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.

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r deta

ils

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2 ● APRIL 2014 CONTROL ENGINEERING ● www.controleng.com

40

42

30

®

Vol. 61Number 4

COVERING CONTROL, INSTRUMENTATION, AND AUTOMATION SYSTEMS WORLDWIDE

30 Cover: Big plans for smallnuclear reactors

More ef� cient nuclear reactor designs havesimpler controls, safety and modularity; seetimelines for startup.

34 Smart manufacturing andnew automation improve livesof engineers

Next-generation automation has a profoundimpact on manufacturing business models andquality of life for engineers.

36 Smart manufacturingtechnologies, intelligent processes

Software enables predictive planning, performance monitoring, big data analytics, virtual modeling,and more informed decisions.

Features

APRIL 2014

Courtesy: NuScale Power LLC

CONTROL ENGINEERING (ISSN 0010-8049, Vol. 61, No. 4, GST #123397457) is published 12x per year, Monthly by CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Jim Langhenry, Group Publisher /Co-Founder; Steve Rourke CEO/COO/Co-Founder. CONTROL ENGINEERING copyright 2014 by CFE Media, LLC. All rights reserved. CONTROL ENGINEERING is a registered trademark of CFE Media, LLC used under license. Periodicals postage paid at Oak Brook, IL 60523 and additional mailing offices. Circulation records are maintained at CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. E-mail: [email protected]. Postmaster: send address changes to CONTROL ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Publications Mail Agreement No. 40685520. Return undeliverable Canadian addresses to: 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Email: [email protected]. Rates for nonqualified subscriptions, including all issues: USA, $150/yr; Canada/Mexico, $180/yr (includes 7% GST, GST#123397457); International air delivery $325/yr. Except for special issues where price changes are indicated, single copies are available for $30.00 US and $35.00 foreign. Please address all subscription mail to CONTROL ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Printed in the USA. CFE Media, LLC does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the material contained herein, regardless of whether such errors result from negligence, accident or any other cause whatsoever.

38 8 ways the cloud is a no-brainer A cloud solution can be the most economical

way to make things happen in a hurry.

40 Industrial cloud improves custody transfer, remote monitoring for oilapplications

Trigg Technologies LLC uses a cloud-basedplatform and remote monitoring to improve custody transfer services.

42 Improve remote HMI and OIT access Smartphones, tablets and industrial software give mobile

access to human machine interfaces (HMIs) and operator interface terminals (OITs).

44 Convergence bene� ts Technology convergence offers new opportunities.

Get the unswerving performance you depend on, while maintaining the safe and reliable systems you need. With Honeywell’s continuous evolution approach and depth of expertise, you can modernize to the most advanced functionality with minimal disruption to operations. No matter what automation system you are running, by modernizing to Honeywell’s technology, you can accelerate production capabilities and extend your automation investment into the future. Your roadmap to the future.

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©2013 Honeywell International, Inc. All rights reserved.

what’s your roadmap?

Map a course for sustained performance.


www.controleng.com ● CONTROL ENGINEERING APRIL 2014 ● 5

8 Think Again Software to go, wireless mobility

10 Apps for Engineers File preview apps for iOS and

Android

12 Anniversary Industrialization, lucrative controls,

e-commerce for manufacturing

14 Research Cyber security report

16 International Interconnecting devices

via Internet

17 IT & Engineering Insight How to justify manufacturing IT

changes

18 Machine Safety Merger: One global

machine safety standard

20 Integrator Update 6 reasons why system

integration is not a commodity

96 Back to Basics Quality management ideas

departments 22 Goodbye MS Windows XP,

engineering train safety

23 Dual-arm concept robot

24 Motion control pro� leexpands, 10 changes tomaterial handling

25 Take risks as manufacturingchanges 8 ways, ODVA likes Ethernet for process industries

news

93 Do Ethernet over A-B Remote IO, Powerlink translation, ground testers, CAN gate-way IO module, cageless high-peak torque motors

94 Integrated logic gate, power supply for dc in plastic or aluminum housing

products

Inside MachinesSections after p. 46. If not, see www.controleng.com/archives for April.

M1 Packaging OEM offers multi-touch enabled machines Edson Packaging puts an industrial spin on consumer electronics technology.

M6 PLCopen part 4 blurs the lines The PLCopen working group for motion control has standardized machine

control programming: PLCs, robots, and motion control.

M11 Increase sampling time for motor control Pulse width modulation (PWM) using opposite voltage vector can extend time

for analog dc (ADC) sampling in motor control applications.

Inside Energy Management

PRODUCTS

COVERING CONTROL, INSTRUMENTATION, AND AUTOMATION SYSTEMS WORLDWIDEOVERING CONTROL, INSTRUMENTATION, AND AUTOMATION ®

APRIL 2014

IEM1 Introduction New methods, high

performance

IEM2 New approaches Manage assets; save energy.

IEM5 Remote machines Improve operations with less energy.

IEM8 New solar � nancing Decrease costs, grow faster.

Exclusive HART Supplement after p. 46

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Fresh content daily: More learning, less sur� ngExclusive blogs at www.controleng.com/blogs� Real World Engineering: Emulating a third-party application in a DCS� Machine Safety: Safety system validation is needed to substantiate the

required safety function� Research analyst blogs: 6 billion Internet-enabled devices will be made in 2014� Ask Control Engineering: What if some of my machines still use MS Windows XP?

Join the discussions at www.linkedin.com/groups?gid=1967039 � What engineering mobile apps do you � nd most useful?� Are governments giving STEM enough support?� Is there a shortage of engineers going into automation-related professions?� Ask a question or start a discussion today.

Topical e-newsletters deliver timely intelligenceStart your subscriptions at www.controleng.com/newsletters� Weekly News: PMI Index increase part of the spring thaw� System Integration: Integrating and optimizing power and mechanical systems� Machine Control: PLC, robotic, and motion control programming� Process & Advanced Control: Create a safety culture, understand

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Point, click, watch VIDEO:Robot picking and packing seriesABB’s IRB 360-6 FlexPicker robot has a reach of 1600 mmand a mid-range payload of 6 kg and is designed for harsh washdown environments like meat and dairy applications.

Go to www.controleng.com/videos to see how itworks, along with other recent video clips, or scanthe code to the right.


APRIL

www.controleng.com

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THINK AGAINTHINK AGAINeditorial

1111 W. 22nd St. Suite 250, Oak Brook, IL 60523630-571-4070, Fax 630-214-4504

The number of mobility applications has exploded, including many for engineers’ use. I had heard some suggest a while back that software

for automation, controls, and instrumen-tation was too complex for smartphones or tablets. A Control Engineering analysis of 225 applications for engineers found that that’s certainly not the case. Of those applications:

85 are Android (Google), 38%141 are iOS (Apple), 62%.

These apps are developed by 115 compa-nies; 61 for Android (53%), and 54 for iOS (47%).

Among the application types: 58 are reference (26%)46 calculator (20%)35 productivity (16%)28 utilities (12%)20 business (9%)13 instrumentation (6%)10 catalog (4%)8 tools (4%)7 suite (3%).

The top five categories of applications for each operating system (OS) ranked equally, as shown above.

Among the categories of applications:62 are general engineering (27%)33 HVAC (15%)32 electrical (14%)23 control methods (10%)14 file preview (6%)13 business admin (6%)11 education (5%)9 mechanical (4%)8 energy (4%)8 motors and drives (4%)7 vision (3%)3 maintenance (1%)2 codes and standards (1%).

Among these, 10 have to do with human machine interface (HMI), supervisory con-trol and data acquisition (SCADA), or visualization, according to the application descriptions.

General engineering is the most preva-lent category for each OS; HVAC was more numerous in iOS and electrical more for Android. Control methods and file preview rounded out the top 5 for each.

Paid versus free analysisAmong the 225 applications, 151 (67%)

are free. Among 74 apps with a fee:43 are iOS (58%) and 31 are Android$10.48 is the average cost$4.99 is the median (and mode) cost$ 149.99 is the highest one (a SCADA

and HMI application)$0.99 is the lowest (5 apps)$ 776 is the sum of the paid apps, and

80% of that is from iOS apps.

Think again if you consider automation and control too complex for use on smart-phones and tablets. The statistics shown indicate otherwise.

Four mobile applications are highlighted in each issue of Control Engineering. See the online box below for more. ce

Mark T. Hoske, Content [email protected]

www.controleng.com/archives

April: This story has links to more information about the applications themselves. Numbers here originate from applications in CFE Media’s Apps for Engineers as of late March.

www.controleng.com/AppsForEngineers

... is where to peruse the apps or submit an app.

Go Online

Software to go,wireless mobilityMobile applications are allowing those in thecontrol engineering profession to take softwarewith them in smartphones and tablets. Whatkinds of mobile apps are available?

Content Specialists/EditorialMark T. Hoske, Content Manager630-571-4070, x2214, [email protected]

Peter Welander, Content [email protected]

Jordan Schultz, Associate Content Manager630-571-4070, x2213, [email protected]

Amanda McLeman, Director of Research630-571-4070, x2209, [email protected]

Chris Vavra, Content [email protected]

Contributing Content SpecialistsFrank J. Bartos, P.E., [email protected]

Jeanine Katzel, [email protected]

Vance VanDoren, Ph.D., P.E., [email protected]

Suzanne Gill, European [email protected]

Ekaterina Kosareva, Control Engineering [email protected]

Marek Kelman, Poland [email protected]

Lukáš Smelík, Czech [email protected]

Andy Zhu, Control Engineering [email protected]

Publication ServicesJim Langhenry, Co-Founder/Publisher, CFE Media630-571-4070, x2203; [email protected]

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Elena Moeller-Younger, Marketing Manager773-815-3795, [email protected]

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Letters to the editor Please e-mail us your opinions [email protected] or fax us at 630-214-4504. Letters should include name, company, and address,and may be edited for space and clarity.

InformationFor a Media Kit or Editorial Calendar, email Trudy Kelly at [email protected].

ReprintsFor custom reprints or electronic usage, contact: Wright’s Media – Nick Iademarco

Phone: 877-652-5295 ext. 102Email: [email protected]

Publication SalesPatrick Lynch, AL, FL, GA, MI, TN630-571-4070 x2210 [email protected]

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630-571-4070 x2206 [email protected]

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978-929-9495 [email protected]

Diane Houghton, classified, product mart, media showcase508-298-9021 [email protected]

Stuart Smith, InternationalTel. +44 208 464 5577 [email protected]

ENGINEERSENGINEERSapps for


File preview appsfor iOS and Android

10

File preview appsfor iOS and Android

BuzzsawAndroid 2.2+, iOS 4.2+Cost: FreeCompany: Autodesk Inc.Website: www.autodesk.comThis app lets users securely access project designs and documents for architecture, engineering, and construction from anywhere. Autodesk, Revit, and Navisworks models, DWF, AutoCAD, DWG, DXF, PDFs, Word, Excel, and PowerPoint are all compatible.

TolomaticiOS 5.1+Cost: FreeCompany: TolomaticWebsite: www.tolomatic.comWith this app, access Tolomatic’s company and product information. Products include: right-angle gear boxes, cone clutches, pneumatic cylinders, industrial caliper brakes, electric linear actuators, and motors and control systems.

eDrawingsAndroid 4.0+, iOS 6.0+Cost: $1.99Company: SolidWorks Corp.Website: www.solidworks.comThis app is a CAD viewer that allows users to view native eDrawings � les and SolidWorks parts, assemblies, and drawings � les. The app integrates e-mail functionality such that users can load and send � les.

Data Dashboard for LabVIEWAndroid 4.0+, iOS 5.0+Cost: FreeCompany: National InstrumentsWebsite: www.ni.comThis app allows NI LabVIEW users to create a custom dashboard that they can use to remotely control and monitor running applications in that program. Users can connect deployed NI shared variables or LabVIEW web services with controls and indicators.

CFE Media’s Apps for Engineers is an interactive directory of more than 240 engineering-related applications for Android and iOS, created by various companies. We’ve organized apps by category, company, and type. This month, gain access to our file preview apps.

www.controleng.com/appsforengineers

SIMATIC HMI WinCC in TIA Portal

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60th AnniversaryHappy 60th, Control Engineering! Help us celebrate by looking at trends. Control Engineering magazine first published in September 1954. This monthly column in 2014 will review coverage in issues 60 (or 59), 30, and 15 years ago. Technologies have progressed since then, topics remain relevant today (Southeast industrialization, the lucrative industrial control field, and e-commerce).

See the Control Engineering history page:www.controleng.com/history

See additional historical links online and more information about each of these excerpts: www.controleng.com/archives

Go OnlineE-commerce is on the rise for manufacturing

E-commerce is emerging rapidly for factory automation and process control products. Internet usage has risen astronomically over the past four years, and it is estimated that the number of Internet users will reach one billion by the year 2005. Looking at current Internet trends, it makes sense that more services are focusing on online consumers.

Until recently, it was difficult to sell goods or services over the Internet, but the boom in web development tools, such as Java, server-side scripting, and secure servers has facilitated the introduction of e-commerce onto the World Wide Web. Nowadays just about anything can be bought via the Internet, including books, CDs, software, clothing, vitamins, airline tickets, and now, automation and control products.

So far, only a few manufacturing companies have set up online stores, but new site announce-ments keep coming in regularly as more companies sell their products online.

History 60 - 30 - 15 years ago

th

ANNIVERSARY

Controls pace southeast industrializationIn 15 years, Florida’s manufacturing output has risen 500%. Nearly 44% of Georgians farmed

in 1940, but today only 28% do. These figures typify the pace of industrialization throughout the Southeast. New and expanded factories have made the region a top market for instrument and control makers. And competition among the myriad small plants is so keen that even some relatively new ones remain steady customers. For example, the Macon Kraft Co., Georgia paper-maker, now uses 50% more instrumentation than it did just seven years ago when the plant was built. Southeastern industry is becoming increasingly control conscious. One power plant spent $2.5 million to reduce operators from 26 to 6 men per shift. A modern hospital being built in Atlanta has a boiler plant whose controls and instruments represented 50% of the boiler room cost. About the region, these generalizations seem valid: More companies are hiring instrument engineers; scanning techniques are becoming popular for assembling and collating the informa-tion on instrument panels; process industries are building more central control rooms; and elec-tronic control systems are interesting, but most plants are sticking to pneumatic systems.

Trends in control: The industrial control field, still lucrativeIf current activities are any indication, the industrial control field has lost none of its glamour as a potentially

lucrative growth business. After lackluster performance in recent years, two of the well-known process control suppliers changed owners, presumably switching to companies that will be better able to take advantage of their inherent capabilities. Newly formed companies with a better technological idea continue to come out of the woodwork, to be joined by major existing companies which in the past have had no interest in the indus-trial control field but have suddenly decided they better get in on the action. Strange things happen as well: a major supplier spins off a system integrating capability, which on the surface seemed crucial to accomplishing its stated objectives.

Programmable controllers and distributed process control systems are still the most popular areas, both in this country and overseas. Accompanying new basic PCs are an endless number of PC accessories, interface devices, documentation and programming systems, service businesses, and control software houses. All of this activity bodes well for the control engineering customer.

APR

IL 1

955

APR

IL 1

984

APR

IL 1

999

-Jordan M. Schultz, associate content manager, CFE Media, edited the excerpts to fit this page.

Easy Call. Big Payoff.

Motor-driven equipment accounts for 63% of your plant’s electricity consumption every minute of every day. Your choices are to let your electricity bills continue to grow or call in Baldor’s Installed Base Evaluation Team to identify improvements you can start making today.

The Baldor IBE Team uses advanced data collection equipment and software to work with your plant maintenance personnel to take an accurate account of your motors, drives and mechanical power transmission products, both in operation and from spares inventory. The IBE Team will produce a comprehensive report and plan,

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targeting inefficient motors and mechanical drives as well as identifying systems where adjustable speed drives could be added to save even more energy. This report will provide recommendations for immediate action along with long term strategies…all positively affecting your bottom line.

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Control system cyber securitythreat levels

Severe

High

Moderate

Low6%

20%

45%

29%

Within past6 months

Within past year

Within past18 months

Withinpast2 years

Never

Most recent vulnerabilityassessment

33%

29%5%

10%

24%

In February 2014, Control Engineering sur-veyed members of its audience who are direct-ly involved in aspects of control system cyber security within their organizations. The study

asked key questions on cyber security practices, including perceived threat levels, system vulner-ability, and recent cyber-related incidents.

In general, nearly half of respondents perceive the control system threat within their organizations to be at a moderate level, but one in four cite a “high” or “severe” threat level in their systems (see Figure 1).

Malware from a ran-dom source with no specific connection to respondents’ respective companies or industries was cited as the most threatening type of cyber-related incident that a control system could experience.

The top three system components respondents are most concerned about are:

1. Computer assets that are running commer-cial operating systems

2. Connections to other internal systems

3. Network devices.

On the other hand, cyber threats don’t seem to be much of a concern on embedded controllers and connections to the field SCADA network.

Systems vulnerabilityWhen asked about the

last time their organiza-tion performed any type of vulnerability assessment,

one-third of respondents said an evaluation was performed within the past six months, 29% said within the past 12 months, 15% said within the past 18 to 24 months, and an alarm-ing 24% said never.

Of the respondents who indicated that their organization has never performed a vulnerability assessment, 33% have been aware of between 1 and 5 malicious cyber incidents in their control system networks and/or control system cyber assets in the last 24 months. One-third of these incidents were declared as accidental infections, while 20% were targeted in nature, and 47% were a combination of targeted and accidental.

Only 25% of all respondents indicated that their organization’s computer emergency response team appears well trained and capable to detect and respond to cyber-related incidents. Nearly half said either such a team does not exist at their organization, or the existing team is not properly trained to identify and react to these attacks.

Here is where the problem may lie: 71% of organizations are teaching their employees about who to contact in the event of a cyber incident or attack, but not how to properly respond in such a scenario.

Forty-one percent of respondents agreed that having industry-required standards without gov-ernment involvement would improve or enable their efforts to implement proper control system cyber security controls, while 21% said that no outside involvement would help at all.

Access the Control Engineering 2014 Cyber Security report with more findings and insights at www.controleng.com/14CyberSecurity. ce

- Amanda McLeman is director of research, Control Engineering, [email protected].

Control Engineering2014 Cyber Security studyCyber threats to control systems are high, frequencies of vulnerability assessmentsare low, and many organizations are lacking a capable cyber incident response team.Are your systems at risk?

RESEARCHRESEARCHcyber security

View other research studies from Control Engineering at www.controleng.com/media-library/research.

Go OnlineFigure 2: Thirty-three percent of respondents cited that their organization performed its most recent vulnerability assessment within the past six months.

Figure 1: More than one-quarter of respon-dents perceive their organization’s control system cyber security threat level to be “high” or “severe.” Graphics courtesy: Control Engineering 2014 Cyber Security study

What was less surprising was the fact that the IceStation - along with the computer and monitor inside it

remained completely unharmed. All ITSENCLOSURES are constructed out of 14-gauge steel and built to last

forever and a day. Should one of our enclosures ever actually fail due to manufacturer defect, we will replace it!

As fast as humanly possible so your business does not skip a beat. Built to meet NEMA 12 standards, IceStation

TITAN protects computer systems from harmful dust, dirt, and splashing fluids. With a large viewing window

designed to accommodate up to 24” wide screen monitors, a retractable keyboard drawer, oversized work

surface, and a track record of 29 years of experience protecting electronics, ITSENCLOSURES is the one name

you can trust. To learn more about IceStation TITAN, call 1.800.423.9911 or visit ITSENCLOSURES.com.

When an overhead crane accidentally dropped a steel pipe 15 feet onto an IceStation, workers were relieved to fi nd the pipe had not been damaged.

TRUE STORY

25


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

www.controleng.com/archivesApril has more Q&A under the headline for this article addressing related network connectivity. See other international coverage at www.controleng.com/international

www.ewon.us

Go Online


The eWon Talk2M concept is well known among eWon followers in the Czech Republic, proven during the vote tally for Control Engineering Czech best products

of the year. Yvan Rudzinski, a representative of the Belgium eWon Group, answered questions about interconnecting devices on the Internet.

Q: Could you describe eWon Talk2M?A: Talk2M cloud-based connectivity services

connect automation engineers to machines via the Internet, using secure virtual private network (VPN) tunnels. On the user side, the software eCatcher establishes, on demand, a communica-tion link between the PC and Talk2M, through the Internet. On the machine side, we install an eWon industrial router connected to a PLC or any automated device and reaching Talk2M using out-bound connections. TalK2M is a cloud structure made of several servers that relay the communica-tions originated by the users to machines.

