Control Design

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U.S. TRADE
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Machine Data
in the Palm of
Your Hand
When Is
Redundancy
a Necessary
Necessity?
Functional Safety
Is TechnologyDependent
Green
Identity
APRIL 2010
An Important First
Step Toward Sustainable
Manufacturing Is Better Machine
Efficiency and Conservation
CD1004_01_Cover3.indd 9
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CONTRLDES_0410:Layout 1 3/23/10 11:16 AM Page 1
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336 Volts of Green Engineering

MEASURE IT FIX IT
Developing a commercially viable fuel cell vehicle has been a significant challenge because
of the considerable expense of designing and testing each new concept. With NI LabVIEW
graphical programming and NI CompactRIO hardware, Ford quickly prototyped fuel cell control
unit iterations, resulting in the worlds first fuel cell plug-in hybrid.
MEASURE IT
Acquire
Acquire and
measure data
from any sensor
or signal
Analyze
Analyze and
extract information
with signal
processing
FIX IT
Present
Present data
with HMIs, Web
interfaces,
and reports
Design
Design optimized
control algorithms
and systems
Prototype
Prototype designs
on ready-to-run
hardware
Deploy
Deploy to the
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you choose
Ford is just one of many customers using the NI graphical system design platform to improve the world around
them. Engineers and scientists in virtually every industry are creating new ways to measure and fix industrial
machines and processes so they can do their jobs better and more efficiently. And, along the way, they are
creating innovative solutions to address some of todays most pressing environmental issues.
>>
Download the Ford technical case study at ni.com/336
800 258 7018
2009 National Instruments. All rights reserved. CompactRIO, LabVIEW, National Instruments, NI, and ni.com are trademarks of National Instruments.
Other product and company names listed are trademarks or trade names of their respective companies. 2009 0834
0834 Green Engineering Ford.indd 1

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20 Cover Story
Green Identity
iet
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features
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f Business Pub
l ic
f Business Pub
An Important First Step Toward Sustainable Manufacturing Is

Better Machine Efficiency and Conservation
Jim Montague, executive editor
Volume 14, No. 4
27 Machine Control
A Look at IEC 61508
The Standard Drives Functional Safety of Machinery in the U.S.
and Europe
Matthias Haynl, TV Rheinland
20
contents
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APRIL 2010
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U.S. TRADE
PUBLICATIONS
32 Product Roundup
Lets Get Mechanical
Components Are Still Easy-to-Install and Operator-Friendly
Columns
7 ControlDesign.com
19 Embedded Intelligence
Technology Goes Green
SCADA, HMI Boundaries

Blur
9 Editors Page
Term Limits
13
11 Machine Builder Mojo

Machine Information in
Your Hand
15 Live Wire
31 TechFlash
IP Opens New Doors for I/O
42 OEM Insight
Dont Fear Accuracy and
Precision
Unnecessary Redundancy?
Hot Buttons
39
CONTROL DESIGN, (ISSN: 1094-3366) is published 12 times a year by
Putman Media, 555 West Pierce Rd., Suite 301, Itasca, Illinois 60143.
(Phone 630/467-1300; Fax 630/467-1124.) Periodical postage paid at
Itasca, IL, and at additional mailing offices. Address all correspondence to
Editorial and Executive Offices, same address. Printed in the United States.
Putman Media 2010. All rights reserved. The contents of this publication
may not be reproduced in whole or part without consent of the copyright
owner. POSTMASTER: Send address changes to Control Design, Post Office
Box 3430, Northbrook, Illinois 60065-3430. SUBSCRIPTIONS: To apply
for a free subscription, fill in the form at www.ControlDesign.com/subscribemag. To non-qualified subscribers in the United States and its possessions,
subscriptions are $60.00 per year. Single copies are $15.00. Subscriptions
for Canada and Mexico are $60.00. Foreign subscriptions outside of Canada
and Mexico accepted at $99.00 per year for surface and $199.00 for airmail. Putman Media also publishes CHEMICAL PROCESSING, CONTROL,
FOOD PROCESSING, industrial networking, PHARMACEUTICAL
MANUFACTURING and PLANT SERVICES. CONTROL DESIGN assumes no
responsibility for validity of claims in items reported. Canada Post International Publications Mail Product Sales Agreement No. 40028661. Canadian
Mail Distributor information: World Distribution Services, Inc., Station A, PO
Box 54, Windsor, Ontario, Canada N9A 6J5. Printed in the United States.
CD1004_05_TOC.indd 5
13 OEM Spotlight
35 Real Answers
Once Upon a Packer

Builder
Can OTS OS Do Embedded

Control?
16 InDiscrete
40 Product Showcase
National Engineers Week

Hits the Books
Control Design Exclusive
39 Beckhoffs Embedded PC Delivers Power
April 2010 Control Design
3/22/10 3:04 PM
CD1004_FPA.indd 6
3/22/10 12:12 PM
New White Papers
Machine Vision Academy

Are you interested in image
processing? Have you thought
about automating the visual
inspection conducted on your
production line? Master the
latest application techniques.
vices are green is not enough.
Recycle. Save energy. Go
You should back up your claim
green. Buy a hybrid. These and
with specific performance and
other things are what people
cost advantages.
constantly talk about today. By
Contributor Loren Shaum
browsing the Internet, I find
wrote a story on sustainable
many articles that suggest how
machines, as well. His report
each of us can do our part for
established that the industry
the environment. Going green
still uses older machines, not
takes time and effort and can
green machines, that continue
be costly. If, for the average
to perform well. However, build-
person, going green costs a
ers and system integrators
lothave you seen the prices
constantly have to worry about
on those hybrid cars? can you
keeping these machines run-
imagine how expensive run-
ning economically while helping
ning a green factory might be?
users migrate to new greener
No matter what, I believe going
technology. Shaum studied

how some builders deal with
and we should make necessary
this issue. Read his article, The
Special to the Web
changes to have that future.
Sustainable Machine, at www.
Focus On: Retaining

Automation KnowHow
Control Design interviews
Haumiller and Concep Machine
to get a closer look at how
companies are retaining
automation knowhow.
articles featuring what some
Market Intelligence
Report: Motion Control
Parts 1 & 2 Learn what
machine builders and system
integrators are using.
CD1004_07_WebTOC.indd 7
You can also log on to our
members are doing to make
Machine Builder Forum and
their plants, machines and
weigh in with your opinion.
products as green as possible.
There, we ask how important
Log on to www.ControlDe-
sustainable manufacturing
sign.com/greenisnotenough to
is to your customers. So far,
read Senior Technical Editor
sustainable manufacturing is
Dan Heberts story, Green
a convenient phrase to collect
Your Way. In this article,
all the energy- and material-
Hebert learns what different
saving initiatives applicable to
companies such as Optimation
manufacturing. Green initia-
Technology, Dynatorch, GL&V
tives for machine builders have
Paper Group and Partner Pak do
been put in place, but what else
to become green.
is being practiced by machine
Building green machines
builders? Can recyclable mate-
isnt just about producing
rials replace certain machine
machines that can save energy.
components, reclaimable at the
Customers today want equip-
end of machine life? Can you
ment that emits fewer pol-
replace wire and cable with
lutants, can be repurposed to
wireless alternatives? Is there a
produce other products, cuts
value proposition for you?
waste and scrap, cuts cycle and
Visit www.ControlDesign.
idle time and uses automation
com/sustain and tell us if you
to replace materials.
believe green manufacturing is
Hebert says that as a
kbonfante@putman.net
controldesign.com
ablemachine to find out more.
Did you know you can

receive Control Design
electronically? Subscribe
to the digital issue of Control
Design and youll be able to
download a high-quality PDF
of the magazine exactly as it
appears in print. Not only that,
well send you an email each
month when its ready for you!
Go to www.ControlDesign.com/
digital.html.
of our Machine Builder Nation
ControlDesign.com/sustain-
managing editor, digital media
View these videos at www.

ControlDesign.com/multimedia.
ControlDesign.com has
green is the answer to our future,
Katherine Bonfante
To download PDF papers, go

to www.ControlDesign.com/
whitepapers.
Save the environment.
CONTROLDESIGN.COM
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Term Limits
555 W. Pierce Rd., Suite 301
Itasca, Illinois 60143
630/467-1300
Fax: 630/467-1124
Editorial team
editor in chief
Joseph Feeley
jfeeley@putman.net
that seems better described as an
machine builders have a growing
attempt at smart manufacturing
need to include energy-efficiency
or responsible manufacturing.
and material-conservation initiatives in their designs.

Customers demand it more
This is an altogether really good

thing. I just dont like finding that
sustainability has been co-opted
often now, and for a variety of
to be another commercialized
reasons beyond the lifecycle cost-
buzzword that means different
saving aspects.
things to different people.
If you dont find these issues
Joe Feeley
executive editor
Theres little argument that
Sustainability in simplest
becoming an important part of
terms is a zero-sum game. It
managing editor
your customers machine require-
means producing power from
mike bacidore
mbacidore@putman.net
ments, I wouldnt count on it stay-
renewable or inexhaustible fuel,
ing that way. This is a rising tide
products from renewable precur-
that will floatand in some cases
sors or recyclable materials. It
sinkall boats.
probably implies not screwing up
senior technical editor
Lori Goldberg
lgoldberg@putman.net
the topics more coverage. April
the surroundings in the process.

