controldesign.com
Despite differences in their approaches
to problem-solving, older and younger
engineers begin to appreciate each
others’ skill sets and methods
CONTROLLER
ROOTS
Look to the OS for
Performance Upgrades
Improving
MOTOR
EFFICIENCY
PANEL
BUILDER
MARCH 2014
Best Pracices
CD1403_Cover.indd 1
3/11/14 4:43 PM
CD1403_FPA.indd 2
3/7/14 1:21 PM
Meetthefamily
OurPCBTrayswelcome
ANYapplication
The newest members of Phoenix
Contact’s family of PCB Trays satisfy
a wider number of applications. These
new trays were developed to address
specific environmental conditions by
integrating optional covers or fully
enclosed trays with an IP65 rating.
The design of these Phoenix Contact
PCB Trays gives you the flexibility of
mounting on a DIN rail, directly on
machinery or directly on the back of
your cabinet wall.
• UM-Proprofile – contains extruded
polyamide for high device-operating
temperatures of up to 100°C
• UM-ALUprofile – features
aluminum extrusion, which delivers
high-temperature performance and
EMC shielding for noisy environments
• HC-ALUprofile – designed for
either handheld or panel-mount
applications, offering reliable, highheat operation, the same effective
EMC shielding and an IP65 rating
Meet the whole family!
Call 1-800-322-3225 or download
a copy of our PCB Tray brochure
and request free samples at:
www.phoenixcontact.com/pcbtrays
© 2014 PHOENIX CONTACT
CD1403_FPA.indd 3
3/7/14 1:23 PM
CD1403_FPA.indd 4
3/7/14 1:24 PM
CONTENTS
Volume 18, No. 3
FEATURES
32
COVER STORY
Work in Harmony
Despite Differences in Their Approach, Older and Younger
Engineers Begin to Appreciate Each Others’ Skill Sets
Sarah Cechowski, associate digital editor
40
MOTOR CONTROLS
The Roots of Controllers
Some Users Reorganize or Replace RTOS and Kernels in Their
Operating Systems to Gain New Manufacturing Capabilities
Jim Montague, executive editor
46
PRODUCT ROUNDUP
Pass It On
Moving Sensor Data to All Corners of the Business Means
Suppliers Offer More Connectivity Options, Compact Sizes
and Ease of Use
CONTROL DESIGN EXCLUSIVE
55
PROSOFT TECHNOLOGY
Media Converter Puts Ethernet
on Blue Hose
CONTROL DESIGN, (ISSN: 1094-3366) is published 12 times a year by Putman Media, 1501 E. Woodfield Rd., Suite 400N, Schaumburg,
Illinois 60173. (Phone 630/467-1300; Fax 630/467-1124.) Periodical postage paid at Schaumburg, IL, and at additional mailing offices.
Address all correspondence to Editorial and Executive Offices, same address. Printed in the United States. ©Putman Media 2014. All rights
reserved. The contents of this publication may not be reproduced in whole or part without consent of the copyright owner. POSTMASTER:
Send address changes to Control Design, Post Office Box 3430, Northbrook, Illinois 60065-3430. SUBSCRIPTIONS: To apply for a free
subscription, fill in the form at www.ControlDesign.com/subscribemag. To non-qualified subscribers in the Unites States and its possessions,
subscriptions are $96.00 per year. Single copies are $15. International subscriptions are accepted at $200 (Airmail only.) Putman Media also
publishes CHEMICAL PROCESSING, CONTROL, FOOD PROCESSING, INDUSTRIAL NETWORKING, PHARMACEUTICAL MANUFACTURING and PLANT SERVICES. CONTROL DESIGN assumes no responsibility for validity of claims in items reported. Canada Post International
Publications Mail Product Sales Agreement No. 40028661. Canadian Mail Distributor information: World Distribution Services, Inc., Station
A, PO Box 54, Windsor, Ontario, Canada N9A 6J5. Printed in the United States.
March 2014 Control Design
CD1403_05_07_TOC.indd 5
5
3/11/14 6:05 PM
FEB14 A&C Ad (CM)_Layout 1 1/9/14 3:15 PM Page 1
Great Minds
Need Great Products
Allied Has What You Need in Automation and Control
1.800.433.5700
© Allied Electronics, Inc 2014. ‘Allied Electronics’ and the Allied Electronics logo are trademarks of Allied Electronics, Inc.
CD1403_FPA.indd 6
An Electrocomponents Company.
3/7/14 1:24 PM
CONTENTS
Volume 18, No. 3
COLUMNS
58 OEM Insight
9 Editor’s Page
Another ‘What’s in a Name?’
Question
Technology Tipping Point?
Joe Feeley, editor in chief
TJ McDermott, project manager, Systems Interface
13 Start Button
Undergrad Prep for Future Jobs
Sarah Cechowski, digital editor
HOT BUTTONS
19 OEM Spotlight
Involvement + Quality = Innovation
17 Live Wire
PLC’s Days Numbered?
24 InDiscrete
Hannover Fair Preview,
Siemens’ Big Truck and More
Jim Montague, executive editor
21 Embedded Intelligence
50 Real Answers
Looking for Panel-Build
Best Practices
The Union Solution
Jeremy Pollard, CET
54 Resources
Safe HMI Operation
45 TechFlash
Motor Efficiency and More
Hank Hogan, contributing editor
56 Product Showcase
Position. Click. Done.
Your conveyor is sensing.
SEE A DEMO AT:
CD201403.indd 1
CD1403_05_07_TOC.indd 7
Simply easy!
02/18/2014 8:49:02 AM
3/11/14 6:05 PM
" I get what I need to keep my line
running, when I need it.
It's great to be an engineer."
Your one-stop source for
INDUSTRIAL
ELECTRONICS
For Industrial Automation and Control, we have the products
& solutions you need from the most trusted brands.
newark.com | 800.463.9275
Newark_Omron_E5CC_Control
CD1403_FPA.indd
8
Design.indd 1
Featured product:
Digital Temperature Controller
(05W3874)
1/28/14
3/7/14 1:24
2:12 PM
PM
Joe Feeley
In Memory of Julie Cappelletti-Lange,
Vice President 1984-2012
•
editor in chief
•
jfeeley@putman.net
editor’s page
Technology Tipping Point?
1501 E. Woodfield Rd., Suite 400N
Schaumburg, Illinois 60173
630/467-1300
Fax: 630/467-1124
We regularly report about
Progress, and Prosperity in a Time of
the way industrial robots have
Brilliant Technologies by MIT Sloan
editorial team
grown to become a frequent addi-
professor Erik Brynjolfsson and
tion to automated and semi-auto-
research scientist Andrew McAfee.
mated machine operations.
“Self-driving cars are exciting, but
editor in chief
Joseph Feeley
jfeeley@putman.net
executive editor
Jim montague
jmontague@putman.net
managing editor
nanCy bartels
nbartels@putman.net
managing editor, digital media
Katherine bonFante
kbonfante@putman.net
associate editor, digital media
sarah CeChowsKi
scechowski@putman.net
senior technical editor
Dan hebert
dhebert@putman.net
contributing editor
hanK hogan
hank@hankhogan.com
In February, Dan Hebert wrote
about the use of machine vision in
The authors call themselves
that raise the performance bar for
mindful optimists. “If we under-
many end-user manufacturers.
stand the problems that we’re fac-
Late last year, we noted a report
facing, and take the right actions, I
Markets that predicts a global CAGR
think we could have a really, really
near 7% into 2016 for industrial ro-
good outcome,” Brynjolfsson said in
bots in the heavy machinery sector.
a recent interview.
And I told you about my introduction to Rethink Robotics’ Baxter,
the two-arm, somewhat-humanacting robot that’s aimed at doing
lower-skill, repetitive factory jobs,
design/production
ing and the opportunities that we’re
from analysts at Research and
lori golDberg
lgoldberg@putman.net
Jeremy pollarD
jpollard@tsuonline.com
long-haul truckers work?” they ask.
conjunction with industrial robots
editorial assistant
columnist
where will all the taxi drivers and
at Automate2013.
I try not to get too entangled in
“Self-driving cars are
exciting, but where will
all the taxi drivers and
long-haul truckers work?”
But at the same time, he recogniz-
the man vs. robot/technology/auto-
es it’s not automatic and will depend
mation debate that boils over, more
on our choices and the policies we
anetta gauthier
assoc. art director
angela labate
often now. Part of my trouble with
have in terms of education, fostering
it is when do you start the debate
entrepreneurship and tax policy.
subscriptions
clock. The Cotton Gin? The first
customer service
automatic dishwasher?
senior production manager
888/644-1803
circulation
audited may 2013
Air & Gas Compressors
921
Engineering & Systems
Integration Services
7,746
Engines & Turbines
1,649
Food Products Machinery
2,145
Industrial Fans, Blowers
& Air Purification Equipment
794
Industrial Heating, Refrigeration
& Air Conditioning Equipment
1,465
Industrial Process Furnaces & Ovens
806
Machine Tools
3,874
Materials Handling, Conveyors
& Conveying Equipment
1,882
Metalworking Machinery
3,537
Mining Machinery & Equipment
627
Oil & Gas Field Machinery & Equipment 1,213
Packaging Machinery
951
Paper Industries Machinery
352
Printing Trades Machinery & Equipment 510
Pumps & Pumping Equipment
785
Rolling Mill Machinery & Equipment
157
Semiconductor Manufacturing
Machinery
1,403
Textile Machinery
232
Woodworking Machinery
275
Other Industries & Special Industrial
Machinery & Equipment NEC
8,696
total
40,020
Where is the point at which the
the idea that there is more wealth,
massive and virtually immeasurable
as seen in steady, long-term GDP
benefits of technology are negated
growth in the U.S. “Spread,” they
by its harmful effects on individu-
say, is the idea of the “one percent.”
als, economies and societies?
Wealth is accruing unevenly, with
For a long time, automation and
the rich getting steadily—and
technology were hand-in-glove in a
sometimes fantastically—richer,
growing, widely beneficial society.
and the poor and middle class
Economies grew, as did the labor
struggling to maintain or improve
force and a strong middle class. For
their standard of living.
reasons other than just the effect
The book also explores Pigou-
of automation and technology, that
vian taxes, which assign costs to
outlook is in serious jeopardy.
negative externalities such as pol-
So the tipping point is when
lution and negative income taxes,
automation and technology and
by which individuals with little
robots wipe out too many jobs for
or no income receive money from
an economy’s own good. Is that a
the government.
non-recoverable tipping point?
I mention this because there’s
a new addition to the discussion
with The Second Machine Age: Work,
controldesign.com
CD1403_09_EDITOR.indd 9
The authors examine two
economic phenomena: “Bounty” is
March 2014 Control Design
9
3/11/14 4:46 PM
THE PULSE OF AUTOMATION
World’s Largest Selection of Ultrasonic Sensors
A product of world-class acoustic engineering
expertise, Pepperl+Fuchs ultrasonic sensors are
completely unaffected by dust, color variations,
gloss, or transparency.
With sub-millimeter precision, software
configurability, and detection ranges from
½ inch to over 30 feet, ultrasonics are ideal for
both switch-point and analog control of
objects as diverse as bottles, refuse containers,
wooden pallets, steel coils, and foods.
Download four
application reports
that show you how to
easily use ultrasonic
technology.
www.sensing.net/pulse
Scan. Learn More.
Pepperl+Fuchs, Inc.
330.486.0001
www.pepperl-fuchs.us
CD1403_FPA.indd 10
3/7/14 1:24 PM
Retroreflective
Photoelectric
Sensors
The usual way of detecting objects of various shapes
or heights has been through the use of an array of
single-beam photoelectric sensors or a thru-beam light
grid using two separate housings. This method can’t
precisely sense an object’s leading edge, especially
when the leading edge is indistinct. For example,
various types of pallets, parts ejected from a die,
stacks of newspapers, and cartons of varying heights,
widths, or shapes, can all provide indefinite leading
edges making part detection erratic.
Retroreflective sensors are now replacing these
older methods. This type of sensor uses multiple
transmitter beams and multiple receiver elements in
a single sensor housing to produce continuous height
detection. The sensor housing mounts opposite a
reflector. Without an object present, light from the
transmitters in the sensor housing travels to the
reflector where it bounces back to the receivers
housed with the transmitters. The simple press of a
pushbutton initiates a teach mode in the sensor that
lets it learn what conditions signify that no target is
present. Conditions change when an object enters the
sensing area between the sensor and the reflector,
triggering the sensor output.
Unlike an array of single-beam sensors that have
conical light patterns with a small diameter,
retroreflective sensors have a rectangular pattern of
light with a continuous height. This makes it possible
to detect the same-size object consistently throughout
the entire sensing area. Moreover, the sensor can
detect an object’s true leading edge even if the object
has no defined shape or position.
Retroreflective area sensors use only a single housing
together with a reflector. This brings material and
installation costs well below those of thru-beam light
grids or a comparable array of single-beam sensors.
Operationally, they are mechanically and electrically
the same as a single beam device.
Now you have a choice:
There or Where
Distance-based photo sensors address more challenging
applications by not just determining if an object is
THERE, but also WHERE it is located. Three methods
have emerged as front runners to show you Where:
n
n
n
Background Suppression
Multi-Pixel Array
Pulse Ranging Technology
Download our e-book that explains how
these technologies will work for you.
www.sensing.net/where
Scan. Learn More.
Distance-based photo sensors will have your standard
photo sensor nervously looking over its shoulder.
Pepperl+Fuchs (www.pepperl-fuchs.us)
Pepperl+Fuchs, Inc. • 330.486.0001 • www.pepperl-fuchs.us
CD1403_FPA.indd 11
3/7/14 1:25 PM
Start
measuring in
seconds.
2-line display
for easy adjustment
More features and
pre-programmed for
100mm to 1000mm
range right out of
the box.
Analog and digital outputs
4-20 mA or 0-10 Vdc
NPN/PNP user configurable
The Banner L-GAGE® LE550
Laser Measurement Sensor is the
low-cost, easy-to-use solution for
demanding measurement applications.
100mm
1000mm
LE550
Laser Sensor
Class 2 laser
visible spot for easy alignment
• Adjustable range from 100mm to
1000mm in 1mm increments
• Advanced imager technology senses a
wider range of materials and surfaces
from metal to black rubber
• Independent digital and analog outputs
Articulated quick disconnect
• Simple pushbutton adjustments
Customers First
Integrity Always
Quality in Everything
New Solutions – Every Day
1-888-373-6767 | bannerengineering.com
LE550 Laser Sensor
© 2014 Banner Engineering Corp., Mpls, MN USA
BA-2242
02.0314.0212
L-GAGE LE Ad_CD.indd 1
CD1403_FPA.indd
2/19/14
AM
3/7/14 10:47
1:25 PM
Sarah Cechowski
•
scechowski@putman.net
START BUTTON
Undergrad Prep for Future Jobs
It waS about this time three years ago when the
development. Koh interned for GE in Summer 2010 and
panic began to sink in. Spring commencement was just
2011, and for Intel during Summer 2012. In August 2012—
around the corner. My peers—and my parents—were
his senior year—Koh accepted a job offer from GE.
asking, “What do you have lined up after graduation?”
Brian Wallden, process engineer for blade-assembly
After four or more years at school, the whole point is to
operations for consumer product manufacturer, Proctor
have a job lined up—but that’s not as easy as it sounds.
& Gamble (P&G, www.pg.com) in Boston, landed his job
I was proud to say that upon graduating I would be
using a similar process. While obtaining his bachelor’s
leaving for Nashville, Tenn., to do a dual internship at an
degree in mechanical engineering from Penn State,
artist management company and an independent record
Wallden used job boards such as LinkedIn and Monster,
label. It was a temporary distraction from fear of the real
but found more promising opportunities via Penn State’s
world, which entailed submitting a million applications
online job-posting system, eCareer, where he could up-
to a job board black hole and competing with thousands
load his resume and cover letter for full-time positions,
of other people who had the same experience I did.
internships, co-op jobs and international opportunities.
Now, there are pre- and post-graduate career opportunities out there that students who secured a job
before graduating, or found one shortly after, will tell
you to take advantage of in order to gain the experience
employers look for in new hires.
Whether it is an internship, co-op program, network-
There are pre- and post-graduate career
opportunities out there to give you the
experience employers look for in new hires.
Wallden did four co-op tours before graduating. The
ing event, career resource center or simply guidance
first two were with multinational engineering and
from your educators, there is an abundance of ways to
electronics firm Robert Bosch (www.bosch.us), Charles-
help prepare yourself for what’s to come after you finish
ton, S.C., in the manufacturing division. The third was
your college degree.
with DuPont (www.dupont.com), Richmond, Va., in the
Brandon Cary, industrial designer for digital part mate-
research and development division. The fourth, in his
rialization company ExOne (www.exone.com) describes
senior year, was again with Robert Bosch, this time in
his job search as “hectic.” Upon graduating in May 2012
Stuttgart, Germany, in the research and development de-
from the Art Institute of Pittsburgh with his bachelor’s
partment. On his return to the U.S., Wallden interviewed
degree in industrial design, Cary used job boards such
with P&G and received a job offer a few days after.
as LinkedIn and Coroflot, a job site specifically for design
jobs, to apply for more than 200 positions.
He gave himself a deadline: After six months he’d
Doing multiple internships rewarded Andy Milluzzi,
research assistant at the National Science Foundation’s
(NSF) Center for High-Performance Reconfigurable
take any job he was offered. Luckily, right before that
Computing (CHREC, www.chrec.org) at the University of
six-month mark hit, he connected with ExOne through
Florida (UF), with several job prospects.
a friend who helped him get an interview and shortly
thereafter receive an offer.
