Control Engineering Magazine

www.controleng.
com
S
O n a fe
e s ty
ys ?
te N
m, a
on tu
e e ra
ng ll y
in
ee In
rin te
g g
to r a
ol
, o te
ne d!
ne
tw
o rk
Se
e
pa
ge
25
fo
rd
et
ai
ls
High speed, low-cost control
with DirectLOGIC PLCs
H0-CTRIO2 (up to 250 kHz)

High-speed Counting / Pulse Output Module for
DirectLOGIC DL05 and DL06 PLCs
H0-CTRIO2
$199.00
Cut-to-length application uses high-speed output

to cutter and encoder feedback to high-speed
If you need precise counting or high-speed outputs for input for precise control
motion control in a low-cost form factor, DirectLOGIC
micro PLCs are just the ticket for small projects. The new PLC with H0-CTRIO2 module
H0-CTRIO2 High Speed Counter I/O Module fits into an Motor

expansion slot on any DL05 or DL06 controller. interface
Motor
control
lines
• Inputs for two up or down counters, or one quadrature Gearbox, clutch and
brake interface
encoder (250 kHz max)
H0-CTRIO2 high
• Two high-speed inputs for edge timing, pulse catch, Encoder speed output
count reset/inhibit/capture or home search Cutter interface
• Two configurable high-speed outputs or one channel

pulse output control (20 Hz-250 kHz) step and direction, Material to be
Cutter assembly
or clockwise (CW) and counter-clockwise (CCW) cut to length
pulse outputs
• Module operates asynchronously from the PLC/controller,
so on-board outputs respond in real time to incoming For more details on this module and
signals DirectLOGIC PLCs, visit:
http://bit.ly/0506spec
The DL05/06 series of controllers are convenient
mciro-bricks with 14 (DL05) or 36 (DL06) built-in I/O, www.automationdirect.com
plus expansion slot(s) for additional discrete, analog or
specialty modules such as the high-speed counter. Go online or call to get complete information,
request your free catalog, or place an order.
A DL05 unit with 8 inputs and 6 outputs starts at just $125.
1-800-633-0405
input #1 at www.controleng.com/information
MAKING MODERN LIVING POSSIBLE
From simple to complex applications

requiring constant or variable torque.
You’ll find expertise in zero downtime
embedded in every drive.
Turn to Danfoss for expertise in variable frequency built in North America specifically for automation along
drive technology that can combine precise positioning with 100% full-load factory testing and local support, can
and synchronization with outstanding reliability and improve uptime significantly.
safety. You’ll find that advanced VLT® AutomationDrives,
full-load tested
Danfoss VLT drives are
factory tested to verify
the reliability you expect
from over four decades
of VFD experience.
energy reduction
Properly applied Danfoss VLT
drives can improve efficiency
up to 50% to meet demanding
energy efficiency goals.
Envision the possibilities at envisioneering.danfoss.com/industry

MAY 2013 Vol. 60
Number 5
®
C OV E R I N G C O N T R O L , I N S T R U M E N TAT I O N , A N D A U TO M AT I O N S YS T E M S W O R L D W I D E
46
40
Control Engineering photo
50
Features
40 A straightforward maintenance strategy yields
improved plant performance
Moving from reactive to preventive maintenance helps Monsanto improve output and reduce costs
at its Muscatine plant.
46 Machine vision speed, quality, innovation

Advanced applications for machine vision in automotive, robotics, quality, and safety use hybrid
technologies, vision for robotic or machine guidance and in-line part inspection, and 3D imaging.
50 Step-motor-based systems stay competitive

Traditional stepper-motor systems represent the only motion-control technology able to operate in
open loop—although the addition of position feedback to enhance performance is on the rise.
54 The industrial Internet of Things

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

Risk assessment and risk management plans help with industrial safety and machine safety efforts,
using standards, processes, hardware, software, and continual education.
CONTROL ENGINEERING (ISSN 0010-8049, Vol. 60, No. 5, GST #123397457) is published 12x per year, Monthly by CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Jim Langhenry, Group Publisher
/Co-Founder; Steve Rourke CEO/COO/Co-Founder. CONTROL ENGINEERING copyright 2013 by CFE Media, LLC. All rights reserved. CONTROL ENGINEERING is a registered trademark of CFE Media, LLC used under license. Peri-
odicals postage paid at Oak Brook, IL 60523 and additional mailing offices. Circulation records are maintained at CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Telephone: 630/571-4070 x2220. E-mail:
customerservice@cfemedia.com. Postmaster: send address changes to CONTROL ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Publications Mail Agreement No. 40685520. Return undeliverable
Canadian addresses to: 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Email: customerservice@cfemedia.com. Rates for nonqualified subscriptions, including all issues: USA, $ 145/yr; Canada, $ 180/yr (includes
7% GST, GST#123397457); Mexico, $ 172/yr; International air delivery $318/yr. Except for special issues where price changes are indicated, single copies are available for $20.00 US and $25.00 foreign.
Please address all subscription mail to CONTROL ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Printed in the USA. CFE Media, LLC does not assume and hereby disclaims any liability
to any person for any loss or damage caused by errors or omissions in the material contained herein, regardless of whether such errors result from negligence, accident or any other cause whatsoever.
2 ● MAY 2013 CONTROL ENGINEERING ● www.controleng.com

Industrial Ethernet Industrial Wireless Serial Connectivity and Networking Embedded Computing
The Era of Scalable 10GbE

Infrastructures is Here
Scalable: High performance full Gigabit core backbone
Complete: Comprehensive edge-to-core networking solutions
Reliable: Non-stop operation services
Rugged: Industrial-grade fanless design
Over
Optimize Your Network Infrastructure with Scalable Edge-to-Core

500for Ed Switches
ge-to-
Industrial Ethernet Solutions co
Solutio re
ns
Moxa is introducing a comprehensive portfolio of edge-to-core switches, including high performance, high capability, 10GbE core
switches that feature innovative network redundancy technologies, the best price to performance ratio, and a rugged industrial design.
Core Layer: High bandwidth 10GbE Distribution Layer: Industrial Modular Edge Layer: Compact, Standalone/Modular
Industrial Core Switches DIN-Rail and Rackmount Switches DIN-Rail Switches
- Full Gigabit L2/L3 - Flexible modular design - Widest selection of switches: from 5 to 19 ports,
- Up to 4 10GbE ports - High port-density FE to full GE, managed to unmanaged
- Up to 24 or 48 1GbE connection - Ideal for control room and outdoor - Cost-effective solutions
- Fanless design cabinet operation - Advanced L2 networking capability
Industrial Core Switches

ICS-G7848/G7850/G7852 Series
48G/48G+2 10GbE/48G+4 10GbE-port
Layer 3 Full Gigabit Modular Managed Ethernet Switches
• Up to 4 10GbE ports
• Up to 52 optical fiber connections (SFP slots)
ports • Layer 3 routing to interconnect multiple LAN segments
Up to 48 Gigabit
• Turbo Ring and Turbo Chain, and RSTP/STP for Ethernet redundancy
• Fanless design, 0 to 60°C operating temperature range
• Isolated redundant power inputs with universal 110/220 VAC power supply range Use your Smart Phone to
• Modular design for maximum flexibility and hassle-free future expansion scan for more information.
• Hot swap interface and power modules for continuous operation
Moxa Americas, Inc.

Tel: 1-888-669-2872
Fax: 1-714-528-6778 input #3 at www.controleng.com/information
usa@moxa.com www.moxa.com
Success Story
Automation Simplified
GE Appliances. When one of the world’s largest manufacturers of major appliances
needed an open, globally supported network that was easy to install, they chose PROFINET.
GE Appliance Park: Louisville, Kentucky
“I needed to reduce
implementation time.
PROFINET does that.”
—Robert Frank, Senior Advanced
Manufacturing Engineer
To learn more, read the complete

application story at www.us.profinet.com.
Or, simply scan the QR code.
MAY 2013
®
C OV E R I N G C O N T R O L , I N S T R U M E N TAT I O N , A N D A U TO M AT I O N S YS T E M S W O R L D W I D E
Inside Process
Starts after p. 63. If not, see www.controleng.com/archive for May.
P1 Working in the cyber security red zone

Do you have enough first responders within your company when it comes to
dealing with cyber security incidents and network violations? How can you
make sure you aren’t developing critical staffing gaps?
P5 Understanding SIS industry standards

Process safety standards and practices are spreading from oil and gas
and other energy-related industries to broader process industry applications.
Here’s basic advice on how to make more sense of the numbers and acronyms.
P9 Innovative energy management strategies

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

8 Think Again 31 International
Manufacturing competitiveness, Is SLM gaining momentum
innovation: National, personal in China?
10 Product Exclusive 33 Machine Safety

Embedded motion controller Incorporating functional safety
12 Tech Update 80 Back to Basics

How to lower PLC software costs Simulators use math to create
virtual processes
14 IT & Engineering Insight
When M2M meets IT
16 Tech Update
How to choose industrial wireless
news
components
PRODUCTS 34 Reports from Hannover
18 Tech Update Messe, CSIA Executive
Achieve fault tolerance with a Conference; new industrial
real-time software design revolution spurs U.S.
22 Application Update manufacturing
Unified platform helps robotics
for packaging
26 Application Update
products
More efficient pumps use VFDs,
76 Flowmeters; light curtains;
consolidate logic
servo motor controller;
28 Application Update non-contact wireless switch;
Simulation software boosts controller programming
machine productivity platform; and more
www.controleng.com ● CONTROL ENGINEERING MAY 2013 ● 5

MAY
www.controleng.com
Channels New Products Media Library Connect Industry News Events, Awards Newsletters Blogs Magazine
Looking for online

training? Earn CEUs
with videos, webcasts
Check out the latest offerings at
www.controleng.com/training
and
www.controleng.com/webcasts
Connect with us!

www.facebook.com/
ControlEngineeringMagazine
www.linkedin.com/
groups?gid=1967039
www.twitter.com/controlengtips
http://tinyurl.com/CEgoogleplus
More learning, less surfing

Exclusive blogs at www.controleng.com/blogs Media library
Real World Engineering: Demystifying the math of PID control www.controleng.com/media-library
Machine Safety: How much ancillary equipment needs to be grounded?
Videos and Webcasts on demand
Pillar to Post: Making personal life decisions based on device diagnostics
Online training center
Join the discussions at www.linkedin.com/groups?gid=1967039
What’s a reasonable lifespan for a PLC if it isn’t abused? Engineering education center
Looking for panel builder software—what are some favorite platforms? Case studies—130+ all in one place
on dozens of topics
What are the challenges when integrating devices with a control system?
How do you do it? Useful white papers on many topics
Services available
Topic-specific e-newsletters
Channels and new product areas
Start your subscriptions at www.controleng.com/newsletters
Visit our specialized microsites providing
Weekly News: Selecting components for wireless communication feature articles, news, products, applica-
Information Control: Worlds collide as M2M meets IT tions, tutorials, research, and more gath-
ered for engineering professionals.
Safety & Security: A new approach for safer networking
Process & Advanced Control: Fundamentals of lambda tuning for PID loops New site search engine
Machine Control: Vision systems for next-generation robots Find content from Control Engineering
magazines from 1997 to the present.
Point, click, watch Electronic newsletters

Keep current with the latest information
VIDEO: Visit Monsanto Muscatine and news with electronic newsletters.
If you want to meet the subjects of this month’s
System Integrator Guide
cover story, read it online at www.controleng.com
Consult our listing of more than 2,300 au-
to see a video produced by Control Engineering
tomation system integrators. You can find
that takes you to the plant and lets you hear what
a specific company or run a seven-way
they’re doing from the participants. To go there
multi-parameter search.
directly, scan the QR code to the right.

800 453 6202
editorial
THINK AGAIN 1111 W. 22nd St. Suite 250, Oak Brook, IL 60523
630-571-4070, Fax 630-214-4504
Content Specialists/Editorial
Mark T. Hoske, Content Manager
Manufacturing
630-571-4070, x2214, MHoske@CFEMedia.com
Peter Welander, Content Manager
630-571-4070, x2213, PWelander@CFEMedia.com
Bob Vavra, Content Manager
competitiveness,
630-571-4070, x2212, BVavra@CFEMedia.com
Amara Rozgus, Content Manager
630-571-4070, x2211, ARozgus@CFEMedia.com
innovation:
Amanda McLeman, Project Manager
630-571-4070, x2209, AMcleman@CFEMedia.com
Chris Vavra, Content Specialist
630-571-4070, x2219, CVavra@CFEMedia.com
National, personal Brittany Merchut, Content Specialist

630-571-4070, x2220, BMerchut@CFEMedia.com
Ben Taylor, Project Manager
630-571-4070 x2219, BTaylor@CFEMedia.com
Science, technology, engineering, and math professions Contributing Content Specialists
Frank J. Bartos, P.E.,
earn 26% more; manufacturing contributes more innovation braunbart@sbcglobal.net
to the economy and accounts for 60% of exports, with 9% Jeanine Katzel jkatzel@sbcglobal.net
Vance VanDoren Ph.D., P.E.,
of the employment. controleng@msn.com
E
Suzanne Gill, European Editor
suzanne.gill@imlgroup.co.uk
arnings are 26% more on average tion.” So for 30 years on the political side, Ekaterina Kosareva, Control Engineering Russia
for those studying science, technol- few worried about that, he said. There’s ekaterina.kosareva@fsmedia.ru
ogy, engineering, and math (STEM) been a rethinking in recent years as people Marek Kelman, Poland Editor-in-Chief
marek.kelman@utrzymanieruchu.pl
subjects, according to Eric Spie- realized the real economy was under-rated
Lukáš Smelík, Czech Editor-in-Chief
gel, president and CEO, Siemens Corp. and the financial economy over-rated. lukas.smelik@trademedia.us
“The best way to close the skills gap is We’re good at innovation, but inventing Andy Zhu, Control Engineering China
andyzhu@cechina.cn
for schools, government, and industry to and making are not separate. If we let our
work together to close the training gap.” manufacturing go, innovation goes with it, Publication Services
Jim Langhenry, Co-Founder/Publisher, CFE Media
Advanced manufacturing is where the world Bloom suggested. A manufacturing job is 630-571-4070, x2203; JLanghenry@CFEMedia.com
is going. This can create opportunities for more valuable than other jobs because of Steve Rourke, Co-Founder, CFE Media
millions of Americans, he noted at an April a multiplying effect to other areas of the 630-571-4070, x2204, SRourke@CFEMedia.com
Trudy Kelly, Executive Assistant,
23 online conference hosted by Washing- economy. If you build an automobile manu- 630-571-4070, x2205, TKelly@CFEMedia.com
ton Post Live and sponsored by Siemens, facturing plant, a Wal-Mart will follow, Elena Moeller-Younger, Marketing Manager
American Small Manufacturers Coalition, but not the other way around, he observed. 630-571-4070, x2215; EMYounger@CFEMedia.com
and Northern Virginia Technology Council. Government should provide supportive Michael Smith, Creative Director
630-779-8910, MSmith@CFEMedia.com
James Manyika, director of McKinsey infrastructure and ensure we have appropri- Paul Brouch, Web Production Manager
Global Institute, recently named to Presi- ate trading partners, Bloom said. Because 630-571-4070, x2208, PBrouch@CFEMedia.com
dent Obama’s Global Development Council, intelligence is embedded into manufactur- Michael Rotz, Print Production Manager
717-766-0211 x4207, Fax: 717-506-7238
said manufacturing is responsible for 9% of ing processes, there are huge opportunities, mike.rotz@frycomm.com
employment, but drives more than 60% of as we think again about what manufacturing Maria Bartell, Account Director
Infogroup Targeting Solutions
exports. Manyika said the U.S. is still the can do for us, Bloom suggested. There’s an 847-378-2275, maria.bartell@infogroup.com
leading manufacturer, but China, India, and interconnectivity between people who think Rick Ellis, Audience Management Director
Russia are gaining, driving demand locally. about stuff and people who make stuff, and Phone: 303-246-1250; REllis@CFEMedia.com
Many nations are reaping benefits from regional ecosystems of talent, with webs of Letters to the editor
Please e-mail us your opinions to
manufacturing-related innovations of their suppliers to help, he noted. ce MHoske@CFEMedia.com or fax us at 630-214-4504.
Letters should include name, company, and address,
own, Manyika suggested. and may be edited for space and clarity.
U.S. innovations are huge, especially
Go Online Information
For a Media Kit or Editorial Calendar,
in materials development, production, and
email Trudy Kelly at TKelly@CFEMedia.com.
analytics; many help smaller manufacturers At www.controleng.com/archive, see “Manu-
facturing in America targets next U.S. industrial Reprints
to effectively compete, Manyika said. Prod- For custom reprints or electronic usage, contact:
uct demand helps determine where com- evolution.”
Wright’s Media – Nick Iademarco
panies are located, along with labor skills, www.usa.siemens.com Phone: 877-652-5295 ext. 102
Email: niademarco@wrightsmedia.com
costs, infrastructure and non-labor inputs, Washington Post Live www.washingtonpostlive.
com Publication Sales
such as energy, natural resources, innova- Patrick Lynch, AL, FL, GA, MI, TN
tion, and business and policy environment. 630-571-4070 x2210 PLynch@CFEMedia.com
Ron Bloom, senior advisor, Lazard, and Bailey Rice, Midwest
630-571-4070 x2206 BRice@CFEMedia.com
former assistant to the president for manu-
Iris Seibert, West Coast
facturing policy, said “For a long time we 858-270-3753 ISeibert@CFEMedia.com
believed decline of manufacturing was both Mark T. Hoske, Content Manager Julie Timbol, East Coast
978-929-9495 JTimbol@CFEMedia.com
inevitable and good, part of a natural evolu- MHoske@CFEMedia.com
Stuart Smith, International
Tel. +44 208 464 5577 stuart.smith@ssm.co.uk
The Sign of Quality
For almost 100 years, Baldor Electric Company • Energy Efficient

has developed a reputation for designing and
manufacturing the highest quality industrial electric
motors available. Beneath the nameplate of every
• Unmatched Quality
Baldor•Reliance® motor, you will find the best industrial
electric motor you can buy. • Superior Reliability
When reliability counts, accept nothing less than the
Sign of Quality from Baldor•Reliance.
• Quickest Delivery Available
baldor.com • American Made Since 1920
Scan to watch a video

and learn more or go to
©2013 Baldor Electric Company http://qr2.it/Go/1398474
product
EXCLUSIVES
Software wizard: easy setup of
embedded motion controller
PMD Pro-Motion software offers axis wizard and support
for digital amplifiers and embedded motion development,
providing easy setup of embedded motion controllers.
P
erformance Motion Devices Inc.
(PMD) announces a major new
A Cut Above
release of PMD Pro-Motion
software for Microsoft Win-
dows-based environments. Pro-Motion
5.0 adds a number of key capabilities
including an upgraded axis setup wizard,
support for SPI-based motion amplifi-
ers, including PMD Atlas digital ampli-
fier products, and support for all-in-one
MAQ®20 embedded motion cards and systems.
The most significant new feature
in Pro-Motion 5.0 is the addition of a
graphical axis wizard facility that pro-
vides step-by-step configuration of all
control signal parameters, including
quadrature feedback, motion output sig-
nals, home signals, Hall sensor signals,
analog input and output, and more. The
A Multifaceted new axis wizard performs automated
System tests to characterize connection and con-
for Industrial figuration information. Users can accept
these automatic parameters or provide
Data Acquisition & Control their own values. Other features include
current loop and position loop auto-tun-
Up to 384 channels all in a standard 19” rack! ing, and system configuration storage.
Another major new feature is sup-
• Industry’s Lowest Cost per Channel port for SPI (serial peripheral interface)-
based solderable motion amplifiers.
• Outstanding Isolation Acquire and Analyze These amplifiers, including the PMD
1500Vrms Atlas line of digital amplifiers, are used
• Unparalleled Accuracy in embedded motion applications where
±0.035% Present the motion processor IC and motion
amplifier are co-
• Wide Operating Temperature located on the Go Online
–40°C to +85°C same card. Step Read more:
• Widest Range Input Power motor, dc brush, www.controleng.com/archives
7-34VDC and brushless www.controleng.com/motors
dc motors are
• Product Integrity Ensured by supported, as are manual or automatic
48-Hour 85°C Factory Burn-in tuning of amplifier gain parameters,
temperature monitoring, and I2t cur-
rent tuning. Embedded motion soft-
ware development is supported via a
www.dataforth.com command window along with a simple
3331 E. Hemisphere Loop • Tucson, AZ 85706 USA scripting facility to program sequences
Toll Free: 800-444-7644 • Tel: 520-741-1404 • Fax: 520-741-0762 of commands. ce
Email: techinfo@dataforth.com Performance Motion Devices (PMD)
input #7 at www.controleng.com/information www.pmdcorp.com
10 ● MAY 2013 CONTROL ENGINEERING

Find Parts Fast and Easy
We make it easy to find the parts

you are looking for at
Explore! sy website tools

U se ou r fr ee an d ea
y!
@ alliedelec.com toda
1.800.433.5700
© Allied Electronics, Inc 2013. ‘Allied Electronics’ and the Allied Electronics logo are trademarks of Allied Electronics, Inc. An Electrocomponents Company.
technology
UPDATE
How to lower
PLC software costs
PLC vendors make much more profit from software licenses than they do selling
hardware. Smart shopping can avoid some of those fees. Advice for lowering PLC
software licensing fees follows.
P
Chuck Karwoski rogrammable logic controllers (PLCs) the purchase of an annual maintenance contract
and now programmable automation and/or technical support, the purchase of periodic
controllers (PACs) are the mainstay of upgrades, and other purchases that can nickel and
discrete factory automation, and they are dime a machine builder or end user for years.
increasingly being used in process control. Under- Vendors prevent users and machine builders
standing how software licenses work can help you from copying the software and loading it onto
understand how you may spend 10 times as much additional PCs. Any software can be copied, of
on software as on PLC hardware. course, and copies can be loaded into other PCs.
A software license governs the use or redis- But they won’t run on any other PC because of
tribution of software. A software publisher can restrictions similar to how Microsoft protects its
charge to buy the software and restrict how software from being “pirated.” Methods include
many PCs the software can be installed on. For requiring a dongle to be plugged in, or a product
a machine builder who uses a PLC as a control activation program. A dongle is a hardware key
system, it generally means the builder has to pay containing an electronic serial number required to
for another software license each time a new run the software. Product activation requires the
machine gets shipped to the customer. Software user to verify the license, typically by entering a
licenses can also restrict users in other ways, such product key or serial number to activate and use
as limiting the number of data points, functions, the software.
or workstations able to access data for control- Software license cost depends on pricing from
ling the machine. The license also may require the software publisher, number of development
licenses, number of data points,
add-on components, number of
run-time licenses, annual mainte-
nance fees, and other factors. These
particular citations did not indicate
whether the price was for shrink-
wrapped software costs alone or if
any services fees were included.
Software needed, costs

A typical PLC application usu-
ally requires purchase of: PLC
programming software, HMI
development software, SQL / data-
base license, data I/O server, add-
Buying PLC programming

software is just the first pur-
chase in a list of expensive soft-
ware programs needed to get an
automation system up and run-
ning. Courtesy: CimQuest Ingear

