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High speed, low-cost control


with DirectLOGIC PLCs
High-speed Counting / Pulse Output Module for DirectLOGIC DL05 and DL06 PLCs

H0-CTRIO2 (up to 250 kHz)

H0-CTRIO2 $199.00

If you need precise counting or high-speed outputs for motion control in a low-cost form factor, DirectLOGIC micro PLCs are just the ticket for small projects. The new H0-CTRIO2 High Speed Counter I/O Module ts into an expansion slot on any DL05 or DL06 controller. Inputs for two up or down counters, or one quadrature encoder (250 kHz max) Two high-speed inputs for edge timing, pulse catch, count reset/inhibit/capture or home search Two congurable high-speed outputs or one channel pulse output control (20 Hz-250 kHz) step and direction, or clockwise (CW) and counter-clockwise (CCW) pulse outputs Module operates asynchronously from the PLC/controller, so on-board outputs respond in real time to incoming signals The DL05/06 series of controllers are convenient mciro-bricks with 14 (DL05) or 36 (DL06) built-in I/O, plus expansion slot(s) for additional discrete, analog or specialty modules such as the high-speed counter. A DL05 unit with 8 inputs and 6 outputs starts at just $125.

Cut-to-length application uses high-speed output to cutter and encoder feedback to high-speed input for precise control
PLC with H0-CTRIO2 module Motor interface Motor control lines Gearbox, clutch and brake interface H0-CTRIO2 high speed output Cutter interface

Encoder

Material to be cut to length

Cutter assembly

For more details on this module and DirectLOGIC PLCs, visit:

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www.automationdirect.com Go online or call to get complete information, request your free catalog, or place an order.

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MAKING MODERN LIVING POSSIBLE

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MAY 2013

Vol. 60 Number 5

C OV E R I N G C O N T R O L , I N S T R U M E N TAT I O N , A N D A U TO M AT I O N S YS T E M S W O R L D W I D E

46

40
Control Engineering photo

Features
40 A straightforward maintenance strategy yields
improved plant performance
Moving from reactive to preventive maintenance helps Monsanto improve output and reduce costs at its Muscatine plant.

50

46 Machine vision speed, quality, innovation

Advanced applications for machine vision in automotive, robotics, quality, and safety use hybrid technologies, vision for robotic or machine guidance and in-line part inspection, and 3D imaging.

50 Step-motor-based systems stay competitive 54 The industrial Internet of Things 59 Safety: Risk management

Traditional stepper-motor systems represent the only motion-control technology able to operate in open loopalthough the addition of position feedback to enhance performance is on the rise.

Should industrial users embrace IP networking? It promises convergence of many technologies, but is it necessary or even beneficial? An examination of why and why not, what, and how.

Risk assessment and risk management plans help with industrial safety and machine safety efforts, using standards, processes, hardware, software, and continual education.

CONTROL ENGINEERING (ISSN 0010-8049, Vol. 60, No. 5, GST #123397457) is published 12x per year, Monthly by CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Jim Langhenry, Group Publisher /Co-Founder; Steve Rourke CEO/COO/Co-Founder. CONTROL ENGINEERING copyright 2013 by CFE Media, LLC. All rights reserved. CONTROL ENGINEERING is a registered trademark of CFE Media, LLC used under license. Periodicals postage paid at Oak Brook, IL 60523 and additional mailing offices. Circulation records are maintained at CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Telephone: 630/571-4070 x2220. E-mail: customerservice@cfemedia.com. Postmaster: send address changes to CONTROL ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Publications Mail Agreement No. 40685520. Return undeliverable Canadian addresses to: 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Email: customerservice@cfemedia.com. Rates for nonqualified subscriptions, including all issues: USA, $ 145/yr; Canada, $ 180/yr (includes 7% GST, GST#123397457); Mexico, $ 172/yr; International air delivery $318/yr. Except for special issues where price changes are indicated, single copies are available for $20.00 US and $25.00 foreign. Please address all subscription mail to CONTROL ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. 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.

MAY 2013 CONTROL ENGINEERING www.controleng.com

Industrial Ethernet

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Success Story

Automation Simplied
GE Appliances. When one of the worlds largest manufacturers of major appliances needed an open, globally supported network that was easy to install, they chose PROFINET.
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I needed to reduce implementation time. PROFINET does that.


Robert Frank, Senior Advanced Manufacturing Engineer

To learn more, read the complete application story at www.us.pronet.com. Or, simply scan the QR code.
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MAY 2013

C OV E R I N G C O N T R O L , I N S T R U M E N TAT I O N , A N D A U TO M AT I O N S YS T E M S W O R L D W I D E

Inside Process
Starts after p. 63. If not, see www.controleng.com/archive for May.

P1 P5 P9

Working in the cyber security red zone


Do you have enough first responders within your company when it comes to dealing with cyber security incidents and network violations? How can you make sure you arent developing critical staffing gaps?

Understanding SIS industry standards


Process safety standards and practices are spreading from oil and gas and other energy-related industries to broader process industry applications. Heres basic advice on how to make more sense of the numbers and acronyms.

Innovative energy management strategies help a Maine paper mill stay competitive
When changing fuel prices forced the mill to reevaluate its generating capacity, it added more sophisticated monitoring and control capabilities.

PRODUCT EXCLUSIVE

departments
8 Think Again
Manufacturing competitiveness, innovation: National, personal

31 International
Is SLM gaining momentum in China?

10 Product Exclusive
Embedded motion controller

33 Machine Safety
Incorporating functional safety

12 Tech Update
How to lower PLC software costs

80 Back to Basics
Simulators use math to create virtual processes

14 IT & Engineering Insight


When M2M meets IT

16 Tech Update
PRODUCTS How to choose industrial wireless components

news
34 Reports from Hannover Messe, CSIA Executive Conference; new industrial revolution spurs U.S. manufacturing

18 Tech Update
Achieve fault tolerance with a real-time software design

22 Application Update
Unified platform helps robotics for packaging

26 Application Update
More efficient pumps use VFDs, consolidate logic

products
76 Flowmeters; light curtains; servo motor controller; non-contact wireless switch; controller programming platform; and more

28 Application Update
Simulation software boosts machine productivity

www.controleng.com

CONTROL ENGINEERING MAY 2013 5

MAY

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VIDEO: Visit Monsanto Muscatine
If you want to meet the subjects of this months cover story, read it online at www.controleng.com to see a video produced by Control Engineering that takes you to the plant and lets you hear what theyre doing from the participants. To go there directly, scan the QR code to the right.

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Consult our listing of more than 2,300 automation system integrators. You can find a specific company or run a seven-way multi-parameter search.

MAY 2013 CONTROL ENGINEERING www.controleng.com

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editorial

THINK AGAIN
Manufacturing competitiveness, innovation: National, personal

1111 W. 22nd St. Suite 250, Oak Brook, IL 60523 630-571-4070, Fax 630-214-4504

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Mark T. Hoske, Content Manager 630-571-4070, x2214, MHoske@CFEMedia.com Peter Welander, Content Manager 630-571-4070, x2213, PWelander@CFEMedia.com Bob Vavra, Content Manager 630-571-4070, x2212, BVavra@CFEMedia.com Amara Rozgus, Content Manager 630-571-4070, x2211, ARozgus@CFEMedia.com Amanda McLeman, Project Manager 630-571-4070, x2209, AMcleman@CFEMedia.com Chris Vavra, Content Specialist 630-571-4070, x2219, CVavra@CFEMedia.com Brittany Merchut, Content Specialist 630-571-4070, x2220, BMerchut@CFEMedia.com Ben Taylor, Project Manager 630-571-4070 x2219, BTaylor@CFEMedia.com

Science, technology, engineering, and math professions earn 26% more; manufacturing contributes more innovation to the economy and accounts for 60% of exports, with 9% of the employment.
tion. So for 30 years on the political side, few worried about that, he said. Theres been a rethinking in recent years as people realized the real economy was under-rated and the financial economy over-rated. Were good at innovation, but inventing and making are not separate. If we let our manufacturing go, innovation goes with it, Bloom suggested. A manufacturing job is more valuable than other jobs because of a multiplying effect to other areas of the economy. If you build an automobile manufacturing plant, a Wal-Mart will follow, but not the other way around, he observed. Government should provide supportive infrastructure and ensure we have appropriate trading partners, Bloom said. Because intelligence is embedded into manufacturing processes, there are huge opportunities, as we think again about what manufacturing can do for us, Bloom suggested. Theres an interconnectivity between people who think about stuff and people who make stuff, and regional ecosystems of talent, with webs of suppliers to help, he noted. ce

Contributing Content Specialists


Frank J. Bartos, P.E., braunbart@sbcglobal.net Jeanine Katzel jkatzel@sbcglobal.net Vance VanDoren Ph.D., P.E., controleng@msn.com Suzanne Gill, European Editor suzanne.gill@imlgroup.co.uk Ekaterina Kosareva, Control Engineering Russia ekaterina.kosareva@fsmedia.ru Marek Kelman, Poland Editor-in-Chief marek.kelman@utrzymanieruchu.pl Luk Smelk, Czech Editor-in-Chief lukas.smelik@trademedia.us Andy Zhu, Control Engineering China andyzhu@cechina.cn

arnings are 26% more on average for those studying science, technology, engineering, and math (STEM) subjects, according to Eric Spiegel, president and CEO, Siemens Corp. The best way to close the skills gap is for schools, government, and industry to work together to close the training gap. Advanced manufacturing is where the world is going. This can create opportunities for millions of Americans, he noted at an April 23 online conference hosted by Washington Post Live and sponsored by Siemens, American Small Manufacturers Coalition, and Northern Virginia Technology Council. James Manyika, director of McKinsey Global Institute, recently named to President Obamas Global Development Council, said manufacturing is responsible for 9% of employment, but drives more than 60% of exports. Manyika said the U.S. is still the leading manufacturer, but China, India, and Russia are gaining, driving demand locally. Many nations are reaping benefits from manufacturing-related innovations of their own, Manyika suggested. U.S. innovations are huge, especially in materials development, production, and analytics; many help smaller manufacturers to effectively compete, Manyika said. Product demand helps determine where companies are located, along with labor skills, costs, infrastructure and non-labor inputs, such as energy, natural resources, innovation, and business and policy environment. Ron Bloom, senior advisor, Lazard, and former assistant to the president for manufacturing policy, said For a long time we believed decline of manufacturing was both inevitable and good, part of a natural evolu8

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Go Online
At www.controleng.com/archive, see Manufacturing in America targets next U.S. industrial evolution. www.usa.siemens.com Washington Post Live www.washingtonpostlive. com

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MAY 2013 CONTROL ENGINEERING www.controleng.com

The Sign of Quality

For almost 100 years, Baldor Electric Company has developed a reputation for designing and manufacturing the highest quality industrial electric motors available. Beneath the nameplate of every BaldorReliance motor, you will find the best industrial electric motor you can buy. When reliability counts, accept nothing less than the Sign of Quality from BaldorReliance. baldor.com

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Scan to watch a video and learn more or go to http://qr2.it/Go/1398474 input #6 at www.controleng.com/information

product

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Software wizard: easy setup of embedded motion controller


PMD Pro-Motion software offers axis wizard and support for digital amplifiers and embedded motion development, providing easy setup of embedded motion controllers.

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erformance Motion Devices Inc. (PMD) announces a major new release of PMD Pro-Motion software for Microsoft Windows-based environments. Pro-Motion 5.0 adds a number of key capabilities including an upgraded axis setup wizard, support for SPI-based motion amplifiers, including PMD Atlas digital amplifier products, and support for all-in-one embedded motion cards and systems. The most significant new feature in Pro-Motion 5.0 is the addition of a graphical axis wizard facility that provides step-by-step configuration of all control signal parameters, including quadrature feedback, motion output signals, home signals, Hall sensor signals, analog input and output, and more. The new axis wizard performs automated tests to characterize connection and configuration information. Users can accept these automatic parameters or provide their own values. Other features include current loop and position loop auto-tuning, and system configuration storage. Another major new feature is support for SPI (serial peripheral interface)based solderable motion amplifiers. These amplifiers, including the PMD Atlas line of digital amplifiers, are used in embedded motion applications where the motion processor IC and motion amplifier are colocated on the Go Online same card. Step Read more: motor, dc brush, www.controleng.com/archives and brushless www.controleng.com/motors dc motors are supported, as are manual or automatic tuning of amplifier gain parameters, temperature monitoring, and I2t current tuning. Embedded motion software development is supported via a command window along with a simple scripting facility to program sequences of commands. ce

input #7 at www.controleng.com/information

Performance Motion Devices (PMD) www.pmdcorp.com


10

MAY 2013 CONTROL ENGINEERING

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Allied Electronics, Inc 2013. Allied Electronics and the Allied Electronics logo are trademarks of Allied Electronics, Inc. An Electrocomponents Company.

technology

UPDATE

How to lower PLC software costs


PLC vendors make much more profit from software licenses than they do selling hardware. Smart shopping can avoid some of those fees. Advice for lowering PLC software licensing fees follows.
Chuck Karwoski

rogrammable logic controllers (PLCs) and now programmable automation controllers (PACs) are the mainstay of discrete factory automation, and they are increasingly being used in process control. Understanding how software licenses work can help you understand how you may spend 10 times as much on software as on PLC hardware. A software license governs the use or redistribution of software. A software publisher can charge to buy the software and restrict how many PCs the software can be installed on. For a machine builder who uses a PLC as a control system, it generally means the builder has to pay for another software license each time a new machine gets shipped to the customer. Software licenses can also restrict users in other ways, such as limiting the number of data points, functions, or workstations able to access data for controlling the machine. The license also may require

the purchase of an annual maintenance contract and/or technical support, the purchase of periodic upgrades, and other purchases that can nickel and dime a machine builder or end user for years. Vendors prevent users and machine builders from copying the software and loading it onto additional PCs. Any software can be copied, of course, and copies can be loaded into other PCs. But they wont run on any other PC because of restrictions similar to how Microsoft protects its software from being pirated. Methods include requiring a dongle to be plugged in, or a product activation program. A dongle is a hardware key containing an electronic serial number required to run the software. Product activation requires the user to verify the license, typically by entering a product key or serial number to activate and use the software. Software license cost depends on pricing from the software publisher, number of development licenses, number of data points, add-on components, number of run-time licenses, annual maintenance fees, and other factors. These particular citations did not indicate whether the price was for shrinkwrapped software costs alone or if any services fees were included.
Software needed, costs

A typical PLC application usually requires purchase of: PLC programming software, HMI development software, SQL / database license, data I/O server, addBuying PLC programming software is just the first purchase in a list of expensive software programs needed to get an automation system up and running. Courtesy: CimQuest Ingear
12

MAY 2013 CONTROL ENGINEERING www.controleng.com

If PLCs are connected to HMI terminals, the end user may have to purchase a run-time license for each one, at a cost of about $1,100 per terminal. Courtesy: CimQuest Ingear

on tools and components, and HMI run-time license. Each, of course, has a separate software license. The software developer still needs to add his skills, experience, and creativity to produce the ing secretive, proprietary, or difficult about HMI/ end product ready for run-time deployment. SCADA, data communications, SQL, and many Run-time license fee is another revenue gen- other software packages. Many such packages can erator for the software publisher. A run-time be purchased from non-PLC vendors on the open license is a way for software publishers to con- market. Anything else can be developed by an trol distribution and generate another revenue experienced MS Visual Studio programmer. stream. Basically the software publisher chargAll a machine builder needs from the PLC es a fee for tools to create applications, places vendor is the PLC and I/O hardware and probrestrictions on the types of applications you ably the programming package (although IEC may create, and then charges fees for distribut- 61131 programming packages are available). ing your works. Everything else can be Alternative software soluSome software has no purchased separately. tions exist on the open market In many cases, these run-time licensing fees, from several vendors. Getting packages dont have users and machine builders to so applications created expensive software and talk about how they avoid these run-time licenses. For can be distributed by costs by purchasing alternative example, the PLC drivsoftware is difficult. In many er software includes a a systems integrator or cases, they have built relationlibrary of programs for machine builder without PLCs that programmers ships with PLC vendors and have standardized on PLC use to create their own added costs. hardware. customer applications For example, a major automation vendor offers using MS Visual Studio. Such software provides a software solution built on OPC to enable con- access to PLC memory, databases, I/O, and comnectivity between HMI software packages and its munications, allowing programmers to obtain PLCs. Once a user builds an interface application information they need from a PLC, process it with that HMI development tool, the software pro- in a PC, and send commands back to the PLC vides drivers and other connectivity components for control. Some such software has no run-time that enable PLC communications. Users are then licensing fees, so applications created can be required to purchase individual software copies distributed by a systems integrator or machine for every machine on which they want to run the builder with no additional costs. application, along with annual software mainteTheres no need to pay the licensing costs of nance fees for each copy. PLC vendor software when alternate solutions Although vendor-supplied software is propri- exist. ce - Chuck Karwoski is president of CimQuest etary, requires licenses, and cant be modified by a customer, most is written in Microsoft Visual Ingear LLC, a supplier of PLC software. Edited Studio. Anything the vendor can do, a machine by Mark T. Hoske, content manager, CFE Media, builder or an end user can do, too. There is noth- Control Engineering, mhoske@cfemedia.com.

Go Online
At www.controleng.com/ archive, read this article for more on cost of software licenses, two examples of savings, more photos, and a link to Products to lower PLC software costs. www.ingeardrivers.com

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CONTROL ENGINEERING MAY 2013 13

IT & engineering

INSIGHT

When M2M meets IT


Subsecond latency and delivery jitter lead to lost production time and production. Do not let your production suffer when M2M network requirements collide with IT policies.

M
Dennis Brandl President of BR&L Consulting

QoS metrics should be collected, monitored, and alarm monitored the same way normal production measurements are handled.

Go Online
At www.controleng.com, search Brandl for more under this headline. www.controleng.com/ archive At www.controleng.com search M2M, industrial network, or Internet of Things.
14

achine to machine (M2) communication was formerly a straightforward engineering job, with outputs from one devices controller fed into inputs of another devices controller. A stalled signal from a downstream device was fed into a delay command in an upstream device. In complicated situations, or where the signals do not exactly correspond, a small PLC might have been placed between the devices to handle complex timing issues and perform simple logic. As M2M communication has moved out of the hardwired model to a data communication model over Ethernet networks, the IT department is now involved in these integration jobs. Some IT departments recognize the special nature of these networks, but many do not. IT departments that recognize the special nature will segment their networks to localize M2M traffic and protect it from general business network interruptions. M2M communication is special because of its specific quality of service (QoS), redundancy, and consistency requirements. In an internal IT network there is little business impact if it takes two extra seconds to view an e-mail or one extra ring on a voice over IP (VoIP) phone call. In production environments using networked M2M, even small subsecond delays can cost millions of dollars in lost yearly production. For example, a 250-millisecond signal delay to a placement robot moving 10 parts per minute will be 1 hour of unproductive time in a 24-hour production run.

4. Error rate usually measured in errors/million communications 5. Delivery jitter or variation in message latency. If your IT department does not segment its production communications from normal business communications network, then it is vital to develop a QoS agreement and a guarantee from the IT department for your industrial networks. However, having a QoS agreement is worthless unless you also have some method of measuring compliance. It is important to monitor QoS metrics on a regular basis to ensure that normally undetected subsecond delays are not creeping into the system due to normal maintenance and system expansion. QoS metrics should be collected, monitored, and alarm monitored the same way normal production measurements are handled. QoS metrics are sometimes available from routers or switches, but they can also be determined with a few lines of ladder logic in a PLC if no other method is available. QoS metrics should at least be monitored per network segment and, if possible, to each device. It can also be valuable to retain the QoS metrics in your plant historian to aid in troubleshooting. This will allow you to pinpoint the time that a QoS went out of specification and maybe relate it to a replaced element, changed configuration, or router patch.
Standard segmentation

5 quality of service measures

Special M2M requirements should be expressed as QoS requirements. QoS has several different measures: 1. Availability or uptime usually measured as a percentage with 100% meaning always available 2. Bandwidth or throughput that is usually measured in total network bandwidth but in M2M environments should be measured in bandwidth available to each device 3. Latency or delays in communication from a source to a destination usually measured in milliseconds

Industrial networks should be separated from normal business networks for safety and security reasons, as specified by the ISA 99 and IEC 62443 standards. However, if your IT organization will not separate them because it is hard to justify the costs, then QoS arguments should be used. Subsecond latency and delivery jitter can be directly related to lost production time and potentially millions of dollars of unrealized production. Do not let your production suffer when M2M requirements collide with IT policies. ce - Dennis Brandl is president of BR&L Consulting in Cary, N.C., www.brlconsulting.com. His firm focuses on manufacturing IT. Contact him at dbrandl@brlconsulting.com.

MAY 2013 CONTROL ENGINEERING www.controleng.com

2010 The MathWorks, Inc.

Q
Find it at

mathworks.com/accelerate

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system. Assemble your model with a graphical interface, or import physical models from CAD systems. Use built-in components or create your own with the Simscape language.

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How to choose industrial wireless components


For industrial wireless networks, choosing the best accessories helps ensure a high-quality wireless network. Most problems in newly installed wireless networks result from poorly chosen or poor-quality accessories.

David Burrell

ver the past decade, wireless technology has become one of the most efficient ways for industrial professionals to reduce operational expenses. The labor and material expenses of a cabled system can cost up to 500% more than a wireless system. Thanks largely to these potential savings, the industrial market has witnessed a rapid increase in the market acceptance of wireless. While the radio device itself is obviously a key piece of equipment, installation practices and auxiliary equipment also affect the reliability of a wireless network. Poor installation practices, coupled with low-quality accessories, can lead to failure in a wireless network.