It’s all about expanding your network, says Allen Koh,
Prior to graduating in 2012 from Rose-Hulman Institute of Technology with a bachelor’s degree in computer
engineering and software engineering, Milluzzi did a
part of the Edison Engineering Development Program
two-year internship with National Instruments (NI,
(EEDP) at General Electric Power & Water (GE, www.
www.ni.com) writing software for the NI CompactRIO
ge-energy.com). By challenging yourself to meet people
that serves as the robot brain used by FIRST Robotics
outside of your classroom and outside of work, you give
Competition (www.usfirst.org). He also worked as a pro-
yourself the opportunity to develop better networking
gram manager intern for Microsoft (www.microsoft.com),
skills, he says. Be proactive when looking for communi-
working on the Xbox gaming system. He also was a soft-
ties to join within and even outside your major, and find
ware development intern for Workflow (www.workflow.
extra curricular activities to get involved in.
com), software development intern for Hyland Software
Koh graduated in May 2013 from Olin College of
(www.hyland.com) and a robotic vision system intern
Engineering with his bachelor’s degree in electrical and
for Rose-Hulman Ventures (www.rhventures.org), an on-
computer engineering. As an undergraduate, Koh took
campus internship program with big-name companies.
advantage of Olin’s post-graduate planning (PGP) career
services to get some guidance on resume and cover letter
controldesign.com
CD1403_13_14_STARTBUTTON.indd 13
Milluzzi was offered a job from Microsoft shortly after
his internship, but declined to attend UF for graduate
March 2014 Control Design
13
3/13/14 12:29 PM
START BUTTON
school to pursue his long-term goal
Kolisetty, user-experience engineer
electrical and computer engineering,
of becoming a professor. To become
for Ford (www.ford.com), is following.
Kolisetty interned with Tesla Motors
a professor, one must know how
Kolisetty works on connectivity
(www.teslamotors.com), Fremont,
research and academia work apart
between personal devices, such
Calif. While this internship was
from having industry experience, he
as the iPhone and iPad, and Ford
beneficial for experience, her most
says. “My philosophy for getting a job
vehicles.
positive influence came from the So-
is to have fun.”
And that’s just the path Aiswarya
Prior to graduating from Olin in
ciety of Women Engineers National
May 2013 with a bachelor’s degree in
Conference, to which she was introduced by Olin’s PGP career center.
After attending the conference, Ford
Rugged Precision
The MAQ®20 Industrial
Data Acquisition & Control System
put her in touch with managers and
supervisors looking to fill new graduate positions.
Kolisetty’s position at Ford
focuses on product development.
Following a user-centric design
approach, her team develops
features that are engaging and
favorable to the customer.
CHREC’s Milluzzi went on to earn
his M.S. in electrical and computer
engineering from UF and is currently pursuing his doctorate, while
working for NSF’s CHREC. As a
project leader, Milluzzi looks at heterogeneous computing systems for
high-performance applications, also
known as “super computing.”
Wallden recently joined the P&G
team doing Gillette Fusion blade assembly operations. His role involves
design improvements, safety and
quality enhancements, better productivity and cost reduction through
mechanical process efficiency.
Signal Integrity, Compact Design
2 Software Packages for DAQ or T&M
GE’s Koh remains in his first year
of the two-year rotational program
EEDP. His current role focuses on
engineering design for wind turbine
• $17 per Channel Possible –
Lowest Cost in Industry
pitch and electrical controls. Koh is
also pursuing his master’s degree in
• Up to 384 Channels in 19”
Instrumentation Rack
electrical and computer engineering
at Georgia Tech.
• Application Software from $250
As an industrial designer, ExOne’s
• ±0.035% Accuracy
Cary reviews part files for customers
• 1500Vrms Channel-to-Bus
Isolation
them for application. He works one-
(industrial and art) and processes
on-one with customers and often
• PID Software Control
- Up to 32 Loops with ReDAQ® Shape
- Unlimited Loops with IPEmotion
• –40°C to +85°C Operating
Temperature
CD1403_13_14_STARTBUTTON.indd 14
needs to teach art process to them so
their engineers have a better idea of
how to design for their own process.
Instrument Class® Signal Solutions
dataforth.com • 800-444-7644
3/13/14 12:29 PM
TRUE STORY
When an overhead crane accidentally dropped a
steel pipe 15 feet onto an IceStation, workers were
relieved to find the pipe had not been damaged.
What was less surprising was the fact that the IceStation - along with the computer and monitor inside it
remained completely unharmed. All ITSENCLOSURES are constructed out of 14-gauge steel and built to last
forever and a day. Should one of our enclosures ever actually fail due to manufacturer defect, we will replace it
as fast as humanly possible so your business does not skip a beat. Built to meet NEMA 12 standards, IceStation
TITAN protects computer systems from harmful dust, dirt, and splashing fluids. With a large viewing window
designed to accommodate up to 24” wide screen monitors, a retractable keyboard drawer, oversized work
surface, and a track record of 29 years of experience protecting electronics, ITSENCLOSURES is the one name
you can trust. To learn more about IceStation TITAN, call 1.800.423.9911 or visit ITSENCLOSURES.com.
25
ITS14_TITAN_7.875x10.5.indd 1
CD1403_FPA.indd 15
2/19/14 10:05 AM
3/7/14 1:25 PM
More power for decentralized motion control.
Room for new
possibilities
Room for new
More power for decentral motion control.
` Motor-mounted ACOPOSmotor servo drives –
Machine modularity in motion.
` Significant space savings in the control cabinet
` Power classes from 500W to 4kW
` Fully integrated safety technology for SIL3
based on openSAFETY: STO, SOS, SS1, SS2, SLS,
SMS, SLI and SDI
` Maximum system productivity: One solution covers
CNC, robotics and motion control
Perfection in Automation
www.br-automation.com
CD1403_FPA.indd 16
3/7/14 1:25 PM
Jim Montague
•
executive editor
•
jmontague@putman.net
LIVEWIRE
PLC’s Days Numbered?
“Mr. Bond, they have a saying in Chicago: ‘Once is
November. However, it’s also been collaborating
happenstance. Twice is coincidence. The third time, it’s ene-
with 3S on using CoDeSys 3.5 PLC software, and the
my action.’ ”—Auric Goldfinger in Ian Fleming’s Goldfinger.
two will soon launch their Sitara AM5x processors,
I’ve always enjoyed this quote from James Bond’s
arch villain, but I never thought I’d experience it directly. Let me explain.
As you might know, I call or email dozens of sources
which will integrate two ARM Cortex-A15 cores.
The CoDeSys runtime software is operating as an
application on top of a Linux 3.8.13 real-time kernel,
and its subsequent PLC application contains a two-axis
for interviews. However, sometimes people call me,
motor-control system that’s using CoDeSys Softmotion
asking to talk about a variety of topics, usually how
module and an embedded EtherCAT master to drive two
terrific their product is. But, I was surprised when in
off-the-shelf EtherCAT servomotors. “Having motors and
the space of one week in February, I was asked to take
communications on the same device allows drives to
calls from three different semiconductor manufactur-
talk to higher-level motion functions, gives users a new
ers about how their chips could perform many of the
architecture for connecting motors, and means better
same functions as PLCs and their supporting Ethernet
intelligence, diagnostics and performance,” explains
networks. Of course, microprocessors have served
Thomas Leyner, TI’s system applications engineer.
inside industrial components for many years, but now
So what’s really going on here? Well, these an-
it appears that the chipmakers are taking a more direct
nouncements could simply coincide with last
role and are less content to labor away in obscurity
month’s Embedded World or last fall’s SPS/IPC/Drives
inside someone else’s modules.
tradeshows, or be linked to other easily explainable
First, Intel’s Internet of Things (IoT) Solutions
Group (ISG) told me about its Industrial Solutions
events. However, I think this might be just what they
want us to think.
System Consolidation Series embedded virtualization product that allows OEMs, machine builders and
system integrators to merge and manage multiple
discrete systems into one machine. Set to launch in
2Q14, this solution consists of an embedded computer
“ Machines with IP addresses and Ethernet
links to PC-based controls may simply
eliminate the need for PLCs altogether.”
with an Intel Core i7 processor and a pre-integrated
virtualization software stack, including Wind River’s
I believe the PLC’s number might be up. Just as
Hypervisor preconfigured to support three parti-
pneumatics were replaced by relays and relays by
tions running two instances of Wind River VxWorks
PLCs, I think microprocessors and their software
for real-time applications, and one instance of Wind
simply are continuing their march onto the plant floor,
River Linux 5.0 for non-real-time applications. Tim
trampling traditional hardware, and reaching the
Appleton, Intel ISG’s industrial marketing manager,
point that PLCs in many applications are going to be
reports that combining operating system (OS), hyper-
irrelevant and unnecessary quite soon.
visor, HMI and security functions will make it easier
In fact, unrelated to the news from Intel, Vitesse
for builders to construct and run virtual machine
and TI, several recent interviewees pointed out that
functions, and that its OS can serve as a home for
machines and equipment with Internet protocol (IP)
software-based PLC applications.
addresses and Ethernet networking can report to and
Second, Uday Mudoi, Vitesse Semiconductor’s
be controlled by upper-level PCs, and may eliminate the
product marketing VP, reported that his company
need for PLCs altogether. I know this isn’t news to some
will soon release its SimpliPHY processors, VSC8501
people, but it can still be a shock when that other shoe
single and VSC8502 dual, which are designed to make
falls, and a longstanding part of your industry dries up.
it easier and use less energy to run synchronous, se-
Personally, I’m hoping that another rule begins to
cure, gigabit Ethernet networking tasks and IoT func-
take effect; namely, as soon as someone writes an
tions. A third processor, VSC8514 quad Cu PHYsrsis,
epitaph for a technology, it immediately experiences
will run on other types of copper wiring.
a renaissance. So PLCs may continue to grow among
Third, Texas Instruments (TI) added its recently
a huge installed base that’s still moving from older
integrated motor control, position feedback and
controls and manual manufacturing methods. Or
the top five fieldbus communication protocols on
those applications could leapfrog right to Internet-
its Sitara AM4x processors, which it launched last
enabled, virtual PC-based control. Eek.
controldesign.com
CD1403_17_LIVEWIRE.indd 17
March 2014 Control Design
17
3/11/14 4:48 PM
Flowing with great possibilities.
Proline Promass 100
Compact without compromise
Proline
simply clever
As a direct, digital Coriolis flowmeter, the
Promass 100 opens entirely new perspectives
• Compact design without limitation of functionality
• Simultaneous measurement of mass or volume
flow, corrected volume, density, temperature and
viscosity (Promass I)
• Seamless integration into process control and asset
management systems via HART®, PROFIBUS® DP,
EtherNet/IP™ or Modbus RS485
• Modern webserver technology provides fast onsite
device configuration without additional software
• Industry optimized sensors for each application
NEW Heartbeat
Technology™
Endress+Hauser, Inc
2350 Endress Place
Greenwood, IN 46143
info@us.endress.com
www.us.endress.com
CD1403_FPA.indd 18
• Heartbeat Technology™ - monitor your process via
continuous diagnostics, multi-parameter monitoring and
onboard verification for maximum process reliability
www.us.endress.com/promass-100
Sales: 888-ENDRESS
Service: 800-642-8737
Fax:
317-535-8498
3/7/14 1:26 PM
OEM SPOTLIGHT
Involvement + Quality = Innovation
Ehrhardt Combines User Input, Experience and Quality to Create Flexible
Machines for Manufacturing Appliances, HVAC Units and Other Products
VARIETY MIGHT BE the spice
of life, but delivering it can be a
headache. So if you need flexible
machines that can make all kinds
of new products and parts, it’s viEHRHARDT TOOL & MACHINE
tal to have an experienced builder
that can provide all the innovations and quality you need.
“Our first job is to get our customers involved up-front and keep
them involved in the design process, so we’ll build a machine that
does precisely what it’s intended to
do,” says John Deibert, special ma-
OFF THE STACK
chines business segment manager
A vertical pallet destacker is the fi rst of fi ve machines in Ehrhardt Tool &
Machine’s Furnace Cabinet line, which its customers use to build enclosures for
residential and commercial furnaces.
at Ehrhardt Tool & Machine (www.
ehrhardttool.com) in Granite City,
Ill., just outside St. Louis. “This
the early 1990s, Ehrhardt began
it’s inexpensive,” Deibert adds.
process is more important now
adding automation and controls to
“We’re also doing remote diag-
because markets are demanding
its machines and sought to bridge
nostics on critical equipment.
changes in the design, look and
its mechanical and electronic
Customers grant us access to their
capabilities of many appliances,
systems. “We wanted to be a one-
VPNs to monitor and adjust ma-
HVAC units and furnaces. So
stop shop for automation, controls
chines, but we’re also looking at
instead of building a machine that
and interfaces,” Deibert says. “So
some Internet-based solutions.”
produces one parts family for a
as part of the engineering group,
furnace cabinet, our users need
I did the mechanics, Dave did the
ers, Dave King, Ehrhardt’s senior
machines that can make more
controls, and our philosophy was
controls engineer, adds that
sizes and types of parts.”
to combine them by taking an ap-
Ehrhardt’s other driving force is
proach from the top on down. For-
quality and delivering a low cost
bles and tests tool and die, auto-
tunately, we had talented people
of ownership to its users. “People
mated equipment and customized
and a team that could provide
might spend a bit more up-front,
machines, mainly for users who
what customers needed, and we’ve
but they’ll spend a lot less on a
need to punch, bend, form, weld
been doing it for 20 years.”
quality machine in the long run,”
Ehrhardt designs, builds, assem-
and braze sheet metal. Most of its
Deibert reports that Ehrhardt’s
Besides involving custom-
King says. “Now our machines can
equipment is used to manufacture
machines and production lines
handle more patterns and make it
commercial and residential HVAC
use PLCs, PACs and HMIs from
easier for operators to enter data
condenser units, heat exchangers,
Rockwell Automation, Mitsubishi,
because our controls use more
furnace cabinets and consumer
Omron, Schneider Electric and
tag-based, portable software.
appliances, such as washers, dry-
GE Intelligent Platforms. These
This means operators can adjust
ers, ovens, stoves and cooktops.
components and its machines are
recipes via on-screen fields for
It also builds leak-testing vessels
typically networked with EtherNet/
different parameters, which is
and heat-exchange cells for forced-
IP. For its load and testing equip-
simpler than typing in code. This
air residential furnaces.
ment, Ehrhardt uses PC-based
is a lot like having reusable func-
controls and LabVIEW software
tion blocks or a software library,
from National Instruments.
which is more flexible than having
Started by Willis Ehrhardt in
1937, the company operated during
World War II and for decades after
as a classic tool and die shop. In
controldesign.com
CD1403_19_OEMSPOTLIGHT.indd 19
“EtherNet/IP is simple and easy
for our users to understand, and
to input a one-off ladder program
for each machine.”
March 2014 Control Design
19
3/11/14 4:51 PM
©2014 Siemens Industry, Inc.
Request a
TIA Portal
Trial License
Scalability between all controller
families and a single engineering
environment generates significant
engineering efficiencies.
usa.siemens.com/plc-cd
SIMATIC Modular Controllers offer
performance, functionality, and value
along the entire production life cycle
for increased engineering efficiency
and reduced costs.
Siemens has redefined
engineering with its TIA Portal
software – a single engineering
framework that allows you to
combine PLC, PC-based control,
HMI, Network configuration,
Drives, and Safety in one
engineering environment.
Performance
• Low-end for discrete and standalone automation
• Mid-range for Factory Automation
• High-end for Factory &
Process Automation
Functionality
• Easy-to-use and program for
reduced downtime
• Modular expansion and scalability
for increased flexibility
• Global libraries for reuse of code
across complete PLC portfolio for
reduced development time and
increased configuration flexibility
• Integrated safety, security, and
diagnostics for increased productivity
Value
• Long-term compatibility and
availability for seamless migration
into future technologies
• Global network offering sales,
service, parts, training, and support
• Operating within our Totally
Integrated Automation (TIA) Portal,
our solution can improve your ROI up
to 30% through increased productivity
and reduced costs
Answers for industry.
CD1403_FPA.indd 20
3/7/14 1:26 PM
jeremy Pollard, CeT
•
jpollard@tsuonline.com
embedded intelligence
The Union Solution
So when will unions actually get it? Did that get
your attention?
Numbers don’t lie, do they? We’re in tough times,
My bride and I were on holiday when Canada 3000
went bankrupt. Passengers were left stranded and had
to pay for return flights from wherever they were. Not
but I believe that unions hold the key. I know it
sure about the refunds, but the reason given was that
sounds odd. Consider that since 1955, when the AFL-
the airline wasn’t making enough money. Really?
CIO was born, manufacturing has steadily declined
in North America, as has union membership.
Private sector unions are only about 10% of the
There was a strike not that long before the bankruptcy was announced. Coincidence? I think not.
And then, in a conversation with Dick Morley about
workforce, down from more than 20% some 30 years
the Internet, he made a comment about availability,
ago. The non-union jobs that rely on their union
meaning that the Internet connection he has doesn’t
brothers probably can’t be accurately counted, but I
always have to work the best, but it always should be
submit that it is a big number. And make no mis-
available, just like the PLC.
take, public sector unions are part of the problem
and solution as well.
The Globe and Mail (www.theglobeandmail.com)
So herein lies the solution to the problem: availability.
Unions and companies need to build an environment of trust and cooperation, but the fulcrum of this
in Toronto reported on Feb. 24 that South African
needs to be the function of availability and removal
mining companies are moving toward mechanized
of the disruption index.
mining to “free themselves from crippling strikes
and labor unrest.”
This is the pivot point in my estimation: the disruption index.
Why would we create more jobs that “require”
the attitude of unions to care nothing about anyone
other than themselves?
Well, allow me cross over here and say that we
should, but with conditions.
Unions are necessary beasts. Management is just
Unions and companies need to build an
environment of trust and cooperation, but
the fulcrum needs to be availability and
removal of the disruption index.
