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AUGUST 2013
Vol. 60 Number 8
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28
Features
Courtesy: Siemens UGS PLM Software
40
28 Integration, software advance product lifecycle management

Smarter project designs result from system integration and planning, collaborative software tools, systems-driven engineering, and agile, integrated programming.
36 IT vs. OT: Bridging the divide
Traditional IT is moving more onto the plant floor. OT will have to accept a greater level of integration. Is that a problem or an opportunity?
40 Machine vision boosts quality for mass-produced robotic workcells

Feedback from machine vision adjusts robotic movement and enhances manufacturing quality. Vision-guided robots have greater position accuracy, providing closed-loop control.
EN1 Industrial energy management
EN4 Take charge of your energy bills EN8 Driving a new generation of power plants EN11 Real-time monitoring is critical for sustaining solar PV energy output
CONTROL ENGINEERING (ISSN 0010-8049, Vol. 60, No. 8, 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.
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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 Machines
Starts after p. 43. If not, see www.controleng.com/archive for August.
M2
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M5
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Closing the loop to maintain precise hydrogen pressure

Case study: A programmable electro-hydraulic motion controller improved standard deviations of the discharge pressure distribution by about 70%, helping improve manufacturing productivity in an Alberta EnvironFuels application. A closed-loop controller runs at 1,000 loops per second to optimize tuning and respond more quickly and automatically to changing conditions.
PRODUCT EXCLUSIVE
departments
8 Think Again
Additive manufacturing: Disruption or evolution?
18 Tech Update
Online mass customization for electronic design
10 Product Exclusive
Touchscreen PLC; entry-level micro PLC
20 International
Smart Factory 1.0 is helping Chinas industry to upgrade
12 Application Update
PRODUCTS Combine old and new wireless industrial networks
22 News
Invensys for sale; machine tool optimization; economic gains
14 Machine Safety
NRTL certified convergence of machine control, safety
86 Products
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16 Application Update
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88 Back to Basics
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17 IT & Engineering Insight

Getting the basics right, first
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VIDEO: Visiting the Inside 3D Printing Expo
This months Think Again column discusses how additive manufacturing (3D printing) techniques are changing the face of industry. Read the story online at www.controleng.com to see a video interview with Hod Lipson, conference chair of the Inside 3D Conference and Expo. To go there directly, scan the QR code to the right.
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editorial
THINK AGAIN
Additive manufacturing: Disruption or evolution?
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Either way, 3D printing (additive manufacturing) needs controls, materials engineers, and technologies to increase speed and quality of these rapidly advancing machines.
D printing, also called additive manufacturing, is going to change every aspect of our lives, said Hod Lipson, associate professor, Cornell University. 3D printing technologies can build with stainless steel and titanium, plastics (where 3D printing began), paper, and other materials, including living tissues (still in development), such as printing a new heart valve and a spinal disc. 3D printers use automation and controls, although they could integrate more. Many machines do not have feedback devices, so do not provide closed-loop control. Speed and accuracy of future machines will benefit from skillfully applied automation.
Lipson, author of the recent book, Fabricated: The New World of 3D Printing (John Wiley, publisher) hosted the Inside 3D Printing Conference & Expo in Chicago. Additive manufacturing whether disruptive or merely an evolution, will have farreaching changes, Lipson said. At present, 3D printing, especially useful for product design and prototypes, increasingly is used for custom end products and production runs up to a few thousand. Huge material savings can result. In aerospace machining, perhaps 85% of a titanium block is cut away. Forming the 15% that is needed could save a lot in time and materials. S. Scott Crump, chairman and chief innovation officer, Stratasys Ltd., one of the largest 3D machine companies, said digital part manufacturing produces completed end-user assemblies. He cited a McKinsey Global Institute report from May that said 3D printing could generate an economic impact of $230 billion to $550 billion per
Contributing Contributing Content Content Specialists Specialists

Jeanine jkatzel@sbcglobal.net Jeanine Katzel, Katzel jkatzel@sbcglobal.net Vance Ph.D.,P.E., P.E., Vance VanDoren, VanDoren Ph.D., controleng@msn.com controleng@msn.com Suzanne Suzanne Gill, Gill, European European Editor Editor suzanne.gill@imlgroup.co.uk suzanne.gill@imlgroup.co.uk Frank Frank J. J. Bartos, Bartos, P.E., P.E., braunbart@sbcglobal.net braunbart@sbcglobal.net
3D printing changes everything
year by 2025 in certain applications, the largest from consumer uses, followed by direct manufacturing, and use of 3D printing to create tools and molds. MGI said additive manufacturing revenue increased four-fold in the past 10 years. 3D technologies provide an idea engine to advance the design power of prototyping and provide production without a production line, Crump said. Delta Airlines uses 3D printing to make spare parts. Anyone who makes anything can use 3D printing. We churn out thousands of parts and assemblies daily with a couple of operators. It is clean, efficient, and flexible. We can make a toy in the morning and an airplane part in the afternoon. Bre Pettis, CEO of MakerBot Industries, helped make 3D printing affordable and accessible. On MakerBots Thingiverse.com site, creators have shared 80,000 designs there, half added in the last 90 days. MakerBot users include the NASA Jet Propulsion Lab for a spacecraft heat shield prototype, and an inventor who lost fingers made a Robohand with less hardware, easier cable installation, and easier sizing. Think again, manufacturing is changing quickly; 3D printing is turning our understanding of manufacturing upside down. ce
Marek Marek Kelman, Kelman, Poland Poland Editor-in-Chief Editor-in-Chief marek.kelman@utrzymanieruchu.pl marek.kelman@utrzymanieruchu.pl Luk Luk Smelk Smelk, , Czech Czech Editor-in-Chief Editor-in-Chief lukas.smelik@trademedia.us lukas.smelik@trademedia.us Andy Andy Zhu, Zhu, Control Control Engineering Engineering China China andyzhu@cechina.cn andyzhu@cechina.cn
Ekaterina Ekaterina Kosareva, Kosareva, Control Control Engineering Engineering Russia Russia ekaterina.kosareva@fsmedia.ru ekaterina.kosareva@fsmedia.ru
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At www.controleng.com/archive August, this article has a video interview with Cornell Universitys Hod Lipson on 3D printing advances, photos, and banter from Crump and Pettis quizzing each other, with humor, on multiple topics.
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counters and motion detection, along with PWM outputs for motor control, are available with this newest release. These new I/O connectors are compatible with the current 3.5-in. and 5.7-in. models, providing many new possibilities. As with the current HMC models, these new units are easily configurable with MAPWare7000. The graphic HMC with compact form factor, enhanced communications features, and flexible design, make it a cost-effective solution for most small to mid-sized automation environments. Other features include support for connection of additional PLCs, allowing the HMC to scale to meet the needs of many applications; new sizes, with Ethernet, 32,000 colors: 4.3-in. (480 x 272 pixels), 3 expansion slots; 7.0-in., (800 x 480 pixels), 5 expansion slots; easy setup of screens and ladder logic for I/O controls; all-touchscreen; no membrane keypad; and an IP65/NEMA 4X rating
Maple Systems www.maplesystems.com
Touchscreen PLC has IO, Ethernet

Maple Systems HMC7000 line of Graphic HMCs (human machine controllers) combine a touchscreen machine interface and a programmable logic controller (PLC) into a small robust unit with a variety of I/O connections.
aple Systems expanded HMC7000 line, Graphic HMCs (human machine controllers), combine a touchscreen machine interface and a programmable logic controller (PLC) into a small robust unit. HMCs can be customized with a variety of I/O connections that allow the HMC to interface with most industrial control environments. The HMC7000 Series is now available in two new sizes, each with an Ethernet connection. Like the current models, these new 4.3-in. (photo on left) and 7.0-in. models are rated for Class 1 Div 2, and are cULus, RoHS, and CE compliant. In addition to the two new screen sizes, nine new I/O units have new features, including 16-bit resolution, and high-speed (25 kHz) data transfer. A newly available analog input/output module has 4 inputs, with individually configurable current, voltage, RTD and thermocouple readouts. High-speed input for
Entry-level micro PLCs join controller platform

Mitsubishi Electric adds entry-level Micro PLC to the FX3 Series; FX3S Micro programmable logic controller provides the lowest cost entry into the FX3 PLC platform.
ddressing the demand for high-performance program- Series performance and flexibility traits, built-in high-speed mable logic control in the price-sensitive factory inputs and outputs, available relay outputs, and multiple, builtautomation market, Mitsubishi Electric Automation in communication ports. It has expansion options for commuInc. introduces the FX3S programmable logic controller. The nications, analog, and temperature control. The FX3S can use newest PLC in the FX3 Series of PLCs, the compact FX3S many of the existing programming resources that are available maintains a high level of functionality while offering entry- for other FX3 Series PLCs, reducing setup time. level accessibility, Mitsubishi said. Notable attributes of the The FX3S PLC is designed to handle basic control tasks, FX3S PLC are its flexibility and expandability. It allows users such as simple positioning, analog, and temperature control to choose only the functionality necessary to perform a specific operations. It excels in small, stand-alone applications that application, saving on hardware costs. dont require complex control tasks. The compact PLC is espeExpansion options really set this super flexible PLC apart cially well suited for food and beverage applications, as well as from other entry-level PLCs, said Ben Omura, product mar- material handling, and fan and pump applications for irrigation keting engineer at Mitsubishi Electric Automation Inc. It fills and building automation. Communication options are available a need in the market for a powerful core PLC for RS232, RS485, Modbus, and Ethernet. The with the flexibility to add functionality for a FX3S micro programmable logic controller has Go Online specific application, while meeting budget For more products, see a 3-year warranty and is available now. ce Mitsubishi Electric Automation Inc. requirements, Omura said. The micro PLC pro- www.controleng.com/products www.meau.com vides full function PLC control, with core FX3
10
application
UPDATE
Combine old and new wireless industrial networks

Existing and emerging industrial standards can be used effectively for rugged industrial applications and other hostile environments. Volcano Eyjafjallajkull exploded, but the wireless monitoring network there survived. For extreme wireless performance, watch for IEEE 802.11ad, WiGig wireless, with 60 GHz, 7 Gbit/sec capabilities. Cut the wires.
ts possible to extend existing wireless networks and integrate new technologies and network topologies to improve performance in highly rugged environments. A new pubGo Online lished standard, IEEE 802.11ad or WiGig, seems likely to make a new tri-band Wi-Fi option At www.controleng.com/ archive read this article available soon. Using 60 GHz, the new standard for links to other Fahrion would provide a theoretical maximum througharticles. put of up to 7 Gbit/s. At 7 Gbit/s you could www.bb-elec.com record everything your factory or plant or volcano was doing while simultaneously watching it www.controleng.com/ all live in 1080-pixel HDTV. wireless In December 2009, seismographs at Icelands Eyjafjallajkull volcano report increasing seismic activity that lead to a mid-April eruption so powerful that the volcanos ash cloud shut down air travel for nearly a week. Yet staff members at the Icelandic Meteorological Office collected and analyzing data from their remote devices. How? Hardwired industrial networks can get the job done, but have ranges measured in thousands of meters. Icelandic Meteorological Office workers installed remote cellular modems that networkenabled various sensors via Ethernet, USB, or serial connections and In December 2009, seismographs at Icelands then transmitted the data Eyjafjallajkull volcano started to report a steady via the cellular telephone increase in seismic activity. Remote GPS units network. Solar panels observed spatial displacement. Flow meters and powered the various piecthermometers in the adjacent river recorded a rise es of equipment and backin water level and water temperature. The rugged up batteries (photo); there network continued to function through the eruption. was no need for vulnerThe Icelandic Meteorological Office wireless netable power lines. Eyjafwork with remote cellular modems network-enabled jallajkull exploded, but various sensors via Ethernet, USB, or serial connecthe network survived. No tions and then transmitted the data via the cellular special sensors were needtelephone network. Solar panels powered the varied. Old and new remote ous pieces of equipment and backup batteries, so devices worked via Modthere was no need to rely upon vulnerable power bus or TCP/IP; the cellines. The network survived. lular router was happy to See another photo and more info with this article accommodate. Thanks to online at www.controleng.com/archive, August. media conversion, virtuCourtesy: B&B Electronics ally any data stream from
Mike Fahrion
12
virtually any device can now be integrated into a modern network and transported via the newer media and protocols. Beyond extending the network edge to a volcano, its possible to create network topologies that span the globe. Until recently, cellular networks couldnt serve as a wire replacement in every application. 3G systems could provide for data rates of several Mbit/s, which was very useful. Specifications for the newer 4G LTE standards call for peak data rates of up to 100 Mbit/s for high mobility devices and up to 1 Gbit/s for low mobility devices. Message latency (in the hundreds of milliseconds for 3G) improves to tens of milliseconds over LTE. With that throughput 4G LTE cellular networks can replace long-range cabling. Cellular providers are winding down 2G services to make room for an expected explosion in 4G LTE data networking.
Improvements in Wi-Fi
Cellular networking requires the purchase of a data plan. For local wireless connections its often more cost effective to deploy Wi-Fi, limited until recently by issues like multipath propagation. IEEE 802.11n Wi-Fi standard has multiple-input multiple-output (MIMO) technology using multiple antennas at the transmitting and receiving sides of the wireless connection and splits the data into numerous spatial streams. Now propagation is an advantage. Wider bandwidth and lower power provide additional advantages. Virtual private network (VPN) tunneling authenticates endpoints before the tunnels can be established, and the data is encrypted before it is sent, providing the same functionality and security from a private network. And this is only the beginning. The IEEE 802.11ad or WiGig, could record everything a plant, factory, or volcano was doing while simultaneously watching it all on 1080p HDTV. ce - Mike Fahrion is director of product management at B&B Electronics.
Super-E Motors
Drive Down Your Consumption

Since our beginning in 1920, Baldor has led the industry in developing industrial electric motors that deliver greater performance and reliability while using less electricity. That commitment continued in 1983 with the introduction of our Super-E line of motors. In horsepower ratings from fractional to 15,000, Baldor offers the broadest choice of energy efficient motors available in the world. Every Super-E motor is designed and built to meet or exceed the efficiency levels defined by NEMA in the USA, NRC in Canada and IEC 60034-30 IE3 in Europe. Many years ago, Baldor Super-E motors were recognized by the Consortium for Energy Efficiency as the first premium efficiency motor line to meet their stringent criteria. And, every Super-E motor meets the compliance standards for the Energy Independence and Security Act of 2007, which became law in December 2010.
To achieve even greater energy savings, adding an ABB or Baldor industrial variable speed drive can dramatically reduce the motors energy consumption while improving process control and reliability for any application. On centrifugal load applications like pumps and fans, reducing the motor speed with a variable speed drive can save as much as 60% in electricity costs! Visit baldor.com and start lowering your energy costs today.
Driven to Save You Money

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Quality Is in the Details

Super-E premium efficient motors represent quality to the highest degree. Look inside a Super-E and youll find premium-grade copper windings, annealed laminations of superior-grade steel, premium bearings and low-loss fans, enabling Baldors Super-E motors to run cooler, quieter and longer with better reliability than any other industrial motor.
2013 Baldor Electric Company
baldor.com
Made in the USA
machine
SAFETY
NRTL certified convergence of machine control, safety

Does a Nationally Recognized Testing Laboratory (NTRL) certify machine control systems? OSHA has identified 15 organizations qualified to test and certify products for use in safety applications for the U.S. workforce. Better machine safety can reduce downtime.
o what the devil is a NRTL, and does device, someone would jumper that device out it actually certify machine control sys- of operation. After some lengthy unplanned tems? How does it impact our busi- machine downtime, production was ultimately ness? NRTL (Nationally Recognized restored but safety was de-activated. Testing Laboratory) is a term established by Continuing in 2002, NRTL certified safety OSHA that identifies 15 organizations quali- PLCs were introduced to U.S. manufacturing. fied to test and certify products for use in safety A new option for safety compliance became applications for the U.S. workforce. available called safety automation. In the last The background I have witnessed is captured 12 years safety automation also has evolved, in the graph shown. OSHA was following the general automaJ.B. Titus, CFSE, created by an act of Congress tion trend line discussed above. Theres a direct Certified Functional in 1971. Within approximately These technological advanceSafety Expert (CFSE) 18 months, programmable ments have allowed safety link between logic controllers (PLCs, also automation and general automachine safety and called automatic sequencers) mation to converge into one productivity. were introduced to manufacplatform. Hardwiring everyturing for machine control. thing for safety is no longer At the beginning of their life, the only option. When it makes PLCs were highly unreliable. Thus, the brand- sense in an application, safety automation is also new OSHA regulations and established safety an acceptable option for safety compliance. standards quickly wrote normative language A business case analysis approach is availrequiring everything safety to be hardwired. able for manufacturers considering the total In my opinion, these divergent approaches cost of ownership for a layered versus integratcaused a layering effect in a machines control ed machine control architecture. For example, architecture. the cost of unplanned machine downtime typiPLCs quickly evolved through the 1970s, cally goes directly to the bottom line. Therefore, 1980s, and 1990s with rapid increases in reli- reducing unplanned machine downtime by as litability, advances tle as 4% can generate huge incremental profits. in technology, and A recent Aberdeen Group study shows a direct adoption through- link between machine safety and productivity. out manufacturing. Is a converged solution your best choice? ce The divergence in -J.B. Titus, Certified Functional Safety Expert technology of gen- (CFSE), writes the Control Engineering Machine eral automation and Safety Blog. Reach him at jb@jbtitus.com. hardwired safety on a machines archiGo Online tecture resulted in Engineering interaction: Go to this blog at huge amounts of www.controleng.com/blogs to link to related articles: unplanned machine OSHA NRTL (Nationally Recognized Testing downtime. One Laboratory) piece of collateral Machine Safety: Managing operational risk damage related to Aberdeen Group - Operational Risk Management, Machine control technology landscape and this phenomenon November 2012 machine safety have changed significantly since was that after find- Machine safety: Functional safety and the steps to be 1970. Courtesy: J.B. Titus & Associates, CFE Media ing the failed safety compliant in the U.S.
used with permission

14
2010 The MathWorks, Inc.
Q
Find it at
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UPDATE
Robotics boost accuracy, flexibility for automated test machines

Amber Precision Instruments augments speed and quality with 6-axis robot to replace a slow, inaccurate gantry motion subsystem. Setup time fell from 1 week to 1 day.
obotics helped with electromagnetic compatibility (EMC) testing and compliance, needed for successful electronics design prior to releasing a product to market. Amber Precision Instruments (API), headquartered in Californias Silicon Valley, recognized it needed a faster, more precise motion control solution. In 2006, the developer of small-scale EMC test stations used a vertical X-Y gantry motion subsystem incorporating stepper motors, worm gears, and custom-made parts. The multi-vendor design was complex to set up and program, and also was noisy and slow in operation. The mechanical design posed inherent challenges to wiring and final assembly, and the resulting system saw limits to accuracy,
Mitsubishi Electric Automations technical sales support and field engineering services in North America helped in APIs decision to purchase the vertically articulated 6-axis RV-3SD for its SmartZap ESD test station. Partnering with Mitsubishi Electric has played a role in improving APIs credibility with current and prospective clients by offering an attractive solution that resolved related engineering issues and provided a 2-year warranty. Mitsubishi has automation, service, and support centers globally. Courtesy: Mitsubishi Electric Automation
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reliability, and performance. Although Go Online APIs proprietary measurement softwww.meau.com ware provided a powerful toolset, the mechanical system was not optimized and would not accommodate anticipated technical growth requirements, including TACT (turn around cycle time) and DUT (device under test) sampling resolution.
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Amber Precision Instruments is a private corporation that manufactures EMI (electromagnetic interference) and ESD (electrostatic discharge) scanners to help electronics suppliers comply with EMC regulations and directives. Samsung, LG, and Intel are among APIs Tier 1 customers. When API began researching methods to improve machine accuracy and reliability in late 2009, the engineering team turned to robots. The cost savings from reduced installation and programming times would help offset the upfront cost of robots as a sub-system. Streamlined multi-axis control adds accuracy for customers. In early 2010, API purchased a vertically articulated 6-axis robot for its SmartZap ESD test station. The stand-alone robot provided a test replacement for the complex X-Y gantry system. The fully automated SmartZap uses 5 cameras to define the DUT geometry (typically a PCB, mobile phone, or tablet) allowing software to calculate 3D points for testing. The robot, with TCP/IP communication, receives discrete move commands from the software to position an ESD gun or finger emulator to locations on the DUT. The result is a comprehensive data map with local ESD characterization information. Using the robot technology improved accuracy and repeatability and helped reduce machine setup time from 1 week to 1 day. ce - Edited by Mark T. Hoske, content manager, CFE Media, Control Engineering, mhoske@cfemedia.com.
16
AUGUST 2013 CONTROL ENGINEERING
Pushing machinery to do the extraordinary.
Energ outperform any a
SmartWire-DT Eatons SmartWire-DT is an innovative solution that reduces panel complexity by consolidating circuit wiring into a single 8-pole cable. Cutting installation time and costs dramatically.
gizing manufacturing to auto production assembly on earth.
Follow the Charge