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

HMI run-time license. Each,
of course, has a separate soft-
ware license. The software
developer still needs to add his
skills, experience, and creativity to produce the ing secretive, proprietary, or difficult about HMI/
end product ready for run-time deployment. SCADA, data communications, SQL, and many
Run-time license fee is another revenue gen- other software packages. Many such packages can
erator for the software publisher. A run-time be purchased from non-PLC vendors on the open
license is a way for software publishers to con- market. Anything else can be developed by an
trol distribution and generate another revenue experienced MS Visual Studio programmer.
stream. Basically the software publisher charg- All a machine builder needs from the PLC
es a fee for tools to create applications, places vendor is the PLC and I/O hardware and prob-
restrictions on the types of applications you ably the programming package (although IEC
may create, and then charges fees for distribut- 61131 programming packages are available).
‘
ing your works. Everything else can be
Alternative software solu- Some software has no purchased separately.
tions exist on the open market In many cases, these
from several vendors. Getting run-time licensing fees, packages don’t have
users and machine builders to so applications created expensive software and
talk about how they avoid these run-time licenses. For
costs by purchasing alternative can be distributed by example, the PLC driv-
software is difficult. In many a systems integrator or er software includes a
cases, they have built relation- library of programs for
ships with PLC vendors and machine builder without PLCs that programmers
’
have standardized on PLC added costs. use to create their own
hardware. customer applications
For example, a major automation vendor offers using MS Visual Studio. Such software provides
a software solution built on OPC to enable con- access to PLC memory, databases, I/O, and com-
nectivity between HMI software packages and its munications, allowing programmers to obtain
PLCs. Once a user builds an interface application information they need from a PLC, process it
with that HMI development tool, the software pro- in a PC, and send commands back to the PLC
vides drivers and other connectivity components for control. Some such software has no run-time
that enable PLC communications. Users are then licensing fees, so applications created can be Go Online
required to purchase individual software copies distributed by a systems integrator or machine
for every machine on which they want to run the builder with no additional costs. At www.controleng.com/
archive, read this article for
application, along with annual software mainte- There’s no need to pay the licensing costs of
more on cost of software
nance fees for each copy. PLC vendor software when alternate solutions licenses, two examples of
Although vendor-supplied software is propri- exist. ce savings, more photos, and
etary, requires licenses, and can’t be modified by - Chuck Karwoski is president of CimQuest a link to “Products to lower
a customer, most is written in Microsoft Visual Ingear LLC, a supplier of PLC software. Edited PLC software costs.”
Studio. Anything the vendor can do, a machine by Mark T. Hoske, content manager, CFE Media, www.ingeardrivers.com
builder or an end user can do, too. There is noth- Control Engineering, mhoske@cfemedia.com.
IT & engineering
INSIGHT
When M2M meets IT
Subsecond latency and delivery jitter lead to lost production time and production. Do not
let your production suffer when M2M network requirements collide with IT policies.
M
achine to machine (M2) communi- 4. Error rate usually measured in errors/mil-
cation was formerly a straightfor- lion communications
ward engineering job, with outputs 5. Delivery jitter or variation in message
from one device’s controller fed latency.
into inputs of another device’s controller. A
“stalled” signal from a downstream device was If your IT department does not segment its
fed into a “delay” command in an upstream production communications from normal busi-
device. In complicated situations, or where the ness communications network, then it is vital to
signals do not exactly correspond, a small PLC develop a QoS agreement and a guarantee from
might have been placed between the devices the IT department for your industrial networks.
Dennis Brandl to handle complex timing issues and perform However, having a QoS agreement is worthless
President of BR&L simple logic. unless you also have some method of measuring
Consulting As M2M communication has moved out of compliance. It is important to monitor QoS met-
the hardwired model to a data communication rics on a regular basis to ensure that normally
model over Ethernet networks, the IT depart- undetected subsecond delays are not creeping
ment is now involved in these integration jobs. into the system due to normal maintenance and
‘
Some IT departments recognize the special system expansion.
QoS metrics nature of these networks, but many do not. IT QoS metrics should be collected, monitored,
should be departments that recognize the special nature and alarm monitored the same way normal pro-
will segment their networks to localize M2M duction measurements are handled. QoS met-
collected, traffic and protect it from general business net- rics are sometimes available from routers or
monitored, and work interruptions. M2M communication is switches, but they can also be determined with
special because of its specific quality of service a few lines of ladder logic in a PLC if no other
alarm monitored
(QoS), redundancy, and consistency require- method is available. QoS metrics should at least
the same ments. In an internal IT network there is little be monitored per network segment and, if pos-
way normal business impact if it takes two extra seconds sible, to each device. It can also be valuable to
to view an e-mail or one extra ring on a voice retain the QoS metrics in your plant historian to
production over IP (VoIP) phone call. In production envi- aid in troubleshooting. This will allow you to
measurements ronments using networked M2M, even small pinpoint the time that a QoS went out of specifi-
’
are handled. subsecond delays can cost millions of dollars in cation and maybe relate it to a replaced element,
lost yearly production. For example, a 250-mil- changed configuration, or router patch.
lisecond signal delay to a placement robot
moving 10 parts per minute will be 1 hour of Standard segmentation
5
unproductive time in a 24-hour production run. Industrial networks should be separated
from normal business networks for safety and
5 quality of service measures security reasons, as specified by the ISA 99
Special M2M requirements should be and IEC 62443 standards. However, if your IT
expressed as QoS requirements. QoS has several organization will not separate them because it
different measures: is hard to justify the costs, then QoS arguments
1. Availability or uptime usually measured should be used. Subsecond latency and deliv-
Go Online as a percentage with 100% meaning always ery jitter can be directly related to lost produc-
At www.controleng.com, available tion time and potentially millions of dollars of
search Brandl for more 2. Bandwidth or throughput that is usually unrealized production. Do not let your produc-
under this headline.
measured in total network bandwidth but in tion suffer when M2M requirements collide
www.controleng.com/ M2M environments should be measured in band- with IT policies. ce
archive
width available to each device - Dennis Brandl is president of BR&L Con-
At www.controleng.com 3. Latency or delays in communication from sulting in Cary, N.C., www.brlconsulting.com.
search M2M, industrial net-
work, or Internet of Things. a source to a destination usually measured in His firm focuses on manufacturing IT. Contact
milliseconds him at dbrandl@brlconsulting.com.
©2010 The MathWorks, Inc.
Q
Find it at
mathworks.com/accelerate
datasheet
video example
trial request
MODEL
PHYSICAL
SYSTEMS
in
Simulink
with Simscape™
• Electrical
• Mechanical
• Hydraulic
and more
Use SiMScape with SiMulink

to model and simulate the plant
and controller of an embedded
system. Assemble your model with a
graphical interface, or import physical
models from CAD systems. Use built-in
components or create your own with
the Simscape language.
technology
UPDATE
How to choose industrial
wireless components
For industrial wireless networks, choosing the best accessories helps ensure a
high-quality wireless network. Most problems in newly installed wireless networks
result from poorly chosen or poor-quality accessories.
David Burrell
O
ver the past decade, wireless Power levels commonly found Polarization of antennas:
technology has become one in wireless communications Polarization refers to the direction in
of the most efficient ways dBm level Power which the radio emits energy through
for industrial professionals to -120 dBm 0.000000000001 mW
space. Antennas can be polarized in three
reduce operational expenses. The labor ways: vertically, horizontally, and radi-
-120 dBm 0.00000000004 mW
and material expenses of a cabled system ally. Cross-polarizing antennas mean that
can cost up to 500% more than a wireless -100 dBm 0.0000000001 mW the receiver will accept only a fraction
system. Thanks largely to these poten- -90 dBm 0.000000001 mW of the transmission power. The anten-
tial savings, the industrial market has -20 dBm 0.01 mW na’s angle determines what that fraction
witnessed a rapid increase in the market -10 dBm 0.1 mW of emitted power is. For example, no
acceptance of wireless. power will be received by an antenna 90
0 dBm 1 mW
While the radio device itself is obvi- degrees out of phase. An antenna 45 or
10 dBm 10 mW
ously a key piece of equipment, instal- 130 degrees out of phase will receive only
lation practices and auxiliary equipment 20 dBm 100 mW half of the power.
also affect the reliability of a wireless net- 30 dBm 1000 mW Cross-polarization is not necessarily
work. Poor installation practices, coupled a bad thing. Two neighboring or overlap-
with low-quality accessories, can lead to Link budget ping networks that are operating in the
failure in a wireless network. The sum of all antenna gains, cable same frequency can result in interference.
losses, radio transmission power, receiv- Changing the polarization of one of the
Power measurements er sensitivity, and path loss is the “link networks can overcome the intrusive sig-
Wireless systems measure all radios’ budget.” The remaining single level is nals between the two networks.
output powers and components’ gains and called the fade margin. This is the cushion
losses with a common unit factor. This between the received signal and the radio Antennas
common factor is known as a decibel. A device’s minimum receive threshold. Omni-directional antennas cover a
decibel (dB) is an abbreviation for the Environmental changes can attenuate 360-degree plane with nearly uniform
power ratio calculated using the formula the transmitted signal, so when design- characteristics across all directions (Fig-
below. Note that both P1 and P2 refer to ing a wireless network, it is important ure 2). Some common applications for
the same power unit. to calculate a 10-20 dB fade margin into omni-directional antennas include cases
dB=10log (P1/P2) the link budget of the path to compensate
for any such changes. Using higher gain Antenna TX Cable RX Path Fade
gain power loss Threshold loss margin
In wireless communication, power is antennas and lower loss coaxial cable, or
referred to as dBm. A dBm is calculated increasing the transmission power (when Figure 1: Overview on how to calculate
as a dB, but P2 always equals 1mW. possible), are two ways to increase the link budget. Items shown in green are
dBm=10log (P/(1 mW)) fade margin. Figure 1 shows an overview added while items shown in red are sub-
of the calculations. tracted. The resultant number is the link
Power levels commonly found in wire- budget. The fade margin is recommend-
less communications are in the table. For Antenna selection ed to be an extra 20 dBm to account
every 3 dBm gain, the effect of power Proper antenna installation is critical for unforeseen interference. Courtesy:
doubles. An increase of 6 dBm will dou- and will affect the entire system’s per- Phoenix Contact
ble the effective line-of-sight range for formance. Choosing an antenna designed
a wireless link; dBi refers to the gain of for use at the proper frequency and with Figure 2: Omni-
isotropic antennas. An isotropic antenna matching impedance are the first steps. directional antenna
radiates equally in all directions. dBi and Select an antenna with an appropriate radiation pattern.
dBm can be added, and the resulting sum gain for the path it will be used for. Courtesy: Phoenix
is expressed in dBm. Contact

Figure 3: Yagi-directional the antenna heading, it should be oriented Go Online
antenna radiation pat- for maximum signal strength.
tern. Courtesy: Phoenix Directional antennas must be mounted n This article at www.controleng.com/archive
Contact securely. Strong winds might sway or has more on cables and power supplies.
wobble an unstable antenna, which could n www.controleng.com/wireless has more
where the position between lead to serious misalignment. ce articles on industrial wireless.
the transmitter and receiver - David Burrell is wireless product n www.phoenixcontact.com
can change, moving applications or a ITS_IceStation_sparks_5.125x8.125_REV_Layout
specialist, Phoenix Contact. 1 4/19/12 1:13 PM Page 1
multipoint network. They are also ideal
when line of sight is obstructed, because
the reflections can be used to send the
signal from the transmitter to the receiver.
The best place to install an omni-
directional antenna is on top of a mast
or on a control cabinet. This allows it as
much free space in all directions as pos- it’s guaranteed to
sible. Unfortunately, it is not always pos-
sible. If an omni-directional antenna must
be mounted on the side of a mast, the
singe your electronics.
installer must observe specific measure-
ments and distances to mount the antenna
away from the mast for the best signal.
If the omni-directional antenna is
mounted to conductive material, such as
a master control cabinet, its directional
characteristics will be affected. The diam-
eter and distance between the antenna
and conductive material can alter the
antenna’s coverage area significantly.
Wall mounting should be avoided, as the
wall has a great impact on the antenna’s
transmission properties. If wall mounting
is the only option, the installation should
have a minimum of half a wavelength of
the respective operating frequency of dis-
tance between the wall and antenna.
Yagi antennas
Yagi antennas (Figure 3) radiate power
we guarantee it won’t.
in a specific direction. This increases the
In manufacturing time is money. We guarantee IceStation TITAN will
range and reduces the chance of inter-
keep your critical computer systems up and running no matter what
ference. As the gain of a Yagi antenna danger presents itself. Built to meet NEMA 12 standards, IceStation
increases, the energy becomes more TITAN protects computer systems from harmful dust, grease, sparks,
focused. This causes the beam width to and splashing fluids. With a large viewing window designed to
decrease, so proper alignment becomes accommodate up to 24'' wide screen monitors, a retractable
even more critical. Aiming these antennas keyboard drawer, oversized work surface, and a track
in the desired direction of communica- record of 27 years experience protecting electronics,
tion (such as at the master station) is very ITSENCLOSURES is the one name you can trust.
important. Remote, fixed stations with To learn more about IceStation TITAN, call
line of sight that cover large distances 1.800.423.9911 or visit ITSENCLOSURES.com.
should use directional antennas. The end
of the antenna (farthest from the support
mast) should face the associated station.
A master location with multiple slave
radios must always have an omni-direc-
tional antenna, and the slave radios can
25
have Yagi antennas to increase distance
possibilities. During final alignment of
CONTROL ENGINEERING MAY 2013 ● 17
technology
UPDATE
Achieve fault tolerance with
a real-time software design
Data Distribution Service (DDS) specification from Object Management Group
(OMG) is a data-centric publish/subscribe (DCPS) messaging standard for
integrating distributed real-time applications. Here’s how process replication
can increase a system’s fault tolerance.
D
Reinier Torenbeek ata Distribution Service (DDS) specifi- application processes. For the sake of simplicity,
cation from Object Management Group the collection of those processes is referred to as
(OMG) is often used to build mission the Manager component. Note that those could
critical systems consisting of multiple be executing in a distributed fashion on multiple
components executing simultaneously and collabo- machines.
rating to achieve a certain task. In such systems,
there are usually several components that are criti- Active process replication
cally important for the overall functioning. Those Simultaneously running multiple Manager
components require extra attention when designing processes with the same purpose will decrease the
the system to ensure that the likelihood of them likelihood that the Manager component will break
failing is minimized. Its focus on reliability, avail- down completely. DDS allows for adding and
ability and efficiency make the DDS infrastructure removing participants on the fly without requir-
particularly suitable to connect the plant floor with ing configuration changes, so the basic concept
other areas of the enterprise. of process replication is supported. Still, there are
DDS provides advanced fea- multiple options from which to choose.
tures that help achieve such goals.
While there are many methods, Plain process replication
fault tolerance for failing publish- The most basic approach is to run multiple,
ing applications or machines can be identical Manager applications. Each acts the
achieved by means of active pro- same, receiving the same transition requests and
cess replication. publishing the same state updates in response. As
a consequence, applications observing the state
Guiding example machine will see multiple instances of that state
For the purpose of illustrating the theory here machine simultaneously. This approach requires a
with an example, the use case of the simple dis- minor adjustment to the data-model to allow mul-
tributed finite state machine (FSM) is described. tiple task instances to exist side-by-side. This is
The most basic
The FSM consists of a few components: a achieved by adding a key attribute that identifies
approach is to run mul-
Master Participant, a Worker Participant, and a the originating Manager application.
tiple, identical Manager
Manager. The Observer component, not essen- An advantage to this approach is its low com-
applications. Courtesy:
tial for the functionality of the pattern, is pas- plexity; just replicating everything is an approach
Real-Time Innovations
sively observing only. This example focuses on everybody understands. There is no impact on the
the interaction between the Manager and the Manager application code, and all participants
Observer. remain completely decoupled from each other.
Let’s assume that the Manager is the most Additionally, the mechanism does not rely on any
critical process in the pattern, which is likely to built-in replication mechanism from the middle-
be the case, especially if the pattern is expand- ware. This could be considered an advantage as
ed to support multiple Masters and Workers. well, because the developer now has every aspect
The most obvious way to make the Manager of the replication process under control.
component more robust is by running multiple On the other hand, that latter argument could
processes simultaneously, all with the same be seen as a disadvantage. Requiring all Observers
responsibility. With that approach, the Manager of the state machine to be able to deal with mul-
component is defined as a conceptual item that tiple, identical versions simultaneously does have
may consist of multiple, simultaneously running an impact on the application code and introduces
Working Together in Harmony
Integrated motion control solutions Representing two decades of R&D investment and
refinement, the next-generation MR-J4 servo series offers
that work perfectly together. more than just a few new splashy features. It delivers
a tightly integrated motion control solution that boosts
productivity with speed, safety and performance.
• Industry-leading 2500Hz speed frequency response

to significantly reduce settling time.
• 4 million pulses/rev absolute encoder as standard
for improved positioning accuracy.
• Dynamic vibration suppression control II to
extend machine life.
• Advanced functions for greater operator
and machine safety.
NEW MR-J4 Servo System

technology
UPDATE
an extra burden on the application developer. update the same data-item simultaneously. This
Also, the number of instances an instance state behavior is called shared ownership, and it is the
updates scales linearly with the number of Man- default setting for the ownership quality of service
ager processes. For this particular (QoS) setting. If the nondefault setting, called
state machine example that is not exclusive ownership, is selected, the infrastruc-
that big of a deal, but in the gener- ture will make one of the publishers the owner
al case, it could have a significant of the data-item—at any time, only the owner of
impact on network bandwidth the data-item can update its state. For this leader
consumption and memory usage. selection, another policy called ownership strength
can be adjusted. This integer value will be inspect-
Process replication, ed by the middleware to identify the current leader
writer-side peer awareness at any time, that is, the publisher with the highest
To avoid disadvantages, another option is to ownership strength. This selection is done consis-
To avoid disadvan- make Manager processes aware of each other at tently through the system.
tages, another option is the application level. If all Manager processes Other than selecting the right QoS, this solu-
to make Manager pro- know which other Manager processes are current- tion is transparent to all system components. The
cesses aware of each ly participating in the infrastructure, then they all different Manager processes are unaware of each
other at the application could decide for themselves, according to a sys- other and execute their tasks independently. Simi-
level. tem-wide consistent selection algorithm, which of larly, the subscribing components do not (have to)
the replicated Manager processes is the currently know that in fact, multiple publishers are present
active one. All Manager processes would be par- in the system. Everything needed to achieve the
ticipating in the pattern and updating the relevant required functionality is handled within the mid-
states accordingly—but only the active Manager dleware. As a consequence, no extra code has to
would actually be communicating those updates be added, nor tested, nor maintained.
to the data-space. If the active Manager leaves the Exclusive ownership functionality is
system for some reason, then the remaining Man- described in the DDS specification and was
ager processes need to decide for designed with the mechanism of process repli-
themselves whether or not they cation in mind. In that sense, it is not a surprise
are the new active Manager and that this solution is usually the best fit. The spec-
adjust their behavior accordingly. ification does not indicate how this functional-
DDS supports the neces- ity should be achieved by the middleware; that
sary features to implement this is left up to the product vendors. However, it is
approach. By subscribing to so- good to know that typically, for optimal robust-
called built-in Topics, applica- ness, implementations do send data over the wire
tions can be made aware of other for each of the active publishers, and the leader
DDS Entities in the cloud. This kind of selection takes place at the receiver side. This
subscription also can notify the application of lost means that the feature does result in extra net-
liveliness or destruction of each of these Entities. working traffic.
Those two aspects combined are sufficient for
The last option here this example. Recovering from faults
takes advantage of This approach has no application-level impact Process replication is an important aspect of
a native DDS feature on subscribing components in the system and, increasing fault tolerance in a system. However,
called exclusive owner- consequently, they do not require code changes. there is more to it. If a system, by virtue of the
ship. Images courtesy: This kind of replication also does not consume process replication, can continue after a fault, then
Real-Time Innovations any extra bandwidth or resources, as plain rep- it will have entered a stage in which it is less fault-
lication does. tolerant simply because one of the replicating pro-
There is some impact at the application level cesses is gone. It is still essential that the system
for the Manager processes. The mechanism of recovers as quickly as possible from the fault and
peer-awareness and leader selection has to be cre- returns to the fault-tolerant state. In our example,
ated. This is not trivial, and the impact of bugs in this means that the failing Manager process will
that piece of code could be high. (It could lead to have to restart, obtain the current state of all task
none of the processes stepping up as the leader!) data-items, and start participating in the pattern
Go Online again. DDS can help make the task of recovery
See this article at www. Process replication, exclusive easier as well. ce
controleng.com/archive for ownership - Reinier Torenbeek is systems architect at
more information. The last option here takes advantage of a RTI. Edited by Mark T. Hoske, content manager,
www.rti.com/products/dds/ native DDS feature called exclusive ownership. CFE Media, Control Engineering, mhoske@cfe-
Normally, DDS allows multiple publishers to media.com.
Only a Fluke ScopeMeter® Oscilloscope is
tough enough to take on the industrial world.
When it’s too dirty and dangerous for
ordinary scopes, and a multimeter isn’t quite
enough, take a ScopeMeter ® Oscilloscope.
Built to solve tough problems in harsh
industrial environment, ScopeMeter even
has a multimeter built-in, plus it’s:
• Rated CAT III 1000 V/ CAT IV 600 V
• The only completely sealed, drip

proof, dust-proof, IP-51 rated scope
• Loaded with functions to make

using an oscilloscope easy
Watch how ScopeMeter was created:

fluke.com/scopemeteristough

application
UPDATE
Unified platform
helps robotics for packaging
Multinational maker of secondary packaging systems, Cama Group, standardizes
robotics on a unified platform to deliver simplified, high-speed automation software and
hardware including a programmable automation controller (PAC), I/O modules, motors,
servo drives, ac drives, and operator interfaces.
C
Mike Wagner ama Group, a multinational maker of “We design and develop our own line of
secondary packaging systems, stan- robots in-house, and integrate them with an
dardizes robotics on a unified plat- array of automated packaging machines,”
form to deliver simplified, high-speed Mosca said. “The result is a complete packag-
automation software and hardware. The company ing and handling solution tailored to each cus-
switched from a proprietary technology mix to tomer’s unique requirements.”
one automation vendor’s hardware and software.
The challenge was to migrate the automation and Simpler controls wanted
motion control systems used by Cama Group’s Increasingly, Cama Group’s customers have
robotic loading units into the new platform. asked for packaging systems with simplified
A Russian confectionary, a large yogurt pro- controls. In response, the company decided to
ducer in China, and a maker of single-serve “cap- research how to migrate the automation and
sule” coffees in Italy are three companies using motion control systems used by its robots from
the Cama Group to custom design, engineer, and a mix of multi-brand technologies to a unified
build secondary-packaging systems. platform.
Using the Rockwell “Our strength lies in combining robot tech- “We strongly believe that the uniformity of
Automation Integrated nology with packaging machinery,” said Paolo our systems is absolutely fundamental, especially
Architecture system, Mosca, electronic department manager at Cama in gaining authority in the market and the trust of
Cama Group robots are Group. The company delivers solutions primarily customers,” Mosca said. “If the machines on a
easily integrated into for the bakery, dairy, and coffee industries, and line are different with regard to hardware archi-
packaging modules, increasingly for manufacturers of nonfood con- tecture, software design, and motor type, product
machinery, or complete sumer items, such as cosmetics and toiletries. reliability can’t be optimized, and more impor-
lines. Courtesy: Rockwell Cama Group provides specialized, advanced tantly, neither can the price for the customer.”
Automation robot technology for the secondary-packaging Cama Group’s engineers recognized that one
industry. The company engineers four types of platform would be much easier to commission,
robotic-loading units, ranging from two to four operate, and manage for customers’ engineers,
axes, each with a different payload capacity and technicians, and maintenance personnel. And,
application capability. they wanted to meet customers’ consistent need
Beyond pick and place, Mosca said, these for more compact packaging systems. However,
“are robot machines that carry out complex tech- simplification and a smaller footprint couldn’t
nical tasks, such as managing and loading prod- come at the expense of performance.
ucts on a continuous motion packaging line.” “There’s enormous pressure in our industry
For example, Cama Group’s Triaflex robot— to give the customer a high-speed solution they
coupled with an intelligent vision system—can can’t find anywhere else,” Mosca said, with
work in three dimensions, with 360-degree head “accuracy and efficiency of packaging process-
rotation, picking random products from the pro- es.” Market competition created a compressed
duction line belt and positioning them correctly time frame to develop and deliver a new solution
into packaging. The Triaflex robot is equipped that standardized on a common control system
with four controlled axes and carbon-fiber arms that could meet these needs.
for gripping or placing products in all positions
at up to 150 cycles per minute. Manufacturers Mechatronic solutions
can use the robot to load a moving flow pack into In 2012, Cama Group’s research and devel-
a horizontal cartoning machine. opment team, along with its mechanical and
application
UPDATE
The system uses servo drives that help elimi-
nate the need for a dedicated motion network and
allow users to support high-performance drives,
I/O modules, smart actuators, and any other Eth-
erNet/IP-connected device on one network.
The drives, with safe-off function, reside
on the same EtherNet/IP network for simpli-
fied machine design and production line opera-
tion. Low inertia servo motors fit compact space
requirements while meeting the demands of the
With 25 years of experience, Cama Group provides robotic systems tailored to high-performance motion system.
end-user needs by designing and developing its own line of robots in-house, and Another important goal of the project was to
integrating them into an array of automated packaging equipment, such as the improve operator safety and deliver a system com-
robotic cartoning system shown. Courtesy: Rockwell Automation pliant with global safety standard EN ISO 13849-
1. The automation vendor conducted a safety risk
electronic engineering department, worked with assessment and implemented an integrated safety
consultants at the automation vendor, providing system, which allows for safety and standard con-
“specific production line requirements. And, of trol on one platform, alleviates complicated hard-
course, we gave them a very ambitious time tar- wiring, and reduces engineering time.
get,” Mosca explained. The experts “helped us With the unified platform, the PAC uses the
‘
understand exactly how the system would per- same configuration, networking, and visualiza-
During the form. We worked together as partners to attain tion environment as the rest of the system. This
the highest speed for the application we were integration provides users with fewer spare parts
project, clear requesting.” to maintain, while the control platform’s openness
definition of Engineers chose a modular approach to help helps ease integration into an existing plant.
Cama Group adapt the solution to unique specifi- Unlike hardwired systems, the integration of
specifications
cations of different manufacturing processes. safety and standard control provides operators
and targets “From a technical point of view, we wanted to and maintenance personnel with visibility to all
helped, along integrate logic and motion on a unique automation machine events—including safety events—via
platform,” Mosca said. “The robot automation and a human-machine interface. The knowledge and
with shared control system had to fit different requirements: insight provided by the integrated system allows
project manage- speed and flexibility in handling operations, syn- users to respond quickly and return the machine or
ment methods. chronization of different axes in the plant, and line to full production.
easy product changeovers.” To manage safety on smaller, individual
These methods At the outset of the project, the blended team machines with the robot system, the team used
helped meet defined technical specifications to size the pro- safety relays.
cost and time-to- grammable automation controller (PAC), I/O “The new control platform gives our custom-
modules, motors, servo drives, ac drives, and ers a linear and lean production line,” Mosca said.
market require- operator interfaces. “The modular approach allows us to apply the
’
ments. At the heart of the system is a control platform standard platform in future projects, saving design
with integrated motion. Having one control plat- and development time.”
form allows users to manage different robot kine-
matics at the same time and synchronize separate Results: Time to market
tracking, handling, and vision systems. The con- Cama Group has just begun installing the new
troller has a SERCOS (Serial Real-time Commu- system in customers’ factories, and one customer
nications System) interface motion module. has requested the same architecture on an addi-
End users can easily share production informa- tional packaging line.
Go Online tion across all equipment through one EtherNet/ During the project, Mosca said, clear defini-
At www.controleng.com/ IP network. EtherNet/IP, an ODVA Ethernet pro- tion of specifications and targets helped, thanks
archive, see this article for tocol, uses the same TCP/IP protocol suite that is to the highly skilled teams involved, along with
more application details used for the Internet, with the open connectivity shared project management methods. These
and products used in uni- and global acceptance of standard Ethernet and methods helped meet cost and time-to-market
fied robotics platform for the real-time performance and security of fieldbus requirements. ce
packaging. networks. - Mike Wagner is global segment business
www.rockwellautomation. Cama Group engineers can link their optical manager for packaging at Rockwell Automation.
com character recognition and optical character verifi- Edited by Mark T. Hoske, content manager, CFE
www.camagroup.com cation vision systems to other automation products Media, Control Engineering, mhoske@cfemedia.
in the robotic cell via EtherNet/IP. com.
©2013 Siemens Industry, Inc.
Cross-over
to the new
safety
dimension!
Safety? Naturally Integrated!