I am not a labor guru by any stretch, but if I knew
that I had the full support of my worker staff and that
they would be available, in other words no strikes,
then my contingency related to production downtime
as bad, overrun with CEOs with golden parachutes,
due to labor disruption would be removed. Also, if I
large salaries and profit margins that bulge, while
knew my customers would always be available for
insisting that the worker bees need to take a pay
my service or product, then the small-and-medium-
cut. Every department seems to have bonuses for ev-
business landscape would look very different. My
ery level of management based on profitability. For
business plan doesn’t have to have that “what if…?”
example, if it costs money to be safe, then unsafe
clause in it. I could have a long-term plan just like the
conditions are what exist.
Chinese have.
Unions have fought for a ton of good issues, but
they have to become thoughtful leaders in order to
allow manufacturing and productivity to come home.
Imagine a workplace based on trust.
China has been the beneficiary of our fall from
grace. Lack of regulation might be a big part of it, but
Take air travel in Hawaii. Additional charges of
it just seems that farming the work out to a third-
$17 per bag both ways on top of an already expen-
party makes it easier. It’s now become pretty clear
sive short-haul flight makes one wonder how that
that it isn’t a wages issue.
revenue could be spent in other areas of the econo-
Unions need to become that third-party and provide
my. Did the baggage handlers, ticketing staff, pilots
a leadership role in bringing back prosperity to the
and/or pension reform cause this massive inflation-
homeland. We, especially our industry, prosper when
ary increase in air travel?
we make things. Now that would be innovative!
We pay for things we shouldn’t have to. How can
we foster a renewed manufacturing front that’s
jeremy Pollard, CET, has been writing about technology
without an “it’s all about the money” attitude?
and software issues for many years. Pollard has been
Then I remembered vacation airline Canada 3000
and Dick Morley.
controldesign.com
CD1403_21_EMBEDDEDINTEL.indd 21
involved in control system programming and training for
more than 25 years.
March 2014 Control Design
21
3/10/14 5:08 PM
CD1403_FPA.indd 22
3/7/14 1:45 PM
CD1403_FPA.indd 23
3/7/14 1:46 PM
INDISCRETE
Sneak Preview: Hannover Fair
ONLY MOVIES OFFER coming
attractions, not industrial trade
shows, right? Wrong.
The organizers of one of the
world’s largest and most comprehensive manufacturing exhibition,
Hannover Messe (www.hannovermesse.de), presented a preview of
its upcoming 2014 edition at the
Radialsystem V hall in Berlin.
The fair will be held April 7-11 in
more than two dozen huge exhibition spaces in Hannover. However,
the preview gave attendees an
early look at some of the event’s
major innovations and exhibitors.
All were focused on its primary
COME TO THE FAIR
Detlef Zuehlke, Dutch ambassador Monique T.G. van Daalan and Jochen Koeckler
answer questions after their presentations during the Hannover Messe Preview.
“Integrated Industry—Next Steps”
theme and the specific steps
Systems (IFS) at the German
network via web servers, which
needed to bring the Smart Factory
Research Center for Artificial Intel-
are already less costly and can be
concept to life using the integrated
ligence (www.dfki.de), which has
combined like Lego blocks to form
tools of Industry 4.0, a.k.a. “The
been developing its Smart Factory
larger systems,” added Zuehlke.
Fourth Industrial Revolution,”
KL program since 2005. “Just as we
which will be driven by Internet-
have smartphones with data avail-
models of how smart factories will
connected devices.
able anywhere and anytime, and
operate, Hannover Messe’s exhibi-
we’re moving toward smart homes
tors will show many Industry 4.0
describe Hannover Messe in
and smart cars, we’re also going
tools fair visitors can use to make
a nutshell, I say it’s all about
to need smart factories,” said
their applications and facilities
competitiveness,” said Deutsche
Zuehlke. “They’ll be more flexible
smarter. For example, Zuehlke
Messe board member Dr. Jochen
and agile to handle more varied
added that one smart factory
Koeckler. “It’s about people coming
products, and have shortened
demonstration will consist of a
together to exchange ideas that
production steps, such as quicker
five-module production line for as-
will produce efficiencies, generate
setup and retooling times and
sembling business card boxes with
investments and make them more
modular components that are easy
secure RFID tags. The integrated
competitive. However, to stay
to plug and play. Smart machines
line consists of a quality assur-
competitive, manufacturers need
are going to need smart opera-
ance section by Lapp Kabel, laser
flexible, intelligent factories of the
tors, smart product designers and
engraving section by Phoenix Con-
future in which machines, plants
smart managers.”
tact, and three assembly sections
“When people ask me to
and products can talk to each
Zuehlke explained these smart
Besides presenting full-scale
by Harting and Bosch Rexroth.
other. The upcoming fair will pres-
factories will be constructed from
Each section will have smart ma-
ent the steps industry must take to
a variety of building blocks, start-
chine components to coordinate
move from its smart-factory vision
ing with cyber physical systems
tasks with the others, network via
to a real-life, integrated, Industry
(CPSs) and smart production line
TCP/IP, Wi-Fi and RJ45 protocols,
4.0 factory.”
components, which will be linked
and follow Han-modular standards
via OPC-UA and other networking
for plug-and-play connectors.
More specific steps for achiev-
Koeckler projected that Han-
ing the fair’s Integrated Industry
protocols to enterprise resource
concept were presented by Prof.
planning (ERP) systems. “Now field
nover Messe is expected to top its
Dr.-ing. Detlef Zuehlke, scientific
devices with their own Internet
last show’s results of 4,872 exhibi-
director for Innovative Factory
protocol (IP) addresses will just
tors from 69 nations.
24
Control Design March 2014
CD1403_24_31_INDISCRETE.indd 24
controldesign.com
3/11/14 6:22 PM
Tough Choice
The American Petroleum Institute created strict
motor performance and manufacturing quality
standards to ensure safe, reliable operation in
tough Petro Chemical applications. In fact, Baldor
engineers participate on the working groups that are
instrumental in establishing API 541 and 547 motor
standards. Today Baldor•Reliance® API 547 general
purpose and API 541 critical service motors are hard
at work for Petro Chemical users around the world.
Count on Baldor•Reliance API motors to make your
next tough Petro Chemical motor application an easy
choice.
baldor.com
479-646-4711
• API Certified
• Custom Built to Your Specs
• Energy Efficient
• Unmatched Quality
©2012 Baldor Electric Company
CD1403_FPA.indd 25
3/7/14 1:48 PM
INDISCRETE
Mining Gets a Really Big Wheel
BELAZ-75710, THE WORLD’S largest, mining, two-
project was completed
axle, all-wheel-drive, dump truck with weight-carrying
from ordering to com-
capacity of 450 metric tons, has demonstrated a perfor-
missioning in less than
mance worth of an entry in the Guinness Book of World
two years.
Records. The new vehicle rolled out of the BelAZ plant
BELAZ-75710 is the
in late 2013, and is being field tested as the biggest ma-
first vehicle in the
chine of its class with a record-breaking capacity.
class of super-high-
To suit the needs of the gigantic haul truck, Siemens
load trucks having
developed a unique AC traction drive system, MMT500.
a weight-carrying
The system is comprised of four 1,200-kW electric mo-
capacity of 450 tons. It
tors, two traction generators, three blowers, a brake re-
is over 20 meters long,
sistor unit and a control cabinet with two ELFA inverters.
nearly 10 meters wide
WE’RE GONNA NEED
A BIGGER GARAGE
BelAZ-75710, the world’s largest, mining,
two-axle, all-wheel-drive dump truck with
weight-carrying capacity of 450 metric
tons, is powered by a Siemens MMT500 AC
traction drive system.
The new dumper has eight wheels, each designed
and eight meters high.
for about 100 tons of load. Therefore, Siemens traction
The turning diameter
division experts chose to develop a reliable and power-
is about 20 meters. The vehicle maximum speed is 64
ful all-wheel drive train with four electrical machines.
km/h. BelAZ-75710 is in high demand in the mines of
The use of the all-wheel gear has opened up new pos-
Kuzbass region of the Russian Federation, and in certain
sibilities of distributing tractive effort to both axles.
coal strip mines of Chile and in North America. The first
Further, in case of failure of one of the driving gears, an
dump truck is due to set off for one of the open mines of
emergency mode can be activated, which would enable
Kuzbass coal field.
the dumper to get to the service station without being
Currently, Siemens also supplies BelAZ OJSC with
towed. The traction motors for the electric gear were
AC traction electric drives for 240-ton and 360-ton
manufactured at Siemens facilities in Nuremberg. The
dump trucks.
G r a p h i c H M I | P L C s | P a n e l P C s | O I Ts
Powerful Industrial HMIs
for Every Need...
4.3” to 15” Display Sizes
• High Resolution Graphics
• Serial, Ethernet, & USB
• SD & USB Expandable Storage
• Audio & Video
• Cast Aluminum Enclosure
• Quick and Easy to Program
...at a fraction of the cost
of competing brands!
Call today for a Free Demo
Every Machine
Needs the Human Touch
CD1403_24_31_INDISCRETE.indd 26
425.745.3229
3/11/14 6:23 PM
CD1403_FPA.indd 27
3/7/14 1:48 PM
INDISCRETE
Asia to Top Market for Machine-Safety Components
THE WORLD MARKET for
2014 to become the second larg-
essary expense by some. There-
discrete machine-safety com-
est regional discrete machine-
fore, simpler and cheaper safety
ponents was estimated at $3.4
safety component market.
components are still more prefer-
This market is largely driven
able in Asia. Indeed safety relays,
fi rm IHS. The American mar-
by China and the other emerging
basic interlock switches and type
ket accounted for 21% and Asia
economies in the region, which
2 light curtains are estimated to
20%. The remaining 59% of 2012
are becoming more conscious
be considerably more common
revenues were in Europe, Middle
of safety in their industrialized
than their more complex equiva-
East and Africa (EMEA).
workplaces.
lents. Safety standards are not
billion in 2012, reports research
Price pressure and a lack of
yet established in countries like
in Asia is higher than that of
safety directives means Asia can
China, but they’re on their way.
the American market, as has
be a tough market to penetrate.
It seems likely they will be based
been the case for a number of
However, influence from multi-
on European standards, which is
years. Machine-safety in Asia is
national companies, as well as
beneficial for European vendors
also playing catch-up. As such,
realization from local end users
operating in Asia. They’re less
machine-safety revenues are
that safety is linked to productiv-
likely to need to modify their
projected to grow more quickly at
ity, means more machine build-
product range. If these standards
12.4% compound annual growth
ers are using safety components
come to fruition, it will mean a
rate (CAGR) to 2017 versus 6.8%
more often, boosting their market
huge boost for the safety compo-
CAGR for the American market.
potential. Regardless of the great-
nent market in Asia.
This means that Asia is forecast
er realizations of the benefits of
to surpass the Americas during
safety, it’s still seen as an unnec-
Overall industrial growth
Safety relays offer the lowest
cost form of controlling safety
samosPRO - Programmable Safety Controller
OEM and MRO applications
Flexible and modular I/O
Online simulation and diagnostics
Function block programming
Simulation and diagnostic tools
safety
Network and gateway options
Contact Wieland for your free, fullversion programming software
Wieland Electric Inc. | 1 800 wieland (1-800-943-5263) | www.wieland-safety.com | technical.support@wieland-electric.com
Wieland - Safety - samosPRO.indd 1
CD1403_24_31_INDISCRETE.indd 28
2/18/2014 3:20:17 PM
3/12/14 4:06 PM
EPSITRON® Power Supplies...
Value + 4 Approvals
CD1403_FPA.indd 29
3/7/14 1:49 PM
INDISCRETE
5,500
16%
and, Japan aside, Asian revenues
are projected to grow more quickly
than those of configurable safety
14%
5,000
modules and safety PLCs. Japan is
a much more mature market, in
line with western regions, and so
12%
4,500
higher-end safety equipment is
more common, but, as the Japanese economy remains flat, this
10%
does not boost the market much.
Globally, safety-component
4,000
revenue growth is forecast to
8%
continue to grow above that of
industrial growth. The realiza-
3,500
6%
tion of cost savings through
integration of safety is evident.
Reducing potential for accidents
3,000
($B)
2012
2013
2014
2015
2016
4%
2017
means less downtime and injuries, which improves productivity
and reduces outlays. Overall, the
IHS
Revenues ($M)
EMEA
Americas
future is strong for safety compo-
Asia Pacific
©2014 IHS
nents, and Asia is proving to be a
large potential market.
CAST STAINLESS STEEL
NE
W
XCESX
ENCLOSURES
 Ideal for offshore applications in oil & gas industry
 5 standard sizes available up to 24”W x 36”H x 10”D
 Rated for Division 1 and Zone 1 Hazardous Areas
 Corrosion resistant, cast stainless steel 316L
 UL, cUL, ATEX, and IECEx Certifications
 Flat plate cover design
BUILT TO LAST
IN HIGHLY
CORROSIVE AREAS
Call for a Free Application Evaluation!
TM
OWN YOUR ENVIRONMENT.
adalet.com • info@adalet.com • TEL 216.267.9000 • FAX 216.267.1681
CD1403_24_31_INDISCRETE.indd 30
3/11/14 6:23 PM
Autodesk to Accelerate
Design-Led Revolution
AUTODESK (www.autodesk.com)
the software and training to cre-
has launched the Autodesk Foun-
ate solutions that address these
dation, which will invest in and
challenges.
support the nonprofit organiza-
One of the program’s fi rst
tions using the power of design
grantees is KickStart Interna-
to help solve epic challenges.
tional. KickStart designs simple
In partnership with the com-
agricultural irrigation tools that
pany, Autodesk Foundation will
help African farmers start profit-
provide select design-oriented
able businesses and rise out of
grantees with software, training
poverty. Others include Mass De-
and fi nancial support.
sign Group, which designs health
Impact design focuses on gen-
facilities in parts of the world
erating significant, measurable
where they’re needed most; D-
progress toward solving to-
Rev, which designs and develops
day’s epic challenges—access to
devices and products to improve
healthcare and education, clean
the health and income of people
energy and water, efficient trans-
living on less than $4 a day; and
portation and others. Through
the Rural Studio at Auburn Uni-
the foundation’s Impact Design
versity, which has a 20K House
Program, carefully selected non-
program that challenges students
profits will receive funding and,
to design energy-efficient homes
in partnership with Autodesk,
that can be built for $20,000.
MERGERS, ACQUISITIONS AND ALLIANCES
The MTConnect Institute (www.mtconnect.org) and the National
Center for Defense Manufacturing and Machining (ncdmm.org) announced a memorandum of understanding to establish a cooperative
forum resulting in collaboration between the two organizations to
continue defining, developing and securing programs aimed at furthering the MTConnect standard. The MTConnect Institute develops
and provides open standards intended to foster greater interoperability between manufacturing controls, devices and software applications by publishing data over networks using the Internet protocol.
NCDMM fosters collaboration between government, industrial and
academic organizations to promote the implementation of best practices to key stakeholders through the development and delivery of
disciplined training, advanced technologies and methodologies.
Sierra Wireless (www.sierrawireless.com) signed an agreement
with Tech Mahindra (www.techmahindra.com) to provide turnkey
M2M solutions globally. The collaboration leverages Sierra Wireless
device-to-cloud offerings and Tech Mahindra’s system integration
and application development expertise to offer turnkey solutions
tailored for prospective M2M customers in markets such as energy,
transportation, industrial and healthcare.
controldesign.com
CD1403_24_31_INDISCRETE.indd 31
March 2014 Control Design
31
3/11/14 6:24 PM
Despite differences in their approach to problem-solving,
older and younger engineers begin to appreciate each
others’ skill sets and methods
by Sarah Cechowski, associate editor, digital media
T
hese kids today. Do they really address engineering problem-solving
in radically different manner than their older peers? Has the Internet
caused some disharmony between the generations that inhibits their working together? Yes and no.
The Control Design 2014 product research and buying habits survey
results, combined with discussions with machine builders and system
integrators, suggest a more nuanced picture. In fact, they suggest that the
“millennial gap”—the differences in the way each generation approaches the
same job—is beginning to narrow.
While there still are age-group-specific differences in how newer and
more seasoned engineers relate to social media and digital access, industry
veterans and recent graduates are becoming codependent on one another.
As these veterans learn to adapt to new technology and web tools that
recent graduates grew up reliant on, younger professionals are learning to
appreciate the knowledge of the older generations.
It’s a Wonderful Web
Machine builders and system integrators say technology has significantly impacted the way they research products, find solutions to on-the-job
problems and stay connected to other professionals.
The survey results show that 33% of respondents say searching a supplier’s website is their most used method for researching and specifying
CD1403_32_39_COVERSTORY.indd 32
3/11/14 5:57 PM
automation and controls, while 24% mostly meet or
help answer questions. But if they’re unable to solve the
speak directly with their automation suppliers’ techni-
problem, his next go-to is to search Google.
cal engineers or product managers. Eighteen percent say
Forums such as MrPLC.com are great for getting an-
they mostly meet or speak with local distributors; 12%
swers from vendors because often the vendor’s technical
search independent, non-vendor websites; 7% read trade
support staff are on them giving feedback on product
magazines; and only 6% visit suppliers at tradeshows.
issues, says Stevic. Online resources like these are much
Somewhat surprisingly, user group conferences were not
more efficient than calling the vendor and “playing ring
valued as a product research tool.
around the keypad on your phone,” he adds.