Powering an auto plant for maximum output with minimum installation time.
When a high-end German auto manufacturer posed the challenge of expanding its existing operation in China, we leapt at the opportunity. A newly designed conveyor system had to be powered to transfer auto bodies to multiple welding stations. As well as integrate into the existing plant automation structure. The complexity of the project inspired us. A tremendous number of signals had to be processed across multiple stations. Motor drives and sensors had to be monitored and controlled centrally. The system had to be tuned to intricate quality control algorithms. Over 1200 motors had to be protected. This was no ordinary project. It demanded extraordinary thinking. Eatons custom solution started with revolutionary SmartWire-DT technology. SmartWire-DT makes traditional point-to-point wiring obsolete. It also enables conventional motor control to be incorporated into systems effortlessly. SmartWireDT cuts wiring effort by more than 60%. Which in turn cut the projects installation time by 22 business days. By looking beyond the now, Eaton powered the conveyor system with never-before-seen exibility, efciency and speed. As well as awlessly integrating into the existing plant automation structure. Looking into the future, the auto manufacturer is looking to Eaton to energize more innovative power management solutions for even greater productivity.
Eaton.com/followthecharge
2013 Eaton. All rights reserved.
Energizing machinery for flawless automation down to the finest filament.
Follow the Charge

A toothbrush may be a simple thing. But consistently producing over 1 million toothbrushes a day is a complex feat in a hands-free automation environment. Thats why M+C Schiffer, an innovator in toothbrush production, counts on Eaton to provide 100% reliable control and automation technologies to drive success. At Eaton, the challenge and intricacy of totally handsfree automation inspire us to think beyond today. To design solutions that keep M+C Schiffer ahead of the industry. Our XP700 operator interface, combined with the XV102 HMI/ PLC, provides powerful functionality and dependability for awless control over precisely coordinated production. While Eaton software provides real-time visualization and seamless project designing. M+C Schiffer consistently meets the exacting production standards of global leaders such as Johnson & Johnson Reach and Procter & Gamble Oral-B. Because Eaton anticipates tomorrows needs today.
Eaton.com/followthecharge
2013 Eaton. All rights reserved.
INSIGHT
IT & engineering
Getting the basics right, first

Proper infrastructure, policies, and procedures for manufacturing IT are critical groundwork before applying the latest technologies to manufacturing.
any new technology gadgets can help manufacturing companies, such as smartphones, tablets, near field communication, big data analysis tools, 100MB wireless networks, and virtual systems. However, using these new technologies requires that a company gets the IT basics right, first. In too many companies there is a rush to apply a new technology when the basic IT infrastructure is broken or incomplete, and there are no effective policies and procedures in place. If it takes months to deploy a simple new server with COTS (commercial offthe-shelf) software and requires the approval and support from dozens of architects without manufacturing IT experience, then you probably dont have the basics right.
Nonbusiness attention
from business systems. When the IT support staff is five or more, most companies find it better to designate one or more manufacturing IT specialists within the IT group. For this size organization, the basics also include development of standards for manufacturing IT assets and training in the HMI, data historians, industrial networks, MES systems, and batch control systems used in the facility.
Support level agreements
Many IT departments are forced into the role of gatekeepers, preventing anything but previously approved applications and systems from being installed. The IT organization must support the entire company, and it needs control in order to provide timely support. This means that nonbusiness users and systems often have lower priority than financial and customer facing users and systems. R&D, manufacturing, laboratories, warehousing, and plant maintenance are often not considered as critical as e-mail and office applications. This often happens when management considers manufacturing as a distraction to the business, and something that it really wishes could be done somewhere else. In these cases, it is important to educate upper management of the dependency of the nonbusiness systems on information technologies. Getting the basics right is different for different size organizations. Small organizations with only a few IT support staff, often three or less, usually have automation engineers handle IT issues. In these cases getting the basics right means keeping track of all manufacturing IT assets in a database (but a spreadsheet can work), providing written policies that define the documentation that must be updated when any change is made to an IT asset, and providing a segmented network to isolate critical control equipment
For large manufacturing companies, manufacPresident of BR&L turing specialists in IT support are usually about Consulting 10% to 20% of the IT staff. A company is missing the basics if there are no designated manufacturing IT specialists and no separate support contacts for manufacturing IT. The larger the support staff is, the more a manufacturing-specific support level agreement (SLA) is needed. Many IT organizations set a five-day maximum response time SLA for nonproduction Ensure your company gets the basics related problems right, then take advantage of the latest and an eight-hour response time for manufacturing IT technologies and the production problems. The same improvements they can bring. SLA applies if the fix takes minutes or days. Unfortunately, this often turns into a five-day or eight-hour minimum, where the problem is not even looked at until the SLA maximum is reached. This means that a five-minute fix may take a week to get implemented. Getting the basics right is critical. Without the proper infrastructure, policies, and procedures for manufacturing IT, it becomes difficult or impossible to apply the latest technologies into manufacturing. Make sure that your company is getting the basics right, first, and then you will be in a position to take advantage of Go Online the latest technologies and the improvements that they can bring. ce At www.controleng.com/
Dennis Brandl
- 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.
www.controleng.com
archive, find more under this headline. At www.controleng.com search related topics.
technology
UPDATE
Online mass customization for electronic design

Geppetto software from Gumstix enables the long tail of electronic devices. Users with basic computer knowledge can design every detail of a customized board, without prior framework restrictions.
Dr. W. Gordon Kruberg, Andrew Simpson
Go Online
www.gumstix.com http://geppetto.gumstix.com
Harry Potter books iPhone Products sales
ass customization at some level has become reality in virtually every industry, from shoes to books to automobiles. In certain markets, products have become easy enough to build in custom fashion: photo albums and books, business cards, and banners have each developed the tools to let anyone design and manufacture (print) a small run of their own design at low cost. Such designs are uniquely attractive, meaning one individual wants the design and full production run (your holiday photo album, affordable, in glossy magazine quality). Customers can design and order their products, often directly from the manufacturer, which produces a unique product, on-demand, and delivers it to the customer. Manufacturers like Nike (with NIKEiD) and the Ford Motor Co. can leverage existing supply chains and manufacturing capabilities to deliver a greater, though limited, number of affordable, customized products to their customers. Tools and technologies used to create customized electronic devices are very new. Electronic devices are ubiquitous today, but the design and manufacture of a personal, custom-shaped, cellphone has been beyond the understanding of the average customer. While some superficial customization might be within reach, design from the ground up certainly has not been.
Electronic designs
Your family photo album
provides. Until now, this was the closest an electronics manufacturer had come to enabling mass customization of electronic devices. The potential for customization that Dell provides, however, is limited because configure-to-order isnt design-to-order. The customer can only select from standard frameworks in choosing the model and the components used: which processor, how much memory, what size of hard disk, etc. Many aspects of system design remain beyond customer control and customization, from simple LED indicators to the number of USB ports. Aftermarket add-ons are possible, but not affordable, customized embedded computers. Dell imposes limits with its PC Configuration Utility. The cost of designing and manufacturing a custom motherboard for one customer would be tremendous. To accomplish this, an OEM would have to assign an electrical engineer to design the necessary circuits, have a PCB specialist to efficiently lay out the schematic, and contract a manufacturer to produce the finished product. In 3 months, the OEM would have the custom motherboard ready to receive components and be shipped, with a price tag reflecting time spent on its singular design. The PCs produced have one of the best supported, standard architectures, guaranteed to work out of the box. Embedded computer users are almost guaranteed to incur another layer of customization (and cost) in creating or adapting software to run custom device hardware.
Expansion boards
Products sorted by decreasing sales
Figure 1 shows the long-tail effect applied to product design. Products on the left offset development costs by selling a large number of units. Lower volume products have either high development costs or are lower cost items.
18
The configure to order model pioneered by Dell is one approach to mass customization: Dell customers can configure many aspects of their computers but must work within the framework that Dell
Gumstix Inc., based in the Silicon Valley, manufactures Linux-based computers-onmodule (COMs) slightly smaller than a stick of gum. COMs, at the heart of embedded systems, use expansion boards to break the COM into standard connectors. Gumstix expansion board designs are open-source so the engineer can expand features by building on the COM framework. This enables an OEM to design many embedded devices at very low cost. Providing essential computer functions on the COM elimi-
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Figure 2 shows the Gumstix Geppetto user interface (UI), which demonstrates drag-and-drop board design and preview features. Figures courtesy: Gumstix
nates the most difficult part of designing a device. With opensource hardware, users are free to build on existing designs and create conventional customized boards with desired features. Designing an expansion board requires knowledge of electrical engineering and embedded systems design, even with the schematics of an existing one as a guideline. After design and layout of an expansion board, manufacturing requires logistics management, especially electrical components within the supply chain. Costs are associated with each step from design to delivery. As a result, low-cost, mass customized electronic devices have remained well out of reach.
Electronic design applications
Gumstix Geppetto is an electronic design application (EDA) that allows a customer to leverage existing manufacturing capabilities to customize electronic devices built around COMs. The most difficult part of any embedded design process is creating a functional design that meets specifications. EDAs do exist that can automate some associated tasks, but users must create schematics and breadboards using their knowledge of electronics. For mass customization and manufacturing, a powerful, flexible, and intuitive design tool is needed to simplify as much of the electrical design process as possible. The web application focuses on fulfillment of specifications using drag-and-drop modules representing typical electronic components and mechanical features. All low-level routing is automatically completed behind the scenes. The software will alert users to modules that have not been properly connected or that are missing other modules required to ensure proper functionality. Users with basic knowledge of computers can design a customized device, free of the prior framework restrictions. The software removes a lot of tedium related to electronics design. The application targets electronics designers, from OEM professionals to hobbyists for prototyping. Easy customization removes the final barrier to mass customization for electronic devices: Users no longer need to know exactly how a computer works at its lowest levels to design one. The software lifts the burden of supply chain management from electronics designers. Completed designs can arrive in about 3 weeks, compared to the 3-month traditional board design. Accessibility in design, rapid time to market, and affordability make the long tail of electronic devices a reality. ce - Dr. W. Gordon Kruberg is president and CEO, and Andrew Simpson is content developer of Gumstix Inc.

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INTERNATIONAL
Smart Factory 1.0 is helping Chinas industry to upgrade

Chinas Smart Factory 1.0 proposes that domestic manufacturing equipment should provide digitization and networking, with the third generation of research and development, facilitating concept, innovation, virtual simulation, and rapid prototyping.
Henry Qiao
Consider this
With China stepping up interconnectivity and digitization efforts, should other areas of the world do the same?
uilding on the Industry 4.0 concept, discussed heavily at the 2013 Hannover industry exhibition and proposed by Germanys government, China has been working on an innovative industrial model called Smart Factory 1.0. Some automation companies, research institutes, and system integrators are working to define this innovative industrial model for Chinas manufacturing, to meet the demands of Chinas industrial reform. A group of companies, including Beckhoff Automation, Elco, and E-Cube, are actively involved in the concepts definition and promotion. The Smart Factory 1.0 concept has proposed a realistic specification for equipment manufacturers and terminal factory users of China. For equipment manufacturers, Smart Factory 1.0 proposes that domestic manufacturing equipment provide digitization and networking, with the third generation of research and development, continuing the steps of concept, innovation, virtual simulation, and rapid prototyping.
tion. Smart Factory 1.0 also suggests that an energy efficiency management system for production equipment and production materials and predictive maintenance should be used as soon as possible. In China, industrial reform often depends on government guidance and the needs of industrial users. Smart Factory 1.0 fits with each. While industrial intellectualization and information integration is the main focus of government industrial policy, domestic equipment manufacturers and factory users are seeking more competitive and economic solutions to cope with increasingly fierce competition.
Practical implementation
Multiple motors with direct drive, industrial Ethernet, smart sensors, modular hardware, and software also should be widely used in manufacturing equipment. Safety, remote monitoring and diagnosis, and optimization of energy efficiency should be supported. For end users, Smart Factory 1.0 proposes using digital network equipment, achieving widespread integration of the automation system of the workshop level and the on-site level. It also proposes interoperability and informaThe Smart Factory 1.0 exhibition area at the tion standardization Industrial Automation Beijing 2013 exhibition. Courfor major equipment, tesy: Control Engineering Chin and flexible produc20
Smart factory technologies
Unlike Industry 4.0, Smart Factory 1.0 is not focusing on the most advanced technology but on the practical implementation of existing leading technologies as needed by industries in China. Despite all the automation technologies introduced into the Chinese market for many years, there are big differences in how industries and enterprises apply those technologies. At the Industrial Automation Beijing 2013 exhibition, Smart Factory 1.0 was shown as an important development. As one of the major promoters of the concept, Jian Wang, the general manager of E-Cube, said, We hope more people and enterprises can understand and accept the Smart Factory 1.0, so they can gain actual economic benefits and high efficiency, and more easily connect to international technology trends. ce - Henry Qiao is an editor, Control Engineering China. Translation from a recent edition of CE China was edited by Mark T. Hoske, content manager, CFE Media, Control Engineering, mhoske@cfemedia.com.
Go Online
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MONTH 2013 AUGUST 2013CONTROL CONTROLENGINEERING ENGINEERING www.controleng.com www.controleng.com
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industry
NEWS
In separate news, Invensys acquired the SmartGlance mobile reporting product of Sarla Analytics LLC, a privately held company headquartered in Barrington, R.I., Invensys said on June 13. Courtesy: Invensys
Invensys for sale: Schneider Electric offers $5 billion

In July Schneider Electric said it is in talks to acquire Invensys, a supplier of industrial software, systems, and control equipment to major industries, for a reported $5 billion. The deal, if successful, would enhance Schneiders position in the industrial, building, and data center markets. On July 12, an industry analyst said the proposed acquisition would create a more powerful industrial automation company and enhance Schneider Electrics position in the commercial and residential building automation markets. Major Invensys brands are Avantis, Foxboro, InFusion, SimSci, Skelta, Triconex, and Wonderware. Frost & Sullivan Industry Manager Konkana Khaund said the industrial business of Schneider Electric... would be the prime beneficiary from such an acquisition, given Invensys core competencies.... But it is hard to ignore the imminent implications this could have on Schneider Electrics buildings, residential and data center businesses. Invensys is based in London; early discussions have centered on how U.K regulators might view the proposed deal. Bloomberg.com reported that Emerson, the St. Louis-based technology company which had previously
pondered a deal for Invensys, also may look to make a counter-offer. Paris-based Schneider Electric officials confirmed interest in Invensys in a July 7 press release, saying discussions are in the early stages. Schneider Electric said acquisition interest centers on the attractive industry automation sector. The enlarged group would significantly expand its access to key electro-intensive segments where Schneider Electric offers leading low and medium voltage as well as energy management solutions. It would also gain a leading position in the fast-growing software business for industrial operational efficiency. That matches Schneider Electric strengths, said Khaund from F&S. Schneider Electric has repositioned
Additive manufacturing is ripe for automation innovation

Speed and precision of 3D printing will increase with application feedback devices and more accurate motion control. Additional material and metallurgical engineering expertise will advance the complexity of materials and integrate printed electronics, reducing need for assembly. Brian Evans, assistant professor, Metropolitan State University of Denver, brought this desktop 3D printer to Inside 3D Printing, Chicago, July 10. See the microphone next to it for size reference. Also see Think Again. Courtesy: CFE Media
22
to be recognized as a global leader in energy management, security, high performance buildings, smart homes and smart cities, Khaund said. In a July 15 report, research firm IHS Inc. said the strength of Invensys in the industrial automation and oil and gas markets makes it an attractive target. This especially is true in the distributed control systems (DCS) market. Invensys accounted for 6.5% of the global DCS market in 2012, which was estimated at $16.8 billion, IHS said. This acquisition would catapult Schneider Electric into the sixth spot in the DCS market and... enhance the companys opportunities in selling its automation goods, including distribution products, into the rapidly growing oil and gas and the refining and petrochemical industries. IHS cited ABB and Siemens as other possible contenders; they combine for 30% of the global DCS market revenue; it also mentioned General Electric. Speculation on the proposed acquisition centered on Schneider Electrics desire to position itself against larger rivals. The Wall Street Journal mentioned Siemens, Rockwell Automation, and Mitsubishi Electric among key rivals. Other major automation companies include Eaton, Honeywell, and Yokogawa, among others. - Bob Vavra, content manager, CFE Media.
2013
GLOBAL SMART MACHINE SAFETY NETWORKS COMPANY OF THE YEAR AWARD
2013 Siemens Industry, Inc.
Save up to 30% in total cost of ownership with SIMATIC Safety Integrated

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Safety Integrated from Siemens is a comprehensive solutions portfolio to effectively meet ever-increasing demands for functional safety in machines and plants. Benefits include: Consistent implementation of proven safety technology by blending seamlessly into Totally Integrated Automation, the comprehensive Siemens system architecture for all automation tasks. That means: One system for standard and safetyrelated automation, one engineering tool, one network for standard and fail-safe communication. Diagnostics of the highest level which help reduce downtime and increase productivity. Long-term investment security and a competitive market edge due to greater reliability, upward system integration and compatibility with safety software and hardware. When you add it all up, Safety Integrated amounts to significantly lower initial and operating costs including a reduction in total cost of ownership of up to 30%. These benefits and our continuous innovations in products and solutions, have made us the global leader in Safety.
Answers for industry.

industry
NEWS
to the MES or ERP system to see how machines are working. As a result, we can increase efficiency of machines up to 50%. In 10-15 years, we are talking about self-optimization of machines. We are on our way. The international machine tool market has more than tripled in the past 20 years up An integrated workpiece measurement system, with a to 2012, EMO said, measurement accuracy of 30 nanometers deployed in the to around $85 billion. worlds biggest precision optics machine, Siemens said, Since 2000, machine allows the production of telescopes capable of seeing up tool consumption (in to 13 billion light years into space. Courtesy: Siemens dollars) has grown almost 7% annually on average. Asia asset situation of many Americans, and was the main driver, where in 2012 the high demand for vehicle replacetwo-thirds of total worldwide machine ments, said EMO officials, with a annutool production output was consumed. al growth rates of 4% to 6% in the U.S. EMO officials said machine tool con- medical technology segment. Europe sumption will increase in 2013 by 8% holds a machine tool market share of to about $92 billion. 42% and is an important growth area Growth is expected to extend to the for U.S. manufacturers. 2013 EMO is U.S. with the significantly improved Sept. 16-21.
NEWS NOTES:
Machine tool optimization:
Future machines will talk to other machines, systems

Manufacturers are standing on the next of the next major step in efficiency with improvements in machine tool optimization, said Siemens officials on Monday, July 29, in advance of the EMO machine tool show in Hannover, Germany, in September. More integrated, self-optimizing future machines will be 50% more efficient. The whole world over, the industrial sector is facing major challenges, said Dr. Wilfried Schfer, executive director of the EMOs organizer VDW (German Machine Tool Builders Association). Drivers in the machine tool market are to boost efficiency and energy efficiency, reduce time to market and increase machine flexibility, said Bernd Heuchemer, global VP of marketing and communications for Siemens AG, drive technologies division, motion control systems business. Product design and production design are growing closer to increase machine productivity, said Heuchemer. [See cover story, this issue.] Heuchemer expects shop floor machines will be interconnected and
Automation industry continues growth

While steady growth is noted, control system integrators continue to wait for a reacceleration in operating environment, according to a recent survey of Control System Integrator Association (CSIA) members by J.P. Morgan. After a steady slide in order momentum that began in mid-2012, system integrators were optimistic that delayed projects would return in 2013. Signs of stabilization began to appear late in 2012. This looks to us like a gradual improvement, but still not a wholesale release of pent-up demand, said C. Stephen Tusa, Jr., CFA, J.P. Morgan Securities LLC. According to the survey results, anticipated growth goes from the 2% to 3% range to the 4% to 5% range over the next year, a degree of acceleration greater than implied in the December survey of CSIA members. We do not see any signs of incremental deterioration. This dynamic reinforces what we heard from our trip to the Hanover Fair, where weakness is isolated to a few pockets regionally and by end market, Tusa said. Strongest end markets for system integrators are auto, oil and gas, power and energy, and industrial OEMs. Water/wastewater, building automation and defense remain weak. J.P. Morgan surveys CSIA members twice a year to gauge demand for automation products and services. System integrators are a crucial link in the sales channel of automation-related equipment, with a focus on capital projects that require a high degree of technical engineering, said Bob Lowe, executive director of CSIA. The next survey will be conducted in September 2013. www.controlsys.org
24
Optimism, consortium, merit, appreciation

The 2013 McGladrey Manufacturing & Distribution report said U.S. manufacturing growth continues; concerns remain about the global economy and over regulation. 10 companies formed the Facility 450 Consortium for better fabrication of 450 mm semiconductors. Merit: AutomationDirect, Radio Shack, VEX, and the Boy Scouts of America began the software Programming Merit Badge. After a Vecoplan food charity donation, an engineering major NASCAR driver of #23 Vecoplan Ford Mustang toured Vecoplan and noted appreciation for high-tech biofuel and bioenergy products.
Developing Advanced Communications for Automation
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How to Design Networks for Plant-wide Communication