Power levels commonly found in wireless communications


dBm level
-120 dBm -120 dBm -100 dBm -90 dBm -20 dBm -10 dBm 0 dBm 10 dBm 20 dBm 30 dBm

Polarization of antennas:

Power
0.000000000001 mW 0.00000000004 mW 0.0000000001 mW 0.000000001 mW 0.01 mW 0.1 mW 1 mW 10 mW 100 mW 1000 mW

Link budget

Power measurements

Wireless systems measure all radios output powers and components gains and losses with a common unit factor. This common factor is known as a decibel. A decibel (dB) is an abbreviation for the power ratio calculated using the formula below. Note that both P1 and P2 refer to the same power unit. dB=10log (P1/P2) In wireless communication, power is referred to as dBm. A dBm is calculated as a dB, but P2 always equals 1mW. dBm=10log (P/(1 mW)) Power levels commonly found in wireless communications are in the table. For every 3 dBm gain, the effect of power doubles. An increase of 6 dBm will double the effective line-of-sight range for a wireless link; dBi refers to the gain of isotropic antennas. An isotropic antenna radiates equally in all directions. dBi and dBm can be added, and the resulting sum is expressed in dBm.
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The sum of all antenna gains, cable losses, radio transmission power, receiver sensitivity, and path loss is the link budget. The remaining single level is called the fade margin. This is the cushion between the received signal and the radio devices minimum receive threshold. Environmental changes can attenuate the transmitted signal, so when designing a wireless network, it is important to calculate a 10-20 dB fade margin into the link budget of the path to compensate for any such changes. Using higher gain antennas and lower loss coaxial cable, or increasing the transmission power (when possible), are two ways to increase the fade margin. Figure 1 shows an overview of the calculations.
Antenna selection

Polarization refers to the direction in which the radio emits energy through space. Antennas can be polarized in three ways: vertically, horizontally, and radially. Cross-polarizing antennas mean that the receiver will accept only a fraction of the transmission power. The antennas angle determines what that fraction of emitted power is. For example, no power will be received by an antenna 90 degrees out of phase. An antenna 45 or 130 degrees out of phase will receive only half of the power. Cross-polarization is not necessarily a bad thing. Two neighboring or overlapping networks that are operating in the same frequency can result in interference. Changing the polarization of one of the networks can overcome the intrusive signals between the two networks.
Antennas

Omni-directional antennas cover a 360-degree plane with nearly uniform characteristics across all directions (Figure 2). Some common applications for omni-directional antennas include cases
Antenna gain TX power Cable loss RX Threshold Path loss Fade margin

Proper antenna installation is critical and will affect the entire systems performance. Choosing an antenna designed for use at the proper frequency and with matching impedance are the first steps. Select an antenna with an appropriate gain for the path it will be used for.

Figure 1: Overview on how to calculate link budget. Items shown in green are added while items shown in red are subtracted. The resultant number is the link budget. The fade margin is recommended to be an extra 20 dBm to account for unforeseen interference. Courtesy: Phoenix Contact Figure 2: Omnidirectional antenna radiation pattern. Courtesy: Phoenix Contact

MAY 2013 CONTROL ENGINEERING www.controleng.com

Figure 3: Yagi-directional antenna radiation pattern. Courtesy: Phoenix Contact

where the position between the transmitter and receiver can change, moving applications or a multipoint network. They are also ideal when line of sight is obstructed, because the reflections can be used to send the signal from the transmitter to the receiver. The best place to install an omnidirectional antenna is on top of a mast or on a control cabinet. This allows it as much free space in all directions as possible. Unfortunately, it is not always possible. If an omni-directional antenna must be mounted on the side of a mast, the installer must observe specific measurements and distances to mount the antenna away from the mast for the best signal. If the omni-directional antenna is mounted to conductive material, such as a master control cabinet, its directional characteristics will be affected. The diameter and distance between the antenna and conductive material can alter the antennas coverage area significantly. Wall mounting should be avoided, as the wall has a great impact on the antennas transmission properties. If wall mounting is the only option, the installation should have a minimum of half a wavelength of the respective operating frequency of distance between the wall and antenna.
Yagi antennas

the antenna heading, it should be oriented Go Online for maximum signal strength. Directional antennas must be mounted n This article at www.controleng.com/archive securely. Strong winds might sway or has more on cables and power supplies. wobble an unstable antenna, which could n www.controleng.com/wireless has more articles on industrial wireless. lead to serious misalignment. ce - David Burrell is wireless product n www.phoenixcontact.com ITS_IceStation_sparks_5.125x8.125_REV_Layout 1 4/19/12 1:13 PM Page 1 specialist, Phoenix Contact.

its guaranteed to singe your electronics.

Yagi antennas (Figure 3) radiate power in a specific direction. This increases the range and reduces the chance of interference. As the gain of a Yagi antenna increases, the energy becomes more focused. This causes the beam width to decrease, so proper alignment becomes even more critical. Aiming these antennas in the desired direction of communication (such as at the master station) is very important. Remote, fixed stations with line of sight that cover large distances should use directional antennas. The end of the antenna (farthest from the support mast) should face the associated station. A master location with multiple slave radios must always have an omni-directional antenna, and the slave radios can have Yagi antennas to increase distance possibilities. During final alignment of
CONTROL ENGINEERING MAY 2013 17

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Achieve fault tolerance with a real-time software design


Data Distribution Service (DDS) specification from Object Management Group (OMG) is a data-centric publish/subscribe (DCPS) messaging standard for integrating distributed real-time applications. Heres how process replication can increase a systems fault tolerance.
Reinier Torenbeek

ata Distribution Service (DDS) specification from Object Management Group (OMG) is often used to build mission critical systems consisting of multiple components executing simultaneously and collaborating to achieve a certain task. In such systems, there are usually several components that are critically important for the overall functioning. Those components require extra attention when designing the system to ensure that the likelihood of them failing is minimized. Its focus on reliability, availability and efficiency make the DDS infrastructure particularly suitable to connect the plant floor with other areas of the enterprise. DDS provides advanced features that help achieve such goals. While there are many methods, fault tolerance for failing publishing applications or machines can be achieved by means of active process replication.
Guiding example

application processes. For the sake of simplicity, the collection of those processes is referred to as the Manager component. Note that those could be executing in a distributed fashion on multiple machines.
Active process replication

Simultaneously running multiple Manager processes with the same purpose will decrease the likelihood that the Manager component will break down completely. DDS allows for adding and removing participants on the fly without requiring configuration changes, so the basic concept of process replication is supported. Still, there are multiple options from which to choose.
Plain process replication

The most basic approach is to run multiple, identical Manager applications. Courtesy: Real-Time Innovations

For the purpose of illustrating the theory here with an example, the use case of the simple distributed finite state machine (FSM) is described. The FSM consists of a few components: a Master Participant, a Worker Participant, and a Manager. The Observer component, not essential for the functionality of the pattern, is passively observing only. This example focuses on the interaction between the Manager and the Observer. Lets assume that the Manager is the most critical process in the pattern, which is likely to be the case, especially if the pattern is expanded to support multiple Masters and Workers. The most obvious way to make the Manager component more robust is by running multiple processes simultaneously, all with the same responsibility. With that approach, the Manager component is defined as a conceptual item that may consist of multiple, simultaneously running

The most basic approach is to run multiple, identical Manager applications. Each acts the same, receiving the same transition requests and publishing the same state updates in response. As a consequence, applications observing the state machine will see multiple instances of that state machine simultaneously. This approach requires a minor adjustment to the data-model to allow multiple task instances to exist side-by-side. This is achieved by adding a key attribute that identifies the originating Manager application. An advantage to this approach is its low complexity; just replicating everything is an approach everybody understands. There is no impact on the Manager application code, and all participants remain completely decoupled from each other. Additionally, the mechanism does not rely on any built-in replication mechanism from the middleware. This could be considered an advantage as well, because the developer now has every aspect of the replication process under control. On the other hand, that latter argument could be seen as a disadvantage. Requiring all Observers of the state machine to be able to deal with multiple, identical versions simultaneously does have an impact on the application code and introduces

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MAY 2013 CONTROL ENGINEERING www.controleng.com

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an extra burden on the application developer. Also, the number of instances an instance state updates scales linearly with the number of Manager processes. For this particular state machine example that is not that big of a deal, but in the general case, it could have a significant impact on network bandwidth consumption and memory usage.
Process replication, writer-side peer awareness

To avoid disadvantages, another option is to make Manager processes aware of each other at the application level.

The last option here takes advantage of a native DDS feature called exclusive ownership. Images courtesy: Real-Time Innovations

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To avoid disadvantages, another option is to make Manager processes aware of each other at the application level. If all Manager processes know which other Manager processes are currently participating in the infrastructure, then they all could decide for themselves, according to a system-wide consistent selection algorithm, which of the replicated Manager processes is the currently active one. All Manager processes would be participating in the pattern and updating the relevant states accordinglybut only the active Manager would actually be communicating those updates to the data-space. If the active Manager leaves the system for some reason, then the remaining Manager processes need to decide for themselves whether or not they are the new active Manager and adjust their behavior accordingly. DDS supports the necessary features to implement this approach. By subscribing to socalled built-in Topics, applications can be made aware of other DDS Entities in the cloud. This kind of subscription also can notify the application of lost liveliness or destruction of each of these Entities. Those two aspects combined are sufficient for this example. This approach has no application-level impact on subscribing components in the system and, consequently, they do not require code changes. This kind of replication also does not consume any extra bandwidth or resources, as plain replication does. There is some impact at the application level for the Manager processes. The mechanism of peer-awareness and leader selection has to be created. This is not trivial, and the impact of bugs in that piece of code could be high. (It could lead to none of the processes stepping up as the leader!)
Process replication, exclusive ownership

update the same data-item simultaneously. This behavior is called shared ownership, and it is the default setting for the ownership quality of service (QoS) setting. If the nondefault setting, called exclusive ownership, is selected, the infrastructure will make one of the publishers the owner of the data-itemat any time, only the owner of the data-item can update its state. For this leader selection, another policy called ownership strength can be adjusted. This integer value will be inspected by the middleware to identify the current leader at any time, that is, the publisher with the highest ownership strength. This selection is done consistently through the system. Other than selecting the right QoS, this solution is transparent to all system components. The different Manager processes are unaware of each other and execute their tasks independently. Similarly, the subscribing components do not (have to) know that in fact, multiple publishers are present in the system. Everything needed to achieve the required functionality is handled within the middleware. As a consequence, no extra code has to be added, nor tested, nor maintained. Exclusive ownership functionality is described in the DDS specification and was designed with the mechanism of process replication in mind. In that sense, it is not a surprise that this solution is usually the best fit. The specification does not indicate how this functionality should be achieved by the middleware; that is left up to the product vendors. However, it is good to know that typically, for optimal robustness, implementations do send data over the wire for each of the active publishers, and the leader selection takes place at the receiver side. This means that the feature does result in extra networking traffic.
Recovering from faults

The last option here takes advantage of a native DDS feature called exclusive ownership. Normally, DDS allows multiple publishers to

Process replication is an important aspect of increasing fault tolerance in a system. However, there is more to it. If a system, by virtue of the process replication, can continue after a fault, then it will have entered a stage in which it is less faulttolerant simply because one of the replicating processes is gone. It is still essential that the system recovers as quickly as possible from the fault and returns to the fault-tolerant state. In our example, this means that the failing Manager process will have to restart, obtain the current state of all task data-items, and start participating in the pattern again. DDS can help make the task of recovery easier as well. ce - Reinier Torenbeek is systems architect at RTI. Edited by Mark T. Hoske, content manager, CFE Media, Control Engineering, mhoske@cfemedia.com.

MAY 2013 CONTROL ENGINEERING www.controleng.com

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Unified platform helps robotics for packaging


Multinational maker of secondary packaging systems, Cama Group, standardizes robotics on a unified platform to deliver simplified, high-speed automation software and hardware including a programmable automation controller (PAC), I/O modules, motors, servo drives, ac drives, and operator interfaces.
Mike Wagner

Using the Rockwell Automation Integrated Architecture system, Cama Group robots are easily integrated into packaging modules, machinery, or complete lines. Courtesy: Rockwell Automation

ama Group, a multinational maker of secondary packaging systems, standardizes robotics on a unified platform to deliver simplified, high-speed automation software and hardware. The company switched from a proprietary technology mix to one automation vendors hardware and software. The challenge was to migrate the automation and motion control systems used by Cama Groups robotic loading units into the new platform. A Russian confectionary, a large yogurt producer in China, and a maker of single-serve capsule coffees in Italy are three companies using the Cama Group to custom design, engineer, and build secondary-packaging systems. Our strength lies in combining robot technology with packaging machinery, said Paolo Mosca, electronic department manager at Cama Group. The company delivers solutions primarily for the bakery, dairy, and coffee industries, and increasingly for manufacturers of nonfood consumer items, such as cosmetics and toiletries. Cama Group provides specialized, advanced robot technology for the secondary-packaging industry. The company engineers four types of robotic-loading units, ranging from two to four axes, each with a different payload capacity and application capability. Beyond pick and place, Mosca said, these are robot machines that carry out complex technical tasks, such as managing and loading products on a continuous motion packaging line. For example, Cama Groups Triaflex robot coupled with an intelligent vision systemcan work in three dimensions, with 360-degree head rotation, picking random products from the production line belt and positioning them correctly into packaging. The Triaflex robot is equipped with four controlled axes and carbon-fiber arms for gripping or placing products in all positions at up to 150 cycles per minute. Manufacturers can use the robot to load a moving flow pack into a horizontal cartoning machine.

We design and develop our own line of robots in-house, and integrate them with an array of automated packaging machines, Mosca said. The result is a complete packaging and handling solution tailored to each customers unique requirements.
Simpler controls wanted

Increasingly, Cama Groups customers have asked for packaging systems with simplified controls. In response, the company decided to research how to migrate the automation and motion control systems used by its robots from a mix of multi-brand technologies to a unified platform. We strongly believe that the uniformity of our systems is absolutely fundamental, especially in gaining authority in the market and the trust of customers, Mosca said. If the machines on a line are different with regard to hardware architecture, software design, and motor type, product reliability cant be optimized, and more importantly, neither can the price for the customer. Cama Groups engineers recognized that one platform would be much easier to commission, operate, and manage for customers engineers, technicians, and maintenance personnel. And, they wanted to meet customers consistent need for more compact packaging systems. However, simplification and a smaller footprint couldnt come at the expense of performance. Theres enormous pressure in our industry to give the customer a high-speed solution they cant find anywhere else, Mosca said, with accuracy and efficiency of packaging processes. Market competition created a compressed time frame to develop and deliver a new solution that standardized on a common control system that could meet these needs.
Mechatronic solutions

In 2012, Cama Groups research and development team, along with its mechanical and

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MAY 2013 CONTROL ENGINEERING www.controleng.com

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The system uses servo drives that help eliminate the need for a dedicated motion network and allow users to support high-performance drives, I/O modules, smart actuators, and any other EtherNet/IP-connected device on one network. The drives, with safe-off function, reside on the same EtherNet/IP network for simplified machine design and production line operation. Low inertia servo motors fit compact space requirements while meeting the demands of the high-performance motion system. Another important goal of the project was to improve operator safety and deliver a system compliant with global safety standard EN ISO 138491. The automation vendor conducted a safety risk assessment and implemented an integrated safety system, which allows for safety and standard control on one platform, alleviates complicated hardwiring, and reduces engineering time. With the unified platform, the PAC uses the same configuration, networking, and visualization environment as the rest of the system. This integration provides users with fewer spare parts to maintain, while the control platforms openness helps ease integration into an existing plant. Unlike hardwired systems, the integration of safety and standard control provides operators and maintenance personnel with visibility to all machine eventsincluding safety eventsvia a human-machine interface. The knowledge and insight provided by the integrated system allows users to respond quickly and return the machine or line to full production. To manage safety on smaller, individual machines with the robot system, the team used safety relays. The new control platform gives our customers a linear and lean production line, Mosca said. The modular approach allows us to apply the standard platform in future projects, saving design and development time.
Results: Time to market

With 25 years of experience, Cama Group provides robotic systems tailored to end-user needs by designing and developing its own line of robots in-house, and integrating them into an array of automated packaging equipment, such as the robotic cartoning system shown. Courtesy: Rockwell Automation

During the project, clear definition of specifications and targets helped, along with shared project management methods. These methods helped meet cost and time-tomarket requirements.

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electronic engineering department, worked with consultants at the automation vendor, providing specific production line requirements. And, of course, we gave them a very ambitious time target, Mosca explained. The experts helped us understand exactly how the system would perform. We worked together as partners to attain the highest speed for the application we were requesting. Engineers chose a modular approach to help Cama Group adapt the solution to unique specifications of different manufacturing processes. From a technical point of view, we wanted to integrate logic and motion on a unique automation platform, Mosca said. The robot automation and control system had to fit different requirements: speed and flexibility in handling operations, synchronization of different axes in the plant, and easy product changeovers. At the outset of the project, the blended team defined technical specifications to size the programmable automation controller (PAC), I/O modules, motors, servo drives, ac drives, and operator interfaces. At the heart of the system is a control platform with integrated motion. Having one control platform allows users to manage different robot kinematics at the same time and synchronize separate tracking, handling, and vision systems. The controller has a SERCOS (Serial Real-time Communications System) interface motion module. End users can easily share production information across all equipment through one EtherNet/ IP network. EtherNet/IP, an ODVA Ethernet protocol, uses the same TCP/IP protocol suite that is used for the Internet, with the open connectivity and global acceptance of standard Ethernet and the real-time performance and security of fieldbus networks. Cama Group engineers can link their optical character recognition and optical character verification vision systems to other automation products in the robotic cell via EtherNet/IP.

Cama Group has just begun installing the new system in customers factories, and one customer has requested the same architecture on an additional packaging line. During the project, Mosca said, clear definition of specifications and targets helped, thanks to the highly skilled teams involved, along with shared project management methods. These methods helped meet cost and time-to-market requirements. ce - Mike Wagner is global segment business manager for packaging at Rockwell Automation. Edited by Mark T. Hoske, content manager, CFE Media, Control Engineering, mhoske@cfemedia. com.

MAY 2013 CONTROL ENGINEERING www.controleng.com

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Answers for industry.


input #14 at www.controleng.com/information

2013 Siemens Industry, Inc.

application

UPDATE

More efficient pumps use VFDs, consolidate logic


Existing drives were not accurate enough to provide desired results and were not offered with conduit fittings. The solution was more energy efficient than prior drives and eliminated the PLC and control panel for logic.
Robert Fenton

chieving consistent water pressure is a challenge for geographical areas that have grown faster than the development of infrastructure to accommodate water demand and for businesses, such as fast-food restaurants and strip malls. Recognizing the residential and light commercial markets need for an energy-saving booster pump to deliver reliable water pressure, QuantumFlo, DeBary, Fla., used its variable speed pump expertise to develop a pump in a box solution that detects low flow conditions accurately and enables users to achieve significant energy savings.
Boosting efficiency

time at 20% load, its energy is being reduced by the cube of the speed reduction, which is massive. As a result, when considering the energy reduction over time, its very significant even on a very small unit. QuantumFlo application engineer Robert Mann said when developing a pressure booster, the goal was to provide a fully contained, fully assembled solution by putting together a motor, pump, bladder tank, and a VFD. Once it was fully plumbed, wired, and tested, we put a few units in the field. It wasnt long before we learned that the VFD we used did not have the accuracy to detect lower flow conditions. Customers also reported that while the exposed wiring did not present a safety hazard in itself, code inspectors did look upon it unfavorably.
Contained wiring

QuantumFlo Atom Simplex Light commercial/residential pressure Booster monitors a systems water pressure and is designed to maintain a set pressure using PID control. Eaton M-Max drive provides pump control and reduces equipment requirements (and space) for the pump system. Courtesy: Eaton

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Although constant speed pressure boosters are available, inefficiency makes them a less-than-desirable option. With a constant speed drive, every time the system comes on at full speed, it runs for a time delay and then turns off. As a result, it is at full speed and full capacity the entire time it is running. In contrast, the variable frequency drive (VFD) solution runs only for the specific capacity and energy required to meet the need at that instant. As the speed of the pump is reduced, the energy is reduced by the cube of the speed reduction. Every reduction in speed below full speed reduces the energy by a factor of eight. In addition, variable speed boosters are also quieter and maintain smooth pressure throughout the facility or residence. QuantumFlo CEO David Carrier said, The effective use of energy is best served with variable-speed drives, particularly in transporting and generating water pressure. There are very few devices in a commercial structure that run almost constantly. Eighty percent of the time a typical water booster system is using 20% capacity or less. If its running 80% of the time at full speed, for 20% of the load, thats a huge amount of waste. In contrast, if it is running 80% of the

While investigating alternatives that would eliminate the accuracy problem and exposed wiring issue, it learned about the capabilities of a VFD that could provide the required accuracy and provide an IP21 kit to contain the wiring. Mann said the new design provided both a pump control solution and a complete control solution in a compact package. Most systems with this complexity rely on a control panel with a PLC to execute the required logic. Since the drive has built-in intelligence, it performs all on/ off operational calculations, soft start and stop, and regulates the pressure of the system. Accomplishing all of that using a PLC would require complex wiring, an added enclosure, and result in a unit with a larger footprint. Plus the PLC alternative would cost at least 50% more. The VFD brings this logic into itself, which eliminates the panel. In addition, the IP21 conduit kit provides a very streamlined, clean installation, he added. The more accurate drive with IP21 conduit kit allowed QuantumFlo to meet energy and functionality needs, while eliminating the PLC and control panel for logic. ce - Robert Fenton is product line manager at Eaton.

MAY 2013 CONTROL ENGINEERING www.controleng.com

Independent High Integrity safety. When safety is all you need.