PDFs are one of the biggest and simplest changes
But Jonathan Hoagland, senior applications engineer
with respect to technology advances, says Steven
for Parker Electromechanical (www.parkermotion.com),
Fage, founder and principal at 5 Nines Automation
disagrees with Stevic. He believes the phone is still the
(www.5ninesautomation.com). In 2007, it still was all
lifeline for his customers to diagnose problems, and it’s
about the catalog, he says. No one went to the Internet to
become easier than ever before. For example, Smith says
learn about the respective product.
if he doesn’t have direct business with Rockwell Auto-
Now everyone asks for a colorful PDF of the product, a
mation, he’s unable to contact the company’s technical
YouTube video or the website on which it can be found.
support because he’s not an authorized user. But he can
“Oftentimes, customers have done their research before
connect with people who work for the company or are
we even get there,” Fage says. “When we go there with a
connected to them through LinkedIn to get the informa-
catalog they say ‘Sure, I guess I’ll take it,’ and it’s usually
tion he’s looking for about their products.
the older guys. I’d say the biggest change is they usually
Social media networks such as LinkedIn open up op-
know more about your product and the competition than
portunities to connect with professionals with similar
you do, because they’ve done their research.”
interests, says Kailash Mariappan, senior automation en-
Tom Kvech, systems engineer for high-speed saw
gineer at manufacturer Saint-Gobain (www.saint-gobain.
manufacturer Metlsaw Systems (www.metlsaw.com),
com). Mariappan was looking for answers on LinkedIn
adds, “We’d have to put in a request and then get the
about using an iPad for automation. “I found a guy who
physical hard copy of the product brochure, or we’d have
lives in Spain, and he gave me insight into mobile appli-
to have a catalog sent to us. By the time we got [the cata-
cations for automation,” he says. “It’s really amazing how
log], it was out of date. Now we download the latest PDF.
social media is changing the professional world.”
You can search for that product online and have the most
up-to-date information.”
In the past, you could get product help only by con-
Facebook too has been an excellent way to stay connected, says Phil Laurette, controls design engineer
for industrial automation system integrator Outbound
tacting vendor support directly or by asking people at
Technologies (www.outboundtech.com). While he uses
your company, says Jason Cleveland, controls engi-
LinkedIn predominantly for professional relationships
neering manager for turnkey solutions and material
and Facebook for personal ones, over time, those lines
handling systems designer Laidig (www.laidig.com).
have become blurred, and many of his professional rela-
Now the Internet has become an avenue for researching
tionships have become personal ones as well.
a particular problem, with search engines spitting out a
“There now are quite a number of engineers that I’ve
ton of URLs where you can find people all over the world
known for 15 or more years that I stay connected to on a
asking the same question.
regular or semi-regular basis,” Laurette says. “In the past,
“[In the past] it was a whole lot of phone calls, tech
I was not able to stay as connected to former colleagues,
support and searching through hard copy manuals,”
and often they fell off the face of the earth when we
says David Smith, systems designer for Johnson Controls
stopped working together. But that’s no longer the case.”
(www.johnsoncontrols.com). “Now I can take a problem
and search Google, Wikipedia or online forums. Rather
Who Uses What for Research
than look at a hard copy manual, if I’ve got a soft copy, I
When asked what types of content listed in search
can just search through the PDF. It saves a lot of time.”
engine results they prefer to view when doing product
Thomas Stevic, controls engineer for PLC and mo-
research, only two categories elicited a substantial fol-
tion control solutions provider, Cincinnati Integration
lowing. Some 81% of survey respondents look to techni-
& Automation (www.cincyintegration.com), says when
cal articles and whitepapers, and 70% said online articles
he first started, his intial point of contact would be the
from publications and news sources were worthwhile.
vendor because most have a technical support staff to
Only 36% value looking at images; 32% prefer YouTube
controldesign.com
CD1403_32_39_COVERSTORY.indd 33
March 2014 Control Design
33
3/11/14 5:58 PM
videos; 31% noted online forums;
new products in electronic design.
Fage, on the other hand, finds
and 12% pointed to blogs.
people will literally have a video
capture of their desktop showing you
white papers difficult to dig
exactly how to go through a specific
there’s really no specific site,” Kvech
through for product research. The
configuration process or program-
says. “There’s no aggregator like
bibles for the plastics industry are
ming procedure,” he says.
there is with other types of indus-
Plastics News and Plastics Today.
tries.” Kvech uses a number of digital
However, Fage says one of the big-
onstrations to help educate industry
trade journals including Control
gest and most up-and-coming tools
professionals. He develops videos
Design, Rockwell Automation’s The
available on the web is YouTube
to train new engineers or creates
Journal and Modern Metals to stay up
because its users can see how a
refresher courses for experienced
to date on the latest products and
process works.
engineers. Two of his most recent
“In the industry, my feeling is
“This is huge because my back-
industry trends.
Hoagland records and posts dem-
videos were on motion control ba-
ground is in automation, and now
sics and programming an ACR9000
tronics maintenance technician for
I’m getting into the plastics process-
controller, and how to create a cus-
weighing systems specialist Comer-
ing side of the business,” he says.
tom servomotor file for Compax3.
cial Such (www.comercialsuch.com),
“Injection molding, extrusion, blow
While Stevic has watched some
reads Vision Systems and Electronic
molding, thermo forming—there are
YouTube videos for his job, he finds
Design to research the latest indus-
so many different processes. If I want
them very non-specific to the subject
try technology. He also watches
new customers, I need to be able to
matter he looks for. If things were
webinars and videos, and receives
understand their process before I can
broken down into much small pieces,
whitepapers from Engineering TV on
help them in their businesses.”
videos would be more helpful, he says.
Tomas Moruno, industrial elec-
The things he looks for in a quality
DEMOGRAPHICS
Respondent industries
Assembly
5%
Electronics pick and place
2%
Material handling/
transport systems
6%
Metalworking
11%
One-off, custom
“For example, I set up a VFD
video include what the technology
[variable-frequency drive] to use
looks like and what the process looks
a DeviceNet card,” he explains. “I
like. Looking at an image or reading
looked through the book and, of
a technical paper does not offer the
course, the book covers everything.
same benefits that video does.
I called the technical people at the
Smith says he watched a recent
factory, but they can’t really show
Microsoft SQL Query about configu-
you what you’re doing. If there were
ration on YouTube that gave him a
a two-minute video on what buttons
step-by-step, how-to breakdown.
to push and which things to select for
17%
“Rather than following through a
setting up a drive on DeviceNet, that
Packaging
4%
thread on how to do something,
would have been wonderful.”
Paper industry
1%
Printing and converting
2%
THE SEARCH FOR A WELL-TUNED ENGINE
Rolling mills
1%
Technical search using global search engines
Semiconductor tools
1%
System integration
24%
Woodworking
1%
Other
24%
Job function
Control system design/
engineering
55%
Company management
14%
Tech support
9%
Research/development
11%
Other
11%
Responses from 250+ study participants
34
Control Design March 2014
CD1403_32_39_COVERSTORY.indd 34
You agree or strongly agree that:
‘14
‘13
‘12
‘11
‘10
‘09
The first page (or more) of results
contains well-focused hits
77%
80%
79%
78%
76%
82%
Too many results are biased, vendor
product plugs
73%
72%
67%
61%
70%
69%
Too many results are outdated
54%
52%
45%
47%
52%
51%
Too many results have nothing to do
with what I’m looking for
66%
69%
71%
70%
75%
73%
It’s a pain to sift through the results,
but at this point there’s no better
web-based research tool for me
76%
73%
77%
74%
73%
76%
I’ve gotten better at search
strategies and techniques, and
that has helped get better results
93%
89%
88%
90%
N/A
N/A
controldesign.com
3/11/14 5:58 PM
Consistent Spot Size
Repeatable Alignment
OLED Graphic Display
180° Rotating Connector
NPN and PNP Outputs
10-30VDC
IP 68
240 Microseconds
Response Time
www.ttco.com/smartdot.aspx
CD1403_FPA.indd 35
3/7/14 1:49 PM
Reliable Resources
within the company,” she says. “It helps me with what
When asked what resources they turn to when they
I need to think about when I want to pitch an idea and
look for answers to a technical problem, 78% of survey
how that will affect the company. ‘System-level’ thinking
respondents indicated they still prefer to meet or speak
is something I am really trying to develop.”
directly with their automation suppliers; 61% read
Other machine builders and system integrators in-
online articles; 41% read online forums; 17% read blogs
dicate using forums such as PLCtalk (www.plctalk.net),
and 9% use LinkedIn groups.
PLCS.net (www.plcs.net), MrPLC.com (www.mrplc.com)
Andy Milluzzi, 2012 Rose-Hulman Institute of Technol-
and Rockwell Automation’s Knowledge Base (www.rock-
ogy graduate and now research assistant at the National
wellautomation.com/knowledgebase) for FactoryTalk for
Science Foundation’s (NSF) Center for High-Performance
answers to on-the-job problems.
Reconfigurable Computing (CHREC, www.chrec.org) at
Fage says LinkedIn is making a huge impact in the
the University of Florida, follows blogs from Intel (www.
automation community through “groups,” which func-
intel.com), Texas Instruments (TI, www.ti.com), Mat-
tion similar to forums. Conducting his own research,
Lab (www.mathworks.com/products/matlab) and Make
Fage found various surveys that said LinkedIn is the
(makezine.com), a hybrid magazine/book devoted to do-
most heavily used social media channel in the plas-
it-yourself (DIY) technology projects.
tics industry. Fage discovered LinkedIn groups such as
Milluzzi also reads forums hosted by TI, National
Injection Molding Technologies, Machinery for Plastics
Instruments (www.ni.com) and robotics platform Vex IQ
Processing, Plastics Today and Plastic Injection Molding
(www.vexiqforum.com). If he has a question, he tends to
were not only useful for industry professionals looking
head to a supplier’s forum first because he’ll usually get
for answers to technical problems, but also help service
immediate feedback from a representative.
providers like himself reach customers and drive discus-
Smith uses HVAC-Talk (hvac-talk.com) to help him
diagnose flow problems. This particular forum is useful
sions around related topics.
“I found that using LinkedIn groups is credible and
for him because it breaks down electrical engineering
people are willing to talk,” he says. “If you look at the sta-
and mechanical engineering into respective sub-forums.
tistics, comments left per week and activity rates, they
With Johnson Controls becoming more IT-centric, Smith
are way up. It’s really not the end-all though. The prob-
has started using Microsoft and TechNet (technet.micro-
lem with the plastics industry is the majority of [workers]
soft.com) forums to find answers to technical problems.
are 35 to 58. They’re a bunch of old-school kind of guys
He also relies on Johnson Controls’ internal company
and not really into social media. So it’s not a shoo-in, but
forums for file sharing and viewing new tools employees
it’s definitely one way to get in touch with them.”
are developing.
Mariappan also references an internal blog on Saint
When asked if they have ever used online forums,
blogs or LinkedIn discussions to help someone else solve
Gobain’s intranet for technical support. If he’s experi-
a problem they were having, 49% of survey respondents
encing a problem, he’ll post a question to the blog, and
said they have helped someone on an online form, 78%
others within the company will provide insight about
never have helped someone on a blog, and 81% never
their own experiences and the steps they took to find a
have helped someone on a LinkedIn discussion.
working solution.
Aiswarya Kolisetty, a 2013 Olin College graduate and
Online Dating
now a user-experience engineer for Ford, relies heavily
We surveyed our audience to see what their relation-
on an internal social site at Ford called Yammer, a space
ship was with several different types of interactive
created for employees to share links about Ford or other
resources. Some 48% say they rarely watch live or
companies and for user feedback.
on-demand webcasts for their jobs. Out of those re-
But at the end of the day, Kolisetty says it’s the
spondents, 13% don’t use them socially either; 40% say
knowledge of experienced members on her team
they occasionally watch videos from vendors about
that helps her develop the most in her role. The team
their products. Out of those respondents, 12% don’t
constantly shares articles back and forth that discuss
use them socially either; 37% say they occasionally
what’s happening in the industry.
read online forums. Out of those respondents, 14%
Talking to experienced peers and asking about their
don’t use them socially either. Twenty-seven percent
experiences has helped in the learning process, Kolisetty
of respondents say they rarely use blogs for their jobs.
says. “Talk to people. Ask them questions about their role
Out of those respondents, 31% don’t use them socially
36
Control Design March 2014
CD1403_32_39_COVERSTORY.indd 36
controldesign.com
3/11/14 5:58 PM
WHAT IS YOUR RELATIONSHIP WITH THESE TYPES OF ONLINE INTERACTIVE RESOURCES?
Use often
(weekly) for job
Use occasionally
(monthly) for job
Use rarely
for job
Never use for
job, but use
socially
Nope, not
even socially
Webcasts (live and on
demand)
9%
25%
48%
5%
13%
Downloads/podcasts
(interview vendors)
5%
15%
41%
12%
27%
Downloads/podcasts
(interview machine builders)
4%
10%
40%
12%
34%
Videos from/about
vendors/products
12%
40%
30%
6%
12%
Video of machine builders
discussing automation
on machine
11%
27%
37%
8%
17%
Online forums/bulletin boards
17%
37%
28%
4%
14%
Web logs (blogs)
8%
22%
27%
12%
31%
Social media sites
(Twitter, Facebook,
LinkedIn, Google+, etc.)
12%
12%
18%
26%
32%
either; 18% of respondents say they rarely use social
media sites for their jobs. Out of those respondents,
33% say they don’t use them socially either.
Webinars tend to be hit or miss in the automation
because of employer restrictions.
Social media use is restricted because otherwise it
would be abused, Mariappan says. “If I want to watch
a YouTube video, I must receive special approval from
community. Machine builders and system integrators say
my boss. I need to let him know what the video is about
some of the most recent webinars they watched were by
and why I want to watch it. Out of all the social media
Rockwell Automation about its RSView Machine Edition
channels out there, there’s not enough of a professional
visualization product and FactoryTalk for HMI software
community built up on them for them to be useful to
and Ethernet/IP; Phoenix Contact on new product re-
the industry yet.”
leases; OPCconnect on software solutions; and Fanuc on
basic training for robotics and vision.
Smith says the most recent webinars he watched were
Laurette says social media use is restricted at his
company because of the overall stereotype that when
employees are on their personal sites during work hours,
for product research, training and online video tutorials
they’re using them for social pleasure and wasting valu-
on a vendor’s website. Johnson Controls hosts a monthly
able work time.
online training webinar that reviews consumer product
“I think, on the whole, we’re far too busy to use social
polls, customer surveys and internal employee surveys.
media for work,” Laurette says. “I also think LinkedIn is
Employees use these training webinars to pinpoint which
thought of as a job search site, so employers don’t want
areas of the business the company needs to invest more
you to be job searching on their time.”
in training programs.
Smith and other users say LinkedIn has become their
Social Skepticism
number one resources for staying connected with other
While social media’s value to the automation industry
industry professionals.
remains debatable, its purpose has become much more
“LinkedIn is the Facebook of professionals,” Cleveland
defined. Machine builders and system integrators are
believes. He’s one of many professionals that restrict
in agreement that social media sites were developed to
their professional relationships to LinkedIn and allow
create a community for users with common interests to
their personal relationships to surface on Facebook.
connect and interact with one another.
Mariappan and Laurette say they use social sites
“At first, I started using it to connect with old friends,
such as LinkedIn, Facebook and Pinterest, a web tool
relatives and colleagues,” Laurette says. “As time goes on
that allows users to organize topics they’re most
though, we discuss issues, politics, activism. I think there
interested in by “pinning” them to their own “board”
are a host of things that could be considered the purpose
for future ideas in their personal and/or professional
of social media.”
lives. But both believe social media use is slow to
grow for professional use in the automation industry
controldesign.com
CD1403_32_39_COVERSTORY.indd 37
Brian Wallden, a 2013 Penn State graduate and now
process engineer for Proctor & Gamble, says he too
March 2014 Control Design
37
3/11/14 5:58 PM
Which social media sites
do you most use?
11%
BLOGS
Do you think social media
offers value to this industry?
13%
FACEBOOK
6%
TWITTER
18%
ONLINE
FORUMS
19%
YOUTUBE
18%
NO
33%
NO
19%
LINKEDIN
Will social media gain value as
new engineers enter the field?
67%
YES
82%
YES
13%
GOOGLE+
started using social media to connect with friends and
a competitive edge is the main reason they avoid using
for entertainment, but as it gets more and more popular,
social media in their jobs. “I don’t want my competi-
it’s starting to be used as a career tool and for network-
tion to know who my customers are and/or whom I’m
ing on a professional level.
serving,” Fage says. “The only things I share online are
There’s nothing else out there that compares to the
technical education or company milestones.”
speed and power that social media sites give users to
Currently, vendors are taking advantage of social
connect with people of common interests, says Saint-
media sites to advertise their products, but the techni-
Gobain’s Mariappan. That initial conversation with the
cal people are looking for communities that provide
gentlemen in Spain who offered his own experiences
resources for researching new ideas, and social media
using an iPad for automation led the two engineers
doesn’t provide that type of platform, says Comercial
to discuss projects their companies could work on
Such’s Moruno. While social sites offer a great avenue
together in the future.
to view new vendor products, those vendors aren’t tell-
Cleveland also has seen great success using LinkedIn
ing users how to troubleshoot a product problem.
for international business opportunities. “We do a lot
“A lot of it has to do with the depth of detail that
of work in China, and we’re getting some pushback on
goes into a purchase in a professional field versus one
some components we wanted to supply to China,” he
that is more consumer-based,” says CHREC’s Milluzzi.
says. “They would prefer a locally built source in China.
“There is a huge process that goes into R&D before a
I happened to make a connection on LinkedIn with a
final purchase is made. Social media doesn’t allow for
guy who supplies, in this case, VFDs, so I started talk-
the deeper research needed to investigate and compare
ing with him. Now he is doing product quotes with the
one product to another. Simply watching a demo video
company for their business in China. I make connec-
of how a product works on a machine will not neces-
tions with people I never would have had before.”
sarily be the final factor for a purchase. It’s not a good
But proprietary and liability issues continue to be
the main reasons automation professionals are wary
marketplace for engineers to sell to engineers.”
Wallden says Facebook has a long way to go to be
to adopt social media more prevalently in the indus-
used for professional development in manufacturing. “If
try. The last thing you want is to accidently reveal too
you look at it as just ‘liking’ a company, than that’s the
much information, and get in trouble with your com-
end of it. With LinkedIn, there’s lot of recruiters looking,
pany for it, Cleveland says.
and you can see who’s viewed your profile. Social media
“The reason I’m hesitant to put information on social
media—whether for personal or professional rea-
is still in that stage where it’s slowly growing.”
