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input #1 at www.controleng.com/information
Make the Invisible Visible
With the most advanced 2D and 3D HMI/SCADA
technology, ICONICS introduces its Holographic Watch our HoloLens
Machine Interface (HMI), enabling users to webcast to learn more
make the invisible visible and experience a new www.iconics.com/HoloLensWebcast
dimension in augmented reality for manufacturing.

VISUALIZE ANALYZE MOBILIZE CLOUD

Celebrating 30 Years of Automation Software

© 2017 ICONICS, Inc. All rights reserved.

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

Vol. 64
Number 8

Features 24
COVER: Cloud-connected automotive welding
robots (above) help realize the vision of Industrie
4.0 by self monitoring. Courtesy: Robotic Indus-
24 Readying robots and workforce tries Association (RIA)/Fanuc America Corp.
for Industrie 4.0 Inset (left): Demonstration shows how workers

Cover Story: Industrie 4.0 is not a distant factory of the 35 with augmented reality (AR) connect with service
for instructions. Courtesy: Iconics
future. Networks of robots are sending data to the cloud and
contributing insights to simplify asset management and maintenance,
maximize equipment and process efficiency, and improve quality.

31 Robotic integration: easier, preconfigured,

flexible, easier programming
Cover Story: Robots are easier to integrate into other systems. Precon-
figuration, greater flexibility, and best-practices in programming help.

32 IIoT-equipped mobile, snake-like robot

Cover Story: Robots-as-a-service are seen as suitable for inspection,
surveillance, and non-destructive testing.

35 Augmented reality for control applications

Manufacturers in factories, buildings, and process control applications
42
are using augmented reality, including with robotics.

37 When to use open- or closed-loop control

Control designs vary depending on need. Here’s how to decide.

38 Open- vs. closed-loop control in fluid power

Fluid power applications are complex; discern which design to use.

41 Choosing open- or closed-loop control

Closing the control loop provides insight into process behavior.

42 Guidelines for closed-loop control

Which factors should be considered to select a control design?

45 How to choose open- or closed-loop control 50

Application examples help explain which, why, and how.

46 Cybersecurity for pipelines, SCADA systems CONTROL ENGINEERING (ISSN 0010-8049, Vol. 64, No. 8, GST #123397457) is published
12x per year, Monthly by CFE Media, LLC, 3010 Highland Parkway, Suite #325 Downers
It’s critical to stay update cybersecurity measures to improve defenses. Grove, IL 60515. 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. Peri-
50 What’s next for motor efficiency? odicals postage paid at Downers Grove, IL 60515 and additional mailing offices. Circulation
records are maintained at 3010 Highland Parkway, Suite #325 Downers Grove, IL 60515. Tele-
Standards efforts shift from motor efficiency to power use; attention to phone: 630/571-4070. E-mail: customerservice@cfemedia.com. Postmaster: send address
the system in the application is very important when optimizing energy changes to CONTROL ENGINEERING, 3010 Highland Parkway, Suite #325 Downers Grove,
IL 60515. Publications Mail Agreement No. 40685520. Return undeliverable Canadian
use, according to NEMA Motor Generator Section representatives. addresses to: 3010 Highland Parkway, Suite #325 Downers Grove, IL 60515. Email:
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USA, $ 150/yr; Canada/Mexico, $180/yr (includes 7% GST, GST#123397457); International air
Digital Edition Exclusives delivery $325/yr. Except for special issues where price changes are indicated, single copies
are available for $30.00 US and $35.00 foreign. Please address all subscription mail to CON-
TROL ENGINEERING, 3010 Highland Parkway, Suite #325 Downers Grove, IL 60515. Printed in
 Five questions to understand data that drives business performance. the 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-
 Maximize a control system’s lifecycle. less of whether such errors result from negligence, accident or any other cause whatsoever.

2 | AUGUST 2017 CONTROL ENGINEERING www.controleng.com

How Smart Factories Are
Getting Connected

Sometimes the best way to learn is to see how others are doing it. We have
helped many customers in their transition to a smart factory, and now we want
to share some of those stories with you. Visit our smart factory portal to see
what worked for different customers, such as a semiconductor manufacturer
that needed real-time dry pump monitoring, or a leading cosmetic company
that wanted to improve production efficiency measurement.

Learn more at www.moxa.com/smartfactory.

 Ensure a Safe Pass With Your HART Data

When it comes to HART data, the SSX/SST

Functional Safety Isolators and Splitters are game
changers by passing on valuable HART data from
your safety loops to your basic process control
system or monitoring system.

Unlike other isolators, the SSX and SST allow

critical HART diagnostic, process and calibration
information to pass through from field transmitters
to HART enabled host systems and vice-versa. 2014
They also serve as “blockers” to protect and isolate
your Safety Instrumented System from inadvertent
disconnections or failures in your auxiliary control
or monitoring system. FINALISTS

Seize the opportunity to access valuable HART data for

your Safety Instrumented Systems with the SSX/SST Safety
Isolators and Splitters.

Call Us at 800-999-2900!

input #3 at www.controleng.com/information Demand Moore Reliability

Visit our website and learn more about our SSX and SST
HART Functional Safety Series Isolators and Splitter
www.miinet.com/ssxsst
 AUGUST 2017

Vol. 64
Number 8

Inside Machines
Appears after page 53; Also, see the Digital Edition:
www.controleng.com/DigitalEdition

M1 Robots resolve
assembly line production challenges
An electronics manufacturer with double-digit product rejection
rates used a collaborative robot that was controlled and monitored
in a cloud-connected system to handle soldering, drilling, silicone
dispensing, and light assembly. This helped rejects fall to near zero
and increased production efficiency almost fivefold.

M7 CNCs in the digital factory

Computer numerical controls (CNCs) are playing a larger role in the
digital factory and are able to make programming easier, reduce M1
downtime, and provide users with more options and flexibility.

Departments
8 Think Again
Control Engineering career assistance

10 New Products for Engineers

Wireless flow transmitter with internet connection; Motion
Products
controller for testing, manufacturing applications 85 High-temperature silicon-

12 Technology Update controlled rectifier (SCR) thyris-

Reducing alert load via data analytics tors (right); Terminal blocks with

16 Research clamps (above)

5 motor drive survey findings

18 Control Engineering International

Moving to a wireless remote monitoring system
86 Fanless module for
88 Back to Basics
Managing common ERP risk factors smart devices; Capacitive ac-
celerometer (below); PC-pro-
grammable Modbus tempera-
News ture transmitter (right)

20 Robots learn to see, interpret 3-D objects like humans;

Improve safety in robotic welding.

22 Hidden figures no more; Infor names AI platform for NASA

mathematics pioneer; Electrical service group leaders

23 Benefits of testing a three-phase electric motor;

online headlines and hot topics

www.controleng.com CONTROL ENGINEERING AUGUST 2017 | 5

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

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

Robotic device designed to detect tiny On-demand

leaks in pipes webcasts:
There’s a lot more to read Couldn’t catch a
online. Go to recent webcast? See
www.controleng.com/news it on-demand at
Webcasts
to read Control Engineering’s www.controleng.com/webcasts.
exclusive Web content.
 July 27: ERP with mobility energizes
field services and plant-floor
 How the connected customer is
execution
changing manufacturing
 June 13: Leave My Things Alone –
 Security a major priority for Getting Ready for IIoT
Industrie 4.0
 June 8: IIoT Webcast Two: Sensing
 Machine vision’s benefits for the smart factory and control at the edge: Microcon-
troller kits
 IIoT and the rise of the cobots.
 May 25: Cloud ERP Streamlines
Operations in an Era of IIoT Data

Control Engineering provides unique automation research: See more on the

Oil & Gas Engineering
motor drives survey in this issue. Read other research summaries and sign up to
August issue
download the full reports at www.controleng.com/ce-research.
Oil & Gas Engineer-
ing August issue in-
cludes the following:
3-D chip developed for combined computing  Contextual mobility
and data storage declutters on-the-go
Keep up with the latest industry news by SCADA
 Custom UPS soft
subscribing to Control Engineering’s
ware empowers
16 newsletters at more secure pipe-
www.controleng.com/newsletters: line control

 Advice from integrators on HMIs, wireless,  Product of the Year

cloud use, thin clients finalists
 News: U.S. remains the world’s top pro-
 Get integrated human-machine interface
ducer of petroleum; Mobile app field-
hardware, software; cautions enables “iron” asset management.
 Video use in data collection rising, according Learn more at
to survey. www.oilandgaseng.com.

Point, click, watch Digital Edition

GAMS 2016: The tablet and digital
Cloud-Based Manufac- editions of this publica-
tion have unique content
turing: Who Will Rule
for our digital subscribers.
the Clouds? See digital exclusives on:
The 2016 Global Automation Five questions to under-
and Manufacturing Summit (GAMS), presented by CFE Media, brought stand data that drives
together experts from all areas of the Industrial Internet of Things (lloT) to business performance;
look at the current state of lloT and the potential benefits of deployment for Maximizing a control
the manufacturing industry. system’s lifecycle.
www.controleng.com

www.youtube.com/user/controlengineeringtv.

6 | AUGUST 2017 CONTROL ENGINEERING www.controleng.com

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

Find This & More

thinkallied.com •1.800.433.5700

© Allied Electronics, Inc 2017.

input #4 at www.controleng.com/information
THINK AGAIN career relevancy
3010 Highland Parkway, Suite 325, Downers Grove,
IL 60515. 630-571-4070, Fax 630-214-4504

Control Engineering Content Specialists/Editorial

Mark T. Hoske, Content Manager
847-830-3215, MHoske@CFEMedia.com

career assistance
Jack Smith, Content Manager
630-907-1622, JSmith@CFEMedia.com
Kevin Parker, Senior Contributing Editor, IIoT, OGE
630-890-9682, KParker@CFEMedia.com
Control Engineering’s purpose is to help subscribers globally to do their Emily Guenther, Associate Content Manager
630-571-4070 x2220, eguenther@cfemedia.com
eguenther@cfemedia.com
jobs better and accelerate their careers; CFE Media and CFE Technol- Amanda Pelliccione, Director of Research
978-302-3463, APelliccione@CFEMedia.com
ogy help. See resources for automation, controls, and instrumentation.

