical power to the load,
. tromechanical device to electrically operate the while the secondary switching mechanism provides
remain powered switching mechanism. This device allows tran- backup. During repair or maintenance, a technician
sitions to be completed more rapidly than they can bypass power around the primary mechanism
without would with manual mode. through the secondary mechanism to ensure that

’
critical loads remain powered without interruption.
interruption. Automatic mode
Automatic mode involves the transfer switch Determine the right configuration
controller completely managing initiation and Transfer switches support multiple operation
operation, which can reduce delay time compared modes and transition types, and feature a range of
to manual and non-automatic mode. Initiation is different switching mechanisms. By understanding
triggered when the automatic controller senses an the configurations and choosing the right switch,
unavailability or loss of source power and opera- control engineers can help keep a facility running
tion typically is performed by an electric solenoid in the event of an outage or power loss, to help the
or motor. While this mode completes the trans- business’ bottom line. ce
fer in the shortest time and isn’t dependent upon
a human operator, automatic transfer switches Charlie Hume is Eaton product line manager, automat-
tend to cost more than devices that operate only in ic transfer switches; edited by Chris Vavra, production
manual or non-automatic mode. editor, Control Engineering, cvavra@cfemedia.com.

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2016-CE_NP4E_HalfHorizontal.indd 1 3/27/2017 4:14:46 PM

INSIDE PROCESS safety integrity

Safety integrity level

for a process application
Safety instrumented systems (SIS) are installed in process plants to mitigate process
hazards, and they must be assigned a target safety integrity level (SIL) during the pro-
cess to determine what needs to be done next.

S
afety instrumented systems (SIS) are Safety lifecycle
installed in process plants to miti- The IEC standards define a concept known as
gate process hazards by taking the the safety lifecycle, which provides a repeatable
process to a “safe state” when prede- framework whereby all process hazards are iden-
termined set points have been exceed- tified and analyzed to understand which haz-
ed or when safe operating conditions have been ards require the use of an SIS for mitigation. By
transgressed. design, this is a cyclical process. Any changes in
The SIS is one protection layer in a multi- process design, operating conditions, or equip-
layered safety approach since no single safety ment require cycling back to the beginning to
measure alone can eliminate risk. A layer of ensure any changes are implemented properly.
protection analysis (LOPA) is a method where- There are many steps to follow to determine
by all known process hazards and all known SIL. The process starts with performing a pro-
layers of protection are scrutinized closely. For cess hazard analysis (PHA).
each process hazard where a LOPA study con- A PHA is a systematic assessment of all
cludes that existing protection cannot reduce potential hazards associated with an industrial
risk to an acceptable or tolerable level, an SIS process. It is necessary to analyze all potential
is required. Not all process hazards will require causes and consequences of:
the use of an SIS. Each hazard that requires the
use of an SIS must be assigned a target safety  Fires
integrity level (SIL).  Explosions
 Releases of toxic, hazardous, or
What are SIL levels? flammable materials, etc.
SILs come from two voluntary standards MORE
used by plant owners/operators to quantify safe- Focus on anything that might impact the pro- ADVICE
ty performance requirements for hazardous cess including: KEY CONCEPTS
operations: Safety instrumented systems (SIS)
 Equipment failures are designed to mitigate process
 IEC 61508: Functional Safety of Electrical/  Instrumentation failures or calibration hazards by taking the process to a
“safe state.”
Electronic/Programmable Electronic Safe- issues
A process hazard analysis (PHA)
ty-Related Systems  Loss of utilities (power, cooling water, is used to determine a plant’s safety
 IEC 61511: Safety Instrumented Systems instrument air, etc.) integrity level (SIL)
for the Process Industry Sector.  Human errors or actions The overall failure probability of a
 External factors such as storms or given safety instrumented function
As defined in the International Electrotech- earthquakes. (SIF) is determined by performing SIL
nical Commission (IEC) standards, there are calculations (SIL calcs).
four SILs (1-4). A higher SIL means a greater Both the frequency and severity of each pro- GO ONLINE
process hazard and a higher level of protection cess hazard must be analyzed: Read this story online at
www.controleng.com and see ad-
required from the SIS. SIL is a function of hazard ditional stories from Cross Company
frequency and hazard severity. Hazards that can  How often could it happen? Tank spills in the “System Integration and Process
occur more frequently or that have more severe could happen any time there’s a manual fill Control” blog.
consequences will have higher SILs. operation (multiple times a year) CONSIDER THIS
To determine SIL of process hazards, it is  How severe is the result? Localized dam- What particular process plants
helpful to understand the safety lifecycle. age, fire, explosion, toxic gas release, death. benefit the most from SIL and why?

www.controleng.com CONTROL ENGINEERING JULY 2017 | P1

INSIDE PROCESS safety integrity

Safety lifecycle model

LOPA
PHA SRS
Conceptual Apply Non-SIS SIS Define
Process Hazard Develop Safety
Process Protection Layers to Required? Target
Analysis & Risk Requirement
Design Prevent Identified SIL
Assessment Specification
Hazards or Reduce Risk

SPECIFICATIONS

?
SIL CALCS
SIS Installation, SIS Start-up,
Perform SIS
Perform SIS Commissioning, Operation, Maintenance, Changes
Conceptual
Detail Design & Pre-Startup Periodic Functional
Design and Verify
SAT Testing
it Meets SRS

DESIGN INSTALL O&M

Example of a safety Core to the PHA analysis is the fact that For every process hazard identified in the PHA:
lifecycle model. Cour- things can and do go wrong. Forget whether it  List all available non-SIS safety measures
tesy: Cross Company, will happen and instead consider when it will  Assign each layer its own hazard risk
adapted from IEC 61511 happen. Each identified hazard is assigned an reduction factor
“acceptable” frequency. You cannot assume a  Calculate an effective hazard frequency
hazard will “never” happen. with protection layers applied.