The trouble with using the
includes another cover story (p20)
term sustainable correctly is
in which Jim Montague identifies
that its largely unachievable.
columnist
more machine builders who are
At least today thats the case. So
Jeremy Pollard
jpollard@tsuonline.com
knee-deep in the process with their
weve seen its meaning change
customers. Youll also find Jim in
to better suit initiatives that
our most recent Focus On video
industry is willing to try.
Design/Production
art director
Derek Chamberlain
(www.ControlDesign.com/green-
Subscriptions
manufacturing) that previews his
customer service
888/644-1803
cover story.
circulation
audited December 2009
column (p7) at a review of our
Air & Gas Compressors

738
Engineering & Systems
Integration Services
8,959
Engines & Turbines
1,526
Food Products Machinery
1,542
Industrial Fans, Blowers,
& Air Purification Equipment
596
Industrial Heating, Refrigeration,
& Air Conditioning Equipment
1,322
560
Industrial Process Furnaces & Ovens
Machine Tools
5,561
Materials Handling, Conveyors
& Conveying Equipment
1,594
Metalworking Machinery
3,555
Mining Machinery & Equipment
481
Oil & Gas Field Machinery & Equipment 1,249
Packaging Machinery
808
Paper Industries Machinery
456
Printing Trades Machinery & Equipment 563
Pumps & Pumping Equipment
924
Rolling Mill Machinery & Equipment
151
Semiconductor
Manufacturing Machinery
1,082
Textile Machinery
222
Woodworking Machinery
244
Other Industries & Special Industrial
7,886
Machinery & Equipment NEC
TOTAL
40,019
Katherine Bonfante aims her

coverage of these subjects in the
recent past and where to find it at
ControlDesign.com.
When we discuss issues that
he trouble with using

T
the term sustainable
correctly is that its
largely unachievable.
I only make the point so that
we can better understand each
other when a retailer talks about
include terms such as green
sustainable manufacturing with
and sustainable, were trying to
the consumer products manu-
keep the terminology consistent.
facturer that, in turn, talks to
Sustainable, in particular, is the
machine builder that, in turn,
it word right now.
talks to suppliers.
Sustainability in manufactur-
jfeeley@putman.net
editorial assistant
Weve certainly been giving
Dan Hebert
dhebert@putman.net
editor in chief
Katherine Bonfante
kbonfante@putman.net
Jim Montague
jmontague@putman.net
managing editor, digital media
editors page
controldesign.com
Maybe we can more uniformly
ing seems to be this overly deep
recognize the value in having
bucket that contains just about
goals to relentlessly, albeit slowly,
everything. Many companies
approach a genuinely sustainable
include machine safety, environ-
manufacturing universe by doing
mental responsibility and employ-
all these good things. And then
ee well-being. Many also include
lets keep score that way.
initiatives and programs such as

lean manufacturing, Six Sigma,
and quality management.
So, we end up with something
CD1004_09_Edit.indd 9
3/22/10 3:07 PM
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The CSA C/US mark signifies these products meet U.S. and Canadian standards for safety or performance. CSA International can
help you streamline product evaluation and reduce time to market. And when supply chain or market opportunities expand
your focus, we also deliver local service in Asia and Europe. Electrical products used in hazardous locations must inspire total
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Mumbai, India Hong Kong, China Guangzhou, China Shanghai, China Seoul, Republic of Korea Tokyo, Japan
CD1004_FPA.indd 10
3/22/10 12:13 PM
RL-384
Machine Information in Your Hand

more Ethernet protocols in their plants, and its
less human-machine interface (HMI) units more
incumbent on the machine builder to ascertain
frequently, its important that you understand
which type of protocol is needed and to provide
how best to make your machines fit their overall
the machine with same.
wireless infrastructures. Increasingly, compatibil-
Although many companies use handheld HMIs
ity with existing and planned wireless machine
for machine monitoring, few are using them to
monitoring systems will be a required feature.
replace the primary machine-mounted HMI. The
For example, Mohawk Fine Papers (www.mo-
handheld HMIs are instead used to extend reach,
hawkpaper.com) in Cohoes, N.Y., uses Transparas
usually via one-way communication of machine
Visual KPI to monitor and control its paper ma-
status. Any problems requiring adjustments to
chinery and other plant components.
the machine control system typically still will be
Key performance indicators (KPIs) are delivered to handheld HMIs, in this case Blackberry
made at the machine.

Future implementations might feature highspeed two-way access. This would allow your
chines, but instead primarily through OSIsofts
customers not only to monitor their machines
PI data historian. Other data are delivered to
remotely, but also to change control parameters
the Blackberry devices through Microsoft SQL
to adjust machine operation. These types of
Server for data extraction, transformation and
adjustments probably will be made by operators
loading, and through Microsoft Sharepoint as
in close proximity to the machine, paving the
an information portal.
way to systems that completely eliminate on-
managers, supervisors, engineers and even the

chief operating officer. Handheld HMIs played an
important role in Mohawks overall 2009 improvement in machine output, customer satisfaction
and energy consumption.
ne handheld HMI could be used to

O
monitor and adjust many different
machines.
In these types of systems, your machine
would be provided with no local HMI. Instead,
real-time access to machine, production and
a handheld wireless HMI would be used to pro-
order status, explains Ben Whitaker, manager of
vide full monitoring of your machine along with
enterprise process reengineering at Mohawk. This
adjustment of machine operating parameters.
allows more responsiveness to customer require-
The advantages of such a system to manufac-
ments and manufacturing issues. In the mainte-
turers are numerous.
nance area, supervisors and senior engineers have
First, one handheld HMI could be used to
access to energy consumption for better response
monitor and adjust many different machines. In
to machine performance issues.
typical plant operations, an operator goes from
Machine OEMs supplying Mohawk and companies using similar systems need to make their
machine control system accessible to the data
one machine to the next to observe operating

conditions and make adjustments.
Second, an operator could access a machine
repositories accessed by handheld HMIs. This
from a safe distance, often outside a hazard-
means that links must be provided to software
ous area. This not only could improve safety,
such as data historians and often to various
but also save time as personal entrance into a
Microsoft products as well.
hazardous area is often a time-consuming task
These links are most commonly Ethernetbased, meaning that your machine should have
an Ethernet port at either the controller or the
requiring special protective personnel equipment (PPE) and lots of paperwork.

Third, linking the handheld HMI to the ma-
HMI level. This takes care of the hardware
chine and to the central control room could allow
connection, but doesnt address the software
an operator to make machine adjustments with
protocol issue. Most manufacturers use one or
the entire process in mind.
controldesign.com
CD1004_11_Mojo.indd 11
dhebert@putman.net
Supervisors and senior managers now have
machine HMIs.
senior technical editor
their Blackberry devices including technicians,
Everyone in the plant has access to the data via
Dan Hebert, PE
devices. Data isnt accessed directly from ma-
machine builder mojo
AS Your customers use handheld wire-
11
3/22/10 10:13 AM
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HMIs
Plant Floor Marquee
Protocol Conversion Panel Meters
Signal Conditioners Temperature

Controllers
Free Programming Platform
Internet
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pull it all
together.
Red Lion helps you manage the complexity of your entire environment with simple, highly-functional
and open integration solutions. Seamlessly leverage multiple legacy devices from a single entry point with a
universal software platform and integrated conversion of over 200 protocols. Enable Ethernet communications
on serial devices, data acquisition, web serving, data logging and remote management via mobile devices.
Connect dissimilar devices and access orphaned data that can be used to make your process run more
efficiently. Red Lion controls awaken your technology, create transparency and span the gaps in your process
environment. Call for free catalog at (717) 767-6511 or visit www.redlion.net
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Signal Conditioning
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Data Acquisition
Red Lion Controls ph: (717) 767-6511 fax: (717) 764-0839 www.redlion.net
RL-384A Corporate Ad_ControlDesign.indd 1

CD1004_FPA.indd 12
2/24/10 9:58 AM
3/22/10 4:06 PM
Once Upon a Packer Builder

OEM SPOTLIGHT
Field Service Engineers and OI Keep Customers Happy Ever After

CASE AND TRAY packers for
the food, beverage, chemical
and personal-care industries are
the primary machines designed
and built by Standard-Knapp
(www.standard-knapp.com), an
employee-owned company located in Portland, Conn. Its prodSTANDARD-KNAPP
uct line also includes uncasers,

multi-packer or bundlers, slitter/
sealers and product laners.
There are unique differences in each of the industries
we serve, says Mario Mazzotta,
customer relations and marketing manager. The food and
beverage industries constantly
FINE TOUCH
Jeff Reilly (right), controls engineer, fine-tunes the control program settings,
as Skip Miller, machine assembler, works on the 989 PakMore continuous
motion case packer with integrated 189 slitter/sealer.
increase the demand for faster

Thirteen engineers10 me-
a large inventory of parts and
handling and more efficiencies.
chanical and three electrical
typically ship part orders the
The chemical and personal care
comprise Standard-Knapps
same day theyre ordered.
industries develop many new
technical staff.
equipment, gentler product
bottle designs that are very at-
Networking on its ma-
Technology plays a major role

in after-sales support, specifi-
tractive but difficult to handle
chines is both hardwired and
cally with maintenance issues.
in a standard case packer.
digital, says Reilly. But were
Our new, graphically driven op-
The 125-year-old company
currently not using wireless
erator-interface (OI) system has
employs around 60 people, and
networking, due to cost and
a very detailed preventive main-
its machines are sold primar-
noise issues associated with
tenance schedule that visually
ily in North America, Central
wireless.
alerts maintenance personnel of
America and Asia. Machines also
All of Standard-Knapps
upcoming servicing, explains
are supported by manufacturing
machines include safety relays.
Mazzotta. Maintenance simply
licenses in Europe and in Japan.
We use safety relays to comply
can navigate to the correct
with NFPA requirements, ex-
screen on the HMI and plan for
Standard-Knapps machines
plains Reilly. New safe-off fea-
upcoming service without stop-
includes a PLC, touchscreen
tures in A-B drives and servos
ping the machine or waiting for
HMI and servos, explains
allow Category 3 safety rating
component failure.
Jeff Reilly, controls engineer.
without the wiring, external
At Standard-Knapp, inno-
Our controls are primarily
contactors and panel space.
vation is driven by customer
Control automation on
PLC-based with no embedded
Standard-Knapp employs field
demand and cost, explains
control, he says. We use PLCs
service engineers (FSEs) in a
Reilly. We believe advances
because of cost, in addition to
variety of locations throughout
in networking will have the
the benefit of having one con-
the U.S. These FSEs also per-
greatest impact on our machine
nection to upload, download
form all of our machine training
design, he says. With ad-
and edit. ControlLogix permits
at the customers facility,
vances in networking, the main
editing with just one software
says Mazzotta. The training is
difference or benefit will be the
package for ac drives, servo
divided between classroom and
use of less wiring for controls
drives and PLCs.
hands-on sessions. We stock
and communications.
controldesign.com
CD1004_13_Spotlight.indd 13
13
3/22/10 10:14 AM
m1500 transmitter shown ConneCted

to a meriam laminar flow unit
perfeCt for hundreds of appliCations

lab data acquisition
test and monitoring applications
barometric pressure reference
production skids
pneumatic / hydraulic go, no go testing