ABBs flagship safety system has now been released for use in standalone applications. This means that the same great proven and TUV certified safety system that is integrated with ABBs System 800xA DCS can now be interfaced with any ABB process control system such as Freelance or Symphony Plus (Harmony and Melody) or our heritage technologies (Advant, MOD 300) as well as 3rd party control systems, PLCs or simple HMIs. Independent High Integrity is the perfect SIL3 certified safety system; when you need safety independent of the control system technology or vendor on your site. www.abb.com/highintegritysafety

ABB Process Automation Division Visit us at our blog or on YouTube: www.processautomationinsights.com www.youtube.com/user/ProcessAutomation input #15 at www.controleng.com/information

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Simulation software boosts machine productivity


Armor increased machine productivity 20% with simulation software to create improvements and decrease downtime.
Chris Baker

This control system was designed using MSC Easy5 multi-domain modeling and simulation software. Courtesy: MSC Software Corp.

rmor increases machine productivity 20% by using simulation software to create improvements, rather than trial and error, which can waste time and product. With sales of 137 million Euros in 2011, Armor produces inked ribbon used in thermal transfer printing for product identification and other applications. Ribbon is produced by applying ink to polyethylene terephthalate (PET) film in a web coating process in which the speed, tension, and position of the web and other variables must be closely controlled to ensure the highest possible quality while maximizing throughput. Gildas Hubert, project manager for Armor, has simulated various coating machines and control systems using multibody dynamics software and multi-domain modeling and simulation software. Simulation helped us work out the optimal coating conditions and make engineering changes to our machines, Hubert said. Over one year we improved productivity by 20% while also increasing quality of the finished film. Simulation is a great way to improve our manufacturing process at a relatively low cost without disrupting production as is required for physical experiments. Armor, Nantes, France, was one of the first to manufacture carbon film, introduce typewriter ribbon cassettes, and introduce thermal transfers in the early 1980s. It has more than 760 employees and produces 110,000 thermal transfer film rolls per day at five production sites. It has the largest European marketshare, 53%, and more than 12,000 ribbon configurations.

over the thermal printhead with the coated side pressed against the label surface. The heat energy produced by each dot causes the pigment to transfer off the carrier film and bond to the surface of the label. The largest application for thermal transfer printing is the marking of individual products during manufacturing with information including model number, serial number, use-by date, composition, price, etc. Other applications include flexible packaging, ticketing, personal identification, and plain paper fax machines. During the manufacturing process, a transparent PET film is unwound as one or several layers of ink are applied on one side and a protective layer (backcoating) is applied on the other side. The PET film used as the carrier has a thickness of 3.2 mm to 5.0 mm, high resistance to tearing, good thermal conductivity, and very good heat resistance. Backcoating protects the printhead as the ribbon unwinds, provides high thermal conductivity to transfer heat to the print medium, and reduces static electricity. Different inks are used, including wax, wax-resin, and resin types. A rubber-coated metering roll feeds the ink to a gravure roll, which in turn feeds the ink to a format transfer roll onto the web. The coating weight is controlled by roll velocity and the footprint between the metering and the gravure rolls. All rolls are heated with thermo oil. A jumbo roll 20 km long is coated then unwound onto smaller rolls as required for customer applications.
Moving past physical experiments

Thermal transfer technology

Thermal transfer printing consists of applying thermofusible ink using a heat source emitted by the printer. The thermal transfer ribbon passes
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We have always been concerned with eliminating defects to ensure a positive experience to our customers while at the same time increasing the productivity of our web coating process, Hubert said. In the past the primary method of improving operations was with physical experiments. There are problems with this approach. First of all, utilizing coating machines to run physical experiments disrupts our production operations. The limited time available for and high cost of physical experiments greatly reduces the number of different conditions that we can evaluate. Physical experiments ... provide limited

MAY 2013 CONTROL ENGINEERING www.controleng.com

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application

UPDATE
lates the proportionalintegralderivative (PID) closed-loop motion controller. He found it very easy to define both the physical and control model using the software. Hubert began his simulation efforts on a machine whose performance he felt left considerable room for improvement. The machine required continual adjustments to avoid defects. He began by simulating the machines current operating conditions. Comparing the simulation results with physical measurements, particularly of web tension, showed that the simulation accurately represented the machine performance. A small change in operating conditions could cause the machine to produce defects. Hubert evaluated changing the operating conditions, and PID control values. He modified the model and re-ran the simulation multiple times, seeking to move the machine to a point where small changes in operating conditions would not impact quality. He discovered more robust operating conditions that improved throughput by reducing downtime for adjusting operating conditions. Hubert also looked at machines that were seemingly operating well to seek improvements in throughput or quality. During this process, he discovered the importance of accurately determining the friction between the web and the rolls to provide accurate simulation results. He evaluated other machines to identify optimal operating conditions. He evaluated different products with varying film thicknesses on each machine. For each product he evaluated different PID control values to identify values that provided stable operating conditions without defects. During this process, he optimized the control values for each film thickness. This required more simulation than would have been possible with physical experiments. Running virtual experiments with the software also eliminated the cost of downtime on production machines.
Precise PID values

This machine model above is simulated in MSC Adams multibody dynamics software below. Courtesy: MSC Software Corp.

Go Online
At www.controleng.com/ archive, the posted version of this article has more information. See related article: Simulation and modeling software www.mscsoftware.com
30

diagnostic information. The number of physical measurements that can be captured during these experiments is limited by the difficulty of instrumenting the coating machines. Armor was interested in using simulation but found it difficult to model the complicated mechanisms and motion control systems involved in roll coating. This challenge was overcome with simulation software that enables control systems to be integrated into mechanical system simulations to optimize system performance. Multibody dynamics simulation software automatically formulates and solves the equations of motion for kinematic, static, quasi-static, and dynamic simulations. A graphics-based software tool modeled multi-domain dynamics systems characterized by differential, difference, and algebraic equations used in digital and analog control systems. An interface block in the software model provides inputs between the software packages.
Optimizing roll coating performance

Hubert constructed a software model of the machine. He defined the rolls as cylinders and added connections between them to represent the gearing in the machine. He defined the material properties of the PET web and entered the friction between the web and the rolls based on physical measurements. The software also simu-

By optimizing control values, Armor increased coating machine throughput about 20% over a one-year period. Primary improvement came from increasing machine reliability and stability so that less time was required for repairs or adjustment. Web speed improvements were often achieved. We are now able to set the PID values much more precisely to optimize the performance of the machine for specific products, Hubert said. Other simulation improvements include increasing the throughput of a cutting machine by 8%. We have plans to apply simulation to additional processes. ce - Chris Baker is the product manager for Adams and Easy5 at MSC Software Corp.

MAY 2013 CONTROL ENGINEERING www.controleng.com

INTERNATIONAL
Is SLM gaining momentum in China?
Service lifecycle management (SLM) is getting increased attention in China and Asia, with development of manufacturing services industries, according to Control Engineering China, citing PTC officials.
Ariel Zhang

evelopment of the manufacturing services industry has been a significant trend in China. For many traditional manufacturing enterprises, their service sectors have became their new growth points. While service is turning a new means of profit, enterprises are starting to focus on management of service processes. With this trend, service lifecycle management (SLM), a solution that is used to enhance enterprise services business management, has been introduced to Chinese enterprises. At a recent press conference, a supplier of manufacturing solutions, PTC, showed strong confidence in this emerging solutions business. With the acquisition of Servigistics, a traditional supplier of SLM, PTC achieved a sales volume of $ 200 million for global SLM business and achieved a growth rate of 20% to 25% in first-quarter 2013.
Managing services momentum

Yucheng Shou is PTCs global division vice president, China. Courtesy: Control Engineering China

Robert Kocis is PTCs Global senior vice president. Courtesy: Control Engineering China

service, quality, and maintenance. There is a similar situation in enterprise informatization. Up to now, many enterprises have had mature solutions for product lifecycle management, supply chain management, and manufacturing execution management, while there is a lack in the service link.
Savings in services, quality, parts

Consider this...
Savings through coordinated lifecycle management of services is an opportunity for manufacturers globally, not just Asia.

Robert Kocis, PTCs global senior vice president, said that throughout the entire strategic layout of PTC, SLM has been very important. Yucheng Shou, PTCs global division vice president, China, also pointed out that SLM had maintained a good momentum of growth in Asia and China. PTCs viewpoint may show that SLM has begun to attract the favor of the market in China. Compared with other solutions that have had a very mature market, like computer-aided design (CAD) and product lifecycle management (PLM), the development of SLM is still in the growth phase. But in recent years the rapid development of manufacturing services will probably be a powerful factor for SLM growth. For example, there are some shortages in the services sector of some domestic industries [in China]. Compared with production and research, enterprises pay less attention to management of

However, in the current competitive environment, such enterprises have to face challenges from service systems, quality assurance, and spare parts management. Some enterprises even want to achieve the continuous improvement of service efficiency and service standards. In this case, SLM, through its several major functional parts, can help enterprises achieve targeted improvements. For the present, SLM still faces a long-term development and promotion process, but in the long term, huge demand will gradually progress, along with the development of manufacturing services. ce - Ariel Zhang is an editor at CE China. Edited by Mark T. Hoske, content manager CFE Media, Control Engineering and Plant Engineering, mhoske@cfemedia.com.

Rapid development of manufacturing services will contribute to growth of service lifecycle management.

Go Online
www.PTC.com On the CE China website, read SLM: Gaining Momentum in China? http://article.cechina. cn/13/0408/11/20130408115322.htm www.cechina.cn
31

www.controleng.com www.controleng.com CONTROL CONTROL ENGINEERING ENGINEERING MONTH MAY 2013

Control Engineering Europe at Hannover Fair 2013

INTERNATIONAL

Machines, PLCs mobile devices, higher-level systems


Bosch Rexroth, won the 2013 Hermes Award at Hannover Messe, for its Open Core Engineering project. Integration solution helps machinery manufacturers.
Suzanne Gill

B
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osch Rexroth, won the 2013 Hermes Award at Hannover Messe, for its Open Core Engineering project, which integrates PLC and information technology for industrial applications. This was the first time that the award has been given to a software development. Open Core Engineering was developed to allow greater flexibility and efficiency in the automation process, by enabling remote maintenance and operation through smart devices and apps, combining advanced industrial algorithms with everyday hand-held devices.

Commenting on the award committees decision, Dr. Jochen Kckler, member of the managing board at Deutsche Messe AG, said: This solution makes a major contribution to integrated industry and will accelerate the trend towards networked industrial production. During a press event at Hannover Messe, Dr. Karl Tragl, chairman of the executive board of Bosch Rexroth, said, Via a new interface from Bosch Rexroth, engineers and software developers are now able to access the control kernel using nearly any high-level language in the IT world and to program new machine functions. ce
www.boschrexroth-us.com

Network organization pushes industrial Ethernet integration


ODVA works to accelerate adoption of industrial Ethernet in process automation and for better machine integration.

Discover more possibilities at

www.eaton.com/smartwiredt
input #17 at www.controleng.com/information

t Hannover Messe 2013, ODVA launched an initiative for process automation in cooperation with ODVA members including Cisco Systems, Endress+Hauser, Rockwell Automation, and Schneider Electric to accelerate adoption of industrial Ethernet in process automation. ODVA also discussed a machine information integration initiative, according to Control Engineering Europe reports. The process initiative will focus on providing new opportunities for integration improvements, optimized network architecture and increased return on investment (ROI). Catherine Voss, executive director of ODVA said: Based on ODVAs industrial EtherNet/IP technology, the results of this initiative will provide end users with more choices to
32

deploy a complete Ethernet solution for process automation, starting with connectivity down to the field level and, in the longer term, expanding to include the full spectrum of process automation needs, including safety, explosion protection, long distances and extensive diagnostic coverage. Also discussed was the formation of a new special interest group to develop standards for the exchange of information between machines, and between machines and supervisory systems. Machine to machine (M2M) information exchange is of increasing importance for machine builders, system integrators, and end users. ce - Suzanne Gill is editor of Control Engineering Europe, www.controlengeuwww.odva.org rope.com.

MAY 2013 CONTROL ENGINEERING www.controleng.com

SAFETY
Safety initiatives, international standards, and conformance responsibilities all play a role in changes, when an organization considers functional safety.

machine

Incorporating functional safety

hen considering functional safety, look at what differs compared to other safety initiatives, consider U.S. versus international standards, examine conformance responsibilities, and think about what changes are needed, if any, as a manufacturer. What is so different about functional safety? Definition from IEC 61508-1: Functional safety is part of the overall safety relating to the equipment under control and the equipment under controls control system which depends on the correct functioning of the Electrical/ Electronic/Programmable Electronic safetyrelated systems, other technology safetyrelated systems and external risk reduction facilities. From my perspective the major difference in approach is to design-in machine safety and consider the lifecycle performance of safety-related functions, such as mean time to fail dangerous, diagnostics, reliable cycles, software and firmware, and many more considerations for each component in a given safety-related circuit. A circuit is also considered as electrical, electronic, pneumatic, and hydraulic. Prior methodologies did not consider these factors, in my opinion. Also, arent functional safety standards intended to encourage designers to focus more on the functions that are necessary to reduce each individual risk, and what performance is required for each function, rather than simply relying on particular components? The primary standard addressing functional safety requirements is ISO 138491: 2006 Safety of machinery Safety-related parts of control systems.
Changes required?

understand and interpret accordingly. In my opinion, more than likely you will have to make some modifications to your machine safety program to incorporate functional safety requirements. Now, this kind of blanket statement needs some granularity for understanding and interpreting its application to your particular business. To begin with, were talking about the current version of ISO 13849-1; 2006 Safety of Machinery Safety-related parts of control systems. In broad scope: As an OEM, machine builder, or systems integrator (aka supplier), you will have to determine the performance level of a complete safety-related circuit including all components and devices and the related software. This performance level must be optimized to meet or exceed the performance level required for that safety function. Testing and validating will be required. As an end user doing an in-house machine retrofit/modification, you have become a supplier doing design and build and should follow the same guidance as suggested above. As an end user simply replacing a defective component or device in an existing safetyrelated circuit, you should make every attempt to replace that component or device with another component or device with the same or greater safety-rated performance. The advice is to not degrade the safety-related performance for the safety function. There are many more details that come along with functional safety and compliance to ISO 13849-1. This provides a high-level opinion of what may be involved and how your safety program might see the need for modifications. Clearly there are engineering-level resource requirements that you may already have access to for performing the incremental design, build, test, and validating requirements. ce - J.B. Titus, Certified Functional Safety Expert (CFSE), writes the Control Engineering Machine Safety Blog. Reach him at jb@jbtitus.com.
www.controleng.com

J.B. Titus, CFSE, Certified Functional Safety Expert (CFSE)

When replacing a defective component or device in an existing safetyrelated circuit, ensure the next one has the same or greater safety-rated performance.

Do we have to change our machine safety program as a manufacturer to meet functional safety compliance requirements? In this discussion the term manufacturer is very broad and includes end users, OEMs, machine builders, and systems integrators, for example. As such, it is strongly advised that the reader

Go Online
Engineering interaction: Go to this blog at www.controleng.com/blogs, see more in a 4-part series on functional safety, and add your comments or questions.

CONTROL ENGINEERING MAY 2013 33

Control System Integrators Association 2013 Executive Conference coverage


Nick Setchell, CEO, Practice Strategies: Numbers matter

Search CSIA at www.controleng.com

industry

NEWS

Hannover Messe, manufacturing:

U.S. drives global growth, innovations, efficiencies


Steve Rourke

at Hannover Messe for outstanding innovation.


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The 2013 Hannover Messe brought industrial automation and manufacturing experts from around the world to showcase the latest innovations and assess the state of the global manufacturing economy. Innovation continues at a brisk pace. The economy is finding its way forward as Europe drags on that global growth, with continental challenges. Bosch Rexroth chairman Dr. Karl Tragl told a press event that global manufacturing would increase slightly in 2013 along with the global economy. The drag of the European economic slowdown would be offset by solid growth in Asia, Russia, and notably in the U.S., where manufacturing has been on the rise both economically and politically. He said Bosch Rexroth is enjoying record business in the U.S., and the company has responded by investing more than $80 million in U.S. plants and people. Tragl said he has had continued optimism in the U.S. manufacturing market. Key issues, such as local production and customization and energy efficiency, continue to dominate the manufacturing discussion worldwide, Tragl said, and that integrated open control systems would help connect current and future operating systems.
Hermes innovation award

Siemens made two major partnership announcements. It will accelerate its collaboration with Bentley Systems in the pharmaceutical and oil and gas markets. The partnership will develop a joint system that with combine Siemens Cosmos engineering software and Bentleys OpenPlant system for plant design to use plant lifecycle data from commissioning to plant operations. Siemens also announced its collaboration with consulting and construction management company CH2M Hill. The argument for Siemens is compelling, as the companys products are used globally, yet supported at the local level with knowledgeable integrators, said CH2M Hill senior automation engineer Steve Blaine.
New ideas on the show floor

input #36 at www.controleng.com/information

Global manufacturer of process control and factory automation solutions

Those comments underscored the Integrated Industry theme of the 2013 Hanover Messe and Bosch Rexroths software system to connect systems, which won this years Hermes Award
34

With more than 6,000 exhibitors and a square mile of show floors at Hannover Messe, manufacturers showcased new ideas to more than 250,000 attendees each year. Those innovations point to new efficiencies that can help manufacturers in Europe and throughout the world. A few highlights on this years show floor at Hannover follow. SEW Eurodrive unveiled its MoviAxis energy buffering system with a regenerative power supply. The system uses capacitors to store potentially wasted energy and transfer it to ener-

MAY 2013 CONTROL ENGINEERING www.controleng.com

Automation engineering research channel


www.controleng.com/research
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gize motor and drive systems. Tobias controleng.com search for Nittel, technology field manager for Apps for Engineers or go SEW Eurodrive, told CFE Media that to the Google Play market. energy savings are projected at between 10% and 15% for select systems. SEW noted that it will unveil new large custom gear sets for the U.S. audience later this year. Production and assembly will come to a U.S. facility for local distribution. The large custom gear sets are designed for heavy applications and can be customized to order. Phoenix Contacts focus for 2013 cell or system. For example, if a robot was on five application solutions for is stopped for any reason, the congrowth markets. Three of those are in trol system senses and reacts to environment and can update local systems the energy sector: Wind Energy: Phoenix Contact has accordingly can turn off local motors, a new lightening detection system to lights, lower HVAC. In working with monitor and report on lightening strikes European auto manufacturers such as to blades. Repeated strikes can be cost- Volkswagen, Audi, and BMW, the comly to replace or repair and cause struc- pany believes this kind of integrated tural failure, which can be dangerous to approach can reduce energy usage by 15% to 20%. workers or others near the windmill. One of Eatons new products Solar: Phoenix Contact has develincludes an extension of oped several new, easy-conits Smartwire-DT technolnect electrical junctions to Local ogy to include outside-thehelp with installation and production, cabinet connectivity. Drivmaintenance. Oil and Gas: Kamran customization, en primarily by machine builders, the benefits will Alam, Phoenix Contacts and energy include lower wiring costs, global industry manager for ease of use, and lower overoil and gas, told CFE Media efficiency all power consumption of his company is working with dominate machines. system integrators in this Eaton officials said they sector to help find solutions manufacturing expect multi-connection to key energy issues, and the discussion junction boxes to be availcompany sees system integlobally. able by the end of 2013. grators as a key to their sales Another new offering is strategy in the sector. improvements to the DC1 and DA1 Line Water, wastewater, automotive of motor starters. The multifunctional Two other areas of emphasis for DA1 allows users to potentially insert Phoenix Contact are infrastructure, espe- custom start up process, with the goal of cially in areas such as power distribu- reducing energy and power costs. tion, water and wastewater and traffic, - Reported by Steve Rourke, CFE and automotive, which is the companys Media, with press release information; largest market, but one that has slowed edited by Bob Vavra, Plant Engineering recently, especially in Europe. and Control Engineering. One of its innovations at Hannover Messe this year ties robot movement See other Hannover coverage on into energy management of the local pages 32 and 36.

www.controleng.com

CONTROL ENGINEERING MAY 2013 35

input #18 at www.controleng.com/information

industry

NEWS

Hannover Messe 2013:

Kuka introduces lightweight robot, gives robocoaster rides


At Hannover Fair 2013, Kuka Systems, Kuka Robotics, and Kuka Laboratories showed welding robots, machine tool capabilities, assembly and testing systems, robotic services, and other products and capabilities, from components to research and development, including complete plant systems. Of course, we are especially proud of the LBR iiwa, the entirely new generation of robots, said Dr. Till Reuter, CEO of Kuka AG, in a pre-show statement. The LBR iiwa fulfills Kukas promise to the market to present a lightweight industrial duty robot. Kuka engineers developed a machine with new automation possibilities. Offering mechanical and drive systems designed for industrial use, the sensitive and yielding LBR iiwa rings in a new era in robotics, the company said. Kuka presented four applications for the LBR iiwa at Hanover Fair all demonstrated the sensitive robots key features. Kuka showed 19 dancing robots in an application about 6 m high. Kukas entire robot family was featured, from the smallest robot, the KR Agilus, to the largest model, the KR 1000 titan. The KR Quantec series, the welding specialists KR 5 arc HW and KR 16 arc HW, and LBR iiwa were shown.

At Hannover Fair 2013, Kuka again gives passengers a wild ride in its latest Robocoaster. In June 2004 information about the ride, Kuka said this is the first and only robot anywhere in the world that is licensed to carry human passengers. See Robocoaster video at www.controleng.com/videos. Courtesy: CFE Media, Steve Rourke video at Hannover Fair 2013

Custom Control Algorithms


When PIDs arent powerful enough
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intelligence in control

input #19 at www.controleng.com/information

Various applications at the Kuka Competence Center demonstrates company expertise in the growing lightweight construction sector. Visitors watched live demonstrations of processes, such as welding aluminum, joining metal alloys and an induction welding process for joining carbon-fiber composites. Results of a joint research project on energy-efficient car body assembly are also being discussed. The display showed how manufacturing systems and solutions can be automated in a sustainable and resource-conserving manner. At another part of the booth, Kuka presented the forming expertise of its machine tool segment. Successfully completed projects for assembling transmissions, engines and drive assemblies have repeatedly demonstrated Kukas performance capabilities in assembly and testing systems. Kuka presentations at Hannover Fair included Energy efficiency in car body assembly systems, Efficient joining technologies for aluminum parts, and Virtual startups for manufacturing systems. The Kuka Robocoaster can seat two passengers at one time, offering brave riders considerable gravitational forces, ranging from a sense of doubled body weight to a feeling of weightlessness, the company said. Kuka Robot Group Robocoasters are certified by the TV Technical Inspectorate in Munich and comply with the relevant safety standards. - Edited by Mark T. Hoske, content manager, CFE Media, Control Engineering, mhoske@cfemedia.com.