 A hazard which necessitates basic First Aid Example: A tank fill operation that happens
intervention could be considered “accept- 250 times per year “could” experience an overfill
able” if it happens only once a year event 250 times per year.
 An explosion and fire due to a tank rup-
ture could have an “acceptable” frequency  A protection layer in the form of a proper
of once in 10,000 years. vent/drain system could reduce the danger
by a (risk reduction) factor of 100
The end result of the PHA is a list of all pos-  The hazard resulting from tank over-
sible process hazards with each one assigned an fill would have an effective frequency of
acceptable frequency of occurrence. The next 250/100 = 2.5 times per year.
step in the safety lifecycle is the layer of protec-
tion analysis. After the effective hazard frequency of each
No single safety measure alone can eliminate hazard is known, the key question to ask is:
risk. For this reason, an effective safety system “With non-SIS protection layers applied, is the
must consist of protective layers. effective frequency lower than the acceptable
This way if one protection layer fails, succes- frequency?”
sive layers will take the process to a safe state. As Once all process hazards are identified and
the number of protection layers and their reli- protection layers assigned, if the PHA/LOPA
abilities increase, the safety of the overall process study concludes that existing protection can-
increases. not reduce risk to an acceptable or tolerable
It is important to understand that each layer level, an SIS will be required. Not every pro-
must function independently from the others in cess hazard, however, actually requires the use
case one or more layers fails. of an SIS.
Some specific examples of protection layers
include: Safety instrumented systems, functions
The purpose of an SIS is to take a process
 Fire suppression systems to a “safe state” when predetermined set points
 Leak containment systems have been exceeded or when safe operating
(dikes or double walls) conditions have been transgressed.
 Pressure relief valves The role of the SIS is to reduce risk by
 Gas detection/warning systems. implementing safety instrumented functions
(SIFs).

P2 | JULY 2017 CONTROL ENGINEERING www.controleng.com

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input #18 at www.controleng.com/information

INSIDE PROCESS safety integrity

‘Each safety instrumented function serves as

a protection layer to bring the effective hazard

For the tank overfill example, the minimum
RRF is 25, the target SIL of the SIF is SIL1 and
this is, therefore, an SIL1 hazard.
For each hazard identified by the PHA
and LOPA that requires an SIF, a target SIL is
assigned using the same methodology. Note
frequency down below the acceptable that it is likely you will have various target SIL.
The next step in the process is to design an SIS

’
hazard frequency. capable of implementing the required SIFs and
reaching the target SIL.

Achievable SIL of the SIF

Two examples of SIFs include: The SIS is a system comprised of numerous
components such as:
 Hazard: Tank overfill. SIF: The SIS stops
the fill pumps at a predetermined safe level  Sensors for signal input
 Hazard: High temperature. SIF: The SIS  Input signal interfacing and processing
opens a relay to cut power to a heater cir-  Logic solver with power and
cuit at a predetermined safe temperature. communications
 Output signal processing, interfacing,
In any case, an SIF is a safety function imple- and power
mented by the SIS to achieve or maintain a safe  Actuators (valves, switching devices)
state. An SIF’s sensors, logic solver, and final ele- for final control function.
ments act in concert to detect a hazard and bring
the process to a safe state. An example SIF that consists of the SIS de-
Each SIF serves as a protection layer to bring energizing a relay to open a heater circuit upon
the effective hazard frequency down below the high temperature could have any or all of the fol-
acceptable hazard frequency. To do this, each SIF lowing loop components:
must have a minimum risk reduction factor.
 Thermocouple
Target SIL level of the SIF  Transmitter
With the tank overfill example, it was deter-  Input signal conditioner or barrier
mined that after applying non-SIS protection lay-  Analog input card
ers there was an effective frequency of 2.5 times  Communication card(s)
per year. If the acceptable hazard frequency is once  CPU
in 10 years, then the SIF must have a risk reduc-  Discrete output card
tion factor (RRF) of at least 25.  Output signal conditioner or barrier
 Heater circuit relay.
 Minimum RRF of SIF = Effective
frequency without SIS/Acceptable One must assume that a hazard will occur
frequency = 2.5/0.1 = 25. at some point. You cannot assume a hazard
 The minimum required RRF of each SIF is will never happen. Similarly, one must assume
used to determine the target SIL level that any of the components of the SIF could
of the SIF. fail to act upon demand.
One very common failure would be an iso-
Target SIL Level is determined directly from the lation valve that remains open under normal
RRF by using the table below. Note the relationship process conditions. If this valve is required to
between SIL and RRF. SIL1 has a minimum RRF of close to achieve a particular SIF, it is possible
101, SIL2 has a minimum RRF of 102, and so on. that the valve could stick in the open position
and not close upon demand. For this reason,
Table1: Required risk reduction factor (RRF) one must know the failure probability the SIF.
SIL Required risk reduction factor (RRF) The overall failure probability of a given SIF
is determined by performing SIL calculations
1 10 to 100 (101 to 102)
(SIL calcs). SIL calcs are somewhat complex,
2 100 to 1,000 (102 to 103) but essentially, the process is to gather failure
3 1,000 to 10,000 (103 to 104) rate data for the SIF components and account
for factors such as test frequency, redundancy,
4 10,000 to 100,000 (104 to 105)
voting arrangements, etc. The end result is that

P4 | JULY 2017 CONTROL ENGINEERING www.controleng.com

for each SIF, you have an overall probability of Table 2: Probability of failure on demand (PFD)
failure on demand (PFD). SIL PFD RRF
Failure rate data for the numerous pieces
1 1 in 10 - 1 in 100 10 to 100
of equipment that make up SIF loops are pub-
lished by equipment manufacturers. Compa- 2 1 in 100 - 1 in 1,000 100 to 1,000
nies frequently contract with consultants to 3 1 in 1,000 - 1 in 10,000 1,000 to 10,000
determine failure rate values.
It is failure rate data that is required as an 4 1 in 10,000 - 1 in 100,000 10,000 to 100,000