Q: Do you provide other solutions?A: Talk2M is for remote access to pro-

grammable logic controllers (PLCs) for machine builders and system integrators. Our second market is remote data online, especially in infrastructure and utilities (such as water, wastewater, and energy). eWon’s VPN hardware appliance is eFive, a central-ized remote management solution, compat-

ible with industrial PLCs and SCADA.

eWon provides a large range of industrial routers used at remote sites. Local connection is ensured through an Ethernet four-port switch or a serial link. Wide area network (WAN) connection is pro-vided by an Ethernet Interface or built-in modem.

Q: What security allows access anywhere?A: At any given time, several thousand engi-

neers from around the world are connected to machines via eWon servers in Europe, America, and Asia to reduce latency between IP packets. Several levels of security are involved. Talk2M VPN protocols are based on Open SSL and Open VPN Version 2. The VPN security model is based on using SSL/TLS for session authentication and the IPSec ESP protocol for secure tunnel trans-port over UDP. It supports the X509 PKI (public key infrastructure) for session authentication, the TLS protocol for key exchange, the cipher-inde-pendent EVP (DES, 3DES, AES, BF) interface for encrypting tunnel data, and the HMAC-SHA1 algorithm for authenticating tunnel data. ce

- Lukáš Smelík is content manager for Control Engineering Czech.

Interconnecting devices“Our mission is interconnecting devices through-out the Inter-net,” announced eWon, a Belgium company, in an interview by Control Engi-neering Czech.

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INSIGHTINSIGHTIT & engineering

Justifying changes can be difficult, espe-cially for projects using information technology in manufacturing. Many benefits from applying IT solutions into

manufacturing operations are indirect and hard to accurately estimate or measure. The the RAVE approach to justifying new investments describes four main reasons for changes: “R” for a revo-lutionary benefit, “A” for an avoidance ben-efit, “V” for a visionary benefit, and “E” for an enhancement benefit. The explanations appear in order of commonality.

1. Avoidance benefitsOne of the most common reasons for imple-

menting IT in manufacturing is avoidance of costs or defects. Avoidance occurs when there are activities that you currently do, that you do not want to do, and new technology can let you avoid them. Avoidance benefits are often the easiest to estimate, easiest to quickly measure, and the easiest to justify. When using avoid-ance as the reason for a project, it is important to actually measure the costs before and after the implementation. Many IT projects have been jus-tified using avoidance, but when the true cost of implementation and potential increased support is added, the avoidance benefits disappear.

2. Enhancement benefitsEnhancement benefits come when a changed

system provides the ability to do things you cur-rently do and want to continue to do, more effi-ciently or effectively. Enhancement projects that increase safety or reduce unexpected shut-downs can provide measurable benefits, but other enhancement projects can be hard to justify because the value gained can be difficult to mea-sure. What is the value of enhanced visibility into the process that prevents a shutdown or accident? That value is difficult measure, so enhancement projects may go to the bottom of the list.

3. Visionary benefitsVisionary benefits come from changes that

deliver the ability to do something you currently do not do, know that you could do, and that you want to do. Visionary changes often occur when you look at other companies in your industry and other industries, and see them doing things with IT that you don’t do today. They had a vision to use IT and have proven that implementations can bring benefits. Benefits from visionary changes can often be estimated using benchmarks and comparisons to other companies. Visionary ben-efits are usually easier to justify than enhance-ments, because you can reference advantages that your competitors have using new technologies.

4. Revolutionary changeA final reason for making a change can be the

extraordinary benefits derived from a revolution-ary change, which occurs when there are activi-ties you currently don’t do, you want to do, and you were not aware were possible. Revolution-ary change requires expanded thinking beyond incremental improvements and examination of the production chain (all activities performed to produce a product, including all primary and sec-ondary activities, testing activities, quality assur-ance activities, packaging activities, inventory movement activities, and maintenance activities). Revolutionary changes occur when entire links in the production chain can be removed. They are the hardest changes to justify because they break with tradition and may force changes on groups unwilling to change. Revolutionary changes can also have the greatest benefit.

When considering a new manufacturing IT project, look for benefits in more than one area; remember the RAVE acronym: revolutionary benefits, avoidance benefits, visionary benefits, and enhancement benefits. List expected benefits to help determine if change is worth the cost. ce

- Dennis Brandl is president of BR&L Consulting in Cary, N.C. His firm focuses on manufactur-ing IT. Comment on the bottom of this article online or e-mail [email protected].

Justify manufacturing IT changes using the RAVE approach

‘Revolutionary changes are

the hardest to justify because they break with

tradition and may force changes on groups unwilling to change. These also can have the greatest benefit.’

Justify investing in and applying new technology by explaining four main benefits: “R” isfor revolutionary benefit, “A” for avoidance, “V” for visionary, and “E” for enhancement (RAVE). Listing all expected benefits will help determine if the change is worth the cost.

At www.controleng.com/archives in April, find more details under this headline.

At www.controleng.com, search related topics.

Go Online

Dennis BrandlPresident of BR&L

Consulting


Ajoint working group is looking at global functional safety standard unification. At present, there are two predomi-nantly accepted functional safety standards for machin-ery in the world:

� IEC 62061, Safety of machinery: Functional safety of elec-trical, electronic and programmable electronic control sys-tems, and

� ISO 13849-1, Safety of machinery - Safety-related parts of control systems - Part 1: General principles for design.

These two standards are often used together by machine original equipment manufacturers (OEMs) to design and build the safety-related parts of the machine control system. Safety experts generally feel that, for a machine’s safety system, 62061

handles the more com-plex components best and that 13849-1 han-dles the less complex components and field devices best for a total solution. They have been in use together for the past eight years and were needed in part because technology advancements required more guidance for their proper application to achieve intended safety functions reliably.

A joint working group has been formed and is working on this project. The new combined functional safety standard has been designated IEC/ISO 17305 and is tentatively scheduled for release in 2016 with a two-year transition period.

In my opinion, for 17305 to be successful it should: 1) Make life simpler for users 2) Resolve some existing issues and 3) capitalize on the best achievements of each standard.

It seems this direction has commitment from standards bod-ies because maintenance work on 62061 and 13849-1 has virtu-ally stopped. It also seems that the existing updated standards are improving levels of safety because they are requiring design-ers to incorporate all aspects relative to the life cycle reliability of components used in safety circuits. Safety rated components are recommended while allowing standard components. Reli-ability data is required by the calculations for all safety rated or standard components engineered into a safety circuit.

While many countries have national (or domestic) safety standards, global trade is increasing, which increases the need for global standards. As the merging process continues, newer, more complex requirements are not expected to be added. The bottom line is that it appears global industry is driving to achieve clarification and simplification for one standard, helping OEMs to provide safer and fewer designs more competitively. ce

- J.B. Titus, Certified Functional Safety Expert (CFSE), writes the Control Engineering Machine Safety Blog. Edited by Mark T. Hoske, Control Engineering, [email protected].

SAFETYSAFETY

Might there be global harmony in func-tional safety standards for machinery? There’s a working group for that. Cour-tesy: Control Engineering Machine Safety Blog, JB Titus and Associates

machine

Merger: One globalmachine safety standardIn a few years, we could have just one functional safety standard. Today the world has two predominantly accepted functional safety standards for machinery: IEC 62061 and ISO 13849-1.

www.controleng.com/blogs

See this post, link to more about machine safety, and add your thoughts about machine safety standard unification.

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ABB’s flagship safety system has now been released for use in standalone applications. This means that the same great proven and TUV certified safety system that is integrated with ABB’s System 800xA DCS can now be interfaced with any ABB process control system such as Freelance or Symphony Plus (Harmony and Melody) or our heritage technologies (Advant, MOD 300) as well as 3rd party control systems, PLCs or simple HMIs. Independent High Integrity is the perfect SIL3 certified safety system; when you need safety independent of the control system technology or vendor on your site.www.abb.com/highintegritysafety

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Reduce risk and improve results by not treating automation and control system integration as a commodity. Control system integrators use engi-

neering, technical, and business skills to help manufacturers and others automate industrial equipment and systems; six reasons follow explaining why system integration shouldn’t be treated as a commodity, according to the Control System Integrators Association (CSIA), a trade association which helps system integrators be more effective.

1. While commodities are shipped with little risk, that isn’t so with high-tech solutions.

A rock is a rock. Oil is oil. A fuse is a fuse. An intelligent, high-tech automation solution is a risk. Will it solve your prob-lem when installed and tested, or won’t it? There is a lot of room for error and many risks must be managed.

2. System integration does not come out of a box.

Though not always apparent, a control or information system is mostly the result of brain power from the system integrator, not the hardware and software platform on which it runs. The hardware and software are the vehicles that carry the intellectual capabilities of the integrator.

3. Not all system integrators are created equal.

Being a successful system integration com-pany requires more than being able to engi-

neer, design, and program. A successful system integration company, one that delivers consistently good results to clients, must also have good business practices to comple-ment the technical skills.

Unfortunately, not all system integrators have good business practices. End-user clients should look for the CSIA Certification mark, which ensures good business practices are in place.

4. Specifying a commodity is easy. Speci-fying a system integration solution is hard.

Have you ever read or written a user requirements specification? That’s what a system integrator needs to provide a solution.

It must include scope of work, project overview, safety and environmental requirements,

performance criteria, terms and conditions, and other details.

5. The dollar value of ser-vices rendered can vary great-

ly between system integrators.For instance, two system integrators

could both be paid $250,000 for the same project. One integrator might take one approach with its team and

provide the client with, say, $500,000 in economic value, while the second integrator might take a different approach and provide $2 million in value. If system integration were a commodity, you would expect the same invest-ment of $250,000 to yield the same econom-ic benefit, but that is not the case in system integration.

6. No system integration company can do it all, or is suited for all.

System integration solutions to automation problems come in all sizes and shapes. A small system integration company may be the most effective solution to a $50,000 project but may not be able to manage a $1 million project. Likewise, a large integration company may over-engineer a small project. ce

- Robert Lowe is CSIA executive direc-tor. Edited by Mark T. Hoske, content man-ager, CFE Media, Control Engineering, [email protected].

UPDATEUPDATEintegrator

6 reasons why systemintegration is not a commodityReduce risk and improve results by not treating automation and control systemintegration as a commodity; six reasons follow explaining why system integrationshouldn’t be treated as a commodity.

www.controleng.com/archivesApril has related links. Watch for CE coverage of the CSIA Executive Conference, April 23-26.

www.controlsys.org

Go Online

Robert Lowe is execu-tive director of the Con-trol System Integrators Association (CSIA), a not-for-profit, global trade association that seeks to advance the industry of control sys-tem integration. Cour-tesy: CSIA

(CSIA), a trade association which helps system integrators be more effective.

While commodities are shipped with little risk, that isn’t so with

automation solution is a risk. Will it solve your prob-lem when installed and tested, or won’t it? There is a lot of room for error

It must include scope of work, project overview, safety and environmental requirements,

performance criteria, terms and conditions, and other details.

vices rendered can vary great-ly between system integrators.

For instance, two system integrators could both be paid $250,000 for the same project. One integrator might take one approach with its team and

provide the client with, say, $500,000

Answers for industry.

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Efficient engineering is the first step towards better production: faster, more flexible, and more intelligent. Totally Integrated Automation (TIA) saves time in engineering as a result of the efficient interoperability of PLCs, HMIs, safety, and drives.

The result:• Lower cost in design, commissioning and maintenance• Reduced downtime• Faster time-to-market• Greater flexibility

An extensive infrastructure of local expertise and global support ensures you benefit fully from Totally Integrated Automation along the entire production process.

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NEWSNEWSindustry

Microsoft Windows XP support ends April 8. What happens April 9? Good-bye Windows XP, you have had your time. You are now obsolete at the ripe old age of 13. It doesn’t matter that there are tens of millions, even hun-dreds of millions, of you still out there. It doesn’t matter that you are running ATMs and point-of-sale terminals, and are in thousands of production facili-ties. It doesn’t matter that you are run-ning in critical infrastructure and mis-sion critical systems. It doesn’t matter that these systems are keeping our water, food, and medicine safe, and keeping our water, natural gas, and gasoline flowing. Your time had passed on April 14, 2009, at the ripe old age of 8, but you have been on extend-ed life support since them. None of these things mat-ter; your final time has now passed, and on April 8, 2014, you will no longer be a support-ed product.

Because Windows XP was the first truly reliable commercial multi-win-dowed system, it became the “go-to” standard for control, human machine interface (HMI), and instrumentation systems. Companies have invested bil-lions of dollars in these systems and expected them to have the same multi-decade lifetime of other industrial sys-

tems. Lifetimes of 15 to 30 years are common in industrial systems.

Microsoft should outsource Win-dows XP support to an independent third party, to provide Lifetime Sup-port XP (lsXP). That organization could then provide critical and important security patches on a subscription basis. It could quickly respond to zero day attacks, and help protect the millions of XP systems in critical infrastructure or mission critical systems.

If lsXP doesn’t develop, then remember to protect, protect, and pro-tect. With zero day attacks continually

being discovered, many that affect operating systems and services,

there will be an ongoing need to protect XP systems from infection. This means stron-

ger firewall rules, stronger password rules, severely

limited outside access, white listing tools, root kit inspections,

tightly constrained external device (USB, CD) connections, and additional security training for system users.

This is a wakeup call for end users to demand software that lasts as long as the hardware.

- Dennis Brandl, president of BR&L Consulting, in Cary, N.C., writes “Engineering and IT Insight” for Con-trol Engineering. His firm focuses on manufacturing IT.

Goodbye Windows XP


Are control engineers missing opportunities to more effectively lower risk for train engineers and their passengers? It seems that easier, less expensive retro-fit applications of automation technology to trains could drastically lower risk of multiple accidents related to apparent errors by train engineers. In Chicago on March 24, a commuter train crashed past a station bumper and went up an esca-lator, resulting in multiple injuries. In New York, a February 2013 crash killed four and injured more than 60. In Spain, July 2013, 80 people died and many more were injured when a train failed to slow for a curve. Manufacturing machines can stop automatically to reduce risk. Automobiles can stop automatically to reduce risk. Some railroads have installed positive train control (PTC) systems. The U.S. National Transportation Safety Board has recommended PTC for years, said a 2007 post on the NTSB site. Current systems, some say, are costly and com-plex. Developments to watch: Smarter, less expensive, easier-to-install machine vision, sensors, and fail-safe controllers to slow or stop trains based on obsta-cles or conditions. Online, see more information and links.

- Mark T. Hoske, content manager, Control Engineering, [email protected].

Developments to watch:Engineering can save train engineers

At www.controleng.com, find more...

Imagine the Possibilities

BOA products are highly integrated vision systems in a tiny smart camera package specifically designed for industrial use. BOA offers a robust and flexible automation inspection system for easy integration and deployment on the factory floor.

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To meet the agile production scenarios frequently found in the consumer electronics industry and increasingly in other market sectors, the proposed concept includes a flexible gripper, camera-based part location, plus all the features that are well known from ABB’s state-of-the-art robot controller, the IRC5. The compact robot is intended to fit into spaces ergonomically designed for human workers. The robot could be interchanged with a human

coworker when the pro-duction order changes or a new layout is required.

Portable dual-arm units come with a controller that is integrated into the torso. They can be car-ried around easily and mounted into workstations with minimum installa-tion requirements. Due to the intrinsic safety of the proposed robot solution, the requirements for per-forming a safety assess-ment of the installation are minimized. Normally, no safeguarding or enclosing

of any kind is required, which allows for very fast installa-tion, commissioning, and relocation.

ABB Robotics showed the DACR at its annual Technol-ogy Days event March 13 and 14 at its North American headquarters and training center in Auburn Hills, Mich. The event had more than 80 product demonstrations and free technical seminars covering general and application-specific information designed to benefit both those con-sidering an initial foray into robotic automation, and those looking to upgrade or expand their existing robotic lines.

Key technology features of DACR:� Harmless robotic coworker for industrial assembly� Human-like arms and body with integrated IRC5

controller� Complements human labor with scalable automation� Padded dual arms ensure safe productivity and

flexibility� Lightweight and easy to mount for fast deployment� Agile motion based on industry-leading ABB robot

technology.The concept robot was created after requests from ABB

Robotics’ existing customer base to develop robotic solu-tions for manufacturing environments in which humans and robots would be able to work together. This 14-axis, dual-arm robot resulted from ABB Corporate Research’s initiative for industries requiring new solutions for small part assembly operations. www.controleng.com/videos has a CE video clip.www.abb.com/robotics

- Edited by Mark T. Hoske, content manager, Control Engineering, [email protected].

Dual-arm concept robot makes North American debut

The ABB Dual Arm Con-cept Robot (DACR) was introduced to North America at the ABB Robotics Technol-ogy Days, March 13 and 14. Though still in the concept stages, and not scheduled for release until 2015, the DACR simulated the assembly of a small electronics part. Courtesy: ABB Robotics

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The internationally standardized CiA 402 motion control and drives profile is among the most-used network profiles for electrical motors. Courtesy: CiA

NEWSNEWSindustry

24 ● APRIL 2014 CONTROL ENGINEERING

The CAN in Automation (CiA) 402 motion control and drives profile origi-nally developed for CANopen systems will be extended for functional safety. In addition, a new process data object (PDO) service mapping was intro-

duced, to control asynchronous and synchronous motors with one device. CiA 402 motion control and drives pro-file (IEC 61800-7-201/301) is one of the most-used network profiles for elec-tric motors, CiA said. Originally used

by CANopen, the standard also speci-fies adaptions for CC-Link IE, EPA, EtherCAT, and Powerlink. Safetynet and Varan, two other industrial Ethernet protocols use CANopen-similar appli-cation layers. In CiA 402-4, mapping of the bus-independent functional safety for motion control developed by the Ether-CAT Technology Group was specified. CiA 402-5 specifies an added PDO map-ping for asynchronous and synchronous motors. Schneider Electric will introduce drives supporting the CiA 402-5 PDO mapping in mid-2014. (See also p. M6.)

- Holger Zeltwanger is CiA manag-ing director, CAN in Automation Interna-tional Users and Manufacturers Group, Erlangen, Germany.

www.can-cia.org

Motion control and drives profile expanded

10 ways material handing is changing

MHI is leading a coalition of lead-ers to look at the expanding and accelerating supply chain. The “Material Handling and Logistics U.S. Roadmap” was unveiled at the MODEX Show in Atlanta (sponsored by MHI, the Association of Material Handling and Logistics Profession-als). In the next decade, the industry should study:

1. The growth of e-commerce2. Relentless competition3. Mass personalization4. Urbanization5. Mobile and wearable computing6. Robotics and automation7. Sensors and Internet of things8. Big Data and predictive analytics9. The changing workforce 10. Sustainability- Bob Vavra is content manager, Plant

Engineering, [email protected].

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The pace of manufacturing change is accelerating. Jump on the trends and take risks, advised futurist Jack Uldrich

at the opening ses-sion of the MFG Meeting in Phoenix on March 6.

To more than 600 manufacturing leaders, Uldrich said: “If we want to future-proof ourselves, we’re going to have to become aware of how little we’re seeing of the world around us.”

The MFG Meet-ing assembles indus-try leaders from the Association for Man-ufacturing Technolo-gy (AMT), the Preci-

sion Metalforming Association (PMA), and the National Tooling and Machin-ing Association (NTMA).

Uldrich, whose title in his consul-

Take risks as manufacturing changes 8 ways

ODVA: EtherNet/IP for process industriesODVA, the industry organization for the EtherNet/IP (EIP) Ethernet protocol,

DeviceNet, and other network technologies, suggested that manufacturers define future network architecture and plan for efficient integration of plant net-work infrastructure into existing business applications. Doing so maintains cost-effective, sustainable production capacity.

ODVA discussed EIP for process industries in a white paper, Optimization of Process Integration, and at the ODVA’s 2014 Industry Conference, in February.

Katherine Voss, ODVA president and executive director, said EIP will help facilitate system integration as “an ideal technology to provide process indus-tries with a unified communication solution from the field to the enterprise.”

Jack Uldrich, whose title in his consultancy is “Founder and Chief Unlearning Officer,” spoke at te MFG Meeting in March. Courtesy: MFG

tancy is “Founder and Chief Unlearning Officer,” cited eight areas where manu-facturing’s future already has arrived:

1. Wearable technology, for connect-ing users to information and transmit-ting information globally

2. 3D manufacturing3. Nanotechnology4. Robotics5. Sensors everywhere 6. Computers, faster and more of them

7. Big data to improve services to customers and manufacturing

8. Collaborative consumption: Does everybody need one of everything?

“You have to give yourself permis-sion to read, to think about how world is changing. If you don’t pick up on these changes, you’re going to be locked up.”

- Bob Vavra is content manager, Plant Engineering, [email protected].

Jack Uldrich,

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Tuning Control Loops with the IMC Tuning Method Lee Payne | CEO, Dataforth

When PI and PID controllers first came to market in the 1930s, there were no clear instructions on how to tune them. Since then, well over 100 controller tuning meth-ods have been developed.