pressure leak testing
process control applications
plant instrumentation
oem applications
laminar flow systems
wet/wet differential monitoring and control
Head type flow metering
re
owe d b
Calibrators CommuniCators transmitters flow produCts manometers gauges
EPI
output & CommuniCation options for any appliCation
usb: power up and communicate through usb type b female

connector
rs-232: db9 female or terminal block connector for point-to-point

communication
rs-485: db9 female or terminal block connector for multi-point

(up to 254 addresses), half duplex communication
Analog: scalable 4-20mA (2-wire) or 0-5VDC (4-wire), field

selectable
digital communications via meriam digital protocol or modbus rtu protocol (pending)
Convenient field set up and re-calibration using supplied PC software or protocol commands
Compact size perfect for din rail or panel mounting; 4.625 l x 2.125 w x 1.25 h, 10 to 16 ounces
pressure ranges from 10 h20 (pending) to 3000 psi full scale
0.025% of f.s. traceable to nist including all affects of linearity, repeatability, hysteresis and
temperature over operating range of -20 to +50 C (-4 to +122 f).
14 pressure updates per second or dampen to suit application
differential (dry/dry or wet/wet), gauge, compound and absolute pressure versions for process
media compatible with 316ss
power with 8-36 VdC or power over usb with the usb option
T h e Tr u s t e d L e a d e r i n M e a s u r e m e n t & C a l i b r a t i o n S o l u t i o n s
SaLeS@MeriaM.CoM
CD1004_FPA.indd 14
800.817.7849
w w w. M e r i a M . C o M
3/22/10 4:03 PM
RL-384
Unnecessary Redundancy?
dual-homing at the edge of a network, which al-
be one of them yourself. The redundant is talker
lows that device to be connected to two separate
can turn a simple sentence into a complicated
points in the network, says House.
web of syntax.
The problem is, is that we need to clarify our
What you need to know is, is that there are
more potential pitfalls lying in wait.
While the redundant is talkers duplication is
maintenance might require minimal or no redundant systems, says Thomas Ferrara, director
of engineering, Atlantic Industrial Technologies
(www.aitzone.com), a designer and manufacturer of hydraulic and pneumatic systems in
be critical. The trick is knowing when redundancy
Shirley, N.Y. The ripple effect of this type of
is necessary and beneficial and when it needlessly
subsystem is containable, and therefore the
complicates the design and increases the cost.
expense of implementing redundant systems
Redundant safety and power systems are often a
is debatable, he says. There exists a middle
given. But what about control and I/O?
ground. A system without redundancy can use
unnecessary, redundant machine subsystems can
Mike Bacidore
objectives.
Some systems that operate intermittently

and have inherent standby time for repair and
LIVE WIRE
Youve heard them speak. You might even
would use a majority voting scheme to circum-
ville, Tenn., believes redundancy of electronics
vent relay or signal failure. These systems can
in plants is extremely overdone. The only ben-
also implement a quick repair cycle procedure
efit usually gained from a redundant controller
to substitute for a true redundant system.
setup is the ability for online upgrades, but this
The need for redundancy comes down to the
is typically outweighed by cost and complexity,
application, explains Tyler Croft, product market-
he says. In 20 years, the only controller failures

that have occurred in facilities I have worked in
were on redundant systems. In fact, redundant
systems have caused me more heartburn than
simplex systems have.
Choy-Hsien Lin, development engineer,
The only benefit usually gained from a

redundant controller setup is the ability
for online upgrades, but this is typically
outweighed by cost and complexity.
process control, Stora Enso Publication Paper,
ing manager, GE Intelligent Platforms (www.ge-ip.
Hylte Mill, (www.storaenso.com), Hyltebruk,
com). There are applications that cannot shut
Sweden, agrees. If a failure doesnt impact the
down, in which case redundant controllers are
bottlenecks of the process, redundancy should
essential, so routine maintenance can be done on
be avoided to reduce the complexity and remove
one controller while the other is controlling the
the additional point of failure, he says.
process. If you cant lose the controller and the
When the organization can live with an inter-
program, then you need to have redundant CPUs.
ruption in the system for the time it takes to fix it,
If they want to ensure that they do not lose I/O,
redundancy is optional, explains Lee House, CTO
then they should have redundant I/O.
and vice president of engineering, GarrettCom
But Helge Hornis, Ph.D, manager, intelligent
(www.garrettcom.com). The availability of re-
systems, Pepperl+Fuchs (www.pepperl-fuchs.
placement equipment can be a factor in determin-
com) adds some words of caution when deal-
ing the need for redundancy, he says. However,
ing with redundant inputs. Its common to use
redundancy is often more cost-effective than
sensors with inverted outputs, he says. As far
dealing with the headache and cost of downtime.
as the logic is concerned, one only works with
Redundancy can involve a variety of technolo-
one output. The second output allows the PLC
gies including rapid-recovery options for a switch
to check that the sensor is still OK. His white
using a ring topology or mesh network that allows
paper on redundancy (www.ControlDesign.
data to continue to flow without interruption in
com/redundancy) explains I/O considerations in
the event that a network switch goes down; and
much greater detail.
controldesign.com
CD1004_15_LiveWire.indd 15
poor mans redundancy. These redundant relays
coats and colorants headquartered in Collier-
inexpensive, redundant relays, which provide a
(www.aoc-resins.com), a supplier of resins, gel
managing editor
Dan Cox, director of engineering at AOC Resins
15
3/22/10 10:15 AM
INDISCRETE
National Engineers Week Hits the Books

ENGINEERS FROM Phoenix Contact in Pennsylvania
and Michigan shared their
enthusiasm for science with
local students during National
Engineers Week, Feb. 14-20, an
annual event that promotes
engineering careers to young
people and honors engineers
PHOENIX CONTACT
contributions to society.
Engineers from Phoenix
Contacts U.S. headquarters,
just outside Harrisburg, Pa.,
worked with students at the
nearby Middletown Area
Middle School. Each day, a team
of engineers taught sixth-grade
CHARGE OF THE BUBBLES

A Middletown Area sixth-grader in Pennsylvania shoots bubbles at a Van de
Graaff generator that repels them.
science class, incorporating

Phoenix Contacts auto-
engineers in Harrisburg have
hands-on activities into the
mation sales and software
had a lot of fun working with
lesson. Students learned about
development office in Ann
local students, said Jack Nehlig,
static electricity with a demon-
Arbor, Mich., also visited a local
president of Phoenix Contact
stration of a Van de Graaff gen-
school. The Ann Arbor team
USA (www.phoenixcontact.com).
erator, built an electric motor,
worked with the seventh- and
These hands-on demonstra-
raced cookie tins to see how
eighth-grade classes at Ann
tions not only show how math
the distribution of mass around
Arbor Open School. Students
and science can be fun, but also
an axis affects the speed of an
learned about the history of
how engineering impacts all of
object and built a catapult to
manufacturing and began work
our lives on a daily basis.
demonstrate momentum and
on the mini-factory project, a
trajectory. This was the third
desktop model of a production
activities, Phoenix Contact
year that the company worked
line that includes a conveyor
honored its practicing engi-
with the school for Engineers
and some simple robots.
neers with lunches in both
a combination of theory and
Week (www.eweek.org).
CD1004_16_18_Indiscrete.indd 16
Middletown and Ann Arbor.
NOTEWORTHY
MERGERS, ALLIANCES & ACQUISITION
American Sensor
Technologies (www.
astsensors.com) expanded
its CE approval for pressure
sensors, transducers,
transmitters and switches.
Sixnet (www.sixnet.com) acquired

JBM Electronics, a networking
connectivity solutions provider in
St. Louis.
IEEE launched an upgrade

to the IEEE Xplore digital
library at www.ieee.org/
newieeexplore.
16
Over the past few years, our
In addition to the school
Control Design April 2010
Cisco (www.cisco.com) joined

the Connected with Kepware
(www.kepware.com) program
to deliver OPC-based network
monitoring and management
drivers for use with its products.
Maxon Precision Motors (www.

maxonmotorusa.com) and
National Instruments (www.
ni.com) collaborated to highlight
mutual areas of interest in the
field of robotics.
Mori Seiki (www.moriseiki.co.jp)
acquired the measuring systems
business of Sony Manufacturing
Systems, a subsidiary of Sony.
controldesign.com
3/22/10 11:49 AM
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CD1004_FPA.indd 17
3/24/10 11:31 AM
INDISCRETE
MHIA: 6%+
Growth in
New Orders
for 2010
Material handling equipment
orders contracted 37% in 2009
but are forecasted to grow more
than 6% in 2010, according to
Material Handling Industry of
America (MHIA).
Industrial production activ-
UCLA STUDENTS WIN SCHOLARSHIPS

Three students at UCLAs Henry Samueli School of Engineering and Applied
Science were selected to receive $2,500 Live EDGE scholarships to help further
their educations in electrical and electronics engineering. Of the 12 Live EDGE
scholarships awarded to engineering students worldwide, UCLA had the most
winners. The UCLA students, Abde Ali Kagalwalla and Meng Ai, who are
both first-year graduate students in electrical engineering, and Armin Axel
Brugger, a junior majoring in electrical engineering, each received $2,500. The
scholarships are part of Premier Farnells Live EDGE Challenge.
ity is increasing even though

factory operating rates remain
very low by historical comparison, said Hal Vandiver, MHIAs
executive vice president of
business development.
Demand created as the
economy shifts from recession into recovery modefilling supply chain pipelines,
OEM Pressure Instrumentation
re-establishing inventories and

responding to pent-up demandis the principal impetus
for improvement over the next
few quarters in manufacturing,
warehousing and distribution,
says Vandiver.
In addition, material handling equipment shipments
contracted 34% in 2009 but are
forecasted to grow 1-2% in 2010.
Domestic demandshipments
plus imports less exportscontracted 35% in 2009 but will
grow 1-2% in 2010. Exports and
imports will improve in 2010 at
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CD1004_16_18_Indiscrete.indd 18
about the same rate.