input to perform SIL calcs for an SIF, not SIL

data. There is no such thing as an SIL-rated or to purchase transmitters with lower published
device. You can’t buy SIL-rated transmitters or failure rates.
SIL-rated control systems. The relationship between SIL level, PFD,
Once the PFD of the SIF is known, then its and RRF is demonstrated in Table 2.
RRF is simply the inverse of PFD (RRF = 1/ Going back to the tank fill example, there
PFD). You can then compare the SIF’s RRF to was a minimum RRF of 25 (SIL1) with an SIF
the minimum required RRF. If the SIF’s RRF is RRF of 300. The achievable SIL level of the SIF
greater than the minimum RRF, then the SIF is SIL2. This means there’s an SIL2-capable SIF
is sufficient to reduce the overall hazard level being used to protect an SIL1 hazard. This is
below the acceptable level. perfectly acceptable and is not unusual. ce
Returning to our tank overfill example, let’s
assume the SIL calcs prove the SIF has an RRF
of 300. Since this is greater than 25, the SIF is David Yoset is a project manager with Cross
sufficient. If the SIL calcs had found an RRF of Company. This article originally appeared on
less than 25, then changing or rearranging the Cross Company’s Integrated Systems blog. Cross
SIF components would be necessary. Company is a CFE Media content partner. Edited
One way to increase the RRF is to install by Chris Vavra, production editor, Control Engi-
redundant transmitters in a voting arrangement neering, CFE Media, cvavra@cfemedia.com.

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input #19 at www.controleng.com/information

 INSIDE PROCESS overall equipment effectiveness

Three ways to increase

efficiency at a spirit
manufacturing plant
Spirit manufacturing plants can increase production and efficiency by setting realistic
expectations, simplifying their models, and having third-parties perform an overall equipment
effectiveness (OEE) analysis.

B
ottling is one of the biggest challeng- not just equipment—and compares your current
es in spirit manufacturing. For spirit operations to what your potential, ideal output
manufacturers, it’s not usually a ques- could be. For example, a simulation may deter-
tion of: “Can we make this product?” mine your equipment is capable of producing
but rather: “Can we get it into a bottle 1,000 bottles in a minute, but an OEE analysis
fast enough to fulfill all our orders?” can reveal how this will actually play out given
How you get your product into its bottle can your current processing and setup.
easily bottleneck your entire operation. If your A variety of factors can affect your plant’s
company is wondering why you’re experiencing efficiency, whether it’s cumbersome change-
inefficiency problems, you might want to look at overs or an unproductive number of meetings.
your equipment, bottle types, and/or overall pro- Simple revisions to your facility’s everyday
cessing lines. Consider these three tips for ramp- activities often can boost efficiency without the
ing up production and boosting efficiency. need to buy new equipment.

1. Set realistic expectations and 2. Consider switching from a

benchmarks with an overall equipment specialized bottle to a standard bottle
effectiveness (OEE) analysis One of the most unique elements of spirit
Processors sometimes question why their manufacturing is the packaging. When it comes
equipment is underperforming, asking, for to liquor, the bottles themselves often are elabo-
example, “We bought a machine that can pro- rate marketing tools.
duce 500 bottles a minute, so why won’t it?” Of However, producing a variety of SKUs means
course, the reason could involve a host of vari- packaging lines have to be designed to handle
ables, but it’s easy to first blame the machine. changeovers for a number of these specialized
MORE Though sometimes increasing throughput is bottles.
ADVICE a matter of buying more equipment, you have If you’re producing multiple products and
to establish realistic key performance indica- considering OEE, ask these questions:
KEY CONCEPTS
Set realistic expectations and
tors (KPIs) before you invest in new technology,
benchmarks with an overall equip- Don’t design for the impossible.  How fast are current changeovers?
ment effectiveness (OEE) analysis. Don’t expect that 500-bottles-per-minute  How many bottles actually stay on the line?
Consider switching from a special- machine to produce 500 bottles per minute if  How fast can the equipment function with a
ized bottle to a standard bottle. you haven’t looked at overall OEE. New equip- specialized bottle versus a standard bottle?
Have a third-party designer conduct ment alone won’t make up for problems in an
an OEE analysis. OEE. If efficient output is a concern, consider
GO ONLINE The first step in improving efficiency is switching to a standard bottle type. Designing
Read this story online at understanding your baseline and establishing a packaging line around a standard bottle will
www.controleng.com for more infor-
mation on spirit manufacturing and
realistic goals. One of the best ways to do that is decrease changeovers and make stocking eas-
overall equipment effectiveness. through an OEE analysis, which incorporates a ier. While marketing is crucial in spirit man-
virtual simulation to study your plant’s existing ufacturing, standardizing the bottle type may
CONSIDER THIS
What overall equipment effective- processes and packaging. be even more important if it’s the difference
ness are you getting from your most This type of analysis factors in all the vari- between inefficiency and an optimized, profit-
critical processes? ables that determine how your plant operates— maximizing throughput.

P6 | JULY 2017 CONTROL ENGINEERING www.controleng.com

INTRINSICALLY SAFE I/O...
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r Modular, compact design – 12 mm width
r Fieldbus Independent

www.wago.us/hazloc

input #20 at www.controleng.com/information

INSIDE PROCESS safety integrity

3. Have a third-party designer conduct

an OEE analysis
If you feel like you’ve hit a plateau in manu-
facturing, a third-party designer may help you
‘ Simple revisions to

your facility’s everyday

get your processing on track:
activities often can boost
 Start by understanding your equipment:
What are its capabilities? How old is it?
 Then analyze how your plant is operating: efficiency without the need
What’s going wrong? What’s being done

’
right? What are your output numbers? to buy new equipment.
You’ll need this information when research-
ing a partner for an OEE analysis, but how do These red flags usually are easy to spot,
you know if it’s worth your time? Here are some but many times they will go unaddressed or
basic signs that it’s time to call a designer: accepted as the norm. Spirit manufacturing
is a unique niche with unique needs. Before
 Lower than expected production rates approving the purchase of major equipment
from equipment or other significant changes, do your research
 Lower than expected plant production to understand where you should invest your
rates overall money to get the best ROI. ce
 Excessive changeovers
 A multitude of floor problems on Scott Baesler is a senior project manager at Stel-
the lines lar. This article originally appeared on Stellar Food
 Extensive bottle breakage for Thought. Stellar is a CFE Media content part-
 Extensive shutdowns ner. Edited by Jack Smith, content manager, Control
 Extensive downtime. Engineering, CFE Media, jsmith@cfemedia.com.

