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AGREEING i 210 Wea Ais sce CONTROL NUMEEDNG sade CTE MeL el rt Tete ey das psa af res oI ado mag isan ese mie 310 Hin Poy. 8 Domes Ge Us Te 3T 70 [Eu tanes credo Patna et ae canes CON GMELIN 3010 phan aay. Sat #2 wns Ss, abate Mal Agee No 489. etm ander Caan ers 310 tan ow Sal #25 Demos oe, IS. Ema comre erEeods bm Ri oer ee ay ls CA. Sa Cus, Sty fc MUSE TART and wey SU he spent pe chang ran, tcp te ra 60 ge aes sn mals OTA EDR 00 Ma ony Sa or eS eda UA he seen sey Seay 9) ect raced art ces ai aaa eo sr hase a hu aa ay ww ce ws vw contolng.com conTROL enawnesenc April 2019 #3The sign of reliability For more than 100 years, ABB has developed a reputation for marketing, designing and manufacturing the most reliable industrial electric motors available. Azima, Inc confirmed this in their Reliability Rating Report in which they stated that “ABB produces the majority of models scoring highest for reliability in 2018." When reliability counts, look for the sign of reliability from ABB. 479.646.4711 baldor.abb.com Input #4 at www controlengcomvinformationINSIGHTS. INTERNATIONAL Aileen Jin, Control Engineering China Digital innovations, AI, Industrie 4.0 Industrial artificial intelligence (Al) technology applications are among the important trends in digital transformation for manufacturing and Industrie 4.0 advancements. ith rapid development of Indus- trial Internet of Things (oT) and Big Data analysi facturing enterprises are creat- ing more demand for artifical intelligence (AI). How to integrate AI with indus- trial applications and enhance value and efficien- cy are among users’ greatest concerns. By applying Industrie 40 digital technologies, leading automation enterprises are well prepared to enter the next stage of Al applications. ‘At the Festo global media conference, Frank Mel- 2er, director of product and technology management and member of the management board of Festo AG & Co. KG, suggested industrial AT applications will become among the most important digital transfor- ‘mation trends for manufacturing and Industrie 40. ‘Melzer, the newly appointed chairman of the steer- ing committee of Platform Industrie 40, said devel- ‘opment of innovative digital technologies, such as Al, ‘would be a priority in the next two years, to advance Industrie 40 initiatives. Alwill accelerate Industrie 4.0 AL is not new. In recent years, inereased demand for Al applications and relevant digital technologies hhas accelerated Al development. Automation enter- prises are making plans. In 2018, Festo acquired Resolto, a company providing real-time AI applica- tions. Resoltos real-time software monitors system and sensor status “Analysis technology and artificial intelligence will exert huge impact on our product portfolio, for artifi- cial intelligence algorithm can be integrated in Festo cloud and onsite components” Melzer sai. [At SPS IPC Drives 2018 in Nuremberg, Festo and Resolto demonstrated the first set of applications, including a controller that uses AI for monitoring and a new motor controller Resoltos machine learning algorithm can extend functionality and provide intl- ligent process monitoring, predicting battery failure. ‘The 2019 Hannover Messe in April will show more Festo products and applications, he sai, ‘With machine learning, bio-mimetic robots and human-machine cooperation, Festo has been advanc- ing automation and Al applications. Festo introduced pneumatic lightweight robot that can be used as an auniliary system. It can alleviate the burden of opera- tors performing dull or dangerous working processes. Extended functions offer simple operability, position ‘monitoring, voice control, machine learning and Al, so the human and robot can cooperate more directly ‘The bio-mimetic lightweight robot has a natural ‘motion pattern and a flexible pneumatic system, mak- ing it suitable for safe human-machine collaboration, which isan economical and high-efficiency advance- ‘ment in robotis. Such an assembly collaborative bot {is applied in the Scharnhausen technology factory area of Festo in Germany, It works with employees without traditional robot safety provisions, such as enclosures, helping with dull, ergonometric challenges related to pneumatic valve assembling. High efficiency, lexibil- ity and safety are among the robot’ characteristics. Cloud-based IloT connections To help with local connections, a Festo loT gate- ‘way enables Industrie 40 digital developments and cases access to data analysis. The gateway can be used {in hardware with unrestricted communication by con- necting elements and field-level modules, such as a pneumatic valve terminal, energy saving pneumatic ‘module, or connections tothe Festo cloud through an. OPC Unified Architecture interface. ‘The Festo cloud display interface provides more digitalization support, showing collected information, supporting machine manufacturers and pneumatic terminal users and improving overall equipment ffec- tiveness. Comprehensive diagnosis, status monitoring and maintenance improvement reduces unplanned shutdowns. The system operator can examine the ‘machine process control system to improve energy savings. ‘A loud: based loT application, Festo’s first dig- ital maintenance application, can be downloaded and install from Apple and Google application mar kets. The production manager's user interface may be opened through the browser. The maintenance software helps pneumatic terminal users plan, mon- itor, and assess system maintenance so maintenance can be realized in a simpler, faster and more reli- able way. ‘This visibility helps the system operator and pro- duction manager improve reliability and saves. lot of ‘work related to process and coordination. e8 Aileen Jin is editor-in-chief, Control Engineering (China. Edited by Mark T: Hoske, content manager, Con- ‘rol Engineering, CFE Media, mhoske@cfemedia.com. CONTROL ENGINEERING At the recent Festo global media conference, Frank Melzer, direc- tor of product and technology management and member of the management board of Festo AG & Co. KG, suggested that industrial Al appli cations will become more important. Courtesy: Control Engineering China, Festo More UB SiGuTs KEYWORDS: Al, Industrie 4.0, IloT, digitaization Actiticialintoligence (Ais advancing Industrie 4.0 and digtazation, Gateways connect manufacturing wth useful ‘loud-based anpications, ‘Smart pneumatic robots fan work collaborative with humans in industria settings. CONSIDER THIS ‘Are your investments in Industrie 4.0 and oT ‘anabing technologies matching or exceeding competitors? April 2019 © 5INSIGHTS. NEWS Automation trends Advantages from automation, controls, and instrumentation implementations were among topics Kevin Barker, president of Beckhoff Automation LLC, discussed with Conirol Engineering and CFE Media ina Feb, 26 interview at the Savage, Minn., Beckhoff US. headquarters. Automation answers Control Engineering, CFE Media: What are a few key trends driving prod- uct design and development? Barker: Theres been more of a focus on open technologies, programming stan- dards, and operating environments as opposed to a particular architecture or pro- grammming language. Greater volumes of data and information are available from thousands of devices. Theres a shortage of engineering talent. All of these factors are creating a need to create better soft- ware tools that adapt to meet people where they'e at, where their skill sets are, and what comfort level they have with automa- tion and controls technologies. CE: What in your past has prepared ‘you for this future? Barker: Working for various so-called underdogs in industry, I've helped cus- tomers overcome the problems of existing automation choices. Incremental improve- ments aren't enough: companies need to be open to new technologies to see fun- damental paradigm shifts in productivity A panel of technology at Beckhoff Automation LLC training room in Savage, Minn., headquarters, pro- vides hands-on experiential learning. Courtes) T. Hoske, Control Engineering, CFE Mi 6 © April2019 — conrmoL encinectING “Good enough’ just isit good enough anymore. For a resur- gence in American. manufac: turing, rapid increases in productivity, visibility flexibility and agility are needed. ‘Were really well-positioned to help. CE: What challenges are customers facing? Are they facing any major differ- ences compared to past challenges? Barker: Manufacturers are under pres- sure from demographic changes due to retiring engineers coupled with too few young people going into engineering disciplines. In addition, our customers’ product proliferation has grown from dozens to thousands of options. Consumer tastes are changing. For many years, major brew- ers touted beer that tasted the same all the time; now consumers want unique experi- ences, People want a custom ear, but only want to pay $40,000. With automation and controls, engineers used to say no one ‘would get fired for using the largest auto- ‘mation suppliers. Today, manufacturing leaders need to do more than not get fired. Every industry wants to deliver rich expe- riences with new strategies, internet, cloud, and with work instructions at the machine level to shorten the supply chain. A variety of industries, such as consumer products, automotive, advanced manufacturing, and material handling, need to advance with higher flexibility and a lot of engineering. CE: What isn't being ‘measured that should be emphasized more? Barker: The old way often focused solely on operational equipment effectiveness measure- ments. Today, we need to go above and beyond this. The first phase is to look at lifecycle costs. Then look at lost opportunity costs, the cost of not doing things because existing process- es arent flexible enough, Are companies. missing ‘opportunities to diversify product lines? Are they meeting changing cus- tomer expectations? Are Mark Kevin Barker, Beckhoff Automa- tion LLC president, discussed automation trends with Control Engineering in a Feb. 26 inter- view at the Beckhoff Savage, Minn., U.S. headquarters. Read more online. Courtesy: Mark T. Hoske, Control Engineering, CFE Media they quantifying those losses? Many indus- tries have duper were partnering wih fos anlage CE: How is raining changing? foie Merona on ke ing with technology providers to get the dan ities tay tee Weave eparnmtaee. > bei Smee Wp ‘peed and focus sound the plans and Sonar fat woot for thee oe pits ae Gini 15 am them whe eye at For instance, Pro pronihg 6 ceding ic tndds tad ther IT sndands in the industrial eng ssa aseomy, (CE Te data transferring into intel pose qolctpatncouadiae Barker: Traditionally, we've had islands of automation. with platforms that dost Se cea Srecncalines Wl ae, lp ad daa de pemceny xew ea Wecan help the industrial worl with ‘using message quewing telemetry transport (MQTT)6 and OPC Unified Architecture, rather tan puting 30-year-old sal eh eco Pend ee by i lt improve system integration, unlike com- pamies tht meet the leer of the le Phe cplanes, Dt atthe ites [tropes], Matioem integration of neta ena, sectine conti, Ie: ‘al temnot of ng, ono ont ing technologies, and analytics is a distinct Sore CE: Do you have a plan and timeline sigan ark eoaned coe aril (fs (rete gated oe to bring new ideas to help or add value, Wee dg i doce. exept Pets toa waica css cameos ‘We have plans to solve many ofthe high eel dang trace be wid preparing the organization for those. ee. Mark T. Hoske is content manager, Con- trol Engineering, mhaske@cfemedia.com. Bailey S. Rice, CFE Media director of busi- ness and market development, helped with the questions and discussion, na controlang comELECTRONICS 8 AUTOMATION We stock enough power to brew a 12 oz. cup of coffee for the entire population of New Orleans. Put that in your mug and drink it. Input #5 at woeucontroleng comvinformation <1 alliedelec.com © 1.800.433.5700INSIGHTS. NEWS Digital eaiion? Glok on Readies for mor datos ‘See news daly ot wwrw.contvoleng.com Realizing the potential and benefits of an MES ‘There are hidden treasures at the manufacturer’ information technolo- ay (IT) shelf of already owned software not being used. More specifically, the manufacturing operations