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the #1 value in automation

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Vol. 66 Number 2

®

FEBRUARY 2019

25 | Network, control system upgrade helps reduce energy costs 26 | Maximize production efficiency with high-end power measurement

M1

Robotic coveR images: Courtesy of Robotic Industries Association (RIA) and clockwise, starting top left, Cenit North America Inc., Hypertherm Robotic Software Inc., Octopuz Inc., and RoboDK Inc. See three related articles in this issue, starting after p. 27.

INSIGHTS 5 | Legalities: Reduce risk of non-payment 6 | Low-cost field control network 8 | Technology Update: R&D tax credit help NEWS

10 | Four machine vision software advances; Special interest group for internet protocol; Online headlines 14 | Think Again: Use the positive effects of automation to plan ahead

ANSWERS

16 | How to select a process control system 18 | Upgrading your hardware, software systems 20 | Proactive management of plant cybersecurity 24 | Best practices to help improve system security

INSIDE MACHINES

M1 | Demystifying robot offline programming M3 | Robotics and AI improve factories of the future M5 | Collaborative robots accelerate M7 | Global low-voltage motor market bounces back M8 | Selecting a scope for a variable frequency drive

INNOVATIONS 38 | 2019 Control Engineering Engineers’ Choice Awards BACK TO BASICS

56 | Help for automation design, selection, implementation ONLINE • Enabling process industry

digital transformations

• Four process closure benefits • Model developed to identify artificial

intelligence blind spots

• Vision-guided robot technology benefits

CONTROL ENGINEERING (ISSN 0010-8049, Vol. 66, No. 2, GST #123397457) is published 12x per year, Monthly by CFE Media, LLC, 3010 Highland Parkway, Suite #325 Downers Grove, IL 60515. Jim Langhenry, Group Publisher/Co-Founder; Steve Rourke CEO/COO/Co-Founder. CONTROL ENGINEERING copyright 2019 by CFE Media, LLC. All rights reserved. CONTROL ENGINEERING is a registered trademark of CFE Media, LLC used under license. Perio dicals 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. Telephone: 630/571-4070. E-mail: [email protected]. Postmaster: send address changes to CONTROL ENGINEERING, 3010 Highland Parkway, Suite #325 Downers Grove, IL 60515. Publications Mail Agreement No. 40685520. Return undeliverable Canadian addresses to: 3010 Highland Parkway, Suite #325 Downers Grove, IL 60515. Email: [email protected]. Rates for nonqualified subscriptions, including all issues: USA, $165/yr; Canada/Mexico, $200/yr (includes 7% GST, GST#123397457); International air delivery $350/yr. Except for special issues where price changes are indicated, single copies are available for $30 US and $35 foreign. Please address all subscription mail to CONTROL ENGINEERING, 3010 Highland Parkway, Suite #325 Downers Grove, IL 60515. Printed in 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, regardless of whether such errors result from negligence, accident or any other cause whatsoever.

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control engineering

February 2019

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INSIGHTS

LEGALITIES FOR AUTOMATION AND INTEGRATION Brian Clifford, Faegre Baker Daniels

Reduce risk of non-payment from new automation customers A letter of credit can help guarantee payment or performance by a customer or integrator that has not yet established a credit history with the other party to the arrangement—especially if offices of the two parties are far apart.

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articipants in the control systems industry are increasingly crossing borders— both national and international—to either find or provide the unique expertise that defines this industry. I am often asked what steps can be taken to ensure payment or performance by a customer or integrator that has not yet established a credit history with the other party to the arrangement, especially when the potential new contract may be with a startup company or business that is headquartered far from the other party’s offices. While there are many techniques, ask if a letter of credit can be posted at the start of a new relationship.

Letter of credit can build trust

Letters of credit are widely available from banking institutions worldwide, have relatively low maintenance costs to the company obtaining the letter of credit, and can provide payment security to the other party (for payment for its services and deliverables for the integrator, or for protection from defaults from the customer) as the parties work together to establish other long-term credit arrangements or to build trust based on positive historical experiences.

Terms in letter of credit

Here are a few key terms companies and integrators should look for in any letter of credit: Irrevocable: As the name implies, an irrevocable letter of credit (ILOC) cannot be cancelled or revised without the consent of the beneficiary (here, the company or integrator providing the services or deliverables). Such a term gives comfort to the beneficiary that payments will be made, or money will be available to address the results of a default, even if the entity providing the ILOC experiences financial difficulty. Term: Even though the letter of credit is irrevocable, it generally will still have a defined expiration date. A beneficiary should check to be sure all payment or performance obligations are satisfied

www.controleng.com

by the entity providing the letter of credit before the end of such term—or that the ILOC is renewed or replaced prior to the expiration date if there is still work to be performed, items to be delivered or payments to be made. At sight instrument: This is a term of art used with letters of credit. Basically, it means the beneficiary is entitled to payment from the bank that issued the letter of credit by presenting a written demand for payment (or other similar documentation stated in the ILOC). The issuing bank generally is not permitted to dispute whether or not the entity providing the letter of credit actually owes the sought-after payment to the beneficiary. For example, the bank generally cannot refuse payment to the integrator by alleging the work was incorrectly performed or that the goods that were delivered had defects. Likewise, the bank could not dispute a default by the integrator providing the letter of credit to avoid making a payment on demand of the integrator’s customer. Amount: All letters of credit have a maximum payment limit. A beneficiary should ensure the amount of the letter of credit is sufficient to cover the expected aggregate amount of all financial obligations that may be outstanding with its counterparty to the contract at any given time. For example, if the integrator has “net 30” payment terms with its customer, this may be the value of 2 to 3 months of average invoices (assuming the beneficiary suspends performance and deliveries if the outstanding balance grows too large or too delinquent). With the added security of a letter of credit, it may be possible to expand customer or service provider base with less risk. ce Brian Clifford is a partner in the automation and robotics practice of Faegre Baker Daniels, a law firm in the U.S., U.K. and China. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, [email protected]. control engineering

‘

A beneficiary should ensure that the amount of the letter of credit is sufficient to cover the expected aggregate amount of financial obliga-

’

tions.

More

M INSIGHTS KEYWORDS: Legalities,

letter of credit, system integrator Hiring newer firms can bring risks. Letter of credit can lower risks. Terms change meaning of a letter of credit.

CONSIDER THIS When other aspects of a young system integrator firm seem positive, a letter of credit can lower potential risk when establishing a business relationship.

ONLINE If reading from the digital edition, click on the headline for more resources. For other discussion of engineering-related legal issues, search “Faegre” at www.controleng.com.

February 2019

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INSIGHTS international

Stone Shi, Control Engineering China

Low-cost networking

CC-link ie Field Basic is an option for smart factory network architectures where low-cost control networks are needed.

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o realize the “one-network for all” smart factory network architecture, more industrial equipment is using real-time Ethernet as control network to realize the interconnection among devices. Is there a more economical and simpler industrial control network? CC-Link IE Field Basic is an optimal choice for realizing low-cost control equipment network according to several sources. Before the release of CC-Link IE Field Basic (the earliest Gigabit industrial Ethernet released in the industry), CC-Link IE has been widely applied in industries such as automobile; liquid crystal display (LCD); rubber; computers, communications, consumer electronics (3C); and others. Its biggest characteristic is it seamlessly fuses high-speed large-capacity communications and the system,

guaranteeing stability and real-time data performance. CC-Link IE has two types of network protocol: CC-Link IE Control used for communication between controllers, and CC-Link IE Field used for communication between controller and field equipment.

Lower cost, ease of use

With the development of industrial Internet of Things (IIoT), the traditional low-end equipment and small-scale equipment often isn’t networked. Compared with high speed networks, such equipment focuses more on the low cost and convenient use of networking. Users always hope for more economical products to build lower-cost systems such as small-scale equipment that can meet control requirements with 100 Mbps

Remote I/ O of CC-Link IE Field Basic was first developed by Tianjin Sentinel Electronics. Courtesy: Control Engineering China, CC-Link

communication performance. Even for small-scale equipment, visualization for connected equipment and connections with higher-level information systems are needed, said Gan Shuang, senior engineer of CC-Link Partner Association (China). Equipment manufacturers hope one hardware device can work with multiple networks while providing lower development costs. Low-cost slave station equipment and simple and low-cost master station functions are under development. The bus network, CC-Link IE Field Basic, based on standard 100 Mbps Ethernet, provides a low-cost control network for small-scale systems that do not need high-speed control. “CC-Link IE Field Basic can realize the real-time communication needed for equipment control via software at network protocol application layer while communication with CC-Link IE is ensured,” Gan Shuang said. Special chip and interface board is not needed. ce Stone Shi is executive editor-in-chief, Control Engineering China. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, [email protected].

M More INSIGHTS KeyWORDs: Industrial networks, device networks Device networks can be lower cost and easier to implement. Using a standard processor decreases networking cost. Having source and sample code eases product development. CONsIDeR THIs What needs networking to increase value?

ONLINe If reading from the digital edition, click on the headline for more on this topic. See links to international editions at www.controleng.com/international. input #5 at www.controleng.com/information

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POWER We stock enough power to brew a 12 oz. cup of coffee for the entire population of New Orleans. Put that in your mug and drink it. input #6 at www.controleng.com/information

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INSIGHTS

Technology UpdaTe Tracy Lustyan, alliantgroup

How the R&D tax credit can benefit control system and process engineers The research and development tax credit can help control systems and process engineers offset the mounting costs from product and service enhancements.

I

t’s not often a company’s day-to-day services can lead to tax relief, but that’s the case for control system and process engineers. Designing and implementing systems that function efficiently is the main priority for these engineers. To do so, system enhancements continuously need to be developed, which more often than not means one thing: spending money. The types of technical enhancements that embody an engineer’s daily work activities are exactly what the research and development (R&D) tax credit, which brings in an estimated $10 billion annually for U.S. businesses, was created to spur.

Complexities turned into credits

Projects involving automation and system communications are becoming more complex, and the trends of staff downsizing do not help. This leaves engineers to create more innovations. As new technologies are condensed and require a direct connection with legaKEYWORDS: R&D, tax credit cy systems, and as work processes become The types of technical more streamlined, the innovations brought enhancements that embody forward by engineers are more than likely to an engineer’s daily work qualify for the R&D credit. activities are what the R&D tax credit was created to Although the R&D credit is underused spur. by many industries, system integrators As new technologies are have claimed approximately $246 million condensed and require a in overall credits. Furthermore, more than direct connection with legacy $22 million in tax credits and incentives systems, the innovations have been claimed for 52 members of the brought forward by engineers are more than likely to qualify National Systems Contractors Association for the R&D credit. since 2002. Companies whose business Companies shouldn’t operate under the practices rely on innovation false assumption the credit is only for comshould consider the credit if panies that don lab coats and work with test they haven’t already done so. tubes. There is no need for innovations to CONSIDER THIS be technical or even complicated to qualiDoes your company qualify fy for the credit. There also doesn’t need to for the R&D Tax Credit? be a heavy engineering presence during the ONlINE design, testing, or implementation process. Link to more online rom From manufacturing to robotics or oil this author, resources, tax and gas extraction, it’s hard to find an indusincentives and related content try involving control systems the R&D credunder www.controleng.com/ magazine February 2019. it couldn’t apply to. The cross-disciplined,

M More INSIGHTS

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Companies with a cross-disciplined approach to design and production in controls and automation can qualify for the R&D tax credit, an estimated $10 billion annually for U.S. businesses that can take advantage it. Courtesy: alliantgroup

technical nature of the work done by system integration companies make them some of the best candidates for the credit, which has saved U.S. businesses billions of dollars. Some applicable activities that would qualify for a control system or process engineer include: • Developing schematic drawings for the integration of system components. • Performing evaluations and system tests to ensure optimal functionality. • System operation sequencing. • Control system programming. • Implementing automated systems such as programmable logic controllers, human-machine interfaces, information systems, motion/process control, robotics, radio frequency identification, and 3-D laser scanning. The power behind the credit will enhance company innovations as well as their contributions to the U.S. economy. ce Tracy Lustyan is a managing director for alliantgroup and is based in the Chicago office. Edited by Jack Smith, content manager, Control Engineering, CFE Media, [email protected]. www.controleng.com

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INSIGHTS

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

NEWS

Four machine vision software advances The capabilities of a given machine vision or embedded vision system rely on more than just the hardware of the camera. The central hardware components of a camera often are viewed as solely responsible for the system’s performance—components such as the sensor, the lens, the interface and more are given all the credit, but software can be just as impactful. The software used in machine vision and embedded vision systems has been making major advances. From the food and beverage industry to the electronics industry, improving machine vision software is having an impact. While advances have happened across the board, there are four areas in which major gains have been made.

1. High dynamic range inspection

The electronics industry is running their lines faster and with higher

resolution, introducing higher signal-tonoise ratios (SNRs). Companies are using machine vision software to reduce SNRs for more accurate inspections. Depending on the manufacturer’s need, this software can be highly customized.

2. Optical character

recognition software

Optical character recognition (OCR) historically has been limited to black text on white backgrounds, but this is rarely the case in real-world manufacturing. New OCR software can detect characters on busy backgrounds, and some of the newest software even can recognize characters when new fonts are introduced.

3. 3-D imaging

A number of manufacturers have been developing photometric 3-D algorithms to read 3-D text, among other things. Some forms of 3-D vision software combine multiple images of the same part to

Special interest group for internet protocol launched

C

AN in Automation’s (CiA) international users’ and manufacturers’ group has established the CAN XL Special Interest Group (SIG). Several original equipment manufacturers (OEMs), Tier 1s, chipmakers, and other interested parties including tool suppliers discussed desired features for the CAN XL data link layer. The participants elected Dr. Arthur Mutter (Bosch) as chairman; Reiner Zitzmann, the CEO of CiA, is the SIG secretary. The SIG experts requested backwards compatibility with CAN FD for the CAN XL protocol. The CAN XL data link layer is intended for TCP/IP communication, simple radar sensors, and eCall devices. “In this two-day inaugural meeting, the experts evaluated already very detailed protocol features,” said Holger Zeltwanger, CiA managing director. Additionally, the participants discussed the requirements for the physical media attachment (PMA) sub-layer, which normally is implemented in a transceiver chip. The desired speed is in minimum 10 Mbit/s. The signal improvement circuitry (SIC) transceivers specified in CiA 601-4 already achieve 8 Mbit/s. The edge symmetry and the voltage amplitude need to be improved. The SIG will organize plug fests to prove prototype implementations. The CAN XL protocol could be used for interoperability tests. “If we are fast, we can schedule a first plug fest beginning of 2020,” Zeltwanger said. - Edited from a CAN in Automation (CiA) press release by CFE Media. CAN in Automation is a CFE Media content partner.