One system, one engineering tool, one network
usa.siemens.com/safety
SIMATIC ® S7-1500 – the new Your Plus in Efficiency: Your Plus in Safety:
generation of controllers along with + Innovative design and easy + Seamless integration with one
the new fail-safe I/O – offers you handling for simple usage and system, one engineering tool
the ultimate plus in automation commissioning as well as
with power, efficiency and safe operation + Standard and fail-safe
safety integrated. communication via the same
+ Integrated system diagnostics
network, to lower initial and
Your Plus in Power: for full transparency of the plant
operating costs
+ Outstanding system performance status, automatically generated
for shortest response times and and consistent appearance
+ Consistent implementation
highest quality of control
+ TIA Portal for highest engineering of proven safety technology
+ Technology integrated efficiency to reduce project to protect lives and increase
for seamless integration of costs – and naturally with productivity
drives and other devices Safety integrated
+ Machine safety lifecycle –
+ Security integrated consistently
savings up to 30% in Total Cost
incorporated for highest
of Ownership
investment protection
Answers for industry.

application
UPDATE
More efficient pumps use
VFDs, consolidate logic
Existing drives were not accurate enough to provide desired results and were not
offered with conduit fittings. The solution was more energy efficient than prior drives and
eliminated the PLC and control panel for logic.
A
Robert Fenton chieving consistent water pres- time at 20% load, its energy is being reduced by
sure is a challenge for geographical the cube of the speed reduction, which is mas-
areas that have grown faster than sive. As a result, when considering the energy
the development of infrastructure to reduction over time, it’s very significant even on
accommodate water demand and for businesses, a very small unit.”
such as fast-food restaurants and strip QuantumFlo application engineer Robert
malls. Recognizing the residential and Mann said when developing a pressure boost-
light commercial markets’ need for an er, the “goal was to provide a fully contained,
energy-saving booster pump to deliver fully assembled solution by putting together a
reliable water pressure, QuantumFlo, motor, pump, bladder tank, and a VFD. Once it
DeBary, Fla., used its variable speed was fully plumbed, wired, and tested, we put a
pump expertise to develop a “pump in few units in the field. It wasn’t long before we
a box” solution that detects low flow learned that the VFD we used did not have the
conditions accurately and enables accuracy to detect lower flow conditions. Cus-
users to achieve significant energy tomers also reported that while the exposed wir-
savings. ing did not present a safety hazard in itself, code
inspectors did look upon it unfavorably.”
Boosting efficiency
Although constant speed pressure Contained wiring
boosters are available, inefficiency While investigating alternatives that would
makes them a less-than-desirable option. eliminate the accuracy problem and exposed wir-
With a constant speed drive, every time ing issue, it learned about the capabilities of a
the system comes on at full speed, it runs VFD that could provide the required accuracy
for a time delay and then turns off. As a result, and provide an IP21 kit to contain the wiring.
QuantumFlo
it is at full speed and full capacity the entire time Mann said the new design provided “both a
Atom Simplex Light
it is running. pump control solution and a complete control
commercial/residen-
In contrast, the variable frequency drive (VFD) solution in a compact package. Most systems
tial pressure Booster
solution runs only for the specific capacity and with this complexity rely on a control panel with
monitors a system’s water
energy required to meet the need at that instant. a PLC to execute the required logic. Since the
pressure and is designed
As the speed of the pump is reduced, the drive has built-in intelligence, it performs all on/
to maintain a set pressure
energy is reduced by the cube of the speed reduc- off operational calculations, soft start and stop,
using PID control. Eaton
tion. Every reduction in speed below full speed and regulates the pressure of the system. Accom-
M-Max drive provides
reduces the energy by a factor of eight. In addi- plishing all of that using a PLC would require
pump control and reduces
tion, variable speed boosters are also quieter and complex wiring, an added enclosure, and result
equipment requirements
maintain smooth pressure throughout the facility in a unit with a larger footprint. Plus the PLC
(and space) for the pump
or residence. alternative would cost at least 50% more.” The
system. Courtesy: Eaton
QuantumFlo CEO David Carrier said, “The VFD brings this logic into itself, which elimi-
effective use of energy is best served with vari- nates the panel. “In addition, the IP21 conduit kit
able-speed drives, particularly in transporting provides a very streamlined, clean installation,”
Go Online and generating water pressure. There are very he added.
few devices in a commercial structure that run The more accurate drive with IP21 conduit kit
At www.controleng.com/
archive see this article for almost constantly. Eighty percent of the time a allowed QuantumFlo to meet energy and func-
more about technologies typical water booster system is using 20% capac- tionality needs, while eliminating the PLC and
inside. ity or less. If it’s running 80% of the time at full control panel for logic. ce
www.eaton.com speed, for 20% of the load, that’s a huge amount - Robert Fenton is product line manager at
of waste. In contrast, if it is running 80% of the Eaton.
Independent High Integrity safety.
When safety is all you need.
ABB’s flagship safety system has now been released for use in standalone
applications. This means that the same great proven and TUV certified safety
system that is integrated with ABB’s System 800xA DCS can now be interfaced
with any ABB process control system such as Freelance or Symphony Plus
(Harmony and Melody) or our heritage technologies (Advant, MOD 300) as well
as 3rd party control systems, PLCs or simple HMIs. Independent High Integrity is
the perfect SIL3 certified safety system; when you need safety independent of the
control system technology or vendor on your site.
www.abb.com/highintegritysafety
ABB Process Automation Division

Visit us at our blog or on YouTube:
www.processautomationinsights.com
www.youtube.com/user/ProcessAutomation
application
UPDATE
Simulation software boosts
machine productivity
Armor increased machine productivity 20% with simulation software to create
improvements and decrease downtime.
A
Chris Baker rmor increases machine productivity over the thermal printhead with the coated side
20% by using simulation software pressed against the label surface. The heat ener-
to create improvements, rather than gy produced by each dot causes the pigment to
trial and error, which can waste time transfer off the carrier film and bond to the sur-
and product. With sales of 137 million Euros in face of the label. The largest application for ther-
2011, Armor produces inked ribbon used in thermal transfer printing is the marking of individual
mal transfer printing for product identification products during manufacturing with information
and other applications. Ribbon is produced by including model number, serial number, use-by
applying ink to polyethylene terephthalate (PET) date, composition, price, etc. Other applications
film in a web coating process in which the speed, include flexible packaging, ticketing, personal
tension, and position of the identification, and plain paper fax machines.
web and other variables During the manufacturing process, a transpar-
must be closely controlled ent PET film is unwound as one or several layers
to ensure the highest pos- of ink are applied on one side and a protective
sible quality while maxi- layer (backcoating) is applied on the other side.
mizing throughput. The PET film used as the carrier has a thickness
Gildas Hubert, project of 3.2 mm to 5.0 mm, high resistance to tearing,
manager for Armor, has good thermal conductivity, and very good heat
simulated various coat- resistance. Backcoating protects the printhead as
ing machines and control the ribbon unwinds, provides high thermal con-
systems using multibody ductivity to transfer heat to the print medium,
dynamics software and and reduces static electricity. Different inks are
multi-domain modeling used, including wax, wax-resin, and resin types.
and simulation software. A rubber-coated metering roll feeds the ink
“Simulation helped us to a gravure roll, which in turn feeds the ink to
This control system work out the optimal coating conditions and a format transfer roll onto the web. The coating
was designed using make engineering changes to our machines,” weight is controlled by roll velocity and the foot-
MSC Easy5 multi-domain Hubert said. “Over one year we improved pro- print between the metering and the gravure rolls.
modeling and simulation ductivity by 20% while also increasing quality All rolls are heated with thermo oil. A jumbo roll
software. Courtesy: MSC of the finished film. Simulation is a great way 20 km long is coated then unwound onto smaller
Software Corp. to improve our manufacturing process at a rela- rolls as required for customer applications.
tively low cost without disrupting production as
is required for physical experiments.” Moving past physical experiments
Armor, Nantes, France, was one of the first “We have always been concerned with elimi-
to manufacture carbon film, introduce typewriter nating defects to ensure a positive experience to
ribbon cassettes, and introduce thermal transfers our customers while at the same time increasing
in the early 1980s. It has more than 760 employ- the productivity of our web coating process,”
ees and produces 110,000 thermal transfer film Hubert said. “In the past the primary method of
rolls per day at five production sites. It has the improving operations was with physical experi-
largest European marketshare, 53%, and more ments.” There are problems with this approach.
than 12,000 ribbon configurations. “First of all, utilizing coating machines to run
physical experiments disrupts our production
Thermal transfer technology operations. The limited time available for and
Thermal transfer printing consists of applying high cost of physical experiments greatly reduces
thermofusible ink using a heat source emitted by the number of different conditions that we can
the printer. The thermal transfer ribbon passes evaluate. Physical experiments ... provide limited
Hazardous Locations Product Testing and Certification
Start it Up!
Choose the testing and certification organization that delivers the support you require. Today the CSA C/US mark is found on
millions of electrical products used in hazardous locations and on other electrical devices that must provide spark-free performance.
The CSA C/US mark signifies these products meet U.S. and Canadian standards for safety or performance. CSA Group 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 confidence. For total
confidence in your testing laboratory, choose CSA Group.
www.csagroup.org 1-866-463-1785
Building Confidence in Products Worldwide.
www.csagroup.org
input #16 at www.controleng.com/information NORTH AMERICA • EUROPE • ASIA
application
UPDATE
lates the proportional–integral–derivative (PID)
closed-loop motion controller.
He found it “very easy to define both the
physical and control model” using the software.
Hubert began his simulation efforts on a machine
whose performance he felt left considerable
room for improvement. The machine required
continual adjustments to avoid defects. He began
by simulating the machine’s current operating
conditions. Comparing the simulation results
This machine model above is simulated in with physical measurements, particularly of web
MSC Adams multibody dynamics software tension, showed that the simulation accurately
below. Courtesy: MSC Software Corp. represented the machine performance.
A small change in operating conditions could
cause the machine to produce defects. Hubert
evaluated changing the operating conditions, and
PID control values. He modified the model and
re-ran the simulation multiple times, seeking to
move the machine to a point where small chang-
es in operating conditions would not impact
quality. He discovered more robust operating
conditions that improved throughput by reducing
downtime for adjusting operating conditions.
Hubert also looked at machines that were
seemingly operating well to seek improvements
in throughput or quality. During this process, he
discovered the importance of accurately deter-
mining the friction between the web and the rolls
to provide accurate simulation results.
diagnostic information. The number of physical He evaluated other machines to identify opti-
measurements that can be captured during these mal operating conditions. He evaluated different
experiments is limited by the difficulty of instru- products with varying film thicknesses on each
menting the coating machines.” machine. For each product he evaluated different
Armor was interested in using simulation but PID control values to identify values that provid-
found it difficult to model the complicated mech- ed stable operating conditions without defects.
anisms and motion control systems involved in During this process, he optimized the control val-
roll coating. This challenge was overcome with ues for each film thickness. This required more
simulation software that enables control systems simulation than would have been possible with
to be integrated into mechanical system simula- physical experiments. Running virtual experi-
tions to optimize system performance. Multibody ments with the software also eliminated the cost
dynamics simulation software automatically for- of downtime on production machines.
mulates and solves the equations of motion for
kinematic, static, quasi-static, and dynamic simu- Precise PID values
lations. A graphics-based software tool modeled By optimizing control values, Armor
multi-domain dynamics systems characterized by increased coating machine throughput about
differential, difference, and algebraic equations 20% over a one-year period. Primary improve-
used in digital and analog control systems. An ment came from increasing machine reliability
interface block in the software model provides and stability so that less time was required for
inputs between the software packages. repairs or adjustment. Web speed improvements
Go Online were often achieved. “We are now able to set the
Optimizing roll coating performance PID values much more precisely to optimize the
At www.controleng.com/ Hubert constructed a software model of the performance of the machine for specific prod-
archive, the posted version
machine. He defined the rolls as cylinders and ucts,” Hubert said. Other simulation improve-
of this article has more
information. See related
added connections between them to represent ments include “increasing the throughput of a
article: Simulation and mod- the gearing in the machine. He defined the mate- cutting machine by 8%. We have plans to apply
eling software rial properties of the PET web and entered the simulation to additional processes.” ce
www.mscsoftware.com
friction between the web and the rolls based on - Chris Baker is the product manager for
physical measurements. The software also simu- Adams and Easy5 at MSC Software Corp.
INTERNATIONAL ®
Is SLM gaining
momentum in China?
Service lifecycle management (SLM) is getting increased attention in
China and Asia, with development of manufacturing services industries,
according to Control Engineering China, citing PTC officials.
Ariel Zhang
D
evelopment of the manufacturing ser-
vices industry has been a significant
trend in China. For many traditional
manufacturing enterprises, their ser-
vice sectors have became their new growth
points. While service is turning a new means of
profit, enterprises are starting to focus on man-
agement of service processes.
With this trend, service lifecycle management
(SLM), a solution that is used to enhance enter-
prise services business management, has been
introduced to Chinese enterprises. Yucheng Shou is PTC’s global divi- Robert Kocis is PTC’s Global senior
At a recent press conference, a supplier of sion vice president, China. Courtesy: vice president. Courtesy: Control
manufacturing solutions, PTC, showed strong Control Engineering China Engineering China
confidence in this emerging solutions business.
With the acquisition of Servigis- service, quality, and maintenance.
tics, a traditional supplier of SLM, There is a similar situation in Consider this...
PTC achieved a sales volume of $ enterprise informatization. Up to Savings through coordinated
200 million for global SLM busi- now, many enterprises have had lifecycle management of services
ness and achieved a growth rate of 20% to 25% mature solutions for product life- is an opportunity for manufacturers
in first-quarter 2013. cycle management, supply chain management, globally, not just Asia.
and manufacturing execution management, while
Managing services momentum there is a lack in the service link.
‘
Robert Kocis, PTC’s global senior vice presi-
dent, said that throughout the entire strategic Savings in services, quality, parts Rapid development
layout of PTC, SLM has been very important. However, in the current competitive environ-
Yucheng Shou, PTC’s global division vice presi- ment, such enterprises have to face challenges of manufacturing
dent, China, also pointed out that SLM had main- from service systems, quality assurance, and services will
tained a good momentum of growth in Asia and spare parts management. Some enterprises even
contribute to growth
China. want to achieve the continuous improvement of
PTC’s viewpoint may show that SLM has service efficiency and service standards. of service lifecycle
’
begun to attract the favor of the market in In this case, SLM, through its several major management.
China. Compared with other solutions that have functional parts, can help enterprises achieve tar-
had a very mature market, like computer-aided geted improvements.
design (CAD) and product lifecycle manage- For the present, SLM still faces a long-term
ment (PLM), the development of SLM is still in development and promotion process, but in the Go Online
the growth phase. But in recent years the rapid long term, huge demand will gradually progress,
www.PTC.com
development of manufacturing services will along with the development of manufacturing
probably be a powerful factor for SLM growth. services. ce On the CE China website, read
“SLM: Gaining Momentum in
For example, there are some shortages in the - Ariel Zhang is an editor at CE China. Edited China?” http://article.cechina.
services sector of some domestic industries [in by Mark T. Hoske, content manager CFE Media, cn/13/0408/11/20130408115322.htm
China]. Compared with production and research, Control Engineering and Plant Engineering, www.cechina.cn
enterprises pay less attention to management of mhoske@cfemedia.com.
www.controleng.com
www.controleng.com
● CONTROL
● CONTROL
ENGINEERING MONTH
ENGINEERING MAY 2013 ● 31
®
INTERNATIONAL
Control Engineering Europe at Hannover Fair 2013
Machines, PLCs mobile

devices, higher-level systems
Bosch Rexroth, won the 2013 Hermes Award at Hannover
Messe, for its Open Core Engineering project. Integration
solution helps machinery manufacturers.
Suzanne Gill Commenting on the award commit-
tees’ decision, Dr. Jochen Köckler, mem-
B
osch Rexroth, won the 2013 ber of the managing board at Deutsche
Hermes Award at Hannover Messe AG, said: “This solution makes a
Messe, for its Open Core Engi- major contribution to integrated industry
neering project, which integrates PLC and will accelerate the trend towards net-
and information technology for indus- worked industrial production.”
trial applications. This was the first During a press event at Hannover
time that the award has been given to a Messe, Dr. Karl Tragl, chairman of
software development. Open Core Engi- the executive board of Bosch Rexroth,
neering was developed to allow greater said, “Via a new interface from Bosch
flexibility and efficiency in the automa- Rexroth, engineers and software devel-
SmartWire-DT tion process, by enabling remote main-

tenance and operation through smart
devices and apps, combining advanced
opers are now able to access the control
kernel using nearly any high-level lan-
guage in the IT world and to program
Now, integrated the Eaton XV industrial algorithms with everyday new machine functions. ce
hand-held devices. www.boschrexroth-us.com
Series HMI-PLC with an
embedded SmartWire-DT
master as your controller.
Network organization pushes
The Eaton SmartWire-DT™
reduces wiring time and allows industrial Ethernet integration
efficient connection to motor ODVA works to accelerate adoption of industrial Ethernet in
control components within process automation and for better machine integration.
minutes:
A
t Hannover Messe 2013, ODVA deploy a complete Ethernet solution for
• Motor Starters & Contactors launched an initiative for pro- process automation, starting with con-
• Pushbuttons & Pilot Devices cess automation – in coop- nectivity down to the field level and, in
• Selector Switches eration with ODVA members including the longer term, expanding to include
Cisco Systems, Endress+Hauser, Rock- the full spectrum of process automa-
• Control Relays well Automation, and Schneider Elec- tion needs, including safety, explosion
• Digital & Analog I/O Modules tric – to accelerate adoption of industrial protection, long distances and extensive
Ethernet in process automation. ODVA diagnostic coverage.”
also discussed a machine information Also discussed was the formation of
integration initiative, according to Con- a new special interest group to develop
trol Engineering Europe reports. standards for the exchange of informa-
The process initiative will focus on tion between machines, and between
providing new opportunities for inte- machines and supervisory systems.
gration improvements, optimized net- Machine to machine (M2M) information
work architecture and increased return exchange is of increasing importance for
on investment (ROI). Catherine Voss, machine builders, system integrators,
executive director of ODVA said: “Based and end users. ce
Discover more possibilities at on ODVA’s industrial EtherNet/IP tech- - Suzanne Gill is editor of Control
www.eaton.com/smartwiredt nology, the results of this initiative will Engineering Europe, www.controlengeu-
provide end users with more choices to rope.com. www.odva.org
SAFETY machine
Incorporating functional safety

Safety initiatives, international standards, and conformance responsibilities
all play a role in changes, when an organization considers functional safety.
W
hen considering “functional understand and interpret accordingly.
safety,” look at what differs com- In my opinion, more than likely you will
pared to other safety initiatives, have to make some modifications to your
consider U.S. versus internation- machine safety program to incorporate func-
al standards, examine conformance respon- tional safety requirements. Now, this kind of
sibilities, and think about what changes are blanket statement needs some granularity for
needed, if any, as a manufacturer. understanding and interpreting its application
What is so different about “functional to your particular business. To begin with,
safety”? we’re talking about the current version of ISO
Definition from IEC 61508-1: Functional 13849-1; 2006 Safety of Machinery – Safe-
safety is “part of the overall safety relating to ty-related parts of control systems. In broad J.B. Titus, CFSE,
the equipment under control and the equipment scope: Certified Functional
under control’s control system which depends As an OEM, machine builder, or systems Safety Expert (CFSE)
on the correct functioning of the Electrical/ integrator (aka supplier), you will have to
Electronic/Programmable Electronic safety- determine the performance level of a complete
related systems, other technology safety- safety-related circuit including all components
‘
related systems and external risk reduction and devices and the related software. This per-
facilities.” formance level must be optimized to meet or When replacing
From my perspective the major difference exceed the performance level required for that
in approach is to design-in machine safety safety function. Testing and validating will be a defective
and consider the lifecycle performance of required. component or
safety-related functions, such as mean time As an end user doing an in-house machine
device in an
to fail dangerous, diagnostics, reliable cycles, retrofit/modification, you have become a sup-
software and firmware, and many more con- plier doing design and build and should follow existing safety-
siderations for each component in a given the same guidance as suggested above. related circuit,
safety-related circuit. A circuit is also consid- As an end user simply replacing a defec-
ered as electrical, electronic, pneumatic, and tive component or device in an existing safety- ensure the next
hydraulic. related circuit, you should make every attempt one has the
Prior methodologies did not consider these to replace that component or device with same or greater
factors, in my opinion. Also, aren’t functional another component or device with the same or
safety standards intended to encourage design- greater safety-rated performance. The advice is safety-rated
’
ers to focus more on the functions that are to not degrade the safety-related performance performance.
necessary to reduce each individual risk, and for the safety function.
what performance is required for each func-
tion, rather than simply relying on particular There are many more details that come
components? The primary standard addressing along with functional safety and compliance to
functional safety requirements is ISO 13849- ISO 13849-1. This provides a high-level opin-
1: 2006 Safety of machinery – Safety-related ion of what may be involved and how your
parts of control systems. safety program might see the need for modi-
fications. Clearly there are engineering-level
Changes required? resource requirements that you may already
Do we have to change our machine safety have access to for performing the incremen-
Go Online
program as a manufacturer to meet functional tal design, build, test, and validating require- Engineering interaction:
safety compliance requirements? In this dis- ments. ce Go to this blog at www.con-
cussion the term “manufacturer” is very broad troleng.com/blogs, see more
in a 4-part series on func-
and includes end users, OEMs, machine build- - J.B. Titus, Certified Functional Safety Expert
tional safety, and add your
ers, and systems integrators, for example. As (CFSE), writes the Control Engineering Machine
comments or questions.
such, it is strongly advised that the reader Safety Blog. Reach him at jb@jbtitus.com.
Control System Integrators Association
2013 Executive Conference coverage
Nick Setchell, CEO, Practice Search CSIA at www.controleng.com
Strategies: Numbers matter
industry
NEWS
Hannover Messe, manufacturing:
U.S. drives global

growth, innovations,
efficiencies
Steve Rourke at Hannover Messe for outstanding
innovation.
The 2013 Hannover Messe brought
industrial automation and manufacturing Partnerships announced
experts from around the world to show- Siemens made two major partner-
case the latest innovations and assess the ship announcements. It will acceler-
state of the global manufacturing econo- ate its collaboration with Bentley Sys-
my. Innovation continues at a brisk pace. tems in the pharmaceutical and oil
The economy is finding its way forward and gas markets. The partnership will
as Europe drags on that global growth, develop a joint system that with com-
with continental challenges. bine Siemens’ Cosmos engineering
Bosch Rexroth chairman Dr. Karl software and Bentley’s OpenPlant sys-
Tragl told a press event that global tem for plant design to use plant life-
Ethernet IP Enabled Servo Drive manufacturing would increase slightly cycle data from commissioning to plant
CMMP-AS-M3 in 2013 along with the global econo- operations.
my. The drag of the European econom- Siemens also announced its collab-
ic slowdown would be offset by solid oration with consulting and construc-
Enhanced Scalability and Flexibility growth in Asia, Russia, and notably tion management company CH2M Hill.
in the U.S., where manufacturing has “The argument for Siemens is com-
• Offers Ethernet IP, ProfiNet, been on the rise both economically and pelling, as the company’s products are
EtherCat, Profibus, and DeviceNet politically. used globally, yet supported at the local
networkability He said Bosch Rexroth is enjoy- level with knowledgeable integrators,”
• Optional slide card with Safe ing record business in the U.S., and the said CH2M Hill senior automation
Torque Off functionality company has responded by investing engineer Steve Blaine.
more than $80 million in U.S. plants
• SD memory card for storing and and people. Tragl said he has had “con- New ideas on the show floor
parameter settings tinued optimism” in the U.S. manufac- With more than 6,000 exhibitors and
turing market. Key issues, such as local a square mile of show floors at Han-
production and customization and ener- nover Messe, manufacturers showcased
For more information: gy efficiency, continue to dominate the new ideas to more than 250,000 attend-
Call: 1-800-Go-Festo manufacturing discussion worldwide, ees each year. Those innovations point
1-800-463-3786 Tragl said, and that integrated open to new efficiencies that can help manu-
control systems would help connect facturers in Europe and throughout the
www.festo.us/CMMP current and future operating systems. world.
A few highlights on this year’s show
Hermes innovation award floor at Hannover follow.
Those comments underscored the SEW Eurodrive unveiled its Movi-
“Integrated Industry” theme of the 2013 Axis energy buffering system with a
Hanover Messe and Bosch Rexroth’s regenerative power supply. The sys-
software system to connect systems, tem uses capacitors to store potentially
input #36 at www.controleng.com/information which won this year’s Hermes Award wasted energy and transfer it to ener-
Global manufacturer of process control and
factory automation solutions 34 ● MAY 2013 CONTROL ENGINEERING ● www.controleng.com
Automation engineering
research channel
www.controleng.com/research
NOW AVAILABLE:
Next Apps
for Engineers
Next version of CFE
Media’s Apps for Engi-
Shown: Motorola Droid Razr Maxx HD