C
Joy Chang, Digital Project Manager
630-571-4070 x2225, JChang@CFEMedia.com
JChang@CFEMedia.com
Chris Vavra, Production Editor
630-571-4070 x2219, CVavra@CFEMedia.com
CVavra@CFEMedia.com
Control Engineering helps those remote-controlled animals, offer engineering Contributing Content Specialists
with interests in automation, controls, and inspiration for science, technology, engineer- Frank J. Bartos, P.E., braunbart@sbcglobal.net
instrumentation to be more effective in the ing, and math careers. Knowledge transfer to Peter Welander, PWelander@CFEMedia.com
workplace and stay relevant in and accelerate and from both of these helps Festo innovate Vance VanDoren, Ph.D., P.E., controleng@msn.com
Suzanne Gill, Control Engineering Europe
their careers. present and future motion control offerings. suzanne.gill@imlgroup.co.uk
Control Engineering coverage includes The Festo Motion Terminal, introduced at Ekaterina Kosareva, Control Engineering Russia
ekaterina.kosareva@fsmedia.ru
print, digital editions (with exclusive content), Hannover Fair 2017, brings advanced control,
Wojciech Stasiak, Control Engineering Poland
online (with more content than will fit in print software apps, and variable pneumatic valves wojciech.stasiak@trademedia.us
and articles, often with more detail and imag- (adapted from Festo Bionic ants) to replace 50 Lukáš Smelík, Control Engineering Czech Republic
lukas.smelik@trademedia.us
es), topical newsletters, webcasts, targeted dig- hardware combinations in one unit. Soft stop,
Aileen Jin, Control Engineering China
ital reports, five international editions, social proportional-integral-derivative (PID), and aileenjin@cechina.cn
media, and Editorial Advisory Board contri- robotic control capabilities were demonstrated Publication Services
butions. CFE Media resources include Con- at the Festo International Press Conference in Jim Langhenry, Co-Founder/Publisher, CFE Media
sulting-Specifying Engineer, Plant Engineering, July. See Festo’s pneumatic collaborative robot 630-571-4070, x2203; JLanghenry@CFEMedia.com
JLanghenry@CFEMedia.com
Steve Rourke, Co-Founder, CFE Media
IIoT for Engineers, Oil & Gas Engineering, CFE in videos and photos with this article online. 630-571-4070, x2204, SRourke@CFEMedia.com
SRourke@CFEMedia.com
Media Research, and Marketing to Engineers, Trudy Kelly, Executive Assistant,
and by CFE Technology platforms, including Process education centers 630-571-4070, x2205, TKelly@CFEMedia.com

Global System Integrator Database, New Prod- Ten process education centers at Elena Moeller-Younger, Marketing Manager
773-815-3795, EMYounger@CFEMedia.com
ucts for Engineers Database, CFE Edu educa- Endress+Hauser facilities provide training ses- Kristen Nimmo, Marketing Manager
tional platform, Content Partner program, and sions for process control engineers and tech- 630-571-4070, x2215, KNimmo@CFEMedia.com
KNimmo@CFEMedia.com
ContentStream products. nicians, while demonstrating capabilities of Brian Gross, Marketing Consultant, Global SI Database
630-571-4070, x2217, BGross@CFEMedia.com
Surveys about Control Engineering cover- products from Endress+Hauser and its part-
Michael Smith, Creative Director
age show our audience appreciates advertising ners. At its Process Training Unit in Green- 630-779-8910, MSmith@CFEMedia.com
(see education section in this issue) as much wood, Ind., Endress+Hauser’s expanding U.S. Paul Brouch, Director of Operations
630-571-4070, x2208, PBrouch@CFEMedia.com
PBrouch@CFEMedia.com
as editorial coverage. Recent other educational headquarters, 120 measurements can be taken
Michael Rotz, Print Production Manager
efforts are worthy of mention. at the two-story atrium-styled facility, with an 717-766-0211 x4207, Fax: 717-506-7238
If that seems like a lot, it is; CFE Media adjacent control room that most engineers mike.rotz@frycomm.com

moved to larger headquarters in Downers would welcome as part of their workplace. See Maria Bartell, Account Director, Infogroup Targeting Solutions
847-378-2275, maria.bartell@infogroup.com
Grove, Ill., in July. additional explanations and photos online. Rick Ellis, Audience Management Director
303-246-1250, REllis@CFEMedia.com

Technology training, inspiration Training: PLC programming Letters to the editor: Please e-mail us your opinions to
MHoske@CFEMedia.com or fax 630-214-4504. Letters should
Five automated manufacturing technol- Part 2 of the 5-part programmable logic include name, company, and address, and may be edited.
ogy educational modules by Festo Didactic controller (PLC) training series at CFE Edu Information: For a Media Kit or Editorial Calendar,
email Trudy Kelly at TKelly@CFEMedia.com.
help teach those interested in automation and from CFE Media began in July, covering how
Marketing consultants: See ad index.
motion control. Nature-inspired motion con- the PLC CPU works, PLC scanning, address- Custom reprints, electronic: Brett Petillo
trol demonstrations from Festo Bionic Learn- ing, and different PLC programming methods. Wright’s Media, 281-419-5725, bpetillo@wrightsmedia.com
ing Network, often mechatronic robotic or
Help others think again if they believe engi- Editorial Advisory Board www.controleng.com/EAB
MORE Doug Bell, president, InterConnecting Automation,
neering education ends when university, col-
ADVICE lege, and trade school degrees arrive. Those
www.interconnectingautomation.com
David Bishop, president and a founder
GO ONLINE Matrix Technologies, www.matrixti.com
with engineering responsibilities learn daily. ce Daniel E. Capano, president, Diversified Technical Services Inc.
More info, educational photos, links to educational of Stamford, CT, www.linkedin.com/in/daniel-capano-7b886bb0
areas mentioned, and the annual career and salary Frank Lamb, founder and owner
survey are with this article online. Automation Consulting LLC, www.automationllc.com
Search the headline at www.controleng.com, or, in Joe Martin, president and founder
Martin Control Systems, www.martincsi.com
the digital edition, click on the headline to go to the Mark T. Hoske, Content Manager
Rick Pierro, president and co-founder
online version with instant access to more education. MHoske@CFEMedia.com Superior Controls, www.superiorcontrols.com
Mark Voigtmann, partner, automation practice lead
Faegre Baker Daniels, www.FaegreBD.com
8 | AUGUST 2017 CONTROL ENGINEERING www.controleng.com
APPLICATION NOTE

Why you should add

motor analysis to your
maintenance routine

Four keys to understanding

motor efficiency, and causes
for failures

Electric motors transfer electrical power to

mechanical rotational forces that are the muscle
of the industrial world. Measuring and analyz-
ing those forces—mechanical power, torque and
speed—as well as power quality characteris-
tics are important to assessing performance of
rotating equipment. These measurements can
not only help predict failure and thus help avert
downtime, they can also help quickly determine
whether additional inspections, such as vibration
testing, shaft alignment analysis or insulation
testing, are needed to corroborate the findings.

Traditionally, obtaining accurate motor analysis

data required costly equipment shutdowns to
allow for the installation of mechanical sensors.
Not only can it be extremely difficult (and some-
times impossible) to properly install mechanical
sensors, the sensors themselves are often cost
prohibitive and introduce variables that decrease
overall system efficiency.

Modern motor analysis tools make it easier than

ever to troubleshoot direct on-line electric motors
by significantly simplifying the process and
reducing the number of components and tools
necessary to make critical maintenance decisions.
For instance, the new Fluke 438-II Power Qual-
ity and Motor Analyzer enables technicians to
discover electrical and mechanical performance
of electric motors, and evaluate power quality by
measuring the three-phase input to the motor,
without mechanical sensors.

input #5 at www.controleng.com/information
NEW PRODUCTS FOR ENGINEERS www.controleng.com/NP4E

Wireless flow transmitter with internet connection

DGet flow data anywhere with an internet connection with an intrinsically safe, wireless flow
transmitter from AW-Lake Co. and SignalFire Wireless Telemetry.

A
AW-Lake Co. and Signal-
Fire Wireless Telemetry have col-
laborated on an Intrinsically Safe
Wireless Flow Transmitter that
wirelessly forwards flow data any-
where in the world with an inter-
Ideal for applications with a limit-
ed power source or no power at all,
the SFS-WP Intrinsically Safe Wire-
less Flow Transmitter incorporates an
internal high-capacity lithium bat-
tery that powers the passive induc-
net connection. tive flow sensor and radio node for
Integrating AW-Lake’s TRG years, even in low temperatures.
turbine or JV-CG or JV-KG positive dis- The flow transmitter can be configured
placement flowmeter with a SignalFire for check-in intervals between five seconds
Sentinel radio node, this innovative to one hour to save battery life. Flow rate
new wireless flowmeter works in a and total data configurations are available.
mesh network to send data via Mod- Eliminating the need for expensive
bus to a gateway where it is transferred cabling, the Wireless Flow Transmitter installs anywhere in
to a PC, PLC, or other control system. minutes with an easy thread-installation. Units cost less than
The wireless radio nodes install themselves automatically running 60 ft of conduit. Featuring an intrinsically safe design,
in the network and adapt to changes, such as data volume, units operate in hazardous areas where hostile or volatile mate-
radio transmission conditions, and power source conditions. rials and liquids exist. ce
Industrial, scientific, and medical bands sustain radio signal SignalFire
strength through terrain, structures, or weather for a range of www.signalfire.com
up to a half mile. Input #200 at www.controleng.com/information

Motion controller for testing, manufacturing

applications
More base modules and power supply options
are available for the RMC200 motion controller
from Delta Computer Systems.

D
Delta Computer Systems Inc. announced
more base modules and power supply options for its RMC200
motion controller to serve larger manufacturing processes and
multi-function testing equipment. The B11 and B15 base mod-
ules support applications from 13 to 32 axes in user-defined
increments, and the new 56-Watt PS6D power supply can han-
axes) and the RMC150 (can control up to eight axes). Delta
RMCs have special capabilities for synchronizing the motion
of multiple axes, enabling the construction of machines with
scalable performance and quick production changeovers. And
all Delta controllers can provide built-in dual loop support
for controlling pressure, force, and torque, as well as position,
dle any possible configuration. These products supplement velocity, and acceleration. The controller can transition effort-
Delta’s previously-announced B7 base module and 35-Watt lessly between these control modes, enabling smooth, reliable
PS4D power supply. motion. ce
“Our customers love the capabilities and ease-of-use of our Delta Computer Systems Inc.
motion controllers, but increasingly need more axes than we www.deltamotion.com
have offered in one controller,” said Steve Nylund, Delta Com- Input #201 at www.controleng.com/information
puter Systems CEO. “The base module options B7, B11, and
B15 with a larger power supply satisfy this increased demand MORE
for scalability.” ADVICE
The RMC200 uses the same RMCTools software as the GO ONLINE
other Delta controllers—the RMC75 (can control one or two More New Products for Engineers: www.controleng.com/NP4E.

10 | AUGUST 2017 CONTROL ENGINEERING www.controleng.com

The New Standard
in Large Motors

Whether you pump it, compress it, blow it or

convey it, Large AC GPM motors from Baldor
• Low & Medium Voltage
Electric Company are the perfect choice for your
application. Available in low voltage or medium
voltage configurations, Baldor•Reliance Large AC
®

GPM motors are inverter ready and in stock for fast • Modifications Available
delivery.

And, if you need a general purpose motor

modified with optional features to fit your exact
specifications, you can count on Baldor•Reliance • In Stock & Ready to Ship
Large AC GPM motors to set the new standard in
performance with the fastest turnaround in the
industry.

baldor.com 479-646-4711 • Designed for Safe Operation

©2017 Baldor Electric Company http://esp.to/wNxjg7

input #6 at www.controleng.com/information
 TECHNOLOGY UPDATE data analytics

Reducing alert load via data analytics

Cloud-based data analytics help plant operators with emergencies, productivity, and downtime.