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enhance contrast in 3-D images for more accurate imaging results.

4. Deep learning

Some companies are making strides in deep learning, and this technology is one of the latest buzzwords. A few of the largest software developers have image classification tools based on deep learning that detect hard-to-define defects and product variations. Machine vision software plays a critical role in the performance of a vision system. Today, identifying the right software for a machine vision application is as important as finding the right hardware. This article originally appeared in Vision Online. AIA is a part of the Association for Advancing Automation (A3), a CFE Media content partner. Edited by Chris Vavra, production editor, CFE Media, [email protected].

Headlines online Top 5 Control Engineering articles Jan. 14-20 Articles about MQTT as an IoT message transport, industrial controller selection, hot 2018 Control Engineering topics, improving industrial network communications, and IIoT software’s future were the most-viewed from Jan. 14-20, 2018. Machine vision use growing in food and beverage industry The food and beverage industry has been an early adopter of machine vision technology. The Benefits of a Standardized Communications Layer: Your Questions Answered Webcast presenters Sam Elsner and Philip Bard answered questions about topics such as data acquisition reliability, communication layers and cybersecurity, and more. Vacuum gripper benefits for collaborative robots Vacuum grippers can be beneficial for collaborative robots, but the type of application and the potential costs associated with them need to be considered. www.controleng.com

The power of space If you could use a product in your control panel that required up to 69% less space than traditional solutions, while providing up to 200 kA SCCR, would you?

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INSIGHTS ThinK AgAin

®

3010 Highland Parkway, Suite 325, Downers Grove, IL 60515. 630-571-4070, Fax 630-214-4504

Use the positive effects of automation to plan ahead

Content Specialists/Editorial Mark T. Hoske, Content Manager 630-571-4070, x2227, [email protected] Jack Smith, Content Manager 630-571-4070, x2230, [email protected]

Automation helps manufacturing employment, exports, and productivity. Key concerns include training, raw materials, and trade.

Kevin Parker, Senior Contributing Editor, IIoT, OGE 630-571-4070, x2228, [email protected]

ositive economic health of manufacturing because of automation, advice about planning, and expansion plans for an automation trade association and standards group were among views shared at the A3 Business Forum in January. The Association for Advancing Automation (A3) annual meeting covered topics related to its constituent organizations, the Robotic Industries Association (RIA), Motion Control and Motor Association (MCMA), and AIA (Advancing Vision and Imaging).

Amanda Pelliccione, Director of Research 978-302-3463, [email protected]

P

mounting interest payments will lead to an economic depression (with a D) around 2030. Without reductions in U.S. government spending and surplus paydowns of the massive debt by 2020, the 2030 depression is unavoidable, Beaulieu explained, with no way to “spend out of it” as the ability to borrow more ends. Options include gaining awareness and foresight within your markets, borrowing during prosperity, and paying down debt in time to get the resources, tools, and talent to prosper during pending downturns, he said.

Manufacturers plan

2019 market, training

Automation is the hero of Alex Shikany, vice president the U.S. manufacturing growth of AIA, part of A3, said optistory because advancing techmism continues to be very high nology creates jobs and opporin the machine vision, motion Mark T. Hoske, tunities as it displaces some Content Manager control, robotics manufacturing people and creates better jobs industries. Many indicators sugwith higher pay. Automation gest solid growth, but he noted helps manufacturing employment, (high- a softening in the market, slower growth, est in 11 years), aids exports, and adds in the last three months. Among the largproductivity, according to Dr. Alan Beau- est concerns for manufacturers, Shikany lieu, president, ITR Economics, who said, are attracting and retaining a quality gave a global 2019 economic outlook and workforce, price increases in raw materials, forecast. trade uncertainties, and rising health care Looking at the rate of change for a and insurance costs. 12-month average growth rate is particuShikany, citing various sources, said 2.4 larly useful for organizations. million jobs will be unfilled because of the He said 2018 growth of 3.9%, while skills gap by 2028, and, as a result, $454 bilrevised upward, is not sustainable because lion in economic output is at risk of being of the large size of the U.S. economy, and lost. While automation may eliminate as recessionary pressure will likely come in many as 75 million jobs globally, 133 milthe second half of 2019 in some markets. lion new jobs will be created by automaEconomic growth will resume from tion, according to the World Economic 2020 to 2022. “What do you need to do Forum, Future of Jobs Survey, 2018. to get ready for that?” he asked, because A3 announcements from president Jeff “Competitors will outdo you.” Burnstein included a plan to increase A3 Continued U.S. deficit spending, infla- branding, and encouragement for attendtion, health care costs, demographics, and ing the Automate show April 8-11. Think again about economic cycles and how your business is planning ahead by investing in automation technologies, workforce, and other areas as www.controleng.com needed to accelerate through economic www.a3automate.org/one-a3 downturns. ce

M More INSIGHTS INSIGHT

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Emily Guenther, Associate Content Manager 630-571-4070, x2229, [email protected]

Chris Vavra, Production Editor [email protected]

Contributing Content Specialists Suzanne Gill, Control Engineering Europe [email protected] Ekaterina Kosareva, Control Engineering Russia [email protected] Seweryn Scibior, Control Engineering Poland [email protected] Lukáš Smelík, Control Engineering Czech Republic [email protected] Aileen Jin, Control Engineering China [email protected]

Editorial Advisory Board

www.controleng.com/EAB Doug Bell, president, InterConnecting Automation, www.interconnectingautomation.com David Bishop, president and a founder Matrix Technologies, www.matrixti.com Daniel E. Capano, president, Diversified Technical Services Inc. of Stamford, CT, www.linkedin.com/in/daniel-capano-7b886bb0 Frank Lamb, founder and owner Automation Consulting LLC, www.automationllc.com Joe Martin, president and founder Martin Control Systems, www.martincsi.com Rick Pierro, president and co-founder Superior Controls, www.superiorcontrols.com Mark Voigtmann, partner, automation practice lead Faegre Baker Daniels, www.FaegreBD.com

CFE Media Contributor Guidelines Overview Content For Engineers. That’s what CFE Media stands for, and what CFE Media is all about – engineers sharing with their peers. We welcome content submissions for all interested parties in engineering. We will use those materials online, on our website, in print and in newsletters to keep engineers informed about the products, solutions and industry trends. www.controleng.com/contribute explains how to submit press releases, products, images and graphics, bylined feature articles, case studies, white papers, and other media. * Content should focus on helping engineers solve problems. Articles that are commercial or are critical of other products or organizations will be rejected. (Technology discussions and comparative tables may be accepted if non-promotional and if contributor corroborates information with sources cited.) * If the content meets criteria noted in guidelines, expect to see it first on our Websites. Content for our e-newsletters comes from content already available on our Websites. All content for print also will be online. All content that appears in our print magazines will appear as space permits, and we will indicate in print if more content from that article is available online. * Deadlines for feature articles intended for the print magazines are at least two months in advance of the publication date. Again, it is best to discuss all feature articles with the appropriate content manager prior to submission. Learn more at: www.controleng.com/contribute

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ANSWERS

CONTROL SYSTEM SELECTION Lynn Njaa, Maverick Technologies

Selecting an effective process control system Selecting a process control system (PCS) involves experienced personnel and understanding critical elements for operations.

T

he process control system (PCS) ties all the automation elements of a process manufacturing unit together and affects every aspect of operations. As the brain and central nervous system of a facility, its performance level and quality is crucial to keep operations running smoothly. As new technology is introduced in the automation and control industry, now is the time for manufacturers to modernize a process control system (PCS) platform to improve efficiency and operational performance.

M More ANSWERS

KEYWORDS: process control

system (PCS) Factors to consider for PCS implementation projects Installing a PCS is an infrequent and complex process. Bringing in an experienced and independent platform automation partner can be invaluable.

COnSiDER thiS What elements would your facility require for a PCS installation?

OnLinE Read more about process control systems online at www.controleng.com.

Factors for choosing a PCS

It is necessary to weigh all system infrastructure options. An educated decision will have a positive impact on the facility’s ability to produce effectively and profitably. The assigned project team, which may include outside consultants, should know the challenges inherent in the decisionmaking process. They must plan early and set a positive course, steering clear of subjective or emotional views based on past experiences and focus on delivering the best strategy. Tools and methods exist to help shed more objective light on these types of projects so groups can make more informed decisions. Teams can then decide

based on the facility’s specific needs and process, while considering the three following critical factors:

1. To begin, the team should review what the

company makes and how these products are produced.

2. Next, they should specify the critical to qual-

ity (CTQ) parameters, which have the greatest effect on quality and efficiency. Key stakeholders—operators, process engineers, maintenance, production management, and others—involved in the automation project must help determine the CTQ list. One of the first questions stakeholders should ask is what makes a day successful from an operational standpoint, and where does the the PCS fit? The list of CTQ elements should be arranged with the most important element at the top (Table). This approach helps sort the strengths and weaknesses of each PCS.

3. The next step is to rank each vendor on its

ability to meet each requirement. All items listed will need to be considered for its performance now and going forward— vendors must be flexible to deal with emerging technology trends. Such track records can be useful to predict how a vendor will respond to new waves of technology.

A PCS installation or migration project is a major investment. Choose wisely when selecting the next PCS platform and consider the experienced people who will help ensure the project is successful. ce

Table: Side-by-side comparison of PCS strengths and weaknesses for various requirements. Courtesy: Maverick Technologies

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Lynn Njaa is a senior consultant for Maverick Technologies’ DCSNext and leads team efforts to provide consulting and other front-end engineering services. Maverick Technologies is a CFE Media content partner. Edited by Emily Guenther, associate content manager, Control Engineering, CFE Media, [email protected]. www.controleng.com

input #11 at www.controleng.com/information

ANSWERS

PROCESS CONTROL SYSTEM UPDATE Travis Cox, Inductive Automation

Upgrading hardware, software An open, interoperable approach allows companies to get best-in-class hardware and software upgrades. See 10 reasons to upgrade process controls.

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istributed control systems (DCSs), supervisory control and data acquisition (SCADA) software, and process controls are vital manufacturing systems. Keeping these systems up-todate is very important. Reasons why these systems need to be upgraded include these 10: 1. Operating system (OS) obsolescence 2. Islands of information (independent systems) 3. Decentralized maintenance 4. Yearly software maintenance costs 5. New requirements the system can’t handle 6. Being stuck to specific OS, hardware, or versions of software 7. Security concerns 8. Open standards rather than proprietary 9. Third-party system integration 10. An open, interoperable, and secure foundation.

Many organizations are faced with aging infrastructure and old software. With the introduction of the Industrial Internet of Things (IIoT) and increased demand for data from the business, the worlds of operations technology (OT) and information technology (IT) are colliding. Upgrades, which may include a newer version of the same software platform or upgrading to a new software platform, are more important than ever. When identifying potential upgrades, there are three main categories to keep in mind: cost, security, and new technology. Keywords: Software

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upgrade, hardware upgrade, cybersecurity Companies need to upgrade hardware and software systems. Upgrade considerations: Costs, cybersecurity maintenance, and technology upgrades. Move to an open, interoperable platform for flexibility, strong ROI.

Consider this What are key criteria when moving to new process control software?

online Read this at www.controleng. com for more on control software upgrades, cybersecurity.

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Reasons for constant upgrades

One of the biggest drivers for upgrades is OS obsolescence. Several industrial software packages rely on specific versions of Microsoft Windows or specific hardware and will not run on newer versions without an upgrade. IT departments are forced to perform these upgrades for security and maintenance reasons. Systems cannot be air-gapped anymore; significant risk is involved when deciding not to upgrade. That gives the operations team little choice in carrying out the upgrade. They must decide—based on cost, maintenance, and technology—to stay with the same

control engineering

software vendor or switch to a new one. Expensive yearly costs for software maintenance and support are another driver toward upgrades. Organizations typically move to new software platforms with lower costs. Many software platforms don’t cover upgrade protection to newer versions, or upgrades to newer versions are not compatible. It’s important to install packages that have backward compatibility or packages that provide a straightforward path to the newest version during an upgrade. It’s important that all communication on an industrial network is encrypted following today’s standards. Software should be pen tested to identify any potential vulnerabilities such as no encryption, “human-in-themiddle” attacks, session hijacking, and others.

Push toward open standards

Sometimes, the largest drivers in upgrades are new requirements, architecture changes, third-party integrations, and a shift to open standards. Customers don’t want proprietary/closed systems that are difficult to upgrade or replace. Instead, the shift to open standards allows for using best-in-class software and hardware from multiple vendors. Using open standards such as OPC UA, MQTT, SQL, HTTP/HTTPS, and REST/SOAP allow for plugand-play interoperable systems. These are standards OT and IT can understand. OT and IT should work together rather than independently. Upgrading these systems can allow for data sharing across the enterprise. Upgrades may be expensive up front, but provide plenty of long-term return on investment (ROI). The most important consideration is understanding how a system will operate by itself and how it fits into the enterprise. Open, interoperable, and secure platforms provide companies flexibility and are easier to maintain. It’s much easier to upgrade or replace individual pieces than the entire infrastructure. The industry is changing and demanding open, interoperable, and secure systems. The good news is modern software and hardware companies are evolving to incorporate these standards. Those upgrading systems should find software and hardware that meet requirements. ce

Travis Cox is co-director of sales engineering at Inductive Automation. Edited by Chris Vavra, production editor, Control Engineering, CFE Media, [email protected]. www.controleng.com

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Learn more and register today at: events.abb/acw input #12 at www.controleng.com/information

ANSWERS

CyberseCurITy In OT And IT Cyberse Camilo Gomez, Yokogawa Electric Corp.

Proactive management of plant cybersecurity A combination of information technology (IT) and operations technology (OT) cybersecurity expertise is required to manage the influx of Industrial Internet of Things (IIoT) devices and increased IT/OT integration.