Learn how an integrated zone cabling plan can slash network deployment time up to 75%, cut down on material and labor costs, and allow for future expansion.
As rapid advancements in networking, computing, data storage and software capabilities increase the value of automation systems, engineers are under pressure to refresh machine and plant-wide system designs with solutions that merge information and control data. To address this challenge, validated architectures and tested physical solutions that integrate information and control systems are growing in importance. To get connected globally into industrial operations, users need validated logical diagrams of the functions in the network and the interface with enterprise systems. This logical networking architecture, developed by Rockwell Automation and its Strategic Alliance Partner Cisco, is commonly known as the Converged Plant-wide Ethernet (CPwE) Design and Implementation Guide. This reference architecture describes the connectivity between the enterprise and industrial zones at a logical level. Figure 1.
Key within the logical architecture is the identification of communications pathways from the Level 3 Site Operations to Levels 0 2 associated within Cell/Area zones on the plant floor (see Figure 1). The physical layer architecture is the infrastructure required to achieve connectivity that addresses data throughput, environment, wiring distances and availability. A structured, engineered approach is essential for the physical layer to ensure that investments in network distribution deliver optimum output.
Making the Right Connections

For physical architecture network support, Layer 3 switching is typically deployed in the Level 3 Site Operations (industrial data center). Layer 2, or direct physical connections, are made into zone enclosures or control panels, or are connected directly to equipment located within the Cell/Area Zone plant floor. The physical environment of plant-floor equipment and the distance away from the control room, which acts as an interface to the Level 3 Site Operations, determines the characteristics of the cabling solution needed. Assess environmental risks by leveraging TIA 568-C.0 Generic Telecommunications Cabling for Customer Premises, Annex F: Environmental Classifications.
Internet External DMZ/ Firewall Enterprise WAN
Enterprise Zone Levels 4 and 5 WAN and Internet network Data Centers Enterprise Security and Network Management Enterprise Resource Planning (ERP) Applications
CPwE Logical Framework
Enterprise WAN Routers Demilitarized Zone (DMZ) Patch Management Terminal Services Application Mirror Anti-Virus Server Access Switch Firewall (Active) Firewalls for segmentation Unified Threat Management (UTM) Authentication and authorization Application and Data Sharing via replication or terminal services Manufacturing Zone Level 3 Layers 2 & 3, Access, Distribution and Core Network Infrastructure Site Operations and Control Multi-service Network Routing Security and Network Management Applications Cell/Area Zone Levels 02 Layer 2, Access Network Infrastructure EtherNet/IP traffic Real-time Control Traffic segmentation, prioritization and management Resiliency with fast Network Convergence
253586
Link for Failover Detection
Firewall (Standby)
Stacked Layer 3 Access/ Distribution Switch FactoryTalk Application Servers
Core Switches
Network Services
Remote Access Server
Stacked Layer 3 Distribution Switch
Layer 2, Industrial Ethernet Access Switches
HMI
VFD Controller Cell/Area (Ring Topology)
When determining the cable solution, consider the mechanical, ingress, climatic and electromagnetic (MICE) conditions. This ensures the entire cable protection scheme cabinets, pathways, grounding/bonding and cable selection is appropriate for the environmental hazards present. Traditional structured cabling deployed in CPwE automation networks involves multiple horizontal copper runs all the way from the Level 3 control room to each automation control panel within the Cell/Area Zone. This type of cabling is also called a home run. For very small deployments, this approach works fine. But in many environments, traditional structured cabling can mean hundreds of lengthy copper cables that are difficult to manage, present electro magnetic interference (EMI) susceptibility challenges, become virtually impossible to change, and are arduous to remove when complying with building codes that require removal of abandoned cable. On the plant floor, traditional structured cabling is routed from the micro data center (MDC) to a control panel or zone box containing active equipment. Alternatively, a zone cabling approach involves a logically placed connection point in the horizontal cable, routing it from the MDC to active zone boxes. Shorter cable runs then extend from the zone box to each device in that zone (see Figure 2). A number of factors must be addressed when connecting the Cell/ Area Zone to the Level 3 Site Operations control room. Users must decide on architectures, physical media and connectivity to distribute networking thats cost-effective while ensuring enough flexibility, environmental ruggedness and performance headroom to hold up to current and future manufacturing needs.
Figure 2. Zone Architecture Benefit
Long-Term Benefits
Validated logical to physical network systems can help remote users manage productivity and profitability. With such a system, users can access real-time data on machine operations and take necessary action if pre-assigned metrics arent met. Plant-wide communications become more efficient and future ready as users migrate proprietary plant-floor networks to a single network technology using the EtherNet/IP open protocol. Whether users are updating existing systems to meet growing information demand needs or planning plant expansions, the amount of development and implementation rework time can be costly. Implementing validated solutions in the physical design of a network system can reduce your deployment time by up to 75%, ensuring that optimum performance and reliability of your networks physical design are obtained. This helps maximize uptime and reduces costs associated with problem solving and network downtime.
Integrated Network Zone Systems

In applications where switching equipment is used on the plant floor, its necessary to place the switch in a protective zone enclosure. The zone enclosure also houses other ancillary equipment required for the switch, such as an uninterruptible power supply (UPS), copper and fiber connectivity. Following a zone topology allows a highly scalable and flexible physical deployment of the CPwE architecture. Managed cabling reduces abandoned cable and the number of home runs throughout a facility, helping make the workplace run more efficiently and safely. An integrated network zone system is used to deploy plant-wide EtherNet/IP networks and helps ensure that management and network control wont hinder the most effective use of data available. An integrated system incorporates all active and passive equipment required for deployment. Features and benefits of using an integrated solution system include: Reduced deployment time by up to 75% with a pre-engineered, tested and validated solution Touch-safe and UL508A-rated integrated industrial and IT networks Reduced downtime with a robust, future-ready, reliable network system that provides simple and easy moves, adds and changes (MACs) Reduced material costs up to 30%
Popular Configuration Drawings

To get started designing your industrial network system, to download your copy of our Industrial Switch Deployment Popular Configuration Drawing.
Visit www.panduit.com/IntegratedZone-CE
The JOURNAL Magazine, March 2013
Panduit 18900 Panduit Drive, Tinley Park, Illinois 60487 800 777 3300 www.panduit.com cs@panduit.com
cover story
Integration, software advance product lifecycle management

Smarter project designs result from systems-driven engineering, collaborative software tools, system integration and planning, and agile, integrated programming environments. See more images and information online at www.controleng.com/archive, August, for each article in these five pages. Click in through each headline in the digital edition.
Edited by Mark T. Hoske, content manager, CFE Media, Control Engineering, mhoske@cfemedia.com.
Systems-driven product development

Automotive engineering challenges include balancing emissions, cost, and brand performance. The latest product lifecycle management software can integrate information from across the enterprise.
Stefan Jockusch
ompeting requirements vehicle manufacturers have to meet have never been more complex, and product lifecycle management (PLM) platforms can help. Engineers must create an exciting product, one that sounds good, feels good, and delivers an exciting experience through more and more intelligent systems that are integrated with the consumers world. At the same time, the product has to become more fuel
Virtual to real: Virtual simulation results in a mechanical model. Courtesy: Siemens UGS PLM Software
efficient, lighter, and more sustainable each year. Engineers have an increasingly difficult job finding the right balance among conflicting needs. More than 20 million lines of code in the average vehicle requires that an ever-growing set of requirements must be managed and validated. Automakers, like Volkswagen with the MQB [Modularer Querbaukasten, which means Modular Transverse Matrix] or Toyota with TNGA [Toyota New Global Architecture] are driving toward modularity, building global and cross-brand systems of compatible components. Componentization helps reduce complexity and degree variation and adds to the engineering challenge of understanding behavior, durability, and overall customer experience with components re-used in many vehicle configurations.
Frontloading decision making
Solving a certain problem in context can influence how a vehicle behaves or is perceived, in a way the engineer cant easily predict. This is PLMs core challenge: bring the knowledge required to make critical decisions to each person involved in the development and manufacturing of the vehicle, when needed, in the exact context. The system needs to enable engineers to make the correct decision earlier in the process, when the impact of changes is much less expensive than later. The system needs to involve the right experts to help impact quality, durability, performance, and manufacturing costs, much earlier. Systems need to front-load decisions by moving the impact of downstream functions earlier, closing the loop between decisions and verification, to ensure that early decisions are correct. The next generation of PLM provides an immersive environment for lifecycle decisionmaking. To do that, people need to become more
Next generation PLM
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Key concepts
Systems design contributes to product development System integrators aid project design Social and mobile tools help product lifecycle management
Energy flow: Simulation shows the complete energy flow in a hybrid vehicle while its being driven on a virtual road. Courtesy: Siemens UGS PLM Software
intrinsically aware. Information should surround them and be brought to them, but only whats relevant and in the right context. This will help them make integrated decisions in the context of systems, and do so on time and with greater accuracy. The goal is to build an immersive decision-making environment where every person in the product lifecycle gets exactly the knowledge needed, when they need it, and in the context of the decision they must make. Such an environment turns complexity into useful knowledge that gives automakers a competitive edge by: 1. Providing one transparent environment for all users across the enterprise, from marketing, quality, design, and engineering, to manufacturing. 2. Gathering data from the many data sources that are key to make the right decisions. 3. Providing tools to define the architecture and models describing the physics, controls, and behavior of a vehicle. 4. Ensuring that only the right information is delivered and in the context of the users job. It is possible to engineer the customer experience using systems-driven product development. The method of systems engineering has been embraced for decades by the aerospace and defense industry and increasingly by the automotive industry. But systems engineering is itself sometimes referred to as a complex process. Not all engineers across the company can understand all complexities of systems engineering. In fact, systems engineering is often done outside of the core design activities, by the few experts within the company often taking it off the critical path. Companies can gain great leverage from the knowledge produced in systems engineering, so they must find a way to use the models created by systems engineers to do their work in the context of all the complex systems that surround
them. So how can organizations leverage systems engineering without being overwhelmed by the complexity of systems engineering itself? That is PLMs job. PLM ensures the complexity of the product is well defined and understood by capturing it in all within PLM and then having PLM make sure its consumable by all the engineers, and others, throughout the product lifecycle.
Systems-driven development
Four key elements of systems driven product development are: 1. Openness. No one software product can do the job. When automakers and top suppliers inventory the number of development, simulation, engineering, and manufacturing software tools they apply, they find hundreds. The PLM systems openness and ability to leverage data that others need without getting clogged with transient information are key for success. 2. Single configuration management. PLM must provide an architecture that determines variation and defines the myriad of theoretical and practical configurations. 3. Change and schedule management. PLM must provide the enterprise change and schedule management process that ensures alignment across the multitude of applications where change happens. 4. Architecting and simulating the customer experience. Program engineers need to understand fuel consumption, driving behavior, noise and vibration, and cost of a vehicle in many configurations. They need accurate models of physical characteristics and of the controls software that they can assemble into a simulation of the vehicle and test drive on the computer. - Stefan Jockusch is vice president product development, Siemens UGS PLM Software.
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Online, read about GM and Daimler Benz applications. www.lmsintl.com
www.plm.automation.siemens.com
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cover story
Social, mobile tools enhance the PLM model

System design: Product lifecycle management (PLM) software models enabled by social business tools can leverage the mobile connected workforce and use new collaborative skills to augment product engineering.
Marlee Rosen
PLM collaboration tools are helping create more effective virtual teams across an extended enterprise.
roduct lifecycle management (PLM), the series of strategies, business practices, and technology design for acquiring and maintaining product information across the entire lifecycle of the product, can provide the ability to boost development speed, enhance customer satisfaction, optimize operations, and create new revenue generation opportunitiesand new social and mobile tools are helping. Product designers and engineers managing their companys PLM are becoming more mobile or distributed. When you couple that with an aging engineering workforce, there has become an even more critical need to capture the implicit knowledge that these team members possess and pass it on to younger generations of engineers. Manufacturers have to make the most productive use of their peoples skills and knowledge regardless of where theyand their business partnersreside and adopt a more collaborative approach to do so. The idea is to provide companies with real-time visibility to product data and share information across planning, design, costing, sourcing, manufacturing, and logistics. Collaboration tools are quickly evolving and helping growing companies to create even better and more effective virtual teams. ARC Advisory Group observes convergence of social real-time collaboration and PLM across product development organizations, connecting people and products they develop to create communities that solve problems and create breakthrough product ideas. PLM vendors offer varied tools. Dassault Systmes promotes its Social 3DExperience platform and PTC and Autodesk have Social PLM. Omnify Software provides a Social Collaboration Portal. Integration of social media for product design has a long way to go. Companies are using social media as a low-cost way to broadcast a message but not necessarily as a means of collecting customer input that can be turned into valuable information. ISG, the sourcing advisory firm, reports
Social media: Making Omnify Empower PLM software an integral part of the companys R&D process via the cloud has enabled Mevion Medical Systems to create a more collaborative environment for innovation. Content sharing is available from any device. Mevion sees its collaborative environment extending past the integration of social networking capabilities and encompassing data sharing from all devices the company uses. Courtesy: Omnify Software
Social computing era, tools
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www.omnifysoft.com
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that social media collaboration among key factors that have impacted global outsourcing in 2012 and will reshape outsourcing in the long term. Companies will use collaboration tools to accelerate growth by using the skills and knowledge of suppliers, partners, and customers in an extended enterprise. The ISG collaboration model generates intellectual capital from relevant constituents, including social networks to use the final customers insights about products. Michael Fauscette, group VP of software business solutions at IDC said: building a collaborative enterprise is about a lot more than just some new software tools; its about fundamental changes to culture and behavior. He said four phases of innovation management are integrated across a business: idea-source, develop, produce, and feedback, built on new social technologies. Bertrand Sicot, CEO of SolidWorks (part of Dassault Systemes), noted that while people still have some insecurity about data sharing in the cloud, the general belief is that more people are growing more comfortable about using it: Regardless of the platform, our customers are always ensuring their IP is protected. There is a bigger concern when data residing outside their infrastructure is contemplated. We have seen a similar scenario with how unsure we were about conducting online banking just a few years back, and now people have come to embrace it. We anticipate the same will happen in our industry. People in time will become more comfortable with security... to protect their designs. - Marlee Rosen is research analyst at Rosen Associates.
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cover story
System integration is a critical element in project design

Involve a system integrator early in project design to help ensure high-quality projects that satisfy project requirements.
Todd Williams
Project cost influence curve show that design changes cost more in later project stages. Courtesy: SAIC
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www.saic.com
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orking for a company that executes large projects using a design-build philosophy, I have witnessed the benefits of the traditional architect and engineer (A&E) approach to the design process. An A&E customer-focused approach uses design milestones for concept/feasibility and 30%, 60%, and 90% design reviews, with customer approvals at each stage. Key project disciplines are represented throughout the process to ensure the design functions as one cohesive solution. Frequently, system integrators arent brought into a project until the detailed design is nearly finalized and the project is moving into the construction phase. At this point in the project, the integrator is unable to positively influence a project without a significant cost impact. Altering this approach and instead involving a systems integrator early can reduce project costs and risks compared to traditional methods, especially those that include a pre-selected product vendor. The project cost influence curve presents the influence opportunity in correlation with project expenditure throughout any project lifecycle. Once the detailed design phase has been reached, the influence opportunity rapidly declines while the cost expenditure quickly increases. Executing a project in this manner causes system integration to be treated as a commodity purchase similar to skilled tradesman and equipment purchases. As a result of the cost impact, projects are typically executed as designed, regardless of whether or not the design encompasses the best
(or even feasible) solution. Multidiscipline system integrators are required to properly design and integrate with various systems including communications networks, systems interoperability, and communications protocols. Also, the recent proliferation of information systems has increased project complexity. The expectation that information is available from all systems has become the norm. Even simple mechanical systems are expected to provide system-level integration capabilities. During the project design, an integrator can apply expertise by leveraging legacy systems, performing a nonbiased analysis of product and architecture offerings, selecting solutions that decrease integration effort and increase sustainability, and determining if a common-off-theshelf (COTS) product or a custom application should be developed. System integrators are tasked with creating a design that matches a customers budget and requirements. To achieve this goal, it is necessary to not only evaluate the project at hand, but also analyze the customers legacy systems and consider possible future enhancements. By leveraging an enterprise-wide viewpoint, an integrator can add more value in the overall design, delivering results that can improve the customers profit, growth, and corporate reputation. The following are some primary system integrator tasks executed throughout the typical project lifecycle: The requirements analysis phase enables a team to accurately determine the current and future customer requirements of the project. Tasks during this phase include: Current system architecture Examine the existing network infrastructure, data pathways, and procedures Customer requirements Identify the current system deficiencies and detail the customer requirements with regard to the existing system Interface coordination Determine the system interfaces, including current and available hardware interfaces and protocols to the system devices Identify project risks Document project integration risks with mitigation plans Areas to be addressed Detail the software, hardware, fieldbus input/output, interface descriptions and approaches, data table layouts, sequence of operations, and graphical user interface concept screens. See online, details on what a design should include. - Todd Williams is a vice president for the System Integration and Controls team at SAIC.
Requirements analysis
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cover story
System design: Agile programming streamlines software development

Identify and prioritize programming tasks that need attention and address each to enhance machine.
Gary Kirckof
Simulation of a rotating wheel with a tool illustrates how code can be effectively developed and tested. Courtesy: Beckhoff Automation
Consider this...
What can you gain with more integrated product lifecycle management?
n the lifecycle of a machine from inception through implementation, code can be effectively developed and tested through simulation. The right programming tools are essential to simplify design, especially as functionalities are integrated. Virtual reality machine design and modeling environment be available in the future. Development, simulation, and modeling software tools are generally implemented in separate packages. The package count increases because the engineering disciplines, such as mechanical, electrical, and control, frequently have their own dedicated software. One programming trick is to start with a framework that already has timesaving error handling and recipe management features. This saves time to concentrate on machine-
specific issues. For those, I use agile programming, which means means identifying and prioritizing programming tasks requiring attention and addressing each in turn. This involves some research, coding, and testing. Users can simplify research, coding, and testing with available aids develop of automation system code and tests it by simulating how it will work on production machinery. This results in proven code thats ready to automate the machine as soon as its assembled. See more programming advice online. - Gary Kirckof is application engineer manager at Beckhoff Automation.
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www.beckhoffautomation.com/TwinCAT3
Simpler software design tools

Integrating hardware and software into embedded systems can be complex. Keep it simple: the right software design tools enhance quality and save time.
James Smith, Brett Burger
ystem design software environments need to provide 1) Support for a wide range of processing elements such as microprocessors, FPGAs, and GPUs. 2) A complete set of models of computation. System design software cannot limit embedded designers to one language or software model of computation. System designers need to use the appropriate language for each aspect of the application from one environment, whether graphical programming, textual math, C/C++/C#, and HDL. 3) Simulation capabilities. System design software simplifies 4) Tools for user interface developprogramming complexity for different ment. 5) Management for system types of processing units and reducdeployment and maintenance. es the need for special expertise. NI System design software can LabVIEW code (left) is more streamfacilitate faster development, prolined for an application than more vide flexibility for design optimizathan 60 pages of VHDL code (right). tion, and support a large collection
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of Intel, Freescale, ARM, TI, and ADI technologies with specific embedded control hardware. Software/hardware platform combinations remove the need for low-level management of constructs that rarely are part of the new intellectual property. Control developers that leverage the same system-level design tools for prototyping and deployment can remove the wall to productivity and drastically reduce time to market. A good embedded system developer will plan for system upgrades and design-in the ability to add or change future code, often through software abstraction. Low-level code spread throughout a codebase is difficult to change, which is why developers construct modules of code that perform higher level functions. System-level design tools are inherently abstract and conducive to upgrades when used properly. Time-to-market benefit calculations include more than simple revenue and profit over time. System design software helps engineers be first to market and have the best product. ce - James Smith is director of embedded systems, and Brett Burger is senior product manager of embedded systems, National Instruments.
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industrial networking
ITvs.OT:
Peter Welander
Bridging the divide