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input #21 at www.controleng.com/information
 CFE Media’s
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DIGITAL EDITION EXCLUSIVES

DE1 Specifying enclosures for machine vision systems
Machine vision enclosure manufacturers aim to better understand and meet their customers’ specific needs
for safe, fully integrated solutions, including solutions for use in harsh and dangerous conditions.

DE3 IT/OT convergence needs conflict resolution from both sides

Information technology (IT) and operations technology (OT) are very different organizations that have
begun to converge, and they must start resolving their issues. Three tips for reducing potential conflict are
highlighted.

ONLINE EXTRAS (Click on the headlines or search www.controleng.com.)

Digitization trends to leave large footprint on automotive industry

A rise in average vehicle life, shift in repair opportunities and sales outlets, and emerging online sales have all
created an opportunity for major growth in the automotive aftermarket industry that will likely continue to
grow in the future.

Industrie 4.0 and the smart services

Committing resources towards money and people for Industrie 4.0 will push manufacturers in the right
direction as smart services are put together based on users’ needs.

Mentoring creates a competitive advantage

Developing and maintaining a mentoring program within an organization can help grow the bottom line.

Robots’ role in the oil and gas industry

With operational costs cutting deep into profits, oil and gas companies are recently adopting automation
technology for more efficient and safer work.

A supportive foundation for Lean excellence

A company’s people-centric focus and its focus on Lean manufacturing has helped the company through
rough patches and has helped the company’s culture.

Eight steps to creating a continuous improvement team

Each member of a continuous improvement team should represent a function or process within the
company so everyone is included.

www.controleng.com CONTROL ENGINEERING JULY 2017 | 57

 DIGITAL EDITION exclusive

Specifying enclosures
for machine vision systems
Machine vision enclosure manufacturers aim to better understand and meet their
customers’ specific needs for safe, fully integrated solutions, including solutions for use
in harsh and dangerous conditions.

W
henever machine vision sys- some type of cleaning fluid in the spray,” McGeary
tems operate in a harsh envi- said. “[Today], companies with food processing
ronment, the systems require lines are selecting IP69K rating, and that will cover
an enclosure that protects the anything that they throw at it.”
investment within. However, The IP69K rating test method specifies a spray
an enclosure on an automotive inspection line nozzle dispensing 176 °F water at 1,160 to 1,450
will have different specifications and regulatory psi at a flow rate of 4 gallons per minute (GPM).
compliance requirements than an enclosure for The nozzle is placed within 4- to 6-in. of the tested
process monitoring in a corrosive environment device, which rotates once every 12 seconds.
like a petrochemical plant. With this in mind, APG modifies its off-the-shelf enclosures
machine vision enclosure manufacturers are lis- according to the needs of the application. “We’ve
tening closely to the specific needs of customers made enclosures with acrylic viewports, but it
as they relate to protective enclosures, and deliv- turns out that on some food lines, the chemical
ering solutions that are safe, robust, cost-effective, used in the cleaning process attacks the acrylic,
and fully-integrated. so you put in a polycarbonate window instead,”
McGeary said. “In some cases it might be a hot
Protection on the factory floor environment, so we need to add a provision for
A food and beverage manufacturing facility cooling in the enclosure.”
may be more hygienic than hazardous, but can In another instance, a food application oper-
still take a beating due to the high-temperature, ating amid potentially explosive gases or dust
high-pressure washdowns with harsh cleaners would require a custom product that includes an
needed to keep food-preparation areas safe. off-the-shelf explosion-proof housing as well as
MORE Machine vision enclosures for food process- a pressurization system that keeps positive pres-
ADVICE ing applications typically are made of type 316 sure within the enclosure.
KEY CONCEPTS stainless steel, which offers increased corrosion The “get tough” trend is also being adopt-
Machine vision enclosure compa- resistance and strength at elevated temperatures. ed by other manufacturing industries, such as
nies are trying to make their products The enclosures also must have food contact-rated automotive. Instead of choosing machine vision
safe and useful for customized ap- gaskets and must be designed to eliminate mois- enclosures that only meet the NEMA 12 stan-
plications and harsh conditions.
ture traps where liquids might collect. What’s dard for designs that keep dust and dripping
Thermal imaging, which is used
in remote condition monitoring and
more, enclosures must be built without glass since water at bay, customers are specifying IP65
process control of critical industrial it could shatter on impact, creating the risk of because it stands up to the pressure of a garden
assets, is a major field for enclosures. shards falling onto the food processing line. hose, McGeary said.
Companies are also developing Nearly all industrial enclosures are designed
enclosures for potentially explosive to an ingress protection (IP) rating. Enclosures The harsh and the hazardous
environments. in food preparation and packaging applications As a general rule, thermal imaging applica-
GO ONLINE require IP65, IP66, and IP66K ratings to with- tions can pose the greatest challenge to the engi-
Read this story online at stand water jets of increasing pressure. neers tasked with protecting sensitive machine
www.controleng.com for more infor-
mation about machine vision systems
Allison Park Group Inc. (APG) specializes in vision technology. “Most thermal cameras are
and enclosures. industrial enclosures for machine vision systems. inherently in rough industrial environments
According to APG president Chris McGeary, more with a lot of heat exposure, or they might be in
CONSIDER THIS
In what other dangerous or unsafe manufacturers are asking for even higher-rated hazardous locations requiring explosion-proof
environments could enclosures be enclosures. “Most food lines are sterilized regular- installations,” said Markus Tarin, president and
useful? ly with a high-temperature pressure washer with CEO of Movitherm.