I
If control systems can identify potential Some basic tools can support engineering staff
issues early, power plant operators can take action in separating critical alarms from background
to avoid downtime and remain in compliance. noise. The lack of automation and analytics support
However, achieving this is far from easy. means engineering time continues to be absorbed
It doesn’t take much for operators to become in evaluating the appropriate response to event noti-
overwhelmed by the alerts and event notification fications. By combining data from three sources,
coming from sensors and operational components. however, it becomes possible to analyze data accu-
As technology has evolved, the number of sensors rately and hand engineers the information they
added to industrial equipment has mushroomed. need to make informed decisions far more rapidly.
While in the early days there were only a few dozen These three data sources are:
sensors inside a gas turbine, there are now thou- Archive data. Historical data, based on an
sands–and the number continues to grow. The archive of alerts, can assist in matching current
advent of the Internet of Things (IoT) means more event notifications with underlying causes. While
sensors are being added to components, machines, some monitoring support tools use this data today,
and auxiliary systems. its usefulness is limited when used in isolation.
MORE
These sensors will intensify an already over- Engineering data. Engineering data plays an
ADVICE whelming flood of alerts appearing on the screens essential role in successful plant operation. In the
KEY CONCEPTS of operators and plant managers. In one case, a util- hands of skilled specialists, it enables them to oper-
Many alerts that operators receive ity had to deal with almost 300 alerts per hour. This ate complex systems. Yet such data typically remains
on the plant floor are low priority and
is far from an isolated incident and such alert rates confined to functional silos—it is available only to a
do not require immediate attention.
are not uncommon. few trained technicians. That has made it difficult
Cloud-based data analytics can help
operators prioritize alarms and focus The bulk of these alerts are triggered by rel- to analyze and cumbersome to apply as a practical
on the emergencies that matter. atively unimportant factors. Yet operators must aid in decision-making. However, it is possible for
In one example, a company used respond to all messages, even if they do no more engineering data to be automatically translated into
cloud-based data analytics to reduce than note the alert and take no further action. other formats and displayed graphically to enhance
the number of event notifications by This absorbs too much of their time and makes it understanding of ongoing alerts and notifications.
90% and improve overall productivity.
harder to address critical issues. Knowledge base. Machinery original equipment
GO ONLINE manufacturers (OEMs) often have access to massive
Read this story online at
Reduce alert volume knowledge bases gathered from thousands of power
www.controleng.com for additional
information about data analytics. It is necessary, therefore, to free up the time plants and turbines running worldwide. Some of
of skilled personnel. The best way to do this is by information data dates back many decades. Intelli-
CONSIDER THIS
What other methods can engineers reducing the number of alerts. This would enable gent use of analytics enables the matching of event
use to reduce the number of alarms them to zero in on priority action, thereby avoiding notifications and alarms with similar events logged
they receive and improve productivity? trips and load restrictions. elsewhere.

Figure 1: The Siemens

Digital Lifecycle Service
Alert Reduction combines
archived historical informa-
tion with engineering and
knowledge base data. Its
advanced analytics engine
identifies unimportant notifi-
cations, focuses attention on
priority alerts, and provides
recommended actions. All
images courtesy: Siemens

12 | AUGUST 2017 CONTROL ENGINEERING www.controleng.com

 Cabinet Confidence
Scalable controllers keep pace with your success
Phoenix Contact’s expertise and commitment to innovation across a wide range
of industries enable you to build your control cabinet with confidence. Control
systems form the heart of automation and require dynamic flexibility to handle
system complexities. Our controllers can run any application and scale easily
to add new features and increase efficiency as you grow.

Call 1-800-322-3225 or visit: www.phoenixcontact.com/confidence_controllers

© PHOENIX CONTACT 2017

input #7 at www.controleng.com/information
TECHNOLOGY UPDATE data analytics

and the precise causes involved (see Figure 1). This

makes it possible to confirm what engineers might
have suspected but could not prove, while offering
previously unattainable insights.
A simple alert-load example concerns sched-
uled maintenance. Equipment downtime can lead
to a major spike in the number of alarms. As gener-
ation systems move out of the established tempera-
ture norms when they cool down, a large number of
components, systems, and machines suddenly will
flood plant operators with alerts and notifications.
It may take a while for those involved to figure out
that all of these notifications can be ignored and
Figure 2: The number of alarms spikes at exactly the moment when the genera- that routine maintenance is taking place (Figure 2).
tion systems are non-operational. Data analytics also can reveal what really hap-
pens when indicators and metrics move above or
below normal performance levels. Such events may
or may not be important. It takes detailed analy-
sis based on multiple data sources to determine if
movements of this kind are a true cause for con-
cern. If that is accomplished rapidly enough, opera-
tors have the time to take effective remedial action.

Example of reducing alarms, workload

A large power generation company in Germany
discovered that notification messages were being
triggered by many different signals. In one case
more than 1,600 notification were received, at a
rate of 281 alerts per hour, yet as few as 10 signals
Figure 3: A dra- were responsible for 43% of those alarms.
matic fall in event The value of data analytics Worse, many alerts continued during periods of
notifications followed Many systems use one of three data sources routine shutdown. This forced maintenance staff to
implementation of offering operators valuable insight, but are limited continue to monitor units offline for planned down-
the Siemens Digital in scope. A few systems available seek to combine time. This wasted resources and deflected attention
Lifecycle Service Alert two of these data streams, some more successfully from more urgent maintenance priorities.
Reduction at different than others. Integrating three sources is a new idea. By zeroing in on those 10 signals and dealing
sites. Even then, bringing together archival, engineer- with the thousands of alarms, the maintenance
ing, and knowledge base information is not enough. staff ’s workload dropped significantly.
That compounds the problem because of the added Digital alert management highlighted which sig-
complexity and increased data volumes. Such an nals led to alarms and why. Visualization techniques
approach may help to identify real situations and presented essential management information in an
determine root causes, but it would be a slow, man- easily digestible format. Engineers turned analysis
ual, and laborious process. By the time the data had into action, addressed the correct problems, and
been combined, filtered, and evaluated, it would be slashed event notifications by 90% (Figure 3).
too late to mitigate damager and avoid downtime. Digital alert management eliminated these
The key to improved maintenance efficiency unnecessary notifications and generated practical
must go beyond the identification of root causes recommendations for specific actions for optimi-
and be capable of reaching conclusions on time. It zations. These ranged from the delay of notifica-
must also encompass a substantial reduction in alert tions for a few seconds to altering certain manual
volume and provide a means of effectively respond- procedures. The changes exerted a transformation-
ing to alerts deemed to be of the highest priority. al impact on operational efficiency. That, in turn,
Cloud-based data analytics, with sophisticat- improved compliance and profitability, while
ed analytics engines, used in tandem with modern streamlining the actions of skilled engineers. ce
microprocessors, can help synchronize, compare,
and evaluate huge volumes of data. This can help Ute Messmer is the head of the Digital Technol-
reduce alert volume and speed decisions. ogy Center at Siemens Power Generation Services.
Data analytics are available that offer an accu- Edited by Chris Vavra, production editor, Control
rate view of why event notifications are happening, Engineering, CFE Media, cvavra@cfemedia.com.

14 | AUGUST 2017 CONTROL ENGINEERING www.controleng.com

 PLC
HMI
ALL IN ONE

Modular, All-in-One PLC+HMI

Complete, Customized Control in 3 Steps
1 Select an HMI – Now with Multi-Touch option!

2 Snap on the powerful CPU

3 Add I/O and Com Modules to meet your requirements

input #8 at www.controleng.com/information
Unitronics, Inc. 1 Batterymarch Park Quincy, MA 02169 USA usa.sales@unitronics.com
Tel: 617-657-6596, Toll Free: 866-666-6033 www.unitronicsPLC.com
 Mobile device security
Rely on each
employee to Don't know
do the right
thing
Other

12%
6%

research
7%
65%
10%

2017 MOTOR DRIVES STUDY

5 motion survey findings Local

K
d
department
t t
prefer separate and 56% look for matched rules IT rules are used
Key trends in variable-speed, servo units. For medium-voltage drives and
and/or stepper, and medium-voltage drives Above NEMA motors: 29% prefer sepa- More than half of facilities follow
follow below from buying and specifying rate and 34% favor matched units. their IT department’s rules when
respondents to the Control Engineering 4. Expenditures: Over the past 12 implementing security on mobile
2017 Motor Drives study. months, respondents estimated an aver- devices. Source: Control Engineer-
1. Usage: 87% of respondents use age of $148,000 having been spent on ing 2016 Mobility, Ethernet, and
or expect to use variable-speed drives variable-speed drives, ac/dc. For the Wireless Study
within the next 12 months; 46% use/ same time frame, respondents also esti-
plan to use servo and/or stepper drives; mated average values of $96,000 for
and 22% use or plan to use medium- servo/stepper drives and $509,000 for

$213,672:
voltage drives. medium-voltage drives.
2. Applications: When specifying 5. Important factors: The most The aver-
variable-speed drives, 90% of applications critical qualities respondents look for age estimated annual budget for
are new, 76% are retrofit, and 73% are when choosing a motor drive are fre- a company’s investment in IIoT,
replacement. The breakdown for servo quent start/stop tolerance for variable- Industrie 4.0, and/or digital manu-
and/or stepper drives is 88% new, 63% speed drives (78%), accurate positioning
facturing. Source: Control Engi-
retrofit, and 71% replacement. For medi- for servo/stepper drives (93%), accurate
neering 2016 Industrial Internet of
um-voltage drives: 92% new, 66% retrofit, speed and torque control for medium-
Things & Industrie 4.0 Study
and 61% replacement. voltage drives (88%). ce
3. Purchasing: 36% of respondents
prefer to buy motors and related vari- www.controleng.com/2017MotorDrives
able-speed drives and ac/dc control- has more information. Amanda
lers separately; 24% prefer matched units.
Regarding servo/stepper drives, only 13%
Pelliccione is the research director at
CFE Media, apelliccione@cfemedia.com.
45: Average number of
hours the automation professional
works each week. Source: Control
Top 10 motor drive evaluation criteria Engineering 2017 Career & Salary
Survey
Drive reliability 70%
Price 62%

9 in 10
Communication interface choices 49%
Customer service and support 49% end users’ HMI
Simple setup/controls 48% software includes alarm summa-
Programmability in software 46% ries and other alarm functions.
Source: Control Engineering 2017
Manufacturing reputation 43%
HMI Software & Hardware Study
Maintenance 43%
Convenient operator interface 38%
Faster troubleshooting 33% More research
Control Engineering covers several
When evaluating any type of motor drive, automation professionals first at reliability,
research topics each year.
followed by price, communication interface choices, customer service and support offer-
All reports are available at
ings, and simplicity of setup/controls. Source: Control Engineering
www.controleng.com/ce-research.
www.controleng.com/ce-research FOR MORE RESEARCH INFORMATION

16 | AUGUST 2017 CONTROL ENGINEERING www.controleng.com

is driving a smarter future
World-class precision. Quality technology. Award-winning energy efficiency.