Traditional IT is moving more onto the plant floor. OT will have to accept a greater level of integration. Is that a problem or an opportunity?
Key concepts
IT is pushing into more areas that were traditionally separated from OT. Expansion of IP-based technologies will displace more industrial protocols. Convergence of IT and OT is growing, and moving into new environments.
36
oure a networking person who works in your plant in operations technology (OT), supporting the systems that keep manufacturing going. An e-mail arrives that strikes terror: Your corporate IT department will be updating networks and implementing new cyber security measures in the plant, and you are to cooperate. In other words, IT is moving into your world. Is this necessarily bad news? It probably isnt good news, but the question is, why does the thought of combining IT and OT normally draw strong reactions? When you take people with an IT background and bring them into an industrial control system environment, theres a lack of understanding from operations why theyre there and there is a lack of understanding of the specific controls environment needs from IT, says Tim Conway, technical director, ICS and SCADA for the SANS Institute. He points out that typically IT professionals are trained and driven to perform a task: They work on a box, a VM (virtual machine), a storage area network, or a firewall. They dont realize that theyre a part of a larger control system operation, and how things that they do can impact others. Conways experience came from many years working in networking engineering and management at a mid-sized electric utility. Hes seen how difficult it can be to develop IT personnel to realize the larger context: If theyre network guys, they see how a change affects their networks and the inter-dependent IT system functions, meaning active directory or workstation authentication, or monitoring and alerting, and all the other IT functions. But they dont think systemically from an operations perspective. For example, the impact out to the breaker in the substation if the communication path is lost. I compare the devel-
opment challenge to what we do with our safety programs where we ask people to think about safety from the perspective of their work product. They have to think about how their actions can impact their own safety, impact the safety of the equipment and operation, and the safety of others. We ask them to all walk through the process and say, Heres what I work on, and heres how it can impact the safety of the people in the field. The same applies to networks they support and the control systems that rely upon them.
Needs of industrial networks
Younger IT people used to working with the latest technologies probably find equipment running a process unit quaint. They have to understand that industrial users arent impressed with new technologies since they are only a means to an end. If it works, who cares how old it is? Thats one of the biggest issues, says Perry Tobin, senior consultant for Matrix Technologies. IT people typically dont have 5 or 10 years working in a manufacturing environment and understanding the legacy issues. The IT person comes down and sees Windows 2000 machines that are deployed and will be there for two or three more years, and says, Oh my, we need to get rid of that. But you say, No, you cant just change that machine out. Theres licensing, there are issues with Rockwell, Siemens, and some of the older software that wont run on a new platform. IT people are not impressed with longevity. Theyre appalled at how long its been static. They dont realize that if something has been running without a reboot for seven years, dont touch it. OT people tend to be in the same position longer. IT people also find themselves largely stripped of their skills and tools when they move into the plant. Techniques used routinely may simply not
The IT person comes down and sees Windows 2000 machines that are deployed and will be there for two or three more years, and says,Oh my, we need to get rid of that.
be available. Conway explains, IT security people who look at a traditional plant control system, would want to engage a standard security package; switchport security, intrusion detection on the backplane of the VLANs, and SNMP rollups, for example. In many cases, the system vendors would simply say You cant do it. These switches have custom code and are built for a certain scan rate, certain throughput, and if you screw with that, we cant ensure the availability and integrity of the controller talking through the switch to the workstation. This is a challenging response to IT security personnel, but it needs to be understood and evaluated because a secure system that does not perform its functions as engineered or perform them safely would not be desirable for anyone. There are approaches working with all stakeholders to achieve a balance.
Dealing with the unknown
When IT people have to take on a problemsolving task in the plant, they often discover many kinds of devices and communication approaches that are much different than theyre used to. Kevin Price, senior product manager of Infor EAM, has seen many situations where a reliability engineer has to work with IT to extract data from an individual machine or system for performance analysis. As he describes, The reliability engineers are trying to reach a specific OEE (overall equipment effectiveness) rating. In order to do that, they need to understand how the asset is running from a quality perspective and an availability perspective. To do that, they need to be able to monitor it. To do that, they need a meter that can talk to that piece of equipment, whether analog, digital, or a system. You have to work with IT in order to do those integrations and pull it to a system like ours. Now that were moving from analog to digital with some of these controls and systems, its becoming more open and the data more accessible to the average IT resource. But if you look at some of the systems installed in the 1990s, theyre proprietary, theyre analog, theyve never been
rebooted, and are running like a champ. The problem is the IT person cant get any data out of it. So the reliability engineer gets frustrated because he cant understand how that equipment could be improved because nobody can to talk to it.
Developing an inferiority complex
In most situations, OT is in a weaker position in the corporate pecking order since there are typically fewer of them and they are more isolated at the device level end of the systems. The corporate culture can leave OT feeling like a second banana and forced to do what those up the chain dictate. Tobin says it doesnt have to be that way. He suggests, When everybody gets together and thinks long term, it definitely builds a much better relationship than if somebody says, Weve been tasked with putting a new network in the plant over the next six months, and heres what youre going to get. Its the knowledge of OT understanding more what IT wants to do, its the understanding of IT knowing what OT needs, and
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industrial networking
There are organizations that have been successful in following the convergence approach, and leveraging what they want out of a converged network. The real transformational business value is by using that inherent integration to get at use cases that drive efficiencies or even outside revenues.
somebody to coordinate that. Theres an education side to it. Companies that are willing to invest the time and money to bring people together to get that dialog going are the ones that are successful. The right technology has to be there and its going to change, but the corporate culture and the communication between IT and OT are the key things to making any success between the two.
Twilight of OT?
Individuals working in OT also need a different kind of motivation or they may feel they are stuck in a career dead end. IT skills can be applied in all sorts of industries so an engineer may move from banking to retailing with relative ease. Such is not the case for people coming from OT. If engineers spend time learning the operations of a particular company or industrial sector, they might be making themselves better in their current job, but not making themselves more marketable or competitive outside of a particular industry, Conway says. Its almost a negative incentive. It is important to ensure personnel development goals are aligned and incentives are in place to train personnel for a role and retain those individuals. The idea of IT moving into the plant may also be a defensive one that is driven more by necessity than any particular strategic objective. It is actually easier to train the OT expert and controls engineers on IT and IP-based technology and management of those assets than vice versa, says Chet Namboodri, managing director of global manufacturing industry sales for Cisco. The controls engineering breed is a bit of a dying one. Theres less of that experience resource available now throughout the world, both in developed economies and more broadly. That said, there are organizations that have been successful in following the convergence approach, and leveraging what they want out of a converged network. The real transformational business value is by using that inherent integration to get at use cases that drive efficiencies or even outside revenues.
transition into IP-based industrial networks, which is the cultural convergence that needs to take place. A number of companies have even gone the next step and organizationally converged manufacturing IT and controls engineering functions under one roof. They recognize that this network, even at the device level, enables visualization with remote access. It enables collaboration between their production experts and operations personnel, maintenance personnel, technicians, and so on, that are on-site through a secure architecture. Instead of sending their experts to another plant on a plane to troubleshoot a problem, theyre able to do that with the visualization since a lot of that is seeing whats happening. They also get data and diagnostic feeds of whats going on so they can troubleshoot with the people on the plant floor to get an operation back up and running much faster. The trust has been built around the value of IT.
Both can have seats at the table
The positive side of convergence
Go Online
n www.cisco.com n www.infor.com n www.matrixti.com n www.mavtechglobal.com n www.sans.org
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While the discussion so far may seem somewhat negative, as Namboodri observes, there are many positive aspects of IT moving more into a manufacturing environment beyond simply filling a staffing gap. There is value in converging IT and OT from a networking standpoint, he suggests. Both IT and OT have a very strong role to play in that integration and the subsequent management of those networks. To highlight one as more important than the other is a disservice to both. There are some technical concerns, but those are less of a problem with technology and network convergence than what is really at the heart of making a successful
Time is not necessarily on the side of traditional OT functions, but given the slow pace of technology change in most manufacturing environments, the devices and networking techniques unique to process plants and manufacturing floors will be around for a long time. Nonetheless, more of those networking functions are going to be replaced by IP-based technologies. For the foreseeable future, both will be necessary, although it may be harder to figure out where the fences are. The IT/OT line is blurring, notes Jason Montroy, client relationship manager for Maverick Technologies. You need engineers that know about both sides. Its going to remain compartmentalized, at least for a while, to where youre going to have an IT resource that knows a bit about automation, and youll have an automation resource that knows a little about IT. Engineers that have skills outside their core competencies will be very highly valued. One positive thing that were seeing as we go into opportunities that involve DCS migrations, youre getting an IT person at the table early in the project. This is very important, because IT is providing the ecosystem that the control system will reside in. Bringing them into the game early on is very beneficial. The challenge going forward will be to get the right people into the right positions, even when highly qualified individuals will be harder to find. Companies will have to be more creative, and that in itself could be the biggest challenge to established practices and existing company cultures. IT is coming, and when its all done, your networks and information management may be vastly different than they are today. ce Peter Welander is a content manager for Control Engineering, pwelander@cfemedia.com
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machine vision
Machine vision boosts quality for mass-produced robotic workcells

Feedback from machine vision adjusts robotic movement and enhances manufacturing quality. Vision-guided robots have greater position accuracy, providing closed-loop control.
Nick Tebeau
n any given day, I can walk out of my office and see dozens, if not hundreds, of robots standing in neat rows waiting to become integration ready. They all look exactly the same, but the truth is, theyre not. Each piece of metal, each servo joint, is subtly different than the next. Put those robots to work, and depending on the temperature in the workcell, the robots physical dimensions will change again as metals expand (or contract) and electrical efficiencies vary. These mechanical and electrical variations (or errors) stack one atop the next to determine the overall accuracy of the robot. Robotic accuracy is defined as the ability to go to a programmed spot in space. Customers regularly fail by trying to use a robot with 0.1 mm repeatability to position a part within 0.1 mm accuracy because they
overlook the robots true accuracythe ability to return to a given spot in space on demand. Vision-guided robotics (VGR), or the use of industrial cameras connected to computers running image processing software to determine an offset for robot control, counter these effects by providing an objective method for determining the robots position and orientation in 3D space versus where it is supposed to be. But machine vision also has a stack error that depends on many factors, from intrinsic changes in lighting and sensor response to extrinsic variations in surface finish and part presentation due to material handling systems. Unfortunately, most end users do not understand the sources of accuracy and repeatability, or how to account for stack errors in robotic and vision systems to create a VGR solution that works. It takes experience with machine vision
40
Mass-produced industrial robots are expected to all be the same, but in reality, subtle differences in metal part construction, servo response, and real-time changes in ambient conditions will directly influence reach, speed, and movement path for an industrial robot. Machine vision systems that monitor where a robot tool is in real time and in real space help to overcome these operational variations. Courtesy: Leoni
and robot programming to define a complete application specification based on true robotic stack error matched with the right machine vision system.
Embracing the unique
rather than fixtures because fixtures are a custom expense, often do not offer the flexibility to handle different parts on the same line without additional costs, or offer the chance to reuse robotic workcells in other parts of the plant. Machine vision systems can be reprogrammed and, assuming the system and its components meet the specific needs of the new application (a big if), can be deployed around the plant like any other asset.
Put vision into VGR
Every VGR application is different. Its different because every robot, environment, manufactured part, and process is different. As a result, there are many ways to peel the proverbial onion, but the ultimate goal is to design a system that accomplishes specific tasks, at a specific rate, based on known parameters, for the least cost. And it all starts with a complete and thorough understanding of the application needs. What is the part? How does it vary in size, texture, and orientation to the robot based on actual production, not just CAD files? From temperature to changes in light, what are the ambient conditions of the workcell? What does the robot need to do with the part, and how will that affect your choice of robot, including speed, force, and the effect of part mass and momentum on robotic position? (See related article, in this issue, on inertia measurements.) Armed with this information (and more), most customers will have a preference for a specific robot original equipment manufacturer (OEM) based on whats already installed on their plant floor. Based on the part variations and part position requirements, the experienced designer can help select the specific robot model for the application. Each robot is a one-of-a-kind kinematic model comprised of unique mechanical segments and unique electrical (or hydraulic) controls. Most robot OEMs provide an absolute accuracy service that will determine that individual robots absolute accuracy, which can be useful for applications where robotic and vision stack error are very close to the applications material handling accuracy and repeatability requirements. After defining the application requirements and selecting the right robot, the designer has to figure out how to program the robot to do its job. The robot will need help finding incoming parts, either through fixtures that consistently present the part to the robot in a given 3D location and orientation, or through the use of a vision system to provide an offset to the standard robot path to accommodate variations in part position and orientation. Today, more manufacturers are using vision
Once the application has been clearly defined, the next step is to determine what sort of information the robot needs from the vision system to perform to the necessary specification. Is the part relatively flat on a flat conveyor so a 2D vision system will be sufficient? Does the application require orientation and relative height information in addition to X and Y information therefore, a 2.5D vision solution? Or do you require absolute 3D information for hole inspection in addition to providing an offset for the lugs or pick points on the part? While 2D and 2.5D solutions are relatively straightforward and usually can be solved with one camera assuming that minimum spatial resolution can be achieved per pixel across the necessary field of view, designers have several options when it comes to 3D vision, namely single-camera 3D, single- or multi-camera 3D with structured light triangulation, and multi-camera stereoscopic vision. Each of these approaches offers advantages and disadvantages. For example, single-camera 3D solutions can be extremely accurate across relatively narrow fields of view but may require multiple images to create the 3D point set. Stereoscopic is highly accurate for large area fields of view and can be further improved with the use of structured light sources, such as light-grating projectors, LED, or laser line generators, but requires more hardware. All these systems depend on frequent calibration routines to ensure bumps, thermal expansion, and other factors do not generate inaccurate 3D data. One of the least understood factors of a machine vision system involves lighting. Lighting and, more importantly, changes in lighting, will greatly affect machine vision systems, regardless of dimensional aspects of the vision solution. Lighting is often considered as the last part of the vision solution but should be considered early in the design since light interaction with the part as perceived by the camera is the basis for a successful machine-vision solution. For example, if your workcell is in a room
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Robotic racking applications like the doorframe application rendered here are good examples of how part position can vary despite well-designed dunnage and mechanical fixtures. Machine vision systems can account for position variations and ensure a successful robotic racking or de-racking application. Courtesy: Leoni
Key concepts
Using feedback from machine vision positions robots more precisely for higher quality. Match the technology to the application. Proper lighting helps machine vision accuracy.
machine vision
This vision guided robot demo developed by Leoni Vision Solutions for the 2013 Automate conference demonstrates the capabilities of visual servoing, or the use of a machine vision system to guide a robot to a moving target. In the case of this demo, a vision system was able to direct a robot to catch a moving Hot Wheel car 85% of the time. (The caught car is visible upper center of the photo on the right as it brings it back to the top of the track.) However, because industrial applications require greater accuracy, visual servoing systems typically restrain part movement in one or more dimensions, such as hanging the part from a metal hook that can only move in two directions, rather than hanging the part from a chain, for example, which would allow the part to move in three dimensions as well as rotate (orientation) around each dimension. Courtesy: Leoni
Consider this...
If vision guides robotics, what other motion-control applications could it enhance?
with windows, infrared lights may not be the best choice because the suns light is strongest in the red and infrared end of the visible spectrum. To determine the best color of light (white, blue, amber, red, etc.), understand the physics of light and optics. Does the VGR workcell need to sense very similar colors on the part, for example, requiring a color camera and light? Or are the colors different enough that a grayscale camera with bandpass filter and a complementary colored light can offer a cheaper solution with less data processing? Much can be said on the art of matching colored illumination, but a basic rule of thumb is: Dont use a light source thats similar to the ambient light in the room, and dont use a light that is opposite the color of the part color because it will absorb that light (unless youre considering backlight or darkfield illumination).
Simple is as simple does
A successful VGR solution requires careful consideration of the application and specific performance requirements for the robot and the vision system, as well as the total performance of the combined VGR solution in respect to the application and associated production equipment. The solution is often complex. And while it would be useful for your VGR designer to have robotic programming and vision-system design expertise, few companies offer both. If you cannot find such an integrator to help guide your system development, be sure to ask your vision or robotic integrator about its partners on the other side of the design equation. What is their experience? What can they demonstrate? In all fairness, VGR solutions are not necessarily the most complex automation problems that machine vision will help solve. Many robotic
42
TRIANGLE RESEARCH
suppliers provide optional machine vision systems that are well integrated into their robotic control systems. However, a vision system is not a vision solution. The physics necessary to optimize the light, camera, and optics part of the equation alone can require considerable knowledge and expertise. Dont be afraid to ask suppliers about their past experiences and client referrals. Also, associations [such as Automated Imaging Association (AIA), the North American trade association for the machine vision industry, and the Control Systems Integrator Association (CSIA)] have lists of companies that have passed certified vision professional and certified systems integrator courses. These companies have proven their system design knowledge across a wide range of applications and design environments. Working with the right supplier, a VGR solution can put the competitive edge back into an operation. ce - Nick Tebeau is manager vision solutions, business unit industrial solutions, Leoni. Edited by Mark T. Hoske, content manager, Control Engineering, mhoske@cfemedia.com.
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inside machines
How to size servo motors:
Advanced inertia calculations

To properly select the appropriate servo motor for a motion control application, find the inertia of the load being rotated. Applications where the center of rotation is on a different axis than the center of mass can lead to some challenging inertial calculations.
Mark Wilder
hen selecting the appropriate servo motor for a motion control application, one must know the inertia of the load being rotated. Most servo motor manufacturers have software for sizing applications using basic mechanisms, such as ballscrews or rack-and-pinion. More complex systems, however, may require manual calculations. Increasingly, applications use mechanisms where the center of rotation is on a different axis than the center of mass. This can lead to some challenging inertial calculations.
Parallel axis theorem
step process: 1. Calculate the inertia of the table as it would be if there were no cutouts. 2. Calculate the mass and inertia of each cutout. 3. Apply the parallel axis theorem to each cutout. 4. Reduce the inertia of the table by six times the value found in step 3 1. Table inertia: The moment of inertia of the table is found using the standard equation for inertia of a cylinder:
The parallel axis theorem is used when a solid is not spinning about a line passing through its center of mass (CM), but instead an axis parallel to this (PA). The theorem states that for a solid rotating about an axis that is parallel to the axis that passes through the center of mass, the moment of inertia for the solid is equal to the inertia of the solid plus the mass of the solid times the square of the distance (d) of the offset axis, or:
Figure 1: The parallel axis theorem is used when a solid is not spinning about a line passing through its center of mass (CM), but instead an axis parallel to this (PA).
where m is the mass and r is the radius of the table. The mass is simply the volume (r2 h) multiplied by the density of steel (7800 kg/ m3), which produces a result of 61.26kg. This makes the moment of inertia about the center
Figure 2: To apply the parallel axis theorem in an example, imagine rotating a rotary table 1 m dia., 10 mm thick, and made of steel. Six cut holes are each 200 mm dia., and the center of each hole is 375 mm from the center of the table. All figures courtesy: Yaskawa America
Example application: Rotary table
For an example of how to apply the parallel axis theorem, imagine that we are rotating a rotary table that is 1 meter in diameter, 10 mm thick, and made of steel. There are six holes cut into the table; each is 200 mm in diameter and the center of each hole is 375 mm from the center of the table. Finding the inertia for this table is a multi-
2. Cutout inertia: The moment of inertia for each cutout is calculated same way as the table. The mass of each cutout is 2.45 kg and the moment of inertia about the center of the cutout is 0.0123 kgm2. 3. Apply the parallel axis theorem: The moment of inertia calculated in the previous step is not an accurate measure of the inertia
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CONTROL ENGINEERING AUGUST 2013 M2
inside machines
applied to servo sizing. Often the table will either carry a part to be machined or some sort of tooling. Revisiting the rotary table example, assume that a mass of unknown shape is resting in each of the cutouts from the previous example. The table indexes these parts through a series of machining processes. The mass of each of these parts is 15kg and their center of gravity is the same 375 mm distance from the center of rotation as the cutout. The moment of inertia for each of these masses can be calculated by assuming the mass is a single point:
Figure 3: An inspection device is mounted to an aluminum frame that does not rotate around its center of mass. The drawing shows a sketch of this mechanism.
Figure 4: The mass of the side element is its volume times the density of aluminum (2660 kg/ m3) = 4.9kg.
reduction due to the cutout. This is because the cutout rotates not about its own center, but about the center of the table. Therefore, we must apply the parallel axis theorem to get an accurate value. This is done by taking our previously calculated moment of inertia and adding to it by the mass of the cutout times the square of the distance between the center of the cutout and the center of rotation:
An inspection device is mounted to an aluminum frame that does not rotate around its center of mass. The drawing shows a sketch of this mechanism. First, the inertia for each of the side elements rotated about its center is calculated: The mass of the side element is its volume times the density of aluminum (2660 kg/m3) = 4.9 kg.
Example application: Inspection
Applying the parallel axis theorem yields:
To simplify the rest of the calculations, the mass of the cross-element (5 kg) can be added to the weight of the tooling. After this, the inertia can be calculated as a point mass:
4. Final calculation: To find the final inertia value of the table, take the moment of inertia of the whole table and subtract the cutout inertia for each cutout:
Thus, the total inertia of the mechanism is:
The most basic moment of inertia is that of a point mass, that is, an object whose mass is assumed to occupy only a point in space. The inertia for rotating this point mass about an axis is calculated by multiplying the mass times the square of its distance from the axis of rotation, or expressed as an equation: Jpointmass=md2. It can be seen that this is the inertia that is added when applying the parallel axis theorem. The concept of a point mass can also be
M3
Point mass inertia
-Mark Wilder is regional motion engineer, Yaskawa America Inc. Edited by Mark T. Hoske, content manager, CFE Media, Control Engineering,mhoske@cfemedia.com.
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Consider this...
Sizing servo motors before knowing application and load rotation inertia can produce unfavorable results.
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inside machines
Achieve EMC-compatibility for industrial RS485 networks