Go Online
Robots assist, next to humans. See: New robotic safety regulations are pending at www.controleng.com/archive, April.

www.kuka-robotics.com
36

MAY 2013 CONTROL ENGINEERING www.controleng.com

Implementing

Industrial Ethernet technology: Which protocol is right for


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input #20 at www.controleng.com/information
4/8/13 10:21 AM

Manufacturing in America targets next U.S. industrial evolution


More manufacturing jobs are returning to U.S. shores while new innovation hubs are being created across the nation. The manufacturing sector is undergoing an evolution where innovation and manufacturing are merging, driving product and process innovation, across the globe and particularly in the U.S. This is making industry more competitive and taking productivity and efficiency to levels never experienced before, said Helmuth Ludwig, CEO of Siemens Industry Sector, North America. This industrial evolution is highly based on software, and companies that have embraced this concept are experiencing a shorter time-to-market through efficient innovation cycles and enhanced flexibility using more data to individualize mass production. Advanced manufacturing is an important part of Siemens growth, and will provide the U.S. an edge in the future of our manufacturing sector, Ludwig said, commenting on the kickoff of the Siemens Manufacturing in America: Making Things Right Thought Leadership Tour, a series of events designed to explore the trends shaping Americas next industrial evolution and the challenges that still exist. More than 2,000 individuals joined the April 23 online Americas New Manufacturing forum, presented by Washington Post Live and sponsored by Siemens, Northern Virginia Technology Council, and the American Small Manufacturers Coalition. The forum assembled government officials and leading industry experts to discuss the new era in manufacturing, expanding manufacturing hubs, trends in manufacturing, workforce training, innovations, and advanced technology. Related research, said Siemens, examines tactical (hiring, improvement programs, and technology) and strategic (capital investments, supplier re-alignment, new product development) trends related to the manufacturing renaissance. According to the study, more than 70% of manufacturing leaders are optimistic about their own companys future. Other Siemens thought leadership events will be held May-July.
Innovation via manufacturing

James Manyika, director of McKinsey Global Institute, recently named to President Obamas Global Development Council, said manufacturing is responsible for 9% of employment, but more than 60% of exports are driven by manufacturing. Courtesy: Washington Post Live

Ludwig said innovation and manufacturing must be aligned, but it is often not the best strategy to design it heremake it there. Only a close connection of innovation and manufacturing allows manufacturers to drive product and process innovation, he said. According to Ron Bloom, senior
www.controleng.com

advisor, Lazard, and former assistant to the president for manufacturing policy, the manufacturing sector should find a means to combine the innovation power of Silicon Valley with the efficiency of the Detroit automotive sector. Statistics provided by James Manyika, director, McKinsey Global Institute, show that while the manufacturing sector represents only 9% of jobs, it represents 61% of exports and 69% of privately funded research and development. Bill Krueger, senior vice president, manufacturing, purchasing and supply chain management for Nissan North America, stated, We want to be fast, frugal, and flexible, which organizations can only be if they are close to their customers. The crossroads of the virtual and real worlds is driven by the

CONTROL ENGINEERING MAY 2013 37

industry

NEWS
high-technology manufacturing sector, suggested Michael Gazarik, director, space technology program, NASA, who described how software ensured the success of the Mars Rover program through flight and landing simulation. Airbus Americas chairman Allan McArtor said there will always be a necessary balance between automation and human functions with highly skilled workers. The notion of a skills gap in the manufacturing sector has to be transferred to a training gap, said Siemens Corp. president and CEO Eric Spiegel. Only by moving the responsibility from the trained to the trainer, and from the individual to the companies and educational institutions, are we addressing this challenge in the right manner. Companies and educational institutions must facilitate development of current and future industrial workers, he said. After completion of the Siemens apprenticeship mechatronics program, students are offered a starting salary of $50,000, higher than the average starting salary of $43,000 for liberal arts graduates. See Think Again, page 8. At www.controleng.com/archive, see more at Manufacturing in America targets next U.S. industrial evolution. www.usa.siemens.com www.washingtonpostlive.com

According to Ron Bloom, senior advisor, Lazard, and former assistant to the president for manufacturing policy, the manufacturing sector should find a means to combine the innovation power of Silicon Valley with the efficiency of the Detroit automotive sector. Courtesy: Washington Post Live

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Rapid expansion of embedded systems helps manufacturing


Embedded systems provide significant benefits in various markets, such as more time-efficient design, greater energy efficiency, and higher machine vision performance, according to the National Instruments Embedded System Outlook 2013. Reconfigurable heterogeneous architectures can help because when faster CPU cores fall short, embedded system designers can combine heterogeneous processing elements to meet advanced embedded control and monitoring application needs. Also, through the democratization of embedded system design, many design teams are abandoning larger specialized organizational structures for smaller groups focused on translating domain expertise into realized innovation, NI said. More companies are adopting a comprehensive approach that considers cost-benefit analysis, flexibility, and risk, NI said. A digital energy revolution, driven by advancement of digital technologies, is changing the way energy is manipulated, moved, and stored. www.ni.com/embedded
38

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input #21 at www.controleng.com/information

MAY 2013 CONTROL ENGINEERING

cover story

Key concepts

A straightforward maintenance strategy yields improved plant performance


Peter Welander

The technical elements of an effective maintenance program are not complicated. Procedural and cultural changes within a plant are critical to ongoing maintenance management success. Many tools are available to support such programs, they are not difficult to implement, and the payoff can be huge.

Moving from reactive to preventive maintenance helps Monsanto improve output and reduce costs at its Muscatine plant. Smart field devices and control valve positioners provide critical diagnostic data to reliability engineers, guiding their efforts.

n many situations, a straightforward and consistently applied maintenance strategy can have results that attract positive attention as production and plant availability increase while maintenance costs decrease. Such is the case at Monsantos Muscatine manufacturing facility. The combination of technical solutions with corresponding work processes has had measurable positive results and earned the facility the 2012 HART Plant of the Year Award. The Monsanto Muscatine facility is located

in southeast Iowa along the Mississippi River. It manufactures Roundup herbicide along with acetanilide select chemistry products, including Harness Xtra, Degree Xtra, and Warrant. The facility covers 150 acres and employs around 450 individuals to operate and manage eight individual process units. These include waste treatment and plant utilities along with the product manufacturing process areas. The majority of the plant operates continuously, year-round, and the oldest parts of the facility date back 50 years.

40

MAY 2013 CONTROL ENGINEERING www.controleng.com

HART Plant of the Year Award Celebrating ingenuity and innovation


Electrical reliability technicians Mike Chaney (left) and Thad Witte follow-up on alerts from AMS to track down problems in the process units before they cause downtime. All photos: Control Engineering

An inherited maintenance platform

The processing units are controlled by a mix of Emerson DeltaV and Provox DCS (distributed control system) platforms tied to more than 3,200 instrument assets, including transmitters and control valve positioners. Of this total installed base, there are currently over 600 HART and 125 Foundation fieldbus instruments within the facilitys AMS Intelligent Device Manager. The outstanding instruments not yet in the AMS Intelligent Device Manager are in large part either not terminated to smart I/O or are simply non-smart devices. One of the pivotal changes in Muscatines operation happened in 2006 when Joel Holmes, site electrical reliability engineer, received a standalone Emerson AMS unit from another Monsanto plant. Having access to that unit enabled him to explore some of the capabilities of a more sophisticated maintenance strategy using diagnostic information gathered from field devices using HART Communication and Foundation fieldbus protocols. Given the facilitys extensive population of maintenance-intensive valves and instrumentation, this was an area where Holmes felt that improvements in reliability would have the largest impact on overall plant performance. Part of the process of integrating his new maintenance tools with the work processes involved assigning a criticality value to the instrument assets in each process unit. Those that could impede production were given the highest priority for monitoring. As Holmes described the process, We utilize an A, B, or C letter designation to denote asset criticality. The highest criticality ranking is an A, with the lowest criticality ranking being a C. Keep in mind, A-ranked critical devices will receive the most attention since their performance is crucial to the on-stream time of the production system, whereas C-ranked devices may, in many cases, be allowed to run till failure since their impact to the production system is minimal or they have in-line spares. As Monsanto gained experience with AMS, use within the plant became more sophisticated with improvements in overall effectiveness. The Alert Monitor became the primary predictive tool integrating the plants asset criticality measure with the Device Manager. The respective device group assignment in turn directly impacts its polling rate, or the frequency at which the Alert Monitor extracts the devices status, health, and diagnostic information from the field. Over time, Holmes created three groups of devices: transmitters, control valves, and vapor

he HART Plant of the Year Award is presented annually by the HART Communication Foundation to recognize people, companies, and plant sites around the world for their ingenuity and innovation in applying and using HART Communication. A HART Plant of the Year takes the capabilities of HART instruments beyond configuration and calibration, or uses real-time diagnostics and process variables of HART-enabled devices integrated with its control, information, and safety systems. Each is a powerful example of how to utilize HART Communications better, and to realize even greater benefits for their company. To nominate your plant, go to www.hartcomm.org.

www.controleng.com

CONTROL ENGINEERING MAY 2013 41

cover story

This control valve positioner communicates with the process units controller using conventional analog I/O, so there is no capability to read the HART data. Adding the wireless THUM allows the diagnostic information to be visible within the AMS Device Manager and its Alert Monitor.

sensors. This helped balance the loading of the Alert Monitor since having too many devices poll at the same frequency overloaded the system, resulting in extremely slow update rates or no response at all. Each device group has a set series of polling rate values dependent upon its criticality ranking.
Working in a legacy environment

While some of the process units have relatively new control systems with HART-enabled I/O, there are other areas where the system is still plain analog. These will be upgraded as the plant moves through a series of migrations to DeltaV control systems with CHARMS I/O, but in some areas that is still years away. The work-around that the plant has developed to gather diagnostic information involves either WirelessHART THUM communication for critical tags, or HART/Foundation fieldbus handheld communicators for devices that require less frequent monitoring. The WirelessHART deployment is growing with about 25 devices currently in operation. Holmes expects that number to grow, and

A case in point
s the Glyphosate Technicals unit was anticipating a scheduled shutdown for catalyst regeneration, Holmes and his team addressed a planned and scheduled deficiency work order with a two-inch eccentric ball control valve that had been identified as suspect through a prior control valve reliability PM route. The AMS Intelligent Device Manager along with its ValveLink Snap-On application had measured increasing friction as the valve moved through its full span of travel. This indicator suggested a problem was developing and triggered a failure when performing the diagnostic scans on the control valve assembly. While the valve was not exhibiting any issues that would be visible to the operators, the valve signature indicated that the amount of force required to open and close the valve had increased substantially. It was still able to perform its control function for the moment, but comparisons with historical signatures revealed that a more drastic situation was developing. Holmes recommended that the electrical reliability technicians change out the valve during the outage; therefore, the reliability technicians proceeded to remove it from service during that time. When they pulled the valve body free from the flanges, they found a 1/4 x 4 in. bolt stuck in the valve that had apparently come off one of the clamps holding a filter element designed to
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Operators were unaware that there was a friction problem with the valve since the step response test results were performing normally. The valve was performing its control functions, but it was only a matter of time before the valve would malfunction.
capture the catalyst. It had been carried down the pipe by the flowing process stream. Had that bolt remained in the valve, at some point it could have initiated flow control issues up to and including the valve refusing to close which would have caused additional problems.

MAY 2013 CONTROL ENGINEERING www.controleng.com

each process unit will soon have its own wireless gateway.
Changing plant mindset

As workflow processes change, so do individuals mindsets. The reliability team members have enjoyed seeing some of the traditional barriers within the company between operations and maintenance crumble as a growing sense of common purpose and cooperation develops. Holmes described one of the changes: Along with the reliability programs and some of the efforts related to how we monitor and look at our deficiency backlog, were also getting into AEM (asset effectiveness management). This method looks at the process units, what they have to make per our sales, and tracks their process downtime. We want to make sure that were not only looking at it from a predictive and preventive standpoint to see whats causing downtime, but to also have those operating units telling us what their biggest pains are. In the past, maintenance was addressing things that they were seeing failing and having problems, but it wasnt always the same issues or biggest problems that the process units felt they had. So there was a kind of disconnect there. With us transitioning and now focusing on AEM, in addition to all of our predictive and preventive efforts, were getting a better grasp on what needs to be addressed and handled to ensure that we have the manufacturing availability we need.

Electrical reliability technician, Mike Chaney, has also seen positive effects as he works with operators. Being in a sold-out state as we are, we get a two day window in some cases to find problems and get them fixed within that window, he said. If we can avoid downtime down the road thats big. Causing downtime right now is not a good thing. So if we can prevent that from happening, it saves the plant lots of money in the long run. Production sees what were finding using this technology. So when we say something to them, theyre not so quick to respond, We arent going to do that. Theyre more willing to say, Well get this valve ready for you to pull out and then see what youve got. They know were saving them headaches. If we can keep things running, it makes their day nicer.
Measuring progress

Throughout the plant there is a large variety of instrumentation types and manufacturers. Most communicate via 4-20 mA/ HART but Foundation fieldbus is also installed where cable routing infrastructure has been a problem. WirelessHART devices are growing in numbers as well.

When this whole program began, Holmes said that they had no good way to distinguish, track, or analyze reliability work performed in

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When the AMS Intelligent Device Manager ValveLink Snapon scan failed, it was clear from the valve signature that there was a serious problem developing. This prompted removal of the valve during the outage.
The bolt had damaged the ceramic plug and seat, so once the valve body was removed and separated from the actuator, it was sent out for rebuilding. A new valve body was mounted on the actuator in the shop. Prior to reinstalling the assembly, it was calibrated and then tested using the ValveLink Snap-On applica-

That type of valve normally has a valve signature like this one, where the opening and closing pressures are in a tight group along with the ideal standard performance indicator.
tion to make sure the valve signature and additional diagnostic scans indicated normal operating parameters using HART. All scans including the valve signature were recorded in AMS so that results can be compared to future analysis in trending for degradation. When approved, the valve was returned to service without delaying the scheduled startup of the process unit.
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CONTROL ENGINEERING MAY 2013 43

cover story

Theres a constant effort to share and communicate, not only with production but our other maintenance workforce. We continue to share what these guys are doing, their successes, findings, and training.

the plant. To remedy that, Monsanto created order codes to work within the SAP CMMS. In order to track labor and material costs to specific equipment, individual deficiency notifications are entered from any findings arising from the facilities preventive (PM) or predictive (PdM) maintenance reliability programs. Each issue identified during PM routes or PdM triggers will have a separate deficiency notification and work order created. This allows for predictive vs. reactive work cost analysis to be performed and KPIs to be generated and tracked. The code analysis data helps quantify planned versus reactive work. In turn, the system generates bad actor lists and provides for a dollar figure that indicates how much of a cost avoidance reliability program initiatives are providing. An average of 12 AMS deficiency orders are entered each month. With a cost avoidance of over $1,600 per work order, it correlates to over $200,000 saved in time and materials annually. However, Holmes points out that this is strictly an out-of-pocket cost avoidance savings and does not reflect increased income from gains in plant manufacturing availability.

One big effective family

There is more work to do within the plant, but Holmes and his plant management see the direction clearly. The big hurdle that we have is that operations doesnt always know what the reliability programs are doing, he said. So theres a constant effort to share and communicate, not only with production but our other maintenance workforce. We continue to share what these guys are doing, their successes, findings, and training. Thats imperative as we try and grow the relationship. Its very apparent to our upper management, so its one of our goals to keep that communication going to tie the three together: maintenance, production, and reliability as one big family. ce Peter Welander is a content manager for Control Engineering. pwelander@cfemedia.com

Go Online
n Search on HART plant at www.controleng.com to read Plant of the Year stories from earlier years. n www.monsanto.com n www.hartcomm.org n www.emersonprocess.com

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machine vision

Machine vision speed, quality, innovation


Advanced applications for machine vision in automotive, robotics, quality, and safety use hybrid technologies, vision for robotic or machine guidance and in-line part inspection, and 3D imaging. Technology and imaging standard advances help.

Quality control measurements for smooth surfaces


Hybrid laser-camera technology is ideal for surface measurement in many industries. The camera detects a laser projected onto an object at a specific angle.
Todd Belt

A gap and flush measurement is shown in an HMI interface example. Automobile panels can be positioned using a laser camera system to accomplish best-fit placement. Images courtesy: Pepperl+Fuchs

any industries require surface measurements, and laser camera combination technology can help. A camera detects a laser line projected onto an object, and then a triangulation calculation determines height and width. Many industries have applications that require smooth, sealed surfaces without gaps, ruts, or protrusions. These industries include glass, metal processing, plastics, tire, automotive, aerospace, and even highway road construction. When it comes to meeting the needs of these different industries, quality checks and process control based on measurement play a vital role. In the past, lasers, mechanical measuring devices, and even wedges were used to check quality, usually just a spot check. Depending on the application, 100% inspection has been too slow and required a large capital investment. A profile scanner, for example, has historically been very expensive and the units being scanned

A laser camera hybrid system can measure along an edge for robot guidance. It can be applied to machines and applications used in many industries, such as glass, metal processing, plastics, tire, automotive, aerospace, and even highway road construction.

generally didnt have an interface to decipher all analog data from the scanner. Generally, a selfdeveloped interface and HMI were required and the cost went up. If a company then wanted to capture data and chart it for process control purposes, database development became necessary. Many companies are being asked to invest in ensuring the quality of the products they are producing. Gap and flush measurement for quality control can take place while automotive body panels are placed onto the vehicle, or as a spot check on each vehicle. Consumers dont want leaks. Leak protection depends on measuring the glue bead being applied for thickness. The hybrid technology is improving inspection and quality. Laser camera combination technology uses a camera to detect a laser line projected onto an object at a specific angle. Triangulation determines height and width information. Applications include measuring the depth of road ruts, up to 4.2 m wide at highway speeds day or night. - Todd Belt is systems sales manager VMT, www.pepperl-fuchs.us Pepperl+Fuchs.

46

MAY 2013 CONTROL ENGINEERING www.controleng.com

Next generation: Robots that see


Visual servo control: Vision used for robotic or machine guidance also can be used for in-line part inspection to enhance product quality with traditional feedback systems. See online video.
Carlton Heard

obotics and automated machines can use visual servo control for robotic guidance, enhancing motion control and improving product quality, while replacing traditional feedback systems. Vision-guided robotics is one of the most common uses for vision technology in robotics. This historically has been applied for factory floor production, assembly, and materials handling, where a camera acquires an image and locates a part or destination before sending coordinates to the robot to perform a specific function, like picking up a part (see online video). Integrating vision technology in applications like these enable machines to become increasingly intelligent and flexible. The same machine can perform a variety of tasks because it can recognize which part it is working on and adapt appropriately based on different situations. The added benefit of using vision for machine guidance is that the same images can be used for in-line part inspection to improve quality. It can be expensive when a high degree of accuracy is essential for the motion components, such as the camera or motion system. Some vision-guided robotics systems use one image at the beginning of the task without feedback to account for small errors later. Visual servo control can resolve this challenge. A camera is fixed to or near the robot, and it provides continuous visual feedback to correct for small errors in the movements. Image processing is used within the control loop, and the image information can replace traditional feedback mechanisms (encoders) by performing direct servo control tasks.
Autonomous robotic boom

Direct servo control accelerates the highspeed performance of applications, such as laser alignment and semiconductor manufacturing among other processes that involve high-speed control. Vision use in robotics is common with industrial applications, and it is becoming more prevalent in the embedded industry, including for mobile robotics. Functions range from service robots in hospital halls to help with healthcare system cost pressures and a shortage of doctors and nurses to autonomous tractors plowing fields to advance planting and harvesting efficiency. Nearly every autonomous mobile robot requires sophisticated imaging capabilities, from

obstacle avoidance to visual simultaneous localization and mapping. In the next decade, the number of vision systems used by autonomous robots is expected to eclipse the number of systems used by fixed-base, robot arms. 3D vision technology can help robots perceive more about their environment, and 3D imaging technology has made great strides in sensor advancements, lighting, and embedded processing. 3D vision is emerging in a variety of applications, from vision-guided robotic bin picking to high-precision metrology and mobile robotics. Newer processors can handle immense data sets and sophisticated algorithms to extract depth information and quickly make decisions. Mobile robots use depth information to measure the size and distance of obstacles for accurate path planning and obstacle avoidance. Stereo vision systems can provide a rich set of 3D information for navigation applications and perform well even in changing light. Stereo vision technology uses two or more offset cameras to look at the same object. By comparing two images, the disparity and depth can be calculated. Other applications can require additional processor performance. In the medical industry, robotic surgery and laser control systems are becoming tightly integrated with image guidance technology. For these types of high-performance vision applications, field programmable gate arrays (FPGAs) manage the image preprocessing or use the image information as feedback in a high-speed control application. FPGAs are well suited for highly deterministic and parallel image processing algorithms and for tightly synchronizing the processing results with a motion or robotic system. During laser eye surgeries, slight movements in the patients eyes are detected by the camera and provide feedback to quickly auto-focus the system. FPGAs support surveillance and automotive with high-speed feature tracking and particle analysis. Machines and robots in industrial and consumer industries are becoming more intelligent with vision technology. The Embedded Vision Alliance (EVA), a partnership of technology suppliers, empowers system designers to more easily integrate embedded vision technologies. - Carlton Heard is National Instruments vision hardware and software product manager.
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Multiple Denso robots pick syringes from a conveyer belt and place them into individual packages. Vision technology enables enough flexibility in the robotics to pick up syringes regardless of orientation on the belt or if the manufacturer uses the same line to sort multiple sizes and types of syringes.

Screen capture from online video partially shows what Denso robots see when picking syringes using NI machine vision and NI LabVIEW. Images courtesy: National Instruments

Go Online
At www.controleng.com/ archive, read this article for video of Denso robots picking syringes using NI machine vision and NI LabVIEW. www.ni.com/vision www.ni.com/robotics www.embedded-vision. com (EVA)

CONTROL ENGINEERING MAY 2013 47

machine vision

3D vision system performs rope wear analysis


Three-dimensional (3D) imaging can be used to verify rope and cable quality to measure pitch length and diameter, and identify rope surface damage and type of wear, with accuracy surpassing current methods, to enhance safety. See photos.
Andrzej Sioma

Geometry of a 3D vision system is shown next to a view of a test station.