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he inward-looking plant control system is giving way to a wider and flatter network architecture, which requires a different cybersecurity focus. Operations technology (OT) is undergoing a sea change in goals, structure, and management—as is information technology (IT) with the integration of the plant control system with the business systems. This makes it necessary to manage giant data flows inside the plant. The physical plant continues to be important, but it is complemented and managed by the virtual plant, a concept that makes possible a “digital twin” of the actual plant. Management and operations can use the digital twin to experiment and improve operational efficiency. New tools and process controls are becoming available. Robots and virtual reality can be used in hazardous areas to improve operator safety, and simpler, easier-to-operate advanced process control systems are becoming common. Outside the plant, the cloud and related applications have made the Industrial Internet of Things (IIoT) practical and useful. An IIoT implementation proliferates new sensors inside and outside the plant to improve plant performance. Open process automation (OPA) initiatives—intended to produce a common platform so controllers, sensors, and software can work together without compatiFigure 1: bility issues (Figure 1)—have Cyber threats been added. are proliferating These trends are occurdue to increased information technolring simultaneously and have ogy/operations technology (IT/OT) contributed to disruption. integration, along with the advent of Old ways of running process the Industrial Internet of Things (IIoT) plants are not competitive and open process automation (OPA) in many process industries. initiatives. All images courtesy: Disruptive events can create Yokogawa Electric Corp. innovation and add value.

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OT cybersecurity transformation

Traditionally, sensors and controllers have been connected to the plant control system using wires or using wireless protocols. OT cybersecurity has focused on protecting the plant control network and keeping unauthorized users from invading the control systems. However, OT cybersecurity is now transforming. The principles and practices of OT cybersecurity are being used in non-traditional automation sectors, such as building automation, transportation, and medical automation. What used to be a hard-wired perimeter has moved outward from the plant and become virtual. The 2-D structure of OT cybersecurity is 3-D with the inner applications, level 0 and 1 devices and applications, and sensor devices connected directly to the cloud. From there, they’re connected to the automation systems; maintenance, repair, and operation (MRO) systems; and plant business systems. Plant operations personnel always have recognized the need for functional safety. The rise of OT cybersecurity has made it clear an insecure plant is an unsafe plant. Cybersecurity and functional safety mirror, overlap, and complement each other. Security of the safety instrumented system (SIS) is a critical function, the same as basic plant control system security. With fully integrated business systems, the cybersecurity of the entire value chain is critical. Making a supply and a distribution chain integrated and secure are essential in today’s enterprise. OT cybersecurity is no longer a static function; it is a fluid and continuously changing entity that must be managed carefully.

OT cybersecurity threats, defenses

As the function and footprint of OT cybersecurity have grown and changed, the threats it faces have broadened. Traditional cybersecurity evolved to deal with threats in the IT environment such as email phishing, human-in-the-middle penetration attacks, malware, and disaffected employees. First-generation OT cybersecurity began with IT-derived implementations such as perimeter security and air gaps. www.controleng.com

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ANSWERS

CyberseCurity in Ot and it Figure 2: Cybersecurity must be applied in the process industries from the enterprise to the application level.

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The plant of the future will integrate operational reliability monitoring, security monitoring, and network monitoring with process monitoring.

’

The second generation of threats was more plantcentered. Advanced persistent threats (APTs) continue stealthy attacks from outside the enterprise aimed at IP theft or destruction of plant operations. The third and current generation of threats is persistent and focused on causing harmful disruption to plant operations. It potentially is destructive to machinery and systems. Threats have evolved to become OT-specific as hacking has evolved, as well. OT cybersecurity defenses have been reactive, complacent, and conformance-oriented. They typically are based on IT technologies, not always a good fit for OT purposes and have often evolved slowly into OT security technologies. They have been based traditionally on conformance to standards and based on lifecycle, certifications, and regulations. These defenses are relatively easy to penetrate, especially with APTs, and provide an unrealistic sense of security. Standards such as ISA/IEC 62443, the NIST framework, NERC CIP, and others have provided a framework and a path forward to designing good OT security postures for plants. The ISA Security Compliance Institute has provided “ISA Secure” component certification since 2010. Standards compliance does not necessarily result in adequate or increased cybersecurity protection.

OT cybersecurity challenges

The basic OT cybersecurity challenge is to deal with the ongoing industry transformation. First, it is necessary to assess the effectiveness of traditional controls and cyber tools. Traditional penetration testing has been used for this. The problem is it is very difficult to operationalize these traditional tools without considerable training and overhead to get from the theoretical to the practical. The current challenge is moving the perimeter from the physical plant and a network-centric focus

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to the virtual, which requires providing security to edge components and applications (Figure 2). Edge devices are numerous and proliferating. This makes it impossible to provide a secure cyber environment without protecting edge devices in real time to maintain security for each Level 0 and 1 device. One main issue is the increase of poorly-secured IIoT devices being installed in plants to send data to the cloud and then to the plant. These IIoT devices can provide intrusion vectors that are overlooked by plant operators and engineers eager to get more data. The plant is insecure if the supply chain is insecure. The high integration between the supply chain and the control system required in modern process plants makes the supply chain a vector for potential attacks. Active anomaly detection is needed to maintain a secure plant network. This makes it possible to achieve the posture of predictive and preventive response instead of reactive and conformanceoriented activity. This includes outside-the-plant threat intelligence. Often the best option is to move from a reactive approach to an adaptive security posture. The plant of the future will integrate operational reliability monitoring, security monitoring, and network monitoring with process monitoring. Detection will be transformed from signaturebased detection to anomaly detection. OT cybersecurity must be integrated with management of change functions, alarm management, safety systems, and security information and event management. The entire plant operational system revolves around security and safety. For many process plants, it can be difficult to implement a modern functional security position. This is where companies specializing in cybersecurity can be of assistance to process plants. ce Camilo Gomez, global cybersecurity strategist, Yokogawa Electric Corp. Edited by Chris Vavra, production editor, Control Engineering, CFE Media, [email protected].

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Keywords: cybersecurity, OT cybersecurity,

Industrial Internet of Things (IIoT) Process cybersecurity threats are more sophisticated. Information technology (IT) and operations technology (OT) are merging and need to cooperate. Process plants need adaptive security.

Consider this How can cybersecurity strategies add security?

online Read this story online at www.controleng.com for more about OT cybersecurity. www.controleng.com

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CYBERSECURITY

Ken Robinson, Southland Energy, a division of Southland Industries

Best practices to help improve system security With increased connectivity between different devices, it’s critical to implement additional cybersecurity measures.

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ybersecurity vulnerabilities can affect our everyday lives. Energy management and control systems (EMCS) are seldom top-of-mind for the general public. An EMCS is, in some ways, a glorified thermostat designed to ensure conditions remain comfortable within a building. Normally, there is no cause to worry about it. However, EMCS, and similar systems called supervisory control and data acquisition (SCADA), control equipment whose proper operation is fundamentally critical to a building. Shutting down any of these mechanical systems threatens the building’s ability to function properly. Sabotaging a building does not necessarily require a direct attack. It can be as simple as shutting down a fan or a boiler at the right moment.

EMCS security

Historically, EMCS security wasn’t an issue. Most had limited or no connections to the outside world and operated on proprietary networks, separate from the standard Ethernets of the information technology (IT) world. In some ways, this anonymity was the best defense since the level of security designed into the systems was often low, and system users gave little attention to the issue. KEYWORDS: Cybersecurity, Cyberattacks on industrial systems cyberattack that control processes are common. In Energy management and control systems (EMCS) control 2015, 295 attacks on such systems were equipment that is fundamentally reported to U.S. authorities. By 2017, that critical to a building. number exceeded 1,000. Despite this, all Best practices against major communication protocols for facilcyberattacks ity and industrial control systems are vulA variety of offline/online nerable to a cyberattack. tactics can be used to improve This problem is exacerbated because cybersecurity. building and industrial engineers are not COnSiDER thiS typically IT or cybersecurity experts. Their Are your employees aware of focus is on ensuring the systems perform measures to take to increase their intended tasks with security as a seccybersecurity? ondary concern. In many cases, the specOnLinE ifying engineers, installers, and building Read more information about operators lack the awareness or training cybersecurity on needed to ensure these systems are secure. www.controleng.com.

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Ways to increase system security

Defending these systems against potential attacks can be broadly divided into two categories: internal and external attacks. External attacks are likely to originate from the internet. For this reason, all internet connections should be treated as potentially hostile and secured against intrusion. Several defense options should be explored such as: • No internet connection – While secure, this severely limits the functionality of modern systems, which need to exchange data with a host of other applications or need to be monitored/ controlled from remote locations. • Remote desktop application – This requires a dedicated software package running on a remote computer. While effective, this creates another point of vulnerability at the remote computer, which must likewise be protected. • Virtual private network (VPN) firewall – Similar to a remote desktop, but with a more secure connection. The remote computer still requires protection. • Dedicated EMCS/SCADA web server – Rather than connecting an EMCS directly to the internet, a separate server is placed behind a firewall with restricted access to the server.

Any of these, or implementing a combination of these options, will improve a system’s security. All of them, however, will be useless if a hacker obtains authentication credentials from an end user. Guarding against this requires the same policies found in IT departments, which mandate strong, frequently changed passwords and active protection against probes such as phishing emails that try to lure users into disclosing their passwords. In addition, physically protecting the system components behind locked access is a must. ce Ken Robinson is the director of operational excellence for Southland Energy, a division of Southland Industries, a CFE Media content partner. Edited by Emily Guenther, associate content manager, Control Engineering, CFE Media, [email protected]. www.controleng.com

ANSWERS

POWER MONITORING CASE STUDY Nelly Ayllon Lazo, PI North America

Network, control system upgrade A system integrator supplied an industrial Ethernet network and PLCs to an expanding food supplier and created $125,000 in annual energy savings.

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national food supplier sought to expand its Boca Raton, Fla. distribution center due to growing business demand. This project required additional refrigeration equipment, which potentially meant higher energy bills. The company was looking to reduce energy costs and modernize its control system. Global Controls Solutions LLC (GCS), a system integrator, wanted to achieve the company’s goal with programmable logic controllers (PLCs) and a Profinet industrial Ethernet network. This network transmits data from the refrigeration system to help the facility limit electrical charges in real time. “At $ 0.02/kilowatt hour (kWh), energy wasn’t a big issue, but now at $ 0.145/kWh, it represents a significant operating burden,” said Vito Lampugnano, GCS president. “Calculations after the control system upgrade showed roughly 960 kW) were load shed, which calculates into a savings of approximately $125,000 per year in utility charges.”

Phase 1: Load shedding

During phase 2 operations, the facility’s electrical system is designed to shed “on” peak loads to take advantage of favorable electric rate schedules. Known as “peak shaving” or “load shedding,” it enables the facility to reduce equipment energy consumption during peak electric utility cost times. During daily load shedding, selected refrigeration equipment and parts of the electrical system are load shed (turned off).

Phase 2: Load shifting

During phase 2 operations, the facility’s energy supply shifts from the electric utility to the on-site generator. This “load shifting” refers to the ability to take the facility off the grid at peak times or at the request of the utility. The refrigeration plant is set up so the local electric utility can ask the facility to go offline during power outages, shortages, and weather-related incidents. During load shift operations, all electrical loads and refrigeration equipment are in full operation, powered by the generator. Expansion included a 2 MW generator and a 4,000 A main switchgear that was interfaced with the existing switchgear. The generator and switchgear were networked to operate the facility during load shifting. A standby generator originally was used to operate the plant at nominal energy levels during normal power

www.controleng.com

Global Controls Solutions LLC (GCS), a system integrator, helped achieve a food supplier’s goal of improved energy efficiency with programmable logic controllers (PLCs) and a Profinet industrial Ethernet network to improve overall operational efficiency. Courtesy: Global Controls Solutions

outages; the generator is designed as a full-time run unit. Fuel oil is sent automatically from large storage tanks to the day tanks used to feed the generator. The distribution center is served by a central ammonia system using liquid recirculation for the low temperature evaporators and direct expansion for the medium and high-temperature evaporators. The old control system could not provide “the kind of data flow we needed to optimize operational efficiency,” Lampugnano said. “The distributed control system now monitors all refrigeration plant pressures and temperatures, atmospheric dry and wet bulb temperatures, equipment operating times, plant operational set points, and system optimal set points.” It controls the switchgear, the generator, and the compressors via a Profinet Keywords: Profinet, programmable logic controller, industrial Ethernet backbone. Pressure Ethernet and temperature data are updated and A system integrator provided recorded to identify operating trends. This PLCs and a Profinet industrial makes it possible to adjust and optimize network to improve operations. the refrigeration equipment. The Profinet network helped Being able to control and monitor an streamline communications and integrated system and analyze the trendenergy efficiency to optimize operations efficiency. ing data this integration enables are “key to The network upgrade will provide optimizing processes, making them more the food supplier with $125,000 of reliable and reducing energy and other utility savings per year. operating costs,” Lampugnano said. ce

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Consider this

Nelly Ayllon Lazo, technical marketing director, PI North America. Edited by Chris Vavra, production editor, Control Engineering, CFE Media, [email protected].

What benefits can smarter networking provide?

online Read this story online at www.controleng.com for more.

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ANSWERS

POWER MONITORING Sree Potluri, Beckhoff Automation

Maximize production efficiency with high-end power measurement Machine-friendly I/O hardware for high-end measurement technology continues to grow, optimizing power monitoring and eliminating harmonic distortion.

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ver the past decade, power measurement technology has continued to advance— giving controls engineers many options. Black box technologies are no longer the only options for power monitoring. High-end measurement strategies exist as extensions of standard machine control platforms. System-integrated input/ output (I/O) terminals gather data to be analyzed in the cloud or on a local PC and also perform power analysis on the hardware. High-end measurement I/O modules provide costeffective options to enhance each of the main energy measurement categories including power monitoring,

power measurement, and maintenance. Because these I/O terminals are open, they help plants expand the range of power measurement data that can be gathered and analyzed. Adding high-end power measurement technology to each machine and production line will allow engineers to optimize equipment performance, diagnose issues faster, and complete predictive maintenance as irregularities begin occurring, which increases plant uptime, efficiency, and profitability. EtherCAT-enabled I/O modules for power monitoring offer sampling rates at a resolution of 50 µs, which is capable of monitoring any dynamic system.