Preserve RS485 signal integrity: Electromagnetic compatibility (EMC) transient protection requires matching the performance of protection components to the characteristic of transceiver component. The suggested circuits can help a designer reduce risk of project slippage due to EMC problems.
Thomas Kugelstadt
Key concepts
Industrial network signal integrity requires protection against transients RS485 serial communications, with distances up to 6000 ft, can be susceptible to interference Ensure transient protection matches network as implemented
odern industrial networks rely on robust RS485 communication links for long distance data transmission, so protecting signal clarity can be a challenge. These networks must operate in harsh industrial environment and hence are subject to strong electromagnetic interference in the form of large transient voltages caused by electrostatic discharge, electrical fast transients, and lightning strikes. Data rates for long distance communication range from 10 kbps up to 250 kbps over distances of up to 4000 ft (1200 m) and lately even up to 6000 ft (2000 m). Due to its differential signaling technique across twisted-pair cable and the ability to operate reliably in a high-commonmode environment, RS485 has become the interface workhorse in industrial applications. To prevent costly network downtimes, due to transceiver damage caused by high voltage and current transients, the International Electrotechnical Commission (IEC) has developed transient immunity tests for electrostatic discharge (ESD), electrical fast transients (EFT), and surge transients. For proper network implementation, understand each of these transients, their application, and design solutions to prevent component damage.
Transient comparison
The ESD test simulates the electrostatic discharge of a human onto electronic equipment. A test pulse has a rise time of approximately 1 ns and lasts less than 100 ns. A test sequence consists of 10 positive and 10 negative pulses with a one-second pause interval between each pulse (Figure 1). ESD has the lowest energy content of all transients. The burst test simulates switching transients caused by inductive switching, relay contact bounce, and so on. This test applies a sequence of test pulses called burst. A test pulse has a 5 ns rise time and lasts about 400 ns. A burst consists of 75 pulses applied at a repetition rate of 5 kHz, followed by a 300 ms pause. A test sequence comprises six 10-second bursts with 10-second pause intervals and produces 14,000 pulses per minute. An EFT pulse train has about 300 times more energy than an ESD pulse of the same test voltage. The surge test simulates switching transients caused by lightning and switching heavy inductive loads. The test distinguishes between an open-circuit and a short-circuit pulse-shape with different rise times and pulse durations. During application, the test pulses are often referred to as a combination waveform. Surge transients
Figure 1: Compared to electrostatic discharge (ESD) and electrical fast transients (EFT) transients, surge transients possess much higher energy. Courtesy: Texas Instruments
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inside machines
Figure 2: Legacy protection schemes could do more harm than good due to wrong component choice or protection method. Courtesy: TI
The EIA485 standard requires solid data transmission across a common-mode voltage range from -7 V to +12 V.
are 1000 times longer than ESD or burst transients. Additionally, the low source impedance of the surge generator assures high surge currents at high voltages. A test sequence consists of five positive and five negative surge pulses with a one-minute pause interval between pulses. A surge transient has approximately 100 times more energy than an EFT pulse train, and about 30,000 times more energy than an ESD pulse of the same test voltage.
Legacy protection methods
Consider this...
Network signal reliability is needed for reliability signal delivery. Will this tutorial help?
M7
Figure 2 shows two classic protection schemes intending to prevent bus transceiver damage and bit errors from high-voltage transients and other common-mode noise. The circuit in Figure 2a uses steering diodes that clamp the signal lines to VCC (common collector voltage) or ground potential in case of a transient event. This circuit stems from a legacy bus termination scheme using Schottky diodes to minimize reflections of an otherwise unterminated bus. In the case of signal reflections, which typically rise to levels above VCC and below ground, these diodes limit the reflected signal to the maximum levels of VCC + VFW (full wave voltage) for positive reflections, and 0 V ground (GND) VFW for negative reflections. There are two major issues with this performance. The first is that the circuit only works in small common-mode environments due to the early clamping action of the diodes. The EIA485 standard, however, requires solid data transmission across a common-mode voltage range from -7 V to +12 V, thus making this circuit RS485 noncompliant. The second issue is that every time these diodes conduct or clamp, which literally occurs at every signal transition, huge peaks of diode currents are diverted or steered either toward VCC or ground. These current peaks contribute to large radiated emissions from the circuit into the environment, so are most likely to fail any electromagnetic interference (EMI) compliance test. While the circuit in Figure 2b uses a more complex protection scheme, the components
applied might prevent it from suppressing fast transients. For example, low-cost transient voltage suppressors (TVS) of the SMAJ, SMBJ, and SMCJ type possess large junction capacitances and, therefore, long response times. In the event of fast transients, voltage overshoots of up to 120 V can occur before the TVS diodes start clamping, making transceiver damage inevitable. The resistors with positive temperature coefficient (PTCs) increase their resistance in the presence of high currents. Their response time lies in the range of milliseconds, which is far too slow for surge transients let alone ESD and EFT pulses. Common-mode chokes often are the preferred tool to filter common-mode noise. Their application, however, requires detailed study of the choke characteristics and how they fit into an application. It is not feasible to just copy a protection circuit from an audio or USB-3.0 reference design and expect it to work in a long-distance RS485 application. Plenty of literature suggests adding filter capacitors to steepen the filter response. However, care must be taken to prevent the filter transfer function from creating an unnecessarily high peak around the cut-off frequency. Fast transients, such as ESD and EFT, have a wide bandwidth exhibiting frequency components from 3 MHz to 3 GHz, some of which could be unintentionally amplified by the filter peak. Moreover, filter capacitors should match in value. Large component tolerances cause different cut-off frequencies between the signal lines, thus converting common-mode into differential noise and leading to data errors.
Modern circuit protection
Figure 3 presents a variety of protection circuits for various levels of transient protection. Circuit in Figure 3a uses a fast, low-capacitance (75 pF), 400-watt TVS with breakdown voltages of 13.5 V and -7.5 V, which assures compliance with the required common-mode voltage range of 12 V to -7 V specified in EIA485. Series resistors, Rs, in the A and B signal lines are among often-overlooked necessities.
Figure 3 shows modern protection schemes for various levels of surge protection. Figures and tables courtesy: TI
These resistors provide current limiting during a transient event, as well as create the necessary voltage drop to keep the TVS turned on for the duration of the transient. The circuits in Figure 3b aim for higher surge protection levels and, therefore, also require use of a transient blocking unit (TBU) and a thyristor transient suppressor (TISP). The TBU is current and voltage triggered. During a surge event the current through the TBU rises to the current limit level, in approximately 10 ns. At this point, an internal voltage switch disconnects the load (TVS and transceiver) within approximately 1 s. During the remainder of the surge, the TBU device remains high-impedance with leakage currents of less than 1 mA in the protected state of very low current and voltage at the load. The TISP device is a symmetrical, voltagetriggered, bidirectional thyristor. Overvoltages are initially clipped by breakdown clamping until the voltage rises to the breakover level, which causes the device to crowbar into a lowvoltage on-state condition. This low-voltage on state causes the current resulting from the overvoltage to be safely diverted through the device. The device switches off when the diverted current falls below the holding current value. As in the previous case with the TVS and series resistors protecting the transceiver SCR, for increased surge transient levels, the TBU and the TISP protect the TVS and its following circuitry. For even higher surge levels, the circuit in Figure 3c replaces the TISPs with a gas discharge tube. Gas discharge tubes (GDTs) are designed to prevent damage from transient disturbances by acting as a crowbar to create a virtual shortto-ground circuit during conduction. When an electrical surge exceeds the defined breakdown voltage level of the GDT, the gas becomes ionized and rapid conduction takes place. When the surge passes and the system voltage returns
Table 1: Protection levels for circuits in Figure 3

Figure 4 circuits a) b) c) ESD
Level 4 4 4 Voltage (contact/air) 8 kV / 15 kV 8 kV / 15 kV 8 kV / 15 kV
EFT
Level 4 4 4 Voltage 2 kV 2 kV 2 kV
Surge
Level 2 4 X Voltage 1 kV 4 kV 6 kV
Table 2. Bill of materials for circuits in Figure 3

Device XCVR Rs TVS TBU TISP GDT Function
3.3V, 250 kbps RS485 transceiver 10, pulse-proof thick-film resistor Bidirectional 400 W transient suppressor Bidirectional 200 mA, (650 V) transient blocking unit 200 A, (180 V) bidirectional thyristor 5000 A, (500 V) Gas Discharge Tube
Order number
SN65HVD72D CRCW060310R0FKEAHP CDSOT23-SM712 TBU-CA-065-200-WH TISP4240M3BJR-S 2038-15-SM-RPLF
Manufacturer
Texas Instruments Vishay Bourns Bourns Bourns Bourns
to normal levels, the GDT returns to its highimpedance (off) state. Table 1 lists the protection levels for the circuits in Figure 3, while Table 2 presents the bill of materials.
Matching characteristics
The key to successful EMC transient protection is to match the performance of the protection components to the characteristic of the transceiver component. While the suggested circuits cannot replace the due diligence required at the system level, they help the designer to reduce the risk of project slippage due to EMC problems. ce - Thomas Kugelstadt is a senior systems engineer with Texas Instruments. Edited by Mark T. Hoske, content manager, CFE Media, Control Engineering, mhoske@cfemedia.com.
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inside machines
Closing the loop to maintain precise hydrogen pressure

CASE STUDY: A programmable electro-hydraulic motion controller improved standard deviations of the discharge pressure distribution by about 70%, helping improve manufacturing productivity in an Alberta EnvironFuels application. A closed-loop controller runs at 1000 loops per second to optimize tuning and respond more quickly and automatically to changing conditions.
Don Denman
Key concepts
Controllers and actuators need to work together smoothly and precisely in many applications. Work-around solutions included restrictors and check valves. Updates included proportional servo valves and an electro-hydraulic motion controller.
aster closed-loop control for compressors has helped Alberta EnviroFuels, a division of Keyera Corp. of Calgary, Alberta, Canada, better produce iso-octane, a blending component of automotive gasoline, from a feedstock of field butane. Several of the internal process steps require high-purity hydrogen. This hydrogen stream is acquired by compressing a low-pressure gas stream that contains about 50% hydrogen by weight, and then feeding the compressed stream into a hydrogen recovery unit. Figure 1 shows one of Alberta EnviroFuels four hydrogen compressors. Because the feed stream into the hydrogen recovery unit is very light, process designers selected positive displacement compressors, specifically wet screw compressors, to accom-
plish the feed compression. Since the demand for high-purity hydrogen can vary from moment to moment, the compression process also needs to provide a method for matching the volume of feed gas delivered by the screw compressors to the demand for purified hydrogen. Instead of supplying a traditional external spillback control valve (which would have been manipulated based on holding a constant discharge pressure), the compressor vendor suggested use of screw compressors with internal slide valves. Extending or retracting these internal slide valves varies the displaced volume (the effective compressor capacity).
Smooth precision
Figure 1 shows a side view of Alberta EnviroFuels hydrogen compressor. All figures courtesy: Delta Computer Systems
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The challenge that we faced, said Phil Prins, senior process control engineer of Alberta EnviroFuels, is that while we are always striving for precise control of our process variables the capacity of the compressors in this casewe often put an even higher premium on smooth control. And positioning of the internal slide valves with the original control scheme was neither precise nor smooth. Technically, Alberta EnviroFuels screw compressors are two-stage models. The first stage takes the gas to 250 psi and the second stage goes from 250 psi to 500 psi. Each stage has its own slide valve. The motors driving the compressors produce about 1250 hp. The compressor is 8 ft long by 2.5 ft across. Hydraulic actuators control the slide valve since moderately highpressure oil was already available to seal the rotor gap inside the compressor and lubricate the radial and thrust bearings. The company initially controlled the slide valves via a distributed control system (DCS)
that communicated a position target for each slide valve, using a 4-20 mA analog link to a Modicon programmable logic controller (PLC). In turn, the PLC energized solenoids to activate two-position hydraulic shuttle valves to energize cylinders to move each compressor slide valve in one direction or the other, based on whether the pressure was above or below its setpoint. We had a very hard time getting the slide valves to move smoothly and precisely to the target position, and so we couldnt hold pressures at equilibrium, said Prins. In the field we had all sorts of restrictors and check valves attempting to try to convert essentially on/off controls into proportional controls. In the PLC, we had all sorts of timers and deadbands trying to balance process needs with hardware limitations. The application needed controls to actuate the slide valves with very precise and smooth movements, continued Prins. Dealing with the hydraulics is an area where we dont have a lot of experience.
Proportional servo valves
Figure 2 is the Moog Direct Drive Explosion Proof proportional valve selected for the Alberta EnviroFuels compressor control upgrade.
After studying the problem and consulting with engineers from motion control distributor PQ Systems of Burnaby, British Columbia, Canada, it was decided to replace much of the field hardware, and to use direct-drive proportional servo valves so that tighter control of the hydraulics could be accomplished (Figure 2). That raised the question of what would replace the position control software, previously in the PLC. Several PLC- and DCS-based options were considered, but the PQ Systems engineer advised that an easier and more effective way would be to interface the DCS setpoint signal for each slide valve to an electro-hydraulic motion controller, designed for smooth and precise closed-loop control of hydraulic actuators in all environmental conditions. Oil temperature was one of the variables that caused the original valve control system to behave poorly. During normal compressor operation the oil temperature is fairly consistent. However, when a compressor is in standby mode (not running, but available for immediate start-up), the oil temperature can vary significantly. This can have an effect on the time that the valve takes to move. The old system with the PLC controlling the bidirectional shuttle valves didnt handle the temperature differences smoothly. PQ systems recommended a motion controller (Figure 3) that can simultaneously control two motion axes, so one controller can control
Figure 3 shows that the motion controller that PQ systems recommended, the RMC75 manufactured by Delta Computer Systems Inc. of Battle Ground, Wash. The RMC75E motion controller supports two axes of control, interfaces directly to analog feedback devices, and connects via Ethernet for remote access.
2-axis control
both slide valves in the application. For feedback on the position of the slide valves, the controller was connected to a potentiometer mounted on each slide, producing an analog voltage relating to slide extension that can be read directly by the controller. Figure 4 shows how the system components are connected. Another analog input module on the controller connects to the output of the DCS-based process pressure controllers. Since the same DCS control scheme is used in the upgraded system, functioning in the same manner, the compressors operator interface needed only very minor changes as a result of the upgrade. This was a big plus for plant operators. The controller improved the way the controls work: The old hardware led to control loops that tended to be undertuned,
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inside machines
Slide valve commissioning took a couple of hours; without plotting, it would have taken much longer, or been nearly impossible.
Figure 4, a control diagram, shows connections between the DCS and motion controller and other system components.
PQ Systems applications specialist Rob Nash did the initial controller programming, with the assistance of Delta Computer engineer Don Denman. Those involved said the controller is easy to program, and since the design was initially implemented, Alberta EnviroFuels engineer Prins has made changes to tweak the systems operation. The controller uses an Ethernet interface, so Prins created an interface with the controller and made software upgrades from his office desk over the corporate network. Thats a lot more convenient than making trips to the plant floor and back, said Prins.
Tuning wizard, plotting function
Figure 5 is a plot from Delta Computer Systems Plot Manager software, showing the position feedback input versus target value and motion control output over time for the slide valves.
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At www.controleng.com/ archive, August, with this article, see other motion control articles. www.deltamotion.com www.moog.com
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which meant that the controls didnt respond well to upset conditions, and operators had to get involved if quick action was needed. Now with the closed-loop controller running at 1000 loops per second, tuning can be optimized and the controls respond more quickly and automatically to changing conditions. As a result, the hydrogen purification process maintains the target pressure more precisely and responds to environmental changes more quickly. Also, the control system no longer induces its own fluctuations that plagued the previous controls.
The tuning wizard and the plotting functions supported by the software provided were very helpful features used during commissioning, said Nash. The entire commissioning process for both slide valves took only a couple of hours, he continued. Without plotting it would have taken much longer, and logistically, since the controller was located across the plant outside of the hazardous area of the compressor and therefore out of sight visually, tuning of a slide valve without plotting capability would have been nearly impossible, Nash said. Figure 5 shows a typical plot produced by software. This application provides an example of how a programmable electro-hydraulic motion controller can be used to bring a process under control that was previously impacting the productivity of a manufacturing operation. Comparing the standard deviations of the discharge pressure distribution before and after the controls upgrade, we saw an improvement of about 70%, said Prins. As Alberta EnviroFuels found out, where precise motion and tight tolerances are involved, it pays to select a control system that is designed for the task. In this case, a motion controller had a clear advantage over a PLC. ce - Don Denman is senior applications engineer, Delta Computer Systems Inc. Edited by Mark T. Hoske, content manager, CFE Media, Control Engineering, mhoske@cfemedia.com.
IndustrialEnergy Management
Custom Energy Management
To maximize energy dollars, adopt strategies that fit your specific business
Curbing energy bills with demand-control technology Fuel cells are driving a new generation of power plants
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AUGUST 2013
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SCADA systems help boost solar system performance EN11
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IndustrialEnergyManagement
Sidney Hill, Jr.
INTRODUCTION
Industrial energy management is not a one-size-fits-all proposition

IT WOULD SEEM THAT cutting energy bills in an industrial facility wouldnt be much more complex than performing the same trick in your home. Sure, the occupants of a manufacturing plant consume a lot more energy than those of the average residence, but the concept of reducing energy useand the corresponding costsis the same. Flip off the lights, heating or air conditioning when a room is empty. Shut down any machinery thats not being used. Seal windows or other potential gaps through which energy can escape. Such measures have proven effective as first steps in an industrial energy management program, with some studies showing manufacturers posting double-digit reductions in energy consumption through these methods alone. Problems arise, however, when companies want to sustain, or even improve upon, those early gains. be used in this fashion. The supplement opens with an article on demandmanagement software, a class of technology that supports multiple approaches for taming energy costs without sacrificing production efficiency. Demand-management software is proving especially effective at reducing energy costs in metal foundries, which are among the biggest users of energy within the manufacturing space. Demand-management software can be equally effective in other industrial sectors, though it would have to be configured in a different fashion. Flip to page EN4 to learn more about these solutions. Next, you can read how fuel cell technology is driving a new generation of power plants. Fuel-cell plants offer a number of potential advantages over the current generation of power plants. Fuel cells produce much cleaner, more efficient, and more reliable energy from the same fossil-based fuels as the current generation of plants. In addition, because fuel cell plants have a much smaller footprint, they dont raise the same environmental concerns that typically accompany the construction of a new power plant. The fuel cell plants weve written about here have an even smaller footprint, thanks to their use of variable frequency drive technology. Get the full story, starting on page EN8. Finally, we have piece detailing how supervisory control and data acquisition (SCADA) technology can give manufacturers confidence that a solar PV system will provide the necessary energy to keep an industrial facility churning. The key is monitoring the performance of that system in real time, which SCADA systems have a long history of doing in industrial settings. That story starts on page EN11. After reading this entire package, we think youll agree that energy management technology vendors are building solutions that On the cover: can be customized to fit almost any Metal foundries, among the largest manufacturing setting. Well be covering many more energy consumers of these solutions in the months to in the manufacturing space, are prime come. If you stay with us, youre sure beneficiaries of to eventually come across one that demand-management will work perfectly in your business. technology. Sidney Hill, Jr., is a CFE Media Contributing Content Specialist, sidhilljr@gmail.com.
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..................................... . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technology vendors are developing a myriad of .. .. . ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . realize twin goals solutions . .. .. .. .. . to .. .help .. .. .manufacturers .. .. .. . .. ........ ........the ..... .. .. .. .. ... ... . . . . . .. .. ... ... ... .. .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . of.reducing energy bills and lowering carbon emissions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. .. .. .. .............. . .. .. .. .. .. .. .. .. .. .. . ..... .. .. .. .. . .. .. .. .. .. .Its .. .hard .. .. to keep cutting energy costs in the face of constantly rising energy prices. It has become harder still with the advent of things like peak-demand pricing programs, under which utilities attach a higher price to energy used at certain times of the day. The logical response would be to not use energy during those peak charge times. But manufacturers, whose first priority is always filling customer orders, cant always halt production for the sole reason of cutting energy costs.
Finding the right tradeoffs

Tradeoffs have to be made, and finding the right tradeoffs is not a one-size-fits-all proposition. Just as every business is different, so will the right solution for optimal management of energy costs. Technology vendors, recognizing that manufacturers have varied energy management needs, are developing a myriad of solutions to help manufacturers realize the twin goals of reducing energy bills and lowering carbon emissions. In essence, technology is starting to allow manufacturers to practice custom energy management, applying solutions to fit their specific business. This industrial energy management supplement presents several examples of technology that can
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Take charge of your energy bills