Two types of steel ropes are shown: 8- and 23-strand.

Go Online
www.controleng.com/ archive has a longer version of this article, more images, and a link to an earlier article referenced. www.agh.edu.pl www.controlengineering.pl Control Engineering International articles: www.controleng.com/international
48

hree-dimensional (3D) imaging can verify rope and cable quality, measure pitch length and diameter of any section of the rope, and identify damage and type of wear on the rope surface, with accuracy surpassing current methods, which can enhance safety. Steel wire and textile ropes are the fundamental element crucial to the safety of operation of all devices in which they are used. They include machines such as cable railways, mine shaft hoists, passenger and cargo lifts, cranes, gantry cranes, and winches. Steel wire ropes are popular because wear characteristics and methods of determining service life are well-known (Tytko A., Sioma A., 2011, Evaluation of the Operational Parameters of Ropes, Solid State Phenomena, Control Engineering in Materials Processing, ISSN 1012-0394, vol. 177, pp. 125134). Ropes are usually tested for characteristic parameters, such as pitch length and rope diameter. Important for commissioning is assessment of visible damage on the rope surface. Pitch length and rope diameter measurements are done periodically using contact measuring instruments. To date, there has not been a simple and accurate measuring method to enable continuous and simultaneous measurement of stroke length and diameter of the rope. Using 3D machine vision technology for continuous measurement of pitch and diameter also allows the control of wear on the rope surface during use. 3D vision systems can be used successfully both in the evaluation of the geometric parameters of studied objects and the evaluation of their surface parameters. The 3D image construction method is based on the use of a camera and a laser light and is discussed in a prior article (Kowal J., Sioma A., 2009, Active vision system for 3D product inspection. Learn how

to construct three-dimensional vision applications by reviewing the measurements procedures, Control Engineering USA, vol. 56, pp. 46-48.) Based on image analysis, height profiles are determined, which are used to build a threedimensional image. Measurement and evaluation of rope parameters are carried out continuously along the ropes entire length. This allows assessment of the variability in parameters along the rope length, and assessment of changes in selected parameters during operation, as well as a wide range of other parameters in the 3D image. The vision system was configured as shown in diagram. The laser beam illuminates the rope at 90 deg in relation to its axis. The camera is set at a 45 deg angle with respect to the plane of the laser (see diagram). With such a configuration, the following resolutions were obtained in each axis, respectively: X = 0.15 [mm], Y = 0.15 [mm], Z = 0.21 [mm]. The vision system acquires an image onto a monochrome CMOS [complementary metaloxide semiconductor] sensor so that the image shows only the laser line, which allows determination of a height profile. After assembly of height profiles as determined on successive images spaced from each other by Y = 0.15 [mm], a three-dimensional image of the rope surface is built. Using a system with three cameras arranged every 120 deg around the rope provides a complete rope surface image and inspection up to several thousand measurements per second. A three-dimensional image of the rope surface is preprocessed before measurement procedures. This is intended to remove any noise visible in the rope surface image and to prepare it for measurements. The measurement algorithm is based on detection of the edges of strands, such as the small wires that form the rope surface and segmentation. A characteristic point is determined for each strand, which defines the largest height of the strand above the axis of the rope. Rope pitch length is measured based on the distance between edges or characteristic strand points. Strand parts are white spots on the 3D image. Another method to measure pitch length is to

MAY 2013 CONTROL ENGINEERING www.controleng.com

Advances in machine vision products, standards


FDA unit-level traceability
Cognex Corp. announced a new version of In-Sight Track & Trace identification and data verification solution for healthcare serialization. This version includes enhancements that address additional requirements for pharmaceutical and medical device manufacturers to achieve Cognex Corp. announced In-Sight unit-level product traceability. CusTrack & Trace 2.0, a identification and tomers can use In-Sight Track & data verification solution for healthTrace 2.0 with multiple networked care serialization, providing unit-level vision systems to decode humanproduct traceability for FDA requirereadable text and 2D and 1D barments. Courtesy: Cognex codes, including Data Matrix, GS1128, GS1 DataBar, securPharm, and Pharmacode. Technical controls for FDA 21 CFR Part 11 validation (with secure user authentication and automatic audit trail generation) are included. www.cognex.com/tracktrace

Four-image figure shows defects on 3D images of rope surfaces: A and B are steel ropes, C and D are fiber ropes. Images courtesy: AGH University of Science and Technology, Control Engineering Poland

configure the vision system so the laser line is parallel to the axis of the rope. In that case, the rope surface shows an arrangement of strands forming the ropes diameter. Pitch length in the proposed configuration may be measured for each of the strands. Analysis of pitch length variation allows indirect assessment of rope wear or damage. Attention should be paid to any strand fiber damage, visible in the image by distortion of the laser line, defining rope damage. Rope diameter is measured on the basis of an analysis of its cross-section acquired from a three-dimensional image of the rope. Coordinates of the rope center and the diameter of each of the cross-sections are determined. In the adopted vision system configuration, it is possible to determine the diameter every 0.15 [mm] along its axis. This allows detection of cracks on individual wires or strands on the surface of the rope and recording of such damage in the form of disturbances in diameter. The use of three-dimensional images of rope surface allows detection of defects. The defects recorded during testing differ for steel ropes and fiber ropes. Steel rope defects include bottlenecks or indentations in the arrangement of strands as visible in the four-image figure A, and cracks to the strands, or wires forming the strand, shown in that figure B. For fiber ropes, deformation of strand arrangement have been identified, as shown in C, as well as frayed surface layer of strands as shown in the laser line image projected in D. Those distortions also can be seen in the bottom part of Figure D in local deformations of strand surface. ce - Andrzej Sioma, PhD, is with the AGH University of Science and Technology, Krakow, Poland. He is also a contributor to Control Engineering Poland; andrzej.sioma@agh.edu.pl.

Higher speeds, better clarity


Teledyne Dalsa, a Teledyne Technologies company and provider of machine vision technology, expanded its Genie TS camera series with new 2 megapixel and 4 megapixel monochrome models that reach speeds up to 76 frames per second (fps) in HD format. These new models are suitable for a wide range of inspection applications. Based on the CMOSIS imaging sensors CMV2000 and CMV4000, the new models are engineered to meet ever-increasing speed and image clarity requirements of machine vision. Features are easily accessible with Teledyne Dalsas advanced software tools or GigE Vision compliant third-party software. The cameras are designed to perform in extreme environments in temperatures from -20 C up to 60 C. www.teledynedalsa.com/genieTS Teledyne Dalsa, a Teledyne Technologies company and Vision standards, connectivity provider of machine vision AIA, a global vision and imaging trade technology, expanded its Genie group, released USB3 Vision v1.0 in JanuTS camera series for faster ary. Like all AIA standards, it is available speeds in HD format. Courtesy: free; licensing is required for those developTeledyne Dalsa ing and market commercial products. V1.1 of the Camera Link HS IP Core Solutions: In March 2013, v1.1 makes IP cores easier to use. These IP cores will vastly reduce the time to market and the cost of support by giving a development team a ready-to-use reference implementation, saving as much as six months development time, AIA said. Pixel Format Naming Convention (PFNC) v1.1 has been released. PFNC 1.0 was created in November 2011 by the GigE Vision committee to generalize the definition and layout of various pixel formats so they can be re-used by various machine vision standards, AIA said. Version 1.1 has an appendix of recommended pixel format ID to be used as unique identifier for a given pixel format. Theres support for GigE Vision 2.0, USB3 Vision 1.0, and CoaXPress 1.0., pluse new pixel formats to support the USB3 Vision 1.0. www.visiononline.org - Articles edited by Mark T. Hoske, content manager, CFE Media, Control Engineering, mhoske@cfemedia.com. ce
www.controleng.com

Consider this...
Where can you apply advanced machine vision technologies to a motion, quality, or inspection application? See other machine vision coverage at www.controleng. com/machinevision.

CONTROL ENGINEERING MAY 2013 49

motion control

Step-motor-based systems stay competitive


Traditional stepper-motor systems represent the only motion-control technology able to operate in open loopalthough the addition of position feedback to enhance performance is on the rise. Simpler controls, lower cost components, and other innovations keep stepper systems competitive with servo motion systems in numerous applications.
Frank J. Bartos, PE

Key concepts
Stepper motion systems: Excel in applications that require less than critical speed and position accuracy Need no system tuning (versus servobased motion) Motors are less costly to produce, and have simpler controls and cabling.

tepper motion systems shine in many applications that require less than critical speed and position accuracy. Among the technologys drawing points are no need for system tuning (versus servo-based motion), motors less costly to produce, and simpler controls and cabling. System price advantage remains even when adding a low-cost feedback device. Other benefits of stepper technology include minimal system setup time, less need of user expertise, and better motor inertia matching for driven loads. Cost savings is a common theme voiced by stepper product suppliers. Step motors have always had a cost advantage over servos, but traditionally this has come at the price of performance, said Clark Hummel, applications engineering manager at Schneider Electric Motion USA. Hummel listed three attributes that allow todays stepper systems to take on many applications requiring servos in the pastwhile still maintaining a considerable cost advantage: Elimination of stalling (desynchronization) Ability to automatically adjust running current to load requirements Ability to provide torque against an overriding load.
Less costly, easier implementation

B&R Industrial Automation Corp. connects lower cost with wide application of step motors and drives. Feedback, if used, is implemented in a lower cost device, according to Corey Morton, B&Rs director of technology solutions. In contrast, high-resolution absolute encoders used with servos can cost as much or more than the motor
50

itself for small power ratings, he said. Morton attributes further cost savings to the stepper drive, especially for smaller sizes. Various drive form factors now availablemachine mounted or in a control cabinetadd to stepper systems versatility. Coupled with many motor variations available, machine builders have the flexibility to select the stepper motor/drive combination that best fits their design and application needs, Morton added. Kollmorgen likewise regards stepper motor/ drive systems as less costly to produce and easy to implement. The lack of a feedback device [in many cases] in particular reduces the cost of the motor, cables, and drive, said Gene Matthews, a product manager at Kollmorgen. Integrating a stepper into a machine can be as simple as pulsing an output on a PLC. With microstepping technology in the drive, stepper system performance can now come closerthough still not equivalentto a servo system. This provides a value solution for applications that can make the performance/price trade-off, Matthews said. Beckhoff Automation considers the choice of stepper or servo as balancing performance and price. Its a balance of available technology against an applications performance requirementsespecially in terms of loadand the available budget, said Bob Swalley, motors and drives specialist at Beckhoff. Step motors, while sensitive in terms of load, are simpler to size than servos. Typically you need to find a motor that can handle twice the peak load torque at the application speed, according to Swalley. Good performance is obtained where required speeds are not substantially

MAY 2013 CONTROL ENGINEERING www.controleng.com

above 800 rpm. Its possible to get functionality suitable by todays standards using steppers and still save money over a more expensive servo alternative, Swalley said.
Constant duty, motor+drive

Standard step motors run at relatively high currents, resulting in excess heat generation that limits their duty cycle. Recently, Oriental Motor USA (and others) have developed a class of constant-duty step motors with higher energy efficiency than standard motors, noted Todd Walker, OMs national marketing manager. Its the result of several factors: control of running current to reduce heating losses, using higher grade steel laminations, magnetic flux pattern enhancement in the motor teeth, and a Open loop or more Properly sized for the application, a stepmore efficient electronic drive. This combination enables torque production with lower run- per system running in open loop offers repeatable positioningtypically within a half-step or ning currents. Another significant stepper system devel- better accuracy (0.9 or better for a 200 step/rev opment has been the integration of the motor, motor), according to B&R Automation. Overdrive, and ancillary components into one pack- all positioning accuracy depends on a number of age. Benefits include simpler (less) wiring, factors associated with the driver and motor conmatched drive and motor, plus options for struction, Morton noted. Microstepping (for closed-loop mode using motors with a pre- example, 1/10th of a full step or 0.18) is a comassembled encoder or with self-correction monly used method to reduce vibrations associated with stepper motors as options similar to servo well as to improve posisystems. A number of Stepper motors are tioning accuracy. manufacturers offer such In open-loop control, motor-drive packages. simpler to size than a generous torque marStepper packages also gin (up to 50%) is used to build communication servos. Adding select the step motor. This options into the driver, incremental serves as a safety factor which will become more against unexpected load common in stepper driver or absolute encoders changes. Feedback contechnology, Walker stattrol minimizes or elimed. (See products table and resolvers can inates the need for this and more on motor-drive provision. developments at Ref. 1 increase positioning For applications that online.) accuracy. require better positionSchneider Electric ing accuracy or overall Motion also values integrated motion. It has long been an advocate performance improvement, stepper motors can of motor-drives, for example, with its MDrive be fitted with different position sensors such as product line, which comprises NEMA 14, 17, incremental or absolute encoders and resolvers. A simple implementation may use the sen23, and 34 step motor sizes (Ref. 2). Combining the motor, drive, encoder, and motion con- sor just to verify reaching a commanded position troller into one package expands the overall and initiate correction moves. A more advanced cost advantage by eliminating long runs of cost- implementation may use full closed-loop posily feedback and power cables, removing most tioning, similar to servo system operation, Morof the control panel space requirements, and ton added. However, a simpler sensor can suffice in a reducing potential failure points in a motion axis, explained Hummel. This provides a true typical stepper application. For example, Orienvalue proposition when evaluating a stepper tal Motors Walker mentioned a 200 pulse/rev encoder priced at under $70, while a servo syssystem against a servo, he stated.

Thermal imaging shows dramatically less heating for Oriental Motors AR Series constant-duty step motor that allows continuous operation. Motor case temperature differential compared to a conventional motor is greater than 40 C. Courtesy: Oriental Motor USA.

www.controleng.com

CONTROL ENGINEERING MAY 2013 51

motion control

Motion control hybridization

Stepper

motor technology
Negatives Loss of synchronization/ stalling 50% torque margin Post-move corrections Constant torque/current Excessive heating Benefits Smooth motion High torque at starting and low speed Cost effective No tuning Stiffness at standstill

Hybrid
motion
Benefits Benefits Variable current/ Peak torque torque High speed Real-time control Torque mode Optimum torque Closed loop at all speeds Lower energy use Eliminates loss of synchronization Never loses functional control of motor Reduced motor heating

Servo

motor technology
Negatives Tuning required Higher price point Error driven Higher complexity Servo dither

Courtesy: Schneider Electric Motion USAs Hybrid Motion Technology and Control Engineering

Hybrid Motion Technology from Schneider Electric Motion, now available with MDrive products, adds various enhanced control capabilities and features to stepper-based motion systems. Courtesy: Schneider Electric Motion USA.

Go Online
At www.controleng.com/ archive read this article for links to: - Ref. 1- Stepper-based motion systems addendum - Ref. 2- Integrated motor communicates - Ref. 3- Beckhoff-Pattyn stepper application www.br-automation.com www.beckhoff.com/drivetechnology www.kollmorgen.com www.motion.schneiderelectric.com www.orientalmotor.com
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tem might need a costly encoder with, say, 16k ppr capability. AR Series motor and driver packages from Oriental feature a self-correction option that simulates servo-like operation and reportedly maintains positioning even under load changes and accelerations. A sensor monitors motor shaft rotation and, in case of overload, AR Series regains control quickly by going to closed-loop Hybridization improves performance Motion control is moving toward what is varimode. If the overload condition continues, the ously termed actuator independent or hybrid drive outputs an alarm signal. Advances implemented in newer stepper technologydriven particularly by manufacturers that supply both servo and drives include control of synchrostepper systems. Among benenism between the motor and drivConsider this... fits of this development is that en load. For example, Encoderless Applying stepper techmachine builders can provide Stall Detect used in Kollmornologies can require less lower cost step motor solutions gens P7000 Stepper drive gives system setup time and user with the same motion control softusers feedback on when the step expertise: Do you have an ware previously used with servos, motor has stalled. An actual feedapplication that a stepper said B&R Automations Morton. back device isnt needed since the motor can simplify? Schneider Electric Motion method is implemented in softcommented similarly that the ware. Instead, the systems commanded current is monitored and if demand advent of modern control designs, such as the exceeds an expected current limit for a posi- companys trademarked Hybrid Motion Technoltioning move, the drive shuts down, Matthews ogy (HMT), has dramatically narrowed the perexplained. It could indicate an abnormal condi- formance gap between steppers and servos. HMT tion such as a jam, obstruction, or other machine features include ability to operate in torque mode issue. This allows for a more advanced control and at 100% of motor torque, which is said to be unique for stepper motors (read more at Refs. 1 scheme at a low cost, he stated. & 2, online). Applications galore Continuing innovations and adoption of new Oriental Motor sees stepper applications hybrid technologies help keep stepper motion in CNC machines and short move x, y, z posi- systems in proper step. ce - Frank J. Bartos, PE, is a Control Engineertioning for assembly or automation machines. Applications that require short, quick moves (1 ing contributing content specialist. Reach him at or 2 shaft revs)or fine positioning and repeat- braunbart@sbcglobal.net.

abilityare ideal for steppers, Walker said. He cited examples in sampling, metering, or pumping applications where controlled volume is required. Expensive gearboxes can possibly be eliminated in some applications since stepper motors tend to have four times the inertia of servos, Walker added. Stepper systems are well suited for indexing, dispensing, and positioning tasks. Kollmorgen mentioned examples in labeling, 3D printing, and driving linear positioners. Step motor-based systems allow manufacturers to create lower performance and less expensive versions of machines than those outfitted with servo motors, Matthews remarked. Stepper motor technology performs well at speeds below 15 revolutions per second [900 rpm]. If you need significant torque at higher speeds, servo is the right technology. Beckhoff Automations Swalley concurred that steppers are not appropriate in applications with changing forces and/or masses or requiring higher operating speeds. That arena remains strictly the domain of servo motion because of potential loss of synchronism, Swalley concluded. (More Beckhoff coverage appears at Ref. 1 and in a packaging machine application using stepper motion control, Ref. 3, online.)

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networking

industrial Internetof things


Herman Storey

The

Should industrial users embrace IP networking? It promises convergence of many technologies, but is it necessary or even beneficial? An examination of why and why not, what, and how.

Editors note: While the concepts related to the Internet of Things are much in the news for consumer applications and products, does this technology belong in the industrial space? Herman Storey sees potential for major benefits, but only if the technology is applied correctly. Storey is co-chair of ISA100 and has been involved in many networking standards groups throughout his career. He offers these thoughts as a starting point for an ongoing dialog. His comments are followed by views from two others.

oncepts referred to as the Internet of Things (IoT) and machine to machine (M2M) communications have attracted a lot of publicity, many interest groups, and many face-to-face meetings. IoT refers to the increasing connectivity of objects of all kinds, from home appliances to devices used in industrial applications, either to the Internet or some kind of Internet-like structure. The general idea behind this effort is that any smart devices should be able to communicate with each other or with human interfaces anywhere on the planetthus driving improvements in productivity. Industrial M2M networks are mature and widely deployed, even though some M2M publicity implies that the concept is new. These industrial networks can benefit from IoT technology if done correctly, but could also suffer if done with a lack of planning and caution. This discussion will propose some general principles for applying IoT to industrial automation systems. To differentiate this from the web-based efforts and call attention to industrial needs, this will be called the Industrial Internet of Things (I2oT). I2oT must give priority to security, robustness, and timeliness requirements of automation networks while providing for remote access as a secondary requirement.
Why and why not

vendors and users. It will be good for the whole automation industry, and all who embrace the technology will benefit. In the short run, this is disruptive technology. It will require changes and will threaten entities that do not have the resources or leadership to make the changes. It will cross organizational lines and blur distinctions between foundations. The challenges of realizing the benefits of this technology will be more organizational in nature than technical. In fact, the technical challenges are minor by comparison. As of now, the effort to incorporate I2oT technology into the world of industrial automation does not have a home or a clear statement of reason for being. This is not for the faint of heart or the impatient.
What is it?

For the world of automation, I2oT represents the opportunity for partial convergence of industrial automation communication on a grand scale. It will allow improvements in functionality, security, flexibility, ease of use, and cost savings. In the long run, it will be good for
54

The intent of this discussion is to provide a model for I2oT. It is oversimplified but should form the basis for more discussion and definition. This is not a proposal for a massive amount of research into new communication technology. It is a plea to use what we already have in a rational manner. A lot of assembly is required and some gaps need to be filled. Essential elementsI2oT will provide a means to integrate multiple physical media and multiple applications into a single system of industrial networks utilizing some common technology. I2oT is not a converged single stack with a single application layer or a single physical media. Indeed, one physical medium will not serve all installation requirements, and we need more than one application layer to serve all use cases. This discussion may miss some elements but

MAY 2013 CONTROL ENGINEERING www.controleng.com

should serve to stimulate discussion to fill in the gaps. The major elements are shown in the following illustration and discussed below. ApplicationsAt the top of the communication stack, we have many application layers (and some user layers that may or may not be a part of the application layer depending on philosophical prejudice). It can easily be argued that we have many more application layers than necessary, but the argument is irrelevant because they now exist and constitute a large installed base. It is also arguable that one new application layer will not displace all of the existing application layers. Each application layer has strengths and weaknesses that allow each one to fill a market niche. It is simpler and more reasonable to assume that multiple interfaces are necessary and that we should expect to support all of them when considering the future of industrial communications technology. IPv6If I2oT supports all existing media and application layers (and it should), what is converged by I2oT? The answer is simple: in the world of I2oT, all protocols would use Internet Protocol version 6 (IPv6) as the network layer of the communication stack. IPv6 has an extension called 6LoWPAN that will allow this network layer to be used on low power and/or bandwidthlimited networks. It was originally designed for use with battery-powered radio networks, but is suitable for wired networks as well. IPv6 with 6LoWPAN literally gives a protocol the ability to address and route messages to and from any device on the planet to any other device on the planet. Any media should be able to support IP, and any application should be able to run on top of IP, and many already do. Use of a common and capable network layer will allow the first phase of convergence including the sharing of media by multiple applications and the selection of the optimum media and application for any particular task without the need for separate infrastructure. Physical media include: Single and multiple twisted-pair wires Coax cable Single- and multi-mode fiber Many types of radio Acoustic, and Infrared. PHY/MAC specifications exist for these media types and do not need reinvention. All of these types of media should continue to be supported. However, many of these physical- and link-layer specifications are now tied to a single application layer by many protocols. This linkage needs to be broken, and it can be broken

Major elements of the I2oT


Multiple applications

More communication stack layers Common time IPv6 / 6LoWPAN common network layer

Common network management and security

Multiple physical media and link layers

quite easily. Furthermore, the linkage should be broken in a way that any media can be shared by multiple applications. Installations that have high latency and low bandwidth because of physical limitations (such as distance) will require some differences in the layers above IP as well as possibly placing limitations on the media that can be used. There are some shortcuts and simplifications that can be made when networks have direct high-speed/ low latency links. A communication stack model that has multiple options at the top and multiple options at the bottom but a single network layer is sometimes called an hourglass model, or a Hedy Lamarr model for history buffs who remember she invented and patented direct sequence spread spectrum technology during World War II. Switching and routingSwitched networks are the technology of choice. Protocols that do not support switching and routing need to be upgraded, and the common network layer will aid in that step. Point-to-point and multi-drop busses will need gateways to communicate in the new world, but new networks should simply be able to connect to a switch or router. In this model, switches or routers can accomplish media conversion without a gateway. With the right switching and routing technology, it may be possible to incorporate IPv4 as an additional option for the network layer. It is worth investigating. Common sense of timeA common sense of time is necessary in real-time networks for event tagging, scheduling of communications and applications, and security. The best time to use is GMT or TAI (convertable to local time for
www.controleng.com

Key concepts
Internet protocol technologies are quickly moving to industrial applications. The Internet of Things offers many potential benefits for industrial users, but only in the right contexts. A careful and purposeful approach can make adoption more practical and avoid many pitfalls.