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These modules also simplify power monitoring by providing values of three-phase voltage up to 690 V ac or 400 V dc and currents up to 5 amps. High-end power monitoring is used for grid analysis and monitoring incoming power. It is often used at the machine level and these modules can provide information necessary to correct harmonics in the power supply from the utility, which cause distortion and undesired results. The combination of fast sample rates and application-specific capabilities leads to better and more actionable data insights. High-end power measurement modules help accomplish this through three key technologies along with the advantages PC-based control platforms provide.

such as message queuing telemetry transport (MQTT), OPC Unified Architecture (OPC UA), or advanced message queuing protocol (AMQP) to further analyze or compare the performance of individual machines against the entire line and plant. Further calculations can determine root-mean-square (RMS) values for voltage and current, minimum and maximum values, and the system’s harmonics. The increased efficiency and produc-

tion delivered by high-end measurement, along with more affordable packages, gives the power for machine and plant optimization directly to the controls engineer. ce Sree Potluri is an I/O product marketer from Beckhoff Automation. Edited by Emily Guenther, associate content manager, Control Engineering, CFE Media, [email protected].

WIRED FOR THE FUTURE

Distributed clocks, oversampling, timestamps

Like other EtherCAT devices, highend power measurement modules rely on distributed clocks, oversampling, and timestamps to provide high-precision data. These EtherCAT technologies work together to provide high sample rates with precise synchronization among all devices at less than 1µs. These technologies are even more effective when they’re combined with PC-based control. When using an industrial PC and automation software for machine control and monitoring, the process data acquired through high-end measurement modules can be further analyzed using existing software libraries on the machine. In addition, the data is transmitted from the local controller to the cloud using common communication protocols

M More ANSWERS KEYWORDS: Power measurement,

harmonics, EtherCAT Eliminating harmonic distortion with highend power measurement technology Benefits of high-end measurement technology.

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How can you use power measurement technology to resolve/predict power quality issues?

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ETHERLINE ®

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lappusa.com input #16 at www.controleng.com/information

ANSWERS

INSIDE MACHINES: COVER STORY Tanya M. Anandan, Robotic Industries Association (RIA)

Demystify robot programming Software suppliers are disproving preconceptions about robot offline programming (OLP) being too complicated or not cost-effective.

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ven though offline programming (OLP) has come a long way, misconceptions about it still linger. A lot of robot programming in the welding industry still is done manually, point by tedious point, with a teach pendant. Many still remember the old days of robotics that overpromised and under delivered. Dreamers and doers have been working to exceed expectations. Simulation and OLP software has evolved and become smarter, faster, more flexible, and reliable. This is a new era in ease of use and OLP software suppliers are here to demystify the softer side of robotics. Most simulation and OLP solution providers will tell you it’s not one or the other. Simulation and OLP go hand in hand. Though the terms oftentimes are used interchangeably, but you can have simulation without OLP but you cannot have OLP without simulation. Robot simulation is the 3-D representation of a robotic cell or production line. It visually demonstrates how a robot moves along a path or trajectory Figure 1: Offline programming (OLP) software accurately simulates a robotic welding process using calibrated data for robot kinematics, external axes, and workpiece positioners. Courtesy: CENIT North America Inc./Robotic Industries Association (RIA)

from one XYZ coordinate to another XYZ coordinate. It can include multiple robots mounted on external axes working with multi-axis workpiece positioners, or coordinating on an assembly line. All this movement and planning, however, can get complicated. “A lot of customers purchase a robot thinking it will behave like a computer numerical control (CNC). This is not the case,” said Albert Nubiola, CEO of RoboDK Inc. “CNCs are easy to program. The workspace is properly defined. It’s like a cube.” However, robots have a spherical workspace, and because of joint limits and robot singularities (points at which a robot movement is not mathematically predictable), there are certain types of movements you cannot do. OLP helps avoid errors when programming a robot. In robotic machining, there could be hundreds to thousands of points,” Nubiola continued. “Nobody would ever be able to program that point by point using a teach pendant. You definitely need software to be able to do that offline.” Simulation can be used for a proof of concept such as a robot integrator’s sales tool to demonstrate how a robotic system will perform. With simulation, users can detect possible collisions between the robot, tooling, fixtures and any safety fences. Simulation can analyze joint limits, singularities, and reach issues. Plus, it can reveal a host of eye-opening issues that save time and money in the long term. OLP uses simulation to output robot-specific code that can be loaded onto the physical robot controller and run the program. Post processors turn programming code into a language the robot can understand. Robot manufacturers have their own proprietary programming languages, which means third-party software must be multilingual.

When OLP makes sense The main impetus for OLP is robot downtime, which is the time required to manually program a robot point by point with a teach pendant. There also are costs associated with the machine’s downtime and the programmer’s labor. “If an end user is manually programming a robot on the teach pendant (online), they have to shut down production in order to program the part,” said Rob House, director of sales at Octopuz Inc. “The benefit of using offline programming is you can be running production, and you can program your next two, three, or five parts offline in the software and

Figure 2: A collaborative robot is programmed offline, saving operators months of manual programming time for this tedious railway maintenance process requiring hundreds of repetitive movements. Courtesy: Hypertherm Robotic Software Inc./RIA

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then once you’re ready to start a new job, you can just switch over the program and then start your production again.” OLP is best-suited for complex path planning applications that require a lot of points such as welding, trimming, laser cutting, deburring, thermal spraying, painting, laser cladding, and additive manufacturing. OLP isn’t as beneficial for simple pick-and-place applications, assembly, packaging, and palletizing. These applications still can be programmed using offline software, but users may not realize their return on investment (ROI). It’s more cost-effective to program manually if the process has only four or five points. “If you’re spending as much time programming in software as you do with a teach pendant every single time you have a new part, you’re not any better off,” said Garen Cakmak, senior director at Hypertherm Robotic Software Inc. “For robots in a high-mix, lowvolume environment, software needs to be easy.” Improving ease of use is top priority for these software developers. But simulation and OLP are pointless if they don’t accurately reflect reality.

Figure 3: An arc welding cell uses OLP to help meet production demand by cutting programming time in half and reducing robot downtime. Courtesy: Octopuz Inc./RIA Figure 4: OLP software simulates robot path planning for a novel inspection system under development at NASA. The system uses collaborative robots equipped with infrared cameras to test for defects in composite aircraft structures. Courtesy: RoboDK Inc./RIA

Calibrate and don’t deviate

For OLP to work, the virtual world must match the real world. This means the simulation must represent the physical robotic cell accurately. “The virtual environment in OLP software has to be an exact replication of the actual workcell on the shop floor, which is not the case in most situations,” said Helmut Ziewers, vice president of digital factory solutions for Cenit North America Inc. “The deviations between a computer-aided design (CAD) model and the physical part associated with that CAD model can be minor or significant, especially in conjunction with less than perfect tooling. We still see major issues and people saying we can’t do this offline, because of those deviations.” However, those deviations are not insurmountable. Calibration is critical. “If we are off just a few millimeters or centimeters, you can create as many offline programs as you wish,” Ziewers said. “They will never fit. We have to know exactly how that robot was set up on the shop floor, and there must not be any deviations or else the OLP won’t work. The toolpath, the trajectory will always be off. This was the case with Crown.” Crown Equipment Corp. manufactures powered forklift trucks. Its Roding, Germany, facility has several complex robotic welding systems with external axes and multi-axis workpiece positioners. Faced with production bottlenecks caused by time-consuming manual robot programming, Crown Roding decided to explore if OLP was feasible. Their journey was not without a few hiccups. Some on the Crown team were skeptical while others were eager to try OLP. Cenit was one of two suppliers brought into participate in a benchmarking study. Ziewers said they took CAD drawings provided by Crown’s automation integrator and created the virtual robotic workcell in their

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software. Based on those drawings, they created the robot program and ran it on the physical workcell. But something was off. Cenit engineers arrived on site to physically calibrate Crown’s workcell. “We found out what the differences were, dimensionally,” Ziewers said. “We applied those differences in our software and then adjusted the offline proKeywords: robots, robot gram based on the new setup in the virtual programming, collaborative robots world. This matched exactly the physical Robot offline programming (OLP) setup from the shop floor, and the robot is though of as complex and costly. program worked perfectly. ce Changes make programs easy-to-

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Tanya M. Anandan is contributing editor for the Robotic Industries Association (RIA) and Robotics Online. RIA is a not-for-profit trade association dedicated to improving the regional, national, and global competitiveness of the North American manufacturing and service sectors through robotics and related automation. This article originally appeared on the RIA website. The RIA is a part of the Association for Advancing Automation (A3), a CFE Media content partner. Edited by Chris Vavra, production editor, Control Engineering, CFE Media, [email protected]. control engineeering

use and flexible for many uses. Program collaborative robots for challenging applications.

oNLINe Read this article at www.controleng.com for more information about robot programming including: Easier programming, fewer constraints, one software with multiple robot brands, collaborative robot programming, less programming more producing, and four additional images related to OLP.

CoNsIder thIs Where can OLP help your company in the short- and long-term?

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ANSWERS

INSIDE MACHINES: COVER STORY Dr. Keshab Panda, L&T Technology Services

Future robotics, AI

Robotics and artificial intelligence (AI) will improve quality, throughput, safety, consistency, and more.

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Robots powered by artificial intelligence and machine learning are being employed to carry out mundane, repetitive tasks and more complex functions such as improving quality, throughput, enhancing employee safety, reducing waste and increasing customer satisfaction. Courtesy: L&T Technology Services

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KeyWORDs: Robotics, artificial intelligence Artificial intelligence and robotics add efficiencies. Human talent augments robotic implementations Software makes robots easier to program. CONsIDeR THIs Does your plant invest in future competitiveness?

ONLINe If reading from the digital edition, click on the headline for more on human talent, robots.

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eployment of robots, artificial intelligence (AI), and machine learning-based systems could bring many performance benefits for organizations. These benefits include improved product and service quality, greater throughput, enhanced employee safety, reduced variability, waste reduction, and, most importantly, higher customer satisfaction. It is incorrect to regard robotics and factories of the future as new concepts because they have existed for decades; it is the perspective around them has evolved over time. When Henry Ford replaced horse carriages with automotive engines, robotics became the driving force of our lives. His assembly line became the blueprint for later designs of manufacturing plants. Contrary to science fiction writer Isaac Asimov’s “Three Laws of Robotics,” which largely set the rulebook for human-machine interactions, progress in robotics, AI, and machine learning have brought in a new age of cognitive automation. The machines of today complement human performance in a range of work activities, including ones requiring perceptive capabilities that are in congruence with Ford’s manufacturing breakthroughs. They are providing the groundwork for the factories of tomorrow. As emerging technologies become more advanced and sophisticated, new knowledge, and portfolios have come into existence at an increasing rate using deep data domain expertise to complement the decision-making process. AI and machine learning-based systems have become economical, more adjustable, more compliant, and are transforming manufacturing. As the technology becomes increasingly straightforward to implement, the business decisions will be augmented by adoption of robotics. However, to capture the full value of these opportunities, organizations will need to take a holistic tactic and bring their automation strategy as close as possible with the current and future needs of the business. A research report by Technavio said the global robotics market size will grow by more than $32 billion from 2018 through 2022, at a compound annual growth rate (CAGR) of more than 11%. An estimate by Statista projected the robotics market to be worth almost $500 billion globally by 2025. The rapid growth of emerging technology, wide-

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control engineering

spread use of wireless applications, surge in the adoption of Internet of Things (IoT), and advancements in AI and machine learning are some factors expected to drive the growth of the global robotics market. These upcoming technology trends are already renovating business models across every sector and unbolting massive market and innovation opportunities. However, it should be also kept in mind these emerging tools and associated competitive advantages will be impermanent if industry leaders don’t capitalize and adapt to disruptive technology opportunities. For manufacturing organizations to remain competitive and relevant, they must conceive a well thought strategy supported by emerging technologies and robots for their value chain, from beginning to end of production and the supply chain.

New robot capabilities

Even robots are expected to think out-of-the-box rather than follow orders. The rise of machine vision technology juxtaposed with the progress in the IoT domain has given machines the ability to process instructions and images on their own and think about the next steps in the sequence of activities. This technology enables the robots to “see” and, as they mature, the robots will augment their ability to apply logic to things, and learn on their own. Collaborative robots will continue to flourish with easier programming, integration, and operations. Robots could be placed anywhere on the manufacturing floor and perform any task. With technology advancements such as embedded 3-D vision, multispectral and hyperspectral imaging combined with AI, machine learning, and deep learning, industrial robots will be empowered to improve themselves. Assembling, using, and maintaining robots have become faster and less costly with exponential increase in computing power, advancements in software-development approaches, and augmentation of networking technologies. Robots are loaded with sensors and actuators that self-monitor and report the status of the robot to the control system, to aid process control and collect data for maintenance, and for continuous improvement and troubleshooting. ce

Dr. Keshab Panda, is CEO and managing director, L&T Technology Services. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, [email protected]. www.controleng.com

2018 input #17 at www.controleng.com/information

WINNER

ANSWERS

INSIDE MACHINES: COVER STORY Enrico Krog Iversen, OnRobot; Michael Majchrzak, Control Engineering Polska

Collaborative robots accelerate Get answers about expansion of industrial robotics from an end-of-collaborative robot tooling company executive.

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Enrico Krog Iversen is CEO of OnRobot. Courtesy: OnRobot and Control Engineering Poland

ollaborative robots add productivity to manufacturing and executives from OnRobot answered related questions on the topic during the Forum Coboty 2018 in Wrocław, Poland, organized by Encon-Koester. OnRobot is a new Danish company that provides plug and product end-of-arm tooling to help manufacturers with collaborative robots. Universal Robots ex-managers formed the company in June 2018. Enrico Krog Iverson, CEO of OnRobot, provides answers while visiting Poland, among more than 80 countries where OnRobot is selling its products.

Control Engineering Poland (CEP): Why would Teradyne, without prior products in robotics, purchase Universal Robots? Enrico Krog Iversen: They were involved in the production of electronics previously, which is a relatively flat market. They asked themselves where can you get 50% or more growth in the industrial sector. Very few companies in the industrial or automation space could experience that sort of growth... and the investment has paid off. They are still growing and are now the leading collaborative robotics company. CEP: How did you get started with Universal Robots? Iversen: Three engineers founded Universal Robots in 2005, and they were out of money. Then the Danish Growth Fund, which is a government-backed venture capital fund in Denmark, invested in the company and asked me if I would be interested in running the company as CEO. I said OK that’s fine, the product is fine, but I did not like the strategy. I spent the next three months revising the business plan, and I invested my own money.

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KEYWORDS: Collaborative

robots, end-effectors Collaborative robots offer manufacturing flexibility. Easier end-effectors help with robotic integration. Programming robotics can be easier.

CONSIDER THIS How could easier to choose and use end effectors help your next robotic implementation?