Metlsaw Systems’ Kvech doesn’t think there’s been
sons—is because one wrong step and there is a ton of
a site developed that’s specific to his industry. “There’s
backlash,” he says. “It’s hard to know where to draw the
no common place that can link us together,” he says.
line, what to share and what not to share. That’s why I
“Obviously certain vendors make a site specific to
try to be on the conservative side, and not share a lot. I
products and questions, but there’s no aggregate site
think that kind of limits its growth.”
that would bring everyone together. That’s where I
For others, protecting their company’s assets to keep
38
Control Design March 2014
CD1403_32_39_COVERSTORY.indd 38
think it lacks.”
controldesign.com
3/11/14 6:01 PM
Too Much Technology?
or test it. [Technology] allows these young engineers to
As the web transforms the way people find informa-
operate in a kind of bubble, behind their keyboards and
tion and communicate now, the next-generation of
search bars. They’re less inclined to rush to failure, to
engineers adopt different processes for the way they
get their hands dirty.”
Smith believes it’s the responsibility of the educa-
solve problems, conduct research and build relationships with other professionals. How will the over-
tion system and automation companies to properly
abundance of technology and accessibility to informa-
educate the younger generations on how to use the
technology they have at their disposal to solve prob-
tion impact the automation industry going forward?
The web and technology will only continue to make
lems correctly. “I have a fairly firm belief that if you
the automation community more collaborative, says
run into a problem, and you can’t solve the problem,
Doug Boozer, chief of control engineering for Pearson
it’s because you were too lazy,” he argues. “Right now,
Packaging Systems (www.pearsonpkg.com). “It seems
between Google, Wikipedia and online forums, some-
the younger generation is connected to so many more
body’s got the answer. Somebody’s seen what you’re
people than I’m used to being connected to. I think
dealing with before, unless it’s a new product. As long
[recent graduates] will take advantage of those connec-
as people feel empowered to do it, there’s no problem
tions by reaching out to a much broader spectrum of
that can’t be solved.”
Milluzzi says technology is both a blessing and a curse.
people. The web provides for a much bigger audience
While it allows him to connect and share information
for feedback and for research to get ideas.”
with others around the world, younger generations have
The younger generations are moving more online
and virtual than ever before, Laurette agrees. Many of
become too reliant on it and are regularly turning to
the younger engineers at Outbound Technologies don’t
Wikipedia for answers. “People don’t want to work with
have a single catalog in their cubicles, while Laurette’s
people directly anymore,” Milluzzi says. “They prefer to be
is full. “As the GenXers move into management, I
in contact over email or through IM to communicate.”
think we’ll see social media become more acceptable
for work use,” he says. “That generation has grown up
totally connected and will be much more inclined to
expect that as a norm.”
But Moruno believes the newer generations are relying too heavily on electronics to find answers rather
than speaking with industry professionals directly to
get the answer. Personal relationships, he says, have
fallen off. Instead of working with people to develop
ideas, the younger generations turn to the web to see
what’s already been done.
“Nothing is personal anymore, and people’s brains
have begun to function like machines,” Moruno says.
IEC 61131
CONTROL
“In this industry, the most important thing is the
IEC 61508
SAFETY
PROFINET
INDUSTRIAL
ETHERNET
SCALABLE
SOFTWARE
PLATFORM
imagination of the people.”
Newer generations don’t have to do anything but
type in a question on Google to get the answer they’re
looking for, Fage says. That’s the difference between
old school and new school processes. Fage says newer
generations use technology too much as a crutch,
which in turn deflates social interaction.
The future of your automation
technology starts here.
“One of my customers just hired a new mechanical engineer fresh out of college,” he says. “One of the
business owner’s main frustrations is that before this
new engineer can do anything, he has to Google it. You
need to be at the point where you can go try your idea.
Go back to the production floor, and build it, measure it
controldesign.com
CD1403_32_39_COVERSTORY.indd 39
March 2014 Control Design
39
kw-software.com
3/11/14 6:01 PM
Machine Control
The Roots of Controllers
Some Users Reorganize or Replace RTOS and Kernels in Their Operating
Systems to Gain New Performance Capabilities
by Jim Montague, executive editor
The mission of every controller is to, by God, get its
products and have extensive prior expertise working
job done and give its users the capability and flexibility
with this type of OS, but the Linux-based RTOS on Com-
to complete their tasks. As Yoda says, “There is no try.”
pactRIO really changes the game,” says Wolfram Koerver
For about 40 years, microprocessors and software
of SEA. “By leveraging the open Linux-based real-time
have worked together in programmable controllers to
OS on a commercial, off-the-shelf (COTS) controller, we
perform the calculations needed to take in and analyze
could port our existing Linux software components in a
data from sensors and I/O points, and then formulate
very short time, which saved us at least three months of
and send out appropriate responses and commands. Just
added development time.”
as PLCs could digitally do the jobs of dozens or hundreds
Sanjay Challa, NI’s embedded software product man-
of relays and reduce wiring and maintenance, many
ager, adds that, “A lot of large, sophisticated builders with
functions in controller operating systems (OSs) have mi-
big teams that always have done custom designs want
grated from dedicated, hard-coded, inflexible firmware
their operating systems to be just as flexible for special
to simpler, purer software that’s easier to manipulate
time synchronization or I/O requirements on high-per-
and reprogram. In short, where users previously had to
formance machines or testing equipment, so they need
swap circuit boards and CPUs or type in complex coding
to go beyond regular PLC functions to custom controller
changes to adjust programs on each controller, now they
designs. Besides reducing costs, users are looking for open
can point and click on a screen and automatically update
and flexible OSs, and they also want to reuse code.”
software on dozens or hundreds of controllers.
However, despite these overall technical gains, there
RTOS Ins and Outs
are still times when it’s crucial to access and adjust pro-
“The RTOS is the controller’s manager, and it works on
gramming at the level of the real-time operating system
top of the controller’s CPU,” says Jeff Payne, automation
(RTOS), kernel and central processing unit (CPU) itself.
controls product manager at Automation Direct (www.
This could be needed to prevent unauthorized software
automationdirect.com), which sells Koyo and other PLCs.
changes, protect intellectual property, ensure security or
“Firmware is written and embedded in the hardware, the
enable other high-priority functions.
RTOS provides hooks into the firmware, and that’s how
they share data. Many CPUs chips are enclosed, so more
Open Source Aids OS
field-programmable gate arrays (FPGAs) are used that al-
S.E.A. Datentechnik (www.sea-gmbh.com) manufactures
low developers to tailor functions to individual specifica-
test and measurement systems in Troisdorf, Germany. It
tions, such as special math or motion tasks.”
recently needed to build an affordable, universal condition
Dan Fenton, product marketing specialist for control-
monitor for recurring applications in machine supervi-
lers and software at Phoenix Contact (www.phoenixcon-
sion and structural health, which would handle modular
tact.com), adds that 95% of machine builders and other
sensor inputs and signals types. As a result, the company
implementing controllers don’t need to alter their OSs,
developed its SEA 3200 rugged, sealed data acquisition
but Phoenix Contact can help the 5% who do. “One user
and processing system, which can continuously moni-
had to access their I/O much more directly, so we added
tor sensor and machine data and is based on a National
software hooks into the backplane of the controller,” Fen-
Instruments (www.ni.com) CompactRIO module with a
ton explains. “Another wanted to swap out entire logic
Linux RTOS, analog-to-digital converter modules and two
programs on the fly to go along with tooling changes for
modules for wireless networking and health monitoring.
manufacturing different products. This was beyond sim-
“We’ve used Angstrom Linux for a long time in our
40
Control Design March 2014 CD1403_40_43_FEATURE2.indd 40
ply changing recipes, but it also had to be done without
controldesign.com
3/11/14 4:55 PM
reprogramming the whole line. So we work with custom-
diameters 16 to 64 inches and lengths over 12 meters
ers with these challenges and decide whether a software
are among the usual formats for us in pipe manufactur-
change or a hardware change is needed.”
ing plants,” says Michael Fabianek, Haeusler’s manager
Likewise, Paul Whitney, commercial program manager for Integrated Architecture at Rockwell Automa-
of automation technology, IT and hydraulics.
To better control its cold-forming process, Haeusler
tion (www.rockwellautomation.com), says his company
decided to replace its former control strategy, which con-
doesn’t usually seek to reprogram OSs on PLCs. “But if a
sisted of separate a CNC and PLC that communicated at
user in the converting or web-printing field needs to run
the I/O level. Consequently, Haeusler developed its Bend-
servo drives at 200% of peak, then we’ll undertake an
IT Swiss Technology control system, which includes its
engineering project, enter the firmware and develop ser-
proprietary solution for the NC controller and a 19-in.
vo drives able to operate at 250% of their former peak,”
panel PC with an embedded Windows XP OS, TwinCAT
Whitney says. “It’s simpler and easier to adjust software
that sits on a controller’s OS by adding a configuration
or runtime file about how to ramp up a drive.” Also, our
Studio 5000 design environment for writing code has
added functions like consistent flow and naming, as
well as modular code sets to help designers share inforHaeusler and BeckHoff
mation and tailor functions.”
Rebuilt Brain for Bending
Just as operating systems can be repartitioned and reorganized to allow new innovations and functions, sometimes they need to be rebuilt or replaced with a whole
new strategy. For example, Haeusler (www.haeusler.
com) in Duggingen, Switzerland, and RheinfeldenHerten, Germany, builds 20 types of plate-bending on
roller plate and section-bending machines and can
process plates up to 320 mm thick (Figure 1). “Bending
Big Bend
Figure 1: Haeusler’s RMS large-pipe-bending machine has a
software-based Bend-IT Swiss Technology NC controller that uses
half of a dual-core CPU to combine PLC and NC or CNC motion
functions to manufacture large, longitudinally welded pipes.
Controller operating SyStem reSourCeS
Learning to program, configure and adjust controller
operating systems (OSs) might seem difficult at first, but
there are many guides that show how it’s done. Here are
a few of the most informative:
• “Introduction to PLC Controllers” by Nebojsa Matic is
a free, online book explaining their inner workings,
how to program operating systems and how to
connect sensors. It’s located at www.mikroe.com/old/
books/plcbook/plcbook.htm.
• Wikipedia’s articles on operating systems and RTOSs
are informative and include lots of historical context.
They’re at www.en.wikipedia.org/wiki/Operating_
system and www.en.wikipedia.org/wiki/Real-time_
operating_system.
• “PC vs. PLC: Key Factors in Comparing Control
Options” is a white paper by Bosch Rexroth that
compares the two technologies and examines many
of the operating system issues of each. It’s at www.
automation.com/pdf_articles/Rexroth_PLCvsPC_L.pdf.
controldesign.com
CD1403_40_43_FEATURE2.indd 41
• “Embedded Linux Applications: An Overview” by
Darrick Addison includes a survey of applications and
step-by-step instructions for setting up hardware and
software environments to develop applications. It’s at
www.ibm.com/developerworks/library/l-embl/.
• “Kernel: Basic Concepts” section of the Operating
Systems Development series from BrokenThorn
Entertainment examines what goes on behind kernel
programs and their responsibilities, which are crucial
for coming up with good OS designs. It’s at www.
brokenthorn.com/Resources/OSDev12.html.
• “Real-Time Processing—The Basis for PC Control”
by Ramon Barth is a white paper about how
Beckhoff Automation employs Microsoft OSs for
its PC-based controls and extends them at the
lowest level for real-time, deterministic behavior
in industrial automation. It’s at www.pc-control.
net/pdf/special_25_years_pcc/pcc_special_0811_
realtime_e.pdf.
March 2014 Control Design
41
3/11/14 4:55 PM
MACHINE CONTROL
Runtime Software
Offline Tools
Development
Environment
PLC software and EtherCAT fieldbus
Programmable Logic Controller
from Beckhoff Automation (www.
User Application
IEC 61131-3
IEC 61499
Workbench
KPA EtherCAT
Studio
Port
beckhoff.com). The core is an HMI
PLC Firmware
based on Microsoft .Net and pro-
KPA
EtherCAT Master
grammed in C# with integrated 3D
Neutrino® RTOS
machine offers both NC and CNC
visualization. “The so-called ‘virtual’
functionality and covers all axes,”
QorIQ Hardware
FREESCALE SEMICONDUCTOR
Port
Port
Fabianek explains. “We use one pro-
Port
cessor core of the dual-core CPU for
Device
(Slave)
the user interface and data manage-
Device
(Slave)
ment, and the other core for PLC and
Port Port Port Port
NC or CNC motion control.”
Reorganize the Core
Ethernet
To offer deterministic, real-time
Freescale Technology
performance for other users,
JOINT-EFFORT OS
Figure 2: Freescale’s QorIQ P1 processor, QNX’s Neutrino RTOS, ISaGRAF’s PLC firmware
and Workbench software, and konig-pa’s KPA Studio and Master stack software have
been integrated using the EtherCAT PLC reference platform to develop a controller that
can act as an EtherCAT master and provide deterministic, real-time performance.
Machines can talk
Freescale Semiconductor (www.
freescale.com) reports it recently
formed a partnership with ISaGraf, QNX Software Systems and
Are you still sending
people for support ?
HMI
PLC
• Easy setup using customer’s LAN
• Firewall friendly
• FREE Talk2M VPN Service
Industrial VPN
Routers
www.ewon.us
CD1403_40_43_FEATURE2.indd 42
The eWON COSY 141 eliminates the need to travel onsite to
troubleshoot your equipment using a secure VPN connection.
Pittsburgh, PA | 412 586 5901
3/11/14 4:55 PM
konig-pa to develop and use the EtherCAT PLC reference
“Machine builders continue to program their own
platform for OEMs that seek to develop a controller that
operating systems, but as more software guys come
can act as an EtherCAT master and provide determinis-
into the industry, many don’t like ladder logic or IEC
tic, real-time performance.
61131 because they’re more comfortable with C++ or
The reference platform combines a Freescale proces-
C#,” says Phoenix Contact’s Fenton. “Many fundamental
sor, QNX RTOS, ISaGraf’s PLC firmware and konig-pa’s
differences still exist between PLCs and PCs, but their
master stack software to deliver 1-ms cycle time with
features are overlapping, and their OSs enable it. So
less than 1% CPU overhead, and it integrates the four
from firmware microcode on PLCs that was very hard
participants at the system-on-a-chip (SoC) level. This
to change, we’re going to full-blown Windows CE OSs
lets them use new Ethernet-based and real-time auto-
running on PLCs with real-time kernels, which are
mation technology, but also reuse or adapt existing au-
more modular and allow features to be moved around
tomation algorithms built from ladder logic or function
more easily as needed.”
blocks. This solution also includes ISaGraf 6 Workbench
software and konig-pa’s KPA Studio software, which
serve as the offline development environment (Figure 2).
Likewise, Intel Corp. (www.intel.com) reports it will
launch its Industrial Solutions System Consolidation
Series in 2Q14. Tim Appleton, industrial marketing manager in Intel’s Internet of Things Solutions Group, says
Software Guys, Chipmakers Get Onboard
this solution will be based on its Intel Core I7 processor
Not surprisingly, once machine and automation build-
and will unify its OS, hypervisor, security capability and
ers start messing with OSs and kernels in controllers,
HMI in one application-ready platform. “This is a home
it’s going to attract the interest from developers on the
for soft PLC applications to sit on, and PLC applications
microprocessor side.
can be delivered from it,” says Appleton.
n.
1
CD1403_40_43_FEATURE2.indd 43
3/11/14 5:03 PM
Running Lean?
Then, lean on us! Our MOVIDRIVE® inverter
requires zero programming. So, you don’t
need an engineer who speaks IEC 61131, C#,
or C++. Simply enter your parameters and
go. MOVIDRIVE also substantially reduces
the load from your main PLC and dramatically
improves the PLC’s performance. Plus, you
can even use your existing control system
because MOVIDRIVE speaks your fieldbus
language! So, keep your bus and leave the
driving to us.
seweurodrive.com / 864-439-7537
CD1403_FPA.indd 44
3/7/14 1:49 PM
hank hogan
•
contributing editor
•
hank@hankhogan.com
TECH FLASH
Motor Efficiency and More
The gains mighT be small and the cost differential
An even-better payoff can arise from varying motor
large if you change from a premium to a super-premi-
speed to match the task at hand. A pump, for instance,
um, or high-efficiency, motor. The extra expense can
might only need to run at full power half the time
be worth it, though, given the duty cycle. However,
and lope along at three-quarters full output the rest
other motor capabilities, such as being able to run ef-
of the time. The power savings grow as the cube of
ficiently enough at an appropriate and variable speed,
the speed, England says, so getting the latter right can
might offer an even better payoff.
outweigh other possible efficiency improvements.
An illustration of these various ways to boost
NovaTorque (www.novatorque.com) manufactures
efficiency comes from Portescap (www.portescap.
brushless, permanent-magnet, ac motors. Alan
com). The company makes motors for smaller
Crapo, vice president of electromagnetics at
applications, with a line of stepper, dc and brushless
NovaTorque, says the company chose to use low-
products. The stepper motors have efficiency as high
cost ferrite materials instead of rare-earth magnets,
as 60%, while the brushless motors come in at +90%,
as the latter can be expensive. Hitting efficiencies
roughly equivalent to the super-premium class of ac
in the 95% range with this approach does require
induction motors.
some careful choices that are designed to boost the
In the last half of 2013, the firm launched its Ultra
EC series of brushless, slotless dc motors. These have
magnetic performance.
“We focus the flux in three dimensions, and we
several innovations, some of which are particularly
have a cone shape, which gives us additional flux
important when it comes to efficiency, according to
focus between the rotor and the stator,” Crapo says.
Dave Beckstoffer, Portescap’s project manager.
“One is the coil design,” he says. “That allowed us
to increase the power density, increase the speed and
have the motor run much cooler.”