Demand-control technology supports multiple approaches for taming energy costs without sacricing production efciency
BY NOW, MOST MANUFACTURING managers fully understand the business case for conserving energy in the production process oever many still struggle ith nding the right energy-conservation strategies. The biggest challenge continues to be striking the proper balance between the twin corporate mandates of cutting energy costs and meeting customer-focused metrics such as high product uality and on-time delivery. The inherent need for precision when building products to specications adds a level of compleity to the energy-management euation.
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agement boom. Our technology is aimed at providing energy management solutions for industrial users, Patty Solberg, product marketing director for Powerit Solutions, said in a recent interview. Powerit offers software applications that address three aspects of industrial energy management: Peak-demand management Automated demand response Automated participation in real-time pricing programs. Powerit has packaged its solutions into a software suite called Spara DM (Demand Manager).
No matter what youre makingan electronic circuit, a wooden piece of furniture, a plastic toy, or a massive piece of metal equipmentparameters such as the amount of time or the temperature at which each operation is performed are crucial to delivering products that customers are willing to buy. And maintaining those exact parameters requires the use of specific amounts of energy. Manufacturers quest to be cost-efficient energy users has become even more complicated in recent years as utilities have instituted billing practices that penalize heavy energy consumers. These programs are especially harsh on those who consume large amounts of energy during times when demand on the power grid is highest, which historically has been right in the middle of most manufacturers workdays.
Avoid pricing penalties

The peak-demand management application, called Spara Demand Control, helps companies avoid the pricing penalties associated with using large amounts of energy when theres heavy demand on the power grid. And it does so without forcing users to lower production throughput, Solberg said. We have more than 180 installations of demandmanagement technology across North America, with a proven track record of reducing peak demand charges in industrial facilities anywhere from 10% to 30%, she said. That translates to a reduction in utility bills of 5% to 10% or more, depending on the size of the facility and its specific demand charges.
The importance of energy management
Navigant Research argues that efficient energy management will soon be as important as product quality in determining manufacturers competitive position within their respective industries. That importance, according to Navigant, is reflected in the compound annual growth rate for industrial energy management software and services. At its current growth rate, the global market for industrial energy management solutions will nearly double over the next 7 years, going from $11.3 billion in 2013 to $22.4 billion in 2020, according to a recent Navigant study. Naturally, the large industrial automation equipment suppliers, such as Rockwell Automation, Siemens, Invensys, Schneider Electric and others will be major beneficiaries of this rapid growth. However, Navigant believes there are potential opportunities for other players as well. For instance, major IT companies like IBM and SAP, with expertise in handling large data sets and sophisticated real-time business analytics, could make inroads, along with smaller niche players who are able to offer unique products and a special level of customer service. When it comes to the niche players, Navigant argues that their ultimate success will be tied to their ability to link their unique solutions to the User-friendly demand management: energy-management ecosystems alPowerit Solutions says its cloud-based ready being built by the larger players. Spara Hub gives its customers and Seattle-based Powerit Solutions technology partners a user-friendly tool fits Navigants profile of a smaller for enhancing their ability to optimize energy vendor thats poised to prosper from use for savings and sustainability. the impending industrial energy manWWW.CONTROLENG.COM
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Energy tech boom: At its current growth rate, the global market for industrial energy management solutions will exceed $22 billion by 2020, according to Navigant Research.
Spara Demand Response, the second application in the Spara DM suite, equips companies to become active participants in a utility companys demand-response program. Under a demand-response program, an industrial user can reap substantial financial benefits by agreeing to severely limit consumption during periods in which theres extreme stress on the power grid. The benefits can be discounts on energy bills, or they can be cash rebates if the user engages the services or a company that specializes in aggregating power and managing energy curtailment programs for groups of users. Its nearly impossible for manufacturers to achieve the full benefits of a demand-response program without the aid of sophisticated technology. Thats because these programs require users to reduce consumption whenever the utility announces a demand-response event. While utilities, through their own use of technology, typically can predict when a demand-response event will occur, there are times when program participants get little advance warning of the need to cut power usage. Most utilities try to give users at least 24 hours to respond to a demand-response event. However, the reality is that as the worlds appetite for power grows, the instances of shorter noticessometimes only a matter of minutesare becoming more frequent. And those short notices can cause major problems for manufacturers who are trying to maintain production schedules while holding the line on energy costs. Thats why manufacturers wishing to participate in demand-response programs need solutions like Spara Demand Response. The application allows for mapping energy consumption across an entire production network, providing the insight necessary to determine which operations can be idled to accommodate any demand-response event without jeopardizing critical production schedules. Finally, Spara Dynamic Pricing helps companies make intelligent choices about cutting energy use if their utility operates a dynamic pricing program, which causes prices
to change constantly based on market conditions. These programs typically offer users even less warning of price changes than they would get from a demand-response event. Under dynamic pricing, the price of energy could change multiple times in a day. However, companies that participate in these programs find them worthwhile because they can yield rate discounts of 20% to 40% when compared to traditional metered rates. Spara Dynamic Pricing currently is the least used of Powerits three applications because utilities have been somewhat slow in rolling out dynamic pricing schedules. Today, were seeing a lot of interest around demand control and automated demand response, Solberg said. Regardless of the specific applications being used, the setup and configuration of the Spara technology is the same. Theres a connection to the facilitys utility meter, which allows for tracking the amount and cost of energy consumed. Then, in consultation with the plants manager, Powerit connects the system to various machines throughout the plant. Were always connected to the utility meter, Solberg explained. Thats the baseline. We need to know the facilitys overall consumption because thats what the utility bill is based on. Then we look at every machine that consumes energy to determine which loads it makes the most sense for us to control. We dont always control just production loads. Sometimes we might control the office HVAC in order to offset a production peak. The implementation includes setting constraints within the Spara system so that any scheduled power shutdowns will be overridden if the system determines that action will disrupt a critical production run. Once configured, Spara functions like what Solberg describes as an omniscient plant manager, making real-time decisions on energy use that always strike the optimum balance between production performance and energy cost.
How the technology works

After the initial installation, Powerit will experiment by reducing loads on certain machines and then monitoring to see how that impacts both peak demand levels and production efficiency. If the effect is positive, those settings stay
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intact; otherwise, they are changed and monitored again. The loads selected for initial monitoring vary by type of facility. However, in line with Navigants theory that small vendors must have special expertise, Powerit has established a strong presence among food and beverage manufacturers and metal foundries. We do have a lot of foundry customers, Solberg said. Metal-melting furnaces are common loads to control in those facilities. Foundries typically have multiple furnaces feeding various casting lines. Without a demand control solution in place, those furnaces operate independently of one another, and its not unusual for one or more of them to run longer than necessary, which means they are wasting large amounts of energy. A demand-control application can, in effect, operate multiple furnaces as if they are a single unit. It allows a plant manager to easily determine which furnaces should be shut down, and for how long, in order to avoid peak demand charges while also protecting production schedules. With Spara technology those decisions are made automatically, based on the constraints that are set during system implementation, Solberg said. Because you have multiple furnaces feeding a casting line, there will be some natural buffers built in, she said. If three furnaces are feeding a single casting line, you can power down the furnace that will be last to feed the line to avoid peak demand. Then, you can power that furnace up again in time for it to meet its schedule for feeding the line. Rochester Metal Products is among the foundries that have benefited from the use of the Spara DM platform. Based in Rochester, Ind., Rochester Metals supplies products to customers in numerous industries, including manufacturers of air compressors, and medical, automotive, heavy construction, and marine equipment. Rochester Metals adopted the Spara platform after learning that its utility was implementing a new peak-demand pricing structure. The system is connected to all furnaces used in Rochesters melting process. When the system recognizes a peak-demand period, it can immediately determine which furnace is not needed at that given moment, and it sheds load from that furnace first.
ing hasnt changed, Solberg said. Whats changed is how, and when, they use those kilowatt hours. That has created a significant decrease in their utility bill. Powerit helps customers configure its applications to tap into its inherent intelligence for selecting the right loads to control for cost-efficient energy management. However, some users have made adjustments to their production processes to take further advantage of the technology. On the first pass, the savings we offer generally dont involve touching the process flow, Solberg said. But the system does allow operators to see everything thats going on in a plant from an energy consumption standpoint. That gives them the power to tweak things to really optimize energy usage. Early this year, Powerit introduced a cloud-based version of its platform that Solberg said will further enhance customers ability to analyze and optimize energy use.
. . .amount . . . .of.kilowatt ..... . . .theyre .... ... . . .changed ..... The hours using hasnt . . .. . . . . . . . . .
and they hours. Whats . .. .. . changed . ........is..how, .... .. .. ..when, .. .. . .. .. .use .. .those .. .. .kilowatt .. .. .. .. .. . .. .. .. .. . . . . . . . . . . . . . . . . . . That has created a significant decrease in their utility bill. ....................... ..................
The new solution, called Spara Hub, offers the typical benefits associated with cloud-based applications, such as faster deployment and streamlined maintenance. But the real advantage, according to Solberg, is the additional functionality we can deliver as a hosted solution. Operating on a hosted platform will allow Powerit to develop a single method for connecting its applications to utility networks as well as to the technology platforms of the larger industrial automation equipment suppliers. The platform lets us build standard connections to utilities and power aggregators for bringing pricing information back to our customers, Solberg said. Were also partnering with major automation vendors to embed our software capabilities into their ecosystems. Ultimately, Solberg believes having the Spara solution in the cloud will make it easier to show manufacturers the true value of an industrial energy management strategy. If a company has a metering system that shows their consumption patterns, they can redirect that data to our hosted platform, where we can do a quick analysis on their potential energy savings, she explained. We can do that analysis without a hosted platform, but we would first have to install hardware at the customers site and do a fair amount of engineering work to get the data we would need. For more information visit: www.poweritsolutions.com
. .. .. .. .. . .... .. .. .. .. .. . ............. .. . .. .. .. .......... . .. .. .. .. .. .. .. .. .. . . . . . . . . ..................... . .. .. .. .. .........
Same usage; much lower bill

Before adopting Spara DM, Rochester Metals typical monthly peak demand was 21,000 kW. After testing the system for a month at 18,000 kW, with no impact on production, the setpoint was adjusted to 17,000 kW. Again, there was no production loss, so the setpoint was moved to 16,000 kW, which is where it remains today with no production loss. In reality, the amount of kilowatt hours theyre usWWW.CONTROLENG.COM
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by Sidney Hill, Jr.
Driving a new generation of power plants

Variable frequency drive technology supports versatile, reliable, low-cost power inverters for industry-leading supplier of fuel cell plants.
FUEL CELL TECHNOLOGY is showing great promise as a potential answer to the worlds growing demand for cleaner, cheaper forms of energy. As a power source, fuel cells, which essentially are electrochemical devices that combine fuel with oxygen to produce electricity and heat, offer many advantages when compared with both traditional fossil fuel power generators and renewable forms of energy. Fuel cells produce much cleaner, more efficient energy from the same fossil-based fuel. And because they dont rely on unpredictableand sometimes unavailablepower sources such as sunlight, wind, or water, fuel cells can offer a more reliable source of energy than the renewables. Companies that build fuel cell power plants also are conquering another issue that is leading to power shortages in much of the industrialized world: the difficulty of adding capacity to the power grid. Fuel cell plants are being built ator very close to the locations at which the power is consumed, breaking the mold of reliance on centrally located plants that employ long strings of unsightly, and potentially dangerous,
Environmentally friendly: The liquid-cooled design of the Rockwell PowerFlex 700L VFD allows for a small footprint, making it easy to fit the drive into a sealed outdoor enclosure, which extends the life of the electrical equipment.
power lines to deliver energy to consumers. The practice of locating fuel cell plants near the point of consumption is known as distributed generation, and
A steady source: FuelCell Energy finds its new VFD solution remarkably reliableenabling its plants to supply continuous power with minimal downtime.
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Champ
Generating power: Fuel cell power plants produce power through the formation of hydrogen from a fuel sourceusually clean natural gas or renewable biogas.
one way to make the energy conversion process more efficient is through integration of variable frequency drive (VFD) technology. FuelCell Energy Inc., of Danbury, Conn., builds three types of fuel-cell systems: One that provides 300 kW of continuous power output A second that produces 1.4 MW of continuous power A third that generates 2.8 MW of continuous power. The company says its 300 kW system is suitable for powering smaller commercial operations such as supermarkets or medium-sized hospitals. Gills Onions, a manufacturer of freshcut, packaged onions based in Oxnard, Calif., relies on two of these systems to run its entire operation.
that waste into enough energy to power its entire operation. The remaining 25% of the waste is sold as cattle feed.
Significant savings cited

Gills estimates that it saves $700,000 a year on power costs and another $400,000 per year in waste disposal costs. FuelCell Energys 1.4 MW units can supply the power needs of large hotels, conventions centers, and similar facilities. The 2.8 MW units can support even larger operations such as universities and large manufacturing complexes. FuelCell Energy also can offer customers even more power by combining several units to form a multi-megawatt fuel-cell park, which it is doing for utility companies. For example, the company has an ongoing project in the city of Bridgeport, Conn., in which 5 of its fuel cell systems will combine to form a 15 MW fuel-cell park providing electricity to the power to the local power grid. A critical step in delivering fuel cell power to consumers is converting the dc power generated by the fuel cells into the ac power that is standard for use on the power grid. That conversion is performed by a piece of equipment called a power inverter, and Rockwell Automation supplies the hardware and supporting technology that drives the power inverters in all of FuelCell Energys systems.
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Saving money, and the planet

Gills Onions also is demonstrating how fuel cell power can help save the environment while also saving money for energy users. Gills takes freshly grown onions and packages them for sale to supermarkets, fast food chains, and manufacturers of food products ranging from salsa to spaghetti sauce. Its production process generates roughly 300,000 pounds of waste each day. Since 2009, Gills has used the FuelCell Energy systems to convert 75% of
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Power Flow: This is the one-line diagram for FuelCell Energys 1.5 MW power plant.
A Rockwell Automation variable frequency drive (VFD) is a core piece of the power inverters that FuelCell Energy employs. FuelCell Energy selected Rockwell as its VFD supplier primarily because Rockwells drive technology met all of FuelCells power conversion needs. However, FuelCell also knew that Rockwell, as a well-established, global company, would be able to support FuelCells growing business, which includes building and installing power plants across North America and Europe. As their partnership expanded, Rockwell and FuelCell decided it made sense to bring together engineering teams from the two companies to develop a drive that would meet FuelCells unique power-conversion needs.
Liquid-cooled VFDs can be built in smaller, tightly sealed enclosures because they dont require extra components such as fans or heat exchangers to prevent the drive from overheating. Temperature fluctuations are one of the main causes of semiconductor failure, said Doug Weber, business development manager for Rockwells Voltage OEM Drive Team. Liquid cooling alleviates that problem by keeping the semiconductors operating at a constant temperature. The tight seal on a liquid-cooled drive also keep air or other substances that might cause damage away from the drive, which lowers the amount of maintenance required for the drive and extends its useful life.
Custom enclosure
Rockwell also built a custom enclosure to provide additional protection for the drives installed in the FuelCell Energy power inverters. We worked with a sheet metal supplier to design an enclosure that was based on our experience with the outdoor enclosures that we have been providing for the oil and water pumping industries for a number of years, said Brian Bosch, program manager for Rockwells low-voltage drives team. Its an outdoor-rated Type 3R enclosure, thats essentially waterproof. We validated that through environmental testing. We also built a custom thermal chamber that fits around the enclosure to allow for temperature testing up to 50 C. Lisowski said Rockwells positive impact on FuelCell Energys business has been wide ranging. The team included every aspect of engineering, production, testing, and support, Lisowski said of the power inverter project. The results were impressive. We were able to streamline the design and reduce parts count by a substantial margin. The size of the power conversion unit was reduced to give us a very high power density and decrease the overall plant size. The liquid cooling increased efficiency and reduced noise. The final designs scalable and modular architecture allowed us to use a single production design building block to power two models of fuel cell power plant. This reduces the cost to our customers without sacrificing performance or reliability. For more information visit: www.fuelcellenergy.com or http://ab.rockwellautomation.com/drives/low-voltageac-drives
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A long-standing partnership
We have been using Rockwells standard VFDs for many years, said Michael Lisowski, vice president, supply chain, for FuelCell Energy. As our power plants evolved and reached a stable design configuration and our installed base grew, it was time for both companies to jointly develop a power-conversion system design. The solution is the culmination of the diverse experience of both companies working in somewhat different industries, coming together with the common goal to release the best product possible. As a result of this collaboration, the system FuelCell Energy uses to convert fuel cell power from ac to dc is built around The Allen-Bradley PowerFlex 700L VFD. This is a standard Rockwell VFD, but it has some characteristics that were particularly attractive to FuelCell Energy. In addition, Rockwells low-voltage drive team worked with FuelCell Energy to develop some additional support components to make the drive more robust and enable it to provide highquality ac power in accordance with and local guidelines. Liquid-cooled drives with exceptional performance, efficiency, and reliability are now the core of the power conversion solution for FuelCell Energy power plants, Lisowski said. Our customers benefit from a high-quality and reliable product.
by Marlee Rosen
11 11 EN
Real-time monitoring is critical for sustaining solar PV energy output

SCADA technology monitors, controls, and delivers system performance data down to the string level.
PRODUCING ODUCING CLEAN ENERGY is the primary function of any renewable energy system. However, regardless of its source of generation, an industrial energy system must consistently produce enough power to support the operations of the facility in which its located. When contemplating the use of a solar electric photovoltaic (PV) system, it is first important to assess how much energy the system can produce according to location, orientation, and plant conversion efficiency. That assessment ultimately will depend on the kind of technology and quality of system components. Making sure an industrial energy system is always producing sufficient power requires monitoring its performance around the clock. That can only be done through use of a real-time performance monitoring system. And its becoming increasingly clear that industrial automation technology particularly the class of systems known as SCADA (supervisory control and data acquisition)provides an ideal platform for both controlling and monitoring the performance of solar electric PV systemsin real time.
Power Maintenance: This is the configuration for using SCADA technology to provide real-time performance monitoring of a solar PV system.
From sunlight to dc current

PV systems use cells to convert, with determined efficiency, sunlight into direct current (dc) electricity. Usually made of silicon, cells come wired together in a panel or a group of panels mounted together on a frame, which is called a PV array. PV systems also include several pieces of equipment in addition to the PV array. The balance of system (BOS) comprises components that typically include racks and other mounting equipment for the solar panels, combiners, inverters, wiring, transformers, and (if desired) a form of electricity storage (typically batteries). We are all familiar with our residential electric meter used by the utility company to record and bill us monthly for the kilowatt-hours consumed. Over the course of a year, these bills can be compared to determine monthly consumption. While this scenario illustrates usage consumption, it is different for monitoring production with PV systems. A meter is also used to measure the energy produced but, instead of a monthly basis, we are interested in the amount of energy produced during short time intervalsperhaps every hour or every 5 minutes. The recording frequency requires more sophisticated meters than the residential ones called data
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loggers. Data loggers feed data into a memory system that can be archived for use at a later time. They also have communication interfaces (Ethernet or serial ports), which allow a computer to connect to it and retrieve the data.
Distributed generation standards

Most electric utilities in the United States have adopted standard criteria and guidelines for interconnection of distributed generation (DG) to their electric distribution systems. Photovoltaic system installations effectively reduce the customer load and, during minimum loading conditions, may export energy back to the utility in a transaction known as net energy metering (NEM). A set of guidelines (IEEE P1547.6) were recommended by the Institute of Electrical and Electronic Engineers (IEEE) to be incorporated within the design of PV systems and operate in parallel with utility systems. One such system designer is Staer Sistemi, which tackled the design of the first PV automated management system in late 2009 and has since revised it over the last 4 years. The initial design comprised the use of a simple DAS (data acquisition system), but Staer Sistemi quickly identified that due to the volatility of solar radiation at ground levelmainly due to atmospheric turbulencea pretty fast sampling pace (5 seconds or less) would be required. Due to this requirement, Staer Sistemi decided the best approach would be to
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System view: The user interface of a solar PV application that employs SCADA technology (left) shows panels, PV arrays and inverters. An HMI interface (right) enables monitoring energy output in real time.
develop the final application in an industrial established SCADA environment. This would allow designers to manage data streams in the range of several thousand measures per second. After conducting numerous system tests as a proof of concept, Staer Sistemi configured a low-weight, industrial SCADA software, PcVue from Arc Informatique, to meet its PV application requirements. This SCADA provided flexibility in monitoring and controlling the various plant component and operations, including trackers, inverters, substations, and meters. PcVue was used in all company flagship installations with some PV plants exceeding 5 MWp (megawatt peak) individually and in some larger multi-tenant, multi-site systems too. Designed for the monitoring of the performance, the system logs any problem and triggers alarms so that the engineering staff can fix or change components or fine-tune the process of plant operation.
Performance management methodology