ONLINE If reading from the digital edition, click on the headline for more answers and resources. www.controleng.com/magazine See other international coverage at www.controleng.com/ international www.controlengineering.pl

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CEP: After having consolidated three acquisitions, what is the overall strategy for OnRobot? Iversen: The overall strategy and goal of OnRobot is to facilitate the transition from collaborative robots to collaborative applications. The robots themselves will soon become commodities, and we are starting to see that with more market

control engineering

competition. We can add value in how you deploy robots, what you put on the robots, and what you put around the robots. The strategy of one robot is to be your hand, your eyes, your ears, your sensing capability, whatever makes your arm do anything. Your arm itself does not do much. We are looking at not just hardware in the form of collaborative robots, but also the software that manages these machines. CEP: Do you see the application development via software, or the robots (hardware) being more important as an R&D investment? Iversen: Software is the largest R&D division at OnRobot, and I think that it will continue. Not only for the physical grippers and sensors and so on, but also for developing a uniform user interface. OnRobot is developing products for UR and for other robot brands. I would like that when a robot picks up a gripper, that the user will have the same experience with one robot as with all other robots that use our software and hardware. It is similar to the PC model: you care much less about the hardware brand than you do about whether not its running [Microsoft] Windows. As long as it’s running Windows you are happy with it. And this is the direction that I would like to go. CEP: How simple must an operating system be? Iversen: If you want robots to be ubiquitous, the programming of the robots needs to be simple. You really have to make sure that the programming can be done by people that have no engineering background. In some countries the level of technology is quite high, and in other countries it is quite low. Our job is to make it easy to use the robots, particularly in programming the robots. CEP: Is the industrial sector the most important sector for OnRobot? Iversen: Yes, the industrial sector is by far the most important sector for us. Of course, there are many applications for our products, however, if you want to stay successful you need to stay focused. ce Enrico Krog Iversen is CEO of OnRobot and Michael Majchrzak is the publisher of Control Engineering Polska. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, [email protected]. www.controleng.com

MEASURE. EVALUATE. VISUALIZE & CONFIGURE.

3-Phase Power Measurement Made Easy with the WAGO-I/O-SYSTEM r Integrate with a variety of networks and I/O modules r Advanced features like Harmonic Analysis r Supports compliance to ISO 50001 Energy Management

www.wago.us/power-measurement

input #18 at www.controleng.com/information

ANSWERS

INSIDE MACHINES By Susie Cumberland, IHS Markit

The human factor of IoT in safety Technology can be part of the safety culture in plants.

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Improper use of a safety interlock switch is a dangerous

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practice.

he Internet of Things (IoT) is not just about improving the production on the factory floor; it can aid in creating a safer working environment. The U.S. Bureau of Labor Statistics reported in 2016 that within the private manufacturing sector there were more than 300 fatalities and more than 410,000 non-fatal occupation injuries. Similar statistics published by the UK-based Health and Safety Executive (HSE), there were 19 fatal injuries and 60,000 non-fatal injuries reported in 2016 to 2017. Contact with machinery accounted for 18% of fatal injuries and 12% of non-fatal injuries, at a cost of more than $700 million. With such significant costs associated to such incidents (both personal and financial), a consideration of how new technologies can mitigate risk for workers is a crucial consideration. Within manufacturing, applications for how IoT can improve processes have been well covered. However, for IoT and safety, the benefits to personnel is less discussed. One application showing how IoT solutions could support preventive safety is by predicting patterns in workers on the factory floor, that would reduce the risk of injury.

Human factors, output contracts

The benefits of safety solutions, especially connected safety solutions, have certainly been emphasised in the recent years as IoT drives industrial automation into the digital age. One benefit that is regularly mentioned is increasing profit, based on improved efficiency and productivity. However, improved safety can also reduce costs resulting from non-fatal and fatal injuries to KeyWORDs: personnel. Machine safety, safety culture The HSE stated that in 2016/2017, Pattern predictions could within the manufacturing sector there improve safety. were 159 court cases related to injuSafety standards had more that ry. The average fine per case was about 50 changes in 2015 and 2016. $213,271, not including other legal fees. Thwarting safety technologies and procedures can increase risk. Lack of proper safety measures can result in fines, compensation, pay for COnsiDeR this sick leave and recovery, as well as addiWhat technologies and tional costs. Globally in in 2015 and procedures are lowering your risk? 2016, there were more than 50 changes Online to safety directives and standards. These At www.controleng.com look changes can be initially costly to impleunder topics and discrete ment; however, they can save lives and manufacturing to find the machine safety page. money in the long term.

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While companies may put safety measures in place for machinery to deter or prevent unsafe or unauthorised access, they can be ignored or misused due to the culture surrounding safety or the industry a worker is in. Poor practice can render a safety measure useless. This has been illustrated in some cases of zero-hour contract workers. Some contracts are paid dependent on output rather than by hour, which can result in a sense of urgency. Safety measures can increase the time taken to do a task and it has been known for workers to disable, or work around safety procedures to save time.

Machine safety and IoT

Industrial IoT (IIoT) is increasingly influencing safety products and solutions, through improved connectivity of more intelligent devices, with vendors able to support customers with data that can provide insight on production, in addition to core safety features. An example of smarter safety technology is laser scanners intended for outdoor and warehouse use. These products can be used to support vehicle navigation, cranes and robots; prevent collisions; and provide protrusion monitoring for storage, which checks for prohibited protruding objects that may result in improper storage, for example in warehouses. This means that laser scanners not only provide safety, but also aid in navigation, logistics, and storage management, therefore increasing efficiency and productivity. IoT is aiding product development, which could help tackle unsafe situations. For example, RFID technology is used with safety interlock switches to allow for single monitoring of doors and provide important insight on usage. Improper use of a safety interlock switch could allow a guard or gate to be opened or unlocked, rendering the product useless. This is a dangerous (but not uncommon) practice pushed by workers chasing productivity gains rather than following safety processes. By better understanding these behaviors, it may be that further training is given, the interlock switch design and gate is adapted, or even the worker contract itself is reviewed. ce

Susie Cumberland is an analyst in manufacturing technology for IHS Markit. Edited by Bob Vavra, CFE Media, [email protected]. www.controleng.com

ANSWERS

INSIDE MACHINES Robert Bonczar, Yaskawa America Inc.

Selecting a scope for a variable frequency drive Select the right oscilloscope to fit a variable frequency drive (VFD) application. Consider scope types, probe, voltage, software, and harmonics.

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here are many brands and styles of oscilloscopes to consider and it’s critical to understand how to select one based on certain criteria. Many of them look very similar leaving it difficult to select one that will suit the user’s needs. There are precautions to take to avoid pitfalls during the selection process. An oscilloscope, sometimes referred to as a “o-scope,” is an electronic piece of test equipment used to measure and monitor and provide a visual representation of signals on a screen. First, the user measures the vertical height of the signal (amplitude) in voltage and the horizontal cycle (period). This is done by connecting probes to the scope and connecting them to the test point of a circuit. A probe is a cable with a banana connection on one end that affixes it to the oscilloscope and the other is the end connect to the point of a circuit to measure so the signal appears on the screen. The probe also will have a connection for the common or ground. Examples of these signals can be voltage, current, or frequency, to name a few. The displayed signal can show any anomalies or problems that might not otherwise be seen with other test equipment such as a digital multi-meter (DMM).

Selecting an oscilloscope

Different types of oscilloscope models are desktop, USB, and portable (handheld). A desktop model is typically used in a facility or lab environment. A handheld model would be suitable for travel because of its portability and built-in features such as ground isolation and rugged design. A USB model would be used in lab or the field for its small portable size, as well as being able to interface with a laptop or PC thus removing the need for a separate screen. This would require also purchasing software to use it on a computer interface. All these scopes do the same thing. So why buy one over the other? What are the differences? See table on M10.

www.controleng.com

Probe to connect to signal

Figure 1: Example of a low-voltage passive probe that comes standard with an oscilloscope. This shows how using the ground clip of the probe is internally tide to ground of the scope. All graphics courtesy: Yaskawa America Inc.

Other line or phase

Although many of the desktops look similar and pricing of the oscilloscope is comparable, they cannot check high voltage by themselves. Oscilloscopes come with a lower voltage passive probe. These probes connect to the oscilloscope to measure the point of a circuit to see the signal. The voltage measured on the probe is the intended signal and the other is the ground or common, which is referenced with 0 V. This common can also be tied to ground internally in the oscilloscope and the plug. The voltages are smaller also for example 5 V, or 24 V dc with low current (see Figure 1). An optional probe is required when checking the higher line voltage like 230 V ac or a variable frequency drive’s (VFD’s) pulse width modulation (PWM) output for the higher power checks. It’s critical to read the side of the probe for the intended voltage levels. They can be damaged if they’re undersized. The ground may also be tied to other probe connections. It is necessary to isolate these concontrol engineeering

Figure 2: A coil probe is shown around the wire it’s measuring.

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ANSWERS

INSIDE MACHINES nections so the scope is not damaged, shorting the power to the ground, or interfering with the other signal connections. The ground clip is now a voltage potential and the signal is compared to the voltage the probe is connected to. When used with a scope that doesn’t have a ground tied to the earth of the scope, a high-voltage differential probe should be used so it isolates the grounds. If someone cuts the ground off the plug and lets it float, this is dangerous because now if someone comes into contact with the scope and touches any metal the person may get shocked or killed. This high-voltage differential probe is not a standard feature, but an option. Depending on the manufacturer then

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When used with a scope that doesn’t have a ground tied to the earth of the scope, a high-voltage differential probe should be

• Windings customized for bus voltage, current, resistance, inductance, BEMF constant

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used so it isolates the grounds.

• Stack motors to increase force

this adds an additional $600 to $1,300 on average per probe. This is another reason why it’s important to review all options before making a decision. A handheld model is an exception to this because it is designed to be able to use the probes that come standard to check high and low voltages. The ground is isolated and the unit is designed against shocks unlike desktops.

• Vacuum or cleanroom compatible

Eight factors to consider for an oscilloscope

The key is to understand what is needed for each application. The following eight factors need to be considered when selecting an oscilloscope: 1. Signal displays: Oscilloscopes typically come with two or four and some with more connections or channels to connect the probes to. This allows the user to have more signals on the screen to compare. 2. Current probes: These are used to measure current by the field around a wire that would go to a motor or line on the side of the voltage supply. This can show the current strength and any imbalance when comparing to another line or phase (see Figure 2). Some of the higher-end scopes will include one in the kit while others require this as a separate add-on option. 3. Harmonics measurement: Some of the more economical scopes will have this as an add-on option or not at all. Looking at the circuit’s harmonics could be important because they might play a part in the performance of a device such as a VFD.

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4. Manufacturer: Users might go with a manufacturer they are familiar with rather than a new one. Do some research. AH0119B-CSG

input #19 at www.controleng.com/information

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Table: Types of oscilloscopes Scope type

Low voltage probes

High-voltage differential probes

Software

Current probes

Handheld

Standard

*

*

Option

Desktop

Standard

Option

*

Option

USB

Standard

Option

Not option, but extra charge

Option

* -not a necessary option

A new manufacturer might be a better fit and more cost-effective for a particular application. 5. Service: Talk to someone in the tech support group. See how much they know about their product. Ask about the product and its specific features. 6. Testing: Request a demo of the product. Typically, companies will be open to a trial period before purchase. They also are often willing to meet to answer questions. This also a good opportunity to get a sense of supplier representation and support. 7. Check the warranty: On average, the typical warranty is from 1 to 3 years.

8. Flexibility: Is this product upgradeable or is this an older model that will be phased out? This might explain why it is such a good price if it’s the latter. An easy setup and economical solution that fits the user’s needs leads to selecting the right type of oscilloscope. ce

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KEYWORDS: Oscillosopes, variable frequency drives, VFDs Factors to consider when selecting oscilloscopes Different types of scopes are desktop, USB, and portable. Choose an oscilloscope that is easy to set up and fits your application.

COnSiDER thiS

Robert Bonczar, is a product training engineer at Yaskawa America Inc. Edited by Emily Guenther, associate content manager, Control Engineering, CFE Media, [email protected].

What criteria do you need to consider to select the right scope for your needs?

OnLinE Read more about scopes online at www.controleng.com.

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2019

ENGINEERS’ CHOICE AWARDS

Spotlight on Innovation Best automation, control, and instrumentation products in 26 categories.

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he 32nd annual Control Engineering Engineers’ Choice Awards shines a light on 26 categories of control, instrumentation, and automation products, revealing the best of those introduced in 2018 as chosen by the Control Engineering print and digital audience. Review the winners and honorable mentions here to see if their innovative solutions can help resolve one of your most pressing problems. Also, join us in congratulating these technological innovators. Let them know you learned about their solutions in Control Engineering, and tell them what problems you need solutions for next. Their continuous improvement ensures that manufacturers, machine builders, and automation system integrators can achieve the levels of agility, efficiency, and effectiveness necessary to compete—and win—in today’s global economy. A total of 102 finalists from 44 companies were listed on the ballot for evaluation. Automation professionals from

Control Engineering’s subscriber lists—all of whom are responsible for or influence technology purchases, or have hands-on day-to-day interaction with the technologies in each category—then voted to identify the products they felt were the most exceptional based on technological advancement, service to the industry, and market impact. The result a list of Engineers’ Choice Awards winners and honorable mentions in 26 categories. A total of 1 grand winner, 26 winners, and 26 honorable mentions were named for 2019. Control Engineering staff extends appreciation to all who nominated products and voted. Find more product innovations in the New Products for Engineers Database at www.controleng.com/NP4E. The 2019 Engineers’ Choice Awards will be presented to the winners on April 8, 2019, in Chicago. Amanda Pelliccione is the project manager of events and awards programs for Control Engineering, CFE Media, [email protected].