Our experts are engineering variable frequency drives to be more communicative and
intuitive, while still enabling reliable, energy-efficient results. With VLT® and VACON®
offering powerful product lines, and a unique service portfolio with DrivePro®, Danfoss has
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even in harsh environments. Choosing the right drive and optimizing your entire system
can yield potential energy savings of up to 60 percent. Danfoss is committed to innovating
drives that can address climate change, rapid urbanization, and successful and sustained
water and wastewater management, so you can tackle your industry’s challenges.

To discover solutions for the future, visit www.danfossdrives.com

input #9 at www.controleng.com/information

5bn
worldwide will
benefit daily from
Danfoss Drives
by 2025
 CONTROL ENGINEERING international

Moving to a wireless
remote monitoring system
Heed this advice on what needs to be considered when moving from a wired remote
monitoring communications to wireless communications.

‘ Beyond
savings on
H Having the ability to automatically
track and control assets remotely is an important
requirement in many applications, and it can help
to improve operations while reducing costs. Using
wired remote sensing systems is the most usual way
to achieve this, especially in the oil and gas indus-
try. Sensors monitoring various assets normally are
equipped with outputs that require hundreds of
requirements, a wireless system can be installed at
the cost of a wired system with 15 m of installed
conduit—less if conduit needs to be buried.

Maintenance
Wired systems: When removing sensors for peri-
odic maintenance, wires connecting to units can
be damaged. Improper wire labeling can result in
yards of wire to connect to a programmable logic incorrect sensor replacement.
wiring, wireless controller (PLC). Analog 4-20 mA current loop and Wireless systems: Wireless nodes integrate to
Modbus interfaces are examples of communication sensors that send data directly to a gateway. During
modules can protocols that can cope with long cable runs. sensor maintenance, a wireless node easily detaches
Wired remote monitoring has advantages over and re-attaches without wire interference.
convert digital manual readings from sensors or gauges, but has
limits—depending on the application—regarding Environmental
information installation cost, sensor flexibility, and environ- Wired systems: Underground conduit often is
into individual mental influences. If a remote monitoring applica- ruined by equipment when digging a trench for
tion requires multiple sensors to monitor various another underground conduit run. Cost to replace
analog channels, parameters, a wired system requires each sensor to conduit and cable systems can be huge. Lightning
be wired back to the controller using an interface strikes on a sensor will propagate along all wires,
simulating the port. For large systems, a wired system requires a often destroying equipment attached to the system.
large interface panel with many different interfaces. Wireless systems: Without underground wires,
existing analog A wireless system, however, often will have a nothing must be dug for wireless. Once installed,

’
digital communications interface (Modbus RS485), lighting strikes to a sensor may damage the single
interface. allowing for many sensors to be wirelessly connect- unit, but not interfere with the complete system.
ed to the controller through one port. While ben-
eficial when configuring a new controller, changing Topography
from a wired interface with lots of individual input Wired systems: Certain locations make it imprac-
ports, to a gateway-based wireless system with a tical to run wires, such as across a highway or river.
digital interface does require planning. Wireless systems: A wireless node can be
In lieu of a complete changeover, wireless modules installed easily on the other side of a highway or
can convert digital information into individual ana- river. Self-configuring, wireless nodes automatically
MORE
log channels, simulating the existing analog inter- connect to the network.
ADVICE face. This provides for a quick changeover, without When moving from a wired solution to a wire-
KEY CONCEPTS software changes and does not use data and diag- less one, consider all the aspects of the job. Is there
Wireless can save time and resourc- nostic benefits made possible by changing com- a problem with the current system? If so, is there
es compared to wired monitoring. munications to a wireless sensor control system. willingness to change the interface at the control-
Savings include maintenance, Factors to consider when evaluating a move to a ler knowing that this change will collect much more
topography, and environmental
considerations. wireless remote monitoring and control system data and diagnostic information than previously? Is
instead of upgrading an existing wired system are: it more cost-effective when considering the absence
GO ONLINE
www.controleng.com/international
of cable, trenching, and interface requirements?
www.controlengeurope.com
Costs Deciding when to invest is the hardest part. ce
Wired systems: What is the area of operation for
CONSIDER THIS wired system? Costs related to running conduit over Scott Keller is CEO at SignalFire Telemetry. This
Where can you cost-effectively
expand your measurements, monitor- large areas, especially if requiring trenching, can appeared July 9 on the Control Engineering Europe
ing, or control by using wireless make a wired system too cost-prohibitive. website. Edited by Mark T. Hoske, content manager,
communications? Wireless systems: With no conduit or trenching Control Engineering, mhoske@cfemedia.com.

18 | AUGUST 2017 CONTROL ENGINEERING www.controleng.com

 Philip Layton
Lead Electrical Engineer
Tekgard

“We use Phoenix Contact’s ILC controllers

in military applications all over the world.”
Tekgard trusts ILC controllers and components from Phoenix Contact.
“Tekgard manufactures mission-critical environmental control units, with extensive military
requirements for documentation and testing. But, whether it’s an environmental chamber
at -40°F or a desert-pounding 130°F, Phoenix Contact controllers never fail.”
Flexible, dynamic control systems from Phoenix Contact give you the confidence to tackle
complex system applications with rigorous standards and extreme operating conditions.

Call 1-800-322-3225 or visit:

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© PHOENIX CONTACT 2017

input #10 at www.controleng.com/information

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

Robots learn to interpret 3-D objects

Autonomous robots can inspect nucle- right side up, upside down or sideways, a technique called probabilistic principal
ar power plants, clean up oil spills in the in full view or partially obscured by other component analysis.
ocean, accompany fighter planes into com- objects. Even when an object is partially When a robot spots something new,
bat, and explore the surface of Mars. Yet hidden, we mentally fill in we can’t see. it doesn’t have to sift through an entire
robots still can’t make a cup of tea. Their robot perception algorithm can mental catalog for a match. It learns,
Turning on the stove, fetching the simultaneously guess what a new object from prior examples, what characteris-
kettle, and finding the milk and sugar is, and how it’s oriented, without examin- tics beds tend to have.
require perceptual abilities that, for most ing it from multiple angles first. It can also Based on that prior knowledge, it gen-
machines, are still a fantasy. Among them “imagine” any parts that are out of view. eralizes like a person would—to under-

‘
is the ability to make sense A robot with this tech- stand that two objects may be different,
of 3-D objects. Most robots nology wouldn’t need to yet share properties that make them a par-
can “see” objects with cam-
Robots recognize see every side of a teapot, ticular type of furniture.
eras and other sensors, for example, to know that it
but interpreting from one
objects three times probably has a handle, a lid, Testing examples
glimpse is more difficult. and a spout, and whether it To test the approach, researchers fed
Duke University
faster and make is sitting upright or off-kil- the algorithm 908 new 3-D examples of

’
graduate student Ben ter on the stove. the same 10 kinds of household items,
Burchfiel said the most
fewer errors. The researchers said viewed from the top. From this single van-
sophisticated robots in their approach results in tage point, the algorithm correctly guessed
the world can’t yet do what most chil- robots recognizing household objects three about 75% of the time what most objects
dren do automatically, but he and his col- times faster while making fewer mistakes. were, and what the overall 3-D shapes
leagues may be closer to a solution. Burchfiel said this is an important step should be, including the concealed parts—
Burchfiel and his thesis advisor, George toward robots that function with humans compared with just over 50% for the state-
Konidaris, now an assistant professor of in homes and other real-world settings, of-the-art alternative.
computer science at Brown University, which are less orderly and predictable than It also could recognize objects that were
have developed a technology that enables the highly-controlled environment of a lab rotated in various ways, which the best
machines to make sense of 3-D objects in a or a factory floor. competing approaches can’t do.
more human-like way. With the framework, the robot is given While the system is reasonably fast—
A robot that clears dishes off a table, for a limited number of training examples, and the whole process takes about a second—it
example, must adapt to a disarray of bowls, uses them to generalize to new objects. is still a far cry from human vision, Burch-
platters, and plates in a variety of sizes and “It’s impractical to assume a robot has a fiel said. Objects from certain perspectives
shapes on a cluttered surface. detailed 3-D model of every possible object look similar and easily fooled the algorithm
Humans can glance at a new object and it might encounter, in advance,” Burch- and previous methods. A table from above
intuitively know what it is, whether it is fiel said. The researchers trained the algo- may be mistaken for a dresser.
rithm on a dataset “Overall, we make a mistake a little less
of roughly 4,000 than 25% of the time, and the best alterna-
complete 3-D tive makes a mistake almost half the time,
scans of house- so it is a big improvement,” Burchfiel said.
hold objects. “But it still isn’t ready to move into your
Each scan was house. You don’t want it putting a pillow in
converted into the dishwasher.”
tens of thousands The team is working on scaling
of little cubes, or approach to enable robots to distinguish
voxels, stacked like among thousands of object types.
interlocking blocks “Researchers have been teaching robots
for easier process- to recognize 3-D objects for a while now,”
ing. The algorithm Burchfield said. What’s new, he explained,
learned catego- is the ability to recognize something and
ries of objects by fill in the blind spots to reconstruct the
combing through parts it can’t see, which may be “invaluable
examples of each in a lot of robotic applications,” he said.
one and figuring
When fed 3-D models of household items in bird’s-eye view out how they vary Robin A. Smith, Duke University. Edited
(left), a new algorithm can guess what the objects are and overall and stay the same, by Chris Vavra, production editor, Control
3-D shapes. The guess is in the center, and the 3-D model is on using a version of Engineering, cvavra@cfemedia.com.
the right. Courtesy: Duke Robotics and Brown Robotics

20 | AUGUST 2017 CONTROL ENGINEERING www.controleng.com

 IT. OT. We speak
both languages.
Industrial Networks by Siemens

The strength of any industrial network depends on the

collaboration of operations and information technologies.
Siemens not only speaks these languages, we also translate.
We have the expertise, products and services to help you create
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usa.siemens.com/industrial-networks

input #11 at www.controleng.com/information

 deceleration of the physical machine. A Pollack: By incorporating native prob- spindle, then the cycles are automatic, but
machine tool emulator for the PC can build ing cycles into some CNC software, users if a manual edge finder is in the spindle,
a virtual twin from a machine archive. Cus- have a vast library of cycles to choose then the same cycles can be used, but they
tomers can have controls with their unique from to simplify part setup. Additionally, perform a manual operation. This allows
original equipment manufacturer commis- these cycles have an inherent intelligence the control to have more versatility and
sioning differences represented virtually. to them. They can change from automat- allows the operator to use his skill set. ce
ic probing to manual operation by recog-
CE: Are CNCs easing programming? nizing what is in the machine’s spindle. If Edited by Chris Vavra, production editor,
the control knows that a probe is in the Control Engineering, cvavra@cfemedia.com.
Pollack: I don’t believe it is enough to
just make a simple conversational control
anymore. It is much more important to
allow the CNC to adapt to the operator’s
skill level, then forcing the user to adapt
to the control. For example, some controls
have been designed to allow for four ways a
user can manufacture a part.