neers for Android-enabled
phones is ready. At www.
gize motor and drive systems. Tobias controleng.com search for
Nittel, technology field manager for Apps for Engineers or go
SEW Eurodrive, told CFE Media that
to the Google Play market.
energy savings are projected at between
10% and 15% for select systems.
SEW noted that it will unveil new
large custom gear sets for the U.S. audi-
ence later this year. Production and
assembly will come to a U.S. facility
for local distribution. The large custom
gear sets are designed for heavy appli-
cations and can be customized to order.
Phoenix Contact’s focus for 2013 cell or system. For example, if a robot
was on five application solutions for is stopped for any reason, the con-
growth markets. Three of those are in trol system senses and reacts to envi-
the energy sector: ronment and can update local systems
Wind Energy: Phoenix Contact has accordingly can turn off local motors,
a new lightening detection system to lights, lower HVAC. In working with
monitor and report on lightening strikes European auto manufacturers such as
to blades. Repeated strikes can be cost- Volkswagen, Audi, and BMW, the com-
ly to replace or repair and cause struc- pany believes this kind of integrated
tural failure, which can be dangerous to approach can reduce energy usage by
workers or others near the windmill. 15% to 20%.
Solar: Phoenix Contact has devel- One of Eaton’s new products
‘
oped several new, easy-con- includes an extension of
nect electrical junctions to Local its Smartwire-DT technol-
help with installation and ogy to include outside-the-
maintenance. production, cabinet connectivity. Driv-
Oil and Gas: Kamran customization, en primarily by machine
Alam, Phoenix Contact’s builders, the benefits will
global industry manager for and energy include lower wiring costs,
oil and gas, told CFE Media efficiency ease of use, and lower over-
his company is working with all power consumption of
system integrators in this
dominate machines.
sector to help find solutions manufacturing Eaton officials said they
to key energy issues, and the
company sees system inte-
discussion expect multi-connection
junction boxes to be avail-
’
grators as a key to their sales globally. able by the end of 2013.
strategy in the sector. Another new offering is
improvements to the DC1 and DA1 Line
Water, wastewater, automotive of motor starters. The multifunctional
Two other areas of emphasis for DA1 allows users to potentially insert
Phoenix Contact are infrastructure, espe- custom start up process, with the goal of
cially in areas such as power distribu- reducing energy and power costs.
tion, water and wastewater and traffic, - Reported by Steve Rourke, CFE
and automotive, which is the company’s Media, with press release information;
largest market, but one that has slowed edited by Bob Vavra, Plant Engineering
recently, especially in Europe. and Control Engineering.
One of its innovations at Hannover
Messe this year ties robot movement See other Hannover coverage on
into energy management of the local pages 32 and 36.
www.controleng.com ● CONTROL ENGINEERING MAY 2013 ● 35 input #18 at www.controleng.com/information
industry
NEWS
Hannover Messe 2013:
Kuka introduces lightweight
robot, gives robocoaster rides
At Hannover Fair 2013, Kuka Systems, Kuka Robot-
ics, and Kuka Laboratories showed welding robots, machine
tool capabilities, assembly and testing systems, robotic ser-
vices, and other products and capabilities, from components
to research and development, including complete plant sys-
tems. “Of course, we are especially proud of the LBR iiwa,
the entirely new generation of robots,” said Dr. Till Reuter,
CEO of Kuka AG, in a pre-show statement.
The LBR iiwa fulfill’s Kuka’s promise to the market
to present a lightweight industrial duty robot. Kuka engi-
neers developed a machine with new automation possibili-
ties. Offering “mechanical and drive systems designed for
industrial use, the sensitive and yielding LBR iiwa rings in a
new era in robotics,” the company said. Kuka presented four
applications for the LBR iiwa at Hanover Fair – all demon- At Hannover Fair 2013, Kuka again gives passengers a wild
strated the sensitive robot’s key features. ride in its latest “Robocoaster.” In June 2004 information about
Kuka showed 19 dancing robots in an application about the ride, Kuka said this is “the first – and only – robot anywhere
6 m high. Kuka’s entire robot family was featured, from the in the world that is licensed to carry human passengers.” See
smallest robot, the KR Agilus, to the largest model, the KR Robocoaster video at www.controleng.com/videos. Courtesy:
1000 titan. The KR Quantec series, the welding specialists CFE Media, Steve Rourke video at Hannover Fair 2013
KR 5 arc HW and KR 16 arc HW, and LBR iiwa were shown.
Various applications at the Kuka Competence Center dem-
onstrates company expertise in the growing lightweight con-
struction sector. Visitors watched live demonstrations of pro-
cesses, such as welding aluminum, joining metal alloys and
an induction welding process for joining carbon-fiber com-
posites. Results of a joint research project on energy-effi-
cient car body assembly are also being discussed. The dis-
play showed how manufacturing systems and solutions can
be automated in a sustainable and resource-conserving man-
Custom Control Algorithms

ner. At another part of the booth, Kuka presented the forming
expertise of its machine tool segment. Successfully complet-
ed projects for assembling transmissions, engines and drive
When PIDs arenʼt powerful enough assemblies have repeatedly demonstrated Kuka’s perfor-
mance capabilities in assembly and testing systems.
• Multiple inputs, outputs, objectives Kuka presentations at Hannover Fair included “Energy
• Strong interactions and non-linearities efficiency in car body assembly systems,” “Efficient joining
• Unpredictable and changing dynamics technologies for aluminum parts,” and “Virtual startups for
manufacturing systems.”
www.neuroblast.net/custom The Kuka “Robocoaster” can seat two passengers at one
time, offering brave riders “considerable gravitational forc-
es, ranging from a sense of doubled body weight to a feel-
ing of weightlessness,” the company said. Kuka Robot Group
Neuroblast “Robocoasters” are certified by the TÜV Technical Inspector-
intelligence in control ate in Munich and comply with the relevant safety standards.
- Edited by Mark T. Hoske, content manager, CFE Media,
Control Engineering, mhoske@cfemedia.com.
Go Online
Robots assist, next to humans. See: “New robotic safety regu-
lations are pending” at www.controleng.com/archive, April.
www.kuka-robotics.com

Implementing
Industrial
Ethernet technology:
Which protocol is right for
your communication challenge? askTURCK.com
©2013 TURCK
TU-1300 44.0513.07 TURCKMan Ad_1-3_ConEng.indd 1 4/8/13 10:21 AM
Manufacturing in America
targets next U.S. industrial evolution
More manufacturing jobs are return- the April 23 online “America’s New James Manyika, director of McKin-
ing to U.S. shores while new innova- Manufacturing” forum, presented by sey Global Institute, recently named to
tion “hubs” are being created across Washington Post Live and sponsored by President Obama’s Global Development
the nation. The manufacturing sector is Siemens, Northern Virginia Technology Council, said manufacturing is responsi-
undergoing an evolution where inno- Council, and the American Small Man- ble for 9% of employ-
vation and manufacturing are merging, ufacturers Coalition. The forum assem- ment, but more than
driving product and process innovation, bled government officials and leading 60% of exports are
across the globe and particularly in the industry experts to discuss the new era driven by manufactur-
U.S. “This is making industry more in manufacturing, expanding manufac- ing. Courtesy: Wash-
competitive and taking productivity turing hubs, trends in manufacturing, ington Post Live
and efficiency to levels never experi- workforce training, innovations, and
enced before,” said Helmuth Ludwig, advanced technology.
CEO of Siemens Industry Sector, North Related research, said Siemens, advisor, Lazard, and former assistant to
America. examines tactical (hiring, improvement the president for manufacturing policy,
“This industrial evolution is high- programs, and technology) and strategic the manufacturing sector should find a
ly based on software, and companies (capital investments, supplier re-align- means to combine the innovation power
that have embraced this concept are ment, new product development) trends of Silicon Valley with the efficiency of
experiencing a shorter time-to-mar- related to the manufacturing renais- the Detroit automotive sector.
ket through efficient innovation cycles sance. According to the study, more Statistics provided by James
and enhanced flexibility using more than 70% of manufacturing leaders are Manyika, director, McKinsey Glob-
data to individualize mass production. optimistic about their own company’s al Institute, show that while the manu-
Advanced manufacturing is an impor- future. Other Siemens thought leader- facturing sector represents only 9% of
tant part of Siemens’ growth, and will ship events will be held May-July. jobs, it represents 61% of exports and
provide the U.S. an edge in the future 69% of privately funded research and
of our manufacturing sector,” Ludwig Innovation via manufacturing development.
said, commenting on the kickoff of the Ludwig said innovation and man- Bill Krueger, senior vice president,
Siemens “Manufacturing in America: ufacturing must be aligned, but it is manufacturing, purchasing and supply
Making Things Right” Thought Lead- often not the best strategy to “design it chain management for Nissan North
ership Tour, a series of events designed here—make it there.” Only a close con- America, stated, “We want to be fast,
to explore the trends shaping America’s nection of innovation and manufactur- frugal, and flexible,” which organiza-
next industrial evolution and the chal- ing allows manufacturers to drive prod- tions can only be if they are close to
lenges that still exist. uct and process innovation, he said. their customers. The crossroads of the
More than 2,000 individuals joined According to Ron Bloom, senior virtual and real worlds is driven by the
industry
NEWS
According to Ron Bloom, high-technology manufacturing sec- skilled workers.
senior advisor, Lazard, tor, suggested Michael Gazarik, direc- The notion of a skills gap in the
and former assistant to tor, space technology program, NASA, manufacturing sector has to be trans-
the president for manu- who described how software ensured ferred to a “training gap,” said Siemens
facturing policy, the man- the success of the Mars Rover program Corp. president and CEO Eric Spie-
ufacturing sector should through flight and landing simulation. gel. “Only by moving the responsibility
find a means to combine the innovation Airbus Americas chairman Allan from the trained to the trainer, and from
power of Silicon Valley with the efficiency McArtor said there will always be a the individual to the companies and
of the Detroit automotive sector. Courtesy: necessary balance between automa- educational institutions, are we address-
Washington Post Live tion and human functions with highly ing this challenge in the right manner.”
Companies and educational institutions
must facilitate development of cur-
rent and future industrial workers, he
| EK11-04USA |
said. After completion of the Siemens’

Why pay more for lower performance? apprenticeship mechatronics program,
students are offered a starting salary of
EtherCAT systems from Beckhoff are high speed, $50,000, higher than the average start-
high performance – and – low cost! ing salary of $43,000 for liberal arts
graduates. See Think Again, page 8.
At www.controleng.com/archive, see
more at “Manufacturing in America tar-
gets next U.S. industrial evolution.”
www.usa.siemens.com
www.washingtonpostlive.com
Rapid expansion of
embedded systems
helps manufacturing
Embedded systems provide sig-
nificant benefits in various markets,
EtherCAT Drives such as more time-efficient design,
EtherCAT I/O Highly dynamic greater energy efficiency, and higher
Real-time Ethernet down Servo Drives
to each I/O module Integrated, ultra
machine vision performance, accord-
PC-based Control with Large, cost-effective fast control ing to the National Instruments
EtherCAT selection for all signal technology Embedded System Outlook 2013.
Solid state IPCs and PACs types
Reconfigurable heterogeneous
with integrated Ethernet
ports; no need for network
architectures can help because when
scanners faster CPU cores fall short, embed-
Use software instead of ded system designers can combine
hardware: PLC and Motion
heterogeneous processing elements
Control on one PC
to meet advanced embedded control
and monitoring application needs.
Also, through the democratization
www.beckhoff.com/EtherCAT-System of embedded system design, many
Beckhoff EtherCAT components: Fast, flexible, precise and always cost-efficient
design teams are abandoning larger
Industrial PC: powerful PCs for any automation task
EtherCAT Terminals: IP 20 I/O for all signal types specialized organizational structures
EtherCAT Box: machine-mountable IP 67 I/O directly in the field for smaller groups focused on trans-
TwinCAT: flexible automation software for multi-PLC, NC, CNC lating domain expertise into realized
TwinSAFE: Safety PLC integrated into I/O terminals
innovation, NI said.
IPC More companies are adopting a
I/O
comprehensive approach that con-
siders cost-benefit analysis, flexibil-
Motion ity, and risk, NI said. A digital energy
Automation revolution, driven by advancement of
digital technologies, is changing the
input #21 at www.controleng.com/information way energy is manipulated, moved,
and stored. www.ni.com/embedded
38 ● MAY 2013 CONTROL ENGINEERING

cover story
Key
concepts
The technical elements
of an effective mainte-
A straightforward
nance program are not
complicated.
Procedural and cultural
maintenance strategy
changes within a plant
are critical to ongoing
maintenance management
success.
yields improved plant

Many tools are available
to support such programs,
they are not difficult to
implement, and the payoff
performance can be huge.
Moving from reactive to preventive maintenance helps Monsanto improve output and
reduce costs at its Muscatine plant. Smart field devices and control valve positioners
provide critical diagnostic data to reliability engineers, guiding their efforts.
I
Peter Welander n many situations, a straightforward and in southeast Iowa along the Mississippi River.
consistently applied maintenance strategy It manufactures Roundup herbicide along with
can have results that attract positive atten- acetanilide select chemistry products, including
tion as production and plant availability Harness Xtra, Degree Xtra, and Warrant. The
increase while maintenance costs decrease. facility covers 150 acres and employs around 450
Such is the case at Monsanto’s Muscatine manu- individuals to operate and manage eight individ-
facturing facility. The combination of technical ual process units. These include waste treatment
solutions with corresponding work processes has and plant utilities along with the product manu-
had measurable positive results and earned the facturing process areas. The majority of the plant
facility the 2012 HART Plant of the Year Award. operates continuously, year-round, and the oldest
The Monsanto Muscatine facility is located parts of the facility date back 50 years.
HART Plant of the Year Award—
Celebrating ingenuity and innovation
Electrical reliability technicians Mike Chaney
(left) and Thad Witte follow-up on alerts from
AMS to track down problems in the process units
T he HART Plant of the Year Award is presented annu-
ally by the HART Communication Foundation to rec-
ognize people, companies, and plant sites around the
before they cause downtime. All photos: Control
world for their ingenuity and innovation in applying and
Engineering
using HART Communication. A HART Plant of the Year
takes the capabilities of HART instruments beyond con-
An inherited maintenance platform figuration and calibration, or uses real-time diagnostics
The processing units are controlled by a mix and process variables of HART-enabled devices integrated with its control,
of Emerson DeltaV and Provox DCS (distributed information, and safety systems. Each is a powerful example of how to uti-
control system) platforms tied to more than 3,200
lize HART Communications better, and to realize even greater benefits for
instrument assets, including transmitters and
their company. To nominate your plant, go to www.hartcomm.org.
control valve positioners. Of this total installed
base, there are currently over 600 HART and
125 Foundation fieldbus instruments within the
facility’s AMS Intelligent Device Manager. The
outstanding instruments not yet in the AMS
Intelligent Device Manager are in large part
either not terminated to smart I/O or are simply
non-smart devices. One of the pivotal changes in
Muscatine’s operation happened in 2006 when
Joel Holmes, site electrical reliability engineer,
received a standalone Emerson AMS unit from
another Monsanto plant. Having access to that
unit enabled him to explore some of the capabili-
ties of a more sophisticated maintenance strategy
using diagnostic information gathered from field
devices using HART Communication and Foun-
dation fieldbus protocols.
Given the facility’s extensive population of
maintenance-intensive valves and instrumen-
tation, this was an area where Holmes felt that
improvements in reliability would have the larg-
est impact on overall plant performance. Part of
the process of integrating his new maintenance
tools with the work processes involved assigning
a criticality value to the instrument assets in each
process unit. Those that could impede production
were given the highest priority for monitoring.
As Holmes described the process, “We uti-
lize an A, B, or C letter designation to denote
asset criticality. The highest criticality ranking is
an A, with the lowest criticality ranking being a
C. Keep in mind, A-ranked critical devices will
receive the most attention since their perfor-
mance is crucial to the on-stream time of the pro-
duction system, whereas C-ranked devices may,
in many cases, be allowed to run till failure since
their impact to the production system is minimal
or they have in-line spares.”
As Monsanto gained experience with AMS,
use within the plant became more sophisticated
with improvements in overall effectiveness. The
Alert Monitor became the primary predictive tool
integrating the plant’s asset criticality measure
with the Device Manager. The respective device
group assignment in turn directly impacts its
polling rate, or the frequency at which the Alert
Monitor extracts the devices status, health, and
diagnostic information from the field.
Over time, Holmes created three groups of
devices: transmitters, control valves, and vapor
cover story
This control valve positioner communicates

with the process unit’s controller using conven-
tional analog I/O, so there is no capability to read
the HART data. Adding the wireless THUM allows
the diagnostic information to be visible within the
AMS Device Manager and its Alert Monitor.
sensors. This helped balance the loading of the

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

While some of the process units have rela-
tively new control systems with HART-enabled
I/O, there are other areas where the system is still
plain analog. These will be upgraded as the plant
moves through a series of migrations to DeltaV
control systems with CHARMS I/O, but in some
areas that is still years away. The work-around
that the plant has developed to gather diagnos-
tic information involves either WirelessHART
THUM communication for critical tags, or
HART/Foundation fieldbus handheld commu-
nicators for devices that require less frequent
monitoring.
The WirelessHART deployment is grow-
ing with about 25 devices currently in opera-
tion. Holmes expects that number to grow, and
A case in point 150
A s the Glyphosate Technicals unit was anticipating a sched-

uled shutdown for catalyst regeneration, Holmes and his
team addressed a planned and scheduled deficiency work order
100
Travel (%)
with a two-inch eccentric ball control valve that had been identi-
fied as suspect through a prior control valve reliability PM route. 50
The AMS Intelligent Device Manager along with its ValveLink
Snap-On application had measured increasing friction as the 0
valve moved through its full span of travel. This indicator sug-
gested a problem was developing and triggered a failure when
performing the diagnostic scans on the control valve assem- -50
-20 0 20 40 60 80 100 120
bly. While the valve was not exhibiting any issues that would Time (secs)
be visible to the operators, the valve signature indicated that
the amount of force required to open and close the valve had
Operators were unaware that there was a friction problem with
increased substantially. It was still able to perform its control
the valve since the step response test results were performing
function for the moment, but comparisons with historical signa-
normally. The valve was performing its control functions, but it
tures revealed that a more drastic situation was developing.
was only a matter of time before the valve would malfunction.
Holmes recommended that the electrical reliability technicians
change out the valve during the outage; therefore, the reliability capture the catalyst. It had been carried down the pipe by the
technicians proceeded to remove it from service during that time. flowing process stream. Had that bolt remained in the valve, at
When they pulled the valve body free from the flanges, they some point it could have initiated flow control issues up to and
found a 1/4 x 4 in. bolt stuck in the valve that had apparently including the valve refusing to close which would have caused
come off one of the clamps holding a filter element designed to additional problems.

each process unit will soon have its own wire-
less gateway.
Changing plant mindset

As workflow processes change, so do indi-
viduals’ mindsets. The reliability team members
have enjoyed seeing some of the traditional bar-
riers within the company between operations and
maintenance crumble as a growing sense of com-
mon purpose and cooperation develops.
Holmes described one of the changes: “Along Electrical reliability technician, Mike Chaney, Throughout the plant
with the reliability programs and some of the has also seen positive effects as he works with there is a large variety of
efforts related to how we monitor and look at our operators. “Being in a sold-out state as we are, we instrumentation types and
deficiency backlog, we’re also getting into AEM get a two day window in some cases to find prob- manufacturers. Most com-
(asset effectiveness management). This meth- lems and get them fixed within that window,” he municate via 4-20 mA/
od looks at the process units, what they have said. “If we can avoid downtime down the road— HART but Foundation field-
to make per our sales, and tracks their process that’s big. Causing downtime right now is not a bus is also installed where
downtime. We want to make sure that we’re not good thing. So if we can prevent that from hap- cable routing infrastructure
only looking at it from a predictive and preven- pening, it saves the plant lots of money in the long has been a problem. Wire-
tive standpoint to see what’s causing downtime, run. Production sees what we’re finding using this lessHART devices are
but to also have those operating units telling us technology. So when we say something to them, growing in numbers as well.
what their biggest pains are. In the past, mainte- they’re not so quick to respond, ‘We aren’t going
nance was addressing things that they were see- to do that.’ They’re more willing to say, ‘We’ll
ing failing and having problems, but it wasn’t get this valve ready for you to pull out and then
always the same issues or biggest problems that see what you’ve got.’ They know we’re saving
the process units felt they had. So there was a them headaches. If we can keep things running, it
kind of disconnect there. With us transitioning makes their day nicer.”
and now focusing on AEM, in addition to all of
our predictive and preventive efforts, we’re get- Measuring progress
ting a better grasp on what needs to be addressed When this whole program began, Holmes
and handled to ensure that we have the manufac- said that they had no good way to distinguish,
turing availability we need.” track, or analyze reliability work performed in
30 30
1st-FAIL-MAX 1st-PASS
25 2nd-FAIL-MAX-STICKSLIP 25 2nd-PASS
Actuator Pressure (psi)
Actuator Pressure (psi)
Best Fit Best Fit

20 FAIL 20 PASS
Closed
Closed
15 15
Valve
Valve
10 10
5 5
0 0
-5 -5
-20 0 20 40 60 80 100 120 -20 0 20 40 60 80 100 120
Travel (deg) Travel (deg)
When the AMS Intelligent Device Manager ValveLink Snap- That type of valve normally has a valve signature like this
on scan failed, it was clear from the valve signature that there one, where the opening and closing pressures are in a tight
was a serious problem developing. This prompted removal of group along with the ideal standard performance indicator.
the valve during the outage.
tion to make sure the valve signature and additional diagnostic
The bolt had damaged the ceramic plug and seat, so once scans indicated normal operating parameters using HART. All
the valve body was removed and separated from the actuator, it scans including the valve signature were recorded in AMS so
was sent out for rebuilding. A new valve body was mounted on that results can be compared to future analysis in trending for
the actuator in the shop. Prior to reinstalling the assembly, it was degradation. When approved, the valve was returned to service
calibrated and then tested using the ValveLink Snap-On applica- without delaying the scheduled startup of the process unit.

cover story
‘
the plant. To remedy that, Monsanto created One big effective family
There’s a order codes to work within the SAP CMMS. In There is more work to do within the plant, but
constant effort order to track labor and material costs to spe- Holmes and his plant management see the direc-
cific equipment, individual deficiency notifi- tion clearly. “The big hurdle that we have is that
to share and cations are entered from any findings arising operations doesn’t always know what the reli-
communicate, from the facilities preventive (PM) or predictive ability programs are doing,” he said. “So there’s
(PdM) maintenance reliability programs. Each a constant effort to share and communicate, not
not only with issue identified during PM routes or PdM trig- only with production but our other maintenance
production gers will have a separate deficiency notification workforce. We continue to share what these guys
and work order created. This allows for predic- are doing, their successes, findings, and training.
but our other tive vs. reactive work cost analysis to be per- That’s imperative as we try and grow the relation-
maintenance formed and KPI’s to be generated and tracked. ship. It’s very apparent to our upper management,
The code analysis data helps quantify so it’s one of our goals to keep that communica-
workforce. We planned versus reactive work. In turn, the sys- tion going to tie the three together: maintenance,
continue to tem generates bad actor lists and provides for
a dollar figure that indicates how much of a
production, and reliability as one big family.” ce
Peter Welander is a content manager for Con-
share what these cost avoidance reliability program initiatives trol Engineering. pwelander@cfemedia.com
are providing. An average of 12 AMS deficien-
guys are doing, cy orders are entered each month. With a cost
their successes, avoidance of over $1,600 per work order, it Go Online
correlates to over $200,000 saved in time and n Search on “HART plant” at www.controleng.com to read
findings, and materials annually. However, Holmes points out Plant of the Year stories from earlier years.
’
training. that this is strictly an out-of-pocket cost avoid- n www.monsanto.com
ance savings and does not reflect increased n www.hartcomm.org
income from gains in plant manufacturing
n www.emersonprocess.com
availability.
SERIOUS ADVANTAGES
FOR SERIOUS CHALLENGES
Built for harsh, mission critical environments,
Sealevel’s COM Express solutions offer you
the advantages of custom solutions with
the convenience of COTS.
Speed to Market
Scalable Processing
Application Specific I/O
Flexible Mechanical Configuration
Vibration Resistance
Long-term Availability
Learn more about our complete COM Express solutions

by visiting www.sealevel.com/cce053/com or by
scanning the QR code to the left.
www.sealevel.com • 864.843.4343 • sales@sealevel.com
CASE STUDY DATABASE:
Application Examples in Action
www.controleng.com/csd
Control Engineering’s Case Study Database allows end-

users to identify relevant solutions and explore what the
experts are doing to effectively implement a variety of
technology and productivity related projects.
Users can upload their

own case studies by
filling out a simple form that
outlines the project title,
abstract and full story in
1,500 words or less.
Photos, videos and a logo
can also be included.
Users can search

for case studies
based on industries
and engineering
specialties. Each
case study will be
hosted on the
Control Engineering
website in the Case
Study Database.
Visit www.controleng.com/csd
machine vision
Machine vision speed,

quality, innovation
Advanced applications for machine vision in automotive, robotics, quality, and safety
use hybrid technologies, vision for robotic or machine guidance and in-line part inspection,
and 3D imaging. Technology and imaging standard advances help.
Quality control
measurements for
smooth surfaces
Hybrid laser-camera technology is ideal for surface
measurement in many industries. The camera detects
a laser projected onto an object at a specific angle.
M
Todd Belt any industries require surface measure- A laser camera hybrid system can measure
ments, and laser camera combination along an edge for robot guidance. It can be
technology can help. A camera detects applied to machines and applications used in
a laser line projected onto an object, and then a many industries, such as glass, metal process-
triangulation calculation determines height and ing, plastics, tire, automotive, aerospace, and
width. Many industries have applications that even highway road construction.
require smooth, sealed surfaces without gaps,
ruts, or protrusions. These industries include generally didn’t have an interface to decipher all
glass, metal processing, plastics, tire, automotive, analog data from the scanner. Generally, a self-
aerospace, and even highway road construction. developed interface and HMI were required and
When it comes to meeting the needs of these dif- the cost went up. If a company then wanted to
ferent industries, quality checks and process con- capture data and chart it for process control pur-
trol based on measurement play a vital role. poses, database development became necessary.
In the past, lasers, mechanical measuring Many companies are being asked to invest
devices, and even wedges were used to check in ensuring the quality of the products they are
quality, usually just a spot check. Depending on producing. Gap and flush measurement for qual-
A gap and flush measure- the application, 100% inspection has been too ity control can take place while automotive body
ment is shown in an HMI inter- slow and required a large capital investment. panels are placed onto the vehicle, or as a spot
face example. A profile scanner, for example, has historically check on each vehicle. Consumers don’t want
been very expensive and the units being scanned leaks. Leak protection depends on measuring the
glue bead being applied for thickness. The hybrid
Automobile panels
technology is improving inspection and quality.
can be positioned
Laser camera combination technology uses a
using a laser camera
camera to detect a laser line projected onto an
system to accom-
object at a specific angle. Triangulation deter-
plish best-fit place-
mines height and width information. Applica-
ment. Images cour-
tions include measuring the depth of road ruts,
tesy: Pepperl+Fuchs
up to 4.2 m wide at highway speeds day or night.
- Todd Belt is systems sales manager – VMT,
Pepperl+Fuchs. www.pepperl-fuchs.us