The system monitors the performance by means of a sophisticated mathematical model initialized once at installation time with some plant design data: PV panels peak power, inverters, manufacturer-provided electric parameters, number of strings, strings length, etc. The model is then continuously fed with local weather data and calculates in real time what would be the correct energy production at 100% of plant capacity. The automatic comparison between the calculated and the real production figures (supplied by the already mentioned data logger) will give a precise indication of the plant performance or plant health every minute or less. Today monitoring and performance analysis of solar PV plants has become extremely critical due to the increasing cost of operation and maintenance as well as reducing yield due to performance degradation during the lifecycle of the plant equipment. This means that the use of a monitoring system can become essential to ensure high performance, low downtime, and fault detection of a solar PV power plant during the entire lifecycle. From a technical point of view, it is interesting to underSUPPLEMENT TO CONTROL ENGINEERING
stand how the overall data acquisition is performed starting from the dc level. Here, string combiner boxes designed for PV installations have built-in string probe units that measure the values of dc current voltage and power made available through a serial RS485 port (different methods or wireless can be used) for communication to the SCADA via ModBus. Some RTUs (remote terminal units) are installed at the field location that connects to multiple string junction boxes on the already mentioned RS485 multi-drop loops. At the ac level, inverters expose RS485 ports to allow an easy connection. The native communication drivers from PcVue collect data from control boxes and RTUs with a time stamp for real-time processing, storage, alarming, reporting, and displaying. This is in order for both dc and ac side parameters, status, and diagnostics to be continuously acquired. The SCADA capabilities are further used in monitoring of grid protection relays, energy meters, weather monitoring station/sensors, LT (low tension) and HT (high tension that starts from 3 kV) control panels, dc switches, transformers, and in general any devices capable of affectingdirectly or indirectlyplant production. Additionally, to make PV applications as efficient, sustainable, and scalable as possible, its important to take into consideration other aspects of the SCADA application. These include dynamic configuration, stand-alone and client-server configurations, redundancy for data protection, historical and real-time trends analysis, as well as advanced alarm management. Looking further at compliance, the support of such protocols as IEC 61850 and DNP3 is considered an asset if you have to communicate with various electric substation devices, for example. In order to access all data points, a user-friendly graphical interface with 2D and 3D displays, report generator, scheduler, and an event-driven engine all make the process much smoother. Finally, Web access capabilities provide all kinds of mobility and access to remote devices the application may need. Marlee Rosen is an energy market research analyst with Rosen Associates. For more information, visit: http://www.staersistemi.it/en
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The following is an alphabetical listing of the participating advertisersin Control Engineerings annual Internet Prole program in-print and on-line:
Allied Electronics ASCO Valve Inc. Automation Direct Banner Engineering Beckhoff Automation Cognex Eaton EMCO High Voltage Corporation Honeywell Kepware Moore Industries Moxa National Instruments OPTO 22 Panduit PanelShop.com, LLC PINA SEW Eurodrive
Please visit the participating advertiser Websites where you will nd the latest multi-media programs, interactive features, and useful product information for engineers.
Allied Electronics Your Top Internet Retailer

Allied Electronics has been named one of the Top 500 Internet Retailers in America by Internet Retailer Magazine for the third consecutive year. Achieving its highest marks ever, Alliedelec.com ranked #126 in the 2013 edition of the guide. 3 Million Products Allied has the products you need when you need them, and searching for them at alliedelec.com couldnt be easier. Search by manufacturers number, Allied SKU number, manufacturer, key word or the easy-to-use Product Finder. Plus, you can view a virtual catalog under the Catalog tab. Information at Your Fingertips Alliedelec.com has the tools you need to help make the best possible purchase for your project. Find product photos, overviews, specs and data sheets. Check real-time inventory, and nd out exactly when your product will ship. If the search result doesnt quite meet your needs, you will nd suggestions for similar products. Featured Products Browse new products, and see whats popular in our Featured Products sections. Product Specials We make it easy to nd our product specials. Click on the Current Specials tab to see all the online discounts, free products with purchase and other special offers. Order Today, Ships Today All orders of in-stock merchandise placed by 10 pm ET will ship the very same day. Next-day delivery is available for orders of in-stock merchandise placed by 8 pm ET. Buy the products you need from Americas Internet retailer of choice at alliedelec.com
Telephone: +1 (866) 433-5722 | www. alliedelec.com
Right. Now.
For ultra-reliable performance and delivery, turn to ASCO: the world leader in solenoid valve technology. Our uid automation offerings control ows of air, gas, water, oil, and steam across the globe. Recent innovations include microminiature designs, low-power solenoid valves, and position indicators with network communications capabilities. With tens of thousands of models available, youll nd just the right solutions for your demanding application. ASCO makes the worlds most reliable ow control solutions delivered and serviced with exceptional speed and responsiveness. Some last up to 500 million cycles; many are shipped within one day with our ASCO Today program. When you need help, we respond fast. We can send a skilled technician onsite within 24 hours. As part Emerson, the planets largest process automation supplier, our experienced representatives provide the industrys best technical support and service, around the clock and around the globe. With our deep applications expertise and global service, ASCO is the uid automation supplier of choice for customers desiring the lowest cost of ownership, greatest asset availability, and highest productivity. ASCOs product lines include: RedHat Solenoid Valves: largest selection of 2-, 3-, and 4-way solenoid valves, designed to handle the most demanding uid control applications ASCO Scientic: highest-quality micro-miniature solenoid valves and accessories for industrial, medical, and analytical applications Valve Monitoring Systems: integrated visual indication technology with network communication capabilities for position indication solutions Process Automation: pilot valves and control accessories for reliable process solutions Pressure/Temperature Switches & Sensors: devices for pressure and temperature monitoring ASCO S Series: compact valve solutions for commercial applications
1-800-972-ASCO (2726) | info-valve@asco.com | www.ascovalve.com
AutomationDirect is a distributor of 13,000+
industrial automation products including Programmable Logic Controllers (PLCs), Programmable Automation Controllers (PACs), AC drives/motors, operator interface panels/HMI, power supplies, DC motors, sensors, push buttons, NEMA enclosures, pneumatic supplies, and much more. In business since 1994, the company headquarters is located just north of Atlanta, Georgia. Our prices are low. Our prices are well below the list price of more traditional automation companies because with our business model and focus on efciency, AutomationDirect has the lowest overhead in the industry.
We make ordering easy and our service is exceptional. Shop online with our exhaustive product listings or browse our online catalog; fax or phone us youll get friendly, efcient service from the most helpful sales team in the business. Independent surveys completed by readers of Control Design magazine placed us at the top of the list for service 12 years in a row in their Readers Choice awards. Other surveys by magazines such as Control Engineering and Control have echoed the results. We ship super fast (and FREE 2-day transit on orders over $49). The majority of our products are stocked for same-day shipping. Orders placed by 6 p.m. EST will ship the same day with approved company credit or credit card. LTL items require 5 p.m. order cutoff and some limitations apply as 2-day transit time does not apply for LTL shipping of heavy itmes. See Terms and Conditions online for full details. We guarantee it. We want you to be pleased with every order. Thats why we offer a 30-day money-back guarantee on almost every stock product we sell, including our software (see Terms and Conditions for certain exclusions).
For more information, contact us at 800-633-0405 or visit www.automationdirect.com.
Customer-First Philosophy Drives Banners Culture and Website

Every 3.5 seconds, a Banner sensor is installed somewhere in the worldand at any given time, web users from at least ve different countries are visiting bannerengineering.com Whether Banner customers are on the manufacturing oor setting up applications or in the ofce designing automation solutions, bannerengineering.com is the go-to tool, delivering valuable, online experiences intended to make customers lives easy. Manufacturing Specialist - Banner Engineering is a leading manufacturer of sensors, machine safety, vision, lighting and indication, and wireless products. With more than 30,000 products available on bannerengineering.com, the sites robust search queries and product selection guides enable customers to quickly identify products to support their factory automation and lean manufacturing objectives. For every product Banner manufactures and sells, users can nd content ranging from model-specic specications, CAD les and user manuals to product images, brochures and accessories. The sites email function allows users to email links to product data and documents. Application Solution Experts - Banners application engineers have practical, hands-on training and extensive industry experience. They can rapidly analyze an application to help customers nd the best solution. Bannerengineering.com users can browse application notesor contact an application engineer directly to receive customized solutions to their specic challenges. Product Innovation - Every year Banner releases many new products for industrial and process automationto help customers increase efciency, ensure quality, monitor and control processes, and safeguard employees. Global Presence - Banner is committed to customers around the world. The company has a worldwide support network of 3,000 professionals who are ready to help you in your plant no matter where you are located. Website visitors can use bannerengineering.com to locate a distributor in their area through the sites distributor look-up function. When using our mobile site, enhanced domestic distributor search functionality relies on users phone/tablets GPS services to automatically determine your location and available distributors in the area. Whatever you industry or location, Banner Engineering has a solution to help you automate your plants, improve efciency and manufacture quality productsand bannerengineering.com can help you nd it.
To learn more, visit or contact Banner at sensors@bannerengineering.com or 1-888-3-SENSOR. To test out our capabilities now, try our new online tower light configurator at bannerengineering.com/towerlights.
Beckhoff Automation
Beckhoff Automation provides advanced, open automation products based upon proven industrial technologies. Manufacturers and machine builders can implement high performance Beckhoff control systems more efciently and at a lower overall cost than traditional PLC and motion control systems. Beckhoff has been a long-time proponent of open controls architectures, full system interoperability, seamless machine-to-machine communication and lean automation solutions. As more technology companies are calling for these types of cost-efcient solutions, Beckhoff is well-positioned today to support them. Beckhoff sales and service are handled directly, with no intermediaries involved for exceptional customer service and consultation. Problem-Solving Technologies On Beckhoffs website, visitors will learn more about the complete Beckhoff product range via informative multimedia content, digital brochures, technical documentation and more. This includes PC-based control, Industrial PCs, Embedded PCs, programmable automation controllers (PACs), PLCs, operator interfaces, I/O compatible with over 15 different eldbuses, EtherCAT (next generation Ethernet eldbus technology), TwinSAFE safety solutions, servo drives and motors. Another advanced solution from Beckhoff is TwinCAT 3, which represents a convergence of automation and the IT world; this is referred to as eXtended Automation Technology (XAT). Feature-Laden Solutions While supporting all IEC 61131-3 programming languages and providing active support of multi-core systems, Beckhoff advances leading edge automation solutions that deliver high performance at a low cost. This includes Scientic Automation, which merges automation, PLC and motion control with advanced condition monitoring and precise measurement technologies. This can be handled all on one powerful, PC-based automation controller and cost-effective EtherCAT Terminals, eliminating the need for many expensive black boxes. Worldwide Presence Beckhoff Automation North American headquarters is located in Savage, Minn. (Minneapolis area). At this location, administration, product and engineering management, warehousing and training occurs. There are also regional technical centers located in Chicago, San Diego, Calif.; Charlotte, NC; Mill Creek, Wash.; Fond du Lac, Wisc. and Mississauga, Ontario. Beckhoffs global headquarters, including product design and assembly facilities, is located in Verl, Germany. Between direct owned subsidiaries and worldwide co-operation with partners, Beckhoff is represented in 60+ countries
Email: beckhoff.usa@beckhoff.com | Phone: 1-877-TwinCAT | www.beckhoffautomation.com
Cognex machine vision and industrial ID products

Improve product quality. Eliminate production errors. Lower manufacturing costs. Exceed customer expectations. Four reasons people choose Cognex vision and ID. Applications include detecting defects, monitoring production lines, guiding assembly robots, and tracking, sorting and identifying parts. Cognex offers the widest range of VISION and ID products available from a single source: Vision Systems In-Sight systems are powerful, self contained products for all kinds of vision applications. They combine camera, processor, and software into a single package, with a simple and exible user interface for conguring your application. Three available hardware platforms offer a range of resolution and performance to match your needs, and offer world class connectivity to all major factory networks. In-Sight also has a full set of robot drivers and can be integrated with all of the top HMI tools. Fixed-Mount Industrial-ID Readers DataMan readers offer the smallest and highest performance in the industry, reading everything from simple bar codes to challenging DPM marks reliably every time. New ground-breaking technologies include autofocus and industrial connectivity capabilities. Vision Sensors Checker sensors are easy to use and affordable. They are used to check the presence and size of parts and products. Can be used in a wide range of applications where traditional sensors cannot provide solutions. Handheld Industrial-ID Readers DataMan offers the widest range of industrial handheld readers in the industry. With innovative lighting, image acquisition, and code reading capabilities, they can read virtually any code on any surface. Vision Software VisionPro software gives the most exibility, by combining the full library of powerful Cognex vision tools with the cameras, frame grabbers and peripherals of your choice. Enables easy integration with PC-based data and control programs. All Cognex products incorporate innovative technology that has led the world since 1981, and are universally recognized as offering the highest accuracy, reliability, and performance. With more than half a million systems installed worldwide, inspecting billions of products every day, Cognex helps manufacturers operating in all industry sectors isolate defective parts, optimize production processes, and implement full traceability programs
Call U.S. Sales: 855-4-COGNEX(855-426-4639) or email: contactus@cognex.com
Energizing automation to meet tomorrows demanding world.

At Eaton, powering a world that demands more inspires us. With over 100 years experience in electrical power management, we have the expertise to see beyond today. Which is why youll nd Eaton engineers collaborating right now with some of the worlds most innovative companies to create solutions that deliver unimagined reliability, efciency and safety. Optimizing automation to meet aggressive, precision-driven production quotas is the very reason M+C Schiffer considers Eaton a critical partner. M+C Schiffer is a global leader in toothbrush manufacturing. They produce 1 million toothbrushes 24/7. The operation demands power dependability and enhanced functionality. The Eaton XV102 HMI/PLC and XP700 operator interface automate a awless start to nish process. When a high-end German auto manufacturer posed the challenge of expanding its existing operation in China, we leapt at the opportunity. A newly designed conveyor system had to be powered to transfer auto bodies to multiple welding stations. As well as integrate into the existing plant automation structure. The complexity made this no ordinary project. It took extraordinary thinking. Eatons custom solution started with revolutionary SmartWire-DT technology. It makes traditional point-to-point wiring obsolete and cuts wiring effort by more than 60%. Which in turn, cut the projects installation time by 22 business days.
Eaton solutions are shaping tomorrows world today. You can read all about these challenging projects at eaton.com/followthecharge.
Leading the Way in High Voltage Technology

EMCO High Voltage Corporation is a world-class high voltage power supply designer and manufacturer. Our high voltage power supply products set industry standards for size, performance, and reliability. Leveraging over four decades of high voltage research and development, EMCO develops products that meet the most demanding application requirements while remaining cost effective. Reliable Power Supply Solutions for Your Industry EMCOs broad array of proportional and regulated DC to HV DC converters offers customers maximum exibility when designing high-precision products. Our advancements in miniaturization expand options and opportunities for designers of hand-held and portable high-voltage applications. The long-term reliability and robust design of EMCO high voltage power supplies make applications for their use almost endless, even in the most hostile environments, allowing utilization across various markets and applications, including: Aerospace Consumer/Industrial Medical Military/Defense Scientic Outstanding Support EMCOs uncompromising commitment to quality and reliability throughout the last four decades has resulted in our products becoming a trusted part in many generations of our customers products. We support our customers through the buying process and beyond. Product Certications EMCO High Voltage is committed to designing and manufacturing the best products. We hold ourselves to the highest standards and actively seek out external certications from authorities such as UL, IPC, REACH, RoHS, and ISO. Our Website Our goal is to understand the customer experience and provide the information our customers need to make educated product selections. We strive to continually offer new resources. On our website, www.emcohighvoltage.com, you can learn more about our power supplies and accessories by viewing technical documentation and tutorials.
Contact EMCO at: Phone: (800)546-3680 | Email: sales@emcohv.com
Experion Virtualization Solutions
Watch the video at www.honeywellprocess.com/virtualization Experion Virtualization Solutions is leading the industry in innovation. Honeywell was the rst automation supplier to provide a comprehensive virtualization solution supported from assessment and virtualized design through implementation and management. Now, Honeywell has introduced a Premium Platform for Experion Virtualization Solutions. Leveraging blade server technology, it delivers advanced virtualization capabilities, including automatic host recovery and upgrades with zero operational disruption. In addition, the platform has a longer lifecycle, reduced facility footprint and remote management capabilities in a package that is pre-congured, saving you time to deploy. Premium Platform capabilities include: Zero downtime for hardware and virtualization software maintenance Automatic host recovery: Mean time to repair of minutes in the event of hardware failure Longer life than traditional server hardware Add new processing capacity online with no conguration required Unmatched space, power, cooling and weight efciency Precongured solution Templating for virtualized design
Honeywell is the proven leader to navigate the world of open systems and changing technology. We are changing control by controlling change.
To learn more please visit HoneywellProcess.com
Kepware Technologies Launching New Website & Account Portal

Answering the Needs of Our Customers and Partners Kepware Technologies will launch a new website that better addresses the needs of the companys Customers and Partners in Fall 2013. The website will offer the following features and functionality: Refreshed content throughout the site, including product information, Support & Maintenance policy information, licensing help, and an enhanced Knowledge Base library. More intuitive navigation based on web-standard navigation tools. The ability to schedule services, such as Training, Support, and a Pre-Sales Consultation with a Kepware Applications Engineer. A comprehensive Support Center with a searchable library of Technical Manuals and Help Documentation. End User access to Kepwares database of domestic and international Distributors and System Integrators. A simplied shopping and checkout process. Our goal is to better educate our customers about our solutions, and ultimately give them a better online experience with our brand, states Torey Penrod-Cambra, Marketing Communications Manager with Kepware Technologies. Kepware.com is an extension of our company, our people, and our products. Therefore, it must meet the high standards our customers have come to expect from Kepware. Providing Easy-to-Access Product Downloads - The new www.kepware.com will offer more accessible product downloads, including the ability to download the latest version KEPServerEX, Kepwares agship product, directly from the homepage. Demonstration software is fully functional and only limited in its runtime to two-hour periods. Designing an Intuitive Account Self-Service Portal - Kepware is launching a restructured and refreshed customer Account portal (formerly My Kepware) with the launch of the website in Fall 2013. The portal will offer a simplied process for creating a new account. Customers will enjoy improved access to licensing information, including the ability to search for a license and view their license eligibility status. About Kepware Technologies - Kepware Technologies, established in 1995, is a private software development company headquartered in Portland, Maine. Kepware has been developing, testing, and delivering advanced communications and interoperability software solutions for the Automation industry for nearly 20 years. Our exible and scalable solutions help our customers connect, manage, monitor, and control disparate automation devices and software applications. To learn more, visit us at www.kepware.com.
(207) 775-1660 | sales@kepware.com | www.kepware.com
Dependable Process Control Instrumentation from Moore Industries

Process control instrumentation isnt about a quick x. Products must be reliable enough to provide accurate readings despite their age or frequency of use while withstanding the harshest working conditions. You need instrumentation that you can install and forget about without having to worry about frequent repairs or replacements. Moore Industries (www.miinet.com) understands how critical this is its why we develop products to the highest standards of safety, reliability and performance. Our products are found in settings worldwide because they can be installed once and relied on to work right every time. Our range of products includes: Temperature Transmitters and Assemblies Signal Isolators and Converters Alarm Trips Fieldbus Device Couplers and Power Supplies Process Controllers Smart HART Loop Interfaces and Monitors Distributed and Remote I/O I/P and P/I Converters Process Indicators Enclosures
Products such as the STA Safety Trip Alarm and the SRM Safety Relay Module have comprehensive FMEDA Reports available and have been SIL-rated by exida. Products That Last Moore Industries focus on reliability throughout the design and manufacturing of our entire product line means that you know our equipment will last. Many installations of our instrumentation have performed awlessly for decades in the toughest environmental conditions. When you need process control instrumentation to perform year after year, turn to Moore Industries.
Moore Industries FS Functional Safety Series Safety Instrumented Systems (SIS) are often the last line of defense between a process and a dangerous operating condition. Because of the importance of an SIS in hazardous settings and the potentially devastating consequences if something goes wrong, safety engineers need complete condence their safety-related instrumentation will work in an emergency. Moore Industries has responded to this need with our FS Functional Safety Series of products designed for SIS or Safety Instrumented Functions (SIF). Our SIL-compliant products can be easily installed and implemented in an SIS. You can trust that they will work because they were built from the ground up in compliance with strict IEC 61508 design and manufacturing standards to ensure safe and reliable functions.
Contact us today at 1-800-999-2900, or visit our web site and tell us what you need.
Moxa, Inc. Optimized Industrial Ethernet Solutions