The Material Handling Equipment Manufacturing (MHEM)
forecast of material handling
equipment manufacturing
is released each quarter by
MHIA and looks 12-18 months
forward to anticipate changes
in the material handling and
logistics marketplace.
controldesign.com
sales@kelleramerica.com
3/22/10 11:50 AM
SCADA, HMI Boundaries Blur

The availability of vital operating information
in real time, data historians, KPIs and data-min-
different, but then theyre not.
ing extensions make the modern-day differences
I thought back to 1984 when I was at Rockwell
between SCADA and HMI systems very blurry.
Automation creating some project screens for a
Machine control interfaces are connected to
client sales presentation on an A-B Advisor em-
the controlling PLCs and PACs, and are connected
bedded graphics system.
to the plant-wide information highway, just as
This device was a CPM-based SCADA system
SCADA systems are. One of the more innovative
that created screen displays using object-like
products that blur the lines is embedded touch-
symbols and used small CRT display units for in-
screen terminals from Invensys/Wonderware.
terfacing. A keyboard was the main interface for
Wonderware is SCADA, but it also is HMI. Its the
the operator with custom inserts for key defini-
same development system with multiple targets.
tion. Plug-in cards were used for everything.
InduSoft is another.
The development system was intensea lot of
Many new technologies are a hit with users

and OEMs alike. A recent poll reported that most
hoop-jumping. There also was a T30 operator/
companies will use the controller vendors HMI
HMI terminal, which had a development system
offering, if available. Once upon a time there were
embedded in the unit. I dont think a touchscreen
many third-party HMI developers. They got pur-
was available in the first few product iterations,
chased by the big boys, so there are very few left.
but there were keypads on the unit faces so the

developer could assign key presses to functions.
The screen components were not complex, but
but was called an HMI.

The only portion of the SCADA component that
wasnt available was the data acquisition part
here isnt a device on the planet that

T
cant be connected and monitored by
any HMI/SCADA system.
since there was no way to offload the data the terminal acquired, except through a serial port, but
by any HMI/SCADA system. Coupled with that,
that normally had a printer attached. As I remem-
proprietary networks are all but gone. Ethernet
ber it, the Advisor system wasnt much better.
wins that battle, wired or not. So all protocols,
Weve traversed so much technology since

then. In 25 years, we have jumped orders of magnitude forward. Most kids dont know what CPM
is, let alone an 8-in. floppy drive.
Whats different, and what hasnt changed?
still somewhat proprietary, propagate over a connectivity standard. Who knew?

So where are we now? Which way do things
migrate? My next few columns will reveal all.
Web-based clients, licensing issues, Visual Basic,
Well, everything and nothing. What has remained
C#/F#, scripting and server-based everything all
the same are applications these devices inter-
have their pros and cons.
face with. Im sure there are 30-year-old plywood
For instance, anyone who would use a fixed
presses with modern industrial computer inter-
HMI with embedded firmware for development, in
faces running Windows-based software that we
my opinion, is crazy. A touchscreen interface with
only dreamed about when the process was first
Embedded XP or Linux and a true development
installed using T30s and Advisor systems.
platform has to be on your radar. And Ill tell you
Whats different is methodologydevelopment
jpollard@tsuonline.com
grayscale. It was a fully embedded SCADA system
With this development, there isnt a device on

the planet that cant be connected and monitored
effective. There were color screens, as well as
The big third-party camp these days is in OPC

servers, which is very odd.
Jeremy Pollard, CET
code generation, driver configuration and object
embedded intelligence
I will be a presenter at a SCADA conference in

Bogota, Columbia, in August. SCADA and HMI are
why next time.
software, options for development and runtime

platforms, connectivity, protocols and transmis-
jeremy Pollard has been writing about technology and
sion methods and tons of third-party support us-
software issues for many years. Publisher of The Software
ing such standards as ActiveX, .NET, Java, AJAX,
User Online, he has been involved in control system
XML and HTTP.
programming and training for more than 25 years.
controldesign.com
CD1004_19_EmbedIntel.indd 19
19
3/22/10 10:17 AM
by Jim Montague, executive editor
An Important First Step Toward Sustainable Manufacturing Is

Better Machine Efficiency and Conservation
The customer is always rightand these
days that can mean going green. Consumers,
carbon footprint, and all of them are concerned about
retailers and pretty much everyone else is waking up
the cost of energy, says Greg Hyatt, Mori Seikis engi-
to the value of saving energy and reducing waste. As
neering vice president. So they ask us to make our
a result, many demand that utilities and manufactur-
machines more energy efficient, but the more interest-
ers run greener and provide tools enabling them to
ing challenge is when they have innovations in their
be more ecologically responsible themselves. In turn,
own products that require us to provide new machin-
manufacturers require machines and equipment that
ing solutions to enable their new technology.
Many of our customers are concerned about their
consume fewer resources and produce more sustainable products. So, some machine builders are rede-
Combining Tasks
signing to run greener and handle greener materials.
While making machines simpler is one way to go
However, the reality of a sustainable manufacturing
green, other builders are joining together several
environmentan environment based on renewable
devices to save energy and materials. For example,
sources of energy and raw materialsis a long way off
Hyatt reports that Mori Seiki MTLs newly released
for many industries. Basically, like so much else, the
grind-hardening process brings together formerly
concept of sustainability rolls downhill.

So, going green is a first step for manufacturers and machine builders. It is
also a way to make some green.
For example, jet fuel is very expensive, and so airlines try to conserve it
by flying planes with lighter airframes.
This is why airplane manufacturers and
separate rough machining, heat treat-
The reality of
a sustainable
manufacturing
environment is a
long, long way off for
many industries.
their parts suppliers use more carbonfiber-reinforced plastic parts. However,
ing and finish machining processes

into one center, such as its NT4250DCG
mill/turning machine that makes
heavy machine parts. Besides combining machining functions, grind
hardening uses heat from rough
machining to selectively heat-treat
machined parts in the same unit. This
allows users to avoid sending parts out
machining carbon-fiber can produce potentially
to an off-site furnace for heat-treating. Hyatt reports
unhealthy particles, and so machine tool builder Mori
this process is 85-95% less costly than traditional
Seiki USAs (www.moriseikius.com) Machining Tech-
machining and heat-treating methods.
nology Lab (MTL) recently developed and implemented

its Zerochip high-pressure vacuum process for many
More Than Efficiency
of its machining centers. The system uses hollow ma-
Is this just good old efficiency dressed up in green
chine spindles through which a specialized vacuum
clothing? No and yes. While traditional efficiency af-
sucks the dust-like chips from machining carbon-fiber,
fects a builder and its end users, green manufacturing
graphite and composite materials into a sealed con-
influences a wider circle of disciplines and require-
tainer. This allows users to safely machine the lighter,
mentseventually touching everyone. In short, green
energy-saving parts they need for green airplanes, as
manufacturing appears to embrace more technical
well as racing cars, bicycles and other future products.
areas and a larger jurisdiction than efficiency.
20
CD1004_20_25_CvrStory.indd 20
controldesign.com
3/23/10 12:58 PM
We see and hear about green and sustainability all the time, so we offer energy savings and simpler designs in the machines we
build, explains Craig Friesen, product manager
at packaging machine builder Thiele Technologies
(www.thieletech.com) in Minneapolis. For instance, we
can do 440 V or 220 V machines that use less current, save
power, cost less to run and help the environment. Or
we simplify the design and have a conveyor that used
to need two motors now operate with one. However,
this doesnt always involve equipment and can instead
involve greener consumables. For example, he says, a
customer might want to use a more recyclable hot adhesive, and Thiele then needs to design around it.
It can be hard to get more efficiency and energy savings out
of a machine that weve been building for 50 years, but wed rather
update a design than invent a whole new machine, and so we have
to be very creative, he adds. We work with our fabrication shop
and engineering group, look at what we usually build, perhaps a
laser cutter and brake, and then design easier-to-manufacture parts.
Its an ongoing process, and there are lots of baby steps. But sometimes, after building the same model for years, an engineering and
assembly guy suddenly says, I think if we did this differently, we
could save some assembly time.
Saving Energy
No doubt the most obvious and significant way
to go green is to conserve energy. Mark Elsass,
applications and technical services manager
for Milacrons (www.milacron.com) U.S.
mold-making operations in Batavia, Ohio,
reports, For us, green means being
more energy-efficient by using larger
and more efficient motors to translate
rotational motion to linear and using
servo-driven motors to drive the axes
on our electric machines instead of
3/23/10 12:58 PM
SO YOU WANT TO GO GREEN?

Creating more efficient machines, applications,
facilities and products requires users to adopt and
follow some better practices. Though each machine and
application is different, here are some basic practices
that can be used across a variety of production settings
and industries.
Measure and evaluate the energy, materials, water,
compressed air and other resources you and your
organization are using now and begin to develop a
plan for conserving those resources. This plan might
include powering down or turning off equipment
when its not being used and replacing simple
induction motors and drives with variable-speed
motors and drives or servo drives that can more closely
match production needs with energy used.
the ac induction motors we used
Check if your machine, application or facility could use

regeneration technology, which typically uses a shared
power source and linked drives to capture power from
decelerating components and use their energy to
accelerate other components.
Conduct a mini-audit of one of your machines or
production processes, investigate which solutions might
help it save energy or reduce materials, implement a test
or trial run and evaluate the savings it generated.
Examine all the materials that your machines consume
or process into products and seek ways to reduce waste,
perhaps by running closer to tolerances or by recycling
materials. Also, check if more sustainable alternative
materials could be used, and determine which design
changes they might require in your machines.
Likewise, to better handle sea-
(www.sew-eurodrive.com) Movigear
on previous machines. Because we
sonally fluctuating demand and
mechatronic drive units in a single-
supply machines to users to make
increasing product varieties and
line network installation (SNI) on the
molds, we work closely with mold
save energy at the same time, Ger-
container and box conveyors serving
manufacturers on what their users
man brewer and bottler C&A Veltins
its new 60,000 bottles/hr filling line
will need as they seek to be more
(www.veltins.com) decided in 2007
in its new plant in its hometown
efficient and sustainable.
to deploy 284 of SEW Eurodrives
of Meschede-Grevenstein. The line

alternates between Veltins Pilsner,
alcohol-free and beer-mixture products, and must quickly change over
between different bottle types.
Movigear optimizes the interfaces between its motor and
gears by directly combining those
gears, motor, drive, motion control
and communications in a single
gear housing, which reportedly
achieves 12-20% better efficiency
and delivers similar energy savings, according to Rich Mintz,
SEW Eurodrives strategic product
marketing manager.
To further simplify its network
infrastructure, the brewerys SNI
daisy-chained its Movigear units
together by their three-phase
power cables, but these wires also
use a PowerLAN method to carry
the applications high-frequency
communication signals, adds
Mintz. This meant that Veltins
didnt need to install about 4600
m of 24 V standard bus wiring,
and so it saved about 60% on its
cable costs, he explains.
controldesign.com
3/23/10 12:59 PM
Speed
using servo drives instead of bleeder resistors. For example, a thermoforming machine that makes yogurt
cups might have platens that press down in sequence
to form the cups rough shape and internal ribs. Each
step requires the drives to use a large spike of energy,
but where the excess energy used to go to a resistor
that dissipated it as heat, it can be put back on the
grid by being stored in capacitors and then shared on
a dc bus between multiple drives.
Conserving Materials
While saving energy is hugely beneficial, its also just
the beginning of going green. Machine builders and
SPARTANICS
end users need to think about how to reduce waste,

recycle and seek alternative materials that are easier
on their communities and the environment. Some
RECYCLING PLASTIC
veteran builders say this challenge is similar to learn-
Figure 1: Spartanics laser die cutting systems can add

components for neatly stacking leftover plastic die cut material.
ing about and adopting any new capability.