management (MOM) or manufacturing execution sys- tem (MES) software the company pur- chased a few years back that hasnt been deployed to its full capabilites. Results from a joint survey with Gartner and MESA International indi- cates that even though most companies have achieved the expected return on investment (ROD, they stil believe there is more value to capture with their MES. It seems easy to achieve the tial benefits and then move on to other things. Does management even know about these potential benefits? Has the organization bothered to present these additional areas of improvement as pos- sible phase 2 or phase 3 projects with its own ROP This is a common occurrence. The first few tasks are easy, but the next steps are perceived as harder work. After the low-hanging fruit in the first phase, the next phase is going to take harder inte- gration work. However, the potential benefits also can be much bigger. In fact, MES is a foundational enabler to the Smart Manufacturing strategy, and it was probably not posi- tioned that way in its first implemen- tation. MES is often implemented and justified based on the benefits of elim- inating paper-based processes in pro- duction. However, companies that fully embrace the MES as an enabler for more process improvement and business transformation are achieving three to ten times the initial benefit in the next three to five years. ‘The MES is not fully rolled out to all facilities and programs might be obvi- ous, but there is more functionality and integration potential left on the table ight be less obvious. Typical areas of process improvement post initial imple- ‘mentation of the MES include: Mechatronics development site, logistics center is underway in Germany ‘enze laid the foundation for its new Mechatronic Competence Cam- [= (MCC) in Extertal, Germany, which is a modern development and production site in North Rhine-Westphalia. The facility, which costs $57 rmlion, covers 81,000 sq ft, with a total of nearly 323,000 sq ft of space avail- able on the campus for development, production, service and storage. ‘The MCC will be “one of the most ground-breaking mechatronies produc- tion facilites in Germany” and “an important reference project for the future of collaboration,” said Christian Wendler, CEO of Lenze. ‘The MCC is expected to help Lenze innovation and processes and sig- nificantly shorten time to market. Industrie 4.0 will be reflected in practice at the MCC. Driverless transport systems will be used in production, while a modern high-bay storage facility with space for more than 16,000 pallets and over 15,000 containers will be directly connected. Around 300 Lenze drives will be mounted in logistics. The make-to-order process aims to be between 50 and 85 percent faster. In extreme cases, the throughput time will drop from 32 days to only five days because unnecessary material movements and idle times are eliminated. ~ Edited from a Lenze press release by CFE Media. B © April 2019. conrmot encinectInG + Integration of in-process. quality management processes, material review board (MBB), rework specifications, and corrective action management + Integration of automated facto- ry equipment (like parts placement and inspection equipment) that collects a lot of data can be pumped into the MES ‘+ Integration of engineering data direetly from the PLM system includ- ing 3-D CAD as the basis for 3-D visuals for work instructions and inte- gration of specification in PMI direct- ly into the MES inspection verification requirements «Integration of the supply chain man- agement processes including supplier quality management. e6 Conrad Leiva is chairman of the MESA Smart Manufacturing Working Group. This article originally appeared on MESA International’ blog. MESA Internation- al is a CFE Media content partner. F ed by Chris Vavra, production editor, CFE Media, cvavra@efemedia.com. Fj Headlines online ‘Top 5 Control Engineering articles ‘Aficles about the RAD tax credit, easy auto- ‘mation, lloT software in manufacturing, IEEE 1584-2018, and the Engineers’ Choice Awards were the most-viewed, March 11-17. Algorithm developed to improve machine-learning models IMIT researchers have developed an algo- rithm that designs optimized machineJeamn- ing models up to 200 times faster than tradi- tional methods. ‘Supercomputer developed ‘Argonne National Laboratory's exascale computer, Aurora, willaunch in 2024 and support machine learning and traditional ‘modeling and simulation workloads. Machine design concepts improve automation, control simulation Virtual design tools and automation software intersect to save time and costs. na controlang com— FEATURED — MANUFACTURERS Tt Down? omron No Problem. vet HOFFMAN Nas? ~~ — [E lumbergautomation BB SmaRTWoRX PannuirAPRIL 2019 ROL ENGINEERING INNOVATIONS NEW PRODUCTS FOR ENGINEERS 59| New Products for Engineers: equip ment power supply; Advanced analytics software for process manufacturers; Hard- ware and software benchtop system; Solid core current transformers; Safety interlock switch; Motor control system for linear axes. See more New Products for Engineers at www.controleng.com/NP4E. BACK TO BASICS 61| Robotics 101: An overview for engineers DSRS eek * Low-power hybrid chip makes small SSS robots more capable a Hot Cloud ‘+ Automation trends, insights from a new company president * Five common automotive robot applications ‘* Hannover Messe focuses on Al, Industrial Internet ‘of Things (IloT) can benefit manufactur. ing applications with digitalization and simulation, more fein eg ing ndatial tenstormation and ‘+ Defense sector applications for —=-: integration of information technol- ‘embedded vision technology. (CC G05 (T) and operations technolo- gies (OT). (Taos ae Eam learning units a and discover exclu is sive content through videos, presenta- tions and access to Oil & Gas Engineering helps maximize uptime and increase productivity through the use of industry best practices and new innovations, increase efficiency experts at CFE Edu, from the wellhead to the refinery an on-demand educa- Ls ddel by implementing tion platform by CFE i re automation and Media monitoring strate- Check out the course catalog today at: efeedu.cfemedia.com/catalog. ie, and main Courses include: safety for workers ‘Introduction to lloT and Industrie 4.0 and the viork ‘Introduction to PLCs environment. The Electrical Bundle Bead the clots Arc Flash Mitigation www.oilandgaseng.com. controleng.com provides new, relevant automation, controls, and instrumentation content daily, access to databases for new products and system integrators, and online training, vw contolng.com convmot excnecans April2019 © 11INSIGHTS. THINK AGAIN ys : Don’t miss automation trends No one wants to miss the next big thing. What if the next big thing in automation has been here, and you haven't noticed yet? cechnological advances tend to sneak up on us, and we may not implement automation advances quickly enough for ‘our own good. Pm particularly reflective on that point in Control Engineer- ing’ 65th anniversary year because: + There’ wisdom in the adage, “You look, but do not see” + April includes the Manufacturing Awards dinner highlighting, which fea- tures the Control Engineering Engineers’ Choice Award win- nets (chosen by subscribers), after a day of innovations at the CFE Media Marketing to Engi- neers conference. «+ Aprils Automate show in Chicago’s McCormick Place (co-located with ProMat) offers Mark T. Hoske, a technologically tasty smor Go horace gasbord of advances. ‘Automation trends you may not have noticed, but should, follow. In the online version of this article, see the related automation vendors April 8 to 11 at Automate 2019, a conference held every other year, coordinated by Association for Advancing Automation (A3) and its con- stituent organizations, RIA, AIA, MCMA. Conference sessions at the show include: Automation return on investment (ROD), system integrator selection, safety oud robotics and automation and more. See other innovations below and online. Enhanced motion, vision “Motion control is avilable with preci- sion ess than 100 nm 3-dimensional 6-axis points from Alio Industries Extend the reach and utilization oppor- tunities fora robot with an overhead (wall or floor mounted) linear track giving the robot another axis of motion. The applica~ tion extends the robot work envelope for ‘material handling, machine tending, weld- ing, and other applications, said Gilde Inc. More. WS insists Pe tomcat cin chi ‘on the headline for more resources, photos, and links. wows.controleng.comiagazine 12 + April 2019 ‘Automated material handiing technolo- gies re enhanced with intelligent software to help optimize the connected distribu- tion center with robotic systems, according to Honeywell Intellgrated. The CoaxPress 2.0 standard, expected to be released in June, offers high frame rates over long distances for demanding ‘machine vision applications. New machine vision technologies are being developed to take advantage of the high-performance capabilities, aecording to Basler, a Silicon Software company. Digital connectivity Radio-frequency identifi cation (RFID) and sensors can combine identifi tion and condition. monitoring to enhance Industrial Internet of ‘Things (HoT) capabilities, accord ing to Fraunhofer-Gesellschaft, said to be Europes largest applica tion-oriented research organization. Digital transformation is enabled with smart factory elements, such as better data ‘management, cloud-based services, rapid IT integration with edge devices and high high-end robotics combined with ROS vision technology (ROS, robot operator system open source software), said Austria- based Keba AG. Single-cable connectivity for servo and stepper kits offers significant cost sav- ings from reduced component count and simplified installation procedures. With smaller motors finding space for two con- rectors can be awkward, sid Posital Integrated robotics AA three-robot mini-factory will simu- late the assembly and packaging of USB flash drives with a single-arm collabora- tive robot, an invert-mounted SCARA, and a light-weight, compact 6-axis robot, driven by the same controller, said ABB Robotics. ‘Advanced automation technologies tenable the factory of the future with trace- ability and flexible manufacturing using robotics, sensing, control, motion, vision and safety technologies in an interactive demonstration, according to Omron. 68 CONTROL ENGINEERING [ROL E EERING S010 Highland Para, Sut 325, Downer Gove, ILeost8 690-571-470, Fax 530214504 ‘Content Specialists/ Editorial Mark Hast, Caran: aay ace Si Cote Marae ‘ios xz semtecFevedacon evn Pana Se Cog Eo, oT OE (Soorovo x22 andrea com ty Gunner Oreo eae es (S017 1208 epothrSOFEV om ‘Amanda Pelicions, Der of Feosch ‘Tear ime svar eon com naa, reacion Et CFE Media Contributor Guidelines Overview Conte Fo ger Thal a CFE a ‘Som arco FE dns a= (Shevcomabetralsosmietsote ‘roi, Howl co Bose mtr oo. 00 ‘hunts ann newts ap ‘tos med abo be protic ck osama ‘rencintongsomfeanebde it o4 {Debt peo kes res, repos os tee is a te * Corso rhe expres ke etore Node tata ae ced ‘leoa per open bo cedExcess Inventory? We buy it! @ info.radwell.com/asset-recovey-program Baan) Liquidate Your Inventory y 5 3 3 ——————___ & g £ & 3 & It takes 3 simple steps ‘Scan with your phone to learn more x 8 & 3b S B a 3 Lower your warehousing costs, reduce your s aging and slow moving inventory by selling it © to Radwell.com 9 input #8 at waw.controleng convinformationOne stop. Smart shop. OUR ns) Odor ogc module ial power supply lecenlosure ! = ir tort r = oa Sssx | — MolUND aS a Rot ed rill nla ities altertsreTt From sensor to control cabinet Er mene eu ear Eke ce uaa Y Awell-rounded selection of industrial automation technology Cost-effective solutions” Top-quality product range wore SIEMENS Sona Qprumscx 3 rverovome cy @conracur SOE Len Yee aslo SR oc uemeo) pee ee aANSWERS. SIMULATION MODELING Christy Starner, Dennis Group, Optimize production line design with simulation modeling Simulation modeling, used properly, can identify and remove risks, maximize value, and help produce successful outcomes. Ask these five questions to ensure the model reflects realistic behavior and constraints. imulation can be a powerful tool through- out a project and enables the project team to visualize many aspects of a production line during the design phase. To plan a new production line or modify an existing one, ‘many questions must be answered including: 4. What will this line produce? 