Engineers’ Choice Awards Index: 1 Grand, 26 Winners, 26 Honorable Mentions 39 Sinamics G120 Smart Access Wireless Module, Siemens

46 Wireless 775 Thum Adapter, Emerson

39 Simatic Industrial Thin Client V3 Pro, Siemens

46 Sitop PSU8600 Power Supply System, Siemens Industry

39 Simatic IFP INOX ETH, Siemens

46 iTherm TrustSens Hygienic RTD Sensor, Endress+Hauser

40 AIM-68 10-in. Industrial Tablet, Advantech

46 DeltaV V14 Distributed Control System, Emerson Automation Solutions

40 UniStream 7-in. PLC+HMI+I/O, Unitronics 40 SilentDefense OT Network Monitoring and Intelligence Platform, Forescout Technologies 40 groov EPIC, Opto 22 42 Allen-Bradley Micro870 PLC, Rockwell Automation 42 3561 FC Vibration Sensor, Fluke

48 Allen-Bradley Guardmaster GuardLink Technology, Rockwell Automation 48 Simatic SIS Compact Safety System, Siemens Industry 48 TwinCAT 3 Building Automation Software, Beckhoff Automation

42 DataMan 470 Fixed-mount Barcode Reader, Cognex

48 Dream Report V4.82 Data Analysis Software, Ocean Data Systems

42 e-Series Collaborative Robot, Universal Robots

49 Simatic Automation Tool, Siemens

44 Digitax HD Servo Drive, Control Techniques

49 AnalytiX-BI, Iconics

44 RAM-6021M12 Industrial Router, Red Lion Controls

49 InduSoft Web Studio, Aveva

44 FL Switch 2000 Managed Industrial Ethernet Switch, Phoenix Contact

49 KEPServerEX V6.5 Industrial Connectivity Platform, Kepware

44 Simatic ET 200SP Fail-safe Module, Siemens

50 Honorable Mentions

READ MORE ONLINE, including how to enter, at www.controleng.com/EngineersChoice.

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®

2019 Engineers’ Choice

Grand award

Hardware – HMI, operator interface, thin-client

Hardware – Industrial PCs

Simatic Industrial Thin-Client V3 Pro

Simatic IFP2200 INOX ETH

Siemens

T Sinamics G120 Smart Access Module Siemens

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he Grand Award—first introduced with the 2017 program—is bestowed upon the product that received the most overall votes in the 2019 program. This year’s Grand Award recipient is the Sinamics G120 Smart Access Module from Siemens. The Sinamics G120 Smart Access module enables wireless connection of mobile devices— such as tablets, smartphones, or laptops—over Wi-Fi to the Sinamics G120, G120C, and G120P converter series. The module is easily set up using a conventional web browser and standard operating system. The web server functionality eliminates the need to download additional software. Warning signals and error messages are quickly detected over the wireless link, which also can be used to save or reset drive settings. The module includes a function that enables the settings from one drive to be copied, sent to other mobile devices, and used to commission additional drives.

he Simatic industrial thin-client (ITC) V3 Pro features high-resolution, capacitive widescreen displays ranging from 15 to 22 inches. Due to diverse communications protocols, the industrial thin-client can be used for complex machinelevel operator control and monitoring as well as connection to control systems (such as SCADA). The ITC V3 Pro allows for direct mounting on support arms and pedestals rather than as built-in devices, and can be configured locally or remotely via a web browser. The industrial thin-client offers four USB 2.0 ports and two Gigabit Ethernet ports (switched). The ITC V3 Pro supports the RDP, VNC, Smart Access, Citrix, and WinCC OA protocols.

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he Simatic industrial flat panel (IFP) 2200 INOX ETH features a projectivecapacitive touch screen for multi-finger operation and stainless-steel front designed for use in the food and beverage, pharmaceutical, and fine chemicals industries, as well as other hygienic areas for machine level operator control and monitoring. For this reason, the IFP2200 has been developed in compliance with EN 1672-2: Food processing machinery – Safety and hygiene requirements. The optimized frame profile and near-flush mounting of the device to the control cabinet allow liquids to run off. The front glass is highly resistant to chemicals, with a minimum of gaps and grooves. It is also shatter-proof and scratch-resistant.

www.usa.siemens.com Input 201 at www.controleng.com/information

www.usa.siemens.com Input 202 at www.controleng.com/information

www.usa.siemens.com Input 200 at www.controleng.com/information

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2019

ENGINEERS’ CHOICE AWARDS

®

Hardware – Industrial tablet

Hardware – Integrated HMI controllers

Industrial cybersecurity

Industrial Internet of Things connectivity

AIM-68 10-in. Industrial Tablet

UniStream 7-in. PLC+HMI+I/O

SilentDefense OT Network Monitoring and Intelligence Platform

groov EPIC

Advantech

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he AIM-68 10-in. industrial-grade tablet with application-oriented peripherals provides portability and flexibility to satisfy various demands in a wide range of applications—such as warehousing, manufacturing, fleet management, field service, transportation, and public safety. Powered by an Intel Atom x7-Z8750 processor with support for dual OS, AIM-68 features a 2-MP front camera and 5-MP rear camera with auto-focus, 4 GB of memory, 64 GB of storage, and a 10-in. WUXGA IPS full HD LCD with scratch-resistant Corning Gorilla Glass 3 and multi-touch PCAP control. The inclusion of Wi-Fi, Bluetooth, WWAN, and NFC wireless communication technologies supports real-time data transmissions and GPS tracking.

Unitronics

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he UniStream 7-in. combines a programmable logic controller (PLC), a 7-in. touchscreen humanmachine interface (HMI), and I/Os into one unit. The UniStream 7-in. is available with six I/O configurations, including options for high-speed inputs and outputs and temperature measurement; all units are fully expandable up to 2048 I/O points. Other features include EtherNet/IP, VNC, FTP, Web Server, Video + RTSP, and SQL Client. The UniStream 7-in. is backed by UniLogic programming software. Built-in COM ports include Ethernet, 1 USB host and 1 Mini-B USB device ports; additional add-on ports for serial and CANbus are available. www.unitronicsplc.com Input 204 at www.controleng.com/information

www.advantech.com Input 203 at www.controleng.com/information

ForeScout Technologies

T

he SilentDefense operational technology (OT) network monitoring and intelligence platform passively analyzes industrial network communications, provides rich information about network assets and alerts in real-time for any threat to operational continuity. SilentDefense empowers industrial operators with visibility, threat detection capability, and control of a network. A user-friendly interface and out-of-the-box detection engines will help to quickly deliver results. The forensic time machine feature lets users perform automatic, back-in-time threat searches and individuation of past compromises, while the enhanced industrial threat library includes vulnerability database and protocol support for more than 1,600 threat indicators and vulnerabilities. www.forescout.com

Opto 22

T

he groov edge programmable industrial controller (EPIC) combines I/O, control, data processing, and visualization into one secure, maintainable, edge-of-network industrial system. Combining reimagined intelligent I/O with an embedded Linux real-time controller, gateway functions, and an integrated display, groov EPIC offers industrial hardware design with a modern software ensemble. Connecting legacy systems, controlling processes and automating machines, subscribing to web services and creating mashups, acquiring and publishing data, visualizing that data wherever it is needed, and mobilizing operators—all of these are within reach with this system. groov EPIC simplifies commissioning and wiring and helps engineers develop rapidly and deploy quickly. www.opto22.com Input 206 at www.controleng.com/information

Input 205 at www.controleng.com/information

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We understand understand how how leading-edge leading-edgeproducts productsand and We process improvements are critical in your business. process improvements are critical in your business.

INNOVATE + ACCELERATE You are are enabled enabledto toachieve achieveaafaster fastertime timetotomarket, market, You improve plant plantproductivity productivityand andreduce reducerisk. risk. improve

iTHERMTrustSens TrustSens TM37x: iTHERM TM37x: iTHERM TrustSens TM37x: The world’s first self-calibrating compact thermometer The world’s first self-calibrating compact thermometer The world’s first self-calibrating compact thermometer • Increases process safety with fully automated, fully traceable ••Increases process safetysafety with fully automated, fully traceable Increases process with fully automated, inline self-calibration inline self-calibration fully traceable inline self-calibration • Offers 100% compliance with automated audit-proof documentation • OffOffers ers 100% compliance with automated audit-proof documentation 100% automated ••Eliminates the riskcompliance of undetectedwith non-conformities with • Eliminates the risk of undetected non-conformities with Heartbeat Technology audit-proof documentation Heartbeat Technology

• Eliminates the risk of undetected nonconformities with Heartbeat Technology

Do you want to learn more? Do to learn learn more? more? www.us.endress.com/tm371 Doyou you want want to www.us.endress.com/tm371 www.us.endress.com/trustsens

input #21 at www.controleng.com/information

2019

ENGINEERS’ CHOICE AWARDS

®

Machine and embedded control – PLCs

Machine sensors

Machine vision, code readers

Motion control

Allen-Bradley Micro870 PLC

3561 FC Vibration Sensor

DataMan 470 Fixed-mount Barcode Reader

e-Series Collaborative Robot

Rockwell Automation

T

he Allen-Bradley Micro870 PLC supports smart micro applications that require up to 304 I/O points, 280 KB of memory, and 20,000 program instructions. The Micro870 PLC uses a flexible design concept that provides designers up to three plug-ins and eight expansion I/O modules. This capability allows easy customization or expansion of the controller to meet each machine type’s unique requirements. The controller’s 280 KB memory capacity supports modular programming and the use of user-defined function blocks to help reduce design time. Additionally, machine builders can use this memory capacity to maintain one program for all machine models that use the Micro870 PLC. www.rockwellautomation.com

Fluke Corp.

T

he 3561 FC vibration sensor allows maintenance teams to improve uptime by adding remote, continuous vibration monitoring to rotating equipment. With a frequency range of 10 to 1,000 Hz, the 3561 FC detects and notifies users of conditional changes caused by critical faults—such as imbalance, misalignment, looseness. and bearing wear—providing warning of impending equipment failure. The 3561 FC sensor is small enough to fit in hard-to-reach locations on equipment, providing a more comprehensive picture of facility health. The triaxial sensors deliver continuous measurements while the asset is in use, permitting maintenance technicians to remain at a safe distance, away from dangerous rotating equipment.

Input 207 at www.controleng.com/information

www.fluke.com Input 208 at www.controleng.com/information

Cognex

T

he DataMan 470 fixedmount barcode reader uses patent-pending imaging technology to solve challenging applications— such as automotive component traceability, tire identification, airport baggage handling, and automated sorting. DataMan 470’s High Dynamic Range Plus (HDR+) technology enhances the image quality of 1D and 2D codes. It also reads low contrast and ultra-small codes not visible to other readers, and covers larger inspection areas with fewer cameras, allowing greater process variation and lower facility design costs. DataMan 470’s expandable technology platform includes multi-core processing power, advanced decoding algorithms, and modular configuration options to significantly improve speed and flexibility.

Universal Robots

T

he e-Series collaborative robot (cobot) is a lightweight, flexible automation tool that works right alongside users on ever changing tasks. The cobot features fast set-up, easy programming, flexible deployment, safe operation, and a short return on investment. The user interface reduces programming to a few clicks on a lightweight, wide-screen teach pendant and adds four digital inputs with an associated interface for use with conveyor tracking. The interface also includes the ability to program stopping time and stopping distance for protective stops, reducing the complexity and uncertainty involved in performing pre-deployment risk assessments. www.universal-robots.com Input 210 at www.controleng.com/information

www.cognex.com Input 209 at www.controleng.com/information

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input #22 at www.controleng.com/information

2019

ENGINEERS’ CHOICE AWARDS

®

Motion control – Drives

Network integration – Ethernet hardware

Network integration – Ethernet switches

Network integration – I/O systems

Digitax HD Servo Drive

RAM-6021M12 Industrial Router

FL Switch 2000 Managed Industrial Ethernet Switch

Simatic ET 200SP Fail-safe Module

Control Techniques

T

he Digitax HD servo drive delivers motor control performance and flexibility from a package. The Digitax HD is focused on high overload, pulse duty applications, provides continuous servo control and induction motor control, and is initially available with two functionality levels. The servo motor is designed as an optimized amplifier for high performance centralized control with EtherCAT integrated on-board and simple rotary switches for fast network address assignment. The base option allows design engineers to add up to two option modules from the existing Unidrive M range such as Profinet, EtherNet/IP, or an IEC 61131 high performance motion controller for decentralized machine control. www.controltechniques.us Input 211 at www.controleng.com/information

Red Lion Controls

T

he RAM-6021M12 IP67 industrial router provides secure network communication between local and wide-area networks. Housed in a rugged IP67, dust-proof and water-resistant metal enclosure, the RAM-6021M12 is designed to withstand harsh industrial environments, including temporary immersion in water, exposure to water jets, and extreme shock and vibration levels, making it ideal for industries where hardened products are required. The RAM6021M12 provides the ability to remotely connect, monitor, and control assets across a variety of industrial applications. The unit’s event engine can be customized to trigger I/O or email alerts to quickly notify personnel of critical events based on operational data. www.redlion.net

Siemens

Phoenix Contact

W

ith easy startup and a variety of available application-specific functions, the 2000 Series managed switch enables the cost-effective management of Ethernet network. The FL Switch 2000 gives machine builders a switch with multicast filter functions and redundancy mechanisms to reduce the data load in the network and maintain communications even in the event of a Layer 1 failure. The device can be configured via an SD card, a Command Line Interface (CLI), or the smart mode button located on the device. The 2000 switch features key functions for Profinet and EtherNet/IP applications, and is available in Gigabit variants for applications that demand high data throughput.

T

he Simatic ET 200SP F-AI 4xI(0)4..20mA failsafe module makes it possible to detect analog signals in the 0(4)..20 mA range. The 15-mm-wide module supports the “NoDIL” concept; PROFIsafe address assignment via DIL switch is not required. Slots for the module can be freely selected. and both central and distributed use is possible. Characteristics include four analog inputs with configurable measuring range, supply voltage L+, external sensor power supply possible, resolution 16-bits, shortcircuit proof power supply for 2- or 4-wire transducers, firmware update support, and RIOforFA-Safety profile support. www.usa.siemens.com Input 214 at www.controleng.com/information

www.phoenixcontact.com/us Input 213 at www.controleng.com/information

Input 212 at www.controleng.com/information

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PLC HMI ALL IN ONE

NEW! 7

”

All-in-One compact PLC + HMI with built-in I/Os 7" color touch HMI Built-in I/O options: digital, analog, high-speed, PWM, temperature Expand up to 2,048 I/Os Built-in ports: Ethernet, USB, Audio* Add-on ports: Ethernet, serial, CANbus COM support: EtherNet/IP, CANopen, MODBUS & more Advanced COM support: Webserver*, SMS & email, GPRS modem, SNMP, FTP, SQL MQTT Remote Access via VNC Media support: .pdf, Video*, RTSP* Program in All-in-One UniLogic - Award-winning software slashes development time in half! * For Pro version only. input #23 at www.controleng.com/information

w w w. u n i t r o n i c s P L C . c o m

Unitronics, Inc. 1 Batterymarch Park Quincy, MA 02169 USA, Tel: 617-657-6596, Toll Free: 866-666-6033 [email protected], www.unitronicsPLC.com

2019

ENGINEERS’ CHOICE AWARDS

®

Network integration – Wireless

Power – Energy, power protection, UPS

Process control – Process sensors

Process control systems

Wireless 775 Thum Adapter

Sitop PSU8600 Power Supply System

iTherm TrustSens Hygienic RTD Sensor

DeltaV V14 Distributed Control System

Emerson

M

ake any HART device wireless with the Wireless 775 Thum Adapter, an adapter that retrofits onto existing 2-, 3- or 4-wire HART devices, in almost every area, from intrinsically safe to explosionproof. The Thum adapter wirelessly transmits HART measurement and diagnostic information from new or previously inaccessible measurement points. With the self-organizing WirelessHART network, users can remotely manage multivariable devices, monitor device health, and gather data with more than 99% data reliability. The explosion-proof certification is especially useful for refineries, chemical plants, and other heavy industry facilities, as well as in SIS applications, where it can be used to access stranded variables and diagnostics from safety systems.