DE1 | JULY 2017 CONTROL ENGINEERING www.controleng.com

 Thermal imaging is commonly used in system to ensure that hazardous particles or gases
remote condition monitoring and process con- have been eliminated from the enclosure.
trol of critical industrial assets where a tempera- “Customers can’t just buy an ex-proof enclo-
ture anomaly could signal a dangerous situation. sure and put their own camera in it,” Tarin said.
For example, infrared cameras can remotely “You need to be certified to integrate these
monitor flare stacks, which burn off gas waste things. The user is not allowed to ever open up
in harsh and hazardous industrial locations like that enclosure because as soon as they do, they
petroleum refineries and gas processing plants. lose the certification for that application.”
Thermal cameras also are exposed to a lot of To meet growing demand for condition mon-
heat in industries such as steel, requiring that itoring in explosion-hazard environments with
enclosures be cooled via air or liquid. extreme climate conditions, Automation Tech-
Because enclosures for thermal cameras have nology GmbH (AT) recently added several fea-
a unique set of operational requirements, Tarin

‘
said customers should use a turnkey machine
vision enclosure solution. “On the surface,
designing an enclosure seems fairly straightfor- Companies with food processing lines are
ward, but many people do not understand all
the technical intricacies required,” Tarin said. selecting IP69K rating, and that will cover
“It can be a daunting task to get the camera inte-

’
grated properly into an enclosure.”
Movitherm calibrates thermal cameras to anything that they throw at it.
account for transmission losses on the view-
ing glass, as well as performs thermal calcula-
tions to determine the correct type of cooling tures to its ex-proof enclosure. The product,
(and engineering those options in-house when which integrates an infrared camera, heater,
applicable). and interface controller and is ATEX certified,
On the other hand, some enclosures require a accommodates cameras with an extended oper-
heating element. “We have designed special high- ating temperature range of -40 to 60 °C. AT also
powered heating systems for applications in Alas- enlarged the protection window and added a
ka, where conditions can be below the camera’s sensor to measure the viewport’s temperature.
minimum operating temperature,” Tarin said.
“We’ve also done heaters to make sure the view- The complete package
ing glass doesn’t fog up or freeze over.” According to Tarin, buying trends in the
Thermal camera enclosure manufacturers enclosure sector act as a microcosm of how U.S.
often offer other add-ons appropriate to the customers currently specify their entire vision
application. These include a sunshield for enclo- system: They’re looking for a one-stop shop.
sures with direct exposure to sunlight, an auto- “They really don’t care about the individual
mated windshield wiper that cleans the viewing components so much as what the end solution
window of dust and debris, and an air barri- can do for them,” he said.
er surrounding the viewing glass that blows a Companies still care about cost and lead
steady stream of compressed air to prevent par- time, though. “We see customers who, if they
ticles from settling. can’t get something off-the-shelf, they would
rather not do it at all and wait it out for another
Explosion containment and prevention year or two to see if somebody comes up with
Thermal cameras operating in explosive atmo- something,” Tarin said. “They don’t want to pay
spheres represent another challenging area that a custom engineering charges for enclosure proj-
qualified integrator can help navigate. Industry ects. But they want a complete turnkey solution
standards and regulations such as Europe’s ATEX at an off-the-shelf price.” ce
directive and UL FM in the U.S. mandate that
equipment be designed to minimize the occur- Winn Hardin is contributing editor, AIA. This
rence and severity of accidental explosions. This article originally appeared on the AIA website.
can be accomplished with explosion-proof (“ex- The AIA is a part of the Association for Advanc-
proof ”) enclosures, which prevent any explosion ing Automation (A3). A3 is a CFE Media content
transmission from the inside of the protection partner. Edited by Chris Vavra, production editor,
system to the outside. Another method, explo- Control Engineering, CFE Media,
sion prevention, uses a purge and pressurization cvavra@cfemedia.com.

www.controleng.com CONTROL ENGINEERING JULY 2017 | DE2

 DIGITAL EDITION exclusive

IT/OT convergence
needs conflict resolution
from both sides
Information technology (IT) and operations technology (OT) are very different organizations
that have begun to converge and they must start resolving their issues. Three tips for reducing
potential conflict are highlighted.

I
nformation technology (IT) and operations Different viewpoints
technology (OT) are both responsible for IT and OT are very different worlds with very
resolving potential cybersecurity risks. How- different responsibilities. Fundamentally, IT secures
ever, both groups have different approaches data. An intentional or unintentional cyber threat
and mindsets on the topic that are incompat- could result in the loss of intellectual property, cor-
ible when they are brought together, which can porate financials, and employee or customer infor-
led to conflict. mation—and the ripple effect can be costly, ranging
Pre-internet, the line between IT and OT was from $200,000 to $4 million per incident.
clear. The line has been blurred as technology In contrast, OT uses ICS logic to execute con-
has brought connectivity to nearly every device trol processes, which produces a physical impact.
on the plant floor and in field locations. That A cyber threat could have devastating physical
enhanced connectivity is connecting IT and OT consequences to critical infrastructure and ser-
in new ways and, as a result, they are starting to vices, employees, human life, and safety and the
converge. environment—as has been shown in numerous
Instead of conflicting with one another, publicized incidents.
MORE which has been the standard mindset, they must
ADVICE start resolving their issues for their sake and the Different priorities
sake of the company as a whole. The different priorities of IT and OT are key
KEY CONCEPTS to understanding why conflicts arise so easily
Information technology (IT) and
operations technology (OT) have
Resisting convergence between the two groups. IT’s top priority is to
different goals and agenda, but they IT and OT are resisting convergence hap- protect the data. OT’s priority is to protect the
need to work together in today’s pening all around them, said Luigi De Ber- availability and integrity of the process, with
modern environment. nardini, chief executive of Autoware, a security (confidentiality) coming last.
IT’s main priority is protecting data manufacturing execution system (MES) and The security solutions each group might
and company assets and OT’s main smart manufacturing automation firm in Italy. choose for the ICS operations environment may
priority is making sure work processes
are not hampered or slowed. When working with clients in large manu- be different due to several variables such a reg-
Strategic alignment, a joint task facturing automation projects he found that, ulatory and compliance requirements, network
force, and pilot projects are three “Many manufacturers still see strong resistance architectures, performance/production require-
ways to get the two sides to work to- to bringing information and operational tech- ments, employee and environmental safety con-
gether and resolve potential conflicts. nologies together, with mistrust coming from siderations, risk tolerance, and management and
GO ONLINE both sides.” security goals.
Read this story online at www. De Bernardini said that must change. “Con- Each group has a bias and a specific per-
controleng.com for more information
about IT and OT and additional stories
tinuing to operate separately not only slows spective when considering ICS cyber risks and
from ISSSource. the adoption of solutions based on technolo- consequences.
gies that fall outside of industrial control sys-
CONSIDER THIS
What other methods/strategies tem (ICS) operations’ comfort zone, but also IT’s perspective
could be used to get the IT and OT to exposes companies to fault or security risks IT’s top priority is protecting data such
work together? that could significantly impact production.” as intellectual property, corporate financials,