1. Manual machining — Here, a

user has access to all of the machine’s con-
versational cycles in the jog area. If a user
wishes to machine a rectangular pocket
without creating an entire part program,
then it is simple to handle this in Jog mode.

2. Milling and turning — This con-

versational interface was designed to han-
dle basic programming requirements and
complex mixed technology. A user can
grow with this programming option. It
can handle basic 3-axis milling or 2-axis
turning all the way to mixed technology,
5-axis, multi-channel machines. In fact,
we find that it is very common when pro-
gramming complex machine tools that
customers tend to leverage shopfloor con-
versational programming methods to cir-
cumvent post-development issues that
render computer-aided manufacturing
(CAM) systems ineffective.

3. Programming guidance —
Advanced G-code programming environ-
ment that combines DIN programming
functionality with ISO command struc-
ture. Additionally, through flexible pro-
gramming, an advanced, variable-based
programming language can be leveraged
for complex machining strategies.

4. ISO programming compatibility

— The control software has the capability
to program or import standard ISO pro-
grams. This allows compatibility with other
CNC programs.

CE: How are CNCs accommodating

the need for easier setup and operations?

CONTROL ENGINEERING AUGUST 2017 | M8 input #22 at www.controleng.com/information

Education and personal development are vital to the advancement
of the engineering community. We invite you to explore and
celebrate the educational efforts of the following companies
participating in our annual Educating Engineers program:

Acromag Inc. Iconics Inc.

Allied Moulded Products, Inc. IDS Imaging Development

Systems Inc.
AutomationDirect
L&T Technology Services
Baldor
Marposs Corp.
Beckhoff Automation
Moore Industries
Bergquist,
a Henkel Company MoxA

Carlo Gavazzi Inc. otek

EZAutomation Phoenix Contact

Fluke SEW Eurodrive Inc.

Hilscher North America, Inc. Unitronics

Huffman Engineering WAGo Corporation

A cromag Supports
Engineers from the
Beginning of their Education
through their Career

Acromag has been designing and

manufacturing industrial I/O for 60 years.
Henry Patton, Acromag’s founder, believed
in helping the next generation of engineers.
He bestowed to the College of Engineering
and Computer Science of the University
of Michigan, Dearborn a scholarship.
This scholarship is awarded on the basis
of academic merit to students pursuing
engineering degrees.

Acromag offers engineering students a customers up-to-date with regard to new products, new
co-op and internship for real-life work training videos, and white papers.
experience. Co-ops and interns work in
areas such as new product design, Technical support is available from the factory from a team
engineering test, and applications of experienced application engineers to help you find the
under the guidance of a senior engineer. best solution or to troubleshoot your system.
Students looking for co-op and internship
opportunities are recruited during job fairs About Acromag
at local universities. Acromag is a multi-million-dollar international corporation
that combines more than 60 years of process monitoring
A global network of sales representatives and control experience with a solid background in high-tech
and distributors gives customers local computer design.
access to friendly, highly-trained control
professionals that can help you select We design and manufacture signal interfacing solutions for raw
the right products for your needs. Industry materials processing; factory automation; oil, gas, and mining;
related application notes and white papers power generation; water/wastewater; OEM machine control;
are available free of charge from our website. defense, security, and aerospace; research and development.
Product information includes detailed user
manuals, technical white papers, and sales@acromag.com
product training videos that are available on 877-295-7057
our website. A monthly eNewsletter keeps www.acromag.com
input #23 at www.controleng.com/information
A utomationDirect’s
education and training
partner, InterConnecting
Automation, has been training
engineers for over 20 years
with no end in sight

training and include time-saving and advanced programming

Since 1996, InterConnecting Automation, techniques, as well as programming examples that are common
an AutomationDirect Federation partner, has on simple automation controls. All InterConnecting Automation’s
educated over 10,000 automation profes- technical instruction is delivered in a clear and concise method
sionals on the ins and outs of PLC hardware and focused on the company’s mission to help students feel
and the fundamentals of PLC programming. comfortable with basic through advanced PLC programming.
InterConnecting Automation instructors pride
themselves on providing a “no hype”, InterConnecting Automation PLC Training Courses include:
“no sales pitch” type of instruction – just • Introductory Course for PLC-Based Controls
thoroughly helping others learn about PLC • Advanced PLC Training Course
products so that they return to their • PID Computer-Based Training
companies ready to use these products to • Analog I/O Training
their fullest potential. • Do-more PLC Training
• Productivity PLC Training
InterConnecting Automation provides both
• CLICK PLC Training
on-site and online instruction with classes
• C-more HMI Training
scheduled across the country from Atlanta,
to Louisville, to Chicago, to Dallas and more.
Visit www.interconnectingautomation.com for more information
On-site classroom instruction provides
on PLC training, or to learn more about the vast selection of
hands-on access to the products with
affordable automation products from AutomationDirect visit
practical lessons including how to program
www.automationdirect.com.
a machine from scratch. This type of real
world knowledge is what is needed for many
to exceed in the automation field.
customersupport@automationdirect.com
InterConnecting Automation’s online videos 1-800-633-0405
and tutorials cover the various levels of automationdirect.com

input #24 at www.controleng.com/information

T he Heat of the Matter:
Motor Selection
Considerations to Reduce
Failure due to Heat

When can you start to actively prevent

motor failures? The answer is, before you
purchase the motor. Motors don’t fail only
because of age or hours of operation.
Stresses from heat, power supply,
moisture, contamination, improper
lubrication, and unusual mechanical loads
work in conjunction with time to degrade Dirty motors will run much hotter, due to a reduction in
components within a motor, resulting in effective cooling properties. Air inlet screens and passages
motor failures. Failures due to excess heat should be kept free of obstruction. Ventilation filters should
show the critical need to properly select be checked periodically and cleaned or replaced as
and size the right motor for your application. necessary. Motor enclosures dissipate heat differently and
offer varying protection levels so it is important to consider
Temperatures over the design rating take both of these needs when selecting enclosure type to ensure
their toll on the motor in various ways. adequate ventilation and protection.
Electrical insulation deteriorates at a rate
that doubles for every 10oC over rated Overloading and high ambient temperatures are other
temperature. This can shorten the life of a contributors to excess heat on the motor. Properly sizing
motor by one-half, making heat the number the motor for the load and ensuring the motor insulation
one cause of reduced insulation life. system is rated for the environment are simple, upfront ways
Excessive temperature also causes to prevent heat failures.
separation of greases and breakdown of
oils causing premature bearing failure.

Motors require proper ventilation and are

designed to dissipate heat. However,
proper motor installation and maintenance
is required. www.baldor.com

input #25 at www.controleng.com/information

T echnical resources
you need from an
automation vendor you can
depend on

At Beckhoff, we work hard to design and

deliver the most advanced automation and
controls technologies available. Of course,
that is only half the battle as offering
best-in-class education and training is
also crucially important. A wide range of
resources are available to engineers on Visit www.beckhoff.com/webinar to learn more.
the Beckhoff website 24/7/365: Don’t forget to visit the webinar archive to view the
complete history of Beckhoff webinars any time.
TwinCAT Engineering Environment
Programmers and engineers can download Technical brochures
the base engineering module of TwinCAT 3, A variety of technology overviews from Beckhoff are
the leading PC-based automation software available to keep you up to date on the latest PC-based
at no charge from Beckhoff (TE1000). control, IoT, industrial Ethernet, motion control technologies
and more. These are presented in general formats for
Visit www.beckhoff.com/twincat3 to automation and controls professionals and in industry-
quickly download and install TwinCAT 3 specific versions with targeted content for numerous
on your programming and development application types. The entire Beckhoff product catalog is
PC today! also available in digital format in the same place.

Webinars To start downloading PDFs of these technical resources,

Pressed for time? Beckhoff offers a wide visit www.beckhoff.com/media
range of webinars throughout the year
on a wide range of topics, particularly
PC-based controls programming,
industrial Ethernet applications, tips for
designing world class automation system For more information:
architectures and much more. www.beckhoffautomation.com

input #26 at www.controleng.com/information

Y our Total Solutions
Provider for
Electronic Materials

Henkel manufactures high performance

BERGQUIST brand thermal management
materials that offer exceptional thermal
control for today’s advanced electron- Gap Pad® EMI 1.0 is a gap filling material offering both thermal
ics devices. With a full range of materials performance and electromagnetic energy absorption
that includes market-leading GAP PAD
and SIL PAD thermal interface materials,
T-CLAD substrates, and thermal absorbent Henkel Technical Library
films, Henkel offers a complete portfolio of The Henkel Technical Library is an engineer’s one-stop
thermal products that deliver exceptional source for Henkel’s extensive product support materials.
performance, low cost of ownership, ease Visit www.bergquistcompany.com/technical_library
of use and reworkability. where you’ll find a handy product search drop-down menu,
as well as the following:
With a global network of research
• Data Sheets for Henkel products
facilities, manufacturing sites and strategic
partnerships, Henkel brings customers the • Product Application Note
local support and global resources they • Published Articles
need to ensure quick time-to-market • Safety Data Sheets
introductions and long-term success.
• Product Selection Guides,

Henkel is directly represented in more than • Testing Reports, and more!

80 countries, ensuring the delivery of
consistent products no matter where
you are. Our philosophy guarantees the
responsiveness and flexibility of a focused
specialist combined with the strength of
one of the world’s largest specialty Toll-free in North America: 800-347-4572
chemical corporations. www.bergquistcompany.com

input #27 at www.controleng.com/information

T he Simple and Most
Cost Effective Method in
Learning Automation Control
Products and their Programming
the EZAutomation Way

At EZAutomation, we pride ourselves

on designing the most innovative, user
friendly, and cost effective automation
control products. 3. Application Notes: For various industries mentioned
above, we have a library of application notes on “Why” and
Having said this however, no matter how “What” EZAutomation products are used.
simple the user interface, each application
out there is different, and often times 4. Field or Webinar Training: For customers wanting in depth
engineers want further education on how training on HMI/PLC programming, or use of EZAutomation
to use automation products for their specific products, we offer hands on training at various programming
application. We educate our users by levels. That is Intro to HMI/PLC programming to more detailed
several methods: application specific programming.

1. Online Tutorial Videos: We offer a broad 5. Educational White Papers: EZAutomation releases through
line of demonstration and more detailed step E-Blasts or Mailers, white papers on either general purpose usage
by step programming instruction videos at of certain automation control products or specific industry trends.
www.EZAutomation.net/tutorial/index.htm.
6. Free Technical Support: With our advanced applications
2. Programming Examples: As support department, EZAutomation offers technical support to
EZAutomation serves over 35,000 different customers needing specific help on certain aspects of his or her
customers with industries ranging from program. Our sales application engineers also offer the basic
Automotive, Packaging, Pharmaceutical, configuration as to what sort of products one would need to
Food & Beverage, Steel etc. all the way to implement an application idea.
crazy applications like “under water dog
treadmill training”, we have a very broad list
of approved programming examples either sales@EZAutomation.net
created by our application department or 1-877-774-EASY (3279)
snit-bits of customer approved programs. www.EZAutomation.net

input #28 at www.controleng.com/information

Q uickly and easily discover
electrical and mechanical
performance of electric motors,
and evaluate power quality with
a single test tool.