2. How fast will it run? ‘3. What line efficiency can I expect? 4, How will this equipment fit within my space? 5. Ifconveyors are used, what are the constraints? (What isthe conveyor’ capacity? What happens to the line during a backup condition and how long will it take to recover? Where should buffers be placed tobe most effective? Can existing con- veyors or unit operations be reapplied?) ‘Technology designed to visualize a line and bring ito life prior to development is more accessible than. ever. 3-D PDFs or videos can be viewed electronical- Iysand many software programs now integrate directly with virtual reality (VR) headsets, which allow stake- holders to step into an accurate interactive line layout This visualization helps everyone understand design parameters more effectively and reach con- sensus on the final design. Augmented reality (AR) smartphone apps and headsets allow a 3-D model to be projected into an existing space, providing anoth- cr view of a line. Static or dynamic modeling shows interferences and obstructions and helps avoid these problems atthe beginning of a project (bottom righ). ‘Another way visualization can be used in the design phase is highlighting dynamics of product movement under different constraints. Simulation enables the user to set up many parameters of line operation ~ machine and conveyor speeds, convey or lengths, device locations, control behavior ~ and. see the system performs under these different set- tings. Animated simulations often uncover potential Tine design issues that are difficult or impossible to see ‘when looking ata line layout or a spreadsheet. Simulation, time ‘A. recent example that underscores the importance of simula- tion involved a machine that filled four cartons at fonee, and then pushed all four cartons out of the machine at the same time. Although the average ‘machine speed was 100 cartons/minute, the actual instantaneous output of the machine was either 0 or 200 cartons/minute. Ifthe conveyor atthe discharge of the machine wasnt running twice as fast as the aver- age speed, the cartons would back up into the machine as they exited, preventing the machine from loading new empty cartons. On paper, the speeds looked correct, but the ‘machine was being blocked. The simulation model {identified this problem during the design phase so it could be corrected before installation. Physics-based modeling is a valuable tool when attempting to understand a product’s real-time interactions on a line. Designers can see how prod- ‘ucts will move on the conveyor and tweak the con veyor design to maintain control of the product. A simulation can demonstrate how products will clump together or jam in a chute or accumula tion table. A simulation example shows how a buffer for frozen dough balls would be used. Previously, this would be done with educated guesswork and_perhaps computer-aided design (CAD) layout. However, Simulation can provide detailed visualization of aline in an existing production facility. (CONTROL ENGINEERING ——— Doi pear A proposed buffer in the line shows level of accumula- tion. All images courtesy: Dennis Group April 2019 «ANSWERS. SIMULATION MODELING TET RRFRR RARE TERETE imulation model and PLC tag interactions help issues earlier in the design process, saving time and money. lentify and address Physics modeling for frozen dough balls puts key product characteristics into the model. the dynamics of dough rolling around on the conveyor belt is hard to predict or visualize accurately. Physics modeling is demanding on computer hardware. Tar _geted models can be created. Lessons learned from the ‘smaller models can be applied to larger models. Equipment choice can cut costs ‘Even with the best-designed line, machine down- times are inevitable. The impact of random va able downtimes can be very difficult to predict. Manufacturers may be hesitant to build in buffers and accumulation, believing they hide problems ‘or encourage unmotivated operators. Some buffers minimally impact performance due to the machines! More ANSWERS KEYWORDS: Simulation modeling, project management ‘Simulation modeling enables the project team to visualize a produetion line during design. ‘Simulation modeling hens users see possible ouicomes impossible fo ses on a spreadsheet, ‘Simulation modeling hens remove risks and produce successtul outcomes. 60 ONLINE Read this article onine at ‘ware controleng.com for more stories about simulation modeling {and its benefits onthe plant floor. What applications in your faclty ‘would Benefit the mast from simulation model? 16 + April 2019 arrangement, resulting in unnecessary capital expense. A simulation can model scenarios and consider normal running conditions to determine optimal number, location, and capacity of buifers to improve line performance and avoid unnecessary expense (prior page, top right), ‘Another important factor simulation can help with is how to control the line. Early in the design process, when no pro- grammable logic controller (PLC) exist, the model allows the design team to con- sider the controls, Placement of photo eyes and other sensors can be tested and op ‘ized before equipment is purchased. Pethaps the most critical time to use simulation is when the PLC program is ready to be tested. Some modeling software can be connected to a PLC. The model signals to the PLC from simulated sen- sors and responds to the PLC signals to its simulated motors. Controls engineers can debug controls with a realistic, responsive system, rather than tracing through code CONTROL ENGINEERING ‘manually or attempting to use the human-machine interface (HMI) to visualize performance. Sensor placement can be fine-tuned in the model to within a few inches of optimal real-world placement. ‘The HMI program can be tested alongside the PLC using the model, and since the model is being con- trolled by the PLC, buttons pressed in the HMI will ‘mimic real-time production scenarios. Line commis- sioning start-up times, therefore, are greatly reduced using the simulation model (top lef). ‘The process of connecting a simulation model to PLC benefits training. A new PLC or HMI program- mer can identify mistakes, test new ideas, and build confidence in a low-risk environment prior to live production. Line operators can practice running the line and learn new PLC programs prior to installation. Discover difficulties earl Simulation has other indirect benefits. Drawing on background knowledge of line dynamics, a model- ing programmer may ask questions early in the design process that normally would not be addressed until later in development. Schedule adherence is anoth- er benefit. Too often, the line has been designed and installed, but constraints result in start-up and com- missioning activities prior to PL program comple- tion Ifthe model is tested before it goes to the factory floor, it helps validate the program more quickly. Simulation has limits. The modet’s output is only as good as its inputs or assumptions. Simulation won't predict poor operator habits, bad materials, or condensation build-up. Its important to revisit and adjust the model to ensure it reflects behaviors and constraints. co Christy Starner is director of simulation and model- ing, Dennis Group. 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Tis nobler (or at least more efficient) to spend the time to create simulation models and test the design rior to deployment, or to spend the time testing the design during deployment? ‘While T can't speak for Shakespeare, I can say in my nearly 40-year career “tis” always been more efficient to perfect the design prior to deployment. 1 hhave successfully applied simulation to applications including many different types of industrial con- trols (IC) systems, electronic printed circuit board (PCB) design, and field programmable gate array (FPGA) design. Five paybacks from simulation ‘Simulation pays for itself many times over due to: 4. The insight simulation models provide, which canit be measured or observed in the actual plant or equipment 2. The ability to determine the merits of alter- nate approaches and choose the option with the lowest overall cost or the best overall performance 3. The ability to test emergency and unusual conditions, which are impossible or dangerous to do with the real equipment 4, The high level of confidence in the design, which provides the corresponding confidence that any issues encountered during commis- sioning must be in the plant or equipment. 5. The ability to perfect the control in paral- lel to the construction of the plant or equip- ‘ment (and avoid the inevitable pressure from the anxious project manager looking for those who reside atthe end of the critical path to ‘make up for delays earlier in the project ‘This return on investment (ROI) becomes even. greater with modern development and simulation, environments, which include object-oriented indus- trial programming (OOIP) techniques to accelerate Tenkbavel_3 “RraiogSonsor| un S @ ralawisetont —}-| oy orm PaTS lke unl 2 tn 2 hv Figure 1: Control design can be ium implemented in Codesys CFC. ies Images courtesy: ControlSphere LLC “8! development, and advanced debugging features that accelerate the time-to-insight. A previously posted article describes OOIP techniques. Strong simulation elements The characteristics of a good IC simulation envi- ronment look very similar to a good IC develop- ‘ment environment: + Versatile and powerful programming languages «+ Full featured language editors + Full suite of debugging tools including code and data breakpoints; single-stepping,step- in, step-out, et. live mode (to show instan- taneous variable values, not just end of cycle values); write and force variables and move the execution point; and virtual digital oscil- loscope, which samples at the controller cycle time + Built-in human-machine interface (HMI) for ‘reating test control panels +A complete controller runtime, which runs as a service on the development computer + Support for OOIP. Creating the simulation code in such an envi- ronment is as easy as creating the original code, and it can run as a software-based programma- ble logic controller (PLC), which is the same full- featured runtime that industrial controller OEMs (CONTROL ENGINEERING More UA ANSwers KEYWORDS: Simulation, ccontrol programming Creating simulations by sing contro programming bean save tne Most industrial processes can be simulated Programming and processes can be tested in the design stage CONSIDER THIS How much time coulc bbe saved by optimizing processes carter in design by using simulation? ONLINE Link to an onine article with ‘much mare information on (OIF reading from the ital eation, click on the headline for mora figures. wonw.contraleng,com/ magazine Search simulation \wanw.controleng,com/NP4E April 2019 © 17ANSWERS. SIMULATION deploy on their hardware. This runtime is installed sa Microsoft Windows service independent of the development environment. The control code cre~ ated and compiled in the integrated development environment (IDE) and deployed to this runtime the same way it is to a PLC or distributed control system (DCS) Example reactor tank Consider the example of a simple reactor tank witha variable speed outlet pump to maintain fluid /ealculate the tine the last e2 cycle DeltaTime := LIME () wviousTine; PreviousTime i= LFIME(); ‘Tanklevel :~ Tanklevel + (InletFlow ~ OutletFlow) + "70 REAL (TO LREAL (DeltaTime) /TO LREAL(TineToFi11 CI) /186); IF Tanklevel > ELSIF TankLevel < ENDIF Figure 2: Tank Simulator (TANK SIM): the tank integrates the differ. ‘ence between the input flow and the output flow and limits the inte- gration to tank full or tank empty. THEN TankLevel := 1007 0 THEN TankLevel := 07 TestBench Step_entry ‘Control. FankLevel Setpoint; 507 Plant_sim.Tank Siml.InletFlow Plant_sim.EnableBodeAnalyaia psten-trenze Dynamic Textbench Dynamic sewve Vl init Figure 3: A testhench can be implemented in Codesys SFC with ST ‘entry and active actions. Guicmm BSE = NTask (EC-Tasks) | © peered) |S ———-] meng ven FOsorctets) eas EF reoes [S Pant Sm oe Figure 4: Creating a task list is part of a simulation project. 