DE3 | JULY 2017 CONTROL ENGINEERING www.controleng.com

employee, or customer private data. They figura-  Shared credentials are common on many
tively look across the demilitarized zone (DMZ) types of systems, new and legacy. This
thinking of the many changes that could bring allows users to quickly gain access with-
a stronger security posture to OT environments. out strong password hygiene and frequent
IT’s potential solutions include: password changes that are difficult to keep
everyone in sync.
 Stronger network segmentation
 Remote access is ideal for staff to connect
 Access control lists to restrict and manage from home or even vendors to connect
permissions and access to key resources from the internet to conduct maintenance
or diagnostics on equipment.
 Geographic or organizational groupings of
data and assets

 Strong password hygiene

 Routine patching processes (automated and

with much higher frequency)
‘ IT and OT each has a bias
and a specific perspective

 Security policies to apply everywhere. when considering ICS cyber

’
OT’s perspective risks and consequences.
OT’s top priorities revolve around availabil-
ity. When considering suggestions from IT to
secure ICS environments, OT will often invoke
cybersecurity inertia to assure control processes Protecting information is important, but pro-
and production yield are not placed at risk. Rea- duction losses translate into business losses.
sonable explanations for why ICS security can- Cyber threats that can disrupt production, cause
not be implemented are: damage, affect visibility and control, or jeopar-
dize safety also could affect business profitabil-
 Fragile programmable logic controllers ity. Changes by IT are not appropriate or allowed.
(PLCs) may not have enough memory to Further, OT is still skeptical of the real risk to
handle high traffic, such as a broadcast their ICS operations and control processes,
storm or unexpected function codes that believing the risks and consequences to be hype
cause a reboot. and rarities.

 Not all patches, even those released by Conflict resolution

ICS vendors, are required. It takes time to Rather than endure a major security breach
assess whether even the ICS-CERT adviso- that affects confidentiality or operations, com-
ries are appropriate for the devices in place. panies should consider these three actions to
reduce conflict and mistrust with IT and OT
 Anti-virus or automatic patching is atyp- convergence while increasing ICS security at the
ical and requires considerable testing, same time.
scheduling, and may even require ven-
dor participation to assure warranties stay 1. Get strategic alignment at the
intact. highest levels.
De Bernardini said most of his clients, “Still
 Flat network architectures are favored, have two strongly separated departments for
with minimal or no subnets or secure operations and IT. They have different people,
zones to isolate unrelated systems and goals, policies, and projects.”
processes. In this way, OT can minimize De Bernardini recommends starting with
performance latency that could disrupt time- reorganizing IT and OT departments to be
sensitive processes, and all resources are strategically aligned and unified. He suggests
easily available to operators should they at least the chief information officer (CIO)/
need to quickly pivot to manage another chief information security officer (CISO), and
set of systems and processes. chief operations officer (COO) should have,

www.controleng.com CONTROL ENGINEERING JULY 2017 | DE4

 DIGITAL EDITION exclusive

“Partly common and overlapping goals and targets,  A member of the physical security
which would force them to work cooperatively.” department.
The CIO/CISO must also accept complete
responsibility for the cybersecurity of the ICS and The task force should also consult: a site
for any safety incidents, reliability incidents, or management/facility superintendent, a control
equipment damage caused directly or indirectly by system vendor and/or a system integrator and
cyber incidents. the CIO/CISO.

3. Develop pilot projects

‘
and a governing structure.
Pilot projects offer value with a low-risk One of the first things the joint cybersecurity
task force can do is to identify pilot projects that
benchmark to help the company train and both groups can work on together. The task force
can compile a list of the most critical ICS assets
progressively build a specific mix of shared that absolutely must be secured and begin to
assess what needs to be done.

’
IT/OT skills. These pilot projects are designed to offer
value with a low-risk benchmark to help the
company train and progressively build a spe-
cific mix of shared IT/OT skills. This also will
2. Coordinate a joint task force. aid in determining how to jointly reduce con-
NIST SP800-82r2 (Industrial Control Systems flict when deciding on steps toward improving
Security Guide) and De Bernardini recommend ICS security.
creating a joint task force as a cross-functional De Bernardini said the joint cybersecurity
cybersecurity team to share varied domain knowl- team should have, “Joint governance and respon-
edge and experience to evaluate and mitigate risk sibility to execute projects, harmonize duplicated
to the ICS. NIST goes so far as to specifically name or overlapping systems and processes, and pro-
titles that should be a part of this cybersecurity mote the development of the interdisciplinary
task force, which should include: skills that are now missing in most companies.”

 A member of the IT staff Marathon, not a sprint

Mitigating the conflicts inherent in IT and
 A control engineer OT convergence and improving ICS security
doesn’t happen overnight.
 A control system operator Managers need to learn to share goals,
jointly evaluate business risks and consequenc-
 A network and system security expert es, and train the broader group on shared skills,
which will ultimately lead to appropriate ICS
 A member of the management staff security products, processes, policies, and
people.
The two collaborating and cooperating depart-
ments need to extend their skills to adapting the

25% of those taking the 2017

Control Engineering Salary and Career
IT security project models for use in operations
with consideration of all the differences inherent
in their security priorities and risk biases.
Survey said their level of understanding While there are many cultural and structural
for Industrial Internet of Things (IIoT) was challenges that come from bringing IT and OT
familiar and being incorporated into together, the long-term benefits far outweigh
any difficulties that might arise in the begin-
automation, controls, and other areas.
ning. ce

23% more said they had

heard of IIoT and are looking at how to Katherine Brocklehurst is with Belden’s Indus-
trial IT group. This article originally appeared on
incorporate it.
ISSSource.com. ISSSource is a CFE Media con-
www.controleng.com/ce-research
tent partner. Edited by Hannah Cox, content spe-
cialist, CFE Media, hcox@cfemedia.com.

DE5 | JULY 2017 CONTROL ENGINEERING www.controleng.com

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NEW PRODUCTS and software
See more New Products for Engineers at www.controleng.com/NP4E.