Pain Points
Inefficiency: Electric motors are crucial
The Fluke 438-II Power Quality and Motor Analyzer — a streamlined
equipment in many industrial processes. and cost-effective method for testing motor efficiency
They can account for up to 70% of the total
energy consumed in an industrial facility
and consume up to 46% of all generated Solution
electricity worldwide. The efficient use of The Fluke 438-II Power Quality and Motor Analyzer provides
electricity is not just a “nice to have.” In a streamlined and cost-effective method for testing motor
many circumstances, energy efficiency can efficiency, while eliminating the need for external mechanical
mean the difference between profitability sensors and costly downtime. The Fluke 438-II, based on
and financial loss. the Fluke 430-II Series Power Quality and Energy Analyzers,
has the full capability to measure power quality while also
Downtime: The traditional method for measuring mechanical parameters for direct-on-line elec-
measuring electric motor performance and tric motors. Using data from the motor name plate coupled
efficiency can be costly to setup and with three-phase power measurements, the 438-II provides
difficult to apply in working processes. In real-time motor performance data including speed, torque,
many cases, motor performance checks mechanical power and efficiency without the need for
require a complete system shutdown and additional torque and speed sensors. The 438-II is the
the transfer of the motor to a test bed— answer to the keeping your facility’s motors up and running.
which can result in costly downtime.
To see more information about this dynamic Fluke tool
Testing electric motors on a motor test bed visit fluke.com/438.
is usually done under the ideal conditions,
rather than the conditions typical to a
motor in service. These variances in Fluke-info@fluke.com
operating conditions contribute to the 1-855-270-5610
degradation of the motor’s performance. www.fluke.com

input #29 at www.controleng.com/information

L earn from the Network
Experts at Hilscher, Your
Source for Fieldbus-Certified,
Future-Proof Solutions

Do you need network connectivity? Maybe

you’re a design engineer who wants to add
fieldbus to a control component. Or an OEM
who needs to include Industrial Ethernet on When you buy from Hilscher, you can be sure that our
a machine. Or an end-user or integrator who software stacks are fieldbus-certified and our technology
has to connect different networks in a plant. solutions are future-proofed to the latest standards.
Then Hilscher has a solution for you.
In 2017, Hilscher experts will travel throughout North
Hilscher is a global specialist in industrial America, educating customers at events, seminars, and
network connectivity, including ASICs, trade shows. On tap are 16 free one-day seminars as
Embedded Modules, Software Stacks, PC part of the PI North America PROFINET series; 11 free
Cards, Gateways, and IIoT Edge Platforms, one-day OPC UA seminars with the OPC Foundation;
Services and Chips. At the heart of the The Automation Conference; Smart Industry show;
Hilscher product portfolio is the netX and various distributor and integrator events.
system-on-a-chip, a highly integrated net-
work controller that can support multiple We invite you to join us at an educational event, or
communication protocols simultaneously. virtually join us via the Hilscher YouTube channel
Hilscher also offers extensive engineering (www.youtube.com/user/HilscherAutomation),
services to develop custom solutions. our Industrial IoT blog (www.netiot.com/), or by
accessing educational DVDs and whitepapers on
Hilscher is an active member in leading our website (www.hilscher.com/).
standards organizations, including ETG
(EtherCAT); ODVA (EtherNet/IP, DeviceNET);
OPC Foundation (OPC UA); PI North America
(PROFINET, PROFIBUS) and Sercos
International. We contribute to Industrie 4.0
and are members of CSIA and Industrial info@hilscher.us
Internet Consortium (IIC), including IIC’s Phone: +1 630-505-5301
Time-Sensitive Networking (TSN) testbed. www.hilscher.com

input #30 at www.controleng.com/information

B eing a Team Player Means
Making Our Customers
Successful in Automation

Automation Boot Camp:

A Hands-On Learning Experience
We understand that nothing can beat an
interactive, hands-on training experience,
so we’ve created Automation Boot Camp.
Teaming with customers to advance automation understanding,
Our Automation Boot Camp provides a Huffman Engineering Inc. has developed a customizable package
customized blend of computer based, called Automation Boot Camp.

in-person and hands-on training program,

led by an instructor with automation industry automation knowledge, increasing their value within their
experience, to give individuals the knowl- organizations. Expertise with many leading manufacturers
edge and experience needed to hit the world of automation equipment including, but not limited to,
of automation running and understand what Allen-Bradley/Rockwell Software, Schneider Electric and
it takes to program and commission a Siemens, makes Huffman Engineering, Inc. a valuable partner
working automation system. in crafting learning plains that fit the customer, the application,
and the individual.
Training Includes:
• What’s a PLC? The Huffman Engineering Difference.
• How do I connect my computer to a Instead of learning just one piece of software inside and out,
PLC so I can program it? the one-week Boot Camp focuses on an overview of what is
needed to be productive in multiple software applications.
• What software do I need?
For example, one week could give a new automation engineer
• Does it matter what version of software exposure to programming software for PLCs and HMIs and an
I have? understanding of how they go together. Customers can tailor
• What is ladder logic? their Boot Camp experiences to their needs. Automation Boot
• And more. Camp is one more way Huffman Engineering, Inc. contributes
to the customer automation team.
For an experienced automation engineer,
these questions are second nature but to an
individual entering the automation workforce, info@huffmaneng.com
they are puzzling. Automation Boot Camp is 402-464-6823
designed to familiarize individuals with basic www.huffmaneng.com

input #31 at www.controleng.com/information

I CONICS: Furthering
Knowledge through
‘Connected Intelligence’

ICONICS has over 30 years’ experience of

providing automation software solutions in
multiple applications worldwide. As part of Just one of ICONICS’ many educational opportunities
these efforts, the company has strived to
provide our customers, partners, and
system integrators with the knowledge to to gather in one location to share insight into the latest
ensure successful installation and continued advances in automation technology solutions. The upcoming
use. This comes from a wide array of 2017 Worldwide Customer Summit will be held October 31
integrated activities such as seminars, through November 3, 2017 in Providence, Rhode Island, with
webcasts, certification programs and a focus on “Connected Intelligence.”
in-depth training (both on-site and online).
Attendees will learn from top industry experts how ICONICS’
As part of its hand-on, instructor-led disruptive software for the Industrial Internet of Things (IIoT),
training, ICONICS has developed the ‘SI augmented reality, and energy smart buildings can help
Gear Up’ program, to provide a fundamental organizations to “Make the Invisible Visible™”. Those who
understanding of how to deploy HMI/SCADA, attend will hear from early adopters who have applied ICONICS
plant historian, building automation, energy solutions across multiple industries, as well as have a chance
management, analytics, mobile, and IoT/ to network with peers.
cloud solutions to integrate with, automate,
and optimize operations. To take advantage of any of ICONICS’ educational opportunities
(training, seminars, webcasts, certification programs, customer
Learn From Top Industry Experts summits, and more), visit us online at www.iconics.com.
Educating those who specify, install, buy
and/or sell ICONICS solutions also includes
special live events that have a broader scope www.iconics.com
than a single seminar. ICONICS’ Worldwide info@iconics.com
+1 (508) 543-8600
Customer Summits provide a venue for
customers, partners and system integrators

input #32 at www.controleng.com/information

E ngineering the Change

L&T Technology Services (LTTS) is a

leading global pure-play engineering services
company, built upon a 75 year old legacy and
heritage of the Larsen and Toubro. We are
engineers who believe in engineering better
products and discovering novel ways to build
L&T Technology Services delivery center in Peoria, IL
a sustainable future.

We provide practical, economical, and industries, and is proud to provide services and solutions to
scalable business solutions in the form of 52 Fortune 500 customers.
Engineering Research & Development
(ER&D) services to help customers achieve Digital Portfolio
faster time-to-market for their end products Through our Digital Engineering (DE) portfolio, we provide
and services, innovate to create new end-to-end support through the entire lifecycle of design,
products and solutions, reduce cost of engineering, planning, production, warehousing and distribution
development and meet increasing regulatory of products. Our Smart Products & Services along with
requirements more effectively. LTTS has 13 Smart Manufacturing offerings provide seamless integration of
delivery centers across the globe, six of them physical and virtual worlds across the industry and technology
in the United States. eco-system.

We also work closely with international scien- LTTS has developed mature solutions such as IoT platform
tific institutions to continually source ideas UBIQWeise™ and smart buildings framework iBEMS in
for engineering solutions. Tech Panorama™ emerging technology areas to support our customers. The
is our largest internal innovation event and UBIQWeise™ platform provides insights on information such as
serves as a platform for employees to operational efficiency and preventive maintenance schedules by
showcase their skills to ideate and innovate collecting operational data on a near real-time basis, which is
on a variety of topics related to major then sent to a cloud platform.
industries and technologies.

Core Engineering
LTTS offers high end services and solutions
that span the entire engineering life cycle Tel: +91 80 6767 5173 • Aniruddha.basu@lnttechservices.com
(conceptualization to aftermarket) to all major www.lnttechservices.com

input #33 at www.controleng.com/information

M arposs BLÚ, a
Single-Cable Machine
Networking Solution

Marposs BLÚ is a distributed control

network for machine tools enabling real time
communication between internal and external
machine functions through a single network
cable. The system is comprised of a central
processing unit located in the machine’s software used in BLÚ networks works with a wide variety of
control panel with compact, easy-to-install fieldbus interfaces to machine PLCs.
nodes that control functions such as part
flagging, gage electromechanical actuation The BLÚ hardware is highly modular, with each node configured
and in-process measurement, acoustic for both specific network functions and the environment in
emission sensing, wheel balancing and which it operates. Processing modules are intended for “Dry”
process monitoring. locations like the control cabinet, while functional modules are
environmentally sealed to operate in “Wet” locations on and
The significant difference between BLÚ around the machine tool.
and existing control networks is its
incorporation of a ‘Daisy Chain’ topology, “Wet” modules feature high-reliability components designed
with the appropriate function node located to operate in demanding environments including hot chips,
near the specific sensor, instead of a ‘Star’ grinding swarf, coolants, vibration and temperature variations.
configuration, which needs a separate cable All BLÚ modules can be located at different distances from
for each connected device linked back to a each other to simplify installation without impacting
central electronic controller. With BLÚ, network performance.
communication between the master
processing unit and the functional nodes is BLÚ is part of Marposs’ Industry 4.0 “smart factory” initiative
handled by a single cable, significantly facilitating data sharing among various control system devices.
reducing cost and simplifying installation,
minimizing the need for extension cables,
maintenance and upgrades.