Endress+Hauser

Siemens Industry

T

he Sitop PSU8600 power supply system features supplementary modules to transform it into an uninterruptible direct current (dc) power supply. To achieve this, the DC UPS module PSU8600 uses the energy stored in BAT8600 battery modules to keep the system up and running in the event of a power failure, and it extends the previous bridging times enabled by the buffer modules from just minutes to hours. The PSU8600 has up to 36 outputs capable of being adjusted between 4 and 28 volts, and all of these can be buffered in the event of a power failure. www.usa.siemens.com Input 216 at www.controleng.com/information

T

he iTherm TrustSens hygienic RTD sensor calibrates itself after every sterilize in place (SIP) operation to provide accurate and reliable temperature measurement. TrustSens eliminates the risk of an undetected calibration drift and the risk of bad batches. It also reduces the need for frequent calibrations by verifying the sensor is working as designed in between manual calibration cycles. The TrustSens calibration procedure can store up to 350 calibrations that can be submitted to various regulatory agencies for verification of compliance issues. TrustSens has built-in heartbeat technology to monitor the sensor and send warnings when it detects a sensor failure, drift, or other measurement errors.

Emerson Automation Solutions

D

eltaV, a cybersecuritycertified control system, is designed to deliver new value in capital projects and make plant operations more connected and productive. Version 14 includes several enhancements to eliminate costs and reduce complexity in capital projects, plus improve productivity during operations through enhanced access to production and equipment data, improved usability and greater security. DeltaV is the pathway for most plant data and using the OPC UA protocol from OPC Foundation, its applications and servers can securely share data to cloud analytics applications, remote monitoring solutions, and third-party technologies. www.emerson.com Input 218 at www.controleng.com/information

http://us.endress.com Input 217 at www.controleng.com/information

http://emerson.com Input 215 at www.controleng.com/information

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Remote Assets. Local Control. Simpler control from smarter cellular RTUs Remote monitoring and control with RAM® industrial cellular RTUs. Managing remote assets and ensuring smooth operations when you are at a distance has never been easier. Red Lion’s Sixnet® series RAM industrial cellular RTUs provide users an intuitive, web-based interface to easily configure event parameters and define alarm states that trigger I/O or send SMS text messages based on real-time operational data. With connectivity options such as I/O, serial, Ethernet and optional Wi-Fi, our rugged RAM RTUs provide a secure all-in-one platform that seamlessly integrates with existing equipment to enable data visibility, control and real-time notifications for field-deployed assets. Visit www.redlion.net/control to learn more.

+1 (717) 767-6511 | [email protected] | www.redlion.net © 2019 Red Lion Controls, Inc. All Rights Reserved. input #24 at www.controleng.com/information

2019

ENGINEERS’ CHOICE AWARDS

Safety – Machine safety

Safety – Process safety, intrinsic safety

Software – Applications

Software – Asset management, reporting

Allen-Bradley Guardmaster GuardLink Technology

Simatic SIS Compact Safety System

TwinCAT 3 Building Automation Software

Dream Report V4.82 Data Analysis Software

Rockwell Automation

T

he Allen-Bradley Guardmaster GuardLink technology is a safety-based communications protocol that helps operators reduce and improve machine diagnostics and downtime while increasing productivity. With GuardLink, safety devices are easily connected in series while providing access to individual device diagnostics. This system provides safety, diagnostics, remote reset, and lock command over one four-conductor cable with up to 32 devices per link. In addition, users can reduce installation cost, with up to 38% reduction in wiring, when using GuardLink. The GuardLink technology seamlessly integrates with Allen-Bradley Guardmaster safety relays and components, allowing users to access status information throughout a safety system.

Siemens Industry

T

he Simatic SIS Compact safety system was designed as a dedicated safety control system for a safety instrumented system (SIS) based on selected system components of the Simatic PCS 7 and the Simatic Safety product portfolio. The functionality and price structure of Simatic SIS Compact has been customized as a stand-alone system to the requirements of a highly price-sensitive market for small to medium-sized safety applications. The Simatic SIS Compact is comprised of hardware and software components and permits easy setup of dedicated SIS. SIS monitors critical processes, and performs immediate and automatic responses to the process when a problem occurs. http://usa.siemens.com Input 220 at www.controleng.com/information

Beckhoff Automation

T

winCAT 3 Building Automation meshes with existing TwinCAT 3 modules for HMI and the Industrial Internet of Things (IIoT), along with analytics and scope, and bundles functions for building automation into one tool. Handling the engineering and control of all building systems on one software platform uncovers significant benefits, such as simple IIoT communication, cloudbased analysis of building data, and the rapid creation of individualized operator interfaces. The meshing of TwinCAT 3 Building Automation with the numerous software modules available in TwinCAT 3 provides system integrators with a comprehensive toolbox that covers all functions and systems found in building automation.

Ocean Data Systems

D

ream Report is a programming-free, userfriendly, automated reporting and data analysis software designed specifically for industrial automation applications. It is designed to be the simplest solution for extracting data from any data source and Dream Report will provide automated reports to anybody, anywhere, and anytime. Dream Report accommodate various types of reporting, from compliance reporting to performance, efficiency, and maintenance reporting in discrete, hybrid and process automation markets. Dream Report makes information gathering and formatting a simple process, encouraging users to create the reports they want in addition to reports needed. http://dreamreport.net Input 222 at www.controleng.com/information

www.beckhoffautomation.com Input 221 at www.controleng.com/information

www.rockwellautomation.com Input 219 at www.controleng.com/information

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®

Software – Control design

Software – Data analytics

Software – HMI software

Software – Industrial Internet of Things connectivity

Simatic Automation Tool

AnalytiX-BI

InduSoft Web Studio

KEPServerEX V6.5 Industrial Connectivity Platform

Siemens

T

he Simatic Automation Tool enables users to manage TIA automation components during commissioning, maintenance tasks and in case of service. The Simatic Automation Tool is based on the TIA Portal projects but the individual tasks can be executed independently of the engineering framework. If updates and optimizations have to be performed during operation due to changed mechanical configurations or program changes, the Simatic Automation Tool lets maintenance personnel make these adjustments without the TIA Portal. If loss of production and downtimes play a crucial role, the last executable version of a plant can be exported with the Simatic Automation Tool before changes are made to the plant; it can then be accessed again in case of error.

Iconics

T

he AnalytiX-BI software analyzes business intelligence (BI) information within an operational context to reduce costs and maximize efficiency. It improves data accessibility, enables analytical processing, and provides data modeling/context with improved performance and intuitive visualization. AnalytiX-BI, combined with KPIWorX, a self-service dashboard technology that turns big data into actionable intelligence. It offers point-and-click data models and query technologies that bridge IT, management, and business systems. KPIWorX is a self-service client tool that allows for the creation, saving, and loading of AnalytiX-BI dashboards via a user-friendly interface to deliver contextualized assetbased information to any smartphone, tablet, or webenabled device.

www.usa.siemens.com

www.iconics.com

Input 223 at www.controleng.com/information

Input 224 at www.controleng.com/information

Aveva

T

he InduSoft Web Studio is a platform agnostic SCADA/HMI development and runtime software that incorporates all the tools users need to create SCADA and HMI applications, business intelligence dashboards, and OEE solutions. With runtimes available for Microsoft Windows, Linux, and VxWorks by Wind River Systems, InduSoft Web Studio can create powerful IIoT applications that can be deployed on small-footprint embedded devices and accessed remotely from mobile devices, such as tablets, smartphones, and wearable gadgets. More than 250 communication drivers, in addition to support to standards such as OPC UA/DA/ XML/.NET/HDA, MQTT, and patented solution for database connectivity, make it easy to integrate sensors, controllers, ERP systems, and cloud analytics into a smart solution that can be accessed anywhere. www.indusoft.com

Kepware

T

he KEPServerEX version 6.5 industrial connectivity platform provides users with the tools and resources needed to address evolving cybersecurity threats to their industrial control system. Version 6.5 includes comprehensive secure deployment guidelines, greater project file protection, enhanced password configuration, and other updated security components. To encourage adoption of security best practices, version 6.5 features a comprehensive secure deployment guide intended to help users implement production instances of KEPServerEX in a way that can help to reduce security risks. The guide provides strategic recommendations on using secure interfaces and the configuration API, on-going server maintenance, KEPServerEX installation, and post-installation actions. www.kepware.com Input 226 at www.controleng.com/information

Input 225 at www.controleng.com/information

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2019

ENGINEERS’ CHOICE AWARDS

Honorable Mentions Hardware - HMI, operator interface, thin-client

EZTouch EZ12 HMI EZAutomation

Industrial cybersecurity

mbNetfix Industrial Firewall MB connect line

The EZTouch EZ12 human-machine interface is designed for indoor and outdoor industrial environments with temperatures up to 131°F.

mbNetfix is an industrial firewall for automation users that provides protection against attacks by using the industrial firewall to segment the production network into manageable and logically separated units.

www.ezautomation.net Input 227 at www.controleng.com/information

Hardware - Industrial PCs

www.mbconnectline.com/en

C6030 Industrial PC Beckhoff Automation

Input 231 at www.controleng.com/information

Industrial Internet of Things connectivity

Benefits of the ultra-compact C6030 industrial PC include small space requirements, universal usage for almost any automation and visualization application and exceptionally flexible installation, and usage in complex applications with highest performance requirements. www.beckhoffautomation.com Input 228 at www.controleng.com/information

EIS-D210 Edge Intelligence Server Advantech The wireless connectivity Edge Intelligence Server EIS-D210 is built on the Intel Apollo Lake series ATOM/Celeron processors’ efficient performance for embedded applications. www.advantech.com/ea Input 232 at www.controleng.com/information

Hardware - Industrial tablet

Machine and embedded control - PLCs

Field Xpert SMT70 Tablet PC Endress+Hauser

Productivity1000 Programmable Controller AutomationDirect

The slim, lightweight, and strong Field Xpert SMT70 tablet PC provides an easy and touch-optimized “tool” to manage field devices.

The Productivity1000 stackable micro programmable logic controller has the to reliably execute the many logic operations and communication requests that modern day industries require. www.automationdirect.com

http://us.endress.com

Input 233 at www.controleng.com/information

Input 229 at www.controleng.com/information

Machine sensors

Hardware - Integrated HMI controllers

MR430 Size 11 Fiber Optic Rotary Position Sensor Micronor

Simatic IPC377E Basic Panel PC Siemens The Simatic IPC377E Basic Panel PC is based on the Intel Celeron processor technology and represents an IPC platform developed for cost-optimized, PC-based applications in the industrial and industry-related environments. www.usa.siemens.com Input 230 at www.controleng.com/information

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The MR430 Fiber Optic Rotary Position Sensor’s small size, non-metallic construction, and 25-bit resolution provide ideal EMI-immune position feedback solution for operating environments stressed by RFI, microwaves radiation, magnetic fields, high voltage, or explosive www.micronor.com atmospheres. Input 234 at www.controleng.com/information

www.controleng.com

®

Machine vision, code readers

Network integration - Ethernet switches

VisionPro ViDi Deep Learning-based Image Analysis Software Cognex

EKI-2525LI Small Ethernet Switch Advantech

The VisionPro ViDi deep learning-based image analysis software is a field-tested, optimized, and reliable software based on a state-of-the-art set of algorithms in machine learning.

The EKI-2525LI runs on 12 to 48 V dc with redundant input design plus one dc power jack secured with power polarity reverse protection. www.advantech.com/ea Input 239 at www.controleng.com/information

www.cognex.com Input 235 at www.controleng.com/information

Motion control

Network integration - I/O systems

FLEX 5000 I/O Module Rockwell Automation

Flexible Transport System FTS Bosch Rexroth The Flexible Transport System (FTS) is a linear motor-based transport system that provides a contactless and particle-free solution for the positioning of materials and work pieces inside or between machines.

The FLEX 5000 I/O includes 2 copper or 2 fiber ports and support for DLR, Star, Linear, and PRP topologies to provide flexibility in users’ network architecture.

www.boschrexroth-us.com

www.rockwellautomation.com

Input 236 at www.controleng.com/information

Motion control - Drives

Input 240 at www.controleng.com/information

Network integration - Wireless

Altivar Machine ATV340 Variable-Speed Drive Schneider Electric

Outdoor Radioline Phoenix Contact The RAD-900-DAIO6 (Outdoor Radioline) combines the 900 MHz Radioline wireless module and six I/O points in one, robust, NEMA 4X housing.

The Altivar Machine ATV340 is a variable-speed drive designed to address the challenges of the smart machine era by combining easy installation with cutting-edge application control and advanced, easyto-integrate automation capabilities.

www.phoenixcontact.com/us Input 241 at www.controleng.com/information

www.schneider-electric.com Input 237 at www.controleng.com/information

Network integration - Ethernet hardware

Patch Panel Interface Module Phoenix Contact

Power - Energy, power protection, UPS

Quint DC UPS Phoenix Contact The Quint DC UPS is an intelligent modular solution that provides critical system-backup voltage to supply loads in the event of mains failure and indicates the operating and battery state.