Piezo stages for 3-D positioning accuracy

Aerotech’s QNP3 series of XYZ piezo positioning
stages combine sub-nanometer resolution, high dynam-
ics, and geometric performance in a compact three-
degree-of-freedom (DoF) package. They come with a 40 x
40 mm clear aperture with closed-loop travels up to 100 x 100
x 10 µm. Their design is ideal for optical and scanning probe microscopy or other
inspection or manufacturing applications where two-sided part access is required
with three-DoF manipulation. QNP3 piezo stages use a parallel-kinematic flex-
ure and metrology design that ensure multi-axis accuracy, high stiffness, and long
device life. The drive design minimizes X and Y yaw errors while still maintaining
IoT edge device for an Abbe-compliant metrology system. Z-axis actuators and capacitive sensors are
monitoring, controlling designed to provide Abbe-compliant feedback in the vertical direction with mini-
real-world processes mal geometric errors. QNP3 stages are available with closed or open-loop feedback.
Sealevel Systems’ SeaConnect 370 Aerotech Inc., www.aerotech.com Input #202 at www.controleng.com/information
IoT edge device is designed to allow
users to monitor and control real-world
processes and trigger actions with Sea- Integrated hybrid servomotor
Cloud, a cloud-based, built-in event QuickSilver Controls’ Inc. SilverMax X34 NEMA 34
engine. It can be used in applications integrated hybrid servo includes an internal and exter-
such as asset management, data acqui- nal clamp, a 20A RMS, 40A peak driver operating from 12
sition, environmental monitoring. The to 72V. The SilverMax X-series includes expanded com-
SeaConnect 370 features two Form C mand and register space as well as several commands and
relays, four digital inputs (wet or dry modes of operation. An improved driver design provides
contact), two 12-bit A/D converters, a smooth motions over a wide speed range. The internal perma-
1-Wire bus interface and a microcon- nent magnet, high-pole count servo motor provides high effi-
troller unit. It also features an optional ciency and full power over a wide range of speeds. It has available torque up to 3200
demonstration kit for testing purpos- in-oz./22.5 Nm for direct drive applications such as medical devices and industrial
es. With integrated Wi-Fi capability, automation.
the SeaConnect 370 also can be config- QuickSilver Controls Inc., www.quicksilvercontrols.com
ured with a cellular modem. For appli- Input #204 at www.controleng.com/information
cations where geolocation is required,
the SeaConnect 370 is available with an
optional cellular and GPS module. Motor series for positioning and velocity control
Sealevel Systems, www.sealevel.com Suited for scanning, pointing, measuring, and cutting,
Input #203 at www.controleng.com/information applications that require smooth velocity control and accurate
positioning, the Agility series is designed to deliver torque rip-
ple and zero cogging. Engineered with ZeroCog slotless motor
technology, the effects of cogging torque, magnetic forces, flux
harmonics, and phase balance and alignment are minimized
to counteract the causes of torque ripple. The Agility series is
offered in a wide range of low-profile form factors with a large
through hole for convenient routing of cables, optics, sensing,
technologies, and other system elements. Models are available
in diameters from 12 to 300 mm, and with peak torques up to 41 Nm. All models are
compatible with a wide range of controllers and drives.
Celera Motion, www.celeramotion.com Input #205 at www.controleng.com/information

Permanent magnet motor with integrated speed control electronics

CI Takiron’s family of 12 mm OD micro slotless brushless permanent magnet (PM) motors are used in a wide range of appli-
cations such as battery-operated handheld power tools, miniature compressors, micropumps, and small robots. This four-mem-
ber motor family provides stall or peak torque values ranging from 0.88 mNm (0.125 oz-in) to 1.14 mNm (0.161 oz-in). The
C12C-XI-S and C12C-X2-S models use sleeve bearings and operate at 6480 and 7920 rpm, respectively. The ball bearing models,
C12C-X2-S-B and C12C-X2-S, are used in applications that handle heavier application mechanical loads. All CI Takiron models
have low current consumption (below 25 ma). The speed constant varies from 2.14 to 2.16 Krpm/volt for the C12C-XI models
and 2.60 to 2.64 Krpm/volt for the C12C-X2 models. All four motors are energized at a low output of 3 volts dc.
CI Takiron, www.takiron.co.jp/english Input #206 at www.controleng.com/information

www.controleng.com CONTROL ENGINEERING JULY 2017 | 59

NEW PRODUCTS and software
See more New Products for Engineers at www.controleng.com/NP4E.

Real-time SCADA solution for OT, IT applications

Honeywell Process Solutions’ (HPS) Experion Elevate is a real-time process supervisory control
and data acquisition (SCADA) solution delivered as a secure and scalable service. Experion Elevate
allows for predictable costs, easy upgrades, and continual support. It is a member of Honeywell’s suite
of cloud-enabled solutions for operations technology and information technology (OT/IT). Experion
Elevate is designed to allow industrial organizations to leverage operational expenditures over capital
expenditures wherever possible. It also is designed to provide flexible and scalable SCADA options
that are suitable for different operations. Experion Elevate provides a scalable, integrated multi-ser-
vice system with a human-machine interface.
Honeywell Process Solutions (HPS), www.honeywellprocess.com Input #207 at www.controleng.com/information

Power supply series with industrial, medical safety approvals

XP Power’s UCP225 series of 225 W ac/dc power supplies feature industrial and medical safety
approvals in a small U-channel footprint. Seven single output voltage models are available rang-
ing from 12 to 48 V dc, providing a wide variety of output voltage options to meet specific appli-
cations. The supplies provide up to 225 W of force-cooled or 150 W of convection-cooled power
leading to very high power densities of 12.2W/in3 or 8.1W/in3. Operating temperature range when
convection cooled is from -40 to 70 °C with full power available to 50 °C, making the product suit-
able for a wide range of applications. An additional 12 V dc, 500 mA fan supply is featured with
all models to support force-cooled applications. The power supply contains two fuses for both line
and neutral and has low leakage current as required by medical applications.
XP Power, www.xppower.comInput #208 at www.controleng.com/information