CONTROL ENGINEERING MAY 2013 55

networking

human interface). A simple time counter or local time will lead to problems in system implementation and maintenance, and could degrade security. Some protocols need an upgrade. Unfortunately, time synchronization is not so easily standardized because of differing needs of networks and applications. Where time synchronization requirements are fairly lax, SNTP can be used. Many networks and some applications require synchronization at the millisecond level, using a variety of methods. This is an area of standards development. Tokens should not be used for scheduling. A proper clock in each device will eliminate the need and allow more efficient and robust scheduling mechanisms. Tokens may be used for some non-scheduled bus control (TCP), but in general tokens and industrial communications should not go together. More networks will require an upgrade.

ArchitectureISA100.15 has published a document that gives models and terminology for architectures suitable for I2oT. It does not spell out in detail how elements of the architecture should be implemented; it just identifies and gives examples of what they do. More detail is needed if some degree of interoperability is to be achieved with I2oT. Architectural principles of I2oT: n ISA100.15 illustrates methods for segregating automation networks in zones and connecting the zones with conduits. The concepts for zones and conduits were developed by ISA99 for ISA/ IEC 62443. n ISA100.15 illustrates methods for creating and enforcing policies that determine which entities can communicate over industrial networks, and the allocation of bandwidth or relative priority of those communications.

Dont miss the ( big space) in the middle

control, distributed sensing, distributed intelligence, M2M communications, and human interface and interaction such as social media, which is driven from an underlying theme and infrastrucver the past 25 years, there are two ends to the specture of e-commerce. This essentially relates to all activities that trum of thought related to this process in which the world are important to a human or other entity. What Herman Storey needs to be viewed in order to properly launch both the describes is the two ends of the spectrum. PCN believes that IoT in general as well as the I2oT. focusing on the interconnectivity of the two ends by enabling Industrial automation and control always needed to be mechintelligent infrastructure for the continuum in the middle is anized through machines, and through that evolution we began required to have a successful IoT or I2oT. adding efficiencies and minimizing labor. We then progressed to distributed control, which led to distributed sensPCN has developed technology and products ing, which then led to distributed intelligence for to enable rapid upgrade to intelligent infrastrucSociety cannot critical systems. ture through repurposing and reusing existing Meanwhile, the other end of spectrumthe legacy infrastructure. I2oT deployments can then simply shut down consumer or human interface endembraced the be realized with linkage specific to the overridto replace legacy devices being produced from the factory whereby ing goals and objectives of what I2oT is suphumans became interested, intrigued, and overly posed to be, and allows the industrial commuinfrastructure with addicted to the great conveniences, comforts, nication revolution to finally take hold. Due to new IP based and improvements to their quality of life. cost, timelines, operational shutdown, security, This ultimately caused two interesting results; and capital expense requirements alone, socicommunication where one extreme improved the mechanism ety cannot simply shut down to replace legacy infrastructure. of production (i.e., industrial and factory floor), infrastructure with new IP based communicathe other caused the benefits and value to be tion infrastructure in order to achieve its overall realized by human users which ultimately developed consumer goals with IoT or I2oT. New technologies on the horizon and markets. bleeding ones here today are stepping stones for deployment of As we all know, the consumer markets that developed for multiple architectures on single communication or existing comradios, televisions, and appliances led to the convenience of cell munication infrastructures. phones, tablet computers, smart devices, consumer GPS, and By being able to use existing functioning infrastructure as is, other intelligent devices that improve our day-to-day lives. and while simultaneously overlaying IP Ethernet networks anyThis created one very important and often overlooked realwhere within that infrastructure, network owners easily deploy izationrecognition of the two extremes often misses the connew devices, applications, and systems without impacting those tinuum between the two extremes, and what that continuum that are currently performing a required task. Managed migrarepresentssuch as the entire commercial industry of services, tions to the industrial Internet and I2oT can now be a successful products, point of sale, payment systems, security, and overall effort that ensures critical infrastructure upgrades within industrial societal infrastructure that we use every day in our life and work. systems, energy, oil and gas, transportation, and other industries. This entire continuum IS the IoT which involves distributed Daniel Drolet is executive vice president of PCN Technology Inc.

Daniel Drolet

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MAY 2013 CONTROL ENGINEERING www.controleng.com

n As a general principle, many automation nodes and networks have limited bandwidth and capability to serve data. The primary source of data from these nodes must be in separate buffers and caches with sufficient bandwidth for expected users. Direct access to nodes requires systematic limitation. n Local autonomous control and local history collection and compression are two techniques used in industrial automation systems to deal with low bandwidth and/or high or variable latency in networks. Many proprietary schemes are used to fill these needs, and there is an opportunity to standardize these features. Common network managementWork has started under ISA100.20 on a recognized need for common network management. This gap needs to be filled. Common network management is intended to provide a way of managing multiple diverse networks with common tools. Some tools already exist, but many networks are not designed to work with external tools. Some networks are unmanaged. This is an opportunity. Common security managementThis aspect will also need work. It is not easy to separate this need from common network management, and it may be handled by the same effort. This will need to include provisioning procedures and tools. Most industrial protocols do not include sufficient security. They need to be upgraded to include this as a standard feature. Specifications and profiles to support compliance certificationWe need plug and play, not plug and pray. This means that we will need enough compliance profiles and specifications that a certification body can do compliance testing. Standards developed by a standards development organization may support this cause, but will not be sufficient to meet industry needs.
What does the future hold?

and network layers (which is also an organizational boundary) is informal at best and sometimes appears to be a turf war. Many foundations have taken a vertical approach to communication stack specifications and have written full top-to-bottom stacks. Many of these support only one PHY and one application and have a single stack in between. Others have multiple PHY layers available but with restricted stacks in between. These foundations are generally market competitors. All of the organizations fill a need whether they are working on a horizontal or vertical slice of the communication problem, or just a little piece of the problem. All of these organizations could slowly converge on best-in-class technology, or not. If market forces do eventually drive this convergence, it is safe to assume that the convergence will happen very slowly and chaotically under market conditions. Lead organizationBuilding a positive outcome will need a lead organization or a consortium of organizations for a successful effort. It will involve liaison work with too many organizations to name, and need executive sponsorship from multiple entities including vendors, standards organizations, and foundations. Herman Storey is chief technology officer of Herman Storey Consulting, LLC.

If market forces do eventually drive this convergence, it is safe to assume that it will happen very slowly and chaotically under market conditions.

Go Online
n For more information, visit: n www.isa.org n www.pcntechnology.com n www.thingworx.com

The technology solutions we create must be easy, flexible, and powerful


Rick Bullotta

There are multiple paths and even multiple end points for this technology migration. It is not certain what path(s) or endpoint(s) will be the final result. The only certainty is that this technology will change, and so far the changes have led to more diversity. Current stateMany organizations are involved in pieces of the problem, but no single organization is involved in all aspects and no organization is well positioned to take the lead in coordinating this technology drift. Some standards organizations have taken on the task of standardizing horizontal layers of the communication stack. IEE writes standards for the PHY/MAC (or link) layers. IETF writes standards for network and transport layers. Coordination at the boundary between the link

ny consideration of applying the concepts from the IoT to the industrial space would be incomplete without addressing the following: n Legacy systems and devicesHow will they participate in this new architecture, at all levels of the stack? While IPv6 and 6LoWPAN are important moving forward, we need to embrace existing devices and endpoints as well. n The IoT and I2oT are not a communications/plumbing problem (or opportunity); they are about creation of useful applications. While standardizing some of the lower level networking is helpful, it will fall far short of truly unlocking the potential and represents only a tiny piece of the requirements. Other critical elements include: 1. A semantic model for discovering, addressing, and consuming the data, services, and events that the elements of the IoT/I2oT will provide. Although the I in the IoT stands for Internet, the reality is that the Internet wasnt necessarily the source of the amazing innovations weve seen that have changed our lives. It was in many cases the WWW and related standards and protocols that ran on top of the Internet. The same will be true of the IoT. 2. Highly granular security models that can protect access to very specific device capabilities. This way, we can allow selective sharing and access control, better deal with cyber security implications, and so on. 3. Quality of service (QoS) and security at the network layer. Not all meswww.controleng.com
CONTROL ENGINEERING MAY 2013 57

networking

sages and bits that are passed on the IoT and I2oT are of equal importance, and this needs to be designed into the stack. IPV6 offers some capabilities in these areas, but more is required. Lets not forget the human side of the discussion. People still represent the sensors, actuators, and knowledge base for a huge amount of industrial processes. Failure to consider how humans will interact in the I2oT will lead to failure! Despite some vendors claims to the contrary, the IoT and I2oT are not simply cloud device architectures. In fact, to be successful, secure, reliable, and capable of performing as required, we need to consider them as a distributed systems architecture. Those of us who come from the industrial automation world have been dealing with these types of problems for decades, and there is much to be learned from past experiences and applied to the IoT and the I2oT. Standards are important, but we need to consider carefully where in the stack to focus our energies first on standardization. For example: Which areas have the most immediate impact/value? n How can we address the issue of legacy integration? n How can we future proof our standardization efforts so that when IPv24 and infinitely fast, zero gravity, powerless wireless communications are available, we arent starting from scratch? n Consider not only the use cases of the past, but the use cases of the future. Moreover, how can we embrace some other key elements of the IoT in the I2oT?

n Location awareness of assets, people, and even data. Data has time, value, quality, and location. n Contextualization of data via metatagging and other mechanisms, such as a move from dumb historians to smart historians n Mobile devices and new modalities for interaction, including push-based notifications, search-based access to information, secure connections from anywhere, and so on, and n Extend the concept of the social graph to the equipment, processes, systems, and people in the work environment. We at ThingWorx are using our extensive experience in the industrial sector (the founders of ThingWorx brought experience from Wonderware, Lighthammer, and Cimnet) to apply those lessons and know-how to the IoT and the I2oT. We share the view that there is huge value to be unlocked. We also passionately believe that the value will be unlocked when we provide technology solutions that are easy, flexible, and powerful. Those elements need not be mutually exclusive. And security and reliability are a given. We also feel strongly that there is much to be gained from sharing experiences and technology in both directionsapplying the lessons learned from the open, mobile collaborative, and composable world of the IoT to the industrial space, and leveraging decades of knowledge and experience in delivering reliable, performance driven, distributed systems that exist in the industrial sector. ce Rick Bullotta is CTO and co-founder of ThingWorx.

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input #22 at www.controleng.com/information

managing risk

Safety:
How to use ISO functional safety standards
Navigate and apply ISO functional safety standards using this roadmap for common-sense machine safety risk reduction.
Bill Stone

Risk management

Risk assessment and risk management plans help with industrial safety and machine safety efforts, using standards, processes, hardware, software, and continual education.

any safety engineers are overwhelmed by the sheer volume of safety standards. A roadmap can help determine the appropriate ISO standard for the project and how it can be applied to achieve desired safety performance. The ISO functional safety standards use a three-tier structure that includes Type A, B, and C standards to define requirements for different machinery types. Understanding the scope of each type will help. Type A standards are the most basic safety standards and apply to all machinery. They use basic machinery-design concepts and provide general principles. ISO 12100 (Safety of machinery General principles for design Risk assessment and risk reduction) is a Type A standard that describes the risk-assessment process accepted for most machinery. Type B standards are divided into B1 and B2 categories. B1 standards define one safety aspect and B2 standards define one type of safeguard. For example, ISO 13849-1 (Safety-related parts of control systems) is a B1 standard that provides guidance for designing the safety-related parts of a control system. It defines the characteristics of each type of safeguarding function. ISO 62061 is a B1 standard offering an alternative to ISO 13849-1 based on Safety Integrity Levels (SIL).

Five steps of the functional safety lifecycle are 1) perform a risk or hazard assessment, 2) determine safety system functional safety requirements, 3) design and verify the safety system, 4) install and validate the safety system, and 5) maintain and improve the safety system. Training is important throughout. Courtesy: Rockwell Automation

ISO 13850 and ISO 13851 are B2 standards that describe specific functional aspects of emergency-stop devices and two-hand control devices, respectively. Type C standards, the most narrowly defined standards, have the most stringent requirements for specific types of machinery. ISO 102181 applies to industrial robots, while mechanical presses are covered by EN692 and hydraulic presses by EN693. When possible, safety engineers should use a Type C standard to evaluate safety-design requirements for new machinery. No standard can completely define the requirements for a given functional safety application. Each ISO functional safety standard typically includes a Normative References section to identify other standards to consult for a more complete picture.
www.controleng.com

Key concepts
Apply ISO functional safety standards to reduce machine safety risk. ISO 13849-1 improves safety and the experience of working with machine safety requirements, with more benefits than EN 954. Machine safety culture change helped close 95% of corrective actions and preventive actions from fatalities, at one manufacturer.

CONTROL ENGINEERING MAY 2013 59

managing risk

Understand 5 standards that take a safety engineer through the functional safety lifecycle.

Go Online
n See more from Rockwell Automation on how to implement ISO functional safety standards. www.rockwellautomation.com/services/safety

Safety engineers should (at a minimum) consider reviewing five specific standards: ISO 12100, ISO 13849, ISO 62061, ISO 61508, and IEC 60204. These define minimum requirements for each step in the functional safety lifecycle (see graphic) as defined in ISO 61508 and 62061, including risk or hazard assessment, design, verification, installation, and validation. Each ISO standard title provides clues on content and alphanumeric designation that indicates its reference number, adoption date, and adoption location(s). Select the standard with the most recent revision date and appropriate adoption location. Consider standard BS EN ISO 120100:2010 (Safety of Machinery General Principles for Design Risk Assessment and Risk Reduction). The title indicates that this standard contains general principles, so it is likely Type A. The title also signifies that it provides guidance for machinery safety-related risk assessments and risk-reduction techniques. The alphanumeric designator provides additional detailthe author is ISO, the reference number is 12100, and Europe (EN) and Britain (BS) adopted it in 2010. A safety engineer can determine that it is the latest Type A standard provid-

Achieve a higher safety performance level with EN ISO 13849-1

ver the past few years, safety has become one of the dominant factors that impact product design processes. European guidelines for machine safety have played a major role in reducing injuries and are bringing new requirements for product and component developers in their goal of working toward creating a better and safer working environment. At the end of 2011, EN ISO 13849-1:2006 Safety of machinery, Safety-related parts of control systems, Part 1: General principles for design took effect. The EN 954-1 (CAT B, CAT 2, CAT3 & CAT4) was replaced by ISO13849-1, because programmable electronic systems were considered insufficiently; there was no consideration for direct connection between risk minimization, category, or complexity. Also, time response (such as testing intervals, lifecycles) and the failure probability of components (such as Common Cause Failures) were not considered. Therefore, due to all these aspects, EN 954-1 did not represent the state of technology anymore. EN ISO 13849-1 addresses the programmable electronic safety devices, used increasingly in modern machines. The standard provides a quantitative approach to risk assessment and safety validation. This ensures that safety is not just component reliability, but also relies on common-sense safety principles, such as redundancy, diversity, and fail-safe behavior. Under this standard, the risk assessment for a given safety function will yield a performance level (PL). This helps eliminate both over- and under-engineering, a costly or risky result of EN 954-1s limitations. Safety designers should start designing products using EN ISO 13849-1. It improves safety and the experience of working with the new requirements, and will have much greater long-term benefits than using EN 954. To help users with ISO 13849-1 safety design aspects, Siemens Industry Inc. and TUV Rheinland provide training and certification courses. -Information provided by Siemens Industry Inc. www.usa.siemens.com
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MAY 2013 CONTROL ENGINEERING www.controleng.com

ing a model for risk assessment and remediation on machinery in Britain. ISO functional safety standards have a consistent organizational format that allows a user to navigate each standard and identify links to several normative references. Each ISO functional safety standard has: n Scope The scope serves as a starting point and provides an abstract of the standards intended use, whether it is Type A, B, or C, and any limitations. Skim the scope to determine whether the standard is suited for the application. Remember that if the standard is Type A or B, there may be a more applicable Type C standard, depending on the specific type of machinery. When reviewing multiple ISO standards, skimming the scope section of each can often help quickly narrow down to a smaller list. n Normative References These typically follow the scope and, as mentioned above, are other ISO standards that can provide a broader, more complete understanding of required processes and documentation. n Terms and Definitions Use the terms and definition to clarify what is meant by phrases and words used frequently in the standard. Definitions help accurately communicate machinery-safety concepts to ensure consistent understanding for those applying the standard. n Body The body indicates the rules to follow when applying the standard. Language in the body is normative and often includes words like shall, should, may, and can to indicate required items, permissible actions, and statements of possibility when conforming to the standard. Compliance requires adherence to all normative content in the standard. Flow charts and tables are often included in the body to help illustrate how the standard relates to its normative references and allow users to more quickly understand the content. In ISO 13849-1 Figures 1, 2, and 3 illustrate the relationship between ISO 12100 and ISO 13849-1 to help users understand how to use the risk-assessment standard (12100) when designing safety-related parts of a control system as defined in 13849-1. n Annex This adds information to help understand the standard. The body uses primarily normative, or prescriptive, language while the annex uses descriptive language for a more practical description of how to apply the standard. In ISO 13849-1, Annex A provides examples of diagnostic coverage and Annex F provides the scoring process for quantifying Common Cause Failure. Both are critical elements for evaluating the achieved required safety Performance Level. - Bill Stone is machine safety expert, Rockwell Automation, and functional safety engineer (TV Rheinland).

Safety first: Put up your guard


Case study: Machine safety culture change at global consumer products manufacturer results in closing of 69% of the major findings from global assessments; and closing of 95% of corrective actions and preventive actions from fatalities.
Sean Daswani, PE

achine safety upgrades offered a manufacturer an opportunity to reduce risk and address operational efficiency when a safety project required equipment overhaul. After risk assessment, and safety culture improvements, many corrective actions and preventive actions were resolved. Safety is more than adding machine guards. Around the time that the Occupational Safety and Health Act (OSH Act) became effective on April 28, 1971, workplace deaths and reported occupational injuries dropped more than 60%. However, as of January 2012, OSHA reports that the United States still faces an unacceptable and preventable number of work-related deaths, injuries, and illnesses. Every day, more than 12 workers die on the jobmore than 4,500 a year, and more than 4.1 million workers suffer a serious job-related injury or illness. A renewed focus on prevention is needed to reduce these numbers. To accomplish this, the occupational safety and health community has developed and initiated systematic approaches to reduce injuries and illness in the workplace. Regardless of the title of the various company programs, all address workplace safety and health hazards to reduce the extent and severity of work-related injuries and illnesses. Ongoing programs help employers find hazards and fix them before injuries, illnesses, or deaths occur. They also help employers meet their obligation under the OSH Act to furnish to each of its employees, a place of employment which is free from recognized hazards that are causing or are likely to cause death or serious physical harm to its employees, according to the January 2012 OSHA Injury and Illness Prevention Programs White Paper. Convinced of the value, effectiveness, and feasibility of injury and illness prevention programs, many countries around the world now require employers to implement and maintain them. These countries include Canada, Australia, the 27 European Union member states, Norway, Hong Kong, Japan, and Korea. This initiative also follows the lead of 15 U.S. states that have already implemented regulations requiring such programs, according to www.OSHA.gov. The Ford Motor Company 2010-2011 Sustainability Report comments positively on such efforts: Improving our safety record is not only good for our employeesits good for our business. We have calculated that progress in

lost-time cases and days lost saves the company approximately $30 million in direct costs each year.
Polytron case study on safety

Top benefits of effective workplace safety program

In 2009, one of the leading global consumer products manufacturers launched a new fatality elimination campaign as a part of its existing environmental, health, and safety (EHS) management system. The stated safety goal is zero workplace fatalities by 2015, according to the companys 2011 Sustainability report. The overall safety brand was implemented as a strategy to drive cultural change and includes employees, contractors, and visitors. To create a fatality-free and incident-free workplace, the strategy applied a two-way commitment: 1) The company committed to providing a workplace that is compliant with all applicable laws and regulations. 2) Individuals are expected to refuse to take part in any action considered unsafe, confront others acting in an unsafe manner, and immediately stop any unsafe actions. Key performance indicators (KPI) for the companys manufacturing facilities were established and defined in the following areas: Total reportable incident rate: Work-related events that result in fatalities, or temporary or permanently disabling injuries or illnesses per 200,000 hours worked per annum. Lost time reportable incident rate: Reportable injuries/illnesses that result in time away from work or restricted work per 200,000 hours worked per annum. Global contact with energized equipment incident rate: Cases resulting from bodily contact with energized equipment (electrical, mechanical, hydraulic, gravity, radiation, pneumatic, thermal, etc.) per 200,000 hours worked per annum. These include incidents arising from inadequate guarding of equipment or machine, or failure to follow energy control work practices, etc. The company took action in the following areas: Culture change Training sessions for all employees at the companys global manufacturing facilities Facility occupational safety and health (OS&H) leader qualification and competency standards Standard minimum qualifications and
www.controleng.com

Courtesy: Polytron, January 2012 OSHA Injury and Illness Prevention Programs White Paper

Training sessions help ensure everyone is on the same, lower-risk, page.