The Internal Model Control (IMC) tuning method, also called Lambda tuning, is an excellent choice when control loop stability is essential. It offers a stable and robust alternative to other tuning techniques, which often aim for speed at the expense of stability.

This Application Note describes how to tune control loops using IMC rules. The IMC tuning method was developed for

use on self-regulating processes (e.g., flow, temperature, pressure) which most control loops contain.

A self-regulating process always stabilizes at some point of equilibrium, which depends on the process design and the controller output. If the controller output is set to a different value, the process will respond and stabilize at a new point of equilibrium.

The target controller algorithm for IMC tuning rules is noninteractive. Dataforth’s MAQ®20 data acquisition and control system supports the most common noninteractive algorithm, which makes the system extremely powerful and adaptable for wide ranging

process control applications.

To apply IMC rules to a self-regulating process, the first step is to time-trend the process variable and controller output so that measurements can be taken from them. The procedure is then: 1) do a step test, 2) determine process characteristics, 3) repeat steps 1 and 2 three times to obtain average values for the process characteristics, 4) choose a desired loop response time for the control loop, 5) calculate controller settings (for PI control: Controller Gain, Kc = τ / ( gp × [τcl + td] ), Integral Time, Ti = τ, Derivative Time, Td = 0), 6) enter the values into the controller, ensure the algorithm is set to noninteractive, and put the controller in automatic mode, 7) change the set point to test the new values, 8) fine-tune if necessary.

Established in 1984, Dataforth is the world leader in data acquisition and control, signal conditioning, and data communication products for industrial applications. All products are manufactured in the USA. The Dataforth Quality Management System is ISO9001:2008 registered.

Dataforth CorporationEmail: [email protected] | www.dataforth.com

Download this paper at: http://www.dataforth.com/catalog/pdf/an124_Tuning_Control_Loops_with_the_IMC_Tuning_Method.pdf


Logic Solvers in Overpressure Protection Systems Tina Lockhart | Director of Engineering, Moore Industries

An overpressure protection system is a critical Safety Instrumented System (SIS) that provides automated overpressure control during the transfer of dangerous substances. If the pressure rises above set limits, it automatically shuts off the input feed by isolating the pump and closing the input valve.

This SIS is made up of multiple components which all must function in order for the control loop to work. One of the key instruments in the loop is the logic solver, which acts as the decision maker and decides when to initiate the final element to make the process safe if the need arises.

Many people believe that the logic solver in an overpressure protection system must be part of a safety PLC. In many cases, a discrete logic device for each loop is sufficient. A single-loop logic solver avoids the complications and expense of a programmable solution while achieving a key objective of functional safety by minimizing the complexity of safety-related functionality. Reducing the complexity of the architecture also reduces the cost of hardware and software while making the entire functional safety system easier to manage without the need for dedicated specialists.

This white paper addresses the possibilities available to the SIS designer of an overpressure protection system when using a single-loop logic solver. It features examples of straightforward system topologies and their associated Safety Integrity Level (SIL) calculations along with step-by-step procedures to help define and evaluate an SIS for a specific application. By reading this white paper you’ll have a better understanding of when and why a single-loop logic solver is the right choice for your overpressure protection system.

Download a copy of the “Logic Solver for Overpressure Protection” White Paper: www.controleng.com/index.php?id=10865

Email: [email protected]


PC-Based Automation Systems Empower the All IP-based FactoryJoe Lin | General Manager, NEXCOM Industrial Computing Solutions Business

With the advent of Industry 4.0 – the push to drive a fourth industrial revolution based on the intelligent factory – PC-based automation systems are a critical piece for enabling all IP-based Factory-of-Things. However, building PC-based automation systems requires computers with high reliability, as well as communication and computing capabilities specifically designed for factory automation applications.

For example, process automation in industries such as petrochemical require a PC-based automation that can remotely collect data from different-branded field devices across a single or multiple petrochemical plants, withstand harsh temperatures of the petrochemical environment, and reliably execute control schemes. Batch manufacturing processes on the other hand, require open architecture PC-based automation systems that can flexibly adapt to customized orders with high feature mix.

To this end, NEXCOM offers a unique solution, the NISE 105 fanless computer based on the Intel® Atom™ processor E3800 product family with integrated Intel® Gen 7 Graphics. Designed to empower the all IP-based factory and help manufacturers realize the vision of smart production, green production and urban production, the NISE 105

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These capabilities enable NISE 105 to provide fieldbus control of widely-used protocols and wide-temperature operation; offer AOI (Automated Optical Inspection) and eSOP (Electronic Standard Operating Procedures) systems the performance to process camera images and 2D/3D animated instructions at a faster rate. While the multitude of I/O connectivity built into the NISE 105 allows support for the peripherals and equipment used for product traceability. Furthermore, the processor’s power efficiency enables the small footprint and fanless design of NISE 105, allowing it to achieve high reliability in harsh factory a utomation environments. In this white paper, NEXCOM will explain how the NISE 105 compact fanless can help streamline factory data collection and management, and facilitate production processes, manufacturing operations, and quality control. Register to download the paper at:www.controleng.com/index.php?id=10871

Email: [email protected] | www.nexcom.com input #21 at www.controleng.com/information


More efficient nuclear power plants, small modular reactors, safety, timeline for next new nuclear power plants, and nucle-ar power were among topics

discussed at a recent American Nuclear Society (ANS) meeting. A simpler controls strategy is part of the small modular reactor (SMR) design.

Nuclear energy in the U.S. continues to prog-ress with a mix of positive and some negative developments. An update on recent progress with a summary of current issues related to the U.S. Dept. of Energy’s (DOE) nuclear energy pro-grams, was presented on Feb. 6 by Dr. Peter B. Lyons, DOE’s assistant secretary for nuclear ener-gy. The American Nuclear Society (ANS) pre-sented Dr. Peter B. Lyons as the speaker for a February 2014 meeting of its Chicago Section. In “Current Issues: DOE’s Nuclear Energy Pro-grams,” Lyons noted that the federal Omnibus Budget (FY’14) has treated nuclear energy quite well, to the tune of $888 million. Dr. Lyons is DOE assistant secretary for nuclear energy and a former commissioner of the U.S. Nuclear Regula-tory Commission (NRC).

DOE has a multitask mission to develop tech-nologies for current and new nuclear reactors. Pro-grams to improve reliability, sustain safety, and extend useful life apply to current reactors—while work to develop “improvements in affordabil-ity” targets new reactor technology. Other related DOE activities noted by Lyons include reducing regulatory and technology risks, managing nucle-ar waste, and understanding and minimizing risks of nuclear proliferation and terrorism. Several areas of nuclear energy received substantial increases in the latest federal budget funding. One example was “advanced nuclear fuels”—an initiative that plans to develop meltdown-resistant fuels, Lyons noted. Driven by the Fukushima Dai-ichi power plant inci-

dent, the accident-tolerant fuels program seeks to reduce hydrogen generation and mitigate hydrogen explosions. This longer range program, still at a research and development stage, includes methods to improve cladding properties of fuel rods.

Advanced reactor technologies, such as high-temperature reactors, represent another area of increased funding, including gas- and sodium-cooled reactor designs. Another research area is how to make aging nuclear power plant compo-nents last longer. It’s difficult to replace concrete structures, cables, and pressure vessels in aging plants; some soon will be more than 60 years old, Lyons said. However, U.S. nuclear power plant designs have allowed license extensions and safe operation beyond original design life.

Thermal cycles, computational toolsCurrent nuclear reactors operate on the Rankine

cycle, which provides about 33% thermal efficien-cy. Work is ongoing to develop reactors that will operate using supercritical thermodynamics based on the Brayton cycle, allowing greater than 40% efficiency. Dramatic turbine size reduction and more efficient thermal conversion are obtainable with Brayton cycle power plants, Lyons said.

High-performance computing and advanced modeling and simulation play a crucial role in managing the complex physics and control requirements of nuclear energy. Initiatives are being pursued to advance existing and new reac-tor designs. New computational tools will allow researchers to focus on details that could advance many areas ranging from nuclear fuels to the oper-ation of complete nuclear power plants, DOE said.

SMR technologiesSMRs—typically under 300 megawatt elec-

tric (MWe) output—represent a relatively new approach for nuclear energy. Industry experts con-

for small nuclear reactorsBig plansU.S. nuclear power plant outlook: more efficient new designs, safety, plant openings are in the nuclear energy spotlight in 2014, according to a American Nuclear Society meeting.

cover story

Keyconcepts� U.S. Dept. of Energy has a mission to develop tech-nologies for current and new nuclear reactors.

� New technologies aim at improving efficiencies and safety.

� Five nuclear power reac-tors are under construc-tion in the U.S.


NuScale Power’s 45 MWe small modular reactors will be trans-portable by barge, truck, or train. An 80-ft high x 15-ft dia (24.4 x 4.57 m) containment vessel hous-es the reactor pressure vessel and steam generator. Courtesy: NuScale Power LLC

Control aspects of small modular reactorsReduced physical size allows imple-

menting simpler instrumentation and control (I&C) systems for small modular reactors (SMRs) compared to large light-water reactors. Simplicity includes use of natural circulation through the reactor—eliminating the need for pumps in some designs—as is the case for NuScale Power’s development. Reactor safety remains the paramount consideration.

SMR plant I&C architecture is com-posed of two main system types: one for safety-related functions and one for non-safety-related functions. Safety-related I&C architecture will be a new hardware logic based system, incorporat-ing multiple layers of diversity to enable simplicity of the overall plant protection system architecture, according to NuS-cale Power. Choice of the non-safety I&C system platform will be left to a site license applicant and will not be specified for design certification.

I&C system functions and process variables to be monitored will be similar to those for a typical pressurized water reactor—for example, pressure, tem-perature, flow, level, and neutron flux. Number of sensors per reactor module is yet to be determined, but will be propor-tionally less than the number for a typical large light-water reactor, NuScale noted.

As for I&C system communications and/or bus networks, a custom and proprietary design will be used for safety-related functions; for non-safety-related functions this area will not be specified for SMR design certification.

LEGEND1. Steam line (to turbine section of plant) 2. Reactor containment (below ground

and submersed in water pool)3. Reactor pressure vessel4. Pressurizer5. Steam generator6. Control rods (drives are at top

of reactor pressure vessel)7. Fuel rods8. Nuclear core9. Pool floor

cover story

sider such smaller reactor designs as a key ele-ment for the resurgence of U.S. nuclear energy. Lyons listed several benefits of SMRs.

Factory-built SMR units can be transported intact to the plant site. Capital costs can be lower, and small reactors could be a more economically feasible investment for more power companies. Modularity allows “bite-sized” additions—as deter-mined by power demand. SMRs also pose poten-tially less strain on the grid. Small modular reactors could more easily live up to construction schedules, fit into smaller electricity grids of many countries, and can be air cooled, said Lyons.

“Overall, small modular reactors could repre-sent a new paradigm for nuclear energy,” Lyons said. “Cost per kilowatt will be key.” DOE has entered into cost sharing agreements with indus-

try to develop SMRs. One recent agree-ment, awarded to mPower America—a partnership of Babcock & Wilcox Co., Tennessee Valley Authority (TVA), and Bechtel—has the goal to support com-mercial operation of a 180-MWe reac-tor by 2022 for TVA’s Clinch River site in Oak Ridge, Tenn. Lyons said mPow-er’s reactor is designed for a 60-year life and 4-year refueling cycle. The rail-

shippable integral pressurized water reactor module design has passive safety systems. mPower Ameri-ca developed a plan that expects to achieve a com-mercial operation in Oct. 2021, said DOE. A second SMR initiative announced in December 2013 was with NuScale Power LLC. DOE said it offers a mix of safety, scalability, transportability, economics, and advanced state of design maturity. This coop-erative agreement with DOE is forecast to achieve commercial operation in the 2025 timeframe.

The U.S. still has the largest number of nucle-ar reactors operating (99), but as a result of recent closings, nationwide electric power generation from nuclear sources has dropped to 18%–down from just above 20% where it stood for decades. One possible scenario under DOE review is the potential closure of one-third of the U.S. reactors by 2035 due to end of design life. Without suf-ficient replacements, such a development would pose serious concerns. Worldwide, 70 nuclear units are under construction, with China, South Korea, and Russia among participants. Lyons said the U.S. “will need far more nuclear power in the future for which we have to be ready.” ce

- Frank J. Bartos, P.E., is a Control Engineer-ing contributing content specialist. Reach him at [email protected].

www.controleng.com/archives

April has more SMR details, a “state of the industry,” references, and more links.

www.ans.org

www.energy.gov/ne/office-nuclear-energy

www.nrc.gov

www.nuscalepower.com

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Impact of remote access to a production line can be dramatic for some. One usually dour, Scottish engineer had a huge smile on his face—the capability to monitor and adjust line and machine controllers from anywhere

meant that on-site night shifts had been replaced by stay-at-home work, with “standby” shifts (sleep until you’re called) planned for the future. Domestic bliss had been restored.

That was about 10 years ago. The advance of smart manufacturing technology has driven the continu-ing transformation of production environments. More automa-tion and better development tools enable improvements at almost every level of a manufacturing system. New concepts, new opti-mum distributions of function, and refinement, improve efficien-cy, quality, and cycle times.

Machine monitoringTechnology creates opportuni-

ties for new business models, and new market entrants. For exam-ple, remote access was disrup-tive to the provision of machine monitoring and service. Histori-cally, service was performed by the owner. This involved asset management systems, scheduled service, and repair by in-house engineers who

probably maintained their own stocks of spare parts. Management initiatives to outsource and focus on core competence tended to hold back in-house service groups, and boost third-party providers. Remote access enabled continuous mon-itoring from service centers, one way that machine builders and their partners could compete for service revenues.

The continuing growth of instru-

mentation means feedback is for operation and control and for product development planning. Design engineers are “in the loop” and can use actual sensor measurements to calibrate and drive machine simulations, and improve their understanding of machine performance. Simu-lations provide data about symptoms that lead to the failure modes that have been studied. The

owners of this information have a strong position when it comes to preven-

tive maintenance; they know exactly which combinations of temperature, pressure, vibration, and other mea-

surements trigger a maintenance call, and which need adjustment.

Intelligent controllersThe intelligent controllers that

are enabling this improved level of instrumentation and monitoring also are allowing functions to be moved from hardware to software. It will be possible to build more machines from standard material handling and other subsystems, assembled onto a common plat-form. The machines will be dif-ferentiated by the software that controls and integrates the stan-

dard units. Even now, higher processor speeds in motion control systems offer designers more choice—lower cost sensors and actuators may be able to deliver the same performance if driven by better algorithms, or even the same algorithm executed at a higher frequency.

Planning and installation tools also are chang-ing, reducing production downtime needed for refurbishment and upgrade projects. ce

- Peter Thorne is director, Cambashi Ltd. Edited by Mark T. Hoske, content man-ager, CFE Media, Control Engineering, [email protected].

Smart manufacturingand new automation improve lives of engineersNext-generation automation has a profound impact on manufacturing businessmodels and quality of life for engineers.

smarter manufacturing

www.controleng.com/archivesApril has more details and links.

www.cambashi.com

Go Online

Keyconcepts� Advance of smart manufacturing technology has driven the continuing transformation of produc-tion environments.

� Intelligent controllers are enabling this improved level of instrumentation and monitoring.

� Planning and installation tools are changing, reduc-ing production downtime needed for refurbishment and upgrade projects.

Consider this...How could smarter applications of technology make your life easier?

Design engineers are “in the loop”

and can use actual sensor measure-

ments to calibrate and drive machine

simulations.


In the manufacturing industry, necessity is driving a new wave of manufacturing soft-ware innovation and creative problem solv-ing, building on the saying, “Necessity is the mother of invention.” A need for prod-

uct differentiation is compelling manufacturers to speed product introductions and design releas-es. This demand, plus current market pressures, requires looking more closely at the internal pro-cesses that are the backbone of modern manu-facturing’s return to profitability. Here, ingenuity reigns.

Manufacturers face more economic, compet-itive, regulatory, and technological challenges than ever. Only companies leveraging technol-ogy tools gain the intelligence quotient to sur-vive. Software solutions provide the insight that fuels smarter decisions, smarter strategies, smarter processes, and smarter design of facto-ry floors.

Today the process is as important as the end product when shaving cents or seconds off the cycle time means added revenue, happy cus-tomers, and increased market share. Optimiz-ing performance is critical to profitability. This includes every step along the product design, development, production, and distribution sup-

ply chain. No depart-ment or function is exempt from scrutiny and refinement.

Process design begins with a symbi-otic balance of product lifecycle management (PLM) functionality to manage product releas-es and intelligent design of the shop floor to sup-port the necessary work flows, quality control, and management of spe-cific configurations—which may change for each customer.

Modern end-to-end enterprise resource

planning (ERP) solutions provide the real-time visibility required to monitor processes with ana-lytical precision—down to the second, not just an hour or day. Data can be collected around key functions, with added attention on the typical roadblocks or stumbling points.

Business intelligence tools are more verti-cal-specific, are easier to use, and can be role-tailored. These applications provide highly consumable insights into decision-making. Con-textual, relevant data is pushed to the user to facilitate decisions, rather than the user having to hunt for information. This impacts behavior and guides the thought process. Users are led through the decision process, based on predefined best practices and parameters set by management.

Dashboards, KPIs, other toolsFor the user, procedures clearly define near-

ly any incident that may occur. Role-based dash-boards show key performance indicators (KPIs) that require continuous monitoring, Automatic alerts signal when an incident or level is outside of parameters. For managers, there is confidence that the workforce is alert and highly respon-sive, and that systems organization-wide are monitored for noncompliance. Personnel and equipment perform at their best, with automatic escalation alerts signaling early of any potential obstacles.

Mobility, 3D modeling, industrial Internet of things, big data anlytics, predictive intelligence all enhance manufacturing decisions and produc-tivity. The future of manufacturing is exciting, and it starts now. ce

- Mark Humphlett is industry and solution strategy director, Infor. Edited by Mark T. Hoske, content manager, CFE Media, Control Engineer-ing, [email protected].

Smart manufacturing technologies,intelligent processesSoftware enables predictive planning, performance monitoring, big data analytics, virtual modeling, and more informed-decision making.

www.controleng.com/archivesApril has more information and links.

Go OnlineSpecialized software tools can manage operations in an integrated, closed loop system; provide complete visibility, unified communication; accommodate future growth and complexity; quickly attain improvement with fast, easy implementation; streamline operations to maximize productivity, savings; and increase accuracy, timeliness, customer satisfaction. Courtesy: Infor www.infor.com/industries/manufacturing/

Keyconcepts� Virtual modeling helps managers spot roadblocks in efficiencies, and helps operators predict capacity and make accurate projec-tions to customers for as-promised delivery.

� Software improves predictive planning, moni-toring of performance, big data analytics, and virtual modeling.

� Exciting future of manu-facturing starts now.

Consider this...What software tools are helping to accelerate manufac-turing efficiency?

smarter manufacturing

EXCLUSIVEEXCLUSIVEdigital edition

Benefits of theControl EngineeringDigital Edition include:

Go to www.controleng.com/digitaledition today!


Industrial Energy Management sectioncover imageThe cover to the Industrial Energy Management section of articles explains that manufacturers need to see energy in a different light. The cover for this section, only in the digital edition, appears prior to the introduction and three articles and links to each one.

Prototyping peer-to-peer applicationsfor the industrial Internet of thingsProgramming peer-to-peer (machine-to-machine) architecture is challenging for the broad application space of the industrial Internet of things. A unified programming environment provides an intuitive method for publishing and subscribing to data of interest over the network. Four diagrams illustrate. Link to the longer version online with more explanations, additional programming examples, and a link to download free software.

www.controleng.com/digitaledition

� Headlines link to the longer version posted online, providing more information, live links to related articles, and, often, more graphics or images

� Live links to more information where a URL is provided anywhere in the issue� Exclusive content in every issue.

IEM-1

DE-1

The industrial Internet of things, IIoT, is a very broad application space. The envisioned applications can be divided into three main architectures:

A client/server architecture where a human, acting through a device (such as a mobile phone), interacts with the Internet, a machine-to-machine (M2M) client/server architecture where remote devices feed data to enterprise

systems for analysis and decision support (such as a vehicle tracking system), and a peer-to-peer (machines-to-machines) architecture where the devices autonomously cooperate and make local decisions (only on exception or periodi-cally connecting to an enterprise system to post alarms or significant data). These peer-to-peer applications often perform local control of a machine or process in response to local data.

This programmatically challeng-ing class of applications can be difficult to prototype.