Extensometer for industrial and Miniaturized MEMS accelerometer

equipment safety applications TDK Corporation’s Tronics AXO215 microelectrome-
Vishay Precision Group’s Model 182 chanical system (MEMS) is designed to provide acceleration
extensometer is a strain gage-based force sensing performance for demanding applications such as pre-
sensor that is designed for industrial, cision instrumentation, unmanned vehicles, and avionics. The
EN15000 and EN280 compliant off-high- AXO215’s closed-loop configuration provides non-linearity
way vehicle and equipment safety appli- that is less than 0.05%. Additionally, the hermetic J-lead pack-
cations. The Model 182 extensometer age (12 x 12 mm) ensures reliable performance levels in harsh
accurately measures deformation, or changes environments, while decoupling the mechanical stresses from
in the length of a solid structural body, with the host system. Providing an in-plane linear accel-
a 500 μ full-scale sensing range and nec- eration measurement, the AXO215 has an input
essary redundancy for EN15000 and EN280 range of 15 g with ultra-low noise of 15
compliance in safety applications. Its design consists of µg/√Hz. The 24-bit digital output is
a high-quality strain gage-sensing element, housed in a delivered with a bias instability of
highly corrosion resistant coated alloy steel, with mount- just 3 µg and an operating vibration
ing via two bolt holes. resistance of 7.3 grms.
Vishay Precision Group, www.vpgsensors.com TDK Corp., www.tdk.com
Input #209 at www.controleng.com/information Input #210 at www.controleng.com/information

HMI for monitoring, controlling machine components

Mitsubishi Electric Automation’s GT2107 wide series human-machine interface (HMI) is
designed to monitor and control machine components with a graphical touchscreen that con-
nects to equipment such as programmable logic controllers, variable frequency drives, and ser-
vos. This compact HMI features a 7-in. wide display with 800 x 480 resolution for clear image
quality and is equipped with a remote connectivity option with an optional VNC server. The
VNC server is designed to provide remote access to the HMI and connected equipment, allow-
ing users to operate the system using tablets or personal computers to view data in real time.
The GT2107 also offers predictive maintenance information, giving plant managers the oppor-
tunity to proactively plan and manage equipment maintenance.
Mitsubishi Electric Automation Inc., http://us.mitsubishielectric.com/fa/en
Input #211 at www.controleng.com/information

60 | JULY 2017 CONTROL ENGINEERING www.controleng.com

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ce2014_digitlEditn_6th.indd 1 2/24/2014 11:44:33 AM

www.controleng.com CONTROL ENGINEERING JULY 2017 | 61
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www.controleng.com CONTROL ENGINEERING JULY 2017 | 63
 BACK TO BASICS worker safety

Seven ways to integrate

worker health and safety
Because of the great effect they have on each other, worker health and safety should be
integrated rather than regulated separately for the benefit of the company and its employees.

W When two functions are so funda-

mentally connected to the condition of employ-
ees and the bottom line, how can they be
motivated to collaborate?
A majority of companies maintain separate
health and safety functions—one dedicated to
employees’ well-being and another committed to
their protection. These silos have been tradition-
2. Make a commitment. Ensure health and
safety activities are key contributors to an orga-
nization’s value system, not just a cost of doing
business.
3. Present the business case. Express value
in terms that senior executives understand.
They intuitively know healthy workers are more
productive, but may need empirical evidence to
ally kept apart because of the specific expertise justify investments.

‘
and processes required in 4. Create an overarching management
Support a culture of each area. In addition, the structure. Create lines of authority and report-
U.S. regulatory environ- ing processes to encourage effective com-
continuous learning; ment reinforces the sepa- munications among all parties. While senior
ration. Occupational Safety executives may have competing priorities, a col-
gain insights from leading & Health Administration laborative structure helps open up the lines of
(OSHA) oversees working communication from bottom up to top down, as
behaviors and conditions conditions with no corre- well as across departments and functions.
sponding regulatory role 5. Prepare for a new profession. Redefine
and lagging indicators, for worker health. professional roles and responsibilities to better

’
The truth is, these two meet current business, health, and safety man-
such as accidents. departments are intrinsi- agement needs and trends.
cally linked: unsafe work- 6. Support a culture of continuous learn-
ing conditions can affect employee health while ing. Learn from behaviors and conditions that
unhealthy employees are a safety risk at work. create risk (leading indicators), not just past
Integrating these two functions can improve accidents (lagging indicators). This continu-
effectiveness and reduce costs. The Integrated um of insights helps employees and employers
Benefits Institute found poor employee health actively identify threats.
MORE costs the U.S. economy $576 billion per year. 7. Get everyone involved. From participa-
ADVICE More than 313 million workplace accidents tion in health and wellness initiatives to the for-
annually occur around the world, according to mation of reporting and learning teams, involve
KEY CONCEPTS the International Labor Organization. Acci- the entire organization in order to foster a cul-
Worker health and safety are dents cost employers an estimated $2.2 tril- ture of health and safety.
intrinsically linked to one another and
should be integrated by companies. lion worldwide and result in more than 2.3 While organizations may face challenges
Companies need to be committed to million deaths per year. When two functions integrating their health and safety departments,
this plan and get everyone involved. are so fundamentally connected to the condi- the benefits of unifying the two functions are
Integrating health and safety helps tion of employees and the bottom line, how can clear. Coordinated health and safety programs
uncover risks and promotes a culture they be convinced to collaborate? UL brought create greater transparency for uncovering risks
of prevention and well-being for together dozens of thought leaders to answer and promote a culture of prevention and well-
workers.
this question. The group identified seven being, benefiting both organizations and their
GO ONLINE actions organizations should take to integrate employees. ce
Read this article online at workplace health and safety.
www.controleng.com and see ad-
ditional stories from ISSSource. 1. Use a holistic approach. Treat health Mark Ward is the general manager for UL-EHS
and safety as one function by designing initia- sustainability. This article originally appeared on
CONSIDER THIS
What other actions can companies
tives—from wellness programs to reporting pro- ISSSource.com. ISSSource is a CFE Media con-
take to integrate workplace health cesses—that incorporate health protection and tent partner. Edited by Carly Marchal, content
and safety? health promotion. specialist, CFE Media, cmarchal@cfemedia.com.

64 | JULY 2017 CONTROL ENGINEERING www.controleng.com

 READY FOR THE
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