Next generation:
Robots that see
Visual servo control: Vision used for robotic or
machine guidance also can be used for in-line
part inspection to enhance product quality with
traditional feedback systems. See online video.
Carlton Heard
R
obotics and automated machines can use obstacle avoidance to visual simultaneous local- Multiple Denso robots pick
visual servo control for robotic guidance, ization and mapping. In the next decade, the syringes from a conveyer belt
enhancing motion control and improving number of vision systems used by autonomous and place them into individual
product quality, while replacing traditional feed- robots is expected to eclipse the number of sys- packages. Vision technology
back systems. Vision-guided robotics is one of tems used by fixed-base, robot arms. enables enough flexibility in
the most common uses for vision technology in 3D vision technology can help robots per- the robotics to pick up syringes
robotics. This historically has been applied for ceive more about their environment, and 3D regardless of orientation on
factory floor production, assembly, and materials imaging technology has made great strides in the belt or if the manufacturer
handling, where a camera acquires an image and sensor advancements, lighting, and embedded uses the same line to sort
locates a part or destination before sending coor- processing. 3D vision is emerging in a variety multiple sizes and types of
dinates to the robot to perform a specific func- of applications, from vision-guided robotic bin syringes.
tion, like picking up a part (see online video). picking to high-precision metrology and mobile
Integrating vision technology in applications robotics. Newer processors can handle immense
like these enable machines to become increasing- data sets and sophisticated algorithms to extract
ly intelligent and flexible. The same machine can depth information and quickly make decisions.
perform a variety of tasks because it can recog- Mobile robots use depth information to mea-
nize which part it is working on and adapt appro- sure the size and distance of obstacles for accu-
priately based on different situations. The added rate path planning and obstacle avoidance. Stereo
benefit of using vision for machine guidance is vision systems can provide a rich set of 3D infor-
that the same images can be used for in-line part mation for navigation applications and perform
inspection to improve quality. well even in changing light. Stereo vision tech-
It can be expensive when a high degree of nology uses two or more offset cameras to look
accuracy is essential for the motion components, at the same object. By comparing two images, Screen capture from online
such as the camera or motion system. Some the disparity and depth can be calculated. video partially shows what
vision-guided robotics systems use one image Other applications can require additional Denso robots see when pick-
at the beginning of the task without feedback to processor performance. In the medical indus- ing syringes using NI machine
account for small errors later. Visual servo con- try, robotic surgery and laser control systems are vision and NI LabVIEW.
trol can resolve this challenge. A camera is fixed becoming tightly integrated with image guidance Images courtesy: National
to or near the robot, and it provides continuous technology. For these types of high-performance Instruments
visual feedback to correct for small errors in the vision applications, field programmable gate
movements. Image processing is used within arrays (FPGAs) manage the image preprocess-
the control loop, and the image information can ing or use the image information as feedback in a
replace traditional feedback mechanisms (encod- high-speed control application.
ers) by performing direct servo control tasks. FPGAs are well suited for highly determinis-
tic and parallel image processing algorithms and
Autonomous robotic boom for tightly synchronizing the processing results
Direct servo control accelerates the high- with a motion or robotic system. During laser
speed performance of applications, such as laser eye surgeries, slight movements in the patient’s
alignment and semiconductor manufacturing eyes are detected by the camera and provide
among other processes that involve high-speed feedback to quickly auto-focus the system. Go Online
control. Vision use in robotics is common with FPGAs support surveillance and automotive with At www.controleng.com/
industrial applications, and it is becoming more high-speed feature tracking and particle analysis. archive, read this article for
prevalent in the embedded industry, including for Machines and robots in industrial and con- video of Denso robots picking
mobile robotics. Functions range from service sumer industries are becoming more intelligent syringes using NI machine
robots in hospital halls to help with healthcare with vision technology. The Embedded Vision vision and NI LabVIEW.
system cost pressures and a shortage of doctors Alliance (EVA), a partnership of technology sup- www.ni.com/vision
and nurses to autonomous tractors plowing fields pliers, empowers system designers to more easily www.ni.com/robotics
to advance planting and harvesting efficiency. integrate embedded vision technologies. www.embedded-vision.
Nearly every autonomous mobile robot - Carlton Heard is National Instruments com (EVA)
requires sophisticated imaging capabilities, from vision hardware and software product manager.
machine vision
3D vision system
performs rope wear analysis
Three-dimensional (3D) imaging can be used to verify rope and cable quality to
measure pitch length and diameter, and identify rope surface damage and type of
wear, with accuracy surpassing current methods, to enhance safety. See photos.
T
Andrzej Sioma hree-dimensional (3D) imaging can veri- to construct three-dimensional vision applica-
fy rope and cable quality, measure pitch tions by reviewing the measurements proce-
length and diameter of any section of the dures,” Control Engineering USA, vol. 56, pp.
rope, and identify damage and type of wear on 46-48.) Based on image analysis, height profiles
the rope surface, with accuracy surpassing cur- are determined, which are used to build a three-
rent methods, which can enhance safety. Steel dimensional image. Measurement and evaluation
wire and textile ropes of rope parameters are carried out continuously
are the fundamental ele- along the rope’s entire length. This allows assess-
ment crucial to the safe- ment of the variability in parameters along the
ty of operation of all rope length, and assessment of changes in select-
devices in which they ed parameters during operation, as well as a wide
are used. They include range of other parameters in the 3D image.
machines such as cable The vision system was configured as shown
railways, mine shaft in diagram. The laser beam illuminates the rope
Geometry of a 3D hoists, passenger and cargo lifts, cranes, gantry at 90 deg in relation to its axis. The camera is set
vision system is shown cranes, and winches. Steel wire ropes are popu- at a 45 deg angle with respect to the plane of the
next to a view of a test lar because wear characteristics and methods of laser (see diagram). With such a configuration,
station. determining service life are well-known (Tytko the following resolutions were obtained in each
A., Sioma A., 2011, “Evaluation of the Opera- axis, respectively: ΔX = 0.15 [mm], ΔY = 0.15
tional Parameters of Ropes, Solid [mm], ΔZ = 0.21 [mm].
State Phenomena, Control Engi- The vision system acquires an image onto a
neering in Materials Processing,” monochrome CMOS [complementary metal-
ISSN 1012-0394, vol. 177, pp. oxide semiconductor] sensor so that the image
125–134). shows only the laser line, which allows deter-
Ropes are usually tested for mination of a height profile. After assembly
characteristic parameters, such as of height profiles as determined on successive
pitch length and rope diameter. images spaced from each other by ΔY = 0.15
Important for commissioning is [mm], a three-dimensional image of the rope sur-
Two types of steel assessment of visible damage on the rope surface. face is built. Using a system with three cameras
ropes are shown: 8- and Pitch length and rope diameter measurements are arranged every 120 deg around the rope provides
23-strand. done periodically using contact measuring instru- a complete rope surface image and inspection up
ments. To date, there has not been a simple and to several thousand measurements per second.
accurate measuring method to enable continuous A three-dimensional image of the rope surface
and simultaneous measurement of stroke length is preprocessed before measurement procedures.
Go Online and diameter of the rope. Using 3D machine This is intended to remove any “noise” visible in
www.controleng.com/ vision technology for continuous measurement of the rope surface image and to prepare it for mea-
archive has a longer version pitch and diameter also allows the control of wear surements. The measurement algorithm is based
of this article, more images, on the rope surface during use. on detection of the edges of strands, such as the
and a link to an earlier article 3D vision systems can be used successfully small wires that form the rope surface and seg-
referenced. both in the evaluation of the geometric param- mentation. A characteristic point is determined
www.agh.edu.pl eters of studied objects and the evaluation of for each strand, which defines the largest height
www.controlengineering.pl their surface parameters. The 3D image con- of the strand above the axis of the rope. Rope
struction method is based on the use of a cam- pitch length is measured based on the distance
Control Engineering Inter-
national articles: www.con-
era and a laser light and is discussed in a prior between edges or characteristic strand points.
troleng.com/international article (Kowal J., Sioma A., 2009, “Active vision Strand parts are white spots on the 3D image.
system for 3D product inspection. Learn how Another method to measure pitch length is to
Advances in
machine vision products,
standards
FDA unit-level traceability
Cognex Corp. announced a new
version of In-Sight Track & Trace
identification and data verification
solution for healthcare serialization.
Four-image figure shows defects on 3D imag- This version includes enhancements
es of rope surfaces: A and B are steel ropes, C that address additional requirements
and D are fiber ropes. Images courtesy: AGH for pharmaceutical and medical
University of Science and Technology, Control device manufacturers to achieve
Engineering Poland Cognex Corp. announced In-Sight
unit-level product traceability. Cus-
Track & Trace 2.0, a identification and
tomers can use In-Sight Track &
data verification solution for health-
configure the vision system so the laser line is Trace 2.0 with multiple networked
care serialization, providing unit-level
parallel to the axis of the rope. In that case, the vision systems to decode human-
product traceability for FDA require-
rope surface shows an arrangement of strands readable text and 2D and 1D bar-
ments. Courtesy: Cognex
forming the rope’s diameter. Pitch length in the codes, including Data Matrix, GS1-
proposed configuration may be measured for 128, GS1 DataBar, securPharm, and
each of the strands. Analysis of pitch length vari- Pharmacode. Technical controls for FDA 21 CFR Part 11 validation (with secure
ation allows indirect assessment of rope wear or user authentication and automatic audit trail generation) are included.
damage. Attention should be paid to any strand www.cognex.com/tracktrace
fiber damage, visible in the image by distortion
of the laser line, defining rope damage. Higher speeds, better clarity
Rope diameter is measured on the basis of Teledyne Dalsa, a Teledyne Technologies company and provider of machine
an analysis of its cross-section acquired from vision technology, expanded its Genie TS camera series with new 2 megapixel
a three-dimensional image of the rope. Coor- and 4 megapixel monochrome models that reach speeds up to 76 frames per
dinates of the rope center and the diameter of second (fps) in HD format. These new models are suitable for a wide range
each of the cross-sections are determined. In the of inspection applications. Based on the
adopted vision system configuration, it is possi- CMOSIS imaging sensors CMV2000 and
ble to determine the diameter every 0.15 [mm] CMV4000, the new models are engineered to
along its axis. This allows detection of cracks on meet ever-increasing speed and image clar-
individual wires or strands on the surface of the ity requirements of machine vision. Features
rope and recording of such damage in the form are easily accessible with Teledyne Dalsa’s
of disturbances in diameter. advanced software tools or GigE Vision com-
The use of three-dimensional images of rope pliant third-party software. The cameras are
surface allows detection of defects. The defects designed to perform in extreme environments
recorded during testing differ for steel ropes in temperatures from -20 C up to 60 C.
and fiber ropes. Steel rope defects include bot- www.teledynedalsa.com/genieTS
Teledyne Dalsa, a Teledyne
tlenecks or indentations in the arrangement of
Technologies company and
strands as visible in the four-image figure A, and Vision standards, connectivity
provider of machine vision
cracks to the strands, or wires forming the strand, AIA, a global vision and imaging trade
technology, expanded its Genie
shown in that figure B. For fiber ropes, deforma- group, released USB3 Vision v1.0 in Janu-
TS camera series for faster
tion of strand arrangement have been identified, ary. Like all AIA standards, it is available
speeds in HD format. Courtesy:
as shown in C, as well as frayed surface layer of free; licensing is required for those develop-
Teledyne Dalsa
strands as shown in the laser line image project- ing and market commercial products.
ed in D. Those distortions also can be seen in the V1.1 of the Camera Link HS IP Core
bottom part of Figure D in local deformations of Solutions: In March 2013, v1.1 makes IP cores easier to use. These IP cores
strand surface. ce will vastly reduce the time to market and the cost of support by giving a devel-
- Andrzej Sioma, PhD, is with the AGH Uni- opment team a ready-to-use reference implementation, saving as much as six
versity of Science and Technology, Krakow, months development time, AIA said.
Poland. He is also a contributor to Control Engi- Pixel Format Naming Convention (PFNC) v1.1 has been released. PFNC 1.0
neering Poland; andrzej.sioma@agh.edu.pl. was created in November 2011 by the GigE Vision committee to generalize the
definition and layout of various pixel formats so they can be re-used by various
Consider this... machine vision standards, AIA said. Version 1.1 has an appendix of recom-
mended pixel format ID to be used as unique identifier for a given pixel format.
Where can you apply advanced machine vision tech- There’s support for GigE Vision 2.0, USB3 Vision 1.0, and CoaXPress 1.0.,
nologies to a motion, quality, or inspection application?
pluse new pixel formats to support the USB3 Vision 1.0. www.visiononline.org
See other machine vision coverage at www.controleng. - Articles edited by Mark T. Hoske, content manager, CFE Media, Control
com/machinevision.
Engineering, mhoske@cfemedia.com. ce

motion control
Step-motor-based
systems stay
competitive
Traditional stepper-motor systems represent the only motion-control technology able to
operate in open loop—although the addition of position feedback to enhance performance
is on the rise. Simpler controls, lower cost components, and other innovations keep
stepper systems competitive with servo motion systems in numerous applications.
S
Frank J. Bartos, PE tepper motion systems shine in many itself for small power ratings,” he said.
applications that require less than Morton attributes further cost savings to the
Key critical speed and position accura-
cy. Among the technology’s drawing
stepper drive, especially for smaller sizes. Vari-
ous drive form factors now available—machine
concepts points are no need for system tuning mounted or in a control cabinet—add to stepper
Stepper motion systems: (versus servo-based motion), motors less cost- systems’ versatility. “Coupled with many motor
Excel in applications ly to produce, and simpler controls and cabling. variations available, machine builders have the
that require less than System price advantage remains even when add- flexibility to select the stepper motor/drive com-
critical speed and ing a low-cost feedback device. Other benefits bination that best fits their design and application
position accuracy of stepper technology include minimal system needs,” Morton added.
Need no system tun- setup time, less need of user expertise, and better Kollmorgen likewise regards stepper motor/
ing (versus servo- motor inertia matching for driven loads. drive systems as less costly to produce and easy
based motion)
Cost savings is a common theme voiced by to implement. “The lack of a feedback device [in
Motors are less costly stepper product suppliers. “Step motors have many cases] in particular reduces the cost of the
to produce, and have
simpler controls and always had a cost advantage over servos, but motor, cables, and drive,” said Gene Matthews,
cabling. traditionally this has come at the price of per- a product manager at Kollmorgen. “Integrating a
formance,” said Clark Hummel, applications stepper into a machine can be as simple as puls-
engineering manager at Schneider Electric ing an output on a PLC.” With microstepping
Motion USA. Hummel listed three attributes that technology in the drive, stepper system perfor-
allow today’s stepper systems to take on many mance can now come closer—though still not
applications requiring servos in the past—while equivalent—to a servo system. “This provides a
still maintaining a considerable cost advantage: value solution for applications that can make the
Elimination of stalling (desynchronization) performance/price trade-off,” Matthews said.
Ability to automatically adjust running cur- Beckhoff Automation considers the choice
rent to load requirements of stepper or servo as balancing performance
Ability to provide torque against an over- and price. “It’s a balance of available technolo-
riding load. gy against an application’s performance require-
ments—especially in terms of load—and the
Less costly, easier implementation available budget,” said Bob Swalley, motors and
B&R Industrial Automation Corp. connects drives specialist at Beckhoff.
lower cost with wide application of step motors Step motors, while sensitive in terms of load,
and drives. Feedback, if used, is implemented in are simpler to size than servos. Typically you
a lower cost device, according to Corey Morton, need to find a motor that can handle twice the
B&R’s director of technology solutions. “In con- peak load torque at the application speed, accord-
trast, high-resolution absolute encoders used with ing to Swalley. Good performance is obtained
servos can cost as much or more than the motor where required speeds are not substantially
above 800 rpm. “It’s possible to get functionality
suitable by today’s standards using steppers and
still save money over a more expensive servo
alternative,” Swalley said.
Constant duty, motor+drive

Standard step motors run at relatively high
currents, resulting in excess heat generation
that limits their duty cycle. Recently, Orien-
tal Motor USA (and others) have developed a
class of “constant-duty” step motors with high-
er energy efficiency than standard motors, noted
Todd Walker, OM’s national marketing manag-
er. It’s the result of several factors: control of
running current to reduce heating losses, using
higher grade steel laminations, magnetic flux
pattern enhancement in the motor teeth, and a Open loop or more Thermal imaging shows
more efficient electronic drive. This combina- Properly sized for the application, a step- dramatically less heating
tion enables torque production with lower run- per system running in open loop offers repeat- for Oriental Motor’s AR
ning currents. able positioning—typically within a half-step or Series “constant-duty” step
Another significant stepper system devel- better accuracy (0.9° or better for a 200 step/rev motor that allows continu-
opment has been the integration of the motor, motor), according to B&R Automation. “Over- ous operation. Motor case
drive, and ancillary components into one pack- all positioning accuracy depends on a number of temperature differential
age. Benefits include simpler (less) wiring, factors associated with the driver and motor con- compared to a conven-
matched drive and motor, plus options for struction,” Morton noted. “Microstepping (for tional motor is greater than
closed-loop mode using motors with a pre- example, 1/10th of a full step or 0.18°) is a com- 40 C. Courtesy: Oriental
assembled encoder or with self-correction monly used method to reduce vibrations associat- Motor USA.
options similar to servo ed with stepper motors as
‘ Stepper motors are tioning accuracy.”

systems. A number of well as to improve posi-
manufacturers offer such
motor-drive packages.
“Stepper packages also
simpler to size than In open-loop control,
a generous torque mar-
build communication servos. Adding gin (up to 50%) is used to
options into the driver, select the step motor. This
which will become more incremental serves as a safety factor
or absolute encoders changes. Feedback con-
common in stepper driver against unexpected load
technology,” Walker stat-
ed. (See products table
and more on motor-drive
and resolvers can trol minimizes or elim-
inates the need for this
developments at Ref. 1 increase positioning provision.
’
online.) For applications that
Schneider Electric accuracy. require better position-
Motion also values inte- ing accuracy or overall
grated motion. It has long been an advocate performance improvement, stepper motors can
of motor-drives, for example, with its MDrive be fitted with different position sensors such as
product line, which comprises NEMA 14, 17, incremental or absolute encoders and resolvers.
23, and 34 step motor sizes (Ref. 2). Combin- “A simple implementation may use the sen-
ing the motor, drive, encoder, and motion consor just to verify reaching a commanded position
troller into one package expands the overall and initiate correction moves. A more advanced
cost advantage by eliminating long runs of cost- implementation may use full closed-loop posi-
ly feedback and power cables, removing most tioning, similar to servo system operation,” Mor-
of the control panel space requirements, and ton added.
reducing potential failure points in a motion However, a simpler sensor can suffice in a
axis, explained Hummel. “This provides a true typical stepper application. For example, Orien-
value proposition when evaluating a stepper tal Motor’s Walker mentioned a 200 pulse/rev
system against a servo,” he stated. encoder priced at under $70, while a servo sys-
motion control
Motion control hybridization ability—are ideal for steppers,” Walker said. He

cited examples in sampling, metering, or pump-
ing applications where controlled volume is
required.
Stepper Hybrid Servo “Expensive gearboxes can possibly be elimi-
motor technology motion motor technology nated in some applications since stepper motors
Negatives Benefits Benefits Benefits Negatives tend to have four times the inertia of servos,”
• Loss of synchronization/ • Smooth motion • Variable current/ • Peak torque • Tuning required
stalling • High torque at torque • High speed • Higher price point Walker added.
• 50% torque margin starting and • Real-time control • Torque mode • Error driven
• Post-move corrections low speed • Optimum torque • Closed loop • Higher complexity Stepper systems are well suited for indexing,
• Constant torque/current • Cost effective at all speeds • Servo dither
• Excessive heating • No tuning • Lower energy use dispensing, and positioning tasks. Kollmorgen
• Stiffness at • Eliminates loss of
standstill synchronization mentioned examples in labeling, 3D printing, and
• Never loses functional
control of motor driving linear positioners.
• Reduced motor
heating “Step motor-based systems allow manufactur-
ers to create lower performance and less expen-
sive versions of machines than those outfitted
with servo motors,” Matthews remarked. “Step-
Courtesy: Schneider Electric Motion USA’s “Hybrid Motion Technology” and Control Engineering
per motor technology performs well at speeds
Hybrid Motion Technology from Schneider Electric Motion, now available below 15 revolutions per second [900 rpm]. If
with MDrive products, adds various enhanced control capabilities and features you need significant torque at higher speeds,
to stepper-based motion systems. Courtesy: Schneider Electric Motion USA. servo is the right technology.”
Beckhoff Automation’s Swalley concurred
that steppers are not appropriate in applications
tem might need a costly encoder with, say, 16k with changing forces and/or masses or requir-
ppr capability. ing higher operating speeds. “That arena remains
AR Series motor and driver packages from strictly the domain of servo motion because of
Oriental feature a self-correction option that potential loss of synchronism,” Swalley conclud-
simulates servo-like operation and reportedly ed. (More Beckhoff coverage appears at Ref. 1
maintains positioning even under load chang- and in a packaging machine application using
es and accelerations. A sensor monitors motor stepper motion control, Ref. 3, online.)
shaft rotation and, in case of overload, AR Series
regains control quickly by going to closed-loop Hybridization improves performance
mode. If the overload condition continues, the Motion control is moving toward what is vari-
drive outputs an alarm signal. ously termed “actuator independent” or “hybrid”
Advances implemented in newer stepper technology—driven particularly by manufac-
drives include control of synchro- turers that supply both servo and
nism between the motor and driv- Consider this... stepper systems. Among bene-
en load. For example, Encoderless fits of this development is that
Stall Detect used in Kollmor- Applying stepper tech- machine builders can provide
gen’s P7000 Stepper drive gives nologies can require less lower cost step motor solutions
users feedback on when the step system setup time and user with the same motion control soft-
motor has stalled. An actual feed- expertise: Do you have an ware previously used with servos,
Go Online back device isn’t needed since the application that a stepper said B&R Automation’s Morton.
At www.controleng.com/ method is implemented in soft- motor can simplify? Schneider Electric Motion
archive read this article for ware. Instead, the system’s com- commented similarly that the
links to:
manded current is monitored and if demand advent of modern control designs, such as the
- Ref. 1- Stepper-based exceeds an expected current limit for a posi- company’s trademarked Hybrid Motion Technol-
motion systems addendum
tioning move, the drive shuts down, Matthews ogy (HMT), has dramatically narrowed the per-
- Ref. 2- “Integrated motor
explained. It could indicate an abnormal condi- formance gap between steppers and servos. HMT
communicates…”
tion such as a jam, obstruction, or other machine features include ability to operate in torque mode
- Ref. 3- Beckhoff-Pattyn
stepper application issue. “This allows for a more advanced control and at 100% of motor torque, which is said to be
scheme at a low cost,” he stated. unique for stepper motors (read more at Refs. 1
www.br-automation.com
& 2, online).
www.beckhoff.com/driv-
etechnology Applications galore Continuing innovations and adoption of new
Oriental Motor sees stepper applications hybrid technologies help keep stepper motion
www.kollmorgen.com
in CNC machines and short move x, y, z posi- systems in proper step. ce
www.motion.schneider-
electric.com tioning for assembly or automation machines. - Frank J. Bartos, PE, is a Control Engineer-
“Applications that require short, quick moves (1 ing contributing content specialist. Reach him at
www.orientalmotor.com
or 2 shaft revs)—or fine positioning and repeat- braunbart@sbcglobal.net.
Connecting
the Global Engineering
Community
Control Engineering is the leader in connecting the global industrial
engineering audience through coverage of and education about
automation, control, and instrumentation technologies in a regionally
focused, actionable manner through online and print media
and in-person events.
ControlEng.com: Visit www.controleng.com for the

information you want in the format of your choice, including:
articles, podcasts, webcasts, videos, etc. Industry channels
provide quick access to focused content on key industries and
related technologies.
• System Integration • Information Control • Process Control
• Machine Control • Sustainable Engineering
Online Training Center: The Online Training Center is
dedicated to providing plant and operations engineers with
practical education on relevant technology, process, and
practice. New courses and topic modules are added regularly.
Electronic Newsletters: Receive timely industry information via

the convenience of email with Control Engineering’s eNewsletters.
• Weekly News • Machine Control
• System Integration • Information Control
• Process Instrumentation & Sensors • Energy Automation
• Process & Advanced Control • Safety & Security
• Product and Media Showcase • Whitepaper Connection
Social Media: Online social media has quickly become an important
tool for many people as a means of staying in touch with their
professional community. Control Engineering connects with you via
Facebook, LinkedIn, Twitter and Google Plus.
Engineers’ Choice Awards: Each year the editors of Control

Engineering rely on the insight of engineers in the field to help
determine the most noteworthy products introduced in the past year.
Automation Integrator Guide: The annual Automation Integrator