That extra performance can be important in some
settings. For instance, the motor could rapidly close a
“Once you get into 50-hp motors that
run 24 hours a day, a couple of efficiency
percentage points end up being a fair
amount of dollars over a year’s time.”
pick-and-place gripper about 80% of the way, with the
final one-fifth completed at a slower and more part-
Employing such motors can bring cascading
friendly rate. The overall effect could be a faster cycle
benefits, he adds. Using a higher-efficiency motor for
time, as well as an efficiency improvement.
a fan, for instance, lessens the overall cooling load
Kollmorgen (www.kollmorgen.com) designs and
because the motor itself is producing less waste heat.
makes ac induction and permanent magnet motors.
Finally, one of the best ways to boost motor ef-
Its products are found, for example, in the fans that
ficiency could lie in doing some upfront work, notes
circulate air within large buildings. In such appli-
Rahil Hasan, motion marketing manager at Rockwell
cations, premium motors might have efficiencies
Automation (www.rockwellautomation.com). This is
around 90%, while super-premium motors might be
based on the premise that right-sizing components
in the low- or near-mid-90% range, says Tom England,
can lead to less wasted power.
Kollmorgen’s vice president of market development.
The efficiency gain is a few to, at most, 5%. But that
small difference can be important.
“Once you get into some big motors, such as 50hp motors that run pumps, fans and compressors
24 hours a day in your plant, a couple of percentage
For that, Rockwell Automation offers software
tools that optimize the sizing of the system. Motors,
drives and, sometimes, mounting frames can be
made smaller, potentially saving money and improving system efficiency.
To help this process, Rockwell Automation
points efficiency end up being a fair amount of dol-
optimizes motors and drives, so they work better
lars over a year’s time,” England says.
together. For instance, when the company launched
That efficiency gain is achieved because some of the
its low-inertia VPL servomotors, it did so after hav-
design and construction techniques include a copper—
ing tweaked the guts of the motor to make it more
instead of aluminum—bar rotor and very high slot-fill in
efficient in the system. “We optimized the windings
the stator. Those add to the cost of the motor, but if the
in the motor, the speeds they operate at and the peak
duty cycle is high enough, the extra expense is justified.
currents they handle,” says Hasan.
controldesign.com
CD1403_45_46_TECHFLASH.indd 45
March 2014 Control Design
45
3/10/14 5:10 PM
PRODUCT ROUNDUP
cdroundup@putman.net
Pass It On
Moving Sensor Data to All Corners of the Business Means Suppliers Offer
More Connectivity Options, Compact Sizes and Ease of Use
Big data, medium data, small data. No matter the
mass, volume, density and temperature of the medium.
magnitude of the amount of machine or process data
It works at pressure levels to 100 bar and temperatures
needed in manufacturing operations these days, sen-
-50 to 200 °C. It communicates with Simatic and all
sor suppliers of every ilk are providing more network
other common process control systems via multidrop-
connectivity possibilities with their devices to help
addressable Modbus RTU485, and can be integrated
report operating and/or condition status to other seg-
into existing and new systems.
ments of the company, as well as enable more direct
Siemens industry; 800/964-4114;
machine control feedback.
www.siemens.com/industry
“The growing popularity of industrial networks has
heavily influenced the expansion of our rotary encoder line,” reports Bob Alesio, AMCI director of sales
FlExiblE lasEr scans
and marketing. “Our most popular shaft encoders now
LS-500 Class 1 digital laser sensors
include an Ethernet, DeviceNet or Profibus interface.”
in a small footprint for dirty set-
Control Design’s audience surveys regarding in-
tings feature 60-ms response time,
dustrial sensor use seem to back that up. In 2008, 78%
built-in “and,” “or” and “xor” logic
of respondents reported that their deployed sensors
functionality, four small sensor
were hardwired. December 2013’s survey pegs that
head configurations, analog 4-20
number at 53% now. Nearly 15% of respondents noted
mA output, eight data banks with
using IO-Link, a solution that wasn’t even asked about
logic functions, four levels of light adjustment, threshold
in 2008, since its North American visibility was pretty
tracking feature and multiple application recipes.
low at that point. Basic serial EIA232/422/485 was used
Panasonic; 877/624-7872;
by 23% of respondents in 2008. This latest survey puts
www.us.panasonic.com/industrial
that use at 10% at present.
What hasn’t yet changed much is the percent of
survey respondents who say they use wireless sens-
lOcatED in thE Vicinity
ing. Only about 30% report using them, a number
Inductive proximity sensors
that’s been largely constant since 2008.
range from M8 to M30 in
nickel-plated brass and stain-
Easy as ODVa
less steel versions. Most are available pre-cabled with
OS32C-DM Type 3 safety laser scan-
M12/M18 connectors, are IP67 (EN 60529)-rated, UL-certi-
ners report status and measure-
fied with reverse polarity protection, output short circuit
ment data via EtherNet/IP, and are
protection and an LED indicator with 360° visibility.
conformance tested to the ODVA
industrial Control direct; 817/375-0023;
standard for connectivity to other ODVA-compliant
www.industrialcontroldirect.com
devices such as PLCs and HMIs. Function blocks are
provided for simple PLC controlled status and data
updates. The scanners provide configurable object
highly transMittablE
resolutions of 30, 40, 50 and 70 mm, and consume just
One Series safety transmitters monitor
5 W (3.75 W in standby).
temperature and pressure, providing a
Omron automation & Safety; 800/556-6766; www.sti.com
NAMUR 4-20 mA output. An internal,
high-speed safety relay can initiate an
alarm or emergency shutdown directly from the instru-
FlOw anD MOrE
ment. The sensor and logic solver functions are built-in.
Sitrans FC410 compact Coriolis
The transmitter is certified for use in SIL 2 applications
flowmeter has 0.1% measuring ac-
and is capable of SIL 3 with redundancy, achieving a safe
curacy with a 10-ms signal update
failure fraction of 98.5% and a risk reduction factor of 806.
and measures flow rate data and the
United Electric Controls; 617/926-1000; www.ueonline.com
46
Control Design March 2014
CD1403_47_49_ROUNDUP.indd 46
controldesign.com
3/11/14 5:20 PM
DOTS THE EYE
LOCK OUT PROBLEMS
Smarteye SmartDot laser sensor
Bulletin 873P ultrasonic
has an OLED graphic display, sensor
sensors have a wide
scope diagnostics, pushbutton au-
range of operating
toset, 240-µs response time, 10-LED
voltages and setpoints,
contrast indicator, and is available in
and output functions
short-range, long-range and retroreflective models.
are selected via pushbutton and protected by a
Tri-Tronics; 800/237-0946; www.ttco.com
lockout feature to prevent tampering or inadvertent
reprogramming. Multiple status LEDs assist
setup and troubleshooting. Select models have
COLOR TELLS IT ALL
synchronization to prevent crosstalk in multiple
S18-2 self-contained, dc-op-
sensor installations. They’re IP67-rated, come in 18-
erated, photoelectric sensors
mm and 30-mm-diameter models with analog, digital
have advanced ASIC technol-
and combination output configurations, and have
ogy, resistance to fluorescent
sensing ranges from 400 mm to 3.5 m.
light and offer a high level of crosstalk avoidance. Their
Rockwell Automation; 440/646-3434; www.ab.com/sensors
visible-red emitter beams reach up to 25 m. Indicators
include a solid green to indicate power is applied and
the sensor is ready, while flashing green specifies a
LONG AND SHORT OF IT
marginal sensing signal. Two yellow LEDs are visible
OPT short- and long-
from both sides of the sensor and indicate the output is
range sensors available
conducting.
with either Class 1 or
Banner Engineering; 888/373-6767;
Class 2 laser options
www.bannerengineering.com
have rectangular plastic
housings and an M12
quick-disconnect. Short-range, diffuse distance
DEVICENET-CAPABLE
sensors use high-resolution CMOS line-array
NR25 series encoders for all PLCs
technology, thereby eliminating material, color and
and PACs that communicate with
brightness-related differences. They have sensing
DeviceNet measure up to 30-bit
ranges of 30-660 mm at 1,500 scans per second. The
total resolution, delivering 16
long-range photoelectric sensors use the transit-time
bits (65536 steps) per revolution and up to an additional
measurement between sensor and the object, and
14 bits (16384 revolutions) for multi-turn versions They
have a sensing range to 10 m. The retroreflective
have IP67 ingress rating, solid shaft and hub shaft ver-
styles sense up to 100 m.
sions, and programmable resolution, count direction,
AutomationDirect; 800/633-0405;
total measurement range, velocity format and position
www.automationdirect.com/laser-sensors
preset. Bus address and bus speed, as well as a reset button, are accessed through the unit’s back cover.
Advanced Micro Controls; 860/585-1254; www.amci.com
NO FOUL, NO HARM
SC24 differential
combined pH sensor
THE ONE PIECE
has a sealed glass
Full Inox-inductive sensors are rated
reference cell that prevents fouling and ensures mea-
to IP68 and IP69K and sized M8 to M30
surement stability. It integrates four functions—pH
with sensing distances up to 40 mm.
sensing, reference cell, temperature compensation
The family includes cable and connec-
and liquid earth (ORP), so the user has to deal with
tor versions with PNP or NPN output
only one sensor and one cable. It’s designed for a 12-
configurations. They have one-piece,
mm PG13.5 mounting. An adapter makes it compat-
stainless steel construction and hermetically sealed
ible with most industrial holders. Usable for ORP/
cable entry, and are weld-immune.
Redox control applications.
Contrinex; 860/388-3573; www.contrinex.com
Yokogawa; 281/340-3800; yokogawa.com/us
controldesign.com
CD1403_47_49_ROUNDUP.indd 47
March 2014 Control Design
47
3/11/14 5:20 PM
PRODUCT ROUNDUP
No Flight Delays
nants, chemicals and abrasion. No-load supply current
O5D Series photoelectric sensor inte-
is less than 10 mA. Through-beam mode sensors offer
grates time-of-flight sensing principle
a sensing range up to 2.5 m, deliver a 600-µs response
with PMD technology for long diffuse-
time and can operate with a 10-30-Vdc supply and
background suppression sensing ranges
temperature range of -25 to 60 °C. R2 series photoelec-
of up to 2 m. The switch point, visible
tric sensors are IP67-rated, and carry the CE mark and
on the sensor’s numeric display, is set by pushbuttons.
UL and cUL approvals.
The O5D100 model displays range in centimeters, and the
Pepperl+Fuchs; 330/486-0001; www.pepperl-fuchs.us
O5D101 model displays range in inches. The Class 2 laser
has a visible red light spot for trouble-free installation,
and has a complementary LO/DO, PNP output.
compute the poWer
ifm efector; 800/441-8246; www.ifm.com/us
APN Series power-monitoring
sensor measures three phases of
current and voltage, and com-
it’s soliD-Free
putes 14 values to track power use
Element Type 8036 transmitter for flow
in the RS485 Modbus RTU format.
rates in solid-free liquids has a sensor
To measure watts in an ac circuit,
with paddlewheel and an enclosure with
the supplied voltage is compared with the current and
cover containing the electronic module
indicates whether the current peaks before the volt-
and a removable display, all attached
age (leading power factor in a mostly reactive circuit)
to a compact, quarter-turn fitting. The transmitter can
or the current peaks after the voltage (lagging power
operate independently of the display, which is required
factor in a more inductive circuit). It can be configured
solely for programming to set parameters, restore default
to accept standard 5-A current transformer inputs or
parameters, program information to be displayed, access
sensors producing 333 mVac proportional to the ac
codes, adjust 4-20 mA outputs, and view measured and
current of the circuit.
processed data. For orifice sizes ¼ to 2½-in., the operating
NK Technologies; 800/959-4014; www.nktechnologies.com
range is 5 to 212 °F. Maximum pressure is 232 psi.
Burkert Fluid Control Systems; 949/223-3100;
www.burkert-usa.com
seNsible seNsiNg
EZ Viz Prox proximity sensors in 8-,
12-, 18- and 30-mm models can be
Watch your speeD
flush or non-flush face with nickel-
SAM inductive sensor for
plated brass or stainless steel hous-
speed and acceleration moni-
ings, 2-m integral cable or industry-
toring gives a raw pulse output and a programmable,
standard M12 connectors, PNP or
discrete switching output. It has a monitoring range
NPN, normally open/close outputs. Standard sensing
of up to 12,000 pulses per minute and a start-up delay.
distances range from 2 mm to 15 mm.
To reduce false trips, SAM offers no delay, fixed-time
EZAutomation; 877/774-3279; www.ezautomation.net
delay and upper-threshold delay modes to account for
fast or slow machine start-up times. On-board adjustment tools make it easy to set parameters and display
NeeDs little poWer
errors directly.
MNU Series ultrasonic sensors
Sick; 800/325-7425; www.sickusa.com
are self-contained and measure
distance, level or volume with a
standard Modbus RTU (RS-485) output. They have sens-
glass tough
ing ranges from 4 in. to 40 ft with accuracy of ±0.25% of
R2 Series ‘ultra-small’ sensors fea-
detected range and resolution 0.1 in. Low current draw
ture an industry-standard mounting
makes them suitable for remote locations where power
footprint and a 45-in. cable outlet. The
conservation with solar panels and batteries is critical.
sensors have a glass optical surface for
Automation Products Group; 888/525-7300;
resistance to environmental contami-
www.apgsensors.com
48
CD1403_47_49_ROUNDUP.indd 48
Control Design March 2014
controldesign.com
3/11/14 5:20 PM
UNTOUCHABLE
by reducing the effects of interference and target color
Non-contact, ultrasonic
or angle. Multiple sensors will not interfere with each
sensors measure fill
other in close proximity because of built-in, crosstalk
levels, heights and sag;
prevention function. They feature both Light-ON and
count and monitor the
Dark-ON outputs in the same unit and also feature M8
presence of objects; and
connector type models.
operate independently of
Keyence; 888/539-3623; www.keyence.com/prprmf
color and surface finish.
Detection ranges extend
from 20 mm to 8 m, and they’re available in switching
T IT UP
or analog versions. All analog versions are available
Configurable SMT-8M-A
with voltage or current output (0–10 V or 4–20 mA). In
proximity sensor for drive
addition, the M30 version includes variants with two
units with T-slot provides
switching outputs.
installation aid via second
Balluff; 800/543-8390; www.balluff.com
LED; one-hand assembly; reversible switching output;
choice of IP65, IP68 or IP69K protection; and ATEX
design configurable up to 30-m cable length.
FRUGAL CONSUMER
Festo; 631/435-0800; www.festo.us
Contelec Vert-X 21 LP noncontact angle sensors consume
only 300 µA at 3.3 V. They have
BUSY WHEN WET
0 to 360° measurement range,
Liquiphant FailSafe FTL8x
12-bit resolution, repeatability
point level switches
to 0.1°, and maximum hyster-
have two relay outputs, a
esis of 0.2°. Power supply range is 1.8–5.5 V. Sensors can
4–20 mA output that con-
be ordered as a simple three-wire angle sensor or a pro-
nects to a fail-safe switch-
grammable version with up to two switch outputs, cus-
ing unit with a two-channel output, safety contacts and
tom measurement angle, start- and end-point settings,
a safety locking function. The 4–20 mA signal jumps
custom characteristic curve and/or sense of rotation.
from high to low current when the MIN or MAX point
Novotechnik U.S.; 508/485-2244; www.novotechnik.com
level is reached, and a permanent live signal of 0.25 Hz is
superimposed on the sensor output to indicate status.
Endress+Hauser; 317/535-1329; www.us.endress.com
ONE CHIP ONLY
BTF Series photoelectric sensors
use a one-chip, photo IC design and
FDA-RATED
include background suppression
Q42 uprox+ long-range,
function, through-beam or diffuse
inductive proximity sensor
reflective types, visible red LED
uses FDA-rated materials for
detection spot and IP67 rating. Stable
washdown applications and
sensing minimizes false detection
choice of top-facing or front-
regardless of the color or glossiness
facing models. It has a sensing range of 50 mm for all
of the target.
types of metals and operates in temperatures ranging
Autonics; 847/680-8160; www.autonics.com
from -40 to 100 °C.
Turck; 800/544-7769; www.turck.us
NOT EASILY SHOCKED
PR-M/F Series miniature
MORE, MORE, MORE
photoeyes have a resin-filled,
Find more industrial sensing products from companies including
Ashcroft, Automation Systems Interconnect, Baumer, Heidenhain,
and Macro Sensors at www.ControlDesign.com/roundupsarchive.
SUS316L stainless steel body
for shock resistance. The devices claim stable detection
controldesign.com
CD1403_47_49_ROUNDUP.indd 49
March 2014 Control Design
49
3/11/14 5:22 PM
real answers
controldesign@putman.net
Looking for Panel-Build Best Practices
When we configure and wire our control panel
defined well, then careful planning can save consider-
housings, we follow all the regulations to the let-
able space. Some engineers want every channel fused
ter. However, because our panels house a constantly
for DI, DO, AI and AO, which can add up very fast. Per-
increasing array of devices, we’re faced with design un-
haps group-fusing, dual-level or compact fuse/terminal
certainties about issues, such as how much expansion
blocks can be used.
space (mostly for I/O) to leave in the panel; the most effi-
Ken Schultze, engineering manager,
cient designs to minimize wiring; how to leave only the
Easter-Owens, www.easter-owens.com
minimum device spacing and deal with device density
and potential overheating; and how to avoid additional
Manage the Wires
cooling requirements. Simply asked, who has some best
Putting too much in one control panel can be costly
practices they’ve learned and would share?