The various protocols that make up the suite of Internet pro-tocols are well suited to the cli-ent/server architectures, as nearly all Internet traffic today follows this architectural model. An area of our interest is applying a peer-to-peer architecture and its required services above the UDP transport layer of the Internet Protocol (IP). The Python envi-ronment has an easy and intuitive method for expressing distributed functions that publish data and subscribe to data of interest over the network. The environment hides the aspect of communica-tion from the application—mak-ing the peer-to-peer, distributed nature of the application implicit. The application program only needs be concerned with the data

DE-1 ● APRIL 2014 CONTROL ENGINEERING ● www.controleng.com

Prototyping peer-to-peer applications for the industrial Internet of thingsProgramming peer-to-peer (machine-to-machine) architecture is challenging forthe broad application space of the industrial Internet of things. A unified programmingenvironment provides an intuitive method for publishing and subscribing to data ofinterest over the network.


Figure 1: This chart shows a network data flow and data con-ditioning.

www.controleng.com ● CONTROL ENGINEERING APRIL 2014 ● DE-2

it manipulates—much as a noncommunicating application. Diverse applications that are com-pliant to this architecture can be prototyped in very little time.

I. Python environment A simple library of classes turns a Python

script into an IIoT device, and elevates a locally operating control application to a networked, IP-based solution. The library is designed for ease of use, centered on a single, main class. This application class and its subclasses are generally self-provisioning by computing useful default settings at initialization time. Application pro-gramming interfaces (APIs) are available to fine-tune the provisioning parameters to meet a specific application’s demands where necessary. The design cycle is Python-centric and does not generally require any other expert tool.

Information between the nodes on the net-work is exchanged via a publisher/subscriber data model where the unit of exchange is a data-point. Datapoints are values with semantics. (See more details below.)

The Python script defines datapoints to inter-face to the network: Input datapoints obtain data received from the network, such as a tempera-ture setpoint. Output datapoints communicate data to the network, such as the current ther-mostat position. Input and output datapoints implement datapoint types, supporting different physical or abstract data, such as temperature values or alarm conditions.

Additional provisioning data is provided with properties. A property is implemented as an input datapoint with persistent value stor-age. Properties expand on simple datapoints to include specific semantics: the upper alarm temperature threshold, the temperature alarm hysteresis, or similar descriptions.

Input and output datapoints and properties are generally grouped into profiles. Profiles are a collection of datapoints that form the net-work visible interface for a service, combined with well-defined behavior. In the example dis-cussed, the service is a carbon dioxide sensor. The role of the service is to publish the amount of carbon dioxide present in the air. The fre-quency of this publication is determined by the properties embedded within the profile. The Python library allows implementation of a com-plete profile, including all related datapoints and properties, through a block object within one simple line of code:

co2Sensor= application.block(co2Sensor())

Definitions of datapoint, property and pro-file can support and promote solutions featuring devices supplied by multiple vendors. Building on existing standards and a rich collection of type and profile definitions, compatible devices can recognize each other and exchange data across different suppliers or hardware solutions.

II. A generic data modelPeer-to-peer control networks must handle

data that arrives in a nondeterministic schedule, representing a diversity of physical, logical, or abstract entities. For example, one data item might represent a temperature value in Cel-sius, encoded in an IEEE 754 double-precision floating point value in big-endian byte order. Another data item might represent the number of beans in a bag using a natural number rang-ing 0 to 999, encoded in an unsigned 16-bit little-endian scalar, while other data might rep-resent the complex definition of a lighting scene through a suitable structure of data, or a postal address in human-readable alphanumeric form using an UTF-16 unicode.

Within data representing a known entity, such as a temperature value, and using a known encoding, such as an IEEE 754 double-precision floating point value in big-endian format, con-trol networks must also recognize semantics: a room temperature setpoint might have a valid value range between 15 and 28 C, and is applied to a control algorithm that drives a thermostatic radiator valve, while another temperature value, encoded in the same manner, might represent

Figure 2: A simple control network shows low-level addressing details need-ed for contracts. All diagrams courtesy: Echelon Corp.

Keyconcepts� Industrial Internet of things has a broad appli-cation space.

� Peer-to-peer (machine-to-machine or M2M) archi-tecture is a challenging class of applications to program.

� A unified programming environment provides an intuitive method for expressing distributed functions that publish data and subscribe to data of interest over the network.

a fire detector’s hysteresis, or define the lower valid value for the room temperature setpoint.

Data must then be conditioned such that the local application can operate with the data. For example, the application may need to rotate the byte order of the 8-byte floating point value upon receipt and interpret the result as a double float value.

When the algorithm produces output data, this data also may need conditioning. For example, a current temperature value might be reported. This might be exchanged over the network as a big-endian 16-bit unsigned inte-ger value, implementing a fixed-point variable ranging from 0 to 655.35 with a resolution of 0.01 C. This programming model conditions this data such that the application is presented with data in its natural form; a floating-point value in this example. Range and resolution limitations are automatically applied by this model, and transcoding between the application presentation and the network presentation of this data is handled transparently.

Peers in the control network must agree on the entity described by each data item, its encoding, and its semantics. Additional aspects (such as explicit range limitations, well-defined

default values, or fallback behavior in the event of a fault) are also commonly agreed upon between peers.

To reach such an agreement, peers in a con-trol network either carry all metadata required to enable receivers to fully understand any data they might encounter, or ensure that data only reaches receivers with a previously established contract and level of trust.

This poses a significant difficulty to the device developer and the person integrating multiple control devices into one distributed, peer-to-peer control network. The device devel-oper generally needs in-depth knowledge in the processes, protocols, and procedures involved to write code that correctly conditions output data, and correctly identifies, classifies, and interprets incoming data. The person integrating multiple devices into one such network needs to understand each device’s attributes and capabil-ities to combine only those devices that “speak the same language.” For example, a generic switch may be able to control a generic lamp, but an industrial washing machine may require a more complex “on/off” signal than what the generic switch can provide.

This programming model includes methods



Figure 3: This chart shows visualization of resource types.


and services that automatically evaluate and apply metadata to data interpretation and data conditioning processes, interfacing the applica-tion with appropriately conditioned data only. These methods greatly improve on existing technology by providing a transparent compre-hensive data conditioning service.

Figure 1 illustrates the data conditioning ser-vices and network data flow provided by this programming model.

III. Data addressingA peer-to-peer network consists of a num-

ber of independently operating devices, gener-ally sharing data on a need-to-know basis. For example, a thermostatic radiator valve may need to receive the current room temperature setpoint from some other device. The same ther-mostatic radiator may not need to know when or why the setpoint changed, and it will not nor-mally need to know about any control operation on the ceiling lights or the garden sprinkler.

That is, a new temperature setpoint value might be communicated from an input device to all thermostatic radiator valves in the same room. At the same time, other rooms’ thermo-static radiator valves may receive other setpoint values from other sources, while the garden sprinkler is controlled as a logically separate unit on the same network.

To facilitate peer-to-peer communication in this manner, devices transmitting data (data publishers) need to know how to reach the applicable targets (data subscribers), and may need to know whether and how to accept or reject incoming data. This mutual knowledge includes knowledge of source and/or destina-tion addresses, information to select the correct datapoint from multiple datapoints defined on the receiver node, routing details, and trans-port properties (such as service types, the time allowed to detect an outage or enable retrans-mission, and similar control data).

This programming model includes abstract services to facilitate contract offers and accep-tances in the terms of the application script, concealing the required low-level details within the implementation of this model. This simplifies development of distributed control applications. By supporting intrinsic contract management services, this programming model also greatly reduces the need for, and in many cases eliminates the need for, dedicated integra-tion steps when forming a network from distrib-uted applications.

Figure 2 shows a simple control network fea-turing four distinct devices, each contributing one application. The figure illustrates the set of low-level addressing details required to estab-

lish and maintain such a contract, and the realm of application expertise.

IV. Device addressingPeer-to-peer control networks implement

distributed algorithms based on contracts and established trust regarding the data and its semantics, and the addressing and transport properties so that peer A can reach peer B over the network.

However, each participating device must also obtain its own unique identity: the physi-cal device A must assume the logical identity A, and the physical device B must assume the logi-cal identity B, to enable data flow from A to B.

In some systems, the logical identity is the same as the physical identity: devices address each other through unique physical aspects such as unique MAC-ID addresses. In most networks, the abstraction of logical addressing is preferred, as it allows for device replace-ment without informing the other nodes of the replacement physical address, is more efficient, and supports network topology composed of multiple links.

Systems using logical addressing must obtain and apply a suitable and unambiguous logical address to each device. In either system, methods are required for devices to address each other using the chosen form of addressing.

This programming model includes services for automatic acquisition and maintenance of unambiguous logical device address data, gen-erally not requiring a dedicated central machine or human involvement. This simplifies instal-lation of devices; the integration of these ser-vices with this programming model enables the creation of such devices with little effort by the developer.

V. Programming modelThe Python programming language provides

a rapid development environment, supporting object-oriented development in an interpreted language with integrated bytecode compilation and optional compilation to native binary code.

Use of Python for creation of applications for distributed peer-to-peer control networks enables the use of popular and very fast-to-mar-ket application development for an application domain, currently dominated by traditional pro-gramming languages and strategies, which as a consequence, generally requires much longer development cycles.

The programming model requires only the Python programming language, as the need for proprietary tools and languages is eliminated, while providing a method, through standard Python language features, to continue to use

‘ This programming

model includes

services for

automatic

acquisition and

maintenance of

unambiguous

logical device

address data to

simplify installation

of devices with

little effort by the

developer.’


existing code.

VI. Contract fulfillmentImplementing an application for an open,

multi-vendor peer-to-peer control network requires the declaration of the application’s interface, and the integration of the applica-tion’s central control algorithms with this interface.

The interface defines how a given applica-tion communicates with its peers on the net-work. Such an interface generally consists of one or more implementations of profile(s), chosen from a library of profiles defined in an open, industry standard.

In traditional technologies, implementing interfaces consists of a largely manual and knowledge-intensive process of providing the correct definitions using an interface definition tool and language.

Below, the example continues, looking at the definition and implementation of a hypothetical application’s interface of the simple standard carbon dioxide sensor profile. This simple stan-dard profile combines one output datapoint for the current level of carbon dioxide with three mandatory datapoints for provisioning the fre-quency and the conditions by which the carbon dioxide level is sent to the subscriber nodes.

Figure 4 illustrates how a particular profile is implemented based on the classes outlined in Figure 3, using the standard carbon dioxide sen-sor profile SFPTco2Sensor as an example.

The Python programming model includes all standard profiles, datapoint and property types, known collectively as resources. In all, over 800 standard, predefined, resources are available to the Python application. Additional, application-specific resources can be defined within the same Python programming model. Applications import those Python resources when necessary to keep resource consumption by unnecessarily loaded resources at a minimum.

Figure 3 visualizes an example of several resource types which an application using this framework can instantiate. Typical applica-tions use the Application class’ block() factory method to implement the desired object. The Application class is a singleton class provided by this framework, which provides all top-level functions and services.

The following eight lines of Python code implement a complete and fully functioning application, including one correct implementa-tion of the standard carbon dioxide sensor pro-file. Not included is the application algorithm, which would sample a physical CO2 sensor device through peripheral inputs and report the current values through the output datapoint(s),

subject to thresholds and timing constraints expressed in the configured property values. The programmed attribute defined in this code example defines a mandatory key for the appli-cation, which is used to identify the application in a network.

from izot.device.application import Application

from izot.resources.profiles.co2Sensor import co2Sensor

app = Application()app.programId = “9F:FF:FF:00:00:00:01”co2Sensor = app.block(co2Sensor())

app.start()while True: app.service()

Figure 4 also illustrates the operation of the block factory, using the example of the same stan-dard carbon dioxide sensor profile. Because the protocol stack’s API is single-threaded, the Appli-cation object allows asynchronous threads to sig-nal events or request activity in several ways:

The control network protocol stack signals the availability of events through an asynchro-nous event that the Application class captures and transforms into a service signal. This allows the synchronous processing of events raised by the protocol stack. These events include notifi-cation of newly arrived network data, or notifi-cation of completion events (failure or success of transactions initiated earlier).

In applications that use concurrent process-ing, one main processing context (such as a thread) instantiates the Application class pro-vided with this model. Other processing threads of the same application may call essentially single-threaded API. In this case, the API call along with all its arguments is entered into a protected function queue by the thread which made this API call, and the service signal is raised. Enqueuing of API calls in this manner is handled automatically by the Application class’s methods and is transparent to the application and application developer.

When the stack indicates the availability of new data for a given datapoint, this raw applica-tion data is collected from the stack, formatted, and forwarded to the application in the manner outlined in Figure 1.

Completion event notifications trigger cor-responding events.

The service method empties the function queue by executing all enqueued API calls in the main processing thread.

This programming model supports applica-tions with concurrent processing in different


‘ The example

shows the

definition and

implementation

of a hypothetical

application’s

interface of the

simple standard

carbon dioxide

sensor profile.’


threads for interaction with datapoint objects and their values. Each datapoint object sup-ports the standard Python with statement. While code executes within a datapoint object’s with statement, the object is locked against access by other threads. When the with clause terminates, the object is unlocked and added to a protected to-do queue. The service signal also is raised at this time.

The service method processes this to-do list by applying the appropriate action to each enqueued datapoint object, unless the object is locked. Worker threads can explicitly lock a datapoint object beyond the with clause, although this is not generally recommended to prevent the risk of deadlock situations.

In another step executed by the service method, the interoperable self-installation pro-tocol (ISI), used to organize and maintain the network, is serviced when necessary.

The service routine also refreshes selected dynamic datapoint properties on a time-guarded round-robin basis. The time-guarded round-robin algorithm processes one datapoint after

another in the order in which they were created, but does not spend longer than a configurable, typically small, amount of time doing so in each service call. When the next service call occurs, this processing continues where the previous cycle left off. When all datapoints have been processed in this manner, processing continues with the first datapoint.

Some attributes associated with datapoints may change as a result of contract establish-ment or maintenance, or other network manage-ment operations performed by another party. For example, a network management tool may connect one input datapoint and one output datapoint. This procedure manages a number of low-level attributes (some shown in Figure 2). The local application may not be aware of these changes. The local application does not gener-ally require knowledge of these changes, but some aspects are frequently inspected by some applications.

To report whether a datapoint is connected, or bound, to at least one other, this service relays the current state of the is_bound data-

threads for interaction with datapoint objects another in the order in which they were created, Figure 4: The block fac-tory, walks through steps in flowchart format.


point property from the stack to the correspond-ing datapoint object, which exposes it through its Boolean is_bound property. For example, an application may use this to enable a timer to monitor the timely arrival of updated input data, and may disable this timer for an input datapoint that is not currently connected.

VII. Data interpretation and conditioning

For transport across the network, data is gen-erally presented in a form suitable for a given technology. For example, XML-based solutions exchange data as human-readable textual infor-mation using a suitable encoding, such as UTF-8. Other systems support binary data exchange

for efficiency, where data is formatted according to rules defined by the network tech-nology. For example, one net-work technology may require that all numeric data consist-ing of more than one byte be exchanged using little-endian byte ordering.

Specific data types often stipulate additional rules. For example, one network data type may be defined as a tempera-ture value in units of 0.01 C, or as a duration, in units of 0.1 s,

both delivered using an unsigned 16-bit integer quantity.

Once a receiver has applied the network-specific rules, such as byte and bit ordering, the resulting raw application data is subject to those additional rules, which are generally sup-plied as part of metadata, or with the contract, which governs reception of this particular data item. Other types implement superficial value range limitations to ensure a match between the network data and the associated physical entity. For example, a temperature value represented by an IEEE 754 double-precision floating point value may be restricted such that the tempera-ture value cannot fall below 0 K.

Using traditional methods, the burden of transforming raw application data into algebraic data useful in computation and other algorithms through application of scaling factors, offsets, and range limitations, and its reversal, is left to the developer.

The Python programming model for distrib-uted peer-to-peer control has built-in access to such metadata, and automatically applies the required transformations when presenting incoming data to the application, and when con-ditioning outgoing data for transmission onto the network.

Figure 1 illustrates how this programming framework provides such services as a fully transparent service to the application.

In this Python programming model, the application developer does not need to be con-cerned with data conditioning duties, as the programming model automatically applies the appropriate rules. This makes the technology easier to learn and more approachable, com-pared to traditional methods, and significantly reduces development time, time invested in staff training, and risk of error in an application.

VIII. Device addressingMost control networks support an exter-

nal entity to allocate and assign unique logical device addresses. This model optionally sup-ports such a central arbitrator, but defaults to an implementation of the interoperable self-instal-lation protocol.

The ISI protocol, and the support for it built into this programming model, automatically assigns and maintains unique device addresses to each participating device.

Traditional programming models require substantial code to take advantage of the servic-es offered by a central arbitrator. One example is code that implements a client to the Dynamic Host Configuration protocol (DHCP).

In this programming model, no code is required to accomplish the same. The core ISI services are automatically and fully transpar-ently handled by the Application class and its underlying service providers. Those include starting, stopping, and periodically servicing the ISI engine; reliable maintenance of persis-tent data storage for nonvolatile, modifiable data required by the ISI implementation; and abstraction of low-level protocol details into the realm of application expertise (Figure 2).

See the online version of this article for more about programming, including more examples, contract establishment, and explanation of how this environment goes beyond a polymorphic API, and download information. ce

- Robert A. Dolin is Echelon’s chief technology officer and system architect. Bernd Gauweiler is a senior software engineer at Echelon Corp. Edited by Mark T. Hoske, content manager, CFE Media, Control Engineering, [email protected].


‘ The application developer

does not need to be

concerned with data

conditioning duties, as

the programming model

automatically applies the

appropriate rules.’

www.controleng.com/archives April has a longer version of this article with additional programming examples, attributed references, more about the authors, and a free download link.

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Consider this...How much more could industrial Internet of things applications developers accomplish with a library that allows implementa-tion of a complete profile with one line of code?

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Some people still debate the merits of using cloud computing in manufac-turing, but there are specific cases when a cloud solution is the obvious choice. Many controversies about

using the cloud come from outdated information about cost. But in the last few years, leading ven-dors have dramatically dropped the cost of run-ning cloud-based solutions. Those economies add to the savings you gain from not having to build and support data centers and IT staff. Certain situ-ations make cloud-based solutions the only ratio-nal option, including these eight situations.

1. Mergers and acquisitionsPressure for top-line revenue growth makes

any number of merger and acquisition (M&A) based strategies inevitable for many manufactur-ers. A successful M&A growth strategy depends on smooth, quick integration.

2. DivestituresSpinoffs have the opposite problem of M&As.

When the IT resources of the old parent organi-zation are no longer available, the spinoff needs a quick way to replace IT capabilities without add-ing new cost burdens and without the distractions of building an IT organization from scratch.

3. Offshoring, near-shoring, reshoringThe economic pressures that drive decisions

to move production offshore change frequently. Cloud computing allows manufacturers to put computing resources where needed quickly and economically to meet the needs of each location.

4. Two-tier company structuresMany manufacturing companies are owned

by larger parent organizations whose core trans-

actions systems, including enterprise resource planning (ERP) and financial management appli-cations, are built to serve the financial function. Expensive customization would be required to address the demands of manufacturing.

5. Strategic alliances, partnershipGoing it alone isn’t necessary in indus-

tries that need to rapidly satisfy new customer requirements or keep up with rapid innovation. Companies that establish strategic alliances or partnerships with companies in other industries often prefer to keep joint operations independent.

6. Special projects, fast turnaroundIn a world of compulsive early adopters, viral

business phenomena, and instant communica-tions, it’s not unknown for a company to need to turn rapid response into a competitive differenti-ator. Cloud technologies roll out rapidly.

7. Test environmentsTesting, essential for any technology rollout,

can create redundant hardware, facilities, and support. Many business software solutions can be implemented either as cloud solutions or on-premise solutions.

8. Expansion, new geographiesTo reduce shipping costs and meet consumers’

increasing demand for speed, many companies build plants close to areas of maximum demand. New facilities need to get online quickly.

Manufacturers have to be ready to change strategies and adopt new tactics faster than ever; cloud computing is the quickest, most economi-cal way to make things happen in a hurry. ce

- Mark Humphlett is industry and solution strategy director, Infor.

Some people still debate the merits of using cloud computing in manufacturing,but there are specific cases when a cloud solution is the quickest, most economical way to make things happen in a hurry.

www.controleng.com/archivesApril has more details and links, including “Advanced process control in the cloud.”www.infor.com/cloud

Go Online

Keyconcepts� Eight ways show when cloud computing is the obvious choice.

� Cloud computing is the quickest, most economical way to make things hap-pen in a hurry.

� Other reasons include: Mergers, acquisitions, divestitures, alliances, special projects.

Consider this...How can cloud computing improve your agility and asset management?

cloud computing

8 waysthe cloud is a no-brainer for

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Cloud-based computing applications are integrated into a Lease Auto-matic Custody Transfer (L.A.C.T.) unit from Trigg Technologies LLC to accurately measure, sample, and

transfer hydrocarbons between buyers and sell-ers. The skid-based unit can be placed at a cus-tody transfer area for oil production facilities, trucks, railcars, pipelines, storage tanks, barges, and tankers.