18 + April 2019 cowrmot enainetRne at a preset level (regardless of the inlet flow rate) ‘The concepts can be extrapolated to larger systems and in other industries. ‘The first step is to design the control system. Using OOIP techniques, instantiate four objects from the plant object library: an analog input for the tank level, a subtraction for the setpoint, a pro- portional-integral-derivative (PID) loop for the control, and a variable frequency drive (VED) for the pump motor, as shown in Figure 1 (p. 17). With OOIP techniques, all the remaining func~ ality is encapsulated within these objects, such as the scaling and alarming for the analog input, and fieldbus communications for the VED. In this example, the plant has a tank that takes 10 seconds to fill at 100% flow rate, which equates toa pole at 0.0 Hz with a gain of 1/(10*2xf). For a loop bandwidth of 1.0 Hz, apply a proportional gain of 10°27. as shown in Figure 1. This provides a phase margin of nearly 90 degrees and a high level of stability. The next step is to design the plant ‘The form of the simulator program mirrors the control, with a VFD input, a tank model, and an analog output object, which are all from the simula- tion object library. ‘Again, each object encapsulates all the func- tionality necessary to carry out the function of the object. For instance, the tank integrates the differ- ‘ence between the input flow and the output flow and limits the integration to tank full or tank empty as shown in Figure 2. The tank model is an example ‘of how simple itis to build simulation objects and by extension the simplicity of adding simulation to a workflow, In the example, configuration inputs and the 1 ‘mapping in the control and simulation programs are hard-coded. In a larger OOTP design this would be configured from a central SQL server or CSV file so the design could be reused. (Online article pro- vides more direction.) Notice the simulator inputs are mapped to the control outputs and the simulator outputs are ‘mapped to the control inputs. The physical 1/0 is ‘mapped in the same way using the same full-path names (that is, Control. OutletPump.Speed_FO), imulator. Virtual testbench ‘The next step is to create the testbench. Just like the physical bench from which the name was coined, the virtual testbench provides all the inputs the system needs inciding: upstream process inputs, operator inputs, and configuration inputs ‘These process inputs could be generated from an HIME screen for a manual test or from a program for an automated test. Likewise, the HMI inputs could be programmatically generated for an automat- ‘ed test or could be generated from the actual HMI na controlang com3M G7 Aihaire BELDEN E.T-N Po) KeysiGHT ° noche Wierg en Somes molex mutticomp BHresvveny ri Telitronix TENMA, input #10.at wawcontoleng comvinformationANSWERS. SIMULATION Loop Gain (dB) 82 deg at - 1.0H; 2 2 = Loop Phase (deg) Figure 5: A first order control loop Bode analysis find the poles and zeros of the control loop. Se a eS State Error on Oram 220ms Dynamic Phase Error << Inlet Flow { { | “! Outlet Flow 2 A steady state and dynamic response is shown in Codetys Figure Trace. _O an Analyzer inserted into loop ‘up P| Tatras | Tarra “iP o Pole at 0.0Hz, Zero at 1.0Hz 7} Stability Mitigation = Figure 7: The Bode loop analyzer shows a second order control loop. 20 © April2019 covreo. enenecans screens (in which case the simulation system could double asa plant operator training tool). This exam- ple generates the stimulus programmatically with a sequential function chart (SEC) program, which first performs a step response, followed by a steady state as shown in Figure 3 (p.18). This SFC also provides the option to perform a Bode loop analysis to find the poles and zeros of the control loop. 6 a Bode loop analyzer measures the poles and zeros of the control loop as well as the gain and phase margin. ‘The testbench also could include programmat- ic measurement and analysis to create an automat- ed test bench. An automated test bench allows the system to be verified under multiple seenarios and allows the system to test itself alter any Future mod- ifications. This is particularly true for future modi- fications made by engineers who are not as familiar with the original system design. The next step is to place these objects into tasks as shown in Figure 4 (p. 18). The control is assigned to its normal task, in this case with a 20 ‘onds (ms) cycle time. Since the simulator and test- bench need to mimic the plant and plant operator, which both run in real-time, the simulator task is, assigned a cycle time that is much faster than the control task. To avoid any possible synchronization issues that could mask potential control problems, the simulator task also is assigned a non-integer submultiple rate of the control task (3 ms). ‘The last step is to download and run the pro- ‘gram on the built-in software-based PLC. Just as in a phy ‘ment equipment is used to verify the systems prop- cer operation. One such virtual instrument is a Bode loop analyzer, which measures the poles and zeros of the control loop as well as the gain and phase ‘margin, This instrument is inserted into the loop as shown in Figure 7, This can be used to test vari- ‘ous control scenarios during simulation as wel as to verify and tweak the control loops in the actual factory or plant. The results of this analysis show a crossover frequency of 1.0 Hz and a phase margin ‘of 82 degrees as shown in Figure 5. Another useful test instrument isa virtual oscillo- scope, which shows the step and dynamic responses of the reactor system as shown in Figure 6. It should be noted this oscilloscope runs on the target hard- ware soit is guaranteed to capture a sample on every «ele, even at microsecond cycle times. na controlang comORACLE Nese] aa CLOUD FOR MAN! OO www.netsuite.com/mfgANSWERS. SIMULATION If this first order control loop perfor- mance did not meet the system require- ments, it possible to enhance the PID with a pole at 0.0 Hz and a zero at 1.0 Hz to improve the accuracy at the cost of stability (which requires mitigation) as shown in Figure 7. This second order system now provides much higher loop Inlet Flow Outlet Flow Figure 8: Second order control loop steady state and dynamic response may provide a higher loop gain. gain and a phase margin of 37 degrees: and dlivers a much better steady-state dynamic response shown in Figure 8 Process, batch, discrete In addition to continuous process, these techniques can be applied to batch and discrete processes, as well as mobile, 0,0001% Steady State Error 20ms Dynamic Phase Error i embedded, or any other industrial auto- mation. Simulation models have been created for conveyors, bottlers, dry ingre- dient augers, systems of pipes and valves, and numerous other applications. Just about any industrial process can be suf ficiently modeled to allow for simulation ‘This simple example demonstrated the insight that can be gained with simulation, the tradeoffs that can be measured and chosen with simulation, the confidence gained by simulation, and the valuable progress simulation can accomplish before the actual hardware becomes available. These techniques can be applied to near- ly any industrial application and scaled to systems of any arbitrary size or compleaity ‘As Shakespeare would say: “To do a great right do a little wrong.” He would have approved of using simulation to fur- ther that goal. ee Gi Pratt, PE., is president of Control- were LLC. Edited by Mark T. Foske, con- tent manager. Control Engineering, CFE ‘Media, mhoske@cfemedia.com. Connecting you to productivity The Core product range from Festo featuring the See 1m actuators to acce et cee Sent a Sc acento ree eg runt ea imply following the stars Ce es Cee cuca See Pere ear oh ea. SreyWell tested Because we want you to be sure Universal UT screw-connection terminal blocks, shock-proof ST spring-cage and PT push-in terminal blocks are all backed up with a reassuring collection of approvals. We demonstrate our high level of quality through recognized tests in national and international standards, as well as page after page of application-specific testing. LIMITED LIFETIME ‘WARRANTY Request a free testing approvals brochure: Filth WiTHcOMFIDENG www.phoenixcontact.com/welltested GD Liters © GD {BPHOENDK CONTACT 2019 INSPIRING INNOVATIONS. Input #13 at wwwcontioleng.cominformationANSWERS. SIMULATION Frank Lamb, Autom: 9 Consulting How simulation helps automation and controls The controls often must be programmed for automated machinery and systems before hardware exists, but controls engineers can use simulations to test syntax, proper tag linking and addressing, and code functionality. en building automated machin- ery and systems, a controls pro- gram often must be written long before there is hardware to test it oon. Controls engineers use various kind of simulation to test syntax, proper tag linking and addressing, and functionality ofthe code. If the programmer is working with other engi- neers, they often will use a shared spreadsheet for program tag names and addresses. As long as the spreadsheet is kept up to date when changes are made, multiple programmers can coordinate Error testing Programmable logic controller (PLC) and other programming software have utilities that check the program for syntax errors; if illegal operations are performed, the software should catch them. Unfor- tunately, there are many programming errors that arenitsyntax- or format-related. For instance, opera tors might put illegal numbers into data registers via an HMI, causing overflows or access data registers Figure 1: Output control with a permissive is shown in this output PLC logic, typical for an actuator. Various addresses need to be in the correct state for the Z Axis Lower SV output to energize. These ‘can be manipulated by the programmer, or in the case of the HM pushbutton, it can link to an HMI program running on the computer and be pressed. Images courtesy: Automation Consulting 24 + April 2019 covrmot enainetRIne that dosit exist. Data entry values need to be limited or protected either in the controller or in the opera: tor interface. Most human-machine interface (HMI) software has a method of linking an application to a PLC program before downloading it to hardware. This allows tag addressing to be checked and catches typo- graphical and formatting errors PLC software usually has simulation packages that will run code without a real PLC. When this is used, there are no physical inputs and outputs connected, so virtual addresses need to be substituted for real ones. “Aliasing” (linking) tags to other addresses is possi- ble on some platforms, or routines also can be written that map one address to another. These routines can be disabled or deleted when simulation is complete. Even when this is done, itis difficult to make sim- ‘ulated input/output (1/0) values react like real devie- «es by toggling bits and changing numbers by hand, Because ofthis, simulation routines are often writen 10 provide feedback like “real” UO. Machine vision simulators Machine vision has had software simulators that process saved images without a physical eamera for a Jong time. Programmers can use this to set up tools sensors before implementing the system. Images should be captured under a variety of lighting condi- tions and in various positions Companies make software simulation modules that run on a computer to simulate actual objects, but most are only for material handling, For complex assembly operations, there are too many possible com- binations of tooling and actuators to make this feasi- ble. Solid modeling software does allow objects to be ‘moved, but there is no method of linking the objects to controls software. The following logic shows an example of how an address mapped to a memory bit can be used to simulate the movement of an actuator and resulting sensor activation. The output PLC logic in figure 1 is typical for an