Green is just one more ripple in the whole process
and history of understanding customers and learn-
Energy in Europe
ing what their real problems are because they dont
Not surprisingly, European manufacturers and machine
always tell you, says Thomas Kleeman, CEO of Spar-
builders have dealt with higher energy costs for a lot
tanics (www.spartanics.com) in Rolling Meadows, Ill.
longer than their counterparts in North America and
For example, about 10 years ago, our European cus-
elsewhere, so they have many lessons to offer about
tomers wanted to stack the leftover material coming
green manufacturing and the goals of sustainability.
off our PVC plastic printing and die cutting machines
Every organization can look at the energy, materi-
that make credit cards, so they could ship it to their
als, water, compressed air and other resources they
recyclers more easily. As a result, we designed and built
consume, says Scott Hibbard, automation vice presi-
a machine to neatly stack all this scrap that used to go
dent at Bosch Rexroth (www.boschrexroth-us.com).
into a bin. This material still goes into a dumpster in the
This can involve plugging in a kilowatt meter and
U.S., but more end users here are looking at this kind of
turning off some lights, but it also can involve looking
recycling. These types of plastic can either be reused by
at the resources consumed by individual processes
their initial manufacturer or used down-market in milk
and changing machine programs to save energy by
jugs, traffic cones and park benches.
Speedway_CD_Apr10 o.indd 1
3/16/10 11:07:12 AM
3/23/10 1:00 PM
Spartanics builds laser and hard-tool die cutting,

screen printing and re-registration, machine vision
inspection and finishing machines, which are used to
produce everything from credit cards to automotive
dashboards and displays (Figure 1).
We also see more users who want to say they employ
materials from more sustainable sources, such as biodegradable plastics made more from corn and grasses, and
less from petroleum, adds Kleeman. However, were
finding bio-plastics have to be handled differently because theyre harder for us to cut. So, were learning how
these plastics act, and were developing some different
tools to make the die cuts. We also work with our end
users and their materials suppliers to test which new
THIELE TECHNOLOGIES
methods work best with these new bio-plastics.
Simplify the Machines

Besides just trying to save energy, green manufacturing
also can mean simplifying packaging machine designs,
so they can run more flexibly and efficiently and also
save on raw materials while making lighter, stronger
packages, adds Friesen. We build packaging machines
for consumer goods manufacturers, and they demand
green equipment, he says. This is because their cus-
STRONGER BOXES
Figure 2: Thiele Technologies SWF Bliss-Matic case former
uses PLCs to increase the machines flexibility and change
corrugated box parts more easily, which enables users to
implement new and stronger designs that use less materials.
Helping progressive process control companies

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Resources for the Worlds Leading Process Control Suppliers
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www.measure.org
3/23/10 1:00 PM
tomers are retailers who use supplier
Computing/HMI
Serial
I/O
standards such as Walmarts Green

Scorecard, which require goods
manufacturers to address environmental impacts and sustainability
issues. So, if a customer needs to
The right connection creates

incredible power.
design a greener package that uses

less material, we have to make sure
Connectivity and control. Making your interface as reliable as the
our machines can handle these
tidesand just as strong. Sealevel creates hardware and software
new designs. Once we understand

what theyre trying to accomplish,
then we can go back to them with
solutions for both digital and serial interface requirements.

We Listen. Think. And Create.
machine design modifications that

achieve what they want.
It can be hard to get more

efficiency and energy
savings out of a machine
that weve been building
for 50 years.
Friesen says Thiele refined the
Experience exceptional computing at low

power with the SBC-R9, an application-ready
platform for your next product design.
design on its Bliss corrugated boxforming machines about a year ago,

so they have fewer parts and use
PLCs instead of relay logic, which
makes them more energy-efficient
and able to do more functions for the
same cost (Figure 2). We can control
all the Bliss functions through its
PLC, which is more flexible and easy
to program than the programmable
logic system and cams and encoders
that we used previously, he says.
This new flexibility allows us to
change box parts to stronger designs
that use less materials.
In the end, green manufacturing
and sustainability are just a couple
more design requirements that
end users can tack onto the next
request for proposal (RFP) and design
specifications. I dont see green and
sustainability backing off anytime
soon, adds Friesen. Were going
to have more regulation of energy
use and waste generation, and so
retailers will push their suppliers
to provide products to accomplish
sealevel.com > sales@sealevel.com > 864. 843. 4343
these goals.
controldesign.com
1986-2010, Sealevel Systems, Inc. All rights reserved.
3/23/10 1:01 PM
Great things come in

small packages
Introducing the 411 Series miniature solenoid valve from ASCO. Designers used to frustrating
tradeoffs are in for a great little surprise. Because compared to competing products, these new valves
deliver up to twice as many cycles of reliable, repeatable performance in medical devices, analytical
products, and instrumentation. Yet they offer 12% to 15% lighter weight, plus better performance for the
same power critical in battery-operated portable devices. These valves also provide 12%-15% higher
flow rates, improved maximum operating pressure differential (MOPD), and full RoHS compliance.
Call ASCO to make a big difference in your design!
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CD1004_FPA.indd 26
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e-mail: info-valve@asco.com
3/22/10 12:13 PM
MACHINE C ONTROL
A Look at IEC 61508

The Standard Drives Functional Safety of Machinery in the U.S. and Europe
by Matthias Haynl, TV Rheinland
In the past, industrial machinery safety functions
Application-Independent, Technology-Dependent
such as e-stop were hardwired, and the failure modes
IEC 61508 is the basic functional safety standard for de-
and failure data of these components, such as relays,
signers of functional-safety-related devices and system
were very well known. The applicable standards
integrators of safety-related systems. The IEC 61508
were EN954-1:1996 (Safety of MachinerySafety Re-
standard is application-independent but technology-de-
lated Parts of Control Systems) for Europe and NFPA
pendent. Its scope includes electrical, electronic and pro-
79:1997 (Electrical Safety for Industrial Machinery) for
grammable electronic (E/E/PE) safety-related systems.
the U.S. Additionally, complex components such as
The standard is written in such a way that it can be used
microcontrollers or microprocessors were not consid-
as a framework for other technologies, as well.
ered or allowed to be involved in the performance of

the safety functions.
Prior to the changes in the standards, the number of
IEC 61508 addresses the functional hazards of new

technological advances. A major feature of this standard considers the possible occurrence of dangerous
devices used to implement and perform safety func-
failure that might arise from incorrect specifications,
tions was not a factor as long as the particular devices
omissions, random or systemic hardware failure,
had the same safety category. With technology moving
software errors, common cause failures, human error
forward and complex componentsfor example, micro-
and other influences. IEC 61508 contains requirements
controllers or microprocessorsbecoming integrated
for preventing failures by avoiding the introduc-
in safety systems, the fault behavior becomes more
tion of faults and for controlling failures by ensuring
sophisticated. When the failure modes and the failure
safety even when faults are present. Additionally, the
data are not well-defined and the fault conditions cannot
standard provides new requirements for a products
be determined completely, the incorrect functioning of
overall safety lifecycle. This takes into consideration
these new technologies has to be addressed.
every phase of a product from initial concept to final
Traditional safety assessments such as for electri-
decommissioning or disposal.
cal safety are not sufficient to cover all of the safety-
The standard uses a risk-based approach to deter-
relevant aspects of todays technologies. As a result,
mine safety integrity requirements of safety-related
functional safety, which is an assessment of the com-
E/E/PE systems. The probability approach targets
ponents or systems that impact functional hazards, is
random hardware faults that could be dangerous and, if
a critical item to be addressed.
undetected, result in loss of the safety function. It spec-
IEC 61508 was introduced in 1999 as the basic
ifies four discrete safety integrity levels (SILs) of safety
standard for functional safety. It is a comprehensive
performance for a safety function. SIL 1 is the lowest
standard composed of seven parts. Parts 1-4 are nor-
level of safety integrity, and SIL 4 is the highest level.
mative, and parts 5-7 are informative.
Requirements to achieve safety integrity at the higher

levels are more meticulous than the lower levels.
One attribute of the SIL classification is the danger-
Where in the World?