—from January’14 Control Design
if you introduce EMI noise, thermal problems or poor
Answers
network connectivity. Up to half of the control panel
space is consumed for wire management that is often
inefficient. Optimize how DIN-rail modules and terminal
blocks are deployed with wiring duct to reduce space
A Lot to Consider
required and provide design flexibility for device spac-
This is a complex question with no easy answer. When
ing and future expansion. A rapidly growing area that
asked to design for future expansion, you need to
consumes significant panel real estate is Ethernet switch
understand the process being controlled, and if the pro-
deployment. A new way to deploy Ethernet switches is
cess has no room or plans for expansion, then maybe
to install separate, pre-wired, integrated zone enclosures
no future space is required. The question of budget is
with optimized spacing for these critical network con-
also paramount when determining how much extra
nections. Panduit and Pentair Hoffman collaborated on a
space and equipment can be included in the panel. A
new website, www.hoffman-panduit.com, to share con-
commonly specified spare space requirement is 20%,
trol panel best practices and learnings on topics includ-
but most engineered drawings and panel layouts do not
ing space optimization, noise mitigation, environmental
show this. Is it the panel builder’s responsibility to cor-
protection (including thermal), security and safety.
rect this at bid time and possibly not capture the work
Dan McGrath, industrial automation solutions manager,
against a panel builder who quoted to the drawings
Panduit, www.panduit.com
which do not show this spare space and equipment?
Make certain the wire duct is sized for some (about
Machine Mount Alternative
25%) extra capacity, some of which may be used in the
When configuring control panels to accommodate ever-
field for the base design I/O.
changing I/O points, consider the worst case. But this
My rules of thumb are:
might result in an oversized control panel, which is not
1. Leave room near the power distribution sections for
cost-effective and could leave the customer asking why
one additional power supply and several (20%) con-
such a large cabinet. Our solution is to not put the I/O
trol fuses or circuit breakers with terminal blocks;
points in the control cabinet, but to use an on-machine
2. Design cooling for 20 to 30% extra capacity, some
solution, such as Allen-Bradley’s 1738 ArmorPoint I/O.
of which is absorbed at the base design level due to
It can be mounted on the machine without a cabinet
dirty filters that often do not get attention;
and close to the sensors and actuators. With connectiv-
3. Side panels in some cases can be added to the interior left and right walls of the enclosure, and if you
ity support for DeviceNet, ControlNet, EtherNet/IP and
Profibus, it can be used with a wide variety of PLCs.
plan for this when designing the enclosure, it can
Joe Allard, controls engineering,
often be a great benefit later. This requires the en-
Pearson Packaging Systems, www.pearsonpkg.com
closure be deeper than specified, but if explained to
the customer, it is easy to sell. A deeper enclosure
Software Aids
also helps when future additions of HMIs or push-
You should take a look at 3D virtual validation. By us-
buttons are done, thus reducing the risk of these
ing some very simple but effective tools you can easily
devices bumping into back panel components;
create, edit and visualize your complete enclosure in 3D
If the panel I/O terminal block arrangement is not
50
Control Design March 2014 CD1403_50_53_REALANSWERS.indd 50
before you decide to manufacture that enclosure.
controldesign.com
3/10/14 5:12 PM
Our Pro Panel, for example, will allow you to link all
account site temperatures and altitude. In any case, I
your components in your enclosure with the schematic
recommend adding the most possible main panel addi-
design, eliminating errors in missing components or
tional capacity (installed or not) and at least a 15% cooling
using the wrong components, thereby adding cost by
capacity reserve. It’s not very nice when the customer
delays in delivery and increased manufacturing times.
adds more and more elements to change the power re-
Through the wire list provided to you by the sche-
quirements, and you must change the cooling system.
matics, the software can route these wires in 3D and
Third, leave some signal I/O in spare. Maybe this is
give you an accurate length calculation. A function to
an extra cost, but for the long term, customers always
minimize wiring is also available based on the current
need something at the last minute. No more than 2 to
position of your devices in the panel. This can be a big
5%. And don’t tell the customer, or they will take this as
money-saving feature since you’ll be using less wire.
available space and find something to put in there.
Once the wires have been optimized and length has
Fourth, leave some power left in your power supplies.
been calculated, the software exports all the wiring data
I prefer 20% minimum, just in case you find on-site more
to wire-cutting machines for automatic labeling, strip-
inductive charges or changes in the engineering design.
ping, adding ferrules and cutting the wires for assembly.
Nowadays, customers want to have simple and small
By capturing power dissipation values on the compo-
cabinets, so put communication-capable devices into
nents, Pro Panel in conjunction with RiTherm from Rit-
the main cabinet (protections, contactors, peripheral
tal can also can give you recommendations on what size
I/O) with terminal connections directly to the process.
of cooling requirements are needed for that enclosure.
Cristian Oyaneder, owner, general manager, SA Asinpro,
Finally, you can capture minimum spacing require-
www.linkedin.com/pub/cristian-oyaneder/3a/b94/b44/en
ments and visualize these in 3D, giving the user visual
validation that the components are correctly positioned
A Size Bigger
and spaced in the enclosure.
Here’s a general tip: Avoid sizing a control panel to the
Sean-Patrick Mulherrin, product manager, Eplan Electric P8,
Eplan, www.eplanusa.com
depth of the tallest component. Go up to the next larger
size. For example, if your tallest component is 7.8 in.,
go with a 10-in. deep enclosure instead of an 8-in.deep
[Here’s a response we received as a result of posting the prob-
enclosure. You might find it helps you avoid issues in
lem to LinkedIn’s Panel Building and System Integration Group.]
design expansion plus other future areas.
Patrick Dowden, president,
Out of the Box
Automation Southwest, www.automationsouthwest.com
Have you considered distributed I/O systems like AS-i?
This makes expansion and redundancy really easy, as
Think Tens
well as reducing the size requirements of your pan-
The basic rule of thumb from experience is basically the
els. With a well-designed, distributed system you can
10-10-10 rule. This is a 10% installed spare per I/O type
reduce your main panel considerably, making consider-
in the panel. The next is to allow for 10% expansion of
able savings on installation in the process.
I/O and termination in existing I/O racks. Third, allow
Ian Salter, electrical and controls design engineer,
for another 10% real estate spare in a panel to allow for
Dematic, www.dematic.com
future remote racks with I/O modules and their terminations. Anything more than that, and the expansion
[Here’s part of a thread about the problem from LinkedIn’s
should be deemed as a major one, and a new RTU can be
Industrial Automation Group.]
placed within that process area. One thing to remember in this rule is to allow for power consumption at
Check List
the maximum installed-equipment level. This should
First, if you (and your customer) agreed to install an ad-
include the maximum space that would be required
ditional peripheral cabinet in case there’s a future need
for distribution of ac and dc circuitry. I also agree with
for expansion, be sure that you will have physical space
Patrick Dowden regarding the sizing of panels. Size is a
to do that. Simple mistakes, big troubles.
small price to pay for the flexibility you gain.
Second, do a thermal calculation to design the necessary cooling for the main control panel, and take into
controldesign.com CD1403_50_53_REALANSWERS.indd 51
Uwe Kurfurst, director,
Moore Process Controls LLC, www.moore.co.za
March 2014 Control Design
51
3/10/14 5:12 PM
real answers
[This is from a thread on LinkedIn’s Industrial Automation and
start of terminal block (TB) rail. This space is required
Process Controls Network Group.]
for dressing the bottom entry cables from field;
Outside the Box After a Point
grouped and identified by group marker. Leave 30%
I usually use 20 to 25% spare space in panels, with 25% if
extra free TB rail for housing TBs in future. This should
I know expansions will happen eventually. If the require-
be evenly distributed;
4. TBs connected to a particular I/O card should be
ment is to keep things as small as possible, then I will
stick to 20% spare, but then make recommendations to
use IP67 I/O for expansions, and most times as a part of
5. Leave minimum 30% space free in cable raceways
to accommodate additional I/O wiring; and
6. Ferruling should be I/O hardware-based with slot/
location reference. User can easily locate grouped TBs
the initial design.
Christopher First, equipment and controls planning engineer,
Altran North America, www.altran-na.com
for each I/O.
Besides that, wiring drawings should be detailed and
easy to follow. This will ensure peace of mind for the
[This response is from LinkedIn’s Automation Engineers group.]
system integrator and panel builder!
Santhiraj Sathanna, consultant director,
Six Steps
Futura Electronics Pvt.,Ltd.
Based on my experience of almost 30 years in design
in.linkedin.com/pub/santhiraj-sathanna/12/b77/a
of control panels using relays and now with PLCs, I can
share with you the following:
Add Access
1. Provide a minimum of 25% I/O expansion space;
Years ago, we were presented with limited floor space
2. Place switched-mode power supply on top, below a
for control panels. When the control panel/operator
roof-mounted exhaust fan. Reserve the first top row for
console is larger than the machine, you have a space
the power supply and for circuit breakers with mini-
crunch! So to pack things as efficiently as possible, the
mum 30% spare space, so that future additions can be
control enclosure was a spilt front/rear enclosure with
made, as well as offer better cooling due to extra space;
swing-out panels. It made for a very tight package with
3. Leave clear space of 300 mm between floor and
a Modicon 984, rack-mounted PC, five power supplies
and DIN-rail-mounted contactors, signal isolators, etc.
maY’S PROBLEM
We’ll save ourselves and our customers
significant money by using wireless sensors in places
to connect multiple machines across varying distances,
many in the 1000-ft range. First issue: Update rates will
vary from 10/sec to 1/sec with some others transmitting
on status-change only. So we have options for powering
the sensors. At these rates, can we use energyharvesting methods? What’s the general state of battery
life for these conditions? There even are a few spots
where PV is an option.
Second issue: We hear that the level of encryption has
a big effect on battery life, which no one seems to talk
about. Any practical advice for these issues?
SEND US YOUR COMMENTS, SUGGESTIONS OR
SOLUTIONS FOR THIS PROBLEM. We’ll include it in
the May ’14 issue, and post it on ControlDesign.com.
Send visuals if you’d like—a sketch is fine. Email us at
RealAnswers@putman.net. Please include your company,
location and title in the response.
Today with remote I/O being more prolific, you can
probably anticipate expansion using this technology.
Also, consolidating functions into one device, such as
an industrial PC, will reduce the component count,
reduce labor assembly cost and reduce wiring mistakes.
Simon Gibson, controls engineer,
Mathews Co., www.mathewscompany.com
[And from LinkedIn’s Business Industrial Network Group.]
The Possible Outcomes
As you said, there are design uncertainties that are an
unknown and hard to design into a panel when it’s a
future requirement. If you’re designing a panel so full
that component spacing and thermal qualities need to
be engineered, then your designs are only to the absolute minimum standard, and that’s not a best practice
but rather just an acceptable practice.
To the question of how much expansion to design in,
I always designed for three possible conditions:
First, to easily contain the components needed to do
HAVE A PROBLEM YOU’D LIKE TO POSE to the readers?
Send it along too.
the job as per requested functions;
Second, to adequately contain the components
needed to do the job, plus any of the most probable
52
Control Design March 2014 CD1403_50_53_REALANSWERS.indd 52
controldesign.com
3/10/14 5:12 PM
additional functions; and
Third, to be capable of being modified in order to
Smaller Wire Ways Possible
At the companies where I have been employed, the rule
contain the components needed to do the job, plus any
of thumb was 80%. That is, when you buy a PLC, don’t use
possible additional functions.
more than 80% of the I/O to leave room for modifications.
I would then design the panels to be capable of the
Components such as power supplies, drivers, etc., have
second condition, build the panel to be capable of the
space requirements for heat dissipation. One should al-
first condition, and have a backup plan for the third
ways follow the manufacturer’s specs. After all, they did
condition. As an example, you can build a panel that
the investments in testing. Why not take advantage of
is perfect for the first condition and is a bit tight if
their money? You’re paying for it anyway when you buy
changed to the second condition, and you have a back-
their product. And should it fail under warranty, the first
up plan of having to add a fan due to thermal concerns
thing they’re going to ask about is installation and how
if you have to go to the third condition.
much room was left for air circulation.
Another example would be a panel intended for
One more thing to look at is wire size. In recent years,
10 motor starters with the likelihood of two more
devices have become more efficient, so amps are down.
starters and the possibility of yet two more starters.
A good example of this is 24-Vdc power supplies. Any-
Consequently, you would design a panel for 12 starters
way, the size of the wires can be decreased, leading to
and build it with 10 starters and two open spaces for
smaller wire ways. This can increase the space around
the two additional starters later. You would also design
the drivers and such.
in the possibility of moving all the existing starters
More and more, companies want smaller electrical
closer together to accommodate the last two starters,
cabinets, so all these things should be considered
provided doing so does not compromise any engineering
when engineering and constructing electrical
standards and only runs them to a tighter limit.
cabinets. Good luck.
DaviD Schumacher, MMP, controls/automation technician,
ca.linkedin.com/pub/david-schumacher-mmp/28/877/a5b
chriS Leber, electrical assembler,
GL&V, www.glv.com
Get Up to
Speed Quickly
With the Control Design Essentials Series
Written by the editors of Control Design, our new Control Design
Essentials series is designed to provide industry professionals with
an up-to-date, top-level understanding of a range of key machine
automation topics. Our intent is to present essential engineering
concepts in a practical, non-commercial fashion, together with a review
of the latest technology and marketplace drivers—all in a form factor
well suited for onscreen consumption. Get in and get out quickly with
just the information you need.
To download your complementary copy,
visit ControlDesign.com/Essentials
CD1403_Essentials_Half.indd 1
CD1403_50_53_REALANSWERS.indd 53
Essentials of
Weighing Systems
Made Possible By
Now available at
ControlDesign.com/Essentials
3/4/14 10:01 AM
3/10/14 5:12 PM
RESOURCES
Safe HMI Operation
Each quartEr, Control Design’s editors pull
tions and standards around the world, and compares
together the latest online tools and resources that we
the Class/Division Hazardous Location versus Zone
can find in a specific topic area and present them here.
Hazardous Area Classifications and Protections
This installment’s topic is HMI in hazardous areas.
primarily for oil and gas refineries, chemical processing and transport operations. Many charts and
E-STOP!
diagrams explain the differences between global
This free white paper
standards, and show which standards apply in
discusses a new gen-
which countries. The paper also defines such basic
eration in emergency
terms as “intrinsic safety,” “explosion-proof,” “non-
stop switches for
incendive” and more, as well as the responsibilities
HMIs. For operators
and obligations of HMI and panel builders under the
facing an emergency
standards. The link is at www.bit.ly/1dIxxXp.
situation, using e-stop switches is the last possible
aIS; www.aispro.com
measure to avoid an accident. Thus, e-stop switches
must send a stop command to machines and systems
UGLY, UNSAFE HMIs
without failure. Many international standards have
The presentation, “HMI
been written to ensure e-stop switches meet func-
Design—The Good, the
tional and structural requirements. However, the
Bad and the Ugly—and
structure of conventional e-stop switches can’t shut
What Makes Them That
down system operations when improperly installed or
Way,” by Paul Gruhn,
operated with excessive force. This paper explains the
PE, gives a quick, basic
design of the next-generation e-stop switches, which
introduction to proper
achieve a safer HMI environment and change the
HMI design best practices and shows why bad design
concept of emergency stop switches. A direct link is at
makes for unsafe conditions, regardless of the envi-
www.bit.ly/1gkYPAh.
ronment. The link is at www.bit.ly/1oG1cC3.
IDEc; www.idec.com
ISa; www.isa.org
DESIGNING HMIs
FOR SAFETY
INSTALLING AUTOMATION
IN HAZARDOUS AREAS
Designing systems
For most process plants,
for installation in
it’s not possible for all
hazardous areas
automation system com-
requires an under-
ponents to be installed
standing of division
in non-hazardous areas.
and zone classifications, and whether off-the-shelf
As a result, some form
components are appropriate. Control Design’s
of protection is required
senior technical editor, Dan Hebert, walks readers
to prevent fires and explosions that could occur
through the complexities of division and zone clas-
when a hazardous gas and energy source combine.
sifications, and delivers some guidance for getting
There are standards and associated products that, if
the right components for your hazardous-duty ap-
properly designed, installed and maintained, virtu-
plication. The direct link is at www.bit.ly/PjXGDi.
ally eliminate the risk of an accidental explosion in
control Design; www.controldesign.com
hazardous areas. This paper will compare, contrast
and explain the IEC and NEMA standards and then
GLOBAL SYSTEMS
AND STANDARDS
explain how to protect automation system compo-
This technical paper
one of the three main methods of protection: energy
explores the basics of fire
limiting, containment and segregation. The link to
and explosion safety is-
examine this free PDF is at www.bit.ly/1qqsL6c.
sues, legislation, regula-
advantech; www.advantech.com
54
Control Design March 2014
CD1403_54_RESOURCES.indd 54
nents—including HMIs—using either standard via
controldesign.com
3/11/14 5:26 PM
EXCLUSIVE
Media Converter Puts Ethernet on Blue Hose
Repurposed Blue Hose®
ControlLogix®
EtherNet/IP™
Industrial Media
Converter (master)
PLC-5®
Remote I/O
Industrial Media
Converter (slave)
Cabinet 1
Industrial Media
Converter (slave)
Cabinet 2
There are hundreds of thousands of Rockwell
same coax cable, and ProSoft applied that same idea,
Automation’s Remote I/O systems in use. Remote I/O
but over Blue Hose, which is twinax.
is being discontinued. Users will need to upgrade, but
These converters support 57.6-K and 115.2-K baud
the new Flex I/O requires Ethernet, not the Remote
rates, and the units are plug-and-play with no configu-
I/O network. So do these users have to replace all
ration required. “You connect to the Blue Hose, power
their network wiring?
up, and there’s no setup,” Roslan says. “It’s completely
The inspiration for ProSoft Technology’s new Eth-
transparent, like an Ethernet to fiber-optic converter.”
ernet to Belden Blue Hose Industrial Media Converter
The system is tailored for retrofits. “A lot of this
came two years ago at Rockwell’s Automation Fair. “A
Blue Hose cable has been out there for many years, at
customer came to us with this problem regarding his
different lengths and various levels of deterioration.
Remote I/O system,” says Ken Roslan, vice president,
The converters monitor communications and pick
global marketing, ProSoft Technology. “Of all those
the best broadband channel for the condition of the
Remote I/O systems currently in use, many use PLC 5
cable,” Roslan says.
and SLC controllers connected with Belden 9463 Blue
The converters do more than avoid replacing cable.