actuator. There are various addresses that need to be i the correct state for the Z_Axis_Lower_SV output na controlang comto energize. These can be manipulated by the programmer, or with the HMI push button, it can link to an HMI program run- ning on the programming computer and can be pressed When the output is activated, it is linked to a tag named “Digital Output Card_PL3” which can drive the simula- tion code in Figure 2. The timer can then be used to latch (set) a bit simulating a sen- sor. The sensor in turn provides feedback to step through a sequence of movements. By turing off the “Sim Output Enable” bit a fault condition can be tested. Faults ust- ally consist of timing an output condition and looking fr the corresponding input. Itcan be as complicated to wrtea sim lation routine as it is to write the origi nal program, s0 this is not often done in real machine building applications. This {s useful in showing programmers how a sequence operates, as indicators and objects on an HMA react to simulated 1/0. Another method of simulation is to build small models representing a machine with sensors and actuators (such as a con- veyor and pneumatic pushers). The simula tor might sort colored blocks into bins. Simulation can be an important tol in the arsenal of an automation professional, but tis no substitute for the debug process conactual machinery. e@ Frank Lamb is founder, owner, and manu facturing and automation business consul- tant at Automation Consulting LLC. Lamb is a Control Engineering Editorial Advi- sory Board member and Automation Con- sulting is a Control Engineering content partner. Edited by Mark . Hoske, con tent manager, Control Engineering, CFE ‘Media, mhoske@efemedia.com. More KEYWORDS: Software simulator, PLC, error testing ‘Automation programming can simulate ‘machine functions resulting in better code. Writing a simulation can be as complicated ‘88 wrting the original program. ‘Simulation code can show sequences runcing, CONSIDER THIS How will you improve control code? ONLINE reading from the digital ection, click on the heacine fo 890 other articles from Frank Lamb, wwww.contoleng,com/magazine April 2019 © 25 7H oC Se Figure 2: In this timer simulation, when the output is activated, itis linked to a ‘tag named “Digital_OutputCard_Pt.3" which can drive the simulation code. cMaple Systems OTe) ce [oR VI ama Q Farr REMOTE ACCESS - Eo Wy cca HOT + MQTT + OPCUA = SQL Three Decades of Quality, Reliability, & Affordability. Pere CNR Cron ote rer)PFC MLielrid amen. September 11-12, 2019 RoI MO digitalindustryusa.com Sere em al at) Compete in a connected worldANSWERS. SOFTWARE SIMULATION John Kowal, 28% Automation Plug and model simulation tools for automation software Simulation, modeling, and virtual commissioning are becoming easier to apply on different levels in automation. Interfaces to third-party simulation tools may be built into development software. he process of commissioning a machine can be accelerated and streamlined with virtual commissioning, It minimizes risk and ensures project deadlines and qual- ity targets are met. The underlying sim- ulation capabilities provide a digital twin required for emerging Industrial Internet of Things (IloT) architectures. ‘The scope and level of detail needed for the sim- ulation are defined during the requirements phase. ‘While modeling certain machine parts is enough in some cases, a full machine model sometimes is. required. This model also might include infrastruc ture and material transport. Using the model, it is possible to generate auto- ‘matically an entire program or individual function. block in C, C++, or any IEC 6131-3 programming language. This ensures reusability and flexibili- ty throughout hardware-in-the-loop (HiL) testing, rapid prototyping, and serial machine production. ‘The model is tested by simulating a variety of defined scenarios. The model can be refined con- tinually as components are sized through testing and verification is supported by diagnostic tools and 3-D graphics, ‘Testing performed during virtual commission- ing can range from simple logical sequences to complex, critical scenarios to ensure the overall effi- ciency and quality of the machine's hardware and software, A simulation concept is developed to meet the defined requirements, and it determines which simulation tools will be used. Automation sup- pliers offer an array of tools for different types of simulation, including automated code generation, ‘machine simulation, electrical drawings, and field- bus and OPC communications. ‘The generated code should be able to be inte- grated seamlessly into the suppliers hardware and software portfolio. The virtual model can be used to perform every aspect of software development from function testing to virtual commissioning, Functional mock-up interface (FMI) is an inde- pendent industry standard and enables models to be exchanged and simulated using various develop- ‘ment tools. Plug and model is the principle behind the FMI. Some automation suppliers offer a mech- anism for importing functional mock-up units (FMUs) in accordance with the FMI 2.0 standard. FMUs are integrated seamlessly as function blocks in some automation software suites. Track system simulation More machine components are entering the marketplace as modules from automation suppliers. ‘That inchides an integrated digital twin capabi to simulate operation and performance before com- mitting to the actual hardware, and before recon figuration of installed systems as required in HoT architecture ‘When developing automated assembly and pro- duction machinery, for example, its important to optimize the number and configuration of shuttles Through an iterative process of testing and verification supported by diagnostic tools and 3-D graphics, the model is refined continually as components are sized. All images courtesy: B&R Automation (CONTROL ENGINEERING April 2019 © 27ANSWERS. SOFTWARE « A3-D visualiza- in of the devel- opment environ- ment allows the user to fine-tune processes in simulation mode before commis- sioning. y SIMULATION and diverters and ensure shuttles do not collide, cross virtual barriers, or violate configurable speed limits. Generally fewer shuttles may be required than first anticipated, as non-sequential track systems are more efficent than conventional conveyor systems. FDA-compliant track and trace also benefits from. software that links the product data with the respec tive shuttles and thus makes the manufacturing pro- cess traceable. Process-oriented programming lation begins with an application created ‘using process-oriented programming provided as part of the machine module development package. A software engineer defines rules for how the shut- tles should behave on the track. The rules become active when shuttles pass virtual trigger points. This makes implementation of motion sequences more cfficient and reduces the amount of programming required for individual shuttles. Simulation, efficient operations With the integrated simulation options, a devel- ‘oper can run tests to identify the optimum number and speed of shuttles to maximize productivity. The simulation and real plant use the same software. ‘This makes it possible to switch between simula- tion and real operation at any time. How the shut- tles interact with additional mechanical elements ‘such as robots can be visualized in such a system. ‘Typical capabilities In such systems, the visualization tool typical- ly displays a 3-D simulation of all movements, as well as subsystems such as robotics and computer ‘The same system software is used in the simulation and the real plant, which make it possible to switch between simulation and real ‘operation at any time. 2B + April 2019 CONTROL ENGINEERING ‘numerical control (CNC) axes synchronized to the system. Machine builders and operators can accel- erate the commissioning process by validating their designs and sequential programming in advance. 3-D simulation, machine code When simulations are based on real machine code, no_additional software or interfaces are required. This also makes it easy to test, modify, and finalize code in the same software development environment ‘A.3-D visualization of the development environ- ‘ment allows the user to fine-tune processes in sirmu- lation mode before commissioning. With a few clicks ‘of a mouse, the optimized machine code is then transferred to a target control hardware. At runtime, the visualization tool processes sen- sor signals to display machine movements on the ‘human-machine interface (HIMI) screen in real time. ‘Also, 3-D visualization can be used to monitor pro- cess manufacturing processes. Integration, simulation help ‘As controls hardware and software merges with lectromechanical systems in a modular format, sim- ulation capability also becomes the responsibilty of a system supplier. The supplier should provide an inte- grated functionality that does not require a third- party simulation package. It also should be accessible through normal programming environments. With manufacturing becoming faster and more flexible, simulations role is becoming increasingly important. The capability to select the correct configuration of modules and shuttles and adapt to various produe- tion scenarios on an ongoing basisis crucial. eo John Kowal is director, business development, B&R Industrial Automation. Edited by Chris Vavra, pro- duction editor, Control Engineering, CFE Media, cvavra@efemedia.com More UW ANSWERS KEYWORDS: Simulation, automation software, visualization Virtual commissioning accelerates and streamlines ‘cornmissioning machines and helps meet project > T63) remain a special challenge. However, RPC dynamic deadtime control isa novel technique that can improve control of deadtime dominant control loops. It can be seen intuitively thatthe RPC mechanism is inherently adaptive to changes in process gain. For example, if process gain becomes larger, the process response will be larger, the prediction vectors will extend farther, and moves will be tapered and halt- ed correspondingly sooner so the PV settles right oon target. By the same reasoning, RPC is inherent- ly adaptive to changes in the pre-set move rate, so that it can be manually tuned at will or dynamically adjusted to meet various high-performance criteria, Several process control advantages in RPC are worth noting. RPC is inherently adaptive to changes in pro- cess gain. This is significant for an industry where the terms tuning, retuning and detuning have found roughly equal usage. Auto-tuning has come up far short of industry’s hopes and expectations. A mod- cl-based control has become perhaps best known for its high model-maintenance. ‘These rocky experiences collectively stem from the same root cause ~ frequently and dynamical- ly changing process gains that can benefit from an. inherently adaptive method. ‘RPC abso is inherently adaptive to changes in the ‘move rate, which means the move rate can be man- ually tuned at will for desired loop performance, or dynamically adjusted, using built-in ancillary RPC features to achieve various high-performance criteria. RPC is more responsive to incipient error and ‘more stable as the PV returns to setpoint because it uses the predicted (apparent or already manifest) value of the PV and not just the current value For example, a conventional PID controller might see a small incipient error whereas RPC might see a larger error and make a much larger move sooner by taking the PV rate-of-change and predicted value into account. For the same reason, RPC is more stable and reliable asthe PV returns to setpoint with litle or no unwanted overshoot or oscillation. To control system. operators, RPC looks identical to conventional PID controllers ~ thas PY, setpoint, output and mode - so itcan be seamlessly adopted in an operations and con- {rol system environment. RPC is easier and more intu- itive to learn and tune for control engineers. Other tuning applications ‘RPC is versatile and can be tuned for other types of performance. For example, asic error-minimization oor quarter-amplitude-damping can be provided by using high move rate and short prediction time, RPC (ike PID) works “as is” for