Flowmeters on the skid transfer information to an enclosure, feed data into the cloud, and the custody transfer is verified in real time. Manu-al paper-based systems pose challenges when discrepancies are found, technology provider Rockwell Automation suggested. Mass flow-meters compensate for errors based on temper-ature. Crude oil expands or contracts at 2% per 40 F temperature change, something typical tank gauges don’t catch; even a 1% error, with $100/bbl oil at 3000 bbl/day means $1 million of lost revenue per year, Trigg Technologies suggested.

Local, remote accessInformation about the custody transfer and

system health can be seen at the enclosure (see photo) human machine interface (HMI) and on enabled and secure laptops, mobile phones, and tablets, as well as by remote monitoring and sup-port personnel tracking real-time system alarms, event faults, and notifications, offering predictive and preventive maintenance to maximize reliabil-ity. The cloud platform also provides secure data storage, workflow assistance, and a cross-plat-form dashboard with reports.

“Cloud technology provides a vehicle to manipulate and manage data. Purchasing software as a service enables an organization to move faster into the realm of operational excellence through

better utilization of existing data. Purchasing oper-ations management tools as a service avoids using capital budgets and ... circumvents issues of fund-ing across assets. Services are paid for as they are used with operating budgets. Using cloud com-puting to share operating conditional data creates an environment for operational improvement,” said a Rockwell Automation white paper, “Help-ing Oil and Gas Companies Achieve Operational Excellence.”

Ted Hutto, owner of Panhandle Meter LLC and president and co-owner of Trigg Technologies, was a panelist at Rockwell Automation’s Automation Fair in November 2013, in Houston. ce

- Mark T. Hoske, content manager, Control Engi-neering, [email protected], with information from Trigg Technologies and Rockwell Automation.

Trigg Technologies LLC uses a cloud-based platform and remote monitoring to improve custody transfer services accuracy and reliability for crude oil and petroleum products.

www.triggtechnologies.comwww.rockwellautomation.com – Search on cloud platform.

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cloud computing

Figure 2: Opening the Trigg Technologies enclosure shows the back of a flat panel operator interface, logic, input/output (I/O) modules, and other Allen-Bradley electrical and control components from Rockwell Automation, as shown at Automation Fair 2013.

Figure 1: A Panhandle Meter custody transfer skid was displayed at Rockwell Automation’s Automation Fair in November 2013. Ted Hutto, owner of Panhandle Meter LLC and president and co-owner of Trigg Technologies, was a panelist at a conference session there. All images courtesy: CFE Media, Mark T. Hoske

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5 p.m.-6:30 p.m. Networking event


Manufacturers and process indus-try companies expect human machine interface (HMI) soft-ware and operator interface ter-minal (OIT) hardware to deliver

remote access to devices, including desktop PCs, laptops, smartphones, tablets, and other devices. Internet connectivity and mobility can improve overall operations, and HMI and OIT solutions can deliver the functionality and features they need. The growth of the Internet and its connected devices has changed how we live and do business. Activities once deemed far-fetched or prohibi-tively expensive, such as conducting a video call among participants from different continents, are now part of everyday life. Today’s smartphones and tablets have more computing power than

the mainframes that filled entire rooms a couple decades ago. As a result of these advances, busi-ness is becoming increasingly mobile.

This paradigm shift is occurring in the auto-mation world as well. Today’s manufacturers face the same challenge as other businesses: how to do more with less. Some of these changes are attrib-uted to a fundamental shift in how manufacturers have done business over the last 10 to 15 years. From Lean manufacturing to Six Sigma, most of today’s plants have implemented some type of continuous improvement initiative to cut ineffi-ciencies, improve quality, and reduce energy use.

This focus on operations is also gaining momentum because more businesses face bud-get restraints and shortages of trained personnel. Many companies can’t afford to hire more work-

ers, while others are trying to cope with the retirement of experienced staff.

Today’s markets demand that businesses must operate and execute in real time. To meet this goal, manufacturers must be able to retrieve and act upon data from anywhere in the plant or outside it to remain competitive. The growth in dependable remote access to human machine interfaces (HMIs) and operator interface terminals (OITs) is one of the methods being used by com-panies to reduce costs and improve operations.

HMIs, OITs, Web browsersThe introduction of PC-based HMIs and

the migration from proprietary systems to ones based on a standardized platform (Microsoft Windows) could be considered the first step toward remote access. Standard network proto-cols in PC-based solutions facilitated commu-nication among diverse equipment and systems, ending the isolation of automation processes.

Following closely were OITs based on embedded Microsoft Windows operating sys-tems. OITs were less capable than PC-based

Improve remoteHMI and OIT accessSmartphones and tablets combined with industrial software can improve remoteaccess to human machine interfaces (HMIs) and operator interface terminals (OITs). Mobile workers demand remote access solutions optimized for smartphones andtablets. Fortunately, there are apps for that.

mobile HMI

Figure 1: Apps developed by HMI software and OIT hardware providers provide users with a superior remote access experience as compared to browser-based access. Courtesy: Indusoft, Invensys, and AutomationDirect

Keyconcepts� Human machine inter-face (HMI) software and operator interface terminal (OIT) hardware deliver remote access.

� Smartphones, tablets, and other devices benefit from applications opti-mized beyond a browser.

� Internet connectivity and mobility can improve overall operations.


HMIs and less expensive to purchase, install, and maintain. This made them a better fit than PC-based HMIs for many lower-end and embedded applications, such as providing the operator inter-face for a simple machine.

Users were initially content with simply view-ing information from multiple machines or pro-cesses on PCs with HMI software in the control room. Each PC was loaded with its own HMI client software, which often required separate, expensive licensing. The PCs were typically con-nected to plant floor or field-mounted PC-based HMIs and OITs by hardwired Ethernet links.

PC-based HMIs proved to be a good method for monitoring and controlling plants from the control room and remain the dominant paradigm, but users soon began to demand remote access from areas outside the control room. Installing and maintaining software on PCs located in offic-es and homes initially accomplished this; howev-er, this became burdensome and expensive.

The next step in remote access solved that problem by using Web browsers to access data from PC-based HMIs and from OITs. This was a huge improvement over older methods; soft-ware didn’t have to be installed and maintained at each remote access device. It also opened remote access to devices with browsers and Internet, such as smartphones and tablets. Users were happy with browser-based access until they used a well-designed app, typically for an everyday task like making a restaurant reservation. Then they saw the superior power, speed, and ease-of-use of an app (compared to browsers) and sought apps for remote access to machines and processes.

Apps arrive and expand User demands for apps instead of browser-

based access led some HMI and OIT suppliers to develop free or very low-cost apps for custom-ers. These apps provided quick and easy two-way access to screens and data, a big improvement over slow and cumbersome browser-based access (Figure 1). Most apps were initially limited to one or two device types, typically iPhones and iPads. Apple’s handheld products all use the same oper-ating system, which made app development, test-ing, and deployment manageable for suppliers.

Other smartphones and tablets, however, have a multitude of different operating systems and screen sizes, which made creating apps for them prohibitively time consuming and expensive. The much larger universe of competing smartphones and tablets based on Google Android and other operating systems was thus largely excluded.

For example, a company first builds a remote access app for iPhones and iPads. If it wants to

include other smartphones and tablets, it must write an app for every brand’s operating system and screen size, typically using a different pro-gramming language for each. To port an applica-tion from one operating system to another can take developers months, and it is often just not done. The HTML5 standard offers a solution.

Standards to the rescue, advantagesSearching for a way to speed and standardize

app development, HMI software and OIT hard-ware suppliers turned to HTML5. With HTML5, mobile applications can be as functionally rich and user friendly as the traditional native applica-tions built using Java or C++.

Moreover, HTML5 eliminates the need to cre-ate numerous apps because it renders the same user interface correctly sized across multiple for-mats and operating systems. All users therefore see a similar screen regardless of the device. Bet-ter yet from the supplier point of view, HTML5 enables developers to write an application once, then instantly deploy it everywhere. This allows suppliers to quickly deploy new and improved apps to virtually all smartphones and tablets, delivering numerous benefits.

Mobile HMI applications can offer enhanced functionality, ability to easily and quickly retrieve and interact with data, device independence, similar screen experience in multiple platforms, and easy navigation methods via multi-touch technology. Some HMI software and OIT hardware suppliers offer products built from the ground up, under-standing that the number of remote access users with smartphones and tablets will rise exponential-ly. Remote access capabilities created for handheld devices, often via apps, often have superior func-tionality compared to browser-based access. ce

- Marcia Gadbois is vice president of InduSoft, Invensys, and Jeff Payne is AutomationDirect auto-mation group product manager. Edited by Mark T. Hoske, Control Engineering, [email protected].

www.controleng.com/archives April has more on bring your own device (BYOD), small screen productivity, multi-touch, and industrial mobile access, with links to related articles. www.indusoft.comwww.automationdirect.com

Go Online

‘The expanded

capabilities of handheld devices have changed how automation

users retrieve and interact with plant data.’

Figure 2: Using familiar multi-touch technology, operators can troubleshoot and execute commands as much as three times faster than with a single-touch interface. Courtesy: Indusoft, Invensys

Consider this...Could the right information to the right people at the right time improve your productivity and competi-tiveness?


The “convergence” buzzword can be used to describe one of the most important ongoing trends in the world of industrial control. It is not a particular type of new technolo-

gy or recently found in this market; indeed, peo-ple have been talking about it for more than a decade. But why is this trend getting more atten-tion now? How does it specifically affect the market for industrial controls?

The trend toward convergence began to take hold early in this century, in the discussion of the role of PC-based control in discrete automation, which was once the sole domain of programma-ble logic controllers (PLCs); and with the role of PLCs in process automation, which had been the sole domain of the distributed control system (DCS). The convergent technology of these prod-ucts has blurred the boundaries of applications.

The debate over PLC versus PC-based control and over DCS versus PLC control still rumbles on, but it reflects only part of the way industrial control is changing. With the merging of automa-tion technologies, new products have been intro-duced to the controller markets in recent years, enriching “convergence” in one way or another. When talking about convergence, people with different backgrounds might have different view-points and understanding of the term.

Control layersConvergence is taking place in all control lay-

ers, mainly from the following three perspec-tives: 1) Convergence of the physical world (industrial systems) and the digital world (cyber-space) 2) Convergence of information technol-ogy, manufacturing and automation technology and software 3) Convergence of industrial devic-es and industrial control hardware.

All these convergence trends have some direct or indirect impact on the industrial control market. Some have been taking place for years; some are on the way. In the past 10 years, technology con-vergence for industrial controllers generally has been limited to hardware convergence, the base layer in the evolution of the technology. The dis-cussion is about the advantages and disadvantages of each controller type, and how they are differ-entiated. The main drivers of this convergence are probably largely the controller vendors, seeking to gain more market share by enhancing the func-tionality and performance of the control hardware.

Technological convergence is the process by which existing technologies merge into new forms that merge different types of products and applica-tions. With the development of industrial software and industrial networking, the focus of technologi-cal convergence for industrial controllers is shift-ing and will change in a more dynamic way.

Mobile phone analogyThis is similar to the evolution of the mobile

phone, which has much in common with indus-trial control. When the mobile phone was invent-ed, its purpose was to make phone (voice) calls. For a long period, the evolution of the mobile phone was largely the result of work by engi-neers and scientists to push the limits of physical and material science and was very hardware-focused; though the role of the mobile phone did not change. Only by taking one step fur-ther (especially through technological conver-gence with multi-level media and networking) can the mobile phone interact with a wider array of media types. As the technology advances, new models increasingly include more features, like the ability to interface with more devices or play other types of media; now it’s a mobile device.

Convergence bringsnew benefits to theindustrial controls worldPreviously separate technologies, such as controllers, sensors, operator terminals,motion controls, software, networking, and services, share resources and act in synergy. Technology convergence offers new opportunities spanning firms and economies.

‘Software, information,

and communication

technology will have a

larger share in the evolution of industrial controls.’

control convergence

Keyconcepts� Convergence benefits the world of industrial controls

� Convergence includes hardware, software, net-working

� Convergence allows focus on resolving the challenge, instead of battles among vendors


Industrial control hardware was used to accomplish some basic control tasks. Software and networking also are changing the pattern of the industrial control world.

Industrial software convergenceAlthough the sales revenues of industrial con-

trol systems still come mainly from control hard-ware, the development of software and its role in manufacturing has become increasingly impor-tant. The software portfolio will expand much more, from product design, planning, engineer-ing, and execution to plant and enterprise man-agement and product lifecycle management, covering the whole production lifecycle and enterprise value chain. Convergence of industrial control hardware and software is the fundamental step for software development.

The proportion of software in the cost of a control system will increase, as it becomes more important. Because software integrates automa-tion technology with other elements of man-ufacturing [for example, PLC software with manufacturing execution systems (MES) and enterprise resource planning (ERP) software], it will improve the functionality of control systems, and move the manufacturing process from being driven by electronics to being driven by software and, finally, by data.

Industrial network convergenceIf we consider the trends discussed in indus-

trial automation, such as Industry 4.0, the Inter-net of things (IoT), industrial Internet, smart factories, big data, and so on, none of them would be realized or even exist without the sup-port from industrial networks. Information and communication technology is the fundamental key to drive the industry revolution into a new era and, naturally, will have a profound impact on industrial controls.

Industrial networking opens the door for industrial controllers to play a more vital role in the whole process. The primary role of industri-al controls always has been to control machin-ery and automated process lines. However, as they become more intelligent and the devices they control become “smart” (with perception, decision-making, and executive functionality), wherever the convergence of industrial control-lers and networking takes place, controllers have the possibility to be transformed from “brick” to “brain.” That happens horizontally, to integrate all intelligent devices, and vertically, by commu-nicating production information to higher level management systems and by processing instruc-tions and data sent.

Returning to the original questions: Why is the technology convergence trend getting increasing attention now? And, what is its impact on the market for industrial controls? Conver-gence weakens the independent existence of industrial controllers. The product type and per-formance parameters that used to be the selling point of a certain industrial controller model will gradually be less important to customers. Cus-tomers will be more excited about the solutions that the whole control platform or system can provide, the problems it can solve, and how it can increase productivity and efficiency. Wheth-er the controller is a PLC, a PLC with PC-based technology, or a DCS will be of little concern. Software, information, and communication tech-nology will have a larger share in the evolution of industrial controls.

Opportunities from convergenceThis turning point represents a great oppor-

tunity for original controller vendors and other automation vendors seeking growth. With con-vergence, lines are blurred as companies diver-sify from their original markets. The industrial controls world is only vendors of PLCs, indus-trial PCs (IPCs), programmable automation controllers (PACs), motion controllers, embed-ded controls, and DCSs, but a multidimension-al arena in which competition and cooperation often occur simultaneously. Previously separate technologies, such as controllers, sensors, oper-ator terminals, motion controls, software, net-working, and services, now share resources and act in synergy. Control technology convergence offers new opportunities spanning firms and economies. ce

- Jan Zhang is the IHS associate director in the Shanghai, China, office.

www.controleng.com/archives April has related articles and information relating to con-vergence trends linked to this article online.www.ihs.com

Go Online

The diagram illustrates which kind of convergence trend will affect indus-trial control systems, when they are likely to be realized in the real world of manufacturing, and the impact on controllers. Courtesy: IHS Convergence Trends Affecting Industrial Controls – 2014 report

Consider this...Convergence versus diver-gence: If automation ven-dors spent more time in the last 20 years focusing on customer needs, and less time carving up proprietary market niches, would end-user processes be more efficient today?

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HART Communication:The next 20 years and beyond

In 2013, the HART Communication Foundation celebrated 20 years serving the process automation industry, an era in which the HART Protocol became the recognized global standard for field communications in the process industry.

What’s next?

InnovationThe sound technology principals of the protocol’s design

have enabled users to “Get Connected” to valuable process and device data within the plant…in a cost-effective way with minimal disruption of the operation. Leveraging HART data in real-time delivers a compelling financial value proposition to improve plant performance from asset intelligence derived from the data. New ways to connect and capture this value will drive the need for more products and solutions and become the basis for our strategy for the next 20 years.

For example, rapid global accep-tance of the WirelessHART standard enhances the technology’s functionality and preserves its viability indefinitely. In addition, the need to connect large amounts of data to enterprise and asset management systems for decision sup-port has resulted in the latest HART capability, HART-IP. HART over Ethernet provides a high band-width connection between host systems, HART-enabled I/O, gateways and devices using standard networking infrastructure.

Global growthHART technology has a rapidly growing global footprint with

over 40 million HART-based devices in use in the majority of industrialized countries of the world. Today high user demand has resulted in suppliers shipping HART-based products in record numbers – according to recent ARC Advisory Group research, nearly 80% of process measurement and control devices deliv-ered each year use HART.

This growth is further evidenced by the now more than 300 Foundation member companies world wide. The Foundation continues to partner with the top innovative manufacturers of process automation solutions to expand these global markets as they expand their use of the HART Protocol.

In addition to our main office in Austin, Texas, Foundation offic-es in Europe, China, and Japan provide strong technical support and leadership in these world areas with local language technical training, seminars, workshops, trade shows and conferences.

We will continue to drive the support and infrastructure for

all of these world areas enabling them to enjoy the benefits of HART technology. In addition, we will continue to work with other leading standards organizations to deliver valuable solutions to industry users.

StandardizationThe HART Communication Foundation is committed to

having our standards approved by all leading standards orga-nizations around the world. The HART Protocol has recently been approved as a China GB/T National Standard; and recent enhancements comply with NAMUR NE107 to standardize device display and alert information. For the global user com-

munity, international standardization reinforces their confidence in the reli-ability and interoperability of this valu-able technology.

Efficient and economically viable device integration with hosts requires multiprotocol standardized technology that makes device information available across systems and applications from different manufacturers. The HCF joined the other major protocol foundations, FDT Group, Fieldbus Foundation, PI, and OPC Foundation, to establish a common technology for device informa-

tion management. A single scalable solution for field device inte-gration, FDI simplifies and standardizes device and host integra-tion to address end user requirements in all areas of the plant.

Business valueFor us, the next 20 years will be about continuing to deliver

bottom-line business benefits to process manufacturers. New offerings from industry suppliers to the HART eco-

system are making it easier than ever for users to adopt the proactive and predictive maintenance strategies that full-time HART communication makes possible. Connectivity to the enterprise for visualization, analytics and integration into other systems will multiply the value that real-time HART communi-cation can bring to a business.

We are excited to work with our members and users to forge the future strategy of HART Communication and lever-age new technologies to help users “Get Connected” in real-time to the valuable information in their HART devices. Users who plan to upgrade or expand an existing plant, or build a new plant for sustainable and globally competitive operation, will reap the benefits when they “Get Connected” using HART communication for the next 20 years and beyond.

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H4 HART Communication: The next 20 years and beyond

In 2013, the HART Communication Foundation cel-ebrated 20 years serving the process automation industry, an era in which the HART Protocol became the recognized global standard for field communica-tions in the process industry. What’s next?

H8 HART Communication adapts for the Internet world

A closer look at the benefits offered by HART-IP, which is the latest enhancement to the HART Protocol Specification.

H10 Building a maintenancemanagement programfor valves

Diagnostics from smart valve actuators using HART communication can save maintenance costs and improve plant reliability when used in a comprehen-sive maintenance management program. This is often the first big victory of a program.

H16 Three wishes foran easier life with HART

At Hannover Messe 2013, Michael Pelz, head of process optimization and automation for Clariant Pigments Business Unit, spoke about his experi-ences with HART technology, while expressing his hopes for future developments to make the technol-ogy even easier to work with.

H18 Integrating HART datafrom smart devices

HART calling! Your field devices and actuators want to tell you more of what is happening in the plant, all you have to do is listen.

Contents

HART,® WirelessHART,® and HART-IP are trademarksof the HART Communication Foundation.

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HART Communication adapts for the Internet world

A closer look at the benefits offered by HART-IP, which is the latest enhancementto the HART Protocol specification.

To address growing industry demand for accessing data over the Ethernet, the HART Communication Foundation added a new capability to the HART Protocol Specification, HART-IP. HART-IP takes HART technology as it exists today and adapts it for the world of the Internet, allowing the exact

same HART protocol to run over an IP-based connection deliv-ering valuable HART data at the speed of Ethernet.

This means that the standard Ethernet infrastructure that is used today in most control systems is now able to run the HART application layer and protocol over the same Ethernet and TCP/IP layer. A HART-IP backhaul network enables soft-ware to gain direct access to information in WirelessHART devices for example, without having to perform any data map-ping through intermediate Modbus or OPC.

Offering comment on HART-IP, Harry Forbes, senior analyst at ARC Advisory Group, said: “The introduction of an IP backhaul will undoubtedly increase the use of WirelessHART.” Frank Fengler, of ABB agrees, saying: “The greater use of HART-IP will lead the way to larger WirelessHART networks because it will be easier to gain access to the intelligent information in HART devices. HART-IP is already being used in many products that have connect-ing devices – such as gateways, remote I/O and multiplexers so just with the addition of a communication driver, users can gain access to HART-IP.”