BLÚ has a sampling frequency of 45,000 Hz Tel: 248-370-0404

and a 10 nanometer measurement resolution. Marposs@us.marposs.com
Additionally, the PLC logic management www.blu.marposs.com/en/

input #34 at www.controleng.com/information

R obust Resources at
Your Fingertips on the
Moore Industries Web Site

Moore Industries strives to provide

the products and resources that solve
process control and monitoring
problems and help engineers succeed. our web site at www.miinet.com/industries. We provide the
industry’s most rugged and reliable interface instrumentation
Explore the White Paper Archive solutions that help make your job easier. Find your industry
and learn more about ways to solve your process control and
The Technical White Papers section of the
monitoring problems. You’ll find Applications, Case Studies,
Moore Industries website is also a great
Papers, Articles, Problem Solvers, Videos and Product links
information resource covering a variety of
specific to each related industry.
topics including:

• Alarm Trips and Logic Solvers E-HELP Express

• Intrinsic Safety You can also communicate directly with our application
• Functional Safety experts. We go beyond simply providing instrumentation by
• Process Control and Distributed helping you solve an application problem, find the right
I/O Networks product for your situation or determine if there is an issue
• Temperature Measurement with your current instrumentation that we can fix or optimize.
• HART and Fieldbus
Our online E-HELP Express service, www.miinet.com/ehelp,
These are just a few of the subjects provides quick solutions and answers on topics including
covered in our technical papers. You’ll custom instrumentation, unique or complex interface
also find several application examples and applications, specifying a product, product installation
case studies where you can read about and configuration, and certification questions.
how customers are using Moore Industries’
instrumentation in real world settings. Visit www.miinet.com, or contact us at 800-999-2900 or
Our White Papers are free to download and info@miinet.com.
just a click away.

Industry Focused Resource

We have a broad spectrum of application www.miinet.com
solutions and resources that are now 800-999-2900
consolidated in a new Industries section of info@miinet.com

input #35 at www.controleng.com/information

L earn About a Smarter
Software Architecture
for Industrial IoT

Robust and Secure Data Transfer

One of the key challenges for Industrial
IoT deployments is achieving robust and
secure data transfer from operational
technology (OT) devices to IT-based cloud
services. Moxa offers a highly scalable
software platform that is designed to
The ThingsPro Suite helps you connect devices securely to the cloud
make this easy for system integrators
and engineers.

The ThingsPro Suite helps you connect About Moxa: Your Trusted Partner in Automation
devices securely to the cloud and Moxa is a leading provider of edge connectivity, industrial
establish data acquisition and remote computing, and network infrastructure solutions for enabling
device management services. It includes connectivity for the Industrial Internet of Things. With over
a ready-to-run Modbus polling engine 30 years of industry experience, Moxa has connected more
with built-in client interfaces to popular than 50 million devices worldwide and has a distribution
cloud services such as Amazon Web and service network that reaches customers in more than
Services (AWS). 70 countries.

With the ThingsPro API, it’s also easy Moxa delivers lasting business value by empowering industry
for developers to build custom with reliable networks and sincere service for industrial
applications and meet nearly any communications infrastructures.
project or customer requirement.

You can learn more about this

software platform or experience it for
yourself at www.moxa.com. Download
the free guidebook or run the free trial
version directly in your browser. usa@moxa.com • 1-888-669-2872
H ow do you INVENT
anything, anyway?

Nine Rules of Invention

When you invent, you give life to something
that never existed. How do you invent? Otek’s Universal Panel Meter (UPM) with alphanumeric display
Observe, Analyze, Document, Research
& Prove It! Add to this four more qualities:
Passion, Persistency, Planning & Purpose.
The reason: my swimming suit pockets kept air and allowed me
These are my nine rules of invention.
to float effortless! I got out and wrote (documented) Otto Floats.
A couple of years later and a prototype (research & prove it),
In 1974 a customer asked me to design a
the Ottofloater was supporting me and family after a disastrous
Digital Panel Meter with “an LED display, AC
divorce. The best of it? It’s IP! My ex couldn’t touch it!
power and able to measure a 4-20 mA current
loop.” Sometime later I stopped in Memphis to
Next: I’m filing for my ~#42 patent/co-patent, as well as my
see another customer. We were having lunch
7th patent on just one invention: The Solid State Analog Meter
by the Mississippi when I noticed (observe) an
(SSAM), which may be the culmination of my love affair with
empty barge going up river puffing smoke.
Current Loop & powerless energy.
Next, a fully loaded barge was going down
river without smoking! I immediately
Make Your Own Luck
analyzed my observation and wrote it down So, as you see you don’t have to be a doctor to invent a medical
(document). I wrote the word “Powerless.” device, or an engineer to invent an engine. Just observe, analyze,
document, research & prove it! Be Passionate, Plan it, have a
That observation changed my life and my Purpose and be Persistent!
company’s future over the next 40 years!
It was the beginning of my love affair with Good luck ! (don’t forget... you make your own luck)
powerless energy! I spent many years
researching a way to use this energy
and I eventually proved it was useful. My
company has been awarded 6 patents for
our Powerless™ Technology.

I dove into my pool and noticed (observed) Dr. Otto P. Fest

that I floated without effort (and, I’m not fat). opfest@otekcorp.com • 520-748-7900 • www.otekcorp.com

input #36 at www.controleng.com/information

H ow do I integrate
my PLC with
networking equipment?

There is a growing need for PLCs to

integrate into networking equipment.
Control engineers and programmers are
increasingly turning to common Information
Technology (IT) protocols to communicate
The Phoenix Contact Axioline Control systems bring your
with these systems. control network into the IoT age

Some of the more common

protocols include: The Phoenix Contact Axioline Control systems implement
all of these functions to give you the most intelligent and
• Simple Network Maintenance Protocol cost-effective control network available on the market.
(SNMP): A protocol that communicates Using SNMP to monitor your network health is a simple way
either “by exception” or by polling to to implement preventive maintenance, as well as for alarming
communicate the health of the network and to reduce downtime, for example: “The system tells me
the problem is switch 5, there seems to be an issue on
• Simple Network Time Protocol (SNTP): port 6. Can we get a technician to check the cable between
Keeping the real-time clocks synchro- the machine and the networking cabinet for the line?”
nized on the network is a critical
function, and SNTP is designed to SNTP’s use cases are self-explanatory; simply making sure
utilize a server, either on the network or every system has the same time. Finally, SQL is a great
via the internet, to make sure all devices way to reduce cost by eliminating expensive, unnecessary
have the same time protocol converter middleware. Use these simple protocols
to bring your control network into the IoT age!
• Structured Query Language (SQL):
SQL is the language that is used to
work with some of the most common
database systems that are used as info@phoenixcon.com
“backend” data storage for www.phoenixcontact.com/usa
SCADA applications 717-944-1300

input #37 at www.controleng.com/information

N eed answers to common
gearmotor questions
at your fingertips?

Tired of looking up multiple sources for

answers to common engineering questions
pertaining to gear units and gearmotors?

SEW-EURODRIVE’s online Technical Notes

can be a real life-saver when you need
answers. Technical Notes provide quick
access to many engineering topics such as
how to properly mount a torque arm, how Selecting a custom reducer or gearmotor is fast and easy!
to determine and design for inertia, or how PT Pilot® is our cutting edge online selection tool that
to properly design your machine to use a provides all of the following features. No installation or
hollow shaft gear unit. purchase is necessary.
5 Quotation with Net Price
Need answers on how the speed,
mounting position, environment, and duty 5 Online Ordering
cycle can affect the thermal rating of a 5 Open/Save Quotations
gear unit and how to protect against too
5 Open Co-workers Saved Quotations
much heat? That’s one of many in-depth
documents you can find by visiting 5 Parts List/Dimensions
www.seweurodrive.com and clicking 5 2D or 3D Electronic CAD Files
Technical Notes.
5 Drive Application Calculator and Formulas
In addition, you can find a full library of 5 Includes Thermal and Mechanical Ratings
parts lists, dimensions, and gearmotor
data online or by using one of our mobile Visit www.seweurodrive.com for quick access to PT Pilot®
device apps. and engineering Technical Notes.

ptpilot.com
seweurodrive.com

input #38 at www.controleng.com/information

U nitronics educates
engineers of every
experience level

Unitronics has been making automation

simple, affordable and efficient for over
twenty-five years. Our all-in-one approach
offers an unbeatable price-performance
ratio; users can enjoy the advanced
features of both the operator panel and advanced users—like implementing PID control and
the PLC in a single easy to use unit. As we communication configurations.
continually update our products with the
latest technology to serve the demands of For those users that can’t attend an in-person training,
the automation industry, we are dedicated Unitronics’ website has a wealth of videos and tutorials on
to offering resources for engineers to stay various areas of PLC programming and configuration.
up-to-date about these developments. From a quick refresher on programming, how-to guide to
implementing a new feature or a full introduction to
Our all-in-one philosophy means that we Unitronics PLCs, our webinars cover a range of topics for
strive to provide educational resources every experience level.
for programmers and engineers.
Unitronics is not only dedicated to educating current
Our industry leading technical support is users, we also invest in preparing the next generation of
available to all Unitronics users; our automation engineers. Unitronics has donated PLCs to high
engineers answer questions, provide schools and colleges all over the country—including
programming examples and guide users California State University, University of Alabama and
through the process of specifying and North Carolina State University—for capstone projects, new
configuring their PLCs. laboratory equipment and even engineering competitions.

In addition to providing direct support, our

application engineers educate users at
training seminars for our programming
platforms. These seminars cover both
basics for new users—including an
introduction to ladder logic and simple Tel: 617-657-6596 • USA.Sales@unitronics.com
HMI design—and more complex topics for www.UnitronicsPLC.com

input #39 at www.controleng.com/information

W AGO Training
Keeps You Up-to-Date
with the Latest in Engineering

Training at Your Location

Let WAGO come to you! Optimize your
training experience at your location with
our customizable training courses. Pick
the content of the class, and the number of Customers benefit from WAGO’s in-person, hands-on training.
training days. Get hands-on experience as
you learn WAGO-I/O-SYSTEM functionality,
networking, IIoT protocols, troubleshooting/ Free Training at WAGO Corporation
commissioning, and PLC programming Classes at our Germantown, WI location offer customers
utilizing WAGO’s IEC61131 programming the chance to gain in-person, hands-on training. Attendees
tools. Email training.us@wago.com for have the option between enriching their understanding of
more information. PLC Programming via e!COCKPIT or the WAGO-I/O-PRO
Trainings. Software classes utilize WAGO PLCs and the
IIoT Seminars 750 I/O system to configure, program, and troubleshoot
New IIoT seminars offered in 2017 can these components in Ethernet/IoT applications. These
help you better understand the opportunities free, three-day trainings provide attendees with all meals
within IIoT and the benefits of implementing and materials throughout the course. Find out more at
these new practices. In addition to www.wago.us/training.
the lecture topics, there will be live
demonstrations of practical applications eLearning
involving OPC/UA, MTConnect and MQTT. Customers can also improve their understanding of our
products through eLearning modules, available on our
By attending, you can learn how IIoT can be website: www.wago.us/elearning.
implemented into your applications and see
how WAGO PLC’s are leading the way in
this technology by being able to solve many
of your network security, data collection (800) DIN-RAIL
and data sharing needs. For more details, info.us@wago.com
email training.us@wago.com. www.wago.us/

input #40 at www.controleng.com/information

Nonmetallic Industrial Enclosures:
A Heavy-Duty, Rigid Alternative to 300 Series
Stainless Steel for Harsh Applications.
Allied Moulded’s fiberglass reinforced polyester (FRP) and poly-
carbonate enclosures offer a cost-effective alternative to stainless
steel and carbon steel, respectively, for a number of reasons.
One reason is due to the flexibility of the manufacturing processes
which allows for a wide range of enclosure sizes — from small
junction boxes up to walk-in, free-standing enclosures. The light-
weight material results in reduced installation and shipping costs.
And our enclosures still have the rigidity and durability to compete
with steel counterparts when it comes to protecting critical elec-
tronic systems. Chemical resistance, UV resistance and electrical
non-conductivity are a few more reasons that Allied Moulded’s
nonmetallic enclosures can outperform steel. Allied Moulded also    

 
offers custom modifications and premium accessories. www.alliedmoulded.com

input #41 at www.controleng.com/information

Carlo Gavazzi puts knowledge at engineers’

fingertips 24/7, on various web-based platforms
GAVAZZI APP is multi-language, free of charge, and puts most
of the power of our website at engineers’ fingertips: data sheets,
user manuals, brochures, inventory, pricing and a quick means
to quickly email links to most of these to others.