CONTROL ENGINEERING MAY 2013 61

managing risk

Plan-do-check-adjust (PDCA), a common methodology also applied in manufacturing programs, including safety, was made popular by Dr. W. Edwards Deming, considered to be the father of modern quality control. Courtesy: Polytron

competency requirements for senior facility OS&H leaders n Machine safety standards Risk-based approach to safeguarding selection to provide flexibility in safeguarding method(s) in compliance with international consensus standards, ISO 14001, and OHSAS 18001 n Plan-do-checkadjust (PDCA) methodology Policy and organization, planning, implementation and operation, checking and corrective action, and management review.
Plan, do, check, adjust for safety

plan and improve with more detail in the next iteration of the cycle, or attention needs to be placed in a different stage of the process.
At-risk equipment

JB Titus and Associates portrays a risk reduction process to determine if the risk is acceptable or requires some action for risk mitigation. In the case study here, a risk assessment was conducted for impacted equipment. The safety team reviewed and assigned risk values, which become the triggers for corrective action. Courtesy: Polytron; produced with permission of JB Titus and Associates

PDCA, a common methodology also applied in manufacturing programs, was made popular by Dr. W. Edwards Deming, considered to be the father of modern quality control. (See graphic.) The steps in each successive PDCA cycle, and the traditional responsibilities are: Plan establish the objectives and processes necessary to deliver results in accordance with the expected output (the target or goals). Do implement the plan, execute the process, and make the changes. Collect data for charting and analysis in the following Check and Adjust steps. Check study the actual results (measured and collected in Do above) and compare against the expected results (targets or goals from the Plan) to ascertain any differences. Information is what you need for the next step, Adjust. Adjust request corrective actions on significant differences between actual and planned results. Analyze the differences to determine root causes. Determine where to apply changes that will include improvement of the process or product. When a pass through these four steps does not result in the need to improve, the scope to which PDCA is applied may be refined to

When the client launched its 2009 zero-fatality program, company manufacturing facilities had equipment that required updating to meet new occupational and machine safety standards. Additionally, multiple original equipment manufacturer (OEM) safety systems existed; therefore, the implementation of safety standards was inconsistent. As part of its strategic plan, the company partnered with preferred vendors to assist with a company-wide risk mitigation of its equipment. The clients dedicated safety team developed standards of safety for all equipment, which included: n Conforming to safety categories based on the risk assessment, maintenance standards, operational consistency, and troubleshooting procedures n Preferred vendors, such as Polytron and E2M, were selected to support the safety initiatives. Selection was made based on the vendors critical understanding of how the risk assessment translates into applied machine safety systems to lower the risk score. n Training meetings were held with preferred vendors, key technology suppliers, and OEMs to share the new standards and requirements to support the machine safety initiative. Those trained were then brought alongside the safety team to provide support in the risk mitigation effort. Since the initiation of the machine safety program in 2009, the company reported zero fatalities in 2010 and 2011. Also 69% of the major findings from the global assessments have been closed; 95% of the corrective action and preventive action from fatalities have been closed. - Sean Daswani, PE, is senior electrical engineer, Polytron.

Go Online
n At www.controleng.com/archive see this article for more on risk mitigation for older equipment, safety implementation, safety climate change, training, and a palletizer machine safety upgrade. n http://polytron.com/think-tank n At www.controleng.com/blogs, read the Machine Safety blog post: n Is OSHA okay with my acceptable risk mitigation? n www.controleng.com/blogs

62

MAY 2013 CONTROL ENGINEERING www.controleng.com

How to make a health, safety, and environmental plan


Making an HSE plan is more than a creating set of rules for manufacturing health, safety, and environmental activities. Heres what you need to know about HSE.
Allan Manzer, CSP; Jennifer Palumbo

health, safety, and environmental (HSE) plan is a crucial step towards mitigating project risks, yet many companies dont use them on every project. They may require more time and planning up front, but the payoff can be huge. An HSE plan is a living document, developed before the project work begins using the scope of work as a starting point. As the project evolves, the plan is revised as the scope changes. Project managers should get a detailed scope of work from the client; get appropriate HSE information from the client contact; distribute the plan with any drawing packages to the project team; review the plan during the initial kickoff meeting; post and maintain the signed plan on the job site; enforce all elements of the plan while on the project; inspect the job site, document and report all safety conditions; revise the plan if the scope of work changes; verify appropriate training for special job tasks for employees and contract labor. Each plan has a checklist to considereye bath locations, whether asbestos or lead is present on-site, chemicals in the work area, and so on. It considers various hazards depending on the type of work performed, such as electrical and confined space hazards. Goal in initiating the plan this way is to allow the project manager or person in charge the opportunity to think about all different aspects of the job throughout the life of the project.
Get it done right, the first time

Why promote using an HSE plan? In some cases, using an HSE plan can prevent the need for the same personal protective equipment (PPE) that many choose not wear. The HSE plan helps the engineer think about the voltage coming into the panel hes working with on-site. Under NFPA 70e, any energized panels operating at 50 V or above require PPE. As a result of using the plan before the project begins, engineers are designing panels differently. Theyre designing a 480 V circuit outside of the control engineers panel. The control engineer gets the power where he needs it; and its at a lower voltage that doesnt require PPE. This is one example of how the front end loading of the HSE plan for this kind of activity eliminates all kinds of extra work. When you dont think about the plan before designing the panel, you dont have the right people who are qualified under

NFPA 70e to perform the install using proper PPE. This usually means having to leave the job site and delaying the project work until you can find a qualified person with PPE. When you use the plan to assess the risks before they begin design, you eliminate these risks, and any controls engineer can do the work. This leads to the mantra Get it done right, the first time, without incident. Using an HSE plan allows you to assess the work hazards to complete the work properly, without having project delays due to unqualified persons or missing required PPE, and without incidents or accidents. The HSE plan can identify other hazards. A controls engineer visiting a paper mill discovered during walk-through that the mill floor had not been cleaned recently. Opening a charged panel with paper dust floating could cause fire or an arc-blast hazard. Many system installs work in tight spaces, around hazards, such as chemicals or pressurized systems. Among excuses for not having an HSE plan is that the client contact wont know what the HSE requirements are and wont want to spend time defining them. While your specific contact may not have the answers to HSE questions, most mid-size to large companies appreciate and expect that you will have a plan in place. To get client buy-in, start by asking for the HSE requirements for wherever the work will be performed. In the proposal, consider requiring HSE information as a part of the client responsibility. Under the NFPA 70e standard, the client has the responsibility to provide this information to the contractor. Occupational Safety and Health Administration (OSHA) also requires that if the client does not provide this information, the contractor has the responsibility to learn these risks and become familiar with the hazards before beginning work. ce - Allan Manzer, CSP, is corporate safety engineer at Optimation; Jennifer Palumbo is marketing communications specialist. Articles edited by Mark T. Hoske, content manager, CFE Media, Control Engineering, mhoske@cfemedia.com.
www.controleng.com

Electrocution-response table: at 200 milliamps, a victim will experience severe burns, severe muscular contractions, and possible heart failure. A 100 W light bulb uses 833 mA. A health, safety, and environmental (HSE) plan addresses risks beyond just electrocution. Courtesy: Optimation

At www.controleng.com/ archive read this article for more HSE advice. www.optimation.us

Go Online

Consider this...
Do those in your organization understand that assessing risk is a continuous process, not a one-time event?

CONTROL ENGINEERING MAY 2013 63

inside process

Working in the cyber security red zone


Do you have enough first responders within your company when it comes to dealing with cyber security incidents and network violations? How can you make sure you arent developing critical staffing gaps?
Tim Conway

Key concepts
Your companys ability to respond to a cyber violation often depends on the actions of a few key individuals A few simple analysis steps can help you evaluate your staffing situation and determine a direction
P1

s I examine a growing problem security, or security responder engineering roles across the identified critical infra- within an operations technology (OT) department. structure sectors within the U.S., I believe we need the 1996 movie Apply traditional management? Many organizations have looked at the impact Multiplicity to become a reality. In the movie, Michael Keaton plays Doug Kinney, these positions have on the operations environthe main character who is overwhelmed with his ments of an organization through traditional responsibilities at work and home. All he can see management processes such as business impact analyses, workforce planning is an ever-growing list of things initiatives, or organization panto do with little or no hope for demic planning. In these tradisuccess. To resolve this issue, tional activities, organizations Doug works with a scientist to attempt to identify a condiclone himself so his surrogates tion that could create an operacan divide all those responsitional problem and then begin bilities and get everything done to identify steps to prevent the with no one the wiser. While problem from occurring. These this comedy is obviously fictraditional approaches identify tional, the immediate needs for operational risks as a result of a talented, trained, and capatechnology loss for a period of ble cyber and operations worktime, loss of specific skill sets force is far too real, and there or knowledge, and potential are individuals within the CI/ loss of employees necessary to KR (critical infrastructure / key Red zone jobs are perform critical operations. resource) sector that we defipositions that are The problem facing CI/KR nitely need to duplicate. While staffing needs ebb essential in performing sector red zone jobs is a mixture of traditional problems and flow in all organizations an operational identified above and challenges and fulfilling strategic staffmission in normal in the available qualified working demands is a continuforce for industries that need ous effort, many believe there and emergency them. The pipeline of people is a real issue developing that conditions. moving into the workforce that will impact CI/KR-essential have necessary skills, knowlroles. A term that was recently introduced to me is red zone jobs. These are edge, and capabilities to perform critical red zone positions or roles that are absolutely essential in jobs compared to the pipeline of people exiting performing an operational mission in normal and those positions is not balanced. This unbalanced emergency conditions. Red zone jobs across the condition seems to be worsening as the number of CI/KR sector would typically be classified as roles individuals exiting is increasing, the need across that have real-time response requirements and per- multiple sectors is growing, and the available proform an essential operational or operational sup- grams or development capabilities has remained port role in a real-time environment. Throughout flat. This problem is unique in that entities do the CI/KR sector, technology jobs often perform not control the process that educates, trains, and system, application, network, communications, develops the necessary capabilities of candidates

MAY 2013 CONTROL ENGINEERING www.controleng.com

YOU CAN DO THAT


Eliminate uncertainty, reduce your risk with DeltaV SIS. Emersons smart safety instrumented system provides an integrated, intuitive set of engineering tools and software that enables your team to handle configuration, alarms and device health monitoringwhile maintaining the systems separation required by IEC 61511 and 61508 standards. The DeltaV SIS system reduces your training and lifecycle costs by eliminating complex data-mapping and multiple databases while helping to ensure that youre meeting safety compliance. Learn more about safety processes and best practices by downloading the Safety Lifecycle Workbook at: www.DeltaVSIS.com/workbook

Our safety experts talk safety. Our operators talk control. But when it comes to keeping our people and plant safe, we all need to speak the same language.

The Emerson logo is a trademark and a service mark of Emerson Electric Co. 2012 Emerson Electric Co.

input #24 at www.controleng.com/information

inside process

until they are hired into the workforce. Most companies cannot independently solve this issue. They can, however, influence a direction that will improve the industry overall and strengthen their own workforces. Many entities have worked with traditional educational institutions or specific training providers to develop programs that will help meet the growing needs of the red zone jobs. The focus is almost always on training content and knowledge assessment, which is an essential first step. However, the gap that remains in these approaches is the capability or right fit issue that exists as a component of all red zone jobs across the CI/KR sector. These companies and other entities will continue to face challenges in assessing a candidates capability to be successful in a red zone job or training candidates to ensure a successful fit. To combat this issue, many entities are moving to technology implementation of active policy enforcement systems or intelligent monitoring and alerting tools. This helps alleviate reliance on a knowledgeable, qualified, and capable workforce to perform these processes; however, it also needs to be acknowledged that adversaries are also automating and implementing intelligent tools and evasion tactics.

Therefore the number and complexity of attacks will grow, and the very complex attacks will require a knowledgeable, qualified, and capable workforce to detect and defend the environment.
Evolving job demands

We also need to discuss the growing reliance on technology for all critical operations across the CI/KR sector that is creating an increase in red zone jobs. Entities across most CI/KR sectors would have identified a very different set of red zone jobs 30 years ago than they would today. For example, electric utilities circa 1983, would have included linemen, substation engineers, switching operators, and dispatch operators for transmission and distribution environments as critical roles. Generation environments would have likely identified generating station control room operators, instrumentation and control engineers, and relay engineers as critical roles. Looking at these same environments in 2013, while the roles previously identified are still critical, they are now performed in a dramatically different fashion, and in many cases rely on additional capabilities and roles that did not previously exist. In addition there are now new functions

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that have moved into an absolutely critical role that likely were not considered all that critical 30 years ago. Consider the criticality of control centers today, RTOs and ISOs, the systems and support functions for communications, and market functions. The interdependencies have grown immensely, and too often individuals do not fully understand how they may impact others within the organization. This interdependence applies across the CI/KR sector and companies need to begin to understand those dependencies in depth. Additionally, in todays red zone jobs that are technology or automation driven, a complex dependency exists on the technology utilized throughout the organization. Within an organization many trusts exist: trusted communication paths, trusted users, trusted external organizations, and trusted applications. As organizations identify these trusts and dependencies, they can identify and mitigate the security risks more effectively. Think about what the phrase red zone conveys in American football: when defensive players have their backs to the goal line, the situation demands peak performance because the threat is imminent and has to be turned back. Similarly, defender roles within the CI/KR sectors red zone

need to be ever present and the capabilities of the individuals in those roles need to be fully developed to achieve peak performance.
Recommended actions

Companies and other entities can begin the analysis process by looking at a few straightforward measures. The first step is to assess their current staff capabilities or limitations: n Identify red zone job positions or roles within your facility that are essential to real-time operations and operational support n Assess organizational capabilities and identify red zone job areas for improvement n Join in industry wide efforts to better equip individuals currently in red zone jobs or better prepare new candidates, and n Understand underlying technologies utilized by operations and the complex interdependencies that exist within and external to the organization. These steps can help guide your efforts to fill these critical positions, since unlike the movies, I dont think we will have human cloning for security purposes anytime soon. ce Tim Conway is technical director, ICS and SCADA for the SANS Institute.

Go Online
n www.sans.org

input #26 at www.controleng.com/information

inside process

Understanding SIS industry standards


Process safety standards and practices are spreading from oil and gas and other energy-related industries to broader process industry applications. Heres basic advice on how to make more sense of the numbers and acronyms.
Robert I. Williams, PE

afety instrumented system (SIS) applications grew primarily out of the oil and gas industries, where they are used to mitigate safety hazards related to many dangerous feedstocks, products, and processes. When applied appropriately, the fundamental concepts of SIS applications are integrated within the total lifecycle of the overall safety system. Understanding these systems involves unraveling the sometimes arcane language of safety engineers with standards numbers and many acronyms. An SIS provides an integrated approach to complete safety loops, as shown in Figure 1. Such a loop includes a sensor, logic solver, and final control element. The SIS system shuts down a process plant or part of a plant when needed for safety, but keeps the plant running safely when devices fail.

Table 1: Safety integrity levels


SIL 1 2 3 4 PFDavg 10-1 to 10-2 10-2 to 10-3 10 to 10
-3 -4 -4 -5

RRF 10 to 100 100 to 1,000 1,000 to 10,000 10,000 to 100,000

10 to 10

What is a safety function?

Safety instrumented functions (SIFs) are actions taken by a SIS to shut down the process plant safely. Each identified SIF consists of a set of actions to protect against a specific hazard. A process plant SIS therefore consists of a number of SIFs which are listed in the process hazard analysis (PHA) report.

Part of the design process is considering many what-if scenarios that examine what happens if various components fail. A safety integrity level (SIL) is a performance measure which tries to quantify the probability of a specific SIF failing to perform its required function when called upon, known as the probability of failure on demand (PFD). Whereas a DCS is performing process control functions continually while the plant is running, the SIS is dormant by design until required to perform a safe shutdown function. Table 1 lists four SIL levels and their related PFDs as defined by IEC 61508 and IEC 61511. All standards are not necessarily the same. For example, ANSI/ISAS84.01-1996 recognizes only three SILs. Techniques to establish the required SIL for a SIF in a SIS are defined in the relevant industry standards. (Some are listed in the online resources for this article.) SIL 4 is the highest level of safety integrity while SIL 1 is the lowest. The risk reduction factor (RRF) for a SIF is the mathematical inverse of the PFDavg for that SIF. It represents a number corresponding to the factor that the SIF reduces the likelihood of the hazardous event that the SIF intended to prevent. Probability of failure on demand (PFD) is the probability that a SIF designed to protect a process plant will fail to shut down the plant safely when the hazard shutdown condition occurs. In other words, the safety function fails to do its job when called upon.
Safety lifecycle

Figure 1. An individual SIS includes three items: sensor, logic solver, and final control element. It needs to be able to perform its function independently and not depend on the basic process control system. Courtesy: Emerson Process Management
P5

The safety lifecycle, as defined by IEC 61508 and ANSI/ISA-S84.01, structurally defines a SIS

MAY 2013 CONTROL ENGINEERING www.controleng.com

THINK

TRICONEX

Thinking Safety? Think Triconex.


For 30 years, Triconex solutions have been helping organizations manage risks and hazards, avoid unscheduled asset downtime and maximize process uptime. So when you are thinking about safety AND maximum performance, THINK Triconex.

iom.invensys.com/thinktriconex

input #27 at www.controleng.com/information


Copyright 2013. All rights reserved. Invensys, the Invensys logo, Foxboro and Triconex are trademarks of Invensys plc, its subsidiaries or afliates. All other brands and product names may be trademarks of their respective owners.

inside process

Functional safety is just one method of dealing with hazards, and other means for their elimination or reduction, such as inherent safety through design, are of primary importance.

development from its initial conceptual design through to its final decommissioning, as follows: 1. Conceptual design 2. Hazard and risk analysis PHA (HAZOP) 3. Safety requirements specification 4. System architecture and detailed engineering 5. Application programming 6. System production 7. System integration 8. Factory acceptance tests (FAT) 9. System installation and commissioning 10. Safety system validationsite acceptance tests (SAT) 11. Operation and maintenance plan 12. System change management 13. Decommissioning, and 14. Information and documentation requirements. Generally, the significant hazards for equipment and any associated control systems have to be identified by the specifier or developer via a hazard analysis. The analysis identifies whether functional safety is necessary to ensure adequate protection against each significant hazard. If so,

then it has to be taken into account in an appropriate manner in the design. Functional safety is just one method of dealing with hazards, and other means for their elimination or reduction, such as inherent safety through design, are of primary importance. IEC 61508 applies to safety-related systems when one or more of such systems incorporate electrical and/or electronic and/or programmable electronic (E/E/PE) devices. It covers possible hazards caused by failure of the safety functions to be performed by the E/E/PE safety-related systems, as distinct from hazards arising from the E/E/PE equipment itself. It is generically based and applicable to all E/E/PE safety-related systems irrespective of the application. The underlying assumptions of the standards recognize that the consequences of failure could have serious economic implications. In such cases the standard could be used to specify any E/E/PE safety-related system used for the protection of equipment or product. The scope of IEC 61508-1 goes into more detail. The range of E/E/PE safety-related systems to which IEC 61508 can be applied includes: n Emergency shutdown systems

input #28 at www.controleng.com/information

n Fire and gas systems n Turbine control n Gas burner management n Crane automatic safe-load indicators n Guard interlocking and emergency stopping systems for machinery n Railway signaling systems, and n Variable speed motor drives used to restrict speed as a means of protection. Relevant means of implementing safety functions include electromechanical relays (electrical), nonprogrammable solid-state electronics (electronic), and programmable electronics. Programmable electronic safety-related systems typically incorporate programmable controllers, programmable logic controllers, microprocessors, application specific integrated circuits, or other programmable devices which could include smart devices such as sensors, transmitters, and actuators. In every case, the standard applies to the entire E/E/PE safety-related system. That could encompass, for example, a sensor, through control logic and communication systems, to final actuator, including any critical actions of a human operator. For safety functions to be effectively specified and

Figure 2. Information from SISs can be sent up to a larger control network for alarms or data collection, but they need to retain the ability to carry out their specific safety assignment independently. Courtesy: Emerson Process Management

implemented, it is essential to consider the system as a whole. The physical extent of an E/E/PE safety-related system is solely determined by the safety function. Working through the entire safety lifecycle is a major undertaking, but it is a process critical to the safety of people, property, and environment. ce Robert I. Williams, PE, is instrumentation and control systems manager at Brinderson, Costa Mesa, Calif.

Go Online
n Detail on IEC safety standards n www.iec.ch/functionalsafety/explained/page1.htm n www.isa.org n www.isa-84.com

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inside process

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ike much of the rest of Maine, the town of Rumford is well known for the beauty of its natural surroundings. But for more than a century Rumford has also played host to one of the largest paper mills in the Northeast, churning out as much as 550,000 tons of paper and 125,000 tons of pulp annually. NewPage, which owns the Rumford facility and is among the leading domestic producers of printing paper and specialty paper, is working in a highly competitive and energy-intensive business. Through creative energy management strategies and the intelligent use of forecasting data, NewPage has transformed the Rumford mills energy costs from a burden to a source of competitive advantage.
Need to improve

Producing paper and pulp is an energy-intensive operation, and the Rumford mill features three boilers and a genera-

tor to provide for the thermal and electrical needs of the mill. The generator can put out as much as 100 MW, or roughly enough to power 100,000 homes. For the last decade or so, the Rumford mill was facing a crisis because the primary fuel for the generator was coal, and the price of coal was steadily rising. According to the U.S. Energy Information Administration, the market price of coal rose substantially from 2000 to 2010, and transportation costs drove the price even higher in Maine. The problem is transportation to get coal from, say, West Virginia up here to western Maine relies on diesel, rail, ship, truck, or any other transportation mode, explains Rick Abradi, head of energy management at Rumford. Faced with increasing coal prices which jeopardized the mills competitiveness, NewPage assigned Abradi the challenge of developing a strategy to bring overall energy costs under control.