Hose wire, which has been the industry standard
“You can change one thing at a time during another
for Remote I/O networks. Much of it is still in use in
scheduled shutdown,” Roslan explains. “You can con-
facilities all over the world.”
tinue to use an old controller while you install a new
Typical systems have 1,000 to 10,000 feet of cable.
controller, convert the code and use a remote I/O card
To put in a new control system, factories would
to test the code while the plant is running on the old
have to add Ethernet using Cat 5 cable and man-
controller, then switch over.”
aged switches, with fiber for distances over 300 feet,
This approach allows users to upgrade I/O as
as well as pull cable all over the facility and work
needed—one node at a time—and move it over to
around running equipment. “Just running the cable
Ethernet. “Being able to simultaneously run Ethernet
itself in an existing plant can be a challenge,” Roslan
and Remote I/O lets you make changes with minimal
says. “Then they have to convert programs and
downtime and little risk,” Roslan says. “You can
schedule downtime to install and commission the
upgrade a node and use the old I/O as spares for
new system. That’s when risk starts going up.”
other old nodes to buy time before you need to
The new converters allow users to upgrade a Remote
I/O system by running Ethernet communications over
the existing Remote I/O network. The patented technol-
replace them. In effect, you’ll never have to replace
the network cable.”
One master handles multiple slaves with cable runs
ogy helps companies upgrade their control systems
up to about 1,750 feet. Up to eight repeaters can be
with minimum downtime. Once the converters are
used to extend runs to 10,000 feet with up to 32 nodes,
installed, users can run Remote I/O and Ethernet data
the same maximum network size as Remote I/O. Sup-
simultaneously on the same cable, letting them up-
porting a minimum of 1-4 Mbps, speed is at least 10
grade individual nodes at their own pace.
times as fast as Remote I/O, and it can handle bursts
Machine builders can use the Ethernet capabilities
to add features to existing machines in a phased mi-
as high as 20 to 30 Mbps.
The Ethernet capabilities are standard Ethernet that
gration with no need to rip and replace the original
can run any Ethernet protocol for any Ethernet device
control system. They can upgrade PanelViews or
that works within the speed limitations, Roslan says.
condition-monitoring and remote-monitoring capabilities over Ethernet.
The cable company runs TV and Ethernet over the
controldesign.com
CD1403_55_EXCLUSIVE.indd 55
For more information, call 661/716-5100, email
info@prosoft-technology.com or browse to www.psft.
com/eiprio.
March 2014 Control Design
55
3/11/14 5:47 PM
PRODUCT SHOWCASE
controldesign@putman.net
Programs Included
speed and acceleration. These motor cables are fully
Adam-5560 seven-slot
compliant with Siemens 800Plus series and Rexroth
programmable auto-
Indramat specifications and with any generic motor
mation controller has
systems covered by the same cable design.
an Intel Atom 1.1-GHz
Lutze; 800/447-2371; www.lutze.com
processor and supports Microsoft Visual Studio .Net
programming and KW Software’s Multiprog IEC611313 control software with Ladder Diagram (LD), Func-
sensItIve swItcH
tion Block Diagram (FBD), Sequential Function Chart
GR400 Series miniature
(SFC), Structured Text (ST) and Instruction List (IL). It
10-mm reed switch has
includes an integrated VGA port that, with the aid of
0-10 W of rated power,
optional HMI software, means users need no added
a switching voltage of
SCADA PCs.
zero to 180 Vdc/Vac, 0.5
Advantech Industrial Automation Group; 800/205-7940;
A maximum switch-
www.advantech.com/ea
ing current and 0.8 A maximum carry current. It
has an operating sensitivity of 7-30 Ampere-turns,
and operating range of -40 to 125 °C. It’s available in
KeePs Its cool
contact form 1A (SPST) (normally open contact) with
SL Series rotary motors and
center gap.
gearmotors, with a 75-mm
Standex-Meder Electronics; 800/870-5385;
frame size, supply torque to
www.standexmeder.com
36 lbf/in. continuous and 73
lbf/in. peak. Its segmented
motor stator design, where
a twIst on safety
each segment contains individual phase wiring, limits
Twist and Secure push-
heat generation. Certifications for the motors include
button and E-stop safety
UL, CE and CSA Class I, Div 2. Frame sizes available
covers temporarily prevent
are 60, 75, 90, 115, 142 and 180 mm.
access to machine start
Exlar; 952/500-6200; www.exlar.com
and engaged emergencystop buttons. Each cover has a durable, red safetytinted cover, so employees will know at a glance that
BrIng It Home
control button is intentionally secured. Color-coded
Linear speed control option for
panel labels are included.
Model RG rolling ring linear
Brady; 414/438-6904; www.bradyid.com
drives lets users fix a specific
linear travel speed in one or
both directions of travel using
flex. flex agaIn
set screws in the drive hous-
Hi-Flex motor
ing. No adjustments to motor speed or controls are nec-
power cables
essary. Motion system designers can use the set screw
are designed for
option in applications where the return stroke of the
repeatable motion,
drive unit brings it to a home position.
tight routing, high
Amacoil; 610/485-8300; www.amacoil.com
voltages, current carrying capacity and heat dissipation. Highstrand-count cables are available in four-conductor,
non-shielded (24 to 4 AWG) and individually shielded
(24 to 10 AWG) versions for servo-controlled, step-
safely flex
per motor and VFD connection applications. Their
Superflex Plus M PUR motor cable line for continu-
tear-resistant Flexx-Sil jackets are self-healing from
ously flexing applications includes optimized braid
small punctures and will not wear, crack or deform.
angle of the shield to increase travel distance, travel
Cicoil; 661-295-1295; www.cicoil.com
56
Control Design March 2014
CD1403_56_57_SHOWCASE.indd 56
controldesign.com
3/11/14 5:50 PM
is the only magazine exclusively
dedicated to the original equipment
manufacturing (OEM) market for
instrumentation and controls—the
largest market for industrial controls.
CAT QUICK
IPC-based ProNumericXCI600 with an Intel i3 processor works with applications with up to 32 interpolating axes. The controller supports the common
CAN over EtherCAT (CoE) profile, which is compatible with nearly all EtherCAT-enabled drives. VxWorks real-time operating system and Windows 8
1501 E. Woodfield Rd., Suite 400N
Schaumburg, Illinois 60173
630/467-1300
Fax: 630/467-1124
embedded run in parallel to facilitate visualization and communication. The
controller can be parametrized on a computer with the Schleicher dialog, and
various interfaces connect peripheral devices, such as DVI/VGA interface and
USB interface, 4x 1-GB Ethernet connections and seven USB interfaces.
PUBLISHING TEAM
Schleicher Electronic; +49-30-33005-0; www.schleicher-electronic.com
GROUP PUBLISHER & VP, CONTENT
KEITH LARSON klarson@putman.net
DIRECTOR OF CIRCULATION
BIG SOFTY
JACK JONES jjones@putman.net
This range of soft starters includes SSW06 with a power range
of 3-1200 hp. Dual display keypad has LED digits for program-
SALES TEAM
ming. Various fieldbus protocols are available, as are analog
NORTHEASTERN AND MID-ATLANTIC REGIONAL MANAGER
and digital I/O for maximum automation functions. Standard
DAVE FISHER dfisher@putman.net
internal bypass contacts eliminate heat losses once the motor is at full operating voltage.
508/543-5172 Fax: 508/543-3061
Weg; 800/275-4934; www.weg.net/us
24 Cannon Forge Dr.
Foxboro, Massachusetts 02035
MIDWESTERN AND SOUTHERN REGIONAL MANAGER
GREG ZAMIN gzamin@putman.net
DATA WHERE YOU NEED IT
630/551-2500 Fax: 630/467-1124
RVG200 videographic recorder with touchscreen and integrated web
1501 E. Woodfield Rd., Suite 400N
server provides easy access to process data onsite, while enabling
Schaumburg, Illinois 60173
secure remote access from any tablet, smartphone, PC or other net-
WESTERN REGIONAL MANAGER
worked device. It has a 100-Mbps Ethernet connection and up to 24
LAURA MARTINEZ lmartinez@putman.net
universal analog inputs.
310/607-0125 Fax: 310/607-0168
ABB Measurement Products; 215/672-2684; www.abb.com/measurement
218 Virginia, Suite 4, El Segundo,
California 90245
DIGITAL SALES SPECIALIST
JEANNE FREEDLAND
jfreedland@putman.net
CHECK
US OUT!
805/773-4299 Fax: 805/773-0451
INSIDE SALES SPECIALIST
POLLY DICKSON pdickson@putman.net
W W W.CONTROLDESIGN.COM
630/467-1300 Fax: 630/467-1124
EXECUTIVE STAFF
AD INDEX
Adalet . . . . . . . . . . . . . . .
Allied Electronics. . . . . . . .
AutomationDirect. . . . . . . .
AVG Automation . . . . . . . .
B&R Industrial Automation .
Baldor Electric . . . . . . . . .
Balluff . . . . . . . . . . . . . . .
Banner Engineering . . . . . .
Beckhoff Automation . . . . .
CC-Link Partner Assn. . . . .
Dataforth . . . . . . . . . . . . .
Endress+Hauser . . . . . . . .
eWon . . . . . . . . . . . . . . . .
Industrial Control Direct . . .
PRESIDENT & CEO
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
. . . 30
.... 6
. . . 60
.... 2
. . . .16
. . . 25
. . . .31
. . . 12
.... 4
. . . 27
. . . .14
. . . 18
. . . 42
22, 23
ITS Enclosures . . . . . .
KW-Software. . . . . . . .
Maple Systems . . . . . .
Newark . . . . . . . . . . . .
Novotechnik . . . . . . . .
Pepperl+Fuchs . . . . . .
Phoenix Contact . . . . .
SEW-Eurodrive . . . . . .
Siemens Industry. . . . .
Telemecanique Sensors
Tri-Tronics . . . . . . . . .
Wago . . . . . . . . . . . . .
Weidmüller . . . . . . . . .
Wieland Electric . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
JOHN M. CAPPELLETTI
. . . .15
. . . 39
. . . 26
.... 8
. . . 43
.10, 11
.... 3
. . . 44
. . . 20
.... 7
. . . 35
. . . 29
. . . 59
. . . 28
CFO
RICK KASPER
VP, CIRCULATION
JERRY CLARK
VP, CREATIVE SERVICES
STEVE HERNER
REPRINTS
FOSTER REPRINTS www.fosterprinting.com
JILL KALETHA
jillk@fosterprinting.com
866-879-9144 ext. 168
controldesign.com
CD1403_56_57_SHOWCASE.indd 57
March 2014 Control Design
57
3/11/14 5:51 PM
OEM INSIGHT
TJ McDermott • tjm@systems-interface.com
Another ‘What’s in a Name?’ Question
One Of the first pieces of industrial machinery I got
form-fill-seal wrapping machine. Inside its electrical
my new engineering hands on was a carton erector.
enclosure, we’ll find contactors, servo drives, a variable-
It used pneumatics to grab flats, pull them into shape
frequency drive (VFD), temperature PID controllers and
and push the carton out of the machine. It caught my
a touchscreen. Each is supplied by a different manu-
eye because it looked like the OEM wanted to support
facturer, just like the case erector. Another potluck
the entire pneumatics industry single-handedly. I saw
case, it would seem. In this case though, I believe the
air-preparation hardware (filter and regulator) from
choices were driven by a different criterion. Oh sure,
one company, electric solenoid valves from a second,
cost to some extent played a role. But in this case, the
tube fittings from a third, vacuum generators from a
OEM leaned toward picking best-in-class components
fourth and pneumatic cylinders from three more. The
(at least in the OEM’s opinion). The components were
memory of that machine and the component choices
picked for their performance and compactness. The
of its designer stay with me to this day.
VFD and servo drives in particular were impressive for
Many designers are faced with a
customer-driven component specification
that reads: “Thou shall use what the
customer demands.”
Why did that designer put such a smorgasbord of
what they could do for their small size. The components
were the same for thousands of built machines, so there
was no shopping for sale prices.
Best-in-class is not necessarily best-for-customer
(at least according to the customer). The wrapping
machine OEM had a problem with that best-in-class
design: Its customers wanted components from a spe-
components on that erector? Were they simply what
cific manufacturer. Many designers are faced with a
was on the OEM’s shelf at the time? Maybe that’s what
customer-driven component specification: “Thou shall
the distributors had available when the machine was
use what the customer demands.”
constructed? Either or both reasons might explain it.
On one hand, the machine now will have a consis-
In fairness, one 1/4-in-tube/90º 1/8 -in.-NPT male fitting
tent, single name on all the commercial components.
is pretty much like any other, so which one gets on a
It certainly will look impressive. On the other hand,
machine is probably not that important. And many
the design might be compromised. Certainly for that
manufacturers of disposable, stainless steel air cylin-
wrapper OEM, the customer’s specification required
ders make theirs dimensionally interchangeable with
changing to a much larger enclosure because the
their competitors’ cylinders. A two-position, single-
drives were so much larger compared to the original
solenoid valve functions like any other, so expediency
compact drives.
might be one justification.
Cost is always a justification, sometimes too much
On the gripping hand, the customer’s specification
means one-stop shopping for all the components.
so. Maybe all those different components repre-
That might have a positive impact on cost. Hopefully
sented the lowest cost for each class of part. Perhaps
the distributor will give a good discount for being
that OEM had a sharp purchasing department that
sole-source to the OEM. It certainly helps simplify an
constantly comparison-shopped for purchased parts.
end user’s spare parts inventory if the equipment in
Each week the case erectors shipped might have dif-
the factory shares a common source. There’s also the
ferent parts from those shipped the previous week
matter of training costs. The end user’s maintenance
because one manufacturer’s valves increased in price,
department has to learn only one programming lan-
or another was having a sale on filter-regulators. The
guage, and there’s less knowledge lost when a techni-
OEM can be sure of maximizing profit by minimizing
cian leaves. Expediency. Cost. Best-in-class. Single-
cost with that method. Spare parts might be a chal-
source. If you’re a lucky designer, all four criteria
lenge though. If the OEM uses its own part number-
merge to a single solution. When they don’t, then you
ing system and has a good relational database, there
have to be a good designer to bring these conflicting
shouldn’t be a problem. That statement used too
requirements into a customer-pleasing system.
many conditionals; I wouldn’t be happy with that
design methodology.
Let’s take a look at a different machine, one about
which I know more. Let’s examine a horizontal,
58
Control Design March 2014
CD1403_58_OEMINSIGHT.indd 58
tJ McDerMOtt is project manager at Systems Interface, a
system integrator in Bothell, Wash. Learn more about the
company at www.systems-interface.com.
controldesign.com
3/10/14 5:15 PM
More Performance. Simplified.
u-remote.
: H L G P X OOH U · V Q H Z U H P R WH , 2 V \ V WHP L V V P D OOL V V L ] H \ H WS D F N H G Z L WK E H Q H IL WV
• u-remote offers a simple, reliable plug and go set up.
• Modular design helps speed up installation and startup.
• Status LEDs on the channel and each module enable rapid error detection
and reliable diagnosis.
• Its incredibly fast station bus delivers high performance and real-time process mapping.
• The integrated web server offers remote testing and diagnosis.
See u-remote in Action
Order a Sample Today
/H W · V F R Q Q H F W
www.weidmuller.com/u-remote
CD1403_FPA.indd 59
3/7/14 1:50 PM
Need control everywhere?
Spend Less.
TM
Local (CPU-based) node
supports up to 256 I/O
Half and full-size modules
Distributed
Machine Control
Basic Process
Fused outputs
standard
Triple stack terminals standard
ETHERNET
Motion
ETHERNET
PLC with H0-CTRIO2 module
H0-CTRIO2 high
speed output
Cutter interface
Do-more®
in small spaces
For control applications that are space-constrained or need
distributed I/O, why not consider the new Do-more T1H series
PLC? We took our popular Terminator field I/O system and
added the Do-more T1H CPUs as a new brain - an incredibly
powerful controller in a compact, flexible form factor.
The Terminator distributed I/O system combines the features of
terminal blocks and I/O modules into one convenient package.
•
Reduces panel space by as much as 30% over
conventional PLC system with terminal blocks
•
Distribute I/O nodes close to field devices for faster and
more efficient wiring and troubleshooting
•
I/O modules fit into individual I/O terminal bases for quick
replacement without disturbing field wiring
•
Easy troubleshooting at the device termination, with
status and blown fuse indicators
The new T1H series CPUs give the Terminator field I/O system
all the super powers of the Do-more PLC family, including
expansive program memory and I/O capacity, fast processing
and an intuitive instruction set.
•
Onboard communication ports include USB, serial,
plus Ethernet (on T1H-DM1E)
•
Up to 256 I/O in local node (with CPU), and thousands
more with optional Ethernet I/O
•
Coupon for 30 days free online video
training included with every CPU
Order Today, Ships Today!
* See our Web site for details and restrictions. © Copyright 2014 AutomationDirect, Cumming, GA USA. All rights reserved.
CD1403_FPA.indd 60
Create your programs and documentation with the
FREE Do-more Designer software. Download it
online - with the built-in simulator, you can try out
your logic right away.
T1H-DM1
T1H-DM1E
USB 2.0 Port (Type B)
• Programming
RS 232 Serial Port (RJ12)
• Programming
• Multipurpose Serial
Communications Port
T1H-DM1
$359 .00
10/100 MB Ethernet Port (RJ45)
• Programming
• Modbus TCP Client and Server
• Ethernet I/O Master
• TCP/IP, UDP/IP
• SMTP Client, SNTP Client,
• TimeSync, PEERLINK
T1H-DM1E
$459 .00
Great prices, plus ...
þ
þ
þ
FREE software
FREE online training
FREE Phone Tech Support
Research, price, and buy at
www.automationdirect.com/
do-more-plcs
1-800-633-0405
the #1 value in automation
3/7/14 1:50 PM