CarloGavazziNA YouTube Channel provides engineers with

both short and long format videos on various product series.
They were designed to quickly provide the type of content,
which engineers are looking for, which can be easily shared.

Online Training Modules: This Fall, Carlo Gavazzi will be

rolling out three levels of product training modules (Basics/
Principles, Product Breadth and Markets/Applications) for our Tel: 847-465-6100
most popular Sensing, Switching and Control product lines. www.GavazziOnline.com

input #42 at www.controleng.com/information

 Ultra-flexible, easy-to-set-up 3D camera system Ensenso X 3D camera features a powerful 100 W
pattern projector unit and integrated GigE switch
The Ensenso X 3D camera system from IDS Imaging
Development Systems takes an entirely different approach
to stereo vision. Projection module and cameras are separate
devices giving you endless flexibility to configure the stereo
3D camera precisely for your application demands. Work at
distances from 0.5 meters to 5 meters and capture images of
large objects with volumes of several cubic meters. The range
of applications includes anything from bin picking, robot vision,
to warehouse and logistics automation.

Good to Know
IDS offers a range of case studies, videos, white papers
and more, to make your decision-making process and the IDS Imaging Development Systems Inc.
use of our products a smooth and easy experience. Please Tel: 781-787-0048 • usasales@ids-imaging.us
visit www.ids-imaging.us/good-to-know.html to learn more. www.ids-imaging.us

ce201708_eduEngHLF_IDS.indd 1 input #43 at www.controleng.com/information 7/18/2017 9:05:12 AM

Control Engineering Webcasts help you

obtain educational information on
specific topics and learn about the latest
industry trends.

Webcasts Check out some of our Webcasts on

topics like:
• Choosing sensors for the application
• lloT series: Get your head into the cloud
• lloT series: Sensing and control at the
edge: Microcontroller kits
• lloT series: lloT transforms predictive
maintenance
• System Integration case studies
• lloT series: Preventive maintenance:
Technologies, applications and business
models
www.controleng.com/webcasts • Motors and drives
• Human-machine interface hardware,
software.
M EDIA SHOWCASE FOR ENGINEERS
NEW PRODUCTS and software
See more products daily at www.controleng.com/products.

Your place for new products, literature, Apps, Videos, Case Studies and White Papers.
Products Head 1

MOTOR
Products Head 1
Text Normal
Products Company Name

PLUGS
Products Company Web
Input #200 at www.controleng.com/information

ICONICS QUICKLY CONNECT

IoTWorX™
& DISCONNECT POWER

Products Head 1 OFF

Button
Products Head 1
Text Normal
Products Company Name
Products Company Web
Input #200 at www.controleng.com/information Safety Shutter
(on receptacle)

Rated up to 200A, 75hp

4 Connector + Switch in 1 device
ReadHead
the whitepaper at 4 Maximizes Arc Flash Protection
Products 1 4 Minimizes PPE Requirements
www.iconics.com/IoTpaper
Products Head 1
meltric.com
Text Normal
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NEW PRODUCTS and software

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High-temperature silicon-controlled rectifier (SCR) thyristors

Littelfuse’s SJxx40x series of 40A standard high-temperature silicon-controlled rectifier (SCR) thyristors
are ideal for use as switches for rectifier and phase control applications such as voltage regulator, heating,
and motor speed controls. The SJxx40x Series is designed to prevent the overheating and thermal runaway
problems SCRs can experience due to an application’s limited cooling capability or occasional overload sit-
uation. They are designed to trigger with just a few milli-amps of current at less than 1.5 V potential. Typi-
cal applications include a variety of end uses such as ac solid-state switches, industrial power tools, exercise
equipment, white goods, and commercial appliances. The SJxx40x Series is capable of handling high load
current and occasional overloads under limited cooling conditions due to high junction temperature (TJ)
of 150 °C. The high rate of voltage change over time (dv/dt) enables the SJxx40X to tolerate more line noise
and surge often found in commercial ac lines.
Littlefuse Inc., www.littelfuse.com
Input #202 at www.controleng.com/information

Terminal blocks with clamps

Wago’s lever-actuated high current PCB Terminal Blocks with Push-In Cage
Clamp is composed of three series (2604, 2606, 2616) offering streamlined, compact
connections for all wire types. The levers are designed to provide 100% tool-less
operation and securely close into place with little effort, leaving no doubts regard-
ing the integrity of the connection. Further benefits include conductor entry at 0
degrees or 90 degrees to PCB (side or top entry) and pin spacing from 5 to 11.5 mm.
Conductor sizes range from 24 to 4 AWG and each body size has a 600 V rating.
Wago Corp., www.wago.com
Input #203 at www.controleng.com/information

www.controleng.com CONTROL ENGINEERING AUGUST 2017 | 85

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

Compact, fanless module for smart devices

Kontron’s energy-efficient Smarc 2.0 module is designed for smart devices in a very compact and
fanless design. It balances processor and graphics performance and retains a very low energy foot-
print, especially useful in Internet of Things (IoT) and Industrie 4.0 applications. The presence of two
Ethernet ports on the board facilitates networking. The Smarc-sAMX7 has a 2x1GHz ARM Cortex
A7 processor with a 200 MHz M4 processor in dual-core configuration; the single-core version runs
at 800 MHz. It uses the Uboot bootloader and supports Yocto Linux as the operating system.
Kontron, www.kontron.com, Input #204 at www.controleng.com/information

Capacitive accelerometer and LCC/JCC chip

Silicon Designs Inc.’s industrial-grade MEMS capacitive accelerometer chips include enhanced
application suitability. The MEMS capacitive accelerometer modules and LCC/JCC chips range from
±2 to 400 g for zero-to-medium frequency instrumentation requirements. Module designs combine
a single axis model or three orthogonally block-mounted models within an epoxy seam-sealed anod-
ized aluminum housing. The use of proprietary manufacturing technologies allows for onboard volt-
age regulation and an internal voltage reference, making the units relatively insensitive to temperature
and voltage changes, while eliminating the need for external power amplification and regulation.
Silicon Designs, www.silicondesigns.com, Input #205 at www.controleng.com/information

PC-programmable Modbus temperature transmitter

Moore Industries’ TMZ Dual (2TPRG) PC-programmable Modbus temperature transmitter allows users to increase
density and reduce costs with dual RTD, thermocouple, mV, resistance, or potentiometer inputs by doubling tempera-
ture monitoring capability in a single unit. The TMZ’s two independent sensor inputs are easy to configure using a free
copy of intelligent PC configuration software available for download. The data from both sensors is available on the
Modbus output, allowing the host to use the data for averaging, differential, or sensor backup. Up to 32 (without repeat-
ers) TMZ or TMZ Duals can be multi-dropped onto one low-cost communication link (such as a twisted wire pair).
Moore Industries, www.miinet.com, Input #206 at www.controleng.com/information

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 BACK TO BASICS ERP

Managing common ERP risk factors

Preparation is crucial for an enterprise resource planning (ERP) project
to combat many risk factors that can occur, including integration with other systems.

E Enterprise resource planning (ERP)

risk factors are real. ERP projects can run into
time delays and cost overruns. The technology
may not drive key business process improve-
ments. Even the go live of a project can fail if a
project was not based on a solid foundation.
ERP risk is compounded when an organi-
zation faces a complicated legacy technology
and system education, and set a clear vision of
the company’s future. One of the major risks to
watch for is when an ERP project loses the focus
on the chance for improvement and transforma-
tion of business information processes. A suc-
cessful ERP project should be thought of as a
business transformation, which requires change
that must be managed.
environment with multiple integration points,
manual workarounds, standalone systems, Change management
changing requirements, or unrealistic schedules. Organizational change management should
These are just a few of the ERP risk factors proj- be woven into the fabric of the project method-
ect teams face as they undergo an ERP project ology and be part of the transformation journey
journey. from the start. Within the change management
phase, it’s important to undertake both an ERP
readiness assessment, and evaluate risk in areas

‘
such as:
To avoid project delays, consider
 Project organization. Look at the ERP
project steering committee, the project
complexity, project organization, scope, manager, and the team process owners.
Are the right people in the right positions?

’
readiness, and schedule.  Scope. Is the scope of the project possible?

 Readiness. Are there readiness

issues and risk?
Common ERP risk factors
Though each journey is as unique as the com-  Schedule. Are schedule expectations
pany and the people conducting the project, the defined, and are they realistic?
MORE
following are three factors common to every
ADVICE ERP project in the manufacturing and distribu-  Budget. Is the project properly funded?
KEY CONCEPTS tion industries:
Common enterprise resource It’s also important to look at the risks of poor
planning (ERP) risk factors are the
 Risk of delays end-user training, or the potential for user resis-
risk of delays, cost overruns, and the
project’s complexity. tance of the new system. Consider an ERP train-
Companies can reduce risks by  Cost overruns ing and education program to make sure users
using proven methodologies at the will be trained adequately in the use of the sys-
beginning of an ERP project.  Complexity. tem. There are cases where an improved edu-
Organizational change manage- cation and training program reduces the risk
ment should be part of an ERP project How to effectively reduce and mitigate com- of end-user resistance. A thorough assessment
from the very beginning.
mon ERP risk factors? Preparation. also addresses any risks associated with the full
GO ONLINE implementation plan including integration, test-
Read this story online at
Preparation is key to reducing risk ing, and data conversion. ce
www.controleng.com for additional
links about ERP and the benefits it can A key success factor in reducing ERP risk fac-
provide manufacturers. tors is leveraging proven, end-to-end methodol- This article originally appeared on Ultra Con-
CONSIDER THIS ogy from the very first stages of an ERP project. sultants’ blog. Ultra Consultants is a CFE Media
What other risks should manufac- It’s imperative to look at current business pro- content partner. Edited by Carly Marchal, content
turers be aware of when using ERP? cesses, be sure the team has proper ERP vendor specialist, CFE Media, cmarchal@cfemedia.com.

88 | AUGUST 2017 CONTROL ENGINEERING www.controleng.com

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