With 25+ years experience in industrial automation and networking, Moxa offers one of the worlds deepest selections of Industrial Ethernet Solutions. Our products are designed for maximum reliability and performance, and currently connect 30 million+ devices worldwide in a wide variety of industries, including factory automation, railway, transportation, and oil and gas. Industrial Ethernet Switches With 500+ different models, from simple unmanaged DIN-rail switches to 52-port layer 3 10GbE rackmount models, Moxa helps ensure that your entire Ethernet network, from edge to core and including the control room, fully meets the demanding requirements of industrial reliability. Industrial Wireless Connectivity Moxa wireless access points and cellular products feature technology such as Turbo Roaming and dual-RF redundancy in order to deliver the most mobile and reliable wireless connections for mining, rolling stock, and other harsh environments. Industrial Ethernet Gateways Not only do Moxa industrial Ethernet gateways enable seamless communication between factory automation networks and open Ethernet backbones, they also feature easy setup and fast throughput for real-time applications. Optimized For Performance and Reliability Moxa also offers smart I/O modules, IP cameras, network management software, security routers, ruggedized computing platforms, and more, all of which have been optimized for top performance and reliability. Nearly every part number features exceptionally high MTBF and temperature tolerance, fanless heat dissipation, and minimal power consumption. Comprehensive Suite of Online Services A comprehensive suite of online services is available on the Moxa website, starting with our product content. Friendly, detailed descriptions, embedded video demos, dimension drawings, and easy evaluation unit ordering make things easy for the busy engineer. A deep library of application examples and white papers is also available for reference. Handy online product selectors help you nd the exact part number you need by port count, interface, or other criteria, and online calculators help calculate tricky items such as eld of view for camera lenses. Deeper knowledge and training is available to our closest partners through Partner Zone and Moxa University.
Contact us at usa@moxa.com | 1-888-669-2872 | www.moxa.com
From Design to Deployment With a Standard Technology Platform

National Instruments provides graphical system tools for engineers and scientists that are developing next-generation control and monitoring systems within industries such as energy, industrial control, life sciences, and transportation. NI recongurable I/O (RIO) hardware and NI LabVIEW system design software provide the best off-the-shelf platform to solve any demanding control and monitoring task. This NI platform-based approach gives smaller design teams the condence to build innovative embedded systems without wasting development time and cost on custom design. Visit the National Instruments website, www.ni.com/embeddedsystems, to learn more. NI RIO Hardware and LabVIEW Software National Instruments embedded systems combine LabVIEW software with off-the-shelf hardware to simplify development and shorten time to market. All NI Recongurable I/O (RIO) hardware products are built on the NI LabVIEW RIO Architecture that features oating point processors, recongurable FPGAs, and modular I/O. And with LabVIEW, engineers can customize hardware and integrate custom timing, signal processing, and high-speed control without requiring expertise in low-level hardware description languages or board-level design. NI offers a variety of hardware platforms based on the LabVIEW RIO Architecture, including NI CompactRIO, NI Single-Board RIO, NI R Series devices, and PXI-based NI FlexRIO modules. With varying degrees of performance, cost, I/O rates, form factor, and ruggedness, NI RIO hardware devices can meet your unique needs of your embedded control and monitoring applications. Embedded Systems Outlook Over 30,000 companies around the world use National Instruments tools. Additionally, NI collaborates with leading technology providers such as Intel, Xilinx, and Analog Devices to ensure that NI embedded systems use the latest and greatest technologies. Learn about some of the most pressing trends and challenges facing design teams building embedded control and monitoring systems. Understand the Hidden Cost of Embedded Design Use an online calculate to help you understand the nancial benets and trade-offs between buying off-the-shelf tools from National Instruments versus building a custom solution with traditional design tools.
U.S. Corporate Headquarters: 11500 N Mopac Expwy Austin, TX 78759-3504 | T: 512 683 0100 | F: 512 683 9300 | info@ni.com International Branch Offices: ni.com/global
New groov makes mobile HMIs simple

Could you use an easy-to-build operator interface for your monitoring or control application? Then take a look at groov. groov is a new product from Opto 22 that makes it easy to develop and view effective operator interfaces using only a web browser. The interfaces you build can be securely viewed on virtually any authorized device with a modern web browsercomputers, tablets, smartphones, even web-enabled HDTVsno matter their size or brand. Imagine what you can do Control equipment in hard-to-reach areas from a laptop. Monitor machine status on an HDTV mounted in the factory. Check a live security video feed or see production gures on your smartphone. Use a tablet as an operator interface for your machine. Videos on groov.com give you more ideas and show you how to get started with groov. Webinar: Introducing groov - See groov in action in our short introductory webinar. In just 30 minutes youll nd out how to build and view groov interfaces, how to securely add groov to your facility or machine architecture, and more. Youll also see how everything on the screengauges, buttons, labels, even live videoscales gracefully to t the device you view it on, but never becomes too small to use on a smartphone. Watch the Introduction to groov webinar at groov.com/webinars. Wheres your groov? - From controlling variable speed drives to monitoring remote pumps to checking product quality via live video, automation professionals are nding a wide variety of uses for groov. Read their case studies on groov.com. Ready for your mobile future - Specications, pricing, compatibility, questions and answers, and much more are on the website at groov.com. About Opto 22 - Control engineers worldwide have counted on Opto 22 products for almost 40 years for control, monitoring, and data acquisition. All Opto 22 products, including groov, are manufactured and supported in the U.S.A. Call us or visit us on the web. We make automation simple.
systemseng@opto22.com | 800-321-6786 | www.groov.com
Building a Smarter Unified Business Foundation

The physical layer connects the power and communication components of automation systems. These systems are tasked with the demands of real-time control, data collection, and device conguration. Each element of the physical infrastructure must be designed and deployed to ensure the industrial networks and control systems provide sufcient performance margin within the specied environmental conditions. Panduit is a world-class developer and provider of physical infrastructure solutions that improve reliability, security, and safety of Industrial Automation systems while reducing deployment and operating costs. Working with industry leaders Panduit bridges the gap between IT and Controls Engineers with building-block architectures for connecting, managing and automating enterprise, industrial networks and control systems. Our Industrial Automation Solutions leverage the Panduit Unied Physical InfrastructureSM (UPI) approach which helps customers integrate core business systems for a smarter, unied business foundation. Application Focused Systems Todays industrial organizations are driven to increase production and reduce costs while maintaining quality and safety. These organizations need partners that understand their unique application requirements to meet todays business challenges and prepare for tomorrow. Whether updating existing systems or planning plant expansions, Panduit Solutions help customers implement validated industrial network and control system designs that reduce deployment time by up to 75%, exceed performance requirements and reduce operation, maintenance and repair costs. Unmatched Expertise Panduit invests in relationships and resources to solve our customers greatest business and technology challenges. Our global network of sales, technical support, distribution, and manufacturing teams makes Panduit solutions readily accessible around the world. Design, Deploy, Manage Panduit has collaborated with other industry leaders to address deployment complexities associated with Industrial Ethernet. This has resulted in the Industrial Ethernet Physical Infrastructure Reference Architecture Design Guide for designing, deploying, and managing the physical infrastructure for an Industrial Ethernet network.
Panduit | 18900 Panduit Drive | Tinley Park, Illinois 60487 | 800 777 3300 | www.panduit.com | cs@panduit.com
PanelShop.com Customer Driven Controls

PanelShop.com has brought streamlined innovation to the forefront of the electrical control panel industry. By combining intricate back-end engineering with an online format, PanelShop.com is changing the way electrical control panels are acquired. This modernization will reduce down time at plants and open what has traditionally been a regional resource to a global landscape. Browse, Build, Buy PanelShop.com users can browse through numerous congurators, seeking out their preferred manufacturer, and build a control panel to meet their needs. After making selections from enclosure type to communication options, users receive instant pricing and the ability to purchase directly from PanelShop.com. Ideal Benets and Features 24/7 availability to design and purchase congured electrical control panels Custom conguration of electrical control panels to users specic needs Real-time quoting & pricing resulting in extensive time and cost savings Lower cost based on pre-engineered components and services Limit risk through standardized pre-engineered products Major manufacturers available all on one site Multiple-bid policy requirements satised by providing several congurable options High-quality general schematics provided for every conguration UL Certied upon request to meet user quality standards Domestically Produced, Globally Deployed Proudly produced in the US at our 40,000 sq. ft. facility, PanelShop.com is fully-equipped to go far beyond meeting regional needs and serve a global marketplace with superior performance. Whether building to UL, CE, CSA or even Class 1 Division 2 guidelines among others, PanelShop.com has the knowledge and resources to reassure customers their control panel will meet their exact specications. Dont be conned to your local panel builder anymore. PanelShop.com is the new way to outsource your electrical control panel needs.
Growing Product Lines Currently offering six congurators, including AC DRIVES, DC DRIVES, COMBINATION STARTERS, OPERATOR STATIONS, SCR CONTROLS, and SOFT STARTERS, PanelShop.com has committed to frequent and consistent evolution of the site in order to always provide the newest and most in-demand products for their customers. Not only will PanelShop.com be regularly rolling out new series and congurators to their site, but current offerings will more than double by the end of 2013.
To nd out more, visit www.PanelShop.com | sales@panelshop.com | 855-PNL-SHOP | Intl 01-412-349-4940
PROFIBUS and PROFINET: Benchmarks in Industrial Automation

PROFIBUS is the worldwide standard when it comes to networks in manufacturing automation. With a majority share of the eldbus market, PROFIBUS has grown to become the unequivocal leader in this industry. PROFINET, the all-encompassing Industrial Ethernet for advanced manufacturing, is the new benchmark for industrial networking in automation. PI North America is dedicated to supporting the discrete and process industries in achieving benecial results using these networks. PI North America also assists device manufacturers in the development and marketing of PROFIBUS and PROFINET products. Engaging Content The PI North America website is the single most comprehensive web location pertaining to the PROFIBUS and PROFINET technologies. For those that are new to the protocols, the PROFINET Technology section in particular contains a robust description of its features. People familiar with the PROFI- technologies have access to a wealth of collateral in the Resources section such as Application Stories, Case Studies, White Papers, Videos, Guidelines, and System Descriptions. The PROFIblog remains a key resource in the industry by providing thought leadership and an interesting point of view on all things related to controls, sensors, actuators, security, and safety. Every month the PROFINEWS newsletter is published, keeping its subscribers up to date on the latest trends and product announcements. Unique Design In addition to its content, the award-winning design is one of the most unique on the Internet, let alone in the Automation Industry. Re-designed from the ground up and launched at the beginning of 2013, us.pronet.com is easy to navigate, a pleasure to view, and highly informative. The homepage allows visitors to quickly see the latest material in the slider, while putting the most important information front-and-center. Around the Country, Throughout the Year Immensely popular among Engineers, Technicians, and Managers, One-Day Training Classes are hosted by PI North America in cities around the United States. Given throughout the year for both PROFIBUS and PROFINET, these free classes serve to educate and assist in all technical aspects of using the protocols. See if there is one in your area, and register today!
PI North America | 16101 N. 82nd Street Suite 3B | Phone: 480-483-2456 | Fax: 480-483-7202 | info@pinorthamerica.com
Are you frequently wasted at work?

Well, forget HR. Go straight to PT Pilot and stop wasting your valuable time fumbling through catalogs, price books, and emails to specify a gear unit. PT Pilot quickly provides a quote, parts lists, a 3D CAD drawing, and all options for a gearmotor or gear unit. The truth is that there are more ways to save energy than using a premium efcient motor. PT Pilot is compatible with smartphones and tablets too. So, you can literally obtain a quote at your ngertips anytime, anywhere. Find PT Pilot at www.ptpilot.com Engineering excellence and customer responsiveness distinguish SEW-EURODRIVE, a leading manufacturer of integrated power transmission and motion control systems. SEW-EURODRIVE solutions set the global standard for high performance and rugged reliability in the toughest operating conditions. With its global headquarters in Germany, the privately held company currently employs over 15,000 employees with a presence in 45 countries worldwide. U.S. operations include a stateof-the-art manufacturing center, six regional assembly plants, more than 63 technical sales ofces and hundreds of distributors and support specialists. This enables SEW-EURODRIVE to provide local manufacturing, service and support, coast-to-coast and around the world. SEW-EURODRIVE . . . Driving the world.
Visit us at www.seweurodrive.com
software &
PRODUCTS
Motion controller designed for end users with third-party controls
The Q170MCPU-EIP motion controller by Mitsubishi Electric is designed for end users who have a third-party control system to incorporate and create Mitsubishi positioning applications via the Ethernet. Users can operate their existing third-party control systems that incorporate Add-On-Instructions (AOIs), selecting from Mitsubishis AOI library with a set of motion instructions to improve the functionality of third-party design and conguration software. These instructions allow users to upgrade easily to a Mitsubishi Electric servo system via Ethernet/IP. This new unit also allows users to create positioning applications within their existing programming environment. It is ideal for applications where end-user specications require a third-party PLC and up to eight axes of servo control. Suitable applications include lling, case packing, conveyors, and assembly.
Mitsubishi Electric Automation Inc.
Industrial-grade computer designed for hazardous use in oil and gas environments
The new EXPC-1319 hazardous location panel computer from Moxa is designed for installations common in oil and gas applications. It meets UL Class 1, Div 2 and IEC ATEX Zone 2 hazardous location codes without the need for special measures such as complex and expensive enclosures or additional certication processes. Because these areas are often subject to high humidity, the panels are sealed off to NEMA 4X and IP66 ingress standards to protect their sensitive electronics even when deployed outdoors. The LCD panel is anti-glare, anti-scratch, and visible in direct sunlight. Moreover, these panels meet T5 ambient temperature requirements of -40 to 60 C (-40 to 140 F). Each unit comes standard with an Intel 1.8 GHz Atom core D525 platform. Depending on preference, the operator can select to use the LCD in either touch-screen or standard mode.
Moxa Americas Inc.
www.moxa.com
Input #204 at www.controleng.com/information
www.meau.com
PRODUCT & LITERATURE SHOWCASE

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Allied Electronics . . . . . . . . . . 21. . . . . . . 12 . . . . . www.alliedelec.com ASCO Valve, Inc. . . . . . . . . . . . 1. . . . . . . . . 2 . . . . . . www.asconumatics.com/RightNow AutomationDirect . . . . . . . . . . C2 . . . . . . . 1 . . . . . . www.automationdirect.com Baldor Electric Company . . . . 13. . . . . . . . 8 . . . . . . www.baldor.com Banner Engineering Corp. . . . 39. . . . . . . 19 . . . . . www.bannerengineering.com Bimba Manufacturing Company . . . . . . . . . . . . . . . . . 35. . . . . . . 18 . . . . . www.bimba.com Eaton Corp. . . . . . . . . . . . . . . . 16A-16D . . . . . . . . . www.eaton.com/followthecharge Honeywell Inc . . . . . . . . . . . . . 31. . . . . . . 16 . . . . . www.becybersecure.com Kepware Technologies . . . . . . 25. . . . . . . 14 . . . . . www.kepware.com/control MathWorks . . . . . . . . . . . . . . . 15. . . . . . . . 9 . . . . . . www.mathworks.com/accelerate Moore Industries - Intl. Inc . . . 4. . . . . . . . . 4 . . . . . . www.miinet.com Moxa Technologies . . . . . . . . . 3. . . . . . . . . 3 . . . . . . www.moxa.com National Instruments . . . . . . . 7. . . . . . . . . 5 . . . . . . www.ni.com Omega Engineering Inc . . . . . 19 . . . . . . . 11 . . . . . www.omega.com OPTO 22. . . . . . . . . . . . . . . . . . 11 . . . . . . . . 7 . . . . . . www.groov.com Panduit. . . . . . . . . . . . . . . . . . . 26, 27. . . . 15 . . . . . www.panduit.com PanelShop.com. . . . . . . . . . . . 33. . . . . . . 17 . . . . . www.PanelShop.com PI North America. . . . . . . . . . . 9. . . . . . . . . 6 . . . . . . www.us.profinet.com SEW Eurodrive Inc . . . . . . . . . C4 . . . . . . 27 . . . . . www.seweurodrive.com Siemens Industry Inc . . . . . . . C1, 23 . . . 13 . . . . . www.sea.siemens.com Triangle Research Intl Inc . . . . 43. . . . . . . 20 . . . . . www.tri-plc.com/ce.htm Unitronics . . . . . . . . . . . . . . . . 16. . . . . . . 10 . . . . . www.unitronics.com Yaskawa America, Inc. . . . . . . C3 . . . . . . 26 . . . . . www.yaskawa.com Industrial Energy Management American Industrial Systems (AIS) . . . . . . . . . . . . . EN9 . . . . . 25 . . . . . www.aispro.com National Instruments . . . . . . . EN3 . . . . . 24 . . . . . www.ni.com Inside Machines Beckhoff Automation LLC. . . . M6 . . . . . . 23 . . . . . www.beckhoff.com Cognex Corporation . . . . . . . . M1 . . . . . . 21 . . . . . www.cognex.com/50L EMCO High Voltage Corporation . . . . . . . . . . . . . . . M4 . . . . . . 22 . . . . . www.emcohighvoltage.com
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BASICS
Radiating cables can solve tricky wireless communication

Leaky feeders can improve communication with moving devices and complex environments.
Jim Ralston and Gary Enstad
Slots in the cables shielding allow the signal to leak through. Courtesy: ProSoft Technology
Go Online
www.prosoft-technology.com Read more on industrial wireless coverage at www.controleng.com/wireless
88
ireless communication depends on tions. Highway and railway tunnels commonly antennas to transmit and receive use it for emergency radio communication and, RF (radio frequency) signals. more recently, cellular phone connectivity. The There are many shapes and sizes technology has also been installed in mines depending on the nature of the type of trans- for underground voice radio communications. mission and frequency. For this discussion, one Now high-speed wireless technologies such as useful analogy can be trying to water your gar- 802.11n with fast roaming may benefit from den with a sprinkler. radiating cable systems, thus extending automaA central nozzle that sends equal amounts of tion networks to moving equipment. spray in every direction is like an omni-direcRadiating cable is similar to standard distional antenna. The signal goes in every direc- crete antennas in many ways. RF energy is tion from a central point. A sent through the cable directional antenna concenand the signal propagates Radiating cable technoltrates the signal in a specifout. Radiating cable, howogy, also known as a leaky ic direction like a sprinkler ever, does not have gain. that sends out a stream. It As the cable gets longer, feeder, has been applied for can carry a longer distance the signal gets weaker. decades in bi-directional low- Slots in the shield part of but covers a smaller area. A third irrigation tech- frequency radio applications. the coax, underneath the nology uses a porous hose Highway and railway tunnels insulation, allow the RF that weeps water over its signal to propagate out length, such that anywhere commonly use it for emergen- and be received along the it runs, water will soak into cy radio communication and, length of the cable. This the ground. The applicamore recently, cellular phone effectively creates a long, tion can be highly conflexible RF antenna at over trolled by placing the hose connectivity. It has also been 100 m in length. in the most critical areas. There are limitations installed in mines for voice The same exists in wirewhen compared with more radio communications. less communication where conventional antennas. special cable can serve as Radiating cable reduces a continuous antenna over a specific distance, available bandwidth, so 802.11n performance receiving the RF signal as well as transmitting. is slower as compared to a multi-stream MIMO Radiating cable is an alternative to tradi- antenna system. The cable itself and all the nectional RF antenna systems. It solves RF design essary mounting hardware can make for higher challenges in certain situations involving mov- material costs and more complex installation. ing equipment such as assembly carriers, over- So, in most industrial wireless applications, head cranes, and automatic guided vehicles traditional discrete antennas are recommended (AGVs). Applications where radiating cable is unless they are not capable of reliable radio a consideration include communication in con- links due to confined spaces or line-of-sight fined spaces, tunnels that snake throughout a challenges. But where traditional antennas are process, and large monorail systems requiring not practical, radiating cable is a good alternaconsistent RF signal thresholds. tive to investigate. ce Radiating cable technology, also known as Jim Ralston and Gary Enstad are product a leaky feeder, has been applied for decades in bi-directional low-frequency radio applica- strategy managers for ProSoft Technology.
NOTHING GOOD HAPPENS AFTER MIDNIGHT
Nobody wants that middle-of-the-night-call telling you systems are down. Not you. Not us. And, certainly not the guy with the problem. Thats one of the reasons you should turn to Yaskawa for drives and motion control. Trust your operations to Yaskawa and the phone wont ring at night. The boss wont be in your ofce. And, maintenance wont be breathing down your neck with another re to put out. Trust Yaskawa and youll get a good nights sleep. Rest easy tonight. Call Yaskawa today.
YA S K A W A A M E R I C A , I N C . DRIVES & MOTION DIVISION 1 - 8 0 0 - YA S K A W A YA S K A W A . C O M

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For more info: 2013 Yaskawa America Inc.
Your bus . . . . . . our driver!

Is your current PLC/eldbus supplier driving you crazy? Then stay on your bus and leave the driving to us! The SEW-EURODRIVE route substantially reduces your startup time on gantries, cranes, hoists, conveyors, turntables, and storage retrieval systems. Our gateways and eldbus cards not only speak to your PLC, they can also eliminate all of your C++ or C# programming. And, as always, our quality customer service is free.
seweurodrive.com / 864-439-7537

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