“In reality, because most WirelessHART networks contain less than 100 devices, multiple networks are created,” Forbes went on to explain. “This can present an integration manage-ment problem as the number of networks grows, because there will be many different gateways that all need to be integrated. Having an IP backhaul, therefore, makes a huge amount of sense, connecting measurements to the Internet. This will enable users to integrate whatever applications they are using for measurements, over a much larger scale.

“It will also make it possible to centralise the manage-ment of multiple networks. Applications consisting of, for example, up to 200 or more wellheads distributed over wide distances, would be able to manage all of the gateways from a single point, connecting to all the measurements,” said Forbes. Once the HART-IP-enabled devices are plugged into the corporate network, the information can travel liter-

ally anywhere in the world over the corporate VPN allowing remote access of process measurements and device and/or process diagnostics.

Increasing uptakeWith more vendors using HART-IP within their product

offerings, Eric Rotvold, distinguished technologist, Emerson Process Management, says that there are now implemen-tations of HART-IP in the real world, and WirelessHART is also being adopted more aggressively by industry. “Many gateways already support HART-IP so its increasing use is a natural progression. There are also devices such as COM DTMs under the FDT umbrella, being developed to talk to these HART-IP gateways and instrumentation, for asset man-agement purposes.” Likewise, many HART-enabled device configuration and asset management applications are already HART-IP enabled.

A big benefit of HART-IP is the ability to gain high-speed access to the standard HART diagnostic information and pro-cess data using the plant’s installed networking infrastructure. Rotvold said: “Although this information has been available for a long time, , up until this point there has not been a great way to get a lot of data out of HART devices and into asset management or enterprise level systems. Multiplexers suffer from data aggregation and with WirelessHART gateways you still need a way to ship all the data up to the host system as quickly as possible. HART-IP provides this capability, allowing for the effective management of many gateways and many thousands of WirelessHART devices.”

Why HART-IP?HART-IP offers the most straightforward way to access all

the standard HART information available in a HART device. It allows the information from these devices to be brought up to the Ethernet level easily, without the need to go through any translation processes and with no loss of information.

According to Rotvold, the main barrier to greater imple-mentation of HART-IP is now the system vendors. He said: “If system vendors make HART-IP available in the same way that they do with Modbus TCP, I believe that there would be a dramatic uptake in the use of HART-IP which would result in an even greater uptake of WirelessHART. Emerson’s system

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controllers already support HART-IP and can talk directly to the Emerson gateway via HART-IP. The HART-IP specification was released in 2012 so I expect that we should start to see introductions from other vendors within the next two years.”

John Yingst, product manager at Honeywell, believes that HART-IP is an essential tool to increase the distance between the source of HART data (the devices themselves and the control systems they are connected to) and the application user of that data (typically some kind of configuration tool or instrument asset management system). Traditionally, HART multiplexers have used RS485 networks to link these togeth-er, which required set-up and configuration of several param-eters (baud rates, adapters, wiring polarity, address switch settings, etc.) and posed some distance limitations. HART-IP significantly simplifies the connection configuration and basi-cally eliminates the distance limitations.

Yingst said: “Several emerging Honeywell products will take advantage of HART-IP. For example, the Wireless Device Manager (WDM), a key part of the OneWireless Network solution, offers HART-IP in Release 220. The WDM serves as the gateway for Honeywell’s wireless product offering. From its initial release, the WDM had the ability to represent wireless sensor data as HART, OPC, Modbus and Honeywell (Experion PKS) CDA data, allowing applications to transpar-ently use this device data. Extending the HART capability in the WDM to support HART-IP is a natural evolution.”

Another development that takes advantage of HART-IP is Honeywell’s RTU2020, aimed at the wellhead control and monitoring market. This RTU features a HART-IP server which gives the ability to remotely maintain and diagnose connected HART valves and transmitters. “A maintenance engineer in such applications might be 1,000 km away from the HART device and the closest maintenance camp might be 200 km away. Having HART-IP will allow better decisions to be made about the health of the remote asset, possibly negating the need for an expensive site visit,” said Yingst.

Implementation issues?Implementing HART-IP is really just about organizing the

communication path,” explained Gerrit Lohmann, manager product group remote systems at Pepperl+Fuchs. “It is noth-ing new or complex. End users need to do nothing because the HART integration mechanism does not care how the HART message went into the system. It is possible to reuse all the DTMs and DDs – the only additional consideration is the communication path. In the DTM world a communication DTM is created to open the Internet communication path. Of course, the connected DCS or asset management system will also need a physical interface.”

Lohmann expects HART-IP implementation to increase in the near future. He said: “HART-IP is now starting to be implemented in DCS systems and asset management sys-tems, which will broaden its usefulness – as these systems will be immediately plugged into the gateway, allowing the

� HART-IP works with any IP-enabled PHY, including packet radio, SAT-radio, WiFi, cell nets, etc., which makes the HART network – including WirelessHART devices – com-patible with commercial and industrial grade LAN switches, fibre optic media converters, Wi-Fi access points, and related equipment.

� Because the application layer is the same for HART field devices an HART-IP, time consuming and error-prone data mapping is eliminated, making HART-IP the most suitable backhaul network for WirelessHART gateways and 4-20 mA HART multiplexers.

HART information to be more widely used.”Pepperl+Fuchs have included a HART-IP interface in its

WirelessHART gateway for many years. “Having this Internet based communication capability broadens the application of HART, enabling it to be used in the same way, and parallel to, other Ethernet-based protocols, using the same infrastructure and using the same principles for integration,” concluded Lohmann.

Suzanne Gill is editor of Control Engineering Europe.


Building a maintenancemanagement program

for valvesDiagnostics from smart valve actuators using HART communication can save

maintenance costs and improve plant reliability when used in a comprehensivemaintenance management program. This is often the first big victory of a program.

W hile most smart devices are field instru-ments, smart valve actuators have the same capabilities, and often users launch a maintenance program for valves ahead of instruments. HART Plant of the Year recipients bear this

out: Dow, Monsanto, and MOL all used HART diagnostics to improve plant reliability and save money on valve mainte-nance. Valves are far more maintenance intensive than instru-mentation and have more wear-prone moving parts than a typical flowmeter or pressure sensor.

The ability of a given valve to function can have a huge impact on a process unit’s operation, depending on where it’s located. Its ability to move as expected and control as needed makes all the difference, so diagnostic information is an enormous advan-tage for reliability. HART Communication can also supply real-time valve position feedback to operators, confirming that a valve is in the position that the control system says it is.

When a valve maintenance program in a large facility is thought out well, implemented with care, and with the right individuals at the helm, a full-time valve engineer can easily be worth $1 million or more when the costs of repair and replacement are combined with improved operations and plant availability.

Establishing criticalityUnless your plant has an unlimited budget, you will likely

find yourself constrained as to how many valves can have smart actuators or positioners installed. So which valves are the most important? Criticality has two main elements: the importance that a given valve has in a unit’s operation, and the likelihood that that it will malfunction.

If you look at the P&ID for a process unit, you can identify certain valves that have to operate 24/7 for the unit to pro-duce, and it may be a large number. If one of those valves fails, the unit goes down, or if it doesn’t perform correctly, product goes out of spec. Plant designers often install back-up units in parallel on equipment like pumps so either can

do the job, but this is not a common practice with valves. Those critical valves working without backup deserve special attention because you can’t reroute the flow and you can’t do without them.

The same thought applies when you have to perform valve maintenance. Can that valve be repaired while the unit is still running. If everything has to be shut down to take it out or fix it in place, that valve is also critical.

Probability of failureThere are valves that can be installed in a process unit

and operate for years with no trouble. Where pressure drop isn’t excessive and the product is benign, there is little wear and tear in daily operation. But this isn’t always the case. Products can be corrosive, erosive, or otherwise aggressive, and there is nothing you can do beyond finding the best pos-sible valve design and most durable materials.

Difficult service valves are also prime candidates to be

Operators can perform step tests on valves to ensure that they are controlling correctly, but that is only part of the picture. Such tests may not show that a friction problem is developing, and every time it moves, it requires more force. Sooner or later the friction will overcome the force and the valve will malfunction.

Operators can perform step tests on valves to ensure that they

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retrofitted to become smart because they are subject to the kind of abuse that shortens lives. A worn stem or one where sticky product has accumulated can be difficult to move, and this is a simple thing for the smart actuator to measure and monitor over time. The system can warn operators of chang-es while there is still time to do something about it.

Planning turnaroundsIf your plant is one that runs continuously and can do so

for years at a time, sooner or later it will have to be shut down for some period of time to fix accumulating problems. Generally this turnaround period has to be as short as pos-sible, so there is much planning in the months and even years leading up to it. Everything has to be staged and ready to follow the repair and refurbishment schedule. That list will include valves since many will have to be repaired or replaced during the outage.

Turnaround planners must know exactly which valves need attention, and what kind of attention so appropriate units and parts can be ordered in advance. Valve diagnostics can help identify those valves and determine what needs to be done. When the turnaround clock is ticking, that is not the time to be discovering valves that need more attention than realized, or some that are scheduled for replacement are actually per-forming just fine.

In the repair shopValves that have been repaired, either in-place or in the

valve shop, should be tested before returning to service. A smart actuator / positioner can measure and record the valve movement and make sure it is operating within acceptable parameters. This requires an appropriate testing procedure for each type of valve with a database where historical informa-tion can be stored.

That historical information is what helps identify developing problems. When the amount of torque required to turn a stem increases slowly over time or takes a sudden jump, trouble is not far away. Keeping that information where it can be accessed easily is a critical element of a larger maintenance program.

After some time in the shop, that valve looks like it is operating as it should. The opening and closing pressures are in a tight group along with the ideal standard performance indicator. HART can be used on the bench to verify correct performance before reinstallation.

Valves that do not have direct HART I/O can send their diagnos-tic information via a wireless add-on device. Photos courtesy Monsanto Muscatine, the 2012 HART Plant of the Year recipient.

Looking at the HART diagnostics for that valve gives a much different picture. The yellow line represents the amount of force that the valve should need to move based on historical perfor-mance. The red and blue lines show what is actually happening now. That valve needs to be serviced soon before it causes an unplanned outage.

Looking at the HART diagnostics for that valve gives a much

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Demand Moore Reliability

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Establishing a programAutomated diagnostic capabilities for valves and other field

devices available through HART communication can provide huge benefits at many levels. Effective diagnostic tools can make these activities quick and easy to perform from a cen-tral control facility or even a remote location. The concept of taking the data to an expert instead of taking the expert to the problem is a powerful and underutilized concept, but depends on proper implementation of a good set of diagnos-tic tools and effective work processes.

Overview of barriersGiven the large incentives and low capital cost for asset

management, it would seem that this technology would be widely used. The reality is far different. Let’s take a look at those barriers and suggest some possible resolutions.

The first impediment has been the technology barrier. There is no question that device diagnostic technologies like HART work, but the tools available to put that information to work for asset management have traditionally been incomplete, hard to use, and poorly integrated. The good news is that the tools are improving and many users have demonstrated effec-tive ways to use them. The bad news is that effective use of the tools and the engineering skills necessary for effective deployment are rare.

Using diagnostic information is especially important for valves that are in congested or remote locations where inspection is difficult.

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The second problem for asset management is manage-ment. Technical problems have solutions given management support, but managers have to be rewarded for doing so. That kind of program requires good metrics, good reporting, and effective audits to produce a scorecard. In the absence of a good management system, poor performance is often treated as a technology problem, or just the normal state of things.

Who’s supposed to be acting on the diagnostic informa-tion? Maintenance? Can you tell a maintenance guy to look at an incomprehensible mass of unprioritized diagnostic data and decide what he should do based on that? Properly imple-mented systems can provide order and priority to make the data useful to engineering and maintenance organizations.

Start earlyImplementing an asset management program is a project

in itself. It can be a stand-alone project for an existing facility, or an add-on to new construction or control system modern-ization. For an existing facility, a lot of stranded (unusable) diagnostics often exist in HART-enabled smart field devices that are not connected to a smart system. The cost of system tool implementation in an existing facility can be an issue, but it is manageable. For new construction, the added cost of asset management tools is almost negligible. But this is just the hardware side. Either way, the work processes, training, metrics, and management processes have to be implemented just the same.

One of the first activities in an asset management pro-gram is creating a criticality ranking for each piece of major equipment and each device. This is often a painful process, because people want to rank everything critical because

ISA108: Intelligent device manage-ment—getting the most from HART enabled and other smart field devices

Reports from companies that have created effective asset management programs suggest that changing individuals’ thinking is more difficult than the technol-

ogy of collecting diagnostic data. There is no question that HART works as advertised, but users find it difficult to bridge the gap between diagnostic information and effective asset management.

Putting intelligent devices to work effectively is what ISA108 is about. As the organization characterizes it, “The purpose of ISA108 is to define standard templates of best practices and work processes for implementation and use of diagnostic and other information provided by intelligent field devices in the process industries.”

ISA108 is not a technical standard in that it does not dis-cuss how the diagnostic information is transmitted. It applies to HART as well as Foundation fieldbus, Profibus PA, and other protocols. The best practices are being created now, and there are opportunities for you to participate. Herman Storey is a co-chair, and he welcomes involvement from end-user companies. The ISA website explains how you can join the effort.

Read this article online at www.controleng.com for more information, including a video interview with Herman Storey discussing the standard’s development.


otherwise it won’t get fixed. You need to know the impact severity and the likelihood of a problem to do a good critical-ity ranking.

You will use this criticality information throughout the design process, while implementing other maintenance activities, and planning. But many people wait until the sys-tem is built and operating, when it is much more difficult. It has to be done during the design phase if you want an effec-tive project.

If you begin early enough and do the work systematically, the plant construction and start-up process will go faster and much smoother. During the design and factory accep-tance testing, you need to do the building, create your tools, and train your people. You want to use all those diagnostics through those phases, during installation, commissioning, and loop checking. Typically, the system will pay for itself right there. You’ve covered the investment by the time you get the plant started up. History says that in most plants where we’ve done that, we get the system de-bugged, start up the plant, back-check and verify everything, correct all the mistakes, and then we turn the asset management system off and never look at it again. When that happens, the facility owner misses out on the big payback during plant operation.

Managing prioritiesTraditional maintenance technology for managing main-

tenance priority is a reliability matrix. We’ve done the risk assessment, and we’ve determined that this device is medi-um-to-low priority. We look at the list of what we have to do, and how many critical things are on the plate today, and all of the low priority stuff gets deferred, sometimes forever. It may not even get addressed during turnarounds because of bud-get. So the low priority stuff accumulates failures. That’s fine for a while but enough low priority failures can cause a larger-

scale system failure, because the operators can’t tell what’s going on. There aren’t enough measurements. There aren’t enough controls. You can’t run the plant. System failures have greater impact than low priority device failures, but treating devices individually can lead to system effects that are not modeled or managed by the simple decision matrix.

Often after a major failure or an operational disaster, an investigation discovers that there were many signs of the growing problem, but nobody was able to see them or cor-rectly interpret what they were seeing. Field device diagnos-tics were trying to warn of a growing problem, but nobody was able to connect the dots. Often it’s an accumulation of small things adding up until they reach a critical mass. An accumulation of small (low priority) problems is common today among operating companies. You’ll see this accumula-tion of problems if you read analysis reports after a catastro-phe. After a while, enough little things line up in series and become a big thing. If you line up all the holes in a Swiss cheese, there’s a hole all the way through it. It’s another man-agement failure.

Getting data to the right placeOnce an appropriate data collection system is in place and

you are working on setting up your work processes, you need to determine where the data stream goes. Should it be main-tenance or operators? This isn’t a difficult process if you fol-low some simple principles: Send alerts to operators as well as maintenance if immediate operator action is required. The alert philosophy for operators is you’re dealing with individual events as they come up. You want a limited number of alerts that the operator can take some unique action on in real time.

On the maintenance side, you don’t want to deal with indi-vidual events. You want to log every little thing that happens, and then you want to use reports to sort through all of those logged events and make some sense out of them. You’re looking at history and analyzing what’s happened once, what’s happened a bunch of times, how high the priority was, and whether it happened to multiple devices. You can see trends from reports that get lost if you’re looking at individual events. A single problem with your air system can cause hundreds of events per day. You need a reporting format that can bring all that together and identify a common source. Clearly, an effec-tive asset management program using diagnostics from smart devices can pay major dividends.

When is it baked?It is really quite easy to tell. If you routinely use diagnos-

tics to find out how something failed after the plant has had an unexpected shutdown, you haven’t finished the job. If you have a large database of saves where diagnostics were used to prevent an unplanned plant shutdown, you are on the right track.

Herman Storey is chief technology officer of Herman Storey Consulting, and a frequent presenter on asset man-agement programs and other topics. Reach him at [email protected].

Using HART in three time domains:1. Periodic testing—HART helps automate and document scheduled

tests and calibrations, particularly collection and analysis of valve signature data, and PSTs (partial-stroke tests) for safety-related valves.

2. Incipient failures—HART diagnostics can alert users at any time to valve problems that are developing, but have not yet become failures. This allows maintenance to react to the problem before it causes and outage. This capability depends on having a process for monitoring diagnostic information, detecting changes, and reporting those to the right people.

3. Real-time performance—Operators place a high value on real-time valve position feedback from positioners via HART. Getting real-time smart device information quickly enough to be useful is the goal and requires the system to have good integration and access to intelligent device information.

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Pelz believes that HART Communication is very use-ful technology for plants, which incorporate a mix of old and new devices, some of which use only 4-20 mA. “HART makes integrating new devices into our legacy system a problem-free task,” he said. “With central device management tools it is possible for us

to configure all our HART devices from a central position, in the control room, which saves us a great deal of technician time. From a single engineering tool it should be possible to work with all the devices and this is the way we want to go. The use of WirelessHART allows us to monitor devices in areas of the plant that would be too costly to achieve using wired devices, helping us achieve our goal of continuously improving plant productivity.”

Pelz also explained that the plant has a lot of moveable assets, and that WirelessHART technology also makes these devices much easier to handle. He concluded by calling on device ven-dors to make life easier for end users of HART devices such as himself in three particular areas. Simplified and unified device integration software; reduced device complexity for basic func-tionality; and simplified device diagnostics capabilities, in line with NAMUR NE 107. He said: “I feel that there are too many different device integration software tools. It would greatly mini-mize our device integration efforts if we had just one, universal device integration tool for all of our HART devices.” For this rea-son he supports FDI which will standardize all of these methods.

On device complexity Pelz said that the increasing functional-ity being built into devices makes them more complex. “If I need the same information from three different devices from three different vendors, I will need to look in three different places! Life would be easier if HART device vendors were to place all the basic functionality, in the same place and maybe bury all the vendor specific functionality a little deeper into the device.”

Finally, he called for the universal implementation of NAMUR NE 107 guidelines which relate to self-monitoring and standard-ized condensed device diagnosis of field devices, with a series of recommendations on how to present diagnostic data and reduce the number of diagnostic indications from a field device to just a few symbols. These comments confirm that HART tech-nology provides significant value to users by providing device and process information that improves plant productivity.

Vendors respondHART device vendors have responded to these requests in

different ways. John Yingst, product manager at Honeywell, believes device vendors will always want to differentiate them-selves by offering additional capabilities, in spite of requests for greater standardisation and simplicity. However, he says that there are a few developments that could help the end user.

Yingst explained: “Firstly, without changing the devices themselves, more vendors are embracing FDT/DTM technol-ogy as a way to create unique user-friendly interfaces for both maintenance and engineering users. A DTM looks the same in any ‘frame’ or system it is used in which helps the maintenance guy who might have more than one control system in his plant. However, the user has to learn each vendor’s look and feel and I do not see this situation changing.

“Although HART now follows NAMUR NE 107 guidelines, there are still a great deal of devices in the field already in use which do not,” continued Yingst. Honeywell can offer a number of system features and capabilities to help with this problem. Experion Station has the ability to direct device alarms away from the operator console, for example. On the device side, Honeywell uses HART capabilities to display messages from the control room on its SmartLine transmitter graphic display.

Kurt Polzer, business development Wireless Products for Process Automation at Siemens responded: “Siemens supports both EDD/EDDL (Electronic Device Description Language)-based solutions and DTMs-based tools approaches, with a focus on EDD/EDDL technology, because our standard tool Simatic PDM is based on EDDL. To enable the user to operate our devices in an FDT-based tool we have the Sitrans DTM which is a single DTM that manages most of our devices just by using EDDs. However, we always strive to make things easier for our custom-ers and have supported the Field Device Integration (FDI) initia-tive from the outset.”