Guide is a unique and comprehensive service directory listing more
than 1,800 automation system integrators and contract engineers.
Subscribe today at www.ControlEng.com/subscribe

networking
The
industrial
Internetof things
Should industrial users embrace IP networking? It promises convergence of many
technologies, but is it necessary or even beneficial? An examination
of why and why not, what, and how.
C
Herman Storey oncepts referred to as the Inter- vendors and users. It will be good for the whole
net of Things (IoT) and machine automation industry, and all who embrace the
Editor’s note: While the to machine (M2M) communica- technology will benefit.
tions have attracted a lot of pub- In the short run, this is disruptive technol-
concepts related to the
licity, many interest groups, and ogy. It will require changes and will threaten
Internet of Things are many face-to-face meetings. IoT refers to the entities that do not have the resources or lead-
much in the news for increasing connectivity of objects of all kinds, ership to make the changes. It will cross orga-
consumer applications from home appliances to devices used in indus- nizational lines and blur distinctions between
and products, does this trial applications, either to the Internet or some foundations. The challenges of realizing the
technology belong in the kind of Internet-like structure. The general benefits of this technology will be more orga-
industrial space? Her- idea behind this effort is that any smart devices nizational in nature than technical. In fact, the
man Storey sees poten- should be able to communicate with each other technical challenges are minor by comparison.
tial for major benefits, or with human interfaces anywhere on the plan- As of now, the effort to incorporate I2oT tech-
but only if the technol- et—thus driving improvements in productivity. nology into the world of industrial automation
ogy is applied correct- Industrial M2M networks are mature and does not have a home or a clear statement of
widely deployed, even though some M2M pub- reason for being. This is not for the faint of
ly. Storey is co-chair of
licity implies that the concept is new. These heart or the impatient.
ISA100 and has been industrial networks can benefit from IoT tech-
involved in many net- nology if done correctly, but could also suffer What is it?
working standards if done with a lack of planning and caution. The intent of this discussion is to provide a
groups throughout his This discussion will propose some general model for I2oT. It is oversimplified but should
career. He offers these principles for applying IoT to industrial auto- form the basis for more discussion and defi-
thoughts as a starting mation systems. To differentiate this from the nition. This is not a proposal for a massive
point for an ongoing web-based efforts and call attention to indus- amount of research into new communication
dialog. His comments trial needs, this will be called the Industrial technology. It is a plea to use what we already
are followed by views Internet of Things (I2oT). have in a rational manner. A lot of assembly is
from two others. I2oT must give priority to security, robust- required and some gaps need to be filled.
ness, and timeliness requirements of automation Essential elements—I2oT will provide a
networks while providing for remote access as a means to integrate multiple physical media
secondary requirement. and multiple applications into a single system
of industrial networks utilizing some common
Why and why not technology. I2oT is not a converged single stack
For the world of automation, I2oT repre- with a single application layer or a single phys-
sents the opportunity for partial convergence ical media. Indeed, one physical medium will
of industrial automation communication on a not serve all installation requirements, and we
grand scale. It will allow improvements in func- need more than one application layer to serve
tionality, security, flexibility, ease of use, and all use cases.
cost savings. In the long run, it will be good for This discussion may miss some elements but
should serve to stimulate discussion to fill in the
gaps. The major elements are shown in the fol- Major elements of the I2oT
lowing illustration and discussed below.
Applications—At the top of the communi-
cation stack, we have many application layers Multiple applications
(and some user layers that may or may not be a
part of the application layer depending on philo-
sophical prejudice). It can easily be argued that
we have many more application layers than nec- More communication
essary, but the argument is irrelevant because stack layers
Common
they now exist and constitute a large installed Common network
base. It is also arguable that one new applica- time management
tion layer will not displace all of the existing and security
IPv6 / 6LoWPAN
application layers. Each application layer has common network layer
strengths and weaknesses that allow each one to
fill a market niche. It is simpler and more rea-
sonable to assume that multiple interfaces are
Multiple physical media
necessary and that we should expect to sup- and link layers
port all of them when considering the future of
industrial communications technology.
IPv6—If I2oT supports all existing media and
application layers (and it should), what is con- quite easily. Furthermore, the linkage should be
verged by I2oT? The answer is simple: in the broken in a way that any media can be shared Key
world of I2oT, all protocols would use Internet by multiple applications. concepts
Protocol version 6 (IPv6) as the network layer of Installations that have high latency and low
Internet protocol
the communication stack. IPv6 has an extension bandwidth because of physical limitations (such
technologies are quickly
called 6LoWPAN that will allow this network as distance) will require some differences in the moving to industrial appli-
layer to be used on low power and/or bandwidth- layers above IP as well as possibly placing lim- cations.
limited networks. It was originally designed for itations on the media that can be used. There
The Internet of Things
use with battery-powered radio networks, but is are some shortcuts and simplifications that can offers many potential
suitable for wired networks as well. IPv6 with be made when networks have direct high-speed/ benefits for industrial
6LoWPAN literally gives a protocol the ability low latency links. users, but only in the right
to address and route messages to and from any A communication stack model that has mul- contexts.
device on the planet to any other device on the tiple options at the top and multiple options at A careful and purposeful
planet. Any media should be able to support IP, the bottom but a single network layer is some- approach can make adop-
and any application should be able to run on top times called an hourglass model, or a Hedy tion more practical and
of IP, and many already do. Lamarr model for history buffs who remember avoid many pitfalls.
Use of a common and capable network layer she invented and patented direct sequence spread
will allow the first phase of convergence includ- spectrum technology during World War II.
ing the sharing of media by multiple applica- Switching and routing—Switched networks
tions and the selection of the optimum media are the technology of choice. Protocols that do
and application for any particular task without not support switching and routing need to be
the need for separate infrastructure. upgraded, and the common network layer will
Physical media include: aid in that step. Point-to-point and multi-drop
Single and multiple twisted-pair wires busses will need gateways to communicate in
Coax cable the new world, but new networks should sim-
Single- and multi-mode fiber ply be able to connect to a switch or router. In
Many types of radio this model, switches or routers can accomplish
Acoustic, and media conversion without a gateway.
Infrared. With the right switching and routing technol-
ogy, it may be possible to incorporate IPv4 as
PHY/MAC specifications exist for these an additional option for the network layer. It is
media types and do not need reinvention. All of worth investigating.
these types of media should continue to be sup- Common sense of time—A common sense
ported. However, many of these physical- and of time is necessary in real-time networks for
link-layer specifications are now tied to a single event tagging, scheduling of communications
application layer by many protocols. This link- and applications, and security. The best time to
age needs to be broken, and it can be broken use is GMT or TAI (convertable to local time for
networking
human interface). A simple time counter or local Architecture—ISA100.15 has published a

time will lead to problems in system implementa- document that gives models and terminology
tion and maintenance, and could degrade security. for architectures suitable for I2oT. It does not
Some protocols need an upgrade. Unfortunately, spell out in detail how elements of the architec-
time synchronization is not so easily standardized ture should be implemented; it just identifies and
because of differing needs of networks and appli- gives examples of what they do. More detail is
cations. Where time synchronization requirements needed if some degree of interoperability is to be
are fairly lax, SNTP can be used. Many networks achieved with I2oT.
and some applications require synchronization at Architectural principles of I2oT:
the millisecond level, using a variety of methods. n ISA100.15 illustrates methods for segregat-
This is an area of standards development. ing automation networks in zones and connecting
Tokens should not be used for scheduling. A the zones with conduits. The concepts for zones
proper clock in each device will eliminate the and conduits were developed by ISA99 for ISA/
need and allow more efficient and robust sched- IEC 62443.
uling mechanisms. Tokens may be used for n ISA100.15 illustrates methods for creating
some non-scheduled bus control (TCP), but in and enforcing policies that determine which enti-
general tokens and industrial communications ties can communicate over industrial networks,
should not go together. More networks will and the allocation of bandwidth or relative prior-
require an upgrade. ity of those communications.
Don’t miss the ( big space) in the middle

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

n As a general principle, many automation
nodes and networks have limited bandwidth and
capability to serve data. The primary source of
and network layers (which is also an organiza-
tional boundary) is informal at best and some-
times appears to be a turf war.
‘ If market
forces do
data from these nodes must be in separate buffers Many foundations have taken a vertical eventually
and caches with sufficient bandwidth for expect- approach to communication stack specifica-
ed users. Direct access to nodes requires system- tions and have written full top-to-bottom stacks. drive this
atic limitation.
n Local autonomous control and local his-
Many of these support only one PHY and one
application and have a single stack in between.
convergence,
tory collection and compression are two tech- Others have multiple PHY layers available but it is safe to
assume that
niques used in industrial automation systems to with restricted stacks in between. These founda-
deal with low bandwidth and/or high or variable tions are generally market competitors.
latency in networks. Many proprietary schemes All of the organizations fill a need wheth- it will happen
are used to fill these needs, and there is an oppor- er they are working on a horizontal or vertical
tunity to standardize these features. slice of the communication problem, or just a very slowly and
Common network management—Work has little piece of the problem. All of these organi- chaotically
started under ISA100.20 on a recognized need zations could slowly converge on best-in-class
for common network management. This gap technology, or not. If market forces do eventu- under market
’
needs to be filled. Common network manage- ally drive this convergence, it is safe to assume conditions.
ment is intended to provide a way of managing that the convergence will happen very slowly
multiple diverse networks with common tools. and chaotically under market conditions.
Some tools already exist, but many networks are Lead organization—Building a positive out-
not designed to work with external tools. Some come will need a lead organization or a consor-
networks are unmanaged. This is an opportunity.
Common security management—This
tium of organizations for a successful effort. It
will involve liaison work with too many orga-
Go Online
aspect will also need work. It is not easy to sep- nizations to name, and need executive sponsor- n For more information, visit:
arate this need from common network manage- ship from multiple entities including vendors, n www.isa.org
ment, and it may be handled by the same effort. standards organizations, and foundations. n www.pcntechnology.com
This will need to include provisioning proce- Herman Storey is chief technology officer of n www.thingworx.com
dures and tools. Most industrial protocols do Herman Storey Consulting, LLC.
not include sufficient security. They need to be
upgraded to include this as a standard feature.
Specifications and profiles to support com- The technology solutions we create
pliance certification—We need plug and play,
not plug and pray. This means that we will need
must be easy, flexible, and powerful
enough compliance profiles and specifications Rick Bullotta
that a certification body can do compliance test-
ing. Standards developed by a standards devel-
A
ny consideration of applying the concepts from the IoT to the industrial
opment organization may support this cause, but space would be incomplete without addressing the following:
will not be sufficient to meet industry needs. n Legacy systems and devices—How will they participate in this
new architecture, at all levels of the stack? While IPv6 and 6LoWPAN are
What does the future hold? important moving forward, we need to embrace existing devices and end-
There are multiple paths and even multiple points as well.
end points for this technology migration. It is n The IoT and I2oT are not a communications/plumbing problem (or
not certain what path(s) or endpoint(s) will be opportunity); they are about creation of useful applications. While standard-
the final result. The only certainty is that this izing some of the lower level networking is helpful, it will fall far short of truly
technology will change, and so far the changes unlocking the potential and represents only a tiny piece of the requirements.
have led to more diversity. Other critical elements include:
Current state—Many organizations are 1. A semantic model for discovering, addressing, and consuming the data,
involved in pieces of the problem, but no single services, and events that the elements of the IoT/I2oT will provide. Although
organization is involved in all aspects and no the “I” in the IoT stands for Internet, the reality is that the Internet wasn’t nec-
organization is well positioned to take the lead essarily the source of the amazing innovations we’ve seen that have changed
in coordinating this technology drift. our lives. It was in many cases the WWW and related standards and proto-
Some standards organizations have taken on cols that ran on top of the Internet. The same will be true of the IoT.
the task of standardizing horizontal layers of 2. Highly granular security models that can protect access to very specific
the communication stack. IEE writes standards device capabilities. This way, we can allow selective sharing and access con-
for the PHY/MAC (or link) layers. IETF writes trol, better deal with cyber security implications, and so on.
standards for network and transport layers. 3. Quality of service (QoS) and security at the network layer. Not all mes-
Coordination at the boundary between the link
networking
sages and bits that are passed on the IoT and I2oT are of equal n Location awareness of assets, people, and even data. Data
importance, and this needs to be designed into the stack. IPV6 has time, value, quality, and location.
offers some capabilities in these areas, but more is required. n Contextualization of data via metatagging and other mecha-
Let’s not forget the human side of the discussion. People nisms, such as a move from dumb historians to smart historians
still represent the sensors, actuators, and knowledge base for n Mobile devices and new modalities for interaction, including
a huge amount of industrial processes. Failure to consider how push-based notifications, search-based access to information,
humans will interact in the I2oT will lead to failure! secure connections from anywhere, and so on, and
Despite some vendors’ claims to the contrary, the IoT and n Extend the concept of the social graph to the equipment,
I2oT are not simply cloud device architectures. In fact, to be suc- processes, systems, and people in the work environment.
cessful, secure, reliable, and capable of performing as required,
we need to consider them as a distributed systems architecture. We at ThingWorx are using our extensive experience in the
Those of us who come from the industrial automation world have industrial sector (the founders of ThingWorx brought experience
been dealing with these types of problems for decades, and from Wonderware, Lighthammer, and Cimnet) to apply those
there is much to be learned from past experiences and applied lessons and know-how to the IoT and the I2oT. We share the
to the IoT and the I2oT. Standards are important, but we need to view that there is huge value to be unlocked. We also passion-
consider carefully where in the stack to focus our energies first ately believe that the value will be unlocked when we provide
on standardization. For example: technology solutions that are easy, flexible, and powerful. Those
Which areas have the most immediate impact/value? elements need not be mutually exclusive. And security and
n How can we address the issue of legacy integration? reliability are a given. We also feel strongly that there is much
n How can we “future proof” our standardization efforts so that to be gained from sharing experiences and technology in both
when IPv24 and infinitely fast, zero gravity, powerless wireless directions—applying the lessons learned from the open, mobile
communications are available, we aren’t starting from scratch? collaborative, and composable world of the IoT to the industrial
n Consider not only the use cases of the past, but the use space, and leveraging decades of knowledge and experience in
cases of the future. delivering reliable, performance driven, distributed systems that
Moreover, how can we embrace some other key elements of exist in the industrial sector. ce
the IoT in the I2oT? Rick Bullotta is CTO and co-founder of ThingWorx.
The biggest thing

in signal conditioning
is only 6 mm wide
The 3000-series of converters and isolators packs the

next generation of microprocessor technologies into
an ultra-slim 6 mm housing. Featuring exceptionally
high signal reliability with 0.05% accuracy and a broad
temperature operation range, the 3000 series is the
ideal solution for multiple applications in factory
automation and the process industry. You can also
count on its high safe isolation for excellent process
reliability – day in and day out.
Experience the 3000 factor, only from PR electronics.

Learn more on www.prelectronics.com

managing risk
Safety:
Risk management
Risk assessment and risk management plans help with industrial safety and machine safety
efforts, using standards, processes, hardware, software, and continual education.
How to use ISO

functional safety
standards
Navigate and apply ISO functional
safety standards using this road-
map for common-sense machine
safety risk reduction.
Bill Stone
M
any safety engineers are overwhelmed
by the sheer volume of safety stan-
dards. A roadmap can help determine
the appropriate ISO standard for the project and
how it can be applied to achieve desired safety Five steps of the functional safety lifecycle are 1) perform a risk or haz-
performance. The ISO functional safety stan- ard assessment, 2) determine safety system functional safety requirements,
dards use a three-tier structure that includes Type 3) design and verify the safety system, 4) install and validate the safety sys-
A, B, and C standards to define requirements for tem, and 5) maintain and improve the safety system. Training is important
different machinery types. Understanding the throughout. Courtesy: Rockwell Automation
scope of each type will help.
Type A standards are the most basic safe- ISO 13850 and ISO 13851 are B2 standards that
ty standards and apply to all machinery. They describe specific functional aspects of emergen- Key
use basic machinery-design concepts and pro- cy-stop devices and two-hand control devices, concepts
vide general principles. ISO 12100 (Safety of respectively.
Apply ISO functional
machinery – General principles for design – Risk Type C standards, the most narrowly defined
safety standards to reduce
assessment and risk reduction) is a Type A stan- standards, have the most stringent requirements machine safety risk.
dard that describes the risk-assessment process for specific types of machinery. ISO 10218-
accepted for most machinery. 1 applies to industrial robots, while mechani- ISO 13849-1 improves
safety and the experience
Type B standards are divided into B1 and B2 cal presses are covered by EN692 and hydraulic
of working with machine
categories. B1 standards define one safety aspect presses by EN693. When possible, safety engi- safety requirements, with
and B2 standards define one type of safeguard. neers should use a Type C standard to evaluate more benefits than EN 954.
For example, ISO 13849-1 (Safety-related parts safety-design requirements for new machinery.
Machine safety culture
of control systems) is a B1 standard that provides No standard can completely define the
change helped close 95%
guidance for designing the safety-related parts of requirements for a given functional safety appli- of corrective actions and
a control system. It defines the characteristics of cation. Each ISO functional safety standard typ- preventive actions from
each type of safeguarding function. ISO 62061 ically includes a Normative References section fatalities, at one manu-
is a B1 standard offering an alternative to ISO to identify other standards to consult for a more facturer.
13849-1 based on Safety Integrity Levels (SIL). complete picture.
managing risk
‘ Understand Safety engineers should (at a minimum) con- ing a model for risk assessment and remediation
sider reviewing five specific standards: ISO on machinery in Britain. ISO functional safety
5 standards 12100, ISO 13849, ISO 62061, ISO 61508, and standards have a consistent organizational format
IEC 60204. These define minimum requirements that allows a user to navigate each standard and
that take for each step in the functional safety lifecycle identify links to several normative references.
a safety (see graphic) as defined in ISO 61508 and 62061, Each ISO functional safety standard has:
including risk or hazard assessment, design, veri- n Scope – The scope serves as a starting point
engineer fication, installation, and validation. and provides an abstract of the standard’s intend-
through the Each ISO standard title provides clues on ed use, whether it is Type A, B, or C, and any
content and alphanumeric designation that indi- limitations. Skim the scope to determine wheth-
functional cates its reference number, adoption date, and er the standard is suited for the application.
safety adoption location(s). Select the standard with Remember that if the standard is Type A or B,
’
the most recent revision date and appropriate there may be a more applicable Type C standard,
lifecycle. adoption location. Consider standard BS EN depending on the specific type of machinery.
ISO 120100:2010 (Safety of Machinery – Gen- When reviewing multiple ISO standards, skim-
eral Principles for Design – Risk Assessment ming the scope section of each can often help
and Risk Reduction). The title indicates that quickly narrow down to a smaller list.
this standard contains general principles, so it n Normative References – These typically
is likely Type A. The title also signifies that it follow the scope and, as mentioned above, are
provides guidance for machinery safety-related other ISO standards that can provide a broader,
Go Online risk assessments and risk-reduction techniques. more complete understanding of required pro-
n See more from Rockwell The alphanumeric designator provides addition- cesses and documentation.
Automation on how to imple- al detail—the author is ISO, the reference num- n Terms and Definitions – Use the terms
ment ISO functional safety
ber is 12100, and Europe (EN) and Britain (BS) and definition to clarify what is meant by
standards. www.rockwellau-
tomation.com/services/safety
adopted it in 2010. A safety engineer can deter- phrases and words used frequently in the stan-
mine that it is the latest Type A standard provid- dard. Definitions help accurately communicate
machinery-safety concepts to ensure consistent
Achieve a higher safety performance