United Electric Controls 180 Dexter Avenue Watertown, MA 02471-9143


input #30 at www.controleng.com/information

The Rumford Paper Mill has seen its energy costs reduced thanks to aggressive energy management strategies. Courtesy: Genscape
P9

MAY 2013 CONTROL ENGINEERING www.controleng.com

Using wireless here and there is one thing. But using it across my entire operation? Theres no one I could trust to do that.

See more, do more and be more profitable with the most trusted partner in wireless Emerson. Emerson is your proven partner with Smart Wireless in more customer sites and with more operating hours than anyone else in the process industry. Smart Wireless has the widest range of technologies to expand your vision into more places across your operations. And its self-organizing mesh network delivers the highest reliability available. It is simply the most intelligent, secure and cost-effective operation-wide wireless option available. See how Smart Wireless can empower your bottom line at EmersonProcess.com/SmartWireless

The Emerson logo is a trademark and a service mark of Emerson Electric Co. 2012 Emerson Electric Co.

input #31 at www.controleng.com/information

inside process

The problem is transportation to get coal from, say, West Virginia up here to western Maine relies on diesel, rail, ship, truck, or any other transportation mode.

Breaking down the problem

Go Online
n www.genscape.com n www.newpagecorp.com

Abradi started by created three broad buckets for energy management strategies: demand, procurement, and conversion. Demand would cover most approaches people identify with energy efficiency, like adding insulation and replacing light bulbs in a house. On an industrial scale, it generally means finding ways to produce more pulp and paper with less steam and electricity. A bigger cost impact, though, came from procurementfinding a way to diversify, away from expensive coal to cheaper fuel sources. Despite being able to use some of its own waste products as fuel, the Rumford mills generator still relied on coal as the largest fuel source for the boilers. With prices rising, diversification was the key to ensuring some measure of cost control. The mill operates two circulating fluidized bed boilers that suspend fuel in jets of air. The Rumford mill is able to burn readily available biomass from wood chips and a fuel called TDFtire-derived fuel. Increasing the volume of these alternative fuel sources allowed Abradi to reduce coals share of total fuel consumption. In addition, NewPage gained greater operational flexibility to adjust fuel sources based on

market prices and availability, reducing the dependence on any single supplier or fuel type.
Using forecasts

With the fuel sourcing problem solved, the next challenge was optimizing conversion. A big part of this is making a determination of when and at what level to run the generator. While the Rumford mills generator is more than capable of meeting its own needs, the plant sits within the region covered by electric utility Maine Central Power, and can just as easily draw power from the grid. When local power prices fall below what NewPage pays for generation costs, the plant can scale back its generator and instead draw from the grid. With so much excess generating capacity, the mill can also export power out onto the grid. When demand on the grid is high and prices rise far enough above the cost point, NewPage is able to take advantage of the cost differential. The biggest difficulty with trying to take advantage of the rise and fall of electricity prices is that it can be difficult to respond quickly to changes. Barring any breakdowns, operators have a good idea how much power the mill will need, but it still takes as much as 15 to 20 minutes to

THE DIFFERENCE BETWEEN OPERATION

AND CONTROL
input #32 at www.controleng.com/information

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change output from the generator, so any mistakes or delay can mean a missed opportunity. This can be an even bigger problem for companies that only have the option of cutting back operations.
Answers in power analytics

Since the early 2000s, NewPage has turned to the energy information firm Genscape for daily forecasts of local power prices and regional power demand. Genscapes teams of analysts and meteorologists provide highly accurate forecasting reports using a combination of neural network models, proprietary monitor data, and fundamental models. When a morning forecast from Genscape calls for high real-time prices later in the day, the control room operators get the advanced notice to ramp up the generator and sell surplus power to the grid at a handsome profit. Sometimes when the price unexpectedly ramps up, we dont see it right away. And due to the nature of our equipment we cannot react instantly, said Abradi. So having a heads-up on that, the operators can anticipate that move.
Casting a small shadow

es are really starting to escalate around the region. Easy as it might seem to avoid demand charges with an on-site generator, making guesses about when a new peak will occur comes along with very real costs. Each hour that the generator runs during a false alarm is an hours worth of expensive fuel being burned. Guess wrong too often and these costs can begin to pile up. Much the same can be said when production is curtailed to lower a businesss usage.
Lessons for the rest of us

A Better Visualization For HMIs

Theres another use of these types of power forecasts that can also have an impact on overall energy costs, namely, minimizing demand charges. Every utility imposes some sort of charge for using its grid, fees that cover everything from maintenance to expansions and upgrades. Generally, utilities charge a fixed amount, distributed among customers based on their proportion of total usage when demand peaks during a given month. NewPage has largely managed to reduce its demand charges significantly by using monthly forecasts to determine which days are likely to result in a usage peak and running the generator to reduce or eliminate net usage from the grid during those periods. (Before these reports) it was me and my fancy Excel spreadsheet I built on the back of an envelope, looking at the National Weather Service weather forecast, remembers Abradi. Before that we didnt worry about it much because the cost penalty was relatively minor, but these transmission chargwww.controleng.com

Most industrial plants dont have a 100 MW generator and the ability to sell surplus power to the grid, but that doesnt mean they cant benefit from the same energy management strategies employed by NewPage. Demand charges are an unfortunate fact of life for every industrial facility, and reducing load during forecasted peak demand periods can go a long way toward reducing overall energy costs. Similarly, economic demand response programs provide a way for industrial facilities with the flexibility to shift or curtail their load to sell power onto the grid during periods of high-forecasted prices without requiring an on-site generator. System operators such as ISO-New England and PJM offer lucrative economic demand response programs which reward businesses for reducing their electricity usage at times of high prices. Not only do participants avoid paying for power during high-price periods, they are actually paid the prevailing wholesale price for every kilowatt-hour they reduce below their baseline level. By using a forecasting service to provide accurate predictions of the days and hours of highest real-time prices, a participant can maximize the financial benefit from these programs and provide a benefit to the grid at the same time. NewPages Rumford mill illustrates the kind of savings that can be achieved through comprehensive energy management and accurate forecast data. In a highly competitive industry like paper, even modest reductions in energy costs can mean a major swing in profitability. ce Hudson Gilmer is vice president of commercial markets at Genscape.
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software &

PRODUCTS
Wireless non-contact switch offers top sensing or side sensing, actuating in the presence of magnets
Honeywells Limitless non-contact switch actuates based on the presence or absence of magnets installed on a customers device. The battery-operated device allows customers to choose either top or side sensing which can reduce installation and maintenance costs compared to traditional wired switches. Instead of a lever, button, or wobble stick, this device can be actuated with a magnet, simplifying use in tight areas often found in machine tools, packaging machinery, lifts, and industrial machines, or in applications where mechanical actuators are not feasible. Honeywell
www.honeywell.com
Input #201 at www.controleng.com/information

Industrial safety light curtain protects fingers and hands while continuously monitoring itself for faults
Ifms low-prole safety light curtains provide nger, hand, and body protection in a variety of industrial applications. These type 4 light curtains provide a multi-beam barrier of infrared light in front of a hazardous area. If any of the beams are blocked by an object, such as a nger or a hand, the light curtain sends a signal to the machine to place it in a safe state. Light curtains in this series are offered in protective heights of 160 to 1,510 mm in increments of 150 mm. The light curtains slim housing design measures only 28 x 30 mm that ts easily in an application for less intrusive mounting. Redundant safetyrated solid-state outputs ensure fast response time. Bright LEDs indicate power, system status and fault conditions. ifm efector inc.
www.ifm.com/us
Input #200 at www.controleng.com/information

Programming software reduces engineering time, speeds development and commissioning


Siemens is characterizing its Simatic Step 7 Professional V12 programming software as its most comprehensive engineering software. The new platform is designed to congure and program all Simatic controllers. Simatic WinCC Basic is also included for simple visualization tasks with Simatic Basic Panels. Step 7 V12 software serves every phase of the production life cycle, reducing engineering times thanks to innovative programming language innovations, integrated functions, and graphical conguration. This supports fast commissioning with efcient error localization, integrated system diagnostics, real-time trace, and high-performance online functions. The new platform connects to the Siemens Totally Integrated Automation Portal offering programming transparency, intelligent user navigation, and straightforward workows. Siemens
www.usa.siemens.com
Input #202 at www.controleng.com/information

Compact Differential Pressure Flowmeter Family uses newest transmitter technology


ABB Measurement has announced an extended family of compact owmeters to include four DP technologies: orice, wedge, averaging pitot, and integral orice. These will be added to its range to complement the existing OriMaster compact orice meter, which itself has been extended and improved. Each family member is a one-piece owmeter, incorporating the primary element, three- or ve-valve instrument manifold, and transmitter in a single assembly, fully pressure-tested. The compact construction enhances both performance and safety as it involves a minimal number of leakage points compared with the many potential sources of leaks often found in a conventional DP ow installation. The compact family saves time and cost in both the procurement and installation processes as the meters provide a complete measurement solution. ABB
www.abb.com/measurement
Input #203 at www.controleng.com/information

76

MAY 2013 CONTROL ENGINEERING www.controleng.com

Servo drive family offers a variety of networking options to simplify integration


The CMMP-AS servo drive family from Festo offers EtherNet/IP, Pronet, EtherCat, Probus, and DeviceNet connectivity. The drive comes with optional slide-in network cards for all supported platforms, which allows OEMs to customize the drive to meet specic application needs and enables easy integration with various control architectures. The CMMP-AS servo drive offers an optional slide card with Safe Torque Off (STO) functionality for increased productivity and personnel safety. With the safe-off capability, tasks such as machine setup, cleaning, removal of jams, and other typical maintenance work that previously required power-down conditions can now be accomplished without removing power from the entire machine. Festo
www.festo.us
Input #204 at www.controleng.com/information

Wash-down ac motors designed for rugged environments like water treatment and machine shops
Omegas WSS stainless steel ac motors are constructed with doubled-dipped polyester insulated windings, a corrosionresistant rotor and double-lip seals plus V-ring shaft slingers. These 3-phase industrial grade wash-down duty motors come in sizes from 1/3 to 2 hp at 1,800 rpm. Other features include a TEFC enclosure, Class F insulation, and O-rings installed on the end bells to eliminate moisture. They are designed for environments where they could get wet, such as water treatment, unprotected outdoor installations, environmental control, and machine shops. Omega Engineering
www.omega.com
Input #205 at www.controleng.com/information

Two-hand safety device allows height adjustability, providing ideal ergonomics for multiple operators
OpGuard is a two-hand control that allows operators to adjust its height instantly. OpGuard reduces workers strains by adding a exible arm to the two-hand controls, enabling operations to reposition their controls to an ergonomic height. The arm has 11 in. of vertical adjustment, enabling the device to accommodate users of all heights. Additional features include availability with electric or pneumatic buttons, and under-counter or wall surface mounting options. OpGuard has easy integration with machine controls and is built of durable steel and die-cast aluminum. Adjustable arms can be purchased independently with brackets to connect existing anti-tie down devices. Easton Lean Tools
www.eastonleantools.com
Input #206 at www.controleng.com/ information

Frame light grids detect and count parts on conveyors and machines
Sick FLGs (Frame Light Grids) are designed to detect and count parts as small as 4 mm in size. With the sender and receiver installed in one frame, the FLG reduces downtime due to its simple adjustment and alignment. Adjustable sensitivity, dynamic and static operating modes, and pulse lengthening features provide additional application exibility. Units are enclosed in a rugged metal housing and include an adjustable pushbutton lock that protects against unwanted parameter adjustments during operation. Options include closed- and open-side designs for applications that require counting small parts on conveyors, ensuring parts are ejected from stamping or presses, detecting feeder parts on machines, or pick-to-light part selection. Sick
www.sickusa.com
Input #207 at www.controleng.com/information

www.controleng.com

CONTROL ENGINEERING MAY 2013 77

software &

PRODUCTS
Compact ac drive for open- and closed-loop applications up to 30 hp
Rockwell Automations AllenBradley PowerFlex 525 ac drive to help machine builders and end users simplify equipment design, operation, installation, and conguration. The drive family features a modular design in power ranges from 0.5 to 30 hp (0.4 to 22 kW) at 100 to 600 V input. Embedded EtherNet/ IP, safety, USB programming, energy savings, and a variety of motor control options are designed for machine-level and stand-alone applications or simple system integration. Suitable for a wide range of applications, including conveyors, material handling, compressors, fans and pumps, the PowerFlex 525 AC drive provides a variety of motor control options to accommodate openand closed-loop applications. Rockwell Automation
www.rockwellautomation.com
Input #209 at www.controleng.com/information

Four-channel sound and vibration data acquisition module for IEPE sensors
Data Translation, Inc., has released its DT9839 USBpowered module for sound and vibration measurements. The unit features a four-channel, 16-bit delta-sigma analog-to-digital converter (ADC) with a nominal input range of 2.5 V, and sampling rates up to 52.7 kHz per channel. Applications that require accelerometer, vibration, noise, or sonar measurements often use IEPE sensors. IEPE conditioning is built-in to the analog circuitry of the DT9839, providing an excitation current source and ac or dc coupling. Data Translation devices include comprehensive driver and software support, and interface tools for National Instruments LabVIEW and MathWorks MATLAB programmers. Data Translation
www.datatranslation.com
Input #208 at www.controleng.com/ information

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Input #100 at www.controleng.com/information

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ABB Inc - Safety Systems. . . . 27. . . . . . . 15 . . . . . www.abb.com/highintegritysafety Allied Electronics . . . . . . . . . . 11 . . . . . . . . 8 . . . . . . www.alliedelec.com AutomationDirect . . . . . . . . . . C2 . . . . . . . 1 . . . . . . www.automationdirect.com Baldor Electric Company . . . . 9. . . . . . . . . 6 . . . . . . www.baldor.com Beckhoff Automation LLC. . . . 38. . . . . . . 21 . . . . . www.beckhoff.com Control Engineering Case Study Database . . . . . . . 45. . . . . . . . . . . . . . . www.controleng.com/csd Control Engineering E-Newsletters . . . . . . . . . . . . . 39. . . . . . . . . . . . . . . www.controleng.com/newsletters CSA Group . . . . . . . . . . . . . . . 29. . . . . . . 16 . . . . . www.csagroup.org Danfoss . . . . . . . . . . . . . . . . . . 1. . . . . . . . . 2 . . . . . . www.envisioneering.danfoss.com/industry Dataforth Corp . . . . . . . . . . . . 10 . . . . . . . . 7 . . . . . . Eaton Corp. . . . . . . . . . . . . . . . 32. . . . . . . 17 . . . . . Festo Corporation . . . . . . . . . . 34. . . . . . . 36 . . . . . Fluke Corp . . . . . . . . . . . . . . . . 21. . . . . . . 12 . . . . . HELUKABEL . . . . . . . . . . . . . . 35. . . . . . . 18 . . . . . ITSENCLOSURES . . . . . . . . . . 17. . . . . . . 10 . . . . . MathWorks . . . . . . . . . . . . . . . 15. . . . . . . . 9 . . . . . . Mitsubishi Electric Automation Inc . . . . . . . . . . . . 19 . . . . . . . 11 . . . . . Moxa Technologies . . . . . . . . . 3. . . . . . . . . 3 . . . . . . National Instruments . . . . . . . 7. . . . . . . . . 5 . . . . . . Neuroblast, Inc.. . . . . . . . . . . . 36. . . . . . . 19 . . . . . Phoenix Contact . . . . . . . . . . . 23. . . . . . . 13 . . . . . PI North America. . . . . . . . . . . 4. . . . . . . . . 4 . . . . . . PR electronics . . . . . . . . . . . . . 58. . . . . . . 22 . . . . . Sealevel Systems Inc . . . . . . . 44. . . . . . . 23 . . . . . SEW Eurodrive Inc . . . . . . . . . C4 . . . . . . 35 . . . . . Siemens Industry Inc . . . . . . . C1, 25 . . . 14 . . . . . Solutions for Engineers . . . . . 53. . . . . . . . . . . . . . . www.dataforth.com www.eaton.com www.festo.com www.fluke.com www.helukabel.com www.itsenclosures.com www.mathworks.com/accelerate www.meau.com www.moxa.com www.ni.com www.neuroblast.net/custom www.phoenixcontact.com/twe www.us.profinet.com www.prelectronics.com www.sealevel.com www.seweurodrive.com www.sea.siemens.com www.ControlEng.com

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Content For Engineers. Thats 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 in nature or that 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

Turck Inc. . . . . . . . . . . . . . . . . . 37. . . . . . . 20 . . . . . www.turck.com Yaskawa America, Inc . . . . . . . C3 . . . . . . 34 . . . . . www.yaskawa.com Inside Process American Industrial Systems (AIS) . . . . . . . . . . . . . P12. . . . . . 33 . . . . . www.aispro.com Emerson Process Management . . . . . . . . . . . . . . P2. . . . . . . 24 . . . . . www.DeltaVSIS.com/workbook Emerson Process Management Rosemount Measurement . . . . . P10. . . . . . 31 . . . . . www.EmersonProcess.com/SmartWireless Invensys Operations Management . . . . . . . . . . . . . P6. . . . . . . 27 . . . . . www.iom.invensys.com/thinktriconex Load Controls Inc.. . . . . . . . . . P3. . . . . . . 25 . . . . . WWW.LOADCONTROLS.COM RGB Spectrum . . . . . . . . . . . . P7. . . . . . . 28 . . . . . www.rgb.com Ultra Electronics, NSPI . . . . . . P8. . . . . . . 29 . . . . . www.ultra-nspi.com United Electric Controls . . . . . P9. . . . . . . 30 . . . . . www.ueonline.com Winsted Corporation . . . . . . . P11 . . . . . . 32 . . . . . www.winsted.com Yokogawa . . . . . . . . . . . . . . . . P4. . . . . . . 26 . . . . . www.utadvanced.com
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CONTROL ENGINEERING MAY 2013 79

back to

BASICS

Simulators use math to create virtual processes


Complex sets of equations can help designers of processes, objects, or control systems experiment and test solutions without prototypes.
Peter Welander

Imagine these situations:

be that I do everything in simulation, all the steps along the way. I then produce one test prototype, and it works, first time, exactly as we designed it. Thats the whole idea.

An ideal would

Go Online
For more information, visit: www.honeywellprocess.com http://iom.invensys.com www.mathworks.com
80

A designer creates a model of an automotive enclosure on a computer. The computer generates code for a machining center to make the item without any additional programming. An engineer creates a new chemical processing unit for a plant that will make a new product from an existing feedstock. When the new unit is built, it performs exactly as expected. To analyze a piping failure, an engineer uses a combination of finite element analysis (FEA) and computational fluid dynamics (CFD) to identify stresses caused by flowing materials that weakened a welded joint. These are possible because of simulation programs that use complex mathematical processes to create virtual representations of actual objects or processes. Real life is reduced to mathematical relationships expressed in different types of equations. There are dozens of kinds of simulators because there are so many applications and requirements. Typically, each uses one type of mathematical function, which makes a given platform suited to a specific type of analysis. Tony Lennon, industry marketing manager for industrial automation at MathWorks, describes Simulink as a broadly applicable platform for many types of systems. We can model any kind of dynamical system, anything thats described by a differential equation, he says. The mathematics underlying Simulink deals with differential equations. This environment mathematically expresses different types of systems, so it opens many possibilities. You can do thermodynamic systems, mechanical systems, hydraulic systems, electrical systems, and you can approach a problem from a multi-domain point of view. Seldom today do you only have one kind of system. Other platforms are more specifically suited to particular applications, such as chemical processing. Most companies that provide large-scale DCSs also offer a simulation platform that works with the control system. For example, Honeywell Process Solutions has its UniSim Design suite to help users design and optimize process units before theyre built. Engineers can rapidly evaluate the most

profitable, reliable, and safest design, says Rafael Coronel, global business manager, engineering effectiveness for Honeywell Process Management. Estimates suggest that on-site design changes made during commissioning constitute 7% of the capital cost of a project. Simulation enables companies to evaluate the impact of their design decisions earlier in the project. Simulation does not stop when the plant is built. We characterize it as plant lifecycle simulation, says Joseph McMullen, SimSci-Esscor simulation software product marketing manager at Invensys Operations Management. It starts in the design phase with conceptual engineering. In the operating phase we look at start-up and shut down, DCS logic, etc. Then we optimize, but since things change in a process, you eventually come back to the start again.
Other kinds of math

While the systems discussed so far depend on ordinary differential equations, FEA and CFD use partial differential equations to make different and often more complex calculations of fluid behavior or stresses in a structural component. However, this capability comes at a cost. The more complex the calculations, the more computing power and number-crunching time is required. The same applies to model fidelity. Your ability to model a process may depend on determining how much product is going to flow through a specific valve under various conditions. Perhaps its enough to know the flow at a given pressure. Or, you may need to know a detailed picture of turbulences and a cross-sectional flow profile as the liquid moves into the next segment of pipe. These are much different pictures and will require different methods. Ultimately, simulation aims at designing or testing something without actually building it. As Lennon summarizes it, An ideal would be that I do everything in simulation, all the steps along the way. I then produce one test prototype, and it works, first time, exactly as we designed it. Thats the whole idea. ce Peter Welander, pwelander@cfemedia.com

MAY 2013 CONTROL ENGINEERING www.controleng.com

NOTEWORTHY

When our engineers work on a motion project with you, they share everything thats in their heads. Sometimes that means turning over 100 pages of notes, formulas and drawings. Other times, its simply having straight forward conversations. At the same time, Yaskawa customers share their proprietary knowledge because they can trust us. Because we give their challenges a lot of thought. Because when they talk to us, they know we are on their side. Trusting the guys across the table from you with your most important product secrets. Thats noteworthy.

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2013 Yaskawa America Inc.

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