integrating and non-inte- grating variables. For loops where there is effectively avery high “speed limit” (not uncommon in single Joop contro, but rare in multivariable contro) a large move rate can be combined with a wide taper band to provide a lage response when far from setpoint, son controleng. com DICTIONARY of RPC terms + SP (or target): Single-loop controller setpoint (SP) or multivariable controller target value ingle-loop controller process variable (PV) or multivari- irect control variable (ICV) + OP (or DCV): Single-loop controller output (OP) or multivariable con- troller direct control variable (OCY), also known as a “handle” RPC tuning parameters also include the following: ‘+ RPC move rate: Pre-selected move rate (for OP, DCV or handle}; selected based on safe operating practice or as a process “speed limit” (in units of the output per second, or per minute for multivari- able control) ‘+ RPC prediction time: Used for PV prediction calculation; normally set ‘equal to or greater than 63 percent process time constant (T63), but also can be set less than T63 for more aggressive error-minimization performance (units of seconds, or minutes for multivariable control) ‘+ RPC taper band: The error band around setpoint at which RPC begins tapering the move rate, so the move rate goes to zero as the error .goes to zero; conceptually based on the point at which an operator Using manual control would begin decreasing step size (same units as the PV). tapering to asafe speed asthe setpoint is approached. RPC is “model-less.” which is another way of saying it is inherently adaptive. It does not use a process model (nor does it attempt to “roll its own” such as with auto-tuning or adaptive modeling). RPC relies on gain direction only, which is equivalent to PID control action (direct or reverse), or the sign of the gain More (eceer roca caerotoce MPANSWERS the most fundamental and immutable KEYWORDS: Advanced process vapect any modal onto Fate predicive conte, TRC uses process esponse time (163), process gain Rate-predictive control (RPO), anew advanced contro! ‘method, has advantages over ‘proportional-integral derivative bbut this can be tuned intuitively (like inte- ¢gral time, Lambda or closed-loop response time), rather than in detail (as in model- based control). RPC performance is mildly (PD algonthms. impacted by variation in actual T63. RPC is adaptive to changes in Gain direction and approximate speed process gai. of responseare the minimum information Gain direction isthe most necessary for effective control of any loop. fundamental aspect of any More detailed model information can be put to further advantage, but italso intro- CONSIDER THIS Would asset optimization be featir with a better behaved ‘advanced control algorithm? ONLINE reading from the cil edtion, cick on the headine for ‘more resources, including more Information and inks to related articles and an RPC math panes \worw.controleng,com/magazine duces more cost, risk and maintenance. From this standpoint, RPC provides a pru- dent and robust compromise among sim- plicity performance, and reliability. eo Allan Kern is owner and consultant with APC Performance LLC. Edited by Mark T. Hecke, content manager, Control Enginees- ing CFE Media, mhaske@femedia.com. ccontaou encineeeane April2019 #41ANSWERS. ADVANCED CONTROLS A Control Engineering tutorial, Understanding feedforward control Feedforward controls applied to a process, with limited, measurable disturbances, can keep the process variable close to the setpoint. raditional feedback control is a lot like ‘tunning backwards. Without looking at the track ahead, a rear-facing runner must rely solely on views behind to determine ‘here to go. While looking backward, the ‘runner can stay inthe lane only by adjusting the left- right position as the edge lines get closer. If the run- ner goes too quickly, its easy to end up wel offcourse before a course correction is applied. (See Figure 1.) Industrial feedback controllers face the same challenge. To keep the controlled process at the desired temperature, pressure, flow rate, etc, a feed back-only controller must wait to see how its been doing, then correct its mistakes and look again, ‘That’ generally not a random trial-and-error pro- cedure. Even ifthe controller knows enough about the process’ behavior to make educated guess- es about necessary corrections, those corrections always must be made after the fact. So like a rear-facing runner. a feedback-only controller must proceed cautiously to avoid over~ FIGURE 1 Run- ning backwards down a straight- away. Like a feedback-only controller, a rear- facing runner can only see the past location, but that's usu- ally enough to stay on course. Even without looking ahead, itis easy enough to observe proximity to the center of the lane and compensate for any slow drift to the left or right. A feedback-only controller has little difficulty keeping the process variable near a constant setpoint if slow drift is the only disturbance. Historical measurements of the process variable usually tell the controller all it needs to know when the control problem is this easy. Graphics courtesy: Control Engineering 42+ April2019conTRo. enaineeaine or under-correcting for past mistakes. This is espe- Gially true when the controller is designed with inaccurate or incomplete knowledge of the process’ behavior. If the controller can't predict the future effects of its current control efforts, it has little ‘choice but to act conservatively over a longer inter- val rather than aggressively over a shorter interval. (See Figure 2) Look forward, not backward ‘The obvious solution to the runner’ dilemma is to tun around and look forward rather than back- ward during the run, With advance knowledge of ‘upcoming curves, a front-facing runner will be able ‘to make much more informed course corrections and will be able to run much faster. ‘An observant runner also can look down the track and take preemptive actions to stay in the middle of the lane when an upeoming curve is seen. ‘The runner can start turning to the left exactly ‘when needed, as shown in the "Running forwards” graphic, Figure 3. ‘A process controller equipped with sensors capable of measuring precursors to upcoming dis- turbanees can operate faster and_preemptively ‘There is no need to wait for the results of past con- trol efforts to appear in measurements. Sensors and controllers work together to observe coming dis- turbances and feed the information forward to help caleulate future control efforts, Feedforward control example ‘A classic application of feedforward control is a steam distribution system where a central boil- er provides steam at a constant pressure to various pieces of equipment throughout the plant. When an idle machine comes online and starts drawing steam from the boiler, the pressure controller can precmptively turn up the heat and inject addition- al ater into the boiler, provided the system can The international lea erin indust automation compon “eres tents > World renowner rely on "technology you can SIEMENS > Innovation, wality, and continuity ‘Automation24 product overview of Siemens You will find a wide range of Siemens products at unbeatable prices. With these products, achieving process automation and control of your machines and systems is made simple and efficient. Look forward to proven Siemens quality. 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Automation24 Inc. 3600 Horizon Drive Phone: +1 610-981-2900 ‘mall@automation24.com Suite 110 +1 800-250-6772 (toll-free) wwwautomation24.com King of Prussia, PA 19406 Fax: +1 610-981-2929ANSWERS INSIDE MACHINES Steven Fales, Emerson Automation Solutions IloT-ready technologies improve machine controls Industrial Internet of Things (IloT) technologies have the potential to improve user benefits through diagnostics, prognostics and predictive maintenance. consider this scenario: An operator on a beer bottling line experiences a sud- den equipment shutdown. The operator hhas no need to access the programma- ble logic controller program or disrupt the network. Instead, the operator pulls out a smart- phone, connects to the machines pneumatic valve system, and pulls up a web page showing diagnos. tic data on the equipment’s pneumatic system per- formance. Its apparent a solenoid coil has burned out. in a directional control valve that controls one of the ‘machine’ actuators. Within minutes, a maintenance technician plugs in a new control valve and the bot thing line is running again with litle lost productivity ‘or major control system intervention. ‘This hypothetical example illustrates one of the ‘many advantages new Industrial Internet of Things (UloT)-ready technologies can bring as they enter the machine control market, These technologies prom- ise to improve user benefits with better diagnos- tics, prognostics and predictive maintenance. As a result, users will experience increased productivity, decreased downtime and reduced maintenance costs at unprecedented levels ToT technologies are stillin their infancy and eur rently are implemented in the machine control envi- ronment on an ad hoc or opportunistic basis. In these experimental and pilot applications, manufacturers are ‘identifying small, focused production problems, and then employ IloT solutions atthe foundation level to solve them. Gateways export data from the machine's control system for analysis and storage on-site or in the cloud. Analytics are run remotely to better under stand the problem and indicate a resolution, CONTROL ENGINEEERING IO-Link provides connectivity at the device and sensor level and allows ‘even the smallest field devices and smart sensors to diagnostic data for analysis to under- stand functional and system status. tion Solutions April 2019 + M4New HoT-enabled machines and net ‘works reach the mar- ket. The new archi tectures will combine smart devices with smart pneumatic valve systems incorporat- ing industrial network sterfaces, integrated VO and local analytics capability. For example, a production supervisor might be concerned about a machine's peak energy usage. The ‘equipments energy usage data is correlated with other ‘operating data pulled from smart sensors installed ‘on the machine, With this analysis, the supervisor can identify the time and operating factors when the spikes in power consumption occur. Connected devices, machine backbone The pilot projects of today will ead to the plant wide projects of tomorrow as new IoT-enabled ‘machines and networks reach the market. The new architectures will combine smart devices (such as sensors, Y input/output (1/0) modules, servo drives, robots, motor start 4 ers, etc.) with smart pneumatic valve systems incorporating indus- trial network interfaces, integrated 1/0 and local analytics capability. These smarter connected devices will form the backbone of the machines’ controls and have HoT connectivity While industrial networking has been used in higher-level devices for decades, its been too expensive to integrate into small field-level sen- sors. Adding a point-to-point communications technology that uses existing cabling infrastruc ture, such as IO-Link communications, allows data extraction from smart sensors and devices. The combination of wireless connectivity, mobile devices and wireless diagnostics and prog. nostics provides smart pneumatic manifolds with the analytical capabilities required for HoT applica- tions. The technologies deliver data from the field devices (smart sensors) through pneumatic mani- folds into a machine control system. This diagnostic and prognostic data also can be routed through a separate gateway and channel that More KEYWORDS: Industral Internet of Things, HoT, 0-Link Easier communications help crvate the Insti Intemet of Things (loT) Less downtime and greater ONLINE Read this story online at wivw.controieng.com and more stories about the loT and its benef for manufacturers in ciferent industries and aopiicatons, CONSIDER THIS ‘What specific benefits can the ‘commurications being to your pla abit wil result. and 1O-Link Downtime is lost time. And lost time means lost profitability. With Nexons Industrial Ethernet Solutions, you're getting @ solution you can trust; one that supports your requirement for 100% uptime. Nexans gives you the confidence to make the connection Visit nexans.us/industrial to learn more at wwwcontrolengccominformationELECTRONIC OR TRADITIONAL CIRCUIT BREAKERS? I Electronic I Traditional 1-CH ECB 45mm Li24mm— l 72mm J Break Tradition “s Try Electronic Circuit Breakers Up to 66% smaller Fast reaction time even at low currents Remote reset via digital inputs/outputs cree 1, 4, or 8 channels with selectable currents up to 12 A Electronic ‘Thermal Magnetic Watch the video at www.wago.us/whyECB Input #22 at wwwecontiolengicomlaformation wiA G oeA Tem cel MACHINE Ce NU) CONTROLLER Pence ene eet enough to handle almost any application. Ga ean et eee wasp's head, to coordinating multiple axes gai acne uc controllers are the answer. Users c ite aCe A ten eee eit ars troller for your needs, Contact us today to get started. & AEROTECH Visit aerotech.com or Call 412-963-7470 Input #23 a wwwcontolengcomvinformation —wesisacs ANSWERS INSIDE MACHINES isnt a part of the control network. This allows external devices to collect, analyze and act upon relevant process data efficient- ly without loading the control network with diagnostic data. It also allows users to analyze this data without affecting the ‘machine’ process or production schedules. This HoT-driven data analysis also can be retrofitted on existing machines. Role of |O-Link 10-Link (IEC 61131-9, a standard for sensor and actua- tor communications) allows even the smallest field devices and smart sensors to communicate their diagnostic data for analysis to-understand functional and system status, 1O-Link technology ‘was conceived for setting and changing functional parameters on smart sensors using the same existing connecting media. It has developed into a communication technology that allows control of non-sensor devices such as proportional pressure regulators and valve systems, 10-Link typically is used in conjunction with a commu- nication gateway to higher-level industrial networks such as EtherNet/IP, Profinet, EtherCAT, etc. to allow network commu- nication to reach the lowest layer of the control system. Through these IO-Link master gateways, smart devices can send diag nostic and prognostic data digitally to high-level processors for analysis, which can take place in a local, on-site or loud environment. ‘New modular fieldbus valve manifolds will have the added benefit of hosting multiple 10-Link masters and act as a gate- ‘way to one Ethernet communication node. This eliminates the requirement to have a communication node for each 1O-Link ‘master, which reduces cost and complexity. Due to the modular nature of today’s fieldbus manifolds, 10- Link master modules designed to integrate to a modular field- bus valve manifold also can be distributed up to 30 meters from the fieldbus communications node, allowing convenient place- ‘ment of sensors and devices on the machine. The TO-Link mas- ter modules can incorporate auniliary power connectors for each individual [O-Link channel to provide machine designers with increased flexibility, efficiency and additional safety options. Local Wi-Fi communication will be integrated on the pneu- ‘matic valve system to simplify machine maintenance and commissioning, The user has easy data accessibility via any Wi Fienabled mobile devices without needing to download any apps. The operator or maintenance technician connects the mobile device to the Wi-Fi network and an HTML web page with the machine’ analytical data is served up to the devie the appropriate format. Plant-wide IloT implementation ‘ter local experimentation, IloT technologies will be imple- ‘mented more readily on a plant-wide, operational level, and sub- stantial benefits will be generated in machine uptime, operator safety, commissioning and product quality MoT technology reduces machine downtime by allowing predictive maintenance, which enables operators to identify and resolve problems in a planned and orderly fashion with- out disrupting the production process. Prognostics allows real- time analysis with the capability to continuously monitor the ‘machines performance without adding overhead to the con- M7 * April 2019. contro. enainesanatrol system, Directional control valves can be monitored for time, distance and the extent of their lifecycle. The user is alert- ed when there are deviations from nor- ‘mal operating parameters. Prognostics are a major step beyond preventive main- tenance and facilitates the adjustment, repair or replacement of a component before it creates an impact on machine performance. 1O-Link communication technol gy allows low-level devices to communi- cate to high-level networks in a simple, but economic way. This also brings indus- trial communication to even the smallest device, enabling the promise of Ho Wireless connectivity also permits ‘maintenance personnel to monitor pneu- matic valve systems and their connected devices in hard-to-reach locations deep inside the machine. They can diagnose a wire break, an inoperable communica- tions module or a failed valve coil with- ‘out shutting down the system or climbing around the equipment. ‘An IO-Link sensor’ status also can be checked with a mobile device. The new smart sensors alert the user if they are broken and why they failed, which makes them easier to fix. Sensor commissioning and replacement is easier since the param- eters already willbe set with an .iodd file. The data generated from IloT-enabled machines also can help diagnose prob- Jems that impact product quality. For example, the data from a machine’ sen- sors might indicate one of its pneumat- ic cylinders is not fully extending. That erosion in movement potentially could cause deterioration in the manufactured products quality over time. The ability to understand a component is drifting out of specification before it affects product quality will be an important advantage. Better information for engineers ‘As these technologies begin appearing in machine control systems over the next few years, they will produce improved ignostics, simplified ing, better safety and more consistent asset availability than before. These ben- cfits will have important ramifications for machine builders and end-user cus- tomers in the automotive, pharmaceuti- cal manufacturing and food and beverage industries. April2019 © MB Users will soon apply these technol- ogies to solve the big problems in their manufacturing systems. For the first time, these solutions will be based on data from lower-level sensors measur- ing machine performance — and the data collected will automatically or sys- tematically improve overall operations. evant information that allows machines to operate more efficiently and effectively with less downtime. e« Steven Fales is product marketing manager, ‘fieldbus electronics and valve systems, Emer- ‘son Automation Solutions, Edited by Chris Vavra, production editor, Control Engineer- ing, CFE Media, cvavra@efemedia.com. Analyzing this new data will create rel- ‘Applied Motion Products s expanding our tne of tegrated motors with the ation of ur frstever integrated motors but on ‘wadttonal 8-pole brushless servo motors Using our inovative approach to integrated motors, developed overtime with our integrated stepper and StepSERVO Integrated Motor praducs, we now introduce MOX Integrated Servo Motors fr higher speed plications. Make it Move [200-525-1609 wen applied-motioncom Hid sales@applied-motion.com input #24 at wan cantroleng comyinformation MDX Integrated Servo Motors + High torque density, fo inertia motors “Integrated drvercortoller +200 or 400 Watts continuous output power + Compact 60 mm frame size + IP6S or 1P20 environmental rating, + Buitin EtherNeutP, CANopen, Modbus, (rSCL over Ethernet or R525 + Dual por communications for easy sisychain connections +0 Programme fr stored program ‘execution and stand-alone operation ‘Applied Motion amon tounteANSWERS INSIDE MACHINES John Ritter, 8 Think safety with automation Machine safety: Physical barriers are often the best choice after a risk assessment is performed in places where machines and workers co-exist. More WV KEYWORDS: Machine Safety, worker safety Use risk assessments toevaluate machine guards, Machine guards, while Use aren't avy appropriate Physical automated barter doors may impare productivity the least. CONSIDER THIS What applications and industnes benef moet ftom physical safety bariers? ONLINE This article online contains more safety information at ‘worw.cantraleng,com. Rick can increase where machines and workers co-exist; safeguards can help protect employees. Courtesy: Rite-Hite M9 © April 2019 ANSWERS ny time a manual task can be turned {nto an automated one is a major oper- ational efficiency boon for a facility, but without adequate safety measures, risks may exceed whats acceptable. As order fulfillments speed up to meet the demands of internet-shopping customers, facility managers look for any edge available. Machinery can perform arduous yet necessary tasks at much faster rates and typically with great- er precision than human workers. Automated oper- ations, like stretch wrapping, can be done much ‘quicker than @ worker can do his or her own, Consid- ering there are more than 1.5 million industrial robots working across the globe, itS a sure bet production would plummet without their use in today’s world, Unfortunately, there is risk in cases where machines and workers co-exist. Facility managers ‘who implement new equipment need to be aware of these risks and think about safeguards to protect their employees. This ist ust best practice; its the law. Understanding regulations The point-of-interaction between robots and workers, like “running” a machine, is where the most risk and regulatory confusion often exist in a plant ‘The best starting point is OSHA. Per 29 CFR 1910.212(a)(3)(ii), OSHAS General Requirements of All Machines, the pro- cess at critical interaction points must be guarded or contained to protect work- cs from injury. The rule states, “The point of operation of machines, whose opera- tion exposes an employee to injury, shall be guard- ed. The guarding device shall be in conformity with any appropriate stan- dards therefore, or, in the absence of applicable spe- ‘CONTROL ENGINEERING cific standards, shall beso designed and construct- ‘ed as to prevent the operator from having any part of his body in the danger zone during the operat- ing cycle” In the OSHA General Duties Clause in section 5: (a) Each employer: (1) Shall furnish to each of his employees employment and a place of employment Which are free from recognized hazards that are causing or are likely to cause death or serious physical harm to his employees; (2) Shall comply with occupational safety and health standards promulgated under this Act. The Robotics Industries Association (RIA) 15.06 Industrial Robot Safety Standard referenc- es ISO 10218-1 and 2, Safety of Industrial Robots and Robot Systems, which address robots, robot systems and integration. RIA 15.06 was written to harmonize standards already in place in Europe. At its core, the standard requires better hazard identi- fication, taking into account robot motion and the specific task being performed. Under this standard, safety-rated motion can be programmed using soft- ware that controls a robot’ operational area and the speed it can move at Risk assessments come first RIA R15.06 requires risk assessments. Point-of- operation guarding is perhaps the trickiest aspect. of this regulation; it represents the intersections of human and machine, as well as safety and efficiency. Facility managers need to always be looking for new technology that can accelerate operations. How- ever, they also must keep safety at the forefront of any decision. A risk assessment to determine the best ‘machine guard i the first step. After the choices have been narrowed down by safety requirement, consider the safety option that interferes with productivity the least-physical automated barrier doors. e John Ritter, product manager, Rite-Hite Doors. 