Functional safety requirements are mandatory
for European machinery, but it can be a different
story for similar safety requirements in North
America. Which regulations do you follow? Join the
functional safety discussion at www.ControlDesign.
com/functionalsafety.
ous failure probability. System integrators have to

consider all devices and components implemented to
perform the safety function and ensure that the dangerous failure probability corresponds to the targeted
SIL. Hence, it is important to know how many devices
implement and perform the safety function, and the
manufacturer of safety-related devices has to determine the specific safety parameters.
controldesign.com
CD1004_27_29_Featr2.indd 27
27
3/22/10 2:37 PM
Another focus of IEC 61508 is the overall safety life-
related electrical, electronic and programmable
cycle, the corresponding E/E/PE system safety lifecycle
electronic control systems) is driven by IEC 61508 and
and the software safety lifecycle. The purpose of this is
makes recommendations for the design, integration and
to avoid systematic faults during design and develop-
validation of safety-related E/E/PE systems for indus-
ment, installation and commissioning, operation,
trial machines. EN 62061:2005 has the same SILs as IEC
maintenance and modification of the safety-related
61508, except SIL 4 is as relevant to the risk reduction
equipment and systems. Systematic faults can occur
requirements normally associated with machinery. The
in either hardware or software designs. Measures and
main focus of EN 62061:2005 is the safety function
techniques to avoid and control them are specified by
from specification to validation. The standard requires
IEC 61508-2 and IEC 61508-3. To address the functional
a complete functional safety assessment in reference to
safety requirements in reference to the overall safety,
IEC 61508 for complex systems or subsystems.
E/E/PE system safety and software safety lifecycle

IEC61508-1 requires an effective management of
functional safety (MFS). The MFS
covers responsibilities, procedures
and activities with respect to the
overall safety, E/E/PE system safety
and software safety lifecycle.
Functional Safety in Europe

IEC 61508, or EN 61508, is not a harmonized European standard. That
It is also important to note that the applicationdependent standard EN 62061:2005 also specifies
The standard provides new

requirements for a products
overall safety lifecycle. This
takes into consideration
every phase of a product
from initial concept to final
decommissioning or disposal.
means it cannot be used exclusively
increased severity levels for EMC

testing. The standard makes references to general electrical safety
requirements for machinery, for
example, to EN 60204-1 for protection against electric shock.
The harmonized European standard EN ISO 13849-1:2008 (Safety of
machinerySafety-related parts
of control systems) combines the
as proof of CE conformity. To comply with the machin-
complex probability method from IEC 61508 and the
ery directives requirements, the harmonized stan-
deterministic category approach from EN 954-1 on the
dards EN 62061:2005 and EN ISO 13849-1:2008 are the
basis of the risk assessment. The safety classifications of
most relevant from the functional safety point of view.
EN ISO 13849-1:2008 are performance levels (PLs), where
The harmonized European standard EN 62061:2005
PL a is the lowest level and PL e the highest. The simpli-
(Safety of machineryFunctional safety of safety-
fied procedure under EN ISO 13849-1:2008 considers

the relevant parameters and architectures to provide a
IEC 61508:
THE BASIC STANDARD
FOR FUNCTIONAL SAFETY
Functional safety assessments of the components
or systems address the correct performance of the
assigned safety functions as required for the necessary
level of risk reduction. In 1999, the new standard
IEC 61508 (Functional safety of electrical/electronic/
programmable electronic safety-related systems) was
issued. IEC 61508 consists of the following parts:
Part 1: General requirements
Part 2: Requirements for E/E/PE safety-related systems
Part 3: Software requirements
Part 4: Definitions and abbreviations
Part 5: Examples of methods for the determination of
safety integrity levels
Part 6: Guidelines on the application of IEC 61508-2
and IEC 61508-3
Part 7: Overview of techniques and measures
practical assessment solution for machinery safety. The

simplified procedures could be used only for the designated architectures described in the standard.
The requirements of EN ISO 13849-1:2008 and EN
62061:2005 are to some extent identical and complementary. The scope or introduction to the standards
determines which of the two is most applicable.
Functional Safety Requirements in the U.S.

In the U.S., the mandatory requirements for certification and validation of safety systems designed for machinery safety are specified under the Code of Federal
Regulations (CFR), available from OSHA. The 29 CFR
1910, Subpart O, specifies the minimum requirements
for machinery and machine guardingfor example,
29 CFR 1910.217 for presence-sensing devices, or 29
CFR 1910.212 for machine guarding.
Requirements can be found in 29 CFR 1910.217 for
safe conditions in the event of any single failure. In
28
controldesign.com
3/22/10 2:37 PM
MACHINE C ONTROL
STANDARDS IN RELATIONSHIP
Overall, there are similarities to the EU and U.S. approaches with regard to the safety loop and the risk-based approach.
The following table shows the advantages and weaknesses of the standards.
Standard
IEC 61508
IEC 62061
EN 62061
Pros
Cons
Assessment of the complete safety lifecycle
Non-harmonized European standard
Covers hardware and software for simple and complex systems
Complex and sophisticated for safety of machinery, especially

for the machine builder
Partly simplified approach as under IEC 61508

(e.g., QM requirements)
References to IEC 61508 can lead to a difficult understanding
Covers configuration, parameterization

and embedded software aspects
Complex systems and components are covered up to SIL3
Harmonized European standard
ISO 13849
EN ISO 13849
Simpler approach as under IEC 61508 (e.g., QM

requirements, calculation of safety-related parameters)
Restrictions apply for complex electronics regarding the PL
Covers configuration and parameterization

and embedded software aspects
Not applicable for complex programmable systems
Continues with the EN 954-1 requirements
Results of the safety parameters are very conservative
Covers non-electrical, electromechanical

and complex electronics
Harmonized European standard
29 CFR 1910, Subpart O
Simpler approach as under IEC 61508

(e.g., QM requirements)
Probability approach is not covered
Regulates the requirements for all kinds of machinery

and the related equipment
Not suitable for complex electronics (e.g., safety-related PLC)
OSHA-recognized third-party validation required
Does not specify specific standards
addition, the term control reliability is specified and
Future Developments and Directions
drives requirements regarding the design, validation
Machine components and safety functions will become
and certification of safety-related systems. Of note is a
more complex and sophisticated. Intelligent and distrib-
requirement that an OSHA-recognized third-party vali-
uted control will manage functions such as an intelli-
dation organization shall be used to validate whether:
gent safety area around hazardous areas or objects. New
The design of components, subsystems, software
communication media such as wireless technology will
and assemblies meets OSHA performance require-
be in the safety loop to reduce wiring and provide more
ments and are ready for the intended use
mobility and flexibility. The use of safety communica-
The performance of combined subsystems meets

OSHAs operational requirements.
tion buses is de facto a standard today.

Functional safety requirements are mandatory for
Typical analysis methods like failure mode and ef-
machinery safety in Europe. Yet it also is wise to consid-
fect analysis (FMEA), as well as the general approach to
er these requirements for machinery in North America.
perform a risk evaluation and a hazard analysis, are ref-
It is likely that updates to related standards are going to
erenced. The probability approachfor example, under
cover new approaches and technological advancements
EN ISO 13849-1:2008 or EN 62061:2005is not considered
to address overall functional safety hazards.
or required under the OSHA requirements at this point

in time; however the deterministic approach regarding
MATTHIAS HAYNL has been manager of functional safety
the system architecture and behavior are similar to the
with TV Rheinlands Functional Safety Division since 2003. He
EN 954-1:1996 requirements. Application-dependent
has experience in the testing and assessment of safety-related
standards for the U.S. would be ANSI B11.19:2003 (Per-
systems of power plants, nuclear power plants, processing
formance criteria for Safeguarding) or NFPA 79:2007
machinery and industrial machinery. He can be reached at
(Electrical Standard for Industrial Machinery).
info@us.tuv.com.
controldesign.com
29
3/22/10 2:37 PM
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3/23/10 9:54 AM
IP Opens New Doors for I/O

Machine-mount I/O has been widely accepted
in European markets for several years now, says
spite its upside, adoption has been relatively slow.
Aaron Henry, marketing manager, Murrelek-
However, recent changes in terminal nodes, wire
tronik (www.murrinc.com). Builders in the U.S.
schemes and IP protection have made machine-
are beginning to understand the benefits of dis-
mount I/O more attractive.
tributed I/O systems, he says. IP67 is an added
John Harmon, networking and connectivity
level of protection for most machine builders,

field-wired installations. Molded cordsets, cap-
ness of machine-mount I/O. Initial node costs
tured gaskets and less upfront preparation also
are about half of what they were just 10 years
allow machine builders to inventory fewer parts,
ago, he says. And today we have higher-
have less pre-assembly time and reduce the
performance I/O networks, more network cable
number of installation errors.
knowledge at the floor level.

Machine-mount I/O has the ability to concen-
IP67-rated and higher-rated control components

have made machine-mount I/O viable, explains
Tracy Lenz, senior product supportWago-I/O-
trate multiple sensor inputs or actuator outputs
System and advanced electronics (www.wago.
on one IP67 interface, says Stephen Arnold, senior
com). While IP67-grade designs make them
automation product marketing specialist, Sch-
physically robust, electromagnetic compatibility
neider Electric (www.us.schneider-electric.com).
(EMC) issues play a role in reliability, says Lenz.
These IP67 blocks connect to the control system
Machine-mounting options and layout are what
with common, open-architecture fieldbus net-
make or break IP67-grade I/O. Does the design
works such as CANopen, eliminating the expense
provide more than one mounting option?
and support issues surrounding proprietary

network solutions, he explains. These I/O blocks
also communicate on Ethernet networks such
as Modbus TCP/IP and EtherNet/IP. When these
networks are used on an I/O block, the application
benefits from the speed and bandwidth available
on the network but keeps the price of sensors and
Today we have higher-performance I/O

networks, more network cable options
and an overall acceptance and deeper
knowledge at the floor level.
In reality, machine-mount I/O can be many
actuators low since the network doesnt need to
different things, explains Karie Daudt, senior
be embedded in each I/O device.
product manager, Turck (www.turck.com). For
The IP67 protection rating is comparable
example, an IP20 I/O node in a small enclosure
to NEMA 6 and 6P, meaning the devices are
is technically machine-mount I/O, says Daudt.
resistant to harsh environments, moisture and
The difference is that the points themselves
dust, says Kurt Wadowick, I/O systems special-
still are physically landed on the I/O rather than
ist, Beckhoff Automation (www.beckhoff.com).
terminal blocks. In this solution, you still hard-
Today, line, tree or star topologies are possible
wire the points themselves.
with machine-mounted boxes.