understanding for those applying the standard.
n Body – The body indicates the rules to fol-
level with EN ISO 13849-1 low when applying the standard. Language in the
body is normative and often includes words like
shall, should, may, and can to indicate required
O ver the past few years, safety has become one of the dominant factors that
impact product design processes. European guidelines for machine safety have
played a major role in reducing injuries and are bringing new requirements for prod-
items, permissible actions, and statements of
possibility when conforming to the standard.
uct and component developers in their goal of working toward creating a better and Compliance requires adherence to all normative
safer working environment. content in the standard. Flow charts and tables
At the end of 2011, EN ISO 13849-1:2006 “Safety of machinery, Safety-related are often included in the body to help illustrate
parts of control systems, Part 1: General principles for design” took effect. The how the standard relates to its normative refer-
EN 954-1 (CAT B, CAT 2, CAT3 & CAT4) was replaced by ISO13849-1, because ences and allow users to more quickly under-
programmable electronic systems were considered insufficiently; there was no con- stand the content. In ISO 13849-1 Figures 1, 2,
sideration for direct connection between risk minimization, category, or complexity. and 3 illustrate the relationship between ISO
Also, time response (such as testing intervals, lifecycles) and the failure probability 12100 and ISO 13849-1 to help users understand
of components (such as Common Cause Failures) were not considered. Therefore, how to use the risk-assessment standard (12100)
due to all these aspects, EN 954-1 did not represent the state of technology any- when designing safety-related parts of a control
more. EN ISO 13849-1 addresses the programmable electronic safety devices, used system as defined in 13849-1.
increasingly in modern machines. The standard provides a quantitative approach to n Annex – This adds information to help
risk assessment and safety validation. This ensures that safety is not just compo- understand the standard. The body uses primar-
nent reliability, but also relies on common-sense safety principles, such as redun- ily normative, or prescriptive, language while the
dancy, diversity, and fail-safe behavior. Under this standard, the risk assessment annex uses descriptive language for a more prac-
for a given safety function will yield a performance level (PL). This helps eliminate tical description of how to apply the standard.
both over- and under-engineering, a costly or risky result of EN 954-1’s limitations. In ISO 13849-1, Annex A provides examples of
Safety designers should start designing products using EN ISO 13849-1. It improves diagnostic coverage and Annex F provides the
safety and the experience of working with the new requirements, and will have much scoring process for quantifying Common Cause
greater long-term benefits than using EN 954. To help users with ISO 13849-1 safety Failure. Both are critical elements for evaluating
design aspects, Siemens Industry Inc. and TUV Rheinland provide training and cer- the achieved required safety Performance Level.
tification courses. - Bill Stone is machine safety expert, Rockwell
-Information provided by Siemens Industry Inc. www.usa.siemens.com Automation, and functional safety engineer (TÜV
Rheinland).
Safety first: Put up your guard
Case study: Machine safety culture change at global consumer products manufac-
turer results in closing of 69% of the major findings from global assessments; and
closing of 95% of corrective actions and preventive actions from fatalities.
Sean Daswani, PE
M
achine safety upgrades offered a manu- lost-time cases and days lost saves the Top benefits of effective
facturer an opportunity to reduce risk company approximately $30 million in workplace safety program
and address operational efficiency direct costs each year.”
when a safety project required equipment over-
haul. After risk assessment, and safety culture Polytron case study on safety
improvements, many corrective actions and pre- In 2009, one of the leading glob-
ventive actions were resolved. Safety is more al consumer products manufacturers
than adding machine guards. launched a new fatality elimina-
Around the time that the Occupational Safe- tion campaign as a part of its exist-
ty and Health Act (OSH Act) became effective ing environmental, health, and safety
on April 28, 1971, workplace deaths and report- (EHS) management system. The stat-
ed occupational injuries dropped more than 60%. ed safety goal is zero workplace fatalities
Courtesy: Polytron, January 2012
However, as of January 2012, OSHA reports by 2015, according to the company’s 2011 Sus- “OSHA Injury and Illness Preven-
that the United States still faces an unacceptable tainability report. tion Programs White Paper”
and preventable number of work-related deaths, The overall safety brand was implemented as
injuries, and illnesses. Every day, more than 12 a strategy to drive cultural change and includes
workers die on the job—more than 4,500 a year, employees, contractors, and visitors. To create
‘
and more than 4.1 million workers suffer a seri- a fatality-free and incident-free workplace, the
ous job-related injury or illness. A renewed focus strategy applied a two-way commitment: Training
on prevention is needed to reduce these numbers. 1) The company committed to providing a
To accomplish this, the occupational safety workplace that is compliant with all applicable sessions
and health community has developed and initi-
ated systematic approaches to reduce injuries and
laws and regulations.
2) Individuals are expected to refuse to take
help ensure
illness in the workplace. part in any action considered unsafe, confront everyone is
Regardless of the title of the various compa-
ny programs, all address workplace safety and
others acting in an unsafe manner, and immedi-
ately stop any unsafe actions.
on the same,
health hazards to reduce the extent and severity Key performance indicators (KPI) for the lower-risk,
’
of work-related injuries and illnesses. Ongoing company’s manufacturing facilities were estab-
programs help employers find hazards and fix lished and defined in the following areas: page.
them before injuries, illnesses, or deaths occur. Total reportable incident rate: Work-relat-
They also help employers meet their obliga- ed events that result in fatalities, or temporary
tion under the OSH Act to “furnish to each of or permanently disabling injuries or illnesses per
its employees, a place of employment which is 200,000 hours worked per annum.
free from recognized hazards that are causing or Lost time reportable incident rate: Report-
are likely to cause death or serious physical harm able injuries/illnesses that result in time away
to its employees,” according to the January 2012 from work or restricted work per 200,000 hours
OSHA Injury and Illness Prevention Programs worked per annum.
White Paper. Global contact with energized equipment
Convinced of the value, effectiveness, and incident rate: Cases resulting from bodily contact
feasibility of injury and illness prevention pro- with energized equipment (electrical, mechani-
grams, many countries around the world now cal, hydraulic, gravity, radiation, pneumatic, ther-
require employers to implement and maintain mal, etc.) per 200,000 hours worked per annum.
them. These countries include Canada, Australia, These include incidents arising from inadequate
the 27 European Union member states, Norway, guarding of equipment or machine, or failure to
Hong Kong, Japan, and Korea. This initiative follow energy control work practices, etc.
also follows the lead of 15 U.S. states that have The company took action in the following
already implemented regulations requiring such areas:
programs, according to www.OSHA.gov. Culture change – Training sessions for all
The Ford Motor Company 2010-2011 Sus- employees at the company’s global manufactur-
tainability Report comments positively on such ing facilities
efforts: “Improving our safety record is not Facility occupational safety and health
only good for our employees—it’s good for our (OS&H) leader qualification and competency
business. We have calculated that progress in standards – Standard minimum qualifications and
managing risk
competency require- plan and improve with more detail in the next
ments for senior facil- iteration of the cycle, or attention needs to be
ity OS&H leaders placed in a different stage of the process.
n Machine safety
standards – Risk-based At-risk equipment
approach to safeguard- When the client launched its 2009 zero-fatal-
ing selection to provide ity program, company manufacturing facilities
flexibility in safe- had equipment that required updating to meet
guarding method(s) in new occupational and machine safety standards.
compliance with inter- Additionally, multiple original equipment man-
national consensus ufacturer (OEM) safety systems existed; there-
standards, ISO 14001, fore, the implementation of safety standards was
and OHSAS 18001 inconsistent.
n Plan-do-check- As part of its strategic plan, the company
Plan-do-check-adjust (PDCA), a common meth- adjust (PDCA) meth- partnered with preferred vendors to assist with a
odology also applied in manufacturing programs, odology – Policy and company-wide risk mitigation of its equipment.
including safety, was made popular by Dr. W. organization, plan- The client’s dedicated safety team developed
Edwards Deming, considered to be the father of ning, implementation standards of safety for all equipment, which
modern quality control. Courtesy: Polytron and operation, check- included:
ing and corrective n Conforming to safety categories based on
action, and manage- the risk assessment, maintenance standards,
ment review. operational consistency, and troubleshooting
procedures
Plan, do, check, n Preferred vendors, such as Polytron and
adjust for safety E2M, were selected to support the safety initia-
PDCA, a com- tives. Selection was made based on the vendor’s
mon methodology critical understanding of how the risk assess-
also applied in man- ment translates into applied machine safety sys-
ufacturing programs, tems to lower the risk score.
was made popular by n Training meetings were held with pre-
Dr. W. Edwards Dem- ferred vendors, key technology suppliers, and
ing, considered to be OEMs to share the new standards and require-
the father of modern ments to support the machine safety initiative.
quality control. (See Those trained were then brought alongside the
graphic.) The steps in safety team to provide support in the risk miti-
each successive PDCA gation effort.
JB Titus and Associ- cycle, and the traditional responsibilities are: Since the initiation of the machine safety pro-
ates portrays a risk Plan – establish the objectives and processes gram in 2009, the company reported zero fatali-
reduction process to necessary to deliver results in accordance with ties in 2010 and 2011. Also 69% of the major
determine if the risk is the expected output (the target or goals). findings from the global assessments have been
acceptable or requires Do – implement the plan, execute the pro- closed; 95% of the corrective action and preven-
some action for risk miti- cess, and make the changes. Collect data for tive action from fatalities have been closed.
gation. In the case study charting and analysis in the following “Check” - Sean Daswani, PE, is senior electrical engi-
here, a risk assess- and “Adjust” steps. neer, Polytron.
ment was conducted Check – study the actual results (measured
for impacted equip- and collected in “Do” above) and compare
ment. The safety team against the expected results (targets or goals
reviewed and assigned from the “Plan”) to ascertain any differences.
Go Online
risk values, which Information is what you need for the next step, n At www.controleng.com/archive see this article for more
become the “triggers” for “Adjust.” on risk mitigation for older equipment, safety implemen-
corrective action. Cour- Adjust – request corrective actions on sig- tation, safety climate change, training, and a palletizer
tesy: Polytron; produced machine safety upgrade.
nificant differences between actual and planned
with permission of JB results. Analyze the differences to determine n http://polytron.com/think-tank
Titus and Associates root causes. Determine where to apply changes n At www.controleng.com/blogs, read the Machine Safety
that will include improvement of the process or blog post:
product. When a pass through these four steps n Is OSHA okay with my ‘acceptable’ risk mitigation?
does not result in the need to improve, the scope n www.controleng.com/blogs
to which PDCA is applied may be refined to
How to make a health, safety,
and environmental plan
Making an HSE plan is more than a creating set of rules for manufacturing health,
safety, and environmental activities. Here’s what you need to know about HSE.
Allan Manzer, CSP; Jennifer Palumbo
A
health, safety, and environmental (HSE) NFPA 70e to perform the
plan is a crucial step towards mitigating install using proper PPE.
project risks, yet many companies don’t This usually means hav-
use them on every project. They may require ing to leave the job site
more time and planning up front, but the payoff and delaying the project
can be huge. work until you can find
An HSE plan is a living document, developed a qualified person with
before the project work begins using the scope of PPE. When you use the
work as a starting point. As the project evolves, plan to assess the risks
the plan is revised as the scope changes. before they begin design,
Project managers should get a detailed scope you eliminate these risks,
of work from the client; get appropriate HSE and any controls engineer
information from the client contact; distribute can do the work.
the plan with any drawing packages to the proj- This leads to the man-
ect team; review the plan during the initial kick- tra “Get it done right, the
off meeting; post and maintain the signed plan first time, without incident.” Using an HSE plan Electrocution-response
on the job site; enforce all elements of the plan allows you to assess the work hazards to com- table: at 200 milliamps, a
while on the project; inspect the job site, docu- plete the work properly, without having proj- victim will experience severe
ment and report all safety conditions; revise the ect delays due to unqualified persons or missing burns, severe muscular con-
plan if the scope of work changes; verify appro- required PPE, and without incidents or accidents. tractions, and possible heart
priate training for special job tasks for employ- The HSE plan can identify other hazards. A failure. A 100 W light bulb
ees and contract labor. Each plan has a checklist controls engineer visiting a paper mill discovered uses 833 mA. A health, safe-
to consider—eye bath locations, whether asbes- during walk-through that the mill floor had not ty, and environmental (HSE)
tos or lead is present on-site, chemicals in the been cleaned recently. Opening a charged panel plan addresses risks beyond
work area, and so on. It considers various haz- with paper dust floating could cause fire or an just electrocution. Courtesy:
ards depending on the type of work performed, arc-blast hazard. Many system installs work in Optimation
such as electrical and confined space hazards. tight spaces, around hazards, such as chemicals
Goal in initiating the plan this way is to allow the or pressurized systems.
project manager or person in charge the opportu- Among excuses for not having an HSE plan
nity to think about all different aspects of the job is that the client contact won’t know what the
throughout the life of the project. HSE requirements are and won’t want to spend
time defining them. While your specific con-
Get it done right, the first time tact may not have the answers to HSE questions,
Why promote using an HSE plan? In some most mid-size to large companies appreciate and
cases, using an HSE plan can prevent the need expect that you will have a plan in place.
for the same personal protective equipment To get client buy-in, start by asking for the
(PPE) that many choose not wear. HSE requirements for wherever the work will be
The HSE plan helps the engineer think about performed. In the proposal, consider requiring
the voltage coming into the panel he’s working HSE information as a part of the client respon- Go Online
with on-site. Under NFPA 70e, any energized sibility. Under the NFPA 70e standard, the client At www.controleng.com/
panels operating at 50 V or above require PPE. has the responsibility to provide this information archive read this article for
As a result of using the plan before the project to the contractor. Occupational Safety and Health more HSE advice.
begins, engineers are designing panels different- Administration (OSHA) also requires that if the www.optimation.us
ly. They’re designing a 480 V circuit outside of client does not provide this information, the con-
the control engineer’s panel. The control engi- tractor has the responsibility to learn these risks
neer gets the power where he needs it; and it’s at and become familiar with the hazards before Consider this...
a lower voltage that doesn’t require PPE. This is beginning work. ce
one example of how the front end loading of the - Allan Manzer, CSP, is corporate safety engi- Do those in your orga-
HSE plan for this kind of activity eliminates all neer at Optimation; Jennifer Palumbo is market- nization understand
that assessing risk is a
kinds of extra work. When you don’t think about ing communications specialist. Articles edited by
continuous process, not a
the plan before designing the panel, you don’t Mark T. Hoske, content manager, CFE Media, one-time event?
have the right people who are qualified under Control Engineering, mhoske@cfemedia.com.
inside process
Working in the
cyber security red zone
Do you have enough first responders within your company when it comes to dealing
with cyber security incidents and network violations? How can you make sure you aren’t
developing critical staffing gaps?
A
Tim Conway s I examine a growing problem security, or security responder engineering roles
across the identified critical infra- within an operations technology (OT) department.
structure sectors within the U.S., I
believe we need the 1996 movie Apply traditional management?
“Multiplicity” to become a reality. Many organizations have looked at the impact
In the movie, Michael Keaton plays Doug Kinney, these positions have on the operations environ-
the main character who is overwhelmed with his ments of an organization through traditional
responsibilities at work and home. All he can see management processes such as business impact
is an ever-growing list of things analyses, workforce planning
to do with little or no hope for initiatives, or organization pan-
success. To resolve this issue, demic planning. In these tradi-
Doug works with a scientist to tional activities, organizations
clone himself so his surrogates attempt to identify a condi-
can divide all those responsi- tion that could create an opera-
bilities and get everything done tional problem and then begin
with no one the wiser. While to identify steps to prevent the
this comedy is obviously fic- problem from occurring. These
tional, the immediate needs for traditional approaches identify
a talented, trained, and capa- operational risks as a result of
ble cyber and operations work- technology loss for a period of
force is far too real, and there time, loss of specific skill sets
‘
are individuals within the CI/ or knowledge, and potential
KR (critical infrastructure / key Red zone jobs are loss of employees necessary to
resource) sector that we defi- perform critical operations.
nitely need to duplicate. positions that are The problem facing CI/KR
While staffing needs ebb essential in performing sector red zone jobs is a mix-
and flow in all organizations ture of traditional problems
an operational
and fulfilling strategic staff- identified above and challenges
ing demands is a continu- mission in normal in the available qualified work-
ous effort, many believe there and emergency force for industries that need
’
is a real issue developing that them. The pipeline of people
conditions.
Key will impact CI/KR-essential moving into the workforce that
concepts roles. A term that was recent- have necessary skills, knowl-
ly introduced to me is “red zone jobs.” These are edge, and capabilities to perform critical red zone
Your company’s abil- positions or roles that are absolutely essential in jobs compared to the pipeline of people exiting
ity to respond to a cyber performing an operational mission in normal and those positions is not balanced. This unbalanced
violation often depends on emergency conditions. Red zone jobs across the condition seems to be worsening as the number of
the actions of a few key CI/KR sector would typically be classified as roles individuals exiting is increasing, the need across
individuals
that have real-time response requirements and per- multiple sectors is growing, and the available pro-
A few simple analysis form an essential operational or operational sup- grams or development capabilities has remained
steps can help you evaluate port role in a real-time environment. Throughout flat. This problem is unique in that entities do
your staffing situation and
the CI/KR sector, technology jobs often perform not control the process that educates, trains, and
determine a direction
system, application, network, communications, develops the necessary capabilities of candidates
P1 ● MAY 2013 CONTROL ENGINEERING ● www.controleng.com
Our safety experts talk safety.
Our operators talk control. But when it
comes to keeping our people and plant safe,
we all need to speak the same language.
YOU CAN DO THAT

Eliminate uncertainty, reduce your risk with DeltaV SIS.
Emerson’s smart safety instrumented system provides an integrated, intuitive set of engineering
tools and software that enables your team to handle configuration, alarms and device health
monitoring–while maintaining the systems separation required by IEC 61511 and 61508
standards. The DeltaV SIS system reduces your training and lifecycle costs by eliminating complex data-mapping and
multiple databases while helping to ensure that you’re meeting safety compliance. Learn more about safety processes
and best practices by downloading the Safety Lifecycle Workbook at: www.DeltaVSIS.com/workbook
The Emerson logo is a trademark and a service mark of Emerson Electric Co. © 2012 Emerson Electric Co.

inside process
until they are hired into the workforce. Therefore the number and complexity of attacks
Most companies cannot independently solve will grow, and the very complex attacks will
this issue. They can, however, influence a direc- require a knowledgeable, qualified, and capable
tion that will improve the industry overall and workforce to detect and defend the environment.
strengthen their own workforces. Many entities
have worked with traditional educational insti- Evolving job demands
tutions or specific training providers to develop We also need to discuss the growing reliance
programs that will help meet the growing needs on technology for all critical operations across
of the red zone jobs. The focus is almost always the CI/KR sector that is creating an increase in
on training content and knowledge assessment, red zone jobs. Entities across most CI/KR sectors
which is an essential first step. However, the gap would have identified a very different set of red
that remains in these approaches is the capability zone jobs 30 years ago than they would today. For
or “right fit” issue that exists as a component of example, electric utilities circa 1983, would have
all red zone jobs across the CI/KR sector. These included linemen, substation engineers, switching
companies and other entities will continue to face operators, and dispatch operators for transmission
challenges in assessing a candidate’s capabili- and distribution environments as critical roles.
ty to be successful in a red zone job or training Generation environments would have likely iden-
candidates to ensure a successful fit. To combat tified generating station control room operators,
this issue, many entities are moving to technology instrumentation and control engineers, and relay
implementation of active policy enforcement sys- engineers as critical roles.
tems or intelligent monitoring and alerting tools. Looking at these same environments in 2013,
This helps alleviate reliance on a knowledgeable, while the roles previously identified are still crit-
qualified, and capable workforce to perform these ical, they are now performed in a dramatically
processes; however, it also needs to be acknowl- different fashion, and in many cases rely on addi-
edged that adversaries are also automating and tional capabilities and roles that did not previous-
implementing intelligent tools and evasion tactics. ly exist. In addition there are now new functions
PROTECT PUMPS
DRY RUNNING • CAVITATION • BEARING FAILURE • OVERLOAD
MONITOR PUMP POWER COMPACT EASY MOUNTING

• Best Sensitivity Only 3.25" x 6.25" x 2"
• Digital Display • Starter Door • Panel
• Raceway • Wall
TWO ADJUSTABLE SET POINTS
• Relay Outputs UNIQUE RANGE FINDER SENSOR
• Adjustable Delay Timers • Works on Wide-range of Motors
• Simplifies Installation
4-20 MILLIAMP ANALOG OUTPUT
WHY MONITOR POWER INSTEAD OF JUST AMPS? PUMP POWER

VALVE CLOSING
PUMPING
POWER
AMPS
VALVE OPENING NO FLUID

No Sensitivity
Power is Linear-Equal Sensitivity For Low Loads
at Both Low and High Loads
NO LOAD FULL LOAD NO LOAD FULL LOAD
CALL NOW FOR YOUR FREE 30-DAY TRIAL 888-600-3247

WWW.LOADCONTROLS.COM

that have moved into an absolutely critical role need to be ever present and the capabilities of the
that likely were not considered all that critical 30 individuals in those roles need to be fully devel-
years ago. Consider the criticality of control cen- oped to achieve peak performance.
ters today, RTOs and ISOs, the systems and sup-
port functions for communications, and market Recommended actions
functions. The interdependencies have grown Companies and other entities can begin the
immensely, and too often individuals do not fully analysis process by looking at a few straightfor-
understand how they may impact others within the ward measures. The first step is to assess their cur-
organization. This interdependence applies across rent staff capabilities or limitations:
the CI/KR sector and companies need to begin to n Identify red zone job positions or roles with-
understand those dependencies in depth. Addi- in your facility that are essential to real-time oper-
tionally, in today’s red zone jobs that are technol- ations and operational support
ogy or automation driven, a complex dependency n Assess organizational capabilities and iden-
exists on the technology utilized throughout the tify red zone job areas for improvement
organization. Within an organization many trusts n Join in industry wide efforts to better equip
exist: trusted communication paths, trusted users, individuals currently in red zone jobs or better
trusted external organizations, and trusted appli- prepare new candidates, and
cations. As organizations identify these trusts and n Understand underlying technologies utilized
dependencies, they can identify and mitigate the by operations and the complex interdependencies
security risks more effectively. that exist within and external to the organization.
Think about what the phrase “red zone” con- These steps can help guide your efforts to fill
veys in American football: when defensive play- these critical positions, since unlike the movies, I
ers have their backs to the goal line, the situation don’t think we will have human cloning for secu-
demands peak performance because the threat is rity purposes anytime soon. ce Go Online
imminent and has to be turned back. Similarly, Tim Conway is technical director, ICS and n www.sans.org
defender roles within the CI/KR sector’s red zone SCADA for the SANS Institute.

inside process
Understanding
SIS industry standards
Process safety standards and practices are spreading from oil and gas and other
energy-related industries to broader process industry applications. Here’s basic advice
on how to make more sense of the numbers and acronyms.
S
Robert I. Williams, PE afety instrumented system (SIS) Table 1: Safety integrity levels
applications grew primarily out of the SIL PFDavg RRF
oil and gas industries, where they are
1 10-1 to 10-2 10 to 100
used to mitigate safety hazards relat-
ed to many dangerous feedstocks, 2 10-2 to 10-3 100 to 1,000
products, and processes. When applied appropri- 3 10 to 10
-3 -4
1,000 to 10,000
ately, the fundamental concepts of SIS applica- 4 10 to 10
-4 -5
10,000 to 100,000
tions are integrated within the total lifecycle of the
overall safety system. Understanding these sys- Part of the design process is considering many
tems involves unraveling the sometimes arcane what-if scenarios that examine what happens if
language of safety engineers with standards num- various components fail. A safety integrity level
bers and many acronyms. (SIL) is a performance measure which tries to
An SIS provides an integrated approach to com- quantify the probability of a specific SIF failing
plete safety loops, as shown in Figure 1. Such a to perform its required function when called upon,
loop includes a sensor, logic solver, and final con- known as the probability of failure on demand
trol element. The SIS system shuts down a process (PFD). Whereas a DCS is performing process con-
plant or part of a plant when needed for safety, but trol functions continually while the plant is run-
keeps the plant running safely when devices fail. ning, the SIS is dormant by design until required
to perform a safe shutdown function. Table 1 lists
What is a safety function? four SIL levels and their related PFDs as defined
Safety instrumented functions (SIFs) are by IEC 61508 and IEC 61511. All standards are
actions taken by a SIS to shut down the process not necessarily the same. For example, ANSI/ISA-
plant safely. Each identified SIF consists of a set S84.01-1996 recognizes only three SILs.
of actions to protect against a specific hazard. A Techniques to establish the required SIL for a
process plant SIS therefore consists of a num- SIF in a SIS are defined in the relevant industry
ber of SIFs which are listed in the process hazard standards. (Some are listed in the online resources
analysis (PHA) report. for this article.) SIL 4 is the highest level of safety
integrity while SIL 1 is the lowest.
The risk reduction factor (RRF) for a SIF is the
mathematical inverse of the PFDavg for that SIF.
It represents a number corresponding to the factor
that the SIF reduces the likelihood of the hazard-
ous event that the SIF intended to prevent.
Probability of failure on demand (PFD) is the
probability that a SIF designed to protect a pro-
cess plant will fail to shut down the plant safely
when the hazard shutdown condition occurs. In
other words, the safety function fails to do its job
when called upon.
Figure 1. An individual SIS includes three items: sensor, logic solver, and
final control element. It needs to be able to perform its function independently Safety lifecycle
and not depend on the basic process control system. Courtesy: Emerson The safety lifecycle, as defined by IEC 61508
Process Management and ANSI/ISA-S84.01, structurally defines a SIS
THINK
TRICONEX
Thinking Safety? Think Triconex.

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

© Copyright 2013. All rights reserved. Invensys, the Invensys logo, Foxboro and Triconex are trademarks of Invensys plc, its subsidiaries or affiliates.
All other brands and product names may be trademarks of their respective owners.
inside process
‘ Functional
safety is just
development from its initial conceptual design
through to its final decommissioning, as follows:
1. Conceptual design
then it has to be taken into account in an appro-
priate manner in the design. Functional safety is
just one method of dealing with hazards, and other
one method of 2. Hazard and risk analysis PHA (HAZOP) means for their elimination or reduction, such as
3. Safety requirements specification inherent safety through design, are of primary
dealing with 4. System architecture and detailed importance.
hazards, and engineering IEC 61508 applies to safety-related systems
5. Application programming when one or more of such systems incorporate
other means for 6. System production electrical and/or electronic and/or programmable
7. System integration electronic (E/E/PE) devices. It covers possible
their elimination 8. Factory acceptance tests (FAT) hazards caused by failure of the safety functions
or reduction, 9. System installation and commissioning to be performed by the E/E/PE safety-related sys-
10. Safety system validation—site acceptance tems, as distinct from hazards arising from the
such as tests (SAT) E/E/PE equipment itself. It is generically based
inherent safety 11. Operation and maintenance plan and applicable to all E/E/PE safety-related sys-
12. System change management tems irrespective of the application.
through design, 13. Decommissioning, and The underlying assumptions of the standards
are of primary 14. Information and documentation recognize that the consequences of failure could
’
requirements. have serious economic implications. In such cases
importance. the standard could be used to specify any E/E/PE
Generally, the significant hazards for equip- safety-related system used for the protection of
ment and any associated control systems have to equipment or product. The scope of IEC 61508-1
be identified by the specifier or developer via a goes into more detail.
hazard analysis. The analysis identifies whether The range of E/E/PE safety-related systems to
functional safety is necessary to ensure adequate which IEC 61508 can be applied includes:
protection against each significant hazard. If so, n Emergency shutdown systems

n Fire and gas systems
n Turbine control
n Gas burner management
n Crane automatic safe-load indicators
n Guard interlocking and emergency stopping
systems for machinery
n Railway signaling systems, and
n Variable speed motor drives used to restrict
speed as a means of protection.
Relevant means of implementing safety func-

tions include electromechanical relays (electrical), Figure 2. Information from SISs can be sent up to a larger control network
nonprogrammable solid-state electronics (electron- for alarms or data collection, but they need to retain the ability to carry out
ic), and programmable electronics. Programmable their specific safety assignment independently. Courtesy: Emerson Process
electronic safety-related systems typically incorpo- Management
rate programmable controllers, programmable logic
controllers, microprocessors, application specific implemented, it is essential to consider the system
integrated circuits, or other programmable devices as a whole. The physical extent of an E/E/PE safe-
which could include smart devices such as sensors, ty-related system is solely determined by the safe- Go Online
transmitters, and actuators. ty function. n Detail on IEC safety
In every case, the standard applies to the entire Working through the entire safety lifecycle is a standards
E/E/PE safety-related system. That could encom- major undertaking, but it is a process critical to the n www.iec.ch/functional-
pass, for example, a sensor, through control logic safety of people, property, and environment. ce safety/explained/page1.htm
and communication systems, to final actuator, Robert I. Williams, PE, is instrumentation and n www.isa.org
including any critical actions of a human operator. control systems manager at Brinderson, Costa n www.isa-84.com
For safety functions to be effectively specified and Mesa, Calif.
New Multi-Channel Contact Closures

Convert Up to 10 Dry Contacts Over Fiber
Features/Benefits:
• Modular design
transmits 2-10 signals
• Electrical isolation
• Reliable EMI, RFI free
communications
• Cost effective, low
maintenance
• Mounts on standard
35mm DIN-Rail
Up to 10 Dry Contact Inputs

(switches, relays, etc.) Applications:
• Remote transmission
1 FIBER, SINGLE OR MULTI-MODE over long distances
• Transmission through
hazardous areas
Call us today for
• Alarm event triggering
complete information.
Up to 10 Form C Relay Outputs
We deliver critical measurements Tel: +1 512 434 2900 Toll-Free: +1 800 880 9333 www.ultra-nspi.com

UE-13-12-mccc ad 7x4.75.indd 1 3/27/12 2:00 PM
inside process
Innovative energy
management strategies
help a Maine paper mill
stay competitive
When changing fuel prices forced the mill to reevaluate
its generating capacity, it added more sophisticated
wmonitoring and control capabilities.
Hudson Gilmer
L
ike much of the rest of Maine, tor to provide for the thermal and electri-
the town of Rumford is well cal needs of the mill. The generator can
One Series known for the beauty of its put out as much as 100 MW, or roughly
Transmitter-Switch natural surroundings. But for enough to power 100,000 homes.
more than a century Rumford For the last decade or so, the Rum-
for Process Monitoring has also played host to one of the larg- ford mill was facing a crisis because the
est paper mills in the Northeast, churn- primary fuel for the generator was coal,
• Monitors pressure or temperature ing out as much as 550,000 tons of paper and the price of coal was steadily rising.
• Provides analog 4-20 mA signal and 125,000 tons of pulp annually. According to the U.S. Energy Informa-
• Programmable switching capability NewPage, which owns the Rumford tion Administration, the market price
• Smart self-diagnostics facility and is among the leading domestic of coal rose substantially from 2000 to
• SIL 2 suitable producers of printing paper and specialty 2010, and transportation costs drove the
paper, is working in a highly competitive price even higher in Maine.
and energy-intensive business. Through “The problem is transportation to get
For more information on the creative energy management strategies coal from, say, West Virginia up here to
One Series, and the intelligent use of forecasting data, western Maine relies on diesel, rail, ship,
NewPage has transformed the Rumford truck, or any other transportation mode,”
call United Electric at mill’s energy costs from a burden to a explains Rick Abradi, head of energy
617-923-6977 source of competitive advantage. management at Rumford. Faced with
or visit us at increasing coal prices which jeopardized
Need to improve the mill’s competitiveness, NewPage
www.ueonline.com
Producing paper and pulp is an ener- assigned Abradi the challenge of devel-
gy-intensive operation, and the Rumford oping a strategy to bring overall energy
mill features three boilers and a genera- costs under control.
United Electric Controls The Rumford Paper Mill has seen its energy costs reduced thanks to aggressive
180 Dexter Avenue energy management strategies. Courtesy: Genscape
Watertown, MA 02471-9143
Using wireless here and there is one thing.
But using it across my entire operation?
There’s no one I could trust to do that.
See more, do more and be more profitable with the most trusted partner in wireless — Emerson.
Emerson is your proven partner with Smart Wireless in more customer sites and with more operating
hours than anyone else in the process industry. Smart Wireless has the widest range of technologies
to expand your vision into more places across your operations. And its self-organizing mesh network
delivers the highest reliability available. It is simply the most intelligent, secure and cost-effective
operation-wide wireless option available. See how Smart Wireless can empower your bottom line
at EmersonProcess.com/SmartWireless
The Emerson logo is a trademark and a service mark of Emerson Electric Co. © 2012 Emerson Electric Co.

inside process
‘ The problem
is transportation
Breaking down the problem
Abradi started by created three broad “buck-
ets” for energy management strategies: demand,
market prices and availability, reducing the depen-
dence on any single supplier or fuel type.
to get coal procurement, and conversion. Demand would Using forecasts

cover most approaches people identify with ener- With the fuel sourcing problem solved, the
from, say, West gy efficiency, like adding insulation and replac- next challenge was optimizing conversion. A big
Virginia up here ing light bulbs in a house. On an industrial scale, part of this is making a determination of when and
it generally means finding ways to produce more at what level to run the generator. While the Rum-
to western Maine pulp and paper with less steam and electricity. ford mill’s generator is more than capable of meet-
relies on diesel, A bigger cost impact, though, came from pro- ing its own needs, the plant sits within the region
curement—finding a way to diversify, away from covered by electric utility Maine Central Power,
rail, ship, truck, expensive coal to cheaper fuel sources. Despite and can just as easily draw power from the grid.
or any other being able to use some of its own waste products
as fuel, the Rumford mill’s generator still relied on
When local power prices fall below what New-
Page pays for generation costs, the plant can scale
transportation coal as the largest fuel source for the boilers. back its generator and instead draw from the grid.
’
With prices rising, diversification was the key With so much excess generating capacity,
mode. to ensuring some measure of cost control. The the mill can also export power out onto the grid.
mill operates two circulating fluidized bed boil- When demand on the grid is high and prices rise
ers that suspend fuel in jets of air. The Rumford far enough above the cost point, NewPage is able
mill is able to burn readily available biomass from to take advantage of the cost differential. The big-
wood chips and a fuel called TDF—tire-derived gest difficulty with trying to take advantage of the
fuel. Increasing the volume of these alternative rise and fall of electricity prices is that it can be
Go Online fuel sources allowed Abradi to reduce coal’s share difficult to respond quickly to changes.
of total fuel consumption. Barring any breakdowns, operators have a
n www.genscape.com
In addition, NewPage gained greater opera- good idea how much power the mill will need,
n www.newpagecorp.com
tional flexibility to adjust fuel sources based on but it still takes as much as 15 to 20 minutes to
THE DIFFERENCE BETWEEN OPERATION