The Patch Panel serves as an interface module between field and control cabinet cabling, with DIN rail devices featuring push-in, IDC or screw connection, in addition to the traditional RJ45 connection.

www.phoenixcontact.com/us Input 242 at www.controleng.com/information

www.phoenixcontact.com/us Input 238 at www.controleng.com/information

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2019

ENGINEERS’ CHOICE AWARDS

Honorable Mentions Process control - Process sensors

Software - Applications

Thermalert 4.0 Spot Pyrometer for Automatic Noncontact Temperature Monitoring Fluke Process Instruments

Syncade Quality Review Manager Emerson Automation Solutions

Thermalert 4.0 is a spot pyrometer for automatic noncontact temperature monitoring between -40ºF to 4,082°F, which allows more measuring points to be set up without cooling accessories and without installing cooling media supplies. www.fluke.com Input 243 at www.controleng.com/information

The Syncade Quality Review Manager reduces the time and effort required to identify, review, and resolve process exceptions. www.emerson.com Input 247 at www.controleng.com/information

Software - Asset management, reporting

FactoryTalk Network Manager Rockwell Automation

Process control systems

Experion Batch Software Honeywell Process Solutions

FactoryTalk Network Manager software provides increased visibility and insight into the performance of users’ network in context of their automation assets.

Experion Batch uses HMI technology that automatically constructs timeline views using visual analytics, presenting the current and future state of operations in a naturally intuitive manner.

www.rockwellautomation.com Input 248 at www.controleng.com/information

www.honeywellprocess.com Input 244 at www.controleng.com/information

Safety - Machine safety

Jokab Safety StatusBus Monitor Function ABB The Jokab Safety StatusBus is an add-on function to the DYNlink solution that offers a simple and cost-effective way to monitor the status of each door or emergency stop.

Software - Control design

iQ Monozukuri Packaging Software Mitsubishi Electric Automation iQ Monozukuri Packaging software concentrates on improving the productivity, quality, and concepts for achieving process improvements associated with the construction and configuration of applications and devices. https://us.mitsubishielectric.com/fa/en Input 249 at www.controleng.com/information

www.abb.com Input 245 at www.controleng.com/information

Safety - Process safety, intrinsic safety

Software - Data analytics

EcoStruxure Triconex Tricon CX Safety System Schneider Electric

Movicon Pro.Lean Functional Software to Measure Overall Efficiency Values Progea North America

The EcoStruxure Triconex safety system delivers safety for life; the measurable operational profitability improvements can cover the cost of the system investment in fewer than 6 months while continually protecting people, production, and profits.

Pro.Lean is a Movicon functional module that allows users to measure the overall efficiency values in real time by collecting and aggregating production process data from different sources at production level.

www.schneider-electric.com Input 246 at www.controleng.com/information

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www.progea.us Input 250 at www.controleng.com/information

www.controleng.com

®

Software - HMI software

New Products for Engineers

FactoryTalk View Site Edition Rockwell Automation

G

The FactoryTalk View Site Edition version 10.0 visualization allows operators added functionality and expanded integration across the Rockwell Automation product offerings.

et coverage in CFE Media websites, newsletters, and magazines through New Products for

Engineers (NP4E), a CFE Technology database for new products appropriate for subscribers of Control Engineering and other CFE Media supplements and

www.rockwellautomation.com Input 251 at www.controleng.com/information

publications, such as Applied Automation, IIoT for

Software - Industrial Internet of Things connectivity

Engineers, Oil & Gas Engineering, Pure Power, Plant

FactoryTalk Linx Control Products and System Data Server Rockwell Automation

Engineering, and Consulting-Specifying Engineer. The

FactoryTalk Linx interfaces with PLC-5, SLC 500 and Micro800 controllers and is specifically optimized to communicate with Logix5000 controllers using EtherNet/IP.

NP4E database uses a detailed taxonomy to automatically feed new products to appropriate areas of our websites and newsletters, and it serves products for print and digital editions and awards programs.

www.rockwellautomation.com

See more New Products for Engineers. www.controleng.com/NP4E

PE

Input 252 at www.controleng.com/information

How to enter the competition

G

et a head start on the 2020 Engineers’ Choice Awards program by listing your products in the New Products for Engineers database (www.controleng.com/NP4E) and completing

the entry form on the Awards Programs tab of your company’s vendor/manufacturer profile. All product nominations, including supporting materials and payment, are conveniently submitted through the database. Submit a new or significantly modified hardware, software, or combination of the two introduced and available in North America from November 2018 through October 2019 for the 2020 awards. The product details provided should be factually convincing and clearly differentiate benefits in the voting criteria: technological advancement, service to the industry, and market impact. (Hint: We observe that engineers often appreciate quantified benefits more than adjectives.) Typically, 85 to 120 products are nominated, with 3 to 10 products in each category. One winner from each subcategory is selected based on subscriber votes. For the 2019 awards, 102 products from 44 companies (or major divisions) were nominated in 26 categories, resulting in one Grand Award to one company (with the highest number of votes among all categories), 26 Engineers’ Choice Awards to 19 companies (highest number of votes in that category) and 26 Honorable Mentions to 19 companies (second highest number of votes in that category).

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Input #101 at controlengineering.hotims.com

Input #102 at controlengineering.hotims.com

PRODUCT & LITERATURE SHOWCASE

Input #106 at www.controleng.com/information

eNewsletters

Subscribe today by visiting: www.controleng.com/newsletters

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Input #103 at controlengineering.hotims.com

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Bailey Rice (630) 571-4070 x2206 [email protected]

Automation24 . . . . . . . . . . . . . . . . .23 . . . . . . . . 14 . . . . . . .www .automation24 .com

AK, AZ, CA, CO, HI, ID, MT, NV, NM, OR, UT, WA, WY, Western Canada

Digi-Key ELECTRONICS . . . . . . . . .17 . . . . . . . . .11 . . . . . . .WWW .DIGIKEY .COM

Iris Seibert (858) 270-3753 [email protected] CT, DE, MD, ME, MA, NC, NH, NY, NJ, PA, RI, SC, VA, VT, WV, DC, Eastern Canada

AutomationDirect . . . . . . . . . . . C2, 1 . . . . . . . . 1, 2 . . . . . . .www .automationdirect .com

Eaton’s Bussmann Business . . . . . . . . . . . . . . . . . 11, 12, 13 . . . . . . 8, 9 . . . . . . .www .CUBEFuse .com Endress + Hauser . . . . . . . . . . . . . .41 . . . . . . . . 21 . . . . . . .www .us .endress .com/trustsens EU AUTOMATION . . . . . . . . . . . . . .6 . . . . . . . . . . 5 . . . . . . . .www .euautomation .com

Julie Timbol (978) 929-9495 [email protected]

hargrove . . . . . . . . . . . . . . . . . . . . .26 . . . . . . . . 15 . . . . . . .www .hargrove-epc .com

International (outside U.S., Canada)

Lapp Usa . . . . . . . . . . . . . . . . . . . . .27 . . . . . . . . 16 . . . . . . .www .lappusa .com

Stuart Smith +44 208 464 5577 [email protected]

Publication Services

Jim Langhenry, Co-Founder/Publisher, CFE Media [email protected] Steve Rourke, Co-Founder, CFE Media [email protected] Elena Moeller-Younger, Marketing Manager 773-815-3795, [email protected] Kristen Nimmo, Marketing Manager [email protected] Brian Gross, Marketing Consultant, Global SI Database 630-571-4070, x2217, [email protected]

Inductive Automation . . . . . . Bellyband . . . . . . . . . . . . . . . .www .inductiveautomation .com/ignition

Moore Industries - Intl . Inc . . . . . . .4 . . . . . . . . . . 4 . . . . . . . .www .miinet .com Ocean Data Systems . . . . . . . . . . .43 . . . . . . . . 22 . . . . . . .www .DreamReport .com OPTO 22 . . . . . . . . . . . . . . . . . . . . . .2 . . . . . . . . . . 3 . . . . . . . .www .opto22 .com RADWELL INTERNATIONAL, INC . . . . . . . . . .15 . . . . . . . . 10 . . . . . . .www .Radwell .com Red Lion Controls . . . . . . . . . . . . . .47 . . . . . . . . 24 . . . . . . .www .redlion .net SEW-EURODRIVE, Inc . . . . . . . . . . .9, C4 . . . . . .7, 26 . . . . . .www .seweurodrive .com

Michael Smith, Creative Director 630-779-8910, [email protected]

Siemens . . . . . . . . . . . . . . . . . . . . . .21 . . . . . . . . 13 . . . . . . .www .usa .siemens .com/tia-portal

Paul Brouch, Director of Operations [email protected]

Unitronics . . . . . . . . . . . . . . . . . . . .45 . . . . . . . . 23 . . . . . . .www .unitronics .com

Michael Rotz, Print Production Manager 717-766-0211 x4207, Fax: 717-506-7238 [email protected]

Yaskawa America, Inc . . . . . . . . . . .C3 . . . . . . . . 25 . . . . . . .www .yaskawa .com

Maria Bartell, Account Director, Infogroup Targeting Solutions 847-378-2275, [email protected]

Inside Machines

Rick Ellis, Audience Management Director 303-246-1250, [email protected]

Aerotech Inc . . . . . . . . . . . . . . . . . .M9 . . . . . . . 19 . . . . . . .www .aerotech .com

Letters to the editor: Please e-mail us your opinions to [email protected] or fax 630-214-4504. Letters should include name, company, and address, and may be edited. Information: For a Media Kit or Editorial Calendar, go to www.controleng.com/mediainfo. Marketing consultants: See ad index. Custom reprints, electronic: Marcia Brewer, Wright’s Media, 281-419-5725, [email protected]

Beckhoff Automation LLC . . . . . . . .M4 . . . . . . . 17 . . . . . . .www .beckhoff .com CONTEMPORARY CONTROLS . . . .M10 . . . . . . 20 . . . . . . .www .ccontrols .com/machine WAGO Corp . . . . . . . . . . . . . . . . . . .M6 . . . . . . . 18 . . . . . . .www .wago .us

Request moRe infoRmation about products and advertisers in this issue by using the http://controleng.com/information link and reader service number located near each. If you’re reading the digital edition, the link will be live. When you contact a company directly, please let them know you read about them in Control Engineering. www.controleng.com

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ENGINEERS’ CHOICE PRODUCT ADVICE

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Help for automation, designs

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Back to Basics: Automation product design, system integration, and application advice follows from some of the 2019 Engineers’ Choice winners.

ngineers’ Choice winners were invited to provide advice for Control Engineering subscribers on product design, system integration, or application advice for the product. Experts from Emerson Automation, Endress+Hauser, Nidec Control Techniques, Siemens, and Universal Robotics offer insights.

Make it easy, extend value

Bob Halgren, DeltaV platform management director, Emerson Automation: Easier is not always easy enough as engineers spend hours integrating control systems on projects to connect systems. This work is harder if an engineer has to re-engineer a product to do something it should do out of the box. Easy software should be intuitive with out-of-the-box functionality that reduces initial work. Other advice includes building on an existing innovation to extend value, reimagining preconceived notions, and applying product innovation today and in the future.

Calibrate sensors in place

Keith Riley, national product manager for pressure/temperature, Endress+Hauser Inc.: The biggest risk for a thermometer in a hygienic system is the calibration process. Opening the device, removing the insert, connecting and disconnecting power cables, introducing the thermometer into the oil bath or block calibrator, or transporting the thermometer to the lab increases the likelihood of mechanical damage. Removing the sensor from the process or thermowell is the biggest reason for RTD failure. Risks are reduced if the temperature sensor can be calibrated in situ.

Open architectures

production, to provide a more flexible, reliable and transparent environment. As machine builders and end users move to a digitalized manufacturing approach, industrial PCs are well suited to ensure increasing production capacity and flexibility to meet variable demand, improving quality while reducing production costs, and improving efficiency in secure settings. Raj Rajendra, consultant/manager, Siemens Industry Inc.: Input/output systems (I/O or IO systems) are designed to be simpler, smaller, and more powerful. Installation and wiring should be simple, done faster, and with fewer or no tools. Compact size, faster response times, diagnostics, and greater functionality are expected. Such designs help companies with automation systems to maximize performance, improve efficiency, increase flexibility, and reduce downtime and footprint. Jana Kocianova, product manager, Siemens: Knowing customer’s current and future needs is the most important part of designing a successful automation product. Machine manufacturers need tools to stay connected with many automation devices, cut costs, and stay independent of an engineering framework. Machine manufacturers and plant operators need machines and plants to keep them informed. Reduce downtime and increase efficiency with one tool to manage automation components. Craig Nelson, product manager, Siemens Industry Inc.: In the digital factory — motion control business: Automation advice: Devices and systems should provide a positive customer experience and be easily connect, monitor, commission, and operate. The customer experience is a driving force behind any successful product development. Ease-of-use often can be the hardest part of product development to justify in the budgeting phase. It also can have the biggest return on the bottom line. Feedback from the field helps. Use the smartphone as an ease-of-use benchmark.

Mike Wolfe, product manager motion control, and Alex Harvey, director of marketing, Americas, for Control Techniques, a Nidec brand: Manufacturers should consider open architectures Easier robot use when designing new automation products for greater flexibilJürgen Von Hollen, president, Universal Robots: Fast set-up, ity, innovation, and competitiveness. From mobile connectivity easy programming, flexible deployment, and safe operation are to Industrial Internet of Things (IIoT) integration, the automothe four core principles that define collaborative robots. Many tive industry is at the forefront of automation innovation. Car people mistake collaborative robot design as only being about manufacturing is about improving productivity through automasafety. Safety is the cost of entry. Upgrading tion because, as an industry, profitability is the collaborative robot’s internal features has directly linked to the speed of manufacture strengthened the four core principles. Builtand machine availability. Designing open in force torque sensing, safety features, and automation systems gives the flexibility to KEYWORDS: Product design improved precision enable faster integration use more protocols and components. Automation should be easy to use. in a wider range of future-proofed applicaReliability and quality are important. Digitalize, I/O, updates, easier tions. Increased repeatability makes collabEasy integration and safety help. Alessandra Da Silva, product marketorative robots suitable for precise finishing, CONSIDER THIS ing manager, Siemens Industry Inc.: The assembly, and electronics tasks. Are your automation products easy to factory floor is undergoing a transforimplement, use, adapt, and update? mation through increased digitalization. Mark T. Hoske is content manager, ONLINE More intelligent automation and conControl Engineering, CFE Media, www.controleng.com/events-and-awards nected devices are changing traditional [email protected].

M More INNOVAtIONs INNOVAt

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input #25 at www.controleng.com/information

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seweurodrive.com / 864-439-7537 input #26 at www.controleng.com/information