The general concept is to locate the control
Decentralized I/O systems are commonly

available in the market but require a vast array of
component as near to the actuators and sen-
wires, says Susanne Walker, product manager
sors as possible, explains Bruce Centofanti, sales
advanced connectivity, Weidmller (www.weid-
manager, fieldbus I/O and control technology, B&R
muller.com). Cable-based solutions, especially
Industrial Automation (www.br-automation.com).
for bus communication, can be problematic or
This can reduce or shorten wiring runs to devices
even impossible in applications with moving sys-
and results in cleaner design and construction
tem parts such as drag chains or slip rings, she
cost savings, he says. Some manufacturers offer
explains. Flexing stress can cause cable breakage
an IP67 I/O that delivers faster update rates to the
and compromise the integrity of the equipment
master PAC, PLC or distributed control system.
and the entire manufacturing line.
controldesign.com
CD1004_31_Techflash.indd 31
options and an overall acceptance and deeper
who struggle to reach IP65 with most current
believes the reduced costs drive the attractive-
Mike Bacidore
product manager, Balluff (www.balluff.com),
techflash
Machine-mount I/O replaces parallel wiring

by extending the network into the machine. De-
31
3/22/10 10:22 AM
cdroundup@putman.net
PRODUCT ROUNDUP
Lets Get Mechanical

Components Are Still Easy-to-Install and Operator-Friendly
even as alternatives have
force outputs can meet most
choose your accuracy
been developed, mechanical
application requirements,
eLine ball rail and cam roller
components remain as much
ranging from a few ounces to
linear guide systems are avail-
a part of the motion profile as
several tons using force-multi-
able in sizes 15, 20, and 25 with
speed and accuracy.
plying air cylinders.
single-piece rail lengths to 4 m.
Advanced mechanical
Installation, operation and
motion control components
maintenance are more easily
working in unison with todays
accomplished with mechanical
electronic controls offer this
motion components, too, says
performance at a cost-effective
Bob Jeter, applications engi-
price point, which maximizes
neer, Amacoil (www.amacoil.
customer value, says David
com). Mechanical components
Hein, vice president of engi-
require little to no training and
neering, Nexen Group (www.
are easy to install and oper-
Users choose between accuracy
nexengroup.com).
ate, he explains. Electronics
classes N and E, with or without
can be complex and require ex-
preload. Family of eLine prod-
ager, Thomson (www.thomson-
pert technical support, while
ucts includes both styles of run-
linear.com), illustrates how the
setup for mechanical devices
ner blocks, end seals and front
technology remains the best
is generally intuitive and they
lube units on standardized rails.
choice in certain applications.
are easy to fix, thereby reduc-
Bosch Rexroth; 800/322-6724;
One example is electrome-
ing downtime.
www.boschrexroth-us.com
John Pieri, product line man-
chanical wrap spring and friction clutches and brakes, which
SERVO GEAR UNITS
are widely used as an alterna-
Low backlash planetary and
BALL SCREW ALTERNATIVE
tive to leading-edge servo tech-
helical-bevel servo gear units
PDP alternative to ball screws is
nology, says Pieri. Clutches
have input speeds to 6000 rpm
made of two ground WMH pin-
and brakes offer flexible or cus-
with 15 integer ratios from 3 to
ions connected through a pre-
tom mounting, simple installa-
100 and circumferential back-
tion, high accuracy, low power
lash as low as 1 arc/min. PSC,
draw and high torque per unit
PSF and BSF gear units span
size, all at an inexpensive cost
ranges of 253000 Nm of torque
compared to servo technology.
in 18 different models with
Servo technology is overkill for

most motion applications, in
that the complexity and cost
far exceed the requirement.
load system to reduce rack-and-
George Edwards, chief engi-
pinion mesh backlash. When
neer, Fabco-Air (www.fabco-air.
mounted at the output flange of
com), agrees that simplicity
SRP, a high-tech planetary gear-
and cost are major attributes
head, PDP offers four different
of mechanical motion. Most

input adapters to accept most
teeth, eight reduction ratios,
follow fairly simple paths, he
any servo motor or be mounted
angle-drive versions, two-output
explains. Pneumatic actuators
directly on SEWs dynamic
pinion diameters for each size,
can provide these motions for
synchronous DS, CM and CMP
and an input interface in-line
low initial cost and follow with
servo motors.
flange or with a 90 angle.
easy, low-cost maintenance
SEW Eurodrive; 888/sew-3876;
Andantex USA; 800/713 6170;
and service as well. Pneumatic
www.seweurodrive.com
www.andantex.com
32
CD1004_32_34_Roundup.indd 32
modules with straight or helical
machine element motions
controldesign.com
3/22/10 10:23 AM
LINEAR ACTUATORS
size; available stroke lengths
Eclipse spring-engaged, servo
MDrive linear actuators with
range 18 in.
motor brakes have a split hub,
integrated step motor and
AutomationDirect; 770/889-2858;
zero backlash clamp collar for
driver technology come in
www.automationdirect.com
attachment to the servo motor
three motor sizes and non-
shaft in a variety of input and
captive and external shaft

styles, with options including
CAGED TECHNOLOGY
programmable controller and
SBK ball screw has a recircula-
motion control technology.
tion structure where balls are
These products have an input
picked up in the tangential

direction and the lead-angle
direction by end caps. It has
Caged Technology with a synthetic resin cage and patented
curvature that cradles each ball
PRODUCT ROUNDUP
SERVO BRAKES
output flange/shaft combinations. Torque ranges 2125 Nm,

with low inertia, high tensional
rigidity with no system wind-
voltage range from +12 to +75
up, integral flanges that adapt
Vdc, nominal load limits of up
to any servo motor and mount-
to 200 lb and full (256 x 200) mi-
ing style and NEMA 23, 34 and
crostepping with an operating
42 frame sizes.
range of 40 to 85 C.
and separates it from the next
Nexen Group; 651/484-5900;
Intelligent Motion Systems;
one. SBK is available with screw
www.nexengroup.com
860/295-6102; www.imshome.com
shaft outer diameters ranging

1532 mm and nut diameters
ranging 3858 mm.
HAve Travel
air power
THK America; 847/310-1111;
Pro Series ballscrew-driven
Nitra pneumatic line of stain-
www.thk.com/us
linear stages in 68 standard
less steel, round body, non-re-
models have travels of 501500
pairable cylinders feature type
mm. The tabletop can be outfit-
304 stainless steel bodies with
WORM GEAR REDUCERS
ted with an optional brush
double rolled-in construction
Ultra Kleen right-angle, worm
with high-strength aluminum
gear reducers are available in
alloy porting ends. Single
quill and three-piece coupled
and double acting models are

available with nose, pivot and
double-end mounting options.
Some models are available with
magnetic pistons for position
assembly and models are avail-
indication. Bore sizes range
able with a 5 mm/rev, 20 mm/
/16 2 in.; depending on bore
rev, or 25 mm/rev ballscrew
input and with solid or hollow
with a matched brushless
output. Made of stainless steel
rotary servo motor to provide
for washdown protection, the
maximum travel speeds to 1400
units are available in ratios of 17,
mm/s with 6 m accuracy, 1
21, 23, 26 and 30 with center dis-
m bidirectional repeatability
tances 1.75-3 in., and a factory-
and up to 0.5 m resolution.
filled H1 food-grade lubricant.
Aerotech; 412/967-6854;
Baldor; 479/414-4711;
www.aerotech.com
www.baldor.com
controldesign.com
33
3/22/10 10:24 AM
PRODUCT ROUNDUP
BE DYNAMIC
Electric actuator EGC is de-
MORE, MORE, MORE
signed for high dynamic speeds
Find more mechanical motion components from companies
and high rigidity. This modular

actuator can be used as an
such as Amacoil, Portescap, Ross Controls and Wittenstein

at www.ControlDesign.com/roundupsarchive.
INDUSTRIAL-GRADE POSITIONER
HD-N industrial-grade positioner offers bending moment
of inertia for rigidity and
individual component adapted
minimal deflection, lubrication
to third-party motors or as a
for life and maintenance-free
complete system provided by

one source. The unit is available in toothed belt and ball
noise or vibration control has
screw designs, as well as differ-
a self-lubricating, polyacetal
ent screw pitches.
nut that is radially preloaded
Festo; 631/404-3173;
on a 303 stainless steel screw.
www.festo.com/us
The assembly offers torque

consistency and repeatabil-
bearings and ball screws. Posi-
ity when traversing in either
tioners can come with custom
ANTI-BACKLASH
direction through its unique
motor mounts.
ZBX Series anti-backlash
load transfer capability.
Parker Electromechanical
linear actuator assembly for
HaydonKerk; 800/243-2715;
Automation Div.; 800/245-6903;
vertical applications requiring
www.haydonkerk.com
www.parkermotion.com/hd
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controldesign.com
3/22/10 11:44 AM
Can OTS OS Do Embedded Control?

controller with a mature homegrown operating
available I/O and peripherals, and ability to leverage
system (OS). Were looking to upgrade, and were
new technology such as multi-core processors and
wondering whats the best choice for an industrial
FPGAs. The startup time alone required to bring
strength OS. There are lots of options at various
up your own board and validate that the RTOS is
prices, and were a bit confused about the best
working correctly can be reduced drastically with
way to go. Were used to supporting our own OS,
an offering that supports commercial-off-the-shelf
so our level of technical expertise is pretty high.
(COTS) hardware, rather than custom-assembled
Does anyone have machine control experience
boards. These savings are on top of the reduced risk
with an off-the-shelf (OTS) OS for embedded con-
and additional time savings gained with vendor-
trol that theyd like to share?
tested, industry-vetted I/O drivers that allow the
from February 10 Control Design
ANSWERS
user to easily expand the systems hardware components and interfaces to the real world when projects
experience feature creep. Any system can be
expanded; however, some platforms require register
Tested and Reliable

The right off-the-shelf OS should be selected on
level development to get support for specific I/O.
RealAnswers@putman.net
Hardware and driver support affects time to

market, flexibility to scale to the right controller,
real answers
Our semiconductor processing machinery is controlled by our proprietary embedded
Kurt Williams, LabView product manager
technical details such as determinism, driver
National Instruments, www.ni.com
availability, hardware support, performance and

footprint, as well as the business impact of the
Real-Time Performance
system, cost, time to market and scalability. Several
We have embedded controllers running vxWorks,
real-time operating systems will do the job; the
Linux and Windows XP Embedded with various
difference will be in the details of the development
real-time extensions. These were selected to
tools and the ecosystem surrounding the platform.
provide a range of real-time performance at dif-
Initially, the control systems current requirements and possible future requirements
ferent price points, while all have mature, robust

development tools.
should be clearly defined and compared with

the potential RTOS platforms. Many soft RTOSs
are marketed for embedded designs, but fail to
provide hard real-time performance for critical
processes or machine control. The requirements
around the level of determinism required should
be well understood. Also, consider the level of
real-time safe communication mechanisms for
inter-process and intra-process communication
included with the platform, along with the availability of application-specific functions and algorithms necessary to complete the project. While
testing and validation is always necessary for a
reliable system, vendor or community-provided
code bases will save time, rather than spend it to
JuneS PROBLEM
WE USE A micro PLC to control our metal-cutting
machines with good results. When customers
see that we use a PLC, they want to specify
brand, causing us multiple headaches in design,
programming and after-sales support. Theres very
little variability in the operating parameters from
machine to machine, so were actually thinking of
switching to a preprogrammed relay that would
be set up and delivered by the vendor ready to go
with its own part number. If a machine needed
something a little different, we would order it
preprogrammed accordingly. Are we mortgaging
future versatility for fewer headaches right now?
design and implement new reusable functions for

communication, analysis and control. Because no
application is written perfectly the first time, the
platforms debugging tools for viewing threads
and tasks, identifying priority inversions and
resource contentions and tracking down errors
SEND US YOUR COMMENTS, SUGGESTIONS OR

SOLUTIONS FOR THIS PROBLEM. Well include it
in the June 10 issue and post it on ControlDesign.
com. Email us at RealAnswers@putman.net. Please
include your company, location and title.
should also be evaluated.

controldesign.com
CD1004_35_37_RealAnswrs.indd 35
35
3/22/10 11:53 AM
real answers
Most machine controllers use COTS devices for
nents and integration tools. Our eVM embedded
vision, motion and process control, and other spe-
virtualization platform enables you to combine
cialized tasks. Suppliers provide an API and/or IDE
the old and new worlds, while saving costs and
and tools that typically run on Windows and spe-
improving reliability at the same time.
cific embedded operating systems. Identify the top
Kim Hartman, vice president, sales and marketing,
candidates for each requirement and determine
TenAsys, www.tenasys.com
which OS will provide integrated API and tools.