AND CONTROL
�nly Winsted control room consoles combine the con�guration �e�ibility you need with
the robust performance you demand. From modular to custom, Winsted consoles offer an
array of options and modi�cations that optimi�e aesthetics, function and ergonomics.
Bring your ultimate control environment to life with our FREE WELS 3D console design
software. Try it now: winsted.com/wels
WEB: winsted.com • EMAIL: info@winsted.com • TEL: 800.447.2257 • FAX: 800.421.3839
POWERED BY MULTI-TOUCH
A Better
Visualization
change output from the generator, so any
mistakes or delay can mean a missed
es are really starting to escalate around
the region.” For HMIs
opportunity. This can be an even bigger Easy as it might seem to avoid
problem for companies that only have the demand charges with an on-site gener-
option of cutting back operations. ator, making guesses about when a new
peak will occur comes along with very
Answers in power analytics real costs. Each hour that the generator
Since the early 2000s, NewPage runs during a “false alarm” is an hour’s
has turned to the energy information worth of expensive fuel being burned.
firm Genscape for daily forecasts of Guess wrong too often and these costs
local power prices and regional power can begin to pile up. Much the same
demand. Genscape’s teams of ana- can be said when production is cur-
lysts and meteorologists provide high- tailed to lower a business’s usage.
ly accurate forecasting reports using a
combination of neural network models, Lessons for the rest of us
proprietary monitor data, and fundamen- Most industrial plants don’t have a 100
tal models. MW generator and the ability to sell sur-
When a morning forecast from Gen- plus power to the grid, but that doesn’t
scape calls for high real-time prices later mean they can’t benefit from the same
in the day, the control room operators get energy management strategies employed
the advanced notice to ramp up the gen- by NewPage.
erator and sell surplus power to the grid Demand charges are an unfortunate
at a handsome profit. fact of life for every industrial facility,
“Sometimes when the price unexpect- and reducing load during forecasted peak
edly ramps up, we don’t see it right away. demand periods can go a long way toward
And due to the nature of our equipment reducing overall energy costs. Similar-
we cannot react instantly,” said Abradi. ly, economic demand response programs
 Enhanced Displays
“So having a heads-up on that, the opera- provide a way for industrial facilities with
tors can anticipate that move.” the flexibility to shift or curtail their load
to sell power onto the grid during periods • Clarity, Accuracy And Simplicity
Casting a small shadow of high-forecasted prices without requir-
There’s another use of these types ing an on-site generator.
Enabled Visibility
 • Faster, Better And Intelligent
of power forecasts that can also have System operators such as ISO-New
an impact on overall energy costs, England and PJM offer lucrative eco-
namely, minimizing demand charg- nomic demand response programs which
es. Every utility imposes some sort reward businesses for reducing their elec-
Optimized Visualization
 • Smart And Intelligent Building
of charge for using its grid, fees that tricity usage at times of high prices. Not
cover everything from maintenance to only do participants avoid paying for
expansions and upgrades. Generally, power during high-price periods, they
utilities charge a fixed amount, distrib- are actually paid the prevailing wholesale
• Building Automation Systems
uted among customers based on their price for every kilowatt-hour they reduce • Building Management Systems
proportion of total usage when demand below their baseline level. • Energy Management Systems
peaks during a given month. By using a forecasting service to pro-
NewPage has largely managed to vide accurate predictions of the days and • Building Control Systems
reduce its demand charges significant- hours of highest real-time prices, a partic-
ly by using monthly forecasts to deter- ipant can maximize the financial benefit
mine which days are likely to result in from these programs and provide a ben-
a usage peak and running the generator efit to the grid at the same time.
Innovation That Drives Results –
to reduce or eliminate net usage from NewPage’s Rumford mill illus-
the grid during those periods. trates the kind of savings that can be The Time to Act Is Now
“(Before these reports) it was me achieved through comprehensive ener-
and my fancy Excel spreadsheet I built gy management and accurate forecast
on the back of an envelope, looking at data. In a highly competitive industry
the National Weather Service weather like paper, even modest reductions in
forecast,” remembers Abradi. “Before energy costs can mean a major swing
that we didn’t worry about it much in profitability. ce
because the cost penalty was relative- Hudson Gilmer is vice president of
American Industrial Systems, Inc. (AIS)
ly minor, but these transmission charg- commercial markets at Genscape. 1768 McGaw Ave. • Irvine, CA 92614
www.controleng.com ● CONTROL ENGINEERING MAY 2013 ● P12
1-888-485-6688 • www.aispro.com
software &
PRODUCTS
Wireless non-contact switch offers top
sensing or side sensing, actuating in the
presence of magnets
Honeywell’s Limitless non-contact switch actuates
based on the presence or absence of magnets installed
on a customer’s device. The battery-operated device
allows customers to choose either top or side sensing
which can reduce installation and maintenance costs
compared to traditional wired switches. Instead of a
lever, button, or wobble stick, this device can be actu-
ated with a magnet, simplifying use in tight areas often
found in machine tools, packaging machinery, lifts, and
Industrial safety light industrial machines, or in applications where mechani-
curtain protects fingers and cal actuators are not feasible.
hands while continuously Honeywell
monitoring itself for faults www.honeywell.com
Ifm’s low-profile safety light cur- Input #201 at www.controleng.com/information
tains provide finger, hand, and body

protection in a variety of industrial
applications. These type 4 light cur-
tains provide a multi-beam barrier of Programming software reduces engineering time, speeds
infrared light in front of a hazardous development and commissioning
area. If any of the beams are blocked Siemens is characterizing its Simatic Step 7 Professional V12 programming
by an object, such as a finger or a software as its most comprehensive engineering software. The new platform is
hand, the light curtain sends a signal designed to configure and program all Simatic controllers. Simatic WinCC Basic
to the machine to place it in a safe is also included for simple visualization tasks with Simatic Basic Panels. Step 7
state. Light curtains in this series are V12 software serves every phase of the production life
offered in protective heights of 160 cycle, reducing engineering times thanks to innova-
to 1,510 mm in increments of 150 tive programming language innovations, integrated
mm. The light curtain’s slim housing functions, and graphical configuration. This supports
design measures only 28 x 30 mm that fast commissioning with efficient error localization,
fits easily in an application for less integrated system diagnostics, real-time trace, and
intrusive mounting. Redundant safety- high-performance online functions. The new plat-
rated solid-state outputs ensure fast form connects to the Siemens Totally Integrated
response time. Bright LEDs indicate Automation Portal offering programming
power, system status and fault condi- transparency, intelligent user naviga-
tions. tion, and straightforward workflows.
ifm efector inc. Siemens
www.ifm.com/us www.usa.siemens.com
Input #200 at www.controleng.com/information Input #202 at www.controleng.com/information
Compact Differential Pressure Flowmeter Family uses

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

Servo drive family offers a variety of networking
options to simplify integration
The CMMP-AS servo drive family from Festo offers EtherNet/IP, Profinet, EtherCat,
Profibus, and DeviceNet connectivity. The drive comes with optional slide-in network
cards for all supported platforms, which allows OEMs to customize the drive to meet
specific application needs and enables easy integration with various control architectures.
The CMMP-AS servo drive offers an optional slide card with Safe Torque Off (STO)
functionality for increased productivity and personnel safety. With the safe-off capability,
tasks such as machine setup, cleaning, removal of jams, and other typical maintenance
work that previously required power-down conditions can now be accomplished without
removing power from the entire machine.
Festo
www.festo.us
Wash-down ac motors designed for rugged Two-hand safety device allows height
environments like water treatment and adjustability, providing ideal ergonomics
machine shops for multiple operators
Omega’s WSS stainless steel ac OpGuard is a two-hand control that allows operators to
motors are constructed adjust its height instantly. OpGuard reduces workers’ strains
with doubled-dipped by adding a flexible arm to the two-hand controls, enabling
polyester insulated operations to reposition their controls to an ergonomic
windings, a corrosion- height. The arm has 11 in. of vertical adjustment, enabling
resistant rotor and the device to accommodate users of all heights. Additional
double-lip seals plus features include availability with electric or pneumatic but-
V-ring shaft slingers. tons, and under-counter or wall surface mounting options.
These 3-phase indus- OpGuard has easy integration
trial grade wash-down with machine controls and
duty motors come in sizes is built of durable steel and
from 1/3 to 2 hp at 1,800 rpm. Other features include a die-cast aluminum. Adjust-
TEFC enclosure, Class F insulation, and O-rings installed able arms can be purchased
on the end bells to eliminate moisture. They are designed independently with brackets
for environments where they could get wet, such as water to connect existing anti-tie
treatment, unprotected outdoor installations, environmen- down devices.
tal control, and machine shops. Easton Lean Tools
Omega Engineering www.eastonleantools.com
www.omega.com Input #206 at www.controleng.com/
Input #205 at www.controleng.com/information information
Frame light grids detect and count parts

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

software &
PRODUCTS
Four-channel sound and vibration data Compact ac drive for
acquisition module for IEPE sensors open- and closed-loop
Data Translation, Inc., has released its DT9839 USB- applications up to 30 hp
powered module for sound and vibration measurements. Rockwell Automation’s Allen-
The unit features a four-channel, 16-bit delta-sigma Bradley PowerFlex 525 ac drive
analog-to-digital converter (ADC) with a nominal input to help machine builders and end
range of ±2.5 V, and sampling rates up to 52.7 kHz users simplify equipment de-
per channel. Applications that require accelerometer, sign, operation, installation, and
vibration, noise, or sonar measurements often use IEPE configuration. The drive family
sensors. IEPE conditioning is built-in to the analog features a modular design in
circuitry of the DT9839, providing an excitation current power ranges from 0.5 to 30
source and ac or dc coupling. Data Translation devices hp (0.4 to 22 kW) at 100 to 600
include comprehensive driver and software support, and V input. Embedded EtherNet/
interface tools for National IP, safety, USB programming,
Instrument’s LabVIEW and energy savings, and a variety of motor
MathWorks MATLAB pro- control options are designed for machine-level and
grammers. stand-alone applications or simple system integration.
Data Translation Suitable for a wide range of applications, including
www.datatranslation.com conveyors, material handling, compressors, fans and
Input #208 at www.controleng.com/ pumps, the PowerFlex 525 AC drive provides a vari-
information ety of motor control options to accommodate open-
and closed-loop applications.
Rockwell Automation
www.rockwellautomation.com
PRODUCT & LITERATURE SHOWCASE

Acromag Signal Conditioners & Ethernet I/O
5B / 7B / 8B Signal Conditioning Solutions We have the experience to
More Models, More Protection, Less Noise, Lower Cost help you solve your process
monitoring and control
580+ different 5B, 7B, and 8B signal conditioners provide accurate, isolated Instrument challenges.
Class® performance to ensure the integrity of your industrial automation, data acquisition,
process control, and quality assurance systems. Custom modules available. Get our new product guide today.
• NEW! USB Transmitters & Ethernet I/O
• ± 0.03 to ± 0.05% Accuracy • ANSI/IEEE C37.90.1 Transient Protection
• 4-20mA Isolators and Splitters
• 1500Vrms Isolation • 3- to 6-Pole Low-Pass Filtering • Ethernet, Modbus, Profibus Remote I/O
• Up to 240Vrms Input Protection • -40°C to +85°C Operating Temperature
• CSA C/US Certified & ATEX Compliant
(5B, 7B) 877-295-7057 www.acromag.com
■
• C-UL-US Listed (8B) Input #101 at www.controleng.com/information
See the latest Control Engineering

Webcasts on-demand:
Call 800-444-7644 or visit www.dataforth.com • Safety Integration • Wireless Technology
Input #100 at www.controleng.com/information • Arc Flash University • Ethernet Technology
Place your Classified, Literature

Showcase or Product Mart ads today!
Contact: Iris Seibert at 858-270-3753 or
ISeibert@CFEMedia.com
Visit www.controleng.com/webcast

Control Engineering
www.controleng.com
AD INDEX
Request more information about products and advertisers in this issue by using the Advertising Sales Offices
http://controleng.com/information link and reader service number located near each. (GA, MI, AL, FL)
If you’re reading the digital edition, the link will be live. When you contact a company directly, Patrick Lynch
please let them know you read about them in Control Engineering. (630) 571-4070 x2210
PLynch@CFEmedia.com
Company Page# RSN Web
AR, IL, IN, IA, KS, KY, LA, MN, MO,
ABB Inc - Safety Systems. . . . 27. . . . . . . 15 . . . . . www.abb.com/highintegritysafety MS, NE, ND, OK, OH, SD, TX, WI,
Allied Electronics . . . . . . . . . . 11 . . . . . . . . 8 . . . . . . www.alliedelec.com Central Canada
AutomationDirect . . . . . . . . . . C2 . . . . . . . 1 . . . . . . www.automationdirect.com Bailey Rice
Baldor Electric Company . . . . 9. . . . . . . . . 6 . . . . . . www.baldor.com (630) 571-4070 x2206
Beckhoff Automation LLC. . . . 38. . . . . . . 21 . . . . . www.beckhoff.com BRice@CFEMedia.com
Control Engineering AK, AZ, CA, CO, HI, ID, MT,
Case Study Database . . . . . . . 45. . . . . . . . . . . . . . . www.controleng.com/csd NV, NM, OR, UT, WA, WY,
Control Engineering Western Canada
E-Newsletters . . . . . . . . . . . . . 39. . . . . . . . . . . . . . . www.controleng.com/newsletters Iris Seibert
CSA Group . . . . . . . . . . . . . . . 29. . . . . . . 16 . . . . . www.csagroup.org (858) 270-3753
Danfoss . . . . . . . . . . . . . . . . . . 1. . . . . . . . . 2 . . . . . . www.envisioneering.danfoss.com/industry ISeibert@CFEMedia.com
Dataforth Corp . . . . . . . . . . . . 10 . . . . . . . . 7 . . . . . . www.dataforth.com
CT, DE, MD, ME, MA, NC,
Eaton Corp. . . . . . . . . . . . . . . . 32. . . . . . . 17 . . . . . www.eaton.com NH, NY, NJ, PA, RI, SC, VA,
Festo Corporation . . . . . . . . . . 34. . . . . . . 36 . . . . . www.festo.com VT, WV, DC, Eastern Canada
Fluke Corp . . . . . . . . . . . . . . . . 21. . . . . . . 12 . . . . . www.fluke.com Julie Timbol
HELUKABEL . . . . . . . . . . . . . . 35. . . . . . . 18 . . . . . www.helukabel.com (978) 929-9495
ITSENCLOSURES . . . . . . . . . . 17. . . . . . . 10 . . . . . www.itsenclosures.com JTimbol@CFEMedia.com
MathWorks . . . . . . . . . . . . . . . 15. . . . . . . . 9 . . . . . . www.mathworks.com/accelerate
Mitsubishi Electric
Automation Inc . . . . . . . . . . . . 19 . . . . . . . 11 . . . . . www.meau.com CFE Media Contributor
Moxa Technologies . . . . . . . . . 3. . . . . . . . . 3 . . . . . . www.moxa.com Guidelines Overview
National Instruments . . . . . . . 7. . . . . . . . . 5 . . . . . . www.ni.com Content For Engineers. That’s what CFE
Neuroblast, Inc.. . . . . . . . . . . . 36. . . . . . . 19 . . . . . www.neuroblast.net/custom Media stands for, and what CFE Media is all
about – engineers sharing with their peers.
Phoenix Contact . . . . . . . . . . . 23. . . . . . . 13 . . . . . www.phoenixcontact.com/twe We welcome content submissions for all
PI North America. . . . . . . . . . . 4. . . . . . . . . 4 . . . . . . www.us.profinet.com interested parties in engineering. We will use
those materials online, on our website, in
PR electronics . . . . . . . . . . . . . 58. . . . . . . 22 . . . . . www.prelectronics.com print and in newsletters to keep engineers
Sealevel Systems Inc . . . . . . . 44. . . . . . . 23 . . . . . www.sealevel.com informed about the products, solutions and
industry trends.
SEW Eurodrive Inc . . . . . . . . . C4 . . . . . . 35 . . . . . www.seweurodrive.com
www.controleng.com/contribute explains
Siemens Industry Inc . . . . . . . C1, 25 . . . 14 . . . . . www.sea.siemens.com how to submit press releases, products,
Solutions for Engineers . . . . . 53. . . . . . . . . . . . . . . www.ControlEng.com images and graphics, bylined feature articles,
case studies, white papers, and other media.
Turck Inc. . . . . . . . . . . . . . . . . . 37. . . . . . . 20 . . . . . www.turck.com * Content should focus on helping engi-
Yaskawa America, Inc . . . . . . . C3 . . . . . . 34 . . . . . www.yaskawa.com neers solve problems. Articles that are com-
mercial in nature or that are critical of other
products or organizations will be rejected.
Inside Process (Technology discussions and comparative
tables may be accepted if non-promotional
American Industrial and if contributor corroborates information
Systems (AIS) . . . . . . . . . . . . . P12. . . . . . 33 . . . . . www.aispro.com with sources cited.)
Emerson Process * If the content meets criteria noted in
Management . . . . . . . . . . . . . . P2. . . . . . . 24 . . . . . www.DeltaVSIS.com/workbook guidelines, expect to see it first on our Web-
sites. Content for our e-newsletters comes
Emerson Process Management from content already available on our Web-
Rosemount Measurement . . . . . P10. . . . . . 31 . . . . . www.EmersonProcess.com/SmartWireless sites. All content for print also will be online.
Invensys Operations All content that appears in our print maga-
Management . . . . . . . . . . . . . P6. . . . . . . 27 . . . . . www.iom.invensys.com/thinktriconex zines will appear as space permits, and we
will indicate in print if more content from that
Load Controls Inc.. . . . . . . . . . P3. . . . . . . 25 . . . . . WWW.LOADCONTROLS.COM article is available online.
RGB Spectrum . . . . . . . . . . . . P7. . . . . . . 28 . . . . . www.rgb.com * Deadlines for feature articles intended for
the print magazines are at least two months in
Ultra Electronics, NSPI . . . . . . P8. . . . . . . 29 . . . . . www.ultra-nspi.com advance of the publication date. Again, it is best
to discuss all feature articles with the appropri-
United Electric Controls . . . . . P9. . . . . . . 30 . . . . . www.ueonline.com
ate content manager prior to submission.
Winsted Corporation . . . . . . . P11 . . . . . . 32 . . . . . www.winsted.com Learn more at:
www.controleng.com/contribute
Yokogawa . . . . . . . . . . . . . . . . P4. . . . . . . 26 . . . . . www.utadvanced.com

back to
BASICS
Simulators use math to create
virtual processes
Complex sets of equations can help designers of processes, objects, or control
systems experiment and test solutions without prototypes.
Peter Welander Imagine these situations: profitable, reliable, and safest design,” says Rafael
A designer creates a model of an automo- Coronel, global business manager, engineering
tive enclosure on a computer. The computer gen- effectiveness for Honeywell Process Management.
erates code for a machining center to make the “Estimates suggest that on-site design changes
item without any additional programming. made during commissioning constitute 7% of the
An engineer creates a new chemical pro- capital cost of a project. Simulation enables compa-
cessing unit for a plant that will make a new nies to evaluate the impact of their design decisions
product from an existing feedstock. When the earlier in the project.”
new unit is built, it performs exactly as expected. Simulation does not stop when the plant is
To analyze a piping failure, an engineer
‘
built. “We characterize it as plant lifecycle simu-
uses a combination of finite element analysis lation,” says Joseph McMullen, SimSci-Esscor
An ideal would
(FEA) and computational fluid dynamics (CFD) simulation software product marketing manager
be that I do every- to identify stresses caused by flowing materials at Invensys Operations Management. “It starts in
that weakened a welded joint. the design phase with conceptual engineering. In
thing in simula- These are possible because of simulation pro- the operating phase we look at start-up and shut
tion, all the steps grams that use complex mathematical processes down, DCS logic, etc. Then we optimize, but
to create virtual representations of actual objects since things change in a process, you eventually
along the way. I or processes. Real life is reduced to mathemati- come back to the start again.”
then produce one cal relationships expressed in different types of
equations. There are dozens of kinds of simula- Other kinds of math
test prototype, and tors because there are so many applications and While the systems discussed so far depend on
it works, first time, requirements. Typically, each uses one type of ordinary differential equations, FEA and CFD
mathematical function, which makes a given use partial differential equations to make differ-
exactly as we de- platform suited to a specific type of analysis. ent and often more complex calculations of fluid
signed it. That’s the Tony Lennon, industry marketing manager for behavior or stresses in a structural component.
industrial automation at MathWorks, describes However, this capability comes at a cost.
’
whole idea. Simulink as a broadly applicable platform for The more complex the calculations, the more
many types of systems. “We can model any kind computing power and number-crunching time
of dynamical system, anything that’s described is required. The same applies to model fidelity.
by a differential equation,” he says. “The math- Your ability to model a process may depend on
ematics underlying Simulink deals with differen- determining how much product is going to flow
tial equations. This environment mathematically through a specific valve under various condi-
expresses different types of systems, so it opens tions. Perhaps it’s enough to know the flow at
many possibilities. You can do thermodynamic a given pressure. Or, you may need to know a
systems, mechanical systems, hydraulic systems, detailed picture of turbulences and a cross-sec-
electrical systems, and you can approach a prob- tional flow profile as the liquid moves into the
lem from a multi-domain point of view. Seldom next segment of pipe. These are much different
today do you only have one kind of system.” pictures and will require different methods.
Go Online Other platforms are more specifically suited to Ultimately, simulation aims at designing or
particular applications, such as chemical process- testing something without actually building it.
For more information, ing. Most companies that provide large-scale DCSs As Lennon summarizes it, “An ideal would be
visit: also offer a simulation platform that works with the that I do everything in simulation, all the steps
www.honeywellprocess.com control system. For example, Honeywell Process along the way. I then produce one test prototype,
http://iom.invensys.com Solutions has its UniSim Design suite to help users and it works, first time, exactly as we designed it.
www.mathworks.com design and optimize process units before they’re That’s the whole idea.” ce
built. “Engineers can rapidly evaluate the most Peter Welander, pwelander@cfemedia.com
NOTEWORTHY
When our engineers work on a motion project with you, they share everything that’s in their
heads. Sometimes that means turning over 100 pages of notes, formulas and drawings. Other
times, it’s simply having straight forward conversations.
At the same time, Yaskawa customers share their proprietary knowledge because they can trust
us. Because we give their challenges a lot of thought. Because when they talk to us, they know
we are on their side.
Trusting the guys across the table from you with your most important product secrets.
That’s noteworthy.
YA S K A W A A M E R I C A , I N C .
DRIVES & MOTION DIVISION
1 - 8 0 0 - YA S K A W A YA S K A W A . C O M
Follow us: For more info:

http://Ez.com/yai469
©2013 Yaskawa America Inc.

We’re Easy!
If you think that adding functionality to your
fieldbus system requires an engineer who
speaks C# or C++, let us show you the easy
way. With our VFD and solution modules, you
can dramatically reduce startup time for gantries,

cranes, hoists, conveyors, turntables, and storage
retrieval systems. Simply enter your parameters.

Zero programming required! And, since our
gateways speak your language, you can even
keep your existing PLC and fieldbus. Wow!
seweurodrive.com / 864-439-7537

Control Engineering Magazine

Caricato da

Informazioni sul documento

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Control Engineering Magazine

Caricato da

Copyright:

Formati disponibili

www.controleng.

H0-CTRIO2 (up to 250 kHz)

Cut-to-length application uses high-speed output

H0-CTRIO2 High Speed Counter I/O Module fits into an Motor

count reset/inhibit/capture or home search Cutter interface

• Two conﬁgurable high-speed outputs or one channel

or clockwise (CW) and counter-clockwise (CCW) cut to length

From simple to complex applications

Envision the possibilities at envisioneering.danfoss.com/industry

46 Machine vision speed, quality, innovation

50 Step-motor-based systems stay competitive

54 The industrial Internet of Things

59 Safety: Risk management

2 ● MAY 2013 CONTROL ENGINEERING ● www.controleng.com

The Era of Scalable 10GbE

Optimize Your Network Infrastructure with Scalable Edge-to-Core

Industrial Core Switches

Moxa Americas, Inc.

GE Appliance Park: Louisville, Kentucky

To learn more, read the complete

P1 Working in the cyber security red zone

P5 Understanding SIS industry standards

P9 Innovative energy management strategies

PRODUCT EXCLUSIVE departments

10 Product Exclusive 33 Machine Safety

12 Tech Update 80 Back to Basics

www.controleng.com ● CONTROL ENGINEERING MAY 2013 ● 5

Looking for online

Connect with us!

More learning, less surfing

Point, click, watch  Electronic newsletters

6 ● MAY 2013 CONTROL ENGINEERING ● www.controleng.com

National, personal Brittany Merchut, Content Specialist

For almost 100 years, Baldor Electric Company • Energy Efficient

Scan to watch a video

10 ● MAY 2013 CONTROL ENGINEERING

We make it easy to find the parts

Explore! sy website tools

Software needed, costs

Buying PLC programming

12 ● MAY 2013 CONTROL ENGINEERING ● www.controleng.com

on tools and components, and

Use SiMScape with SiMulink

16 ● MAY 2013 CONTROL ENGINEERING ● www.controleng.com

• Industry-leading 2500Hz speed frequency response

NEW MR-J4 Servo System

input #11 at www.controleng.com/information

• Rated CAT III 1000 V/ CAT IV 600 V

• The only completely sealed, drip

• Loaded with functions to make

Watch how ScopeMeter was created:

input #12 at www.controleng.com/information

Safety? Naturally Integrated!

Answers for industry.

ABB Process Automation Division

Machines, PLCs mobile

SmartWire-DT tion process, by enabling remote main-

Incorporating functional safety

U.S. drives global

Shown: Motorola Droid Razr Maxx HD

Custom Control Algorithms

36 ● MAY 2013 CONTROL ENGINEERING ● www.controleng.com

TU-1300 44.0513.07 TURCKMan Ad_1-3_ConEng.indd 1 4/8/13 10:21 AM

said. After completion of the Siemens’

Point, click, watch Electronic newsletters