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VV wea: Ir = ; Check out some of our webcasts on topics like: = Machine Vision and Industry 4.0 loT series: Cloud and mobility in field operations lloT series: The role of connectivity in collaborative projects lloT series: Simulation, analytics & modeling Cloud ERP lloT series: Current issues & applications Motors and drives beasts Human-machine interface hardware, softwareWhite Paper Connection Cec) r Redefine Capital Project Success Emerson Companies around the globe are rethinking capital projects and achieving transformat results through innovation and expertise. They are executing effective capital projects that eliminate cost, reduce complexity, and accommodate change. nal See how organizations are transforming capital project efficiency with moder project management strategies, inno- vative engineering practices, and digital technologies. Transformational results include: © Completing a multi-national project 11 days ahead of schedule © Shaving 5% from EPC and client instrumentation hours © Coming in under budget and with an on-spec first batch No matter the project challenges, a well-formed plan with integrated expertise and technologies can deliver improved value, an on-time and on-budget start, and a comprehensive handover to operations. In project after project around the globe, Emerson's Project Certainty methodologies and solutions meet or exceed expectations EMERSON and build a bridge to operational excellence. Download this paper here: www3.emersonprocess.com/projectcertainty/projectideabook input #26.at wwwcontoleng.comvinformationWhite Paper Connection Meet the Future: Edge Programmable Industrial Controllers For today’s engineers, new demands to use and share data present three main challenges: security, complexity, and ‘expense. These data intensive automation applications typically require many steps and a lot of middleware: computers, gateways, drivers, parsers, custom software, licenses. Time-consuming to set up, difficult to maintain and change, they also open major security concerns. ‘As automation engineers, we're familiar with PLCs and PACs. Both have been improved over many years. But for the applications we want to do now and in the future, we need a new product that does much more than a PLC or PAC. We need an automation product that shrinks the middleware and lets us move data from where it’s produced to where it needs to go in much fewer steps. That product has recently appeared on the market. It’s called EPIC—an Edge Programmable Industrial Controller. An EPIC eliminates middleware and reduces the steps required to get the data we need, thus reducing complexity, lessening security risks, and decreasing the time and expense required for installation and maintenance. This white paper explores the differences between an EPIC and a PLC or PAC and shows why an EPIC is more suited to, Benson Hougland | Opto 22 Vice President of Marketing and Product Strategy et ne rate ge rogaine the data-intensive = automation and industrial internet of things (lloT projects wwe are designing and building now. Using examples of two companies—a glass products manufacturer and an OEM (original equipment manufacturer) of industrial and commercial ovens—the paper explains the key features of EPICs and how they can solve real automation problems. ‘Combined into one industrially hardened device, an EPIC offers: + Real-time industrial control + Gateway security standards and functions ‘+ Computer-like intelligence, speed, and ‘communication ports ‘+ Multiple programming languages and methods + Avariety of software and protocols for data communications + An integrated high-resolution touchscreen and web-based HMI for commissioning and system visualization + Software upgrades to add new features Learn how this new kind of industrial controller can simplify and secure your automation and lloT projects, while reducing cost and complexity. Download this paper at: https://op22.co/EPICwhitepaper OPTO 22 The Future of Automation. systemseng@opto22.com + www.opto22.com Input #27 at wwcontoleng.comvinformationWhite Paper Connection ‘TURN REMOTE SITES INTO SMART REMOTE SITES Turn Remote Sites Into Smart Remote Sites - Cellular Networking Solutions to Connect, Monitor and Control Remote Assets Red Lion Controls Every business strives to protect revenue, as well as ensure uptime and availability for customers. The oil and gas, alternative energy, power, utilities, water and wastewater spaces face unique challenges when working toward these goals. They must achieve seamless connectivity, regardless of expansive territories, asset age and types of communication technology. Using cellular networking to build smart remote sites over- ‘comes many infrastructure, financial and safety barriers. Today's energy and utility companies operate in competitive, closely scrutinized business environments. These organizations must adhere to stringent regulatory requirements to prevent downtime for customers. When equipment fails, the resulting downtime leads to immediate financial and safety consequences. As competitive forces grow and business demands intensify, companies can capitalize on the benefits of the Industrial Internet of Things (IT) to improve their processes and data assets. Companies require more consistency, better visibility of networks, reduction of waste and loss, and increased compliance with regulatory requirements. Smart technology has the ability to connect all devices and control systems. It also delivers the visibility to collect and analyze data from both new and legacy devices. High-availability smart sites can: = Minimize or eliminate unscheduled downtime i ‘i 2, e + Reduce time to repair re mn + Provide continuous operation, regardless of communication + Increase visibility of equipment and sites + Prevent unsafe conditions + Comply with increasing regulatory conformity inseslesorecsonie www.rediion.net Register to download the paper at: https://marketing.redlion.net/acton/media/34560/smart-remote-connected-sites-white-paper Input #28 at wwcontoleng.comvinformationSee mare New Products for Engineers. ‘www.controleng.com/NP4E INNOVATIONS____— NEW PRODUCTS FOR ENGINEERS ae «{ Medical and information technology equipment power supply Power Partners’ PDAMI20 Series of 120W acide power supplies are designed for use in either medical or information technology equipment (ITE) applications. The PDAM120 Series s an industry standard 2 x3-in, platform, available in open-fram options—all focused on high-efficiency and high-power models: 12,24, and 48 Va. 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R21 fea- tures reflect the growing use of publishing analytics-based views to other employ- of the use cases. R21 ces, and the increased complex! adds frequency analysis capabilities, referred to as FFT, to transform segments of a time-series signal into the fre- quency domain. Seeq Corp... wivw.seeg.com pst sunmsonlngcewinomaton chassis, de input and output modules, a temperature input module and an analog input module. 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These rugged modules provide avery cost-effective and highly Keyence Corp. of America dependable solution to interface sensors, actuators, relays, instruments, and other devices to an etheret-based contrl system, Motor control system Y ‘Acromag Advantages Rock-Solid Reliability for linear axes 1 High channel density for very 1 igh-rotage isolation and Igus' D3 dryve is costefectve solutions surge protection dissipate designed to control lin- harmful signals ear and rotary systems ™ Ethemet/P Profinet, Modbus TCP, without software ora or peer-to-peer communication 1 Redundant power and personal computer. The ‘communication prevent DB control system is suit- 1 Easy configuration via USB/Windows costly downtime able forall standard de orbuiltin web server motors. Itconnects to a 24 V power sup- ‘= 40 10 85°C operation and ply: End users can set parameters on 1 Duol Ethemet ports for Class 1 Div 2 hazloc approvals operating mode, end position switch off, daisy chain connections and ATEX certification acceleration, and the motor via the DiP switch. The speed can be adjusted with an onboard potentiometer. The current lim- iting is done on the controller. After a few simple steps, the control system can be put Into operation. A LED display indicates = Counter, integrator and totalzer functions @ Visit wn Acromag.com/XT TO LEARN MORE the eurrent status ofthe control system to the user with several colors. acromagcom | sales@acromag.com | 877-295-7057 Weguee Rous gus, wivwigus.com Input #205 an eonaleng convintoation Input #30 at wiew-controleng.convinformation OD» Apel 2019) icone evcnennees:INNOVATIONS BACK TO BASICS: ROBOTICS Robotic Industries Association Robotics 101: An overview for beginners Robots have advanced dramatically over the past few decades and are able to automate a wide range of tasks in an even wider range of industries inside and outside of the factory setting. obots have advanced dramatically over the past few decades since their initial use in the automotive industry. Over the years, they've come to be a reliable way to automate difficult, dirty and dangerous tasks for human workers. ‘Today’s robots are flexible and profitable. ‘They're able to automate a wide range of tasks in an even wider range of industries inside and outside of the factory setting. Robots are different than they were even 10 years ago. They have built-in safety features to ‘minimize workplace incidents and work alongside human workers. With a diverse range of end-elfec- tors and robot designs, they've aso been expanded. their potential uses compared to earlier robots. Robots are also easier to program than ever before. Some robots dont even need programming knowledge; traditional robots require unique pro- ‘gramming expertise. Robots are also connected to internal manu- facturing execution systems (MES) and enterprise resource planning (ERP) systems and deliver per- formance feedback and advanced production ana- Iytics. As these features have been added to modern robots, their initial costs have been steadily deereas- ing, This is making robots a viable solution for just. about any industrial operation. How are robots used? ‘Today's robots, whether they're industrial, col- laborative, or professional service robots, are used in a wide range of industries. ‘While robots used to be exclusive to the automo- tive industry, that mindset is changing. According to an RIA press release, almost half ofall robot sales in 2018 were to non-automotive companies. While automotive sales continued to hold a slim majority, sales were at its lowest level since 2010, The shift in 2018 reflects the technology advances as wel as. their increased affordability Robots, as @ result, are more common in every~ day plant operations and can be seen industries such as: G Today's robots are... able to automate a wide range of tasks in an even wider range of industries inside and outside of the factory setting. 5 + Automotive + Assembly + Welding + Painting + Blectronies + Medical device + Packaging + Material handling + Nuclear + Pharmaceutical ining + Agriculture + Service +Food ‘Today's robot feature a range of intel- ligent, safe, and even mobile technol- ogies that expand their capabilities Robots were once limited to performing ‘one simple task repetitively. Now, robots can perform a variety of tasks in a wide range of settings, which boosts their profitability. c@ This article originally appeared on the Robotics Online Blog. Robotic Indus- tries Association (RIA) is a part of the Association for Advancing Automa- tion (A3), a CFE Media content partner. Edited by Chris Vavra, production edi- tor, Control Engineering, CFE Media, cvavra@ cfemedia.com. ‘CONTROL ENGINEERING More INNOVATIONS KEYWORDS: Robotics, automotive Industry Robots are moving beyond the automotive industry and being used in ‘ter applications, Technology advances allow robots to work inside and outside the factory settings Robots are capable of perorming many 128s, which increases their value fon the plant floor GO ONLINE ead this at wwrw-controleng.com for addtional stories about robots and articles from the FIA. CONSIDER THIS How does your company use robots and for what applications? 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