The IDE needs to support your preferred pro-
Interfaces and Safety
gramming language and should have debugging
Look beyond current requirements. Although
tools to reduce development time. We should be fo-
deterministic real-time response and low OS
cused on improving process, not building and sup-
overhead are important, so is how the RTOS ad-
porting development tools. Consider the third-party
dresses growing software complexity, demand for
APIs and whether you plan to run the HMI directly
better user interfaces and expectations for safety
on the machine controller or via an external panel.
and security certification.
Regarding maturity, reliability and portabil-
At some point, your design could need to mi-
ity, choose an OS that supports a broad range of
grate to a multicore processoreither its the only
processors and base hardware platforms. Make
viable choice or user demand for advanced fea-
a decision that considers future advances in CPU
tures increases software complexity, generating
technology and provides a clear roadmap to lever-
the need for greater processing capacity. Either
age current investment on future designs.
way, an RTOS with proven multicore support can
Josh Jensen, product manager,

Kollmorgen, www.kollmorgen.com
provide an invaluable migration path.

Multicore chips come in a variety of configurations, including a single general-purpose processor
Embedded Virtualization
with a DSP, multiple general-purpose processors
It is not always necessary to purchase a new OS.
and multiple DSP accelerators and stand-alone
A complex motion system can be constructed
dual- or quad-core general-purpose processors. If
by combining your existing software with new
your system requires pure computing capacity, you
devices and new application code.
probably need the third option, in which case the
The combination of these elements and the abil-
RTOS should support parallel processing through
ity to handle multiple operating environments at
symmetric multiprocessing (SMP). The RTOS
the same time is possible through virtualization,
vendor should also provide system-tracing tools
but not the type often used in office and server
that can analyze the highly complex system-level
environments that sometimes fails in time-critical
interactions that characterize multi-core designs
applications. Embedded virtualization technology
to focus on areas that yield the greatest gains in
maximizes the predictability of the response of
parallelism and performance.
the application code in order to support a multi-
The complexity of your software design probably
OS environment to hardware-generated signals. It
is growing. However, this complexity cannot be
does so by isolating hardware between virtual en-
passed along to your end users; the system must re-
vironments so as not to detract from the systems
main easy to use. This is particularly true now that
ability to respond quickly.
consumer devices like iPhones have dramatically
Your existing embedded OS runs in parallel with Windows on a standard PC-compatible

platform enabling faster migration from out-
raised user expectations about attractive, easy-touse human-machine interfaces (HMIs).

It is difficult to create appealing HMIs without
dated hardware to modern embedded platforms.
support from the RTOS. It should support hard-
In addition to preserving your legacy system, the
ware-accelerated 2D/3D-graphic APIs and high-
technology provides the deterministic response
level user interface design tools. Also, to create
necessary for time-critical events by partitioning
a sophisticated user interface, developers must
and allocating hardware devices ensuring that
often combine multiple graphics technologies
time-critical I/O resources arent virtualized.
such as Adobe Flash, native 2D/3D graphics ap-
The solution sounds complicated, but its sold
plications, HTML content and video on the same
out-of-the-box with all of the necessary compo-
display. Thus, the RTOS must provide facilities
36
controldesign.com
3/22/10 11:53 AM
ment, it can be important to keep your options
Look for standard interfaces to ensure portability.
open. An RTOS that can be upgraded to a certifi-
Many off-the-shelf RTOSs support time

partitioning, which allows developers to place
programs into virtual compartments and to al-
able version without API changes is a real benefit.

Kerry Johnson, senior product manager,
QNX Software Systems, www.qnx.com
locate a guaranteed amount of CPU time to each

compartment. Such guarantees simplify the job
Heres a Product
of integrating software subsystems from multiple
In the past, machine builders had to venture
development teams or vendors. They can also
outside their core competencies to design custom
contain runaway threads and denial-of-service
operating systems because PC operating systems
attacks, enabling higher availability, and allow a
were not designed to be real-time and not stable
developer to debug a live system without starving
enough for machine control.
critical processes of CPU time.

As systems grow more connected and complex,
Our Simatic WinAC RTX is a programmable logic

controller designed to run on open platform PC
so do concerns for safety and security. IEC 61508
systems. It offers the I/O logic control of a PLC with
defines a number of safety integrity levels, such as
integration to standard PC platform interfaces and
SIL 3, that define measures to prevent systematic
high-level languages.
failures (bugs) from being designed into a system.
Its real-time and deterministic capabilities are
Likewise, The Common Criteria for Information
met by operating in an extremely stable Ardence
Technology Security Evaluation defines a set of se-
RTX real-time OS extension. With its Open De-
curity requirements that can be applied to embed-
velopers Kit, migrating high-level programs and
ded devices. A certifiable RTOS can greatly reduce
intellectual designs is possible.
the effort required to achieve such certifications.

Even if certification isnt an immediate require-
real answers
to layer these multiple technologies seamlessly.
Eric Kaczor, product manager, discrete automation,

Siemens Industry, www.industry.siemens.com
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41
3/23/10 10:01 AM
Ned Lecky ned@lecky.com
oem insight
Dont Fear Accuracy and Precision

Accuracy. Precision. GR&R. Two words
and the lines are sort of worn off here and there.
and an acronym that strike fear into the hearts
Maybe there is dirt or grit in the gauge. Our mea-
of many a manufacturing engineer or control
surement technician does his best, but it should
system designer. The terms and principles are ex-
be no surprise that if we measure the block over
tremely well-understood by most QA and process
and over again, the readings will vary consider-
control specialists, but what about the rest of us
ablyin this case, over a range of more than 0.1
mortals trying to wade through statistics without
in. Clearly, a much less precise gauge.
getting bogged down in too many details? To
Loss of precision can come from gauge inade-
start with, we have some object that we wish to
quacies or from operator training. Differentiating
measure. We could be measuring weight, length,
between the two is important and commonly is
color, shapethe type doesnt matter. The mea-
accomplished using analysis of variance gauge re-
surement device we needa scale or a ruler or a
peatability & reproducibility (ANOVA GR&R), often
colorimeteris called a gauge.
just called GR&R. A precise statistical technique
The accuracy of a measurement is the degree
(ANOVA) is used to analyze multiple measure-
to which it is close to the actual, true measure-
ments made by multiple operators using the same
ment. The true measurement is taken, if you will,
gauge. This not only determines the precision of
by some sort of perfect measurement system or a
the gauge, but it also analyzes how the precision
measurement system that is calibrated and tested
and accuracy vary from operator to operator. Each
to some extremely trustworthy degree. The ac-
gauge most likely has some tricks to its use and
curacy of our on-the-floor measurement would be
requires a certain amount of training, patience
the difference between that perfect measurement
and practice to use well. The GR&R study provides
and the one we get. If we have a block measured
a way to determine not only how good the gauge
he GR&R provides a hugely

T
important data point for
interpreting measurements
coming from the factory floor.
is, but how consistent each operator is in using

the gauge and what each operators skill level is.
GR&Rs are quite easy to do, contrary to factory
myth. Just five or 10 measurements with three
operators or so is usually enough to give great
insight into the quality of the gauge and the
and certified to really be exactly 1 in. and our
consistency of operator training. A more detailed
in-process gauge reads 1.053 in., this one single
study with 20 measurements using, say, 10 opera-
measurement is accurate to within 0.053 in.
tors, is often as complicated as one needs to get to
That makes sense. Precision could be a little
differentiate between accuracy, repeatability and
harder to grasp. Precision is a measure of how
operator training. The GR&R provides a hugely
easy it is to repeat a measurement taken with a
important data point for interpreting measure-
gauge. In fact, repeatability is another name for
ments coming from the factory floor.
precision. What if I measure the block with the
In todays automated measurement world, are
same gauge three more times and get: 1.051, 1.052
GR&Rs obsolete? Absolutely not. In my industry,
and 1.054? Well, this is a relatively precise gauge.
machine vision, we always use GR&R studies to
Our measurements only vary over a range of
evaluate our calibration (accuracy), the quality
0.004 in., and I might be tempted to say that the
of our image acquisition and analysis algorithms
precision of the gauge is something like 0.002 in.
(which affect precision) and the ability to run the
In practice, we would use statistical methods to
same parts through different inspection stations
analyze all of these readings and use a statistical
and get the same measurements. Automated
tool such as standard deviation to determine that,
GR&Rs are quite easy to design and perform.
say, 90% of our readings would range over some

particular window.
What if my three measurements were: 1.041,
in control systems and machine vision. As owner of Lecky
1.101, 0.987. We see gauges like this in real fac-
Integration (www.lecky.com), he consults for OEMs,
tories all the time. Maybe its an old micrometer
system integrators and machine vision providers.
42
CD1004_42_Insight.indd 42
Ned Lecky is an ME and EE with 25 years of experience
controldesign.com
3/22/10 10:32 AM
Even with all of my experience in

the industry, AutomationXchange
provided opportunities for me to find
solutions to advance my machines
that I was not aware of before.
Dr. Thomas Pool
Manager of Electrical Engineering
KLIKLOK-WOODMAN
SM
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3/23/109:48
9:43
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3/22/10 12:13 PM

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