Further steps being taken by the company to offer easier inte-gration and improved diagnostic capabilities include the introduc-tion of Sitrans Library which offers easy integration of Siemens field devices into its Simatic PCS 7 process control system and the Simatic automation environment. “Because the integration of all field devices into control systems is standardized – with

Three wishes for an easierlife with HART

At Hannover Messe 2013, Michael Pelz, head of process optimization and automationfor Clariant Pigments Business Unit, spoke about his experiences with HARTtechnology, while expressing his hopes for future developments to make the

technology even easier to work with.

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identical function blocks to build up the control strategy and identical faceplates in the HMI for the operator – additional fea-tures which are not supported by the standard are not displayed in the faceplates. Such features and the information provided by them are known as being “stranded in the field.” Users of Sitrans Library have full access to all device features, and faceplates will include both a direct view of all information, diag-nostics and events and direct access to all relevant functions,” said Polzer. “Once initial devices have been added to the Sitrans Library, we will integrate further devices.”

Adherence to NAMUR NE 107Frank Fengler, head of device integration management at ABB

Automation Products GmbH, stated that ABB already adheres to NAMUR NE 107 requirements. “We started this process with the integration of asset management into our systems,” he said. The company’s Asset Optimiser tool, for example, includes an Asset Monitor application that shows all the diagnostic infor-mation of devices in accordance with the NAMUR guidelines. “In addition, this provides a description, possible cause, and suggested actions for each message displayed. Asset monitor is a vendor independent tool that works with all DTM or EDD-enabled devices.”

On device integration software tools, Fengler explained that ABB now has a single integration tool and in the future will also offer an FDI-based solution. The devices themselves will not change, but will simply be given an additional ‘file’ in the driver.

Finally, Fengler mentioned some ABB moves towards reduced device complexity. He said: “ABB can offer its Asset Vision Basics tool as an application with a graphic interface that con-nects directly to a device and brings up the screen needed to configure the most important functions of the device. Further, the ABB pressure transmitter range features a single device file so it is not necessary to search for the correct device driver soft-ware for a particular pressure application.”

Bob Lattimer, senior principal engineer at Emerson Process Management said that Emerson fully supports the provision of NAMUR NE 107. “We have not yet registered any devices, However, NE 107 functionality will be included in all new field devices in the near future – starting in 2014,” he promised.

Emerson is also working hard to provide consistent integration across its product range, ensurig consistent behavior of all devic-es. “The introduction of FDI should remove the configuration inconsistencies that occur in all communication protocols today,” continued Lattimer. “The primary goal for FDI is to ensure good consistency across all host vendors, for any given protocol and it should make device integration easier. Emerson recognizes diag-nostics capabilities as a valuable feature for field devices and we are always innovating in this area, particularly around instrumen-tation. Delta V already includes NE 107 type functionality and our HART devices have had NE107 functionality for several years in the host system. The next step is to move this functionality down to the device to offer higher functioning systems, even when NE107 capability is not built into the host system.”

Vendors will always want to make individual products, but it seems that recognition is now growing in the vendor community that end users want devices to be simpler. The introduction of standards appears to be helping, but this is a sensitive area for vendors who will always want to differentiate themselves with ever more distinctive features and functions.

For Mr. Pelz’s wishes, there are options and solutions available today that fulfill simplified and unified device integration. FDI will standardize and unify device and host integration and is sup-ported by all major field communications organizations.

To improve simplicity in basic functions, in addition to what was mentioned above, HART has Universal and Common Practice Commands that provide the majority of the configuration param-eters needed to commission a device. HART also defines device families (like pressure, temperature, level, etc.) that identify com-mon parameters for devices and standardize the basic functions for each different type of measurement reducing the complexity for the parameterization of basic functions.

Lastly, the simplified or standardized condensed diagnostics as outlined in NE107 is currently available in several HART-enabled applications and more implementations are expected in the future. HART Communication is indeed making life easier!

Suzanne Gill is editor of Control Engineering Europe.


Integrating HART datafrom smart devices

HART calling! Your field devices and actuators want to tell you more ofwhat is happening in the plant, all you have to do is listen.

There is a resource present in your plant that can help facilitate asset management, but if you’re like most companies, you aren’t using it, or you aren’t using it to the extent that you could. That resource is HART Communication, and many, if not most of the field instruments deployed in your process

probably have it. This article will discuss how HART works, and the variety of ways you can integrate HART data from process sensors and actuators in your plant.

Most companies have hand-held communicators that use HART technology, and that becomes the main method for setting up new field devices or changing configuration set-tings in the plant. The underused aspect is the variety of ways that new and installed instruments can communicate with the automation system, delivering the main process variable, additional variables, and diagnostic information. In fact, HART can be the main technical enabler for a device management program.

What HART can doThe information available via HART can tell a great deal

about individual field devices, how they’re performing, and the networks serving them. The diagnostic information can warn

you if there are individual device problems, loop current faults, or if a device needs maintenance. It can help ensure the accuracy of process variable data, that individual instruments are ranged correctly, and if there are deviations between the analog and digital communications.

But beyond diagnostics, HART Communication can also deliver the secondary process variables available on most smart devices already installed in your plant. Any instrument purchased over the last 10+ years is probably ready to send that information if you have the means to integrate it in your control and asset management systems.

Configuring communicationsThere are two methods for transactions between the host

and device. The most common is a master/slave approach where the host requests information from the slave device. The device sends information only when requested by a host such as a DCS, PLC, or asset management system.

HART-enabled devices can also be configured to publish process data in a burst mode. This only works for specific process data commands, but the host can still request other information as needed.

Choosing master-slave or burst will be driven by the needs of the process and criticality of a specific process variable. Each device can use either approach as the situation dictates.

Multi-drop: HART as a fieldbusIn normal applications the primary process variable is

transmitted via the 4-20 mA analog signal, and the additional variables are carried within the superimposed digital informa-tion. This may be the traditional method, but it requires a cable for every device. HART can transmit the primary vari-able with the digital information if desired, making each field device entirely digital.

When using that method, multiple devices can be con-nected via a single cable wired in parallel, similar to a fieldbus, reducing the amount of cabling. Up to 15 devices can be connected on one segment, using a handheld com-municator or PC-based configuration tool to assign the poll address for each. The 4-20 mA signal is fixed at a low value, typically 4 mA, so the loop can carry power to each device. Communication follows a master/slave pattern with the host

TABLE 1: Advantages of HART1. Existing instruments and valves can often be used

2. Existing 4-20 mA wiring can be used

3. Secondary variable information can be used to improve operations

4. Calibration is simplified

5. Instruments and valves can be accessed remotely

6. Certain operations such as valve testing can be per-formed automatically

7. Test and maintenance data can upload automatically to an asset management platform

8. Personnel training is easier than with more sophisticated communication protocols

9. High interoperability eliminates need to depend on one specific manufacturer


polling each device such that it can send process variables and diagnostic information.

This approach does not provide the constant updat-ing of the primary process variable as the normal 4-20 mA loop would, but if a small amount of latency can be tol-erated, it can deliver a cost-effective and reliable stream of process data.

More than one variableMost field instruments

available today are actually multi-variable devices, even if this is not an obvious feature. Pressure sensors, flowmeters, and other instruments gather additional information to cor-rect the primary variable or to monitor another aspect of performance. For example, many types of pressure sensors need temperature data to calculate the pressure value. This temperature or other secondary infor-mation can be sent to the host via HART Communication.

While these secondary variables (SV) might not be used for critical control, they are available and can help fill in gaps of information coverage without additional intrusions into the process or buying more hardware. A typical use case example is ensuring that a device is not frozen or overheated. Many host systems can be set up to access this data, with the best way being natively HART-enabled I/O at the host system.

This method allows delivery of information easily and as quickly as possible with effortless integration to control and maintenance platforms. All variables are available from every device using a minimum of cabling and hardware. Unfortunately, many systems running in process plants were installed before HART-enabled I/O cards were common, so finding smart devices deployed in conventional 4-20 mA I/O card situations is typical. Users and system vendors have cre-ated many work-around approaches to fill this gap.

Loop convertersA HART loop converter is an individual modem that can

read the HART data lifted off an individual 4-20 mA loop. Loop converters are typically designed to access a secondary pro-cess variable and convert the digital signal representing this variable to an additional 4-20 mA signal.

Such a unit can send the signal to a larger automation system, and/or convert the data and display it in appropriate engineering units. Depending on the sophistication of the device, it can be programmed with relay outputs for alarms or other functions.

Individual converters are useful when a small group of devices need to be addressed, but when larger numbers are required, there are better ways to deal with the situation.

MultiplexersFor an installation where a user wants to extract HART

data from a large number of field devices but there are no native HART I/O cards installed in the process automation system, the typical approach is to use a HART multiplexer. These systems come in a variety of configurations and from a variety of manufacturers, but they have some basic charac-teristics that are common.

Multiplexers contain multiple HART modems that are ganged together such that they can extract and convert the digital data from a device while not interfering with the normal 4-20 mA loop signal. The I/O of the existing host device does not see a difference in the 4-20 mA signal, and it can continue to control and monitor the process just as it always has.

This approach is typically retrofitted to an existing control system and field wiring. The multiplexer takes the information from however many devices it handles, and typically sends the data to some sort of asset management system via an RS485 serial bus, Modbus TCP, Ethernet link, or the new HART-IP. Communication is bi-directional so the asset manage-ment system can both read information from a field device and remotely access and read its configuration.

The downside of working with multiplexers is that they can be complicated to install, since each individual field device needs to be connected. This effect can be minimized by mak-ing connections where the cables have already been brought together in one place like marshaling cabinets. Latency is also

Figure 1. HART Communication provides a means to access digital data superimposed on exist-ing 4-20 mA wiring, making it a low cost fieldbus option. Courtesy: Yokogawa


a factor since multiple inputs have to share one HART modem for given number of inputs. With careful planning and network management, multiplexers can still be a very effective and economical way to handle large deployments.

WirelessHARTAnother solution that uses the HART Protocol is

WirelessHART. Using a simple, reliable and secure mesh net-work, WirelessHART can be viewed as a remote I/O system. Using mesh network technology multiple devices communi-cate to a gateway that collects all of the process and device diagnostics information and communicates it to a control, asset management or other host system via HART-IP, Modbus TCP, RS485 or others. WirelessHART can be a cost-effective solution for adding new measurements to an existing plant or accessing HART information from existing devices. Typical applications include tank farm monitoring, pipelines, rotating or moving assets, etc.

Many field instruments are now available as native wire-less devices, or a wireless adapter can be added to a wired device. Adapters can use the same communication method as a native WirelessHART device.

HART-IPThe latest enhancement to the HART Protocol, HART-IP,

defines a standard solution to gain high-speed access to HART device diagnostics and process measurements using a plant’s installed networking infrastructure. HART-IP offers the most straightforward way to access all the standard HART information available in a HART device. It allows the informa-tion from these devices to be brought up to the Ethernet

level easily, without the need to go through any translation processes and with no loss of information. HART-IP can be used for the integration of device information from mul-tiplexer, remote I/O and WirelessHART. When used with WirelessHART, it provides a very cost-effective solution to access measurement information from anywhere in the plant or the enterprise.

Handhelds and single modemsIn many situations, a maintenance person or instrumenta-

tion engineer may need to configure or check the diagnostic information from an individual field device. There are many types of single HART modems and handheld communicators that can provide an interface easily and inexpensively. Such devices are not limited by manufacturer and can communicate with any instrument or actuator, thanks to the interoperability built into the HART Protocol.

Small single modems can be inserted into a loop whenever needed in the plant or maintenance shop. Such devices can communicate with a laptop or other host system using USB, RS232, or even Bluetooth wireless when a configuration or asset management application is installed.

Today’s handheld communicators and calibration tools are hugely versatile and can contain device descriptors for hun-dreds of devices. The maintenance technician can connect the unit to a field device and it can call up the relevant informa-tion from its memory. If necessary, the configuration can be changed or the diagnostic data retained for downloading back at the maintenance shop.

While these individual communication devices can be very useful, they have the inescapable limitation that they require a technician to be involved and can only communicate with one device at a time. By contrast, a fully HART-enabled I/O system can perform all of the above functions on any HART-enabled field instrument or actuator at any time from the control room or maintenance shop.

Work practices:Commissioning and maintenance

When new field devices are going to be installed or brought in for maintenance in the shop, HART Communication can be the means to get them configured properly and tested before returning to operation. The abil-ity to check and verify performance before installation can save an enormous amount of time compared to installing and then removing sensors that aren’t ready for use. During the commission phase of a project, HART information can be used to reduce the commissioning time.

Once a new device has had its HART tag name assigned and ranged for that application in the process, it can be ready for the next round of checks where HART information can be provide ease during the checks:

� Verification of the device’s location, physically and I/O;� Calibration;� Configuration and loop check;

Figure 2. Pressure sensors, flowmeters, and other instruments usu-ally gather other information in addition to the primary variable that can be useful to the process. These secondary variables can be accessed with HART. Courtesy: Monsanto Muscatine

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� Alarm and interlock validation; and,� Online operation validation.

Similarly, field instruments and smart valve controllers/positioners can be checked in the shop before returning to operation. A well-developed maintenance program can prescribe a routine of tests tailored to an individual device or group via HART communication to check what-ever attributes are most critical. Working through this procedure avoids problems and helps train new technicians.

Once back in place, transmitters and valves can be given final verification before resuming the process. Or, tests can be performed in-situ rather than in the shop. HART can help test a variety of critical attributes, including:

� Verify proper tag and location;� Verify wiring and power supply;� Check signal integrity and grounding;� Re-zero, check range and span cali-

bration;� Verify analog trim for DCS output;� Send simulated process variable to verify DCS reading;� Capture new valve signature for baseline;� Set alarms and security configuration; and,� Configure and calibrate additional process variables.

Many device management platforms can record and catalog the results of these tests and adjustments for maintenance recordkeeping.

Work practices: Partial-stroke valve testingIn a plant that is performing well, emergency shutdown

(ESD) valves may go for years without having to perform their function. While avoiding upsets and accidents is a good thing, safety protocols require that ESD valves be tested to verify that they still work properly. Valves that aren’t operated regularly can fail when called upon due to excessive stem friction, packing problems, air pressure leakage, or other maintenance issues.

ESD valve testing using a full-stroke test (FST) is prob-lematic since cycling these valves can interfere with pro-duction. Safety protocols therefore make provisions for partial-stroke testing (PST) of ESD valves in many situations in a way that verifies their performance while minimizing operational disruptions.

Companies that use this technique perform PSTs at regu-lar intervals, allowing for less frequent FSTs. The ways in which ESD valve testing fits into a larger safety program is beyond the scope of this discussion, but once the protocols are established and approved for a given plant, HART-enabled valve positioners and controllers makes PSTs easier to per-form and document.

An asset management program can automate the mechan-

ics of PST programs, performing the tests and gathering diag-nostic information via HART via this straightforward method:

� Valves are categorized into device groups;� Program sets schedules in keeping with larger safety sys-

tem requirements; and,� Program retains historical data from each test, allowing

identification of trends that may indicate developing main-tenance problems.

Your next stepHopefully this discussion has convinced you that there

are many ways in which HART Communication can support improved plant performance and asset management. The most difficult step is often making the effort to put it to work. There are many stories of companies that have done it suc-cessfully and enjoyed the benefits of higher production and reduced maintenance costs, but implementation requires procedural and often cultural changes among your production, reliability, and maintenance teams.

HART may not deliver all the performance of an advanced fieldbus such as Foundation fieldbus or Profibus PA, but it is much less expensive to implement as it often can use exist-ing instruments and valves.

The issues are not technical since hardware and software solutions are readily available. Often a successful HART-enabled maintenance program can trace its origin to a single enthusiastic individual that emerged as a champion, leading the company into a new period of improved performance and reduced costs.

Amit Ajmeri, is a consultant for wireless and field network technology at Yokogawa Corporation of America.

Figure 3. Native HART-enabled I/O (left field control unit) gathers HART information seamlessly. In systems where HART I/O isn’t available, multiplexers can gather infor-mation and send it to an asset management system without interfering with the exist-ing I/O flow (right control unit). Courtesy Yokogawa

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Working all the time...so you don’t have to.HART Communication is working – 24/7 – to identify problems for corrective action to avoid a potential plant shutdown – and help you move from scheduled to predictive maintenance. For maximum benefit your plant control, safety and asset management systems should “get connected” to continuously communicate with HART-enabled devices and unlock their real-time diagnostics and intelligent capabilities.

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www.controleng.com ● CONTROL ENGINEERING APRIL 2014 ● M1

Machinery original equipment manufacturers (OEMs) are starting to incorporate the intu-itive multi-touch display func-tionality well known by many

who have grown accustomed to using smart-phones and tablets. Multi-touch technology for computer touchscreens has become so pervasive that it’s not uncommon for children to know how to play a game of Angry Birds (by Rovio Enter-tainment) about the same time they learn to talk. With this type of interface common in our every-day lives, it has also begun to shape the expec-tations of users of industrial human machine interface (HMI) technology. Long before the first tablet reached consumer hands, Edson Packag-ing, based in Hamilton, Ontario, had been inte-grating new enabling technologies into case packing machinery for a wide range of industries, especially for tissue products.

Edson continued that trend with the introduction of multi-touch enabled case packing machinery.

A 2012 acquisition by Pro Mach provided a new business structure at Edson Packaging, which offered more resources for initiatives such as lean manufacturing and other initiatives to advance packaging technology.

“When we were a privately owned compa-ny, we invested 3% to 5% of our revenue into R&D, which certainly was quite good,” recalled Brianne Moar, sales and marketing, Edson Pack-aging. “Since becoming a part of Pro Mach, we now invest significantly more revenue into R&D, bolstering our competitive advantage in the pack-aging industry.”

Multi-touch helps machine operatorsAfter intense R&D efforts and attention to

customer feedback, the company introduced the Edson Packaging InteleSuite, a range of

enabling solutions that promotes connected machinery in the pack-aging industry. Early innovations include Edson Packaging Intele-Link, a solution based on near field communication (NFC) technology. InteleLink provides instant transfer of information through radio fre-

quencies, similar to “tap to pay” chips integrat-ed into some credit cards. This feature provides instant access to videos, PDF files, images, and links to blogs, and enables directs phone calls to Edson Packaging support. Users simply tap an NFC-enabled phone or tablet and the requested information is instantly transferred to the device.

Another part of the InteleSuite is Edson Pack-aging InteleTül, a radio frequency identification (RFID) tracking system for change part tools. InteleTül verifies that the right tooling is placed on the machine, which avoids costly equipment collisions that could damage the machine and cause downtime for several hours or days.

Packaging OEM offersmulti-touch enabled machinesEdson Packaging, a manufacturer of case packing machinery, turns the pageto a new era of multi-touch enabled machinery, putting an industrial spin on oneof the most popular consumer electronics technologies.

Figure 1: Now part of the Pro Mach consortium of packag-ing machine builders, Edson Packaging invests a significant portion of company revenue toward initiatives, such as lean manufacturing and other innovative solutions to drive packaging technology forward. Photos courtesy of Canadian Packaging magazine, 2013

inside machines

KeyconceptsMulti-touch human machine interfaces helpa machine builder to:

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Also in the InteleSuite is the Edson Packaging InteleVüe, introduced on an Edson SR3550 high-speed horizon-tal case packer machine at the Pack Expo 2013 trade show in Las Vegas. InteleVüe is a multi-touch enabled packaging machine interface that uses a 24-in. multi-touch control panel and indus-trial PC (IPC). The Edson Packaging machine can

store many file types that can be enlarged with typical multi-touch gestures such as zooming, scrolling, flicking, and others. In addition, videos for setup, training, tutorials, and troubleshooting can be stored. Implementation of live video feeds that display and record machine processes also is possible.

The IPC has a third generation Intel Core i7 processor (2.3 GHz, 4 cores) and is designed to match the vibrations specifications and operat-ing temperature requirements for Edson Pack-aging machinery. The compact design is sleek and saves cabinet space. Edson uses a 64 GB solid-state drive for stability and reliability, and 15 to 25 times more storage capacity than the prior solution.

Zooming in on new HMI functionalityEdson Packaging began its InteleVüe initia-

tive to use multi-touch technology shortly after Hannover Fair 2013.

Jeff Werner, Edson vice president of tech-nology, said, “New multi-touch technology for industrial applications stood out. We rec-ognized early on that multi-touch technology that enables useful and compelling new features would become a big selling point for our cus-tomers,” Werner explained.

“We always strive to expand machine inter-face capability and utilize the latest technolo-gies that most people have grown accustomed to. So Edson asked, ‘why can’t you use func-tions commonly used on tablets and smart-phones on your capital equipment?’ The answer today, obviously, is that you can. Still, Edson is early to the game so our customers enjoy a sig-nificant edge with these features that most other machine builders are not providing yet.”

InteleVüe’s ability to easily integrate video and all kinds of machine data on the multi-touch HMI became very important for Edson. Increased resolution “enables us to put mean-ingful trend data up on the screen,” Werner explained.

“Instead of seeing square waves, we actu-ally see curves and much improved trend data. Edson has also created incredible value through the ability to integrate rich multimedia for train-ing, tutorial, and troubleshooting purposes—none of that was possible with the previous...HMI hardware.

“Also, five-finger multi-touch can boost func-tionality and give us the ability to create useful features such as rotary dials for jogging servo

inside machines

Figure 2: Five-finger multi-touch on the Beckhoff Automation CP3924 can boost functionality and give Edson Packaging the ability to create useful features such as rotary dials for jogging servo axes, fine-tuning speeds, and other functions. Photos courtesy of Canadian Packaging magazine, 2013

Figure 4: A standard webcam is used on the Edson Packaging InteleVüe system to deliver live video feeds on the Beckhoff Automation CP3924 multi-touch Control Panel.

Figure 3: Edson Packaging has delivered the capabil-ity to use typical multi-touch gestures such as zooming, scrolling, flicking, and others. Videos for set up, training, tutorials, and troubleshooting can be stored and live video feeds can display processes within the machinery.

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axes, fine tuning speeds, etc. Another possibil-ity is to include two-handed confirmation on the screen,” Werner explained. The elegant con-struction and design of the control panels was another key consideration for Edson: “We and our customers appreciate a very slim and sleek-looking display. The fact that we could select a 24-in. multi-touch screen also provided a much larger display area than we typically would have through any of the traditional single-touch HMI screens. There is simply no contest when com-paring the two panel types.”

Multi-touch reduces risk for operatorsNot only has Edson Packaging increased user

functionality and access to machine data with InteleVüe and multi-touch technology, the com-pany has improved operator safety. The need for operators to go inside the machine for change-overs and maintenance has been drastically reduced because of the amount of information available from the control panel/IPC when paired with a web cam or high-speed camera. For exam-ple, when plant personnel are troubleshooting or setting up for a new product that has never been manufactured before, they can see the machine process safely from the outside by viewing on the control panel.

In terms of viewing angles, Edson can imple-ment the control panel on a swing arm that piv-ots around a central point, but some machines, such as the one demonstrated at Pack Expo 2013, can feature a linear rail system for the display to glide it back and forth. This mechanical add-on

permits full travel of the control panel down one side of the machine with an approximate 10 ft travel range. This provides enhanced functional-ity, more flexible positioning of the HMI, and a clearer view of the display as machine operators perform setup routines.

“This translates to far fewer instances of the operator needing to be within a hazard zone,” Werner reported. “This is very important because every single time an operator must enter the machine to verify product position, high-volt-age power to the servo motors must be turned off. Servos have an expected life cycle of a cer-tain number of power-up and shutdown sequenc-es. If the operator can view the inside of the machine without having to go through the guard equipment and power down the servos, it trans-lates into fewer power cycles and higher life expectancy for numerous components,” Werner said. Because of the control panel video feed, “required power cycles to the safety circuit have decreased by at least 25%.”

While Edson Packaging has enjoyed imme-diate positive results with InteleVüe, including very tangible ones by using multi-touch technol-ogy, the company marches on in modernizing the technology on its machines.

“We will continue developing and improv-ing our InteleSuite offering, including many new installations and even retrofits,” using a 24-in. multi touch control panel, Werner said.

Additional automation innovations may be incorporated into the new top load Edson Packaging Raptor case packing machine,he suggested. ce

- Shane Novacek is marketing communica-tions manager, Beckhoff Automation. Edited by Mark T. Hoske, content manager, CFE Media, Control Engineering, [email protected].

inside machines

www.controleng.com/archive April has additional informa-tion, photos, and a link to product-specific details.www.edson.com www.beckhoff.ca

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Consider this...How could multi-touch technologies help your installed base?

Figure 5: The major Edson Packaging InteleSuite innovation for human machine interfaces (HMIs) is Edson Packaging InteleVüe, which uses a CP3924 multi-touch Control Panel from Beckhoff Automation. InteleVüe was introduced on an Edson SR3550 high-speed horizontal case packer at the Pack Expo 2013 trade show in Las Vegas. Photos courtesy of Canadian Packaging magazine, 2013

Figure 6: Another InteleSuite innovation is InteleLink, a solution based on Near Field Com-munication (NFC) technology, to access related assets, such as video, manual, and email contact with a smartphone or tablet.

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inside machines

More end users are asking for robots, motion controllers, and programmable logic controllers (PLCs) to be programmed in familiar PLC languages, which

are easier for machine builder programmers to understand, and for end users’ service personnel to maintain. To reduce the complexity and har-monize the look, feel, and function of three sepa-rate platforms, the PLCopen working group for motion control has come up with a set of stan-dardized tools to allow coordinated motion to be run directly from a PLC-like programming environment.

Traditionally, industrial robots have been pro-grammed in complex proprietary languages that are difficult for anyone but robot programmers to understand. Motion controllers are wide and varied, and are usually programmed using a PC library or another proprietary language, while PLCs tend to be programmed in ladder logic. In today’s automation environment, PLCs, motion controllers, and robots must be tightly integrated. Many elements are incorporated into the machine design with each requiring the programming strengths exhibited by a proprietary language.

PLC programmingSince their inception in 1968 through a

request by General Motors (to come up with a way to replace hardwired relays), PLCs have been programmed in ladder logic. They can eas-ily control processes that require digital and ana-log devices, but more complex processes that are sequential in nature are more difficult than they would be in programming languages such as BASIC, C, or C#. PLCs have evolved to include programming in BASIC or C, but most still rely

on ladder logic [among the IEC 61131-3 pro-gramming languages].

Many low-end PLCs support motion control via step and direction outputs. Some higher level motion control can be achieved through expen-sive dedicated modules that must be added to the basic system. Even though most devices are pro-grammed in ladder logic, most require an intimate knowledge of the programming environment, which changes from manufacture to manufac-ture, and their higher level functions are usually achieved through specialized function blocks.

Motion controllersMotion controllers for the general market typ-

ically include interpolated motion (linear and cir-cular), coordinated motion, gearing, camming, and event triggered motion (where a sensor and position latch are used). Older controllers used dedicated inputs and outputs per axis. Motion inputs such as enable, over travel limits, and encoder inputs (one or two per axis) and motion outputs like servo command (normally +/- 10 V analog) and/or stepper command (step and direction) were provided. Most controllers also have some general purpose I/O capability. New controllers rely on digital networks like Ether-CAT [EtherCAT Technology Group] or Mecha-trolink [Mechatrolink Members Association] to pass control signals to the drives and receive and transmit the digital IO connection, which is wired directly to the drive.

When dealing with the motion on linked axes, the typical motion controller cannot compete with robot controllers. With typical motion controllers, if the end effector had to move to a specific point, it was necessary to figure out the correct positions for each of the axes. Inverse kinematics is needed

PLCopen part 4 blurs the lines among PLCs, robotic, and motion controlThe PLCopen working group for motion control has standardized and logicallydefined all aspects of machine control programming, providing one of the best attemptsof integrating PLC, robot, and motion control in an easy-to-understand languagecommon among many manufacturers.

Keyconcepts� PLCopen motion stan-dard part four contains function blocks for coordi-nated motion.

� The standard integrates PLC, robot, and motion control in an easy-to-understand language common among many manufacturers.

� When automation ven-dors support the standard, the programmer is free from learning proprietary languages associated with each manufacturer.


for robots and other machines with mechanically linked mechanisms. The use of inverse kinematics requires formulas to translate the specific point in world space to the individual positions that each joint (or axis) needs to be at to move the mechan-ically connected mechanisms to the end point. Again, as these systems are wide and varied, most require an intimate knowledge of a specific pro-gramming environment.

Robotic controllersRobot controllers have been engineered to

achieve the best control of specific complex mechanisms. Most controllers are manufactured for a specific device and are programmed in a specialized language created by the manufac-turer that varies greatly from platform to plat-form. Robot controllers are very efficient when controlling the library of devices for which they were designed; however, most are not the best in terms of communications, integration, or pro-gramming power.

In the past, often only the dedicated robot controllers supported kinematics and inverse kinematics. Now, it’s a lot more common for many motion controllers to offers some subset

of robot-type commands, especially in control-lers targeted for packaging automation. The lines are being blurred between robot controllers and motion controllers, but it is still up to the pro-grammer to coordinate between these different systems, with each programmed in a different language usually designed for a specific purpose.

PLC and motion togetherThe PLCopen working group for motion con-

trol has standardized and logically defined all aspects of machine control programming. This is one of the best attempts of marrying PLC, robot, and motion control in one easy-to-under-stand language that is common among many manufacturers.

Many of the function blocks are basic; for example, relative and absolute moves are func-tion blocks which are easily understood in any motion control system. The standardization and common look and feel of multiple control sys-tems is an advantage when the difficulty of the required motion increases.

For example, it is easy to string relative or absolute moves together when each individ-ual move stops before the next move begins. But imagine a more complex set of movements where the axis is required to transition to the next move at some nonzero velocity, blend-ing the individual moves into one fluid motion throughout the entire path of the axis. PLCopen Motion Control defines standard blending oper-ations to allow the programmer to achieve this fluid motion with common blending and transi-tion modes that a manufacturer can implement.

One of the basic issues when moving mul-tiple axes together with a mathematical model that controls mechanically linked axes, is that it is not always clear which axes are critical to move in synchronization. So when a fault occurs, the motion controller cannot always tell which other axes are affected. PLCopen addresses this by defining a motion group, so that the control-ler can generate a proper error response when one of the grouped axes has an error. This group-ing concept allows the programmer freedom to concentrate on the specific task required of the machine and have the controller take care of the function of the group through implementation of the group state machine shown in the diagram.

The PLCopen motion standard includes part four, which contains function blocks for coordi-nated motion. They define a standardized set of function blocks for the complex control of move-ment within 3D space that includes blocks for kinematic transformations. Typically, these trans-formations have to be supplied by the vendor, so for most manufacturers, if the motion controller

inside machines

The PLCopen motion standard includes part four, which contains function blocks for coordinated motion, integrating PLC, robot, and motion control in an easy-to-understand language common among many manufacturers. The function blocks include kinematic transformations. Typically, such transforma-tions have to be supplied by the vendor, so for most manufacturers, if the motion controller doesn’t support it, it cannot be added. Mechanisms like SCARA and delta are supported, but in addition to these, any programmer is allowed to write kinematic transforms. Yaskawa provides specialized functions used to call these kinematic routines whenever a world position needs to be converted into joint space, or vice versa. Courtesy: Yaskawa America Inc.

PLCopen motion standard hasmotion function blocks.

‘The PLCopen motion standard contains function

blocks for coordinated motion.’

inside machines

doesn’t support it, it cannot be added. There are the basic supported mechanisms

like SCARA and delta, but in addition to these, any programmer is allowed to write his own kinematic transformations. Specialized functions are available to call these kinematic routines whenever a world position needs to be converted into joint space, or vice versa.

This standard is now creating a bridge between the once separate worlds of PLCs, com-puter numerical controls (CNCs), robotics, and motion. It is now possible to program the com-plete control of the machine from one PLC-like system. This standard has allowed robots and motion controllers to become integral parts of a control system, rather than independent sys-tems. They integrate motion control and logic control, the two primary requirements for mod-ern machine control. There are definitive advan-tages to having motion control and logic control in the one package, including, but not limited to, practically unlimited exchange of data between the logic and motion engines, without the laten-cy, which can limit performance in traditional systems. In fact, it is now possible to perform perfect synchronization between a robot and

additional servo axes using a machine control-ler, a feat which was previously possible purely in the robot controller domain.

Programming independenceUltimately, the goal of the PLCopen stan-

dard is to allow the program code to be com-pletely independent of the hardware or specific manufacturer. When different hardware ven-dors support the same underlying code, and behave in the same manner, the programmer is free from learning proprietary languages asso-ciated with each manufacturer. This results in allowing complex complete machine control systems with improved accuracy and through-put to be developed in a shorter time to mar-ket. PLCopen has allowed this development by reducing engineering complexity and the spe-cialized training required so that the overall system is more familiar to wide array of exist-ing PLC programmers. ce

- Jamie Solt is senior motion product engi-neer at Yaskawa America Inc. Edited by Mark T. Hoske, content manager, CFE Media, Control Engineering, [email protected].

www.controleng.com/archives April has more information and links to related articles.

www.ethercat.org

www.mechatrolink.org

www.plcopen.org

www.yaskawa.com

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Consider this...Can this standard make software interoperate with any hardware used for motion control?

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Modulation can increase active sampling time by opposite volt-age vector insertion. In motor control applications, the pro-posed method increases time

suitable for sampling of analog values.While examples show modulation for brush-

less dc (BLDC) electric motors, modulation can be used in other applications. Options for back electromotive force (BEMF) sensing depend on modulation techniques, and there advantages and disadvantages. Measurements examples are pro-vided on a BLDC motor, and an implementation of a GTM (general timer module) for SPC57xP-WT microcontrollers is provided.

Pulse width modulation, samplingAnalog values typically are sampled in spe-

cific time, synchronized with PWM to exclude sampling during ringing. Ringing is a transient state after the power switches to commutation. Depending on the application and type of sam-pled values, the sampling could be done during off-time or during on-time. The time required for ADC sampling limits duty-cycle range, which could limit motor speed. During motor free-wheeling, less BEMF may occur.

Such modulation can insert an opposite volt-age vector for the minimal required on-time overvoltage range. The proposed method does not affect unipolar modulation at high speed, and reduces EMC compared to bipolar modulation. The modulation also is suitable for dual motor control, where current sourced from the capaci-tor could be suppressed by opposite current from the second motor with shifted PWM.

Pulse width modulation,active time extension

The PWM (pulse width modulation) is designed to ensure sufficient active time for BEMF sampling in BLDC motor control appli-cations. The equal distribution of switching and conductive losses over all transistors also is con-sidered. The BEMF is sampled in the unpowered

phase where the other two phases can be sup-plied (sampling in active time / on-time) or con-nected to same terminal (sampling in off-time). The sampling in off-time is typically more sensi-tive, but the half of BEMF period (typically neg-ative) is cut by bridge diodes. When the BEMF is sampled during active time, the motor node is in half of supply voltage. The trend of BEMF can be observed in both polarities.

For low duty-cycle, the active time can be shorter than the time required for BEMF sam-pling for unipolar modulation. The minimum required time is given by ADC sample/conver-sion time, number of consecutive measurements, and time of transient rippling after switches com-mutation. Rippling time depends on motor con-struction and power stage design. Any design asymmetry and parasitic impedance should be minimized to reduce the rippling time. Minimum voltage will be limited for unipolar modulation.

This limitation does not occur for bipolar modulation, where the second phase is switched complementary to the first phase. In this case the

Increase sampling timefor motor controlPulse width modulation (PWM) using opposite voltage vector can extend time for analog dc (ADC) sampling in motor control applications.

Figure 1: Pulse width modulation (PWM) using opposite voltage vector can extend the time for analog dc (ADC) sampling in motor control applications. All graphics and tables courtesy: STMicroelectronics

inside machines

Keyconcepts� Pulse width modulation (PWM) using opposite voltage vector can extend time for analog dc (ADC) sampling in motor control applications.

� Insertion of the oppo-site vector ensures the required active time to measure needed analog values.

� Modulation slightly increases current rippling compared to unipolar modulation, but the cur-rent rippling and losses are less than in standard bipolar modulation.


average voltage is zero for 50% duty-cycle. The main disadvantage of bipolar modulation is high current rippling and higher switching losses.

The proposed PWM extends the active time in unipolar modulation to the required width (see Figure 1). The pulse width extension is compen-sated by the opposite voltage vector. Inserting the opposite voltage vector doubles the switching frequency. In this case the switching losses are doubled. Because the opposite vector insertion is needed only for low speed where the conductive

losses are typically low, the maximum power dis-sipation of transistors is not increased. The need for the active time extension should not occur even in the application, where the high current is expected also during low speed. The required voltage is higher in this case due to compensa-tion of voltage drop on winding resistance.

The alternate PWM generation could be used to exclude a short time between the tran-sistor switches (see alternative phase A and B in Figure 1). This could be required by transistors for switching losses diversion. The disadvan-tage of this modulation is more complex gen-eration mainly in transient between generation with compensation pulse and without compensa-tion pulse. There are two possibilities for solv-ing the transient state. The first is to continue with phase shifting. The second possibility is to reduce frequency to half as soon as the negative pulse reaches zero width. In this case the motor voltage UAB will be the same as in Figure 1, but the handling of the modulation is more complex. The PWM frequency also is doubled by inserting the opposite voltage vector, as Figure 1 shows.

Read this article online for more about gen-eration of PWM by GTM, compare value cal-culations, and measured results for the opposite vector. ce

- Jiri Ryba, PhD, is field applications engi-neer, STMicroelectronics.

inside machines

www.controleng.com/archives April: the posted version has more information and links to related articles.

www.st.com

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Figure 3 shows the motor current when an opposite vector is inserted.C1 – PWM top transistor; C2 – PWM bottom transistor; C3 – phase-to-phase voltage; and C4 – current.

Figure 2: In this PWM graph, the following abbreviations apply. TFPOFF - Switch OFF first event time, positive phaseTFPON - Switch ON first event time, positive phaseTRPON - Switch ON second event time, positive phaseTRPOFF - Switch OFF second event time, positive phaseTFNON - Switch ON first event time, negative phaseTFNOFF - Switch OFF first event time, negative phaseTRNOFF - Switch OFF second event time, negative phaseTRNON - Switch ON second event time, negative phase The formulas are valid for the voltage vector

where the first phase (A) is positive, second phase (B) is negative, and third phase (C) is off. The other vectors are generated in same way, but the phases are changed accordingly. The input is required duty-cycle.

Table: Phase stateVoltage Vector Phase State

0 (330°el)

A Positive

B Negative

C OFF

1 (30°el)

A Positive

B OFF

C Negative

2 (90°el)

A OFF

B Positive

C Negative

3 (150°el)

A Negative

B Positive

C OFF

4 (210°el)

A Negative

B OFF

C Positive

5 (270°el)

A OFF

B Negative

C Positive

Control Engineering is the leader in connecting the global industrial engineering audience through coverage of and education about automation, control, and instrumentation technologies in a regionally focused, actionable manner through online and print media and in-person events.

ControlEng.com: Visit www.controleng.com for the information you want in the format of your choice, including: articles, podcasts, webcasts, videos, etc. Industry channels provide quick access to focused content on key industries and related technologies.• System Integration • Information Control • Process Control• Machine Control • Sustainable Engineering

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WWW.CONTROLENG.COM SUPPLEMENT TO CONTROL ENGINEERING

IEM1

If you’ve ever been chargedwith bringing fundamental change to an organization, you know that one of two scenarios typically play out in the early stages of the transformation:

� The people you’re working with resist change, and you have to work extra hard to show them the bene� ts of doing things differ-ently, or

� You have a group that’s hungry for change and your efforts pro-duce a quick payback.

Even if you’re lucky enough to en-counter the second scenario, it’s only a matter of time before your organization-al makeover hits a wall. That’s when you discover that even when positive results come quickly, it’s dif� cult to sus-tain that momentum over time.

Many people responsible for im-proving the energy ef� ciency of manu-facturing organizations have reached that stage. To move forward, they must see energy in a different light.

This supplement to Control Engi-neering magazine highlights individuals and organizations doing just that.

Asset managementas energy saver

It starts with the cover story that explains how intelligent use of control technology can do more than keep pro-duction equipment running smoothly. It also can maximize a plant’s energy ef� ciency by, among other things, mak-ing sure equipment runs only when it’s needed to support plant operations.

Our second article explores ad-vances in remote machine manage-ment, speci� cally emerging off-the-

shelf solutions that are easy to install. These solutions ease asset management by offering near-immediate problem di-agnosis without human intervention.

Ultimately, this type of mainte-nance prevents machines, and their associated parts, from deteriorating to the point that just continuing to work causes them to consume extra energy.

Taking solar powerto Wall Street

Finally, we look at a new � nancing method that promises to accelerate the pace at which solar power becomes a mainstream source of electricity. The idea is to bundle groups of solar power purchase agreements into � nancial in-struments that can be sold to inves-tors, much like corporate bonds.

Our article includes an interview with the chairman of the SunSpec Al-liance, which has become the primary developer of technical standards for the solar industry, and is now working to create standards for the solar secu-ritization market.

We’re all about uncovering new methods for improving performance

INTRODUCTION

IndustrialEnergyManagement

Sidney Hill, Jr., is a CFE Media contributing content specialist.Send comments to [email protected].

Intelligent use of control technology can do more than keep production equipment running smoothly. It also can maximize a plant’s energy ef� ciency by, among other things, making sure equipment runs only when it’s needed to support plant operations.

All other brands and product names may be the trademarks or service marks of their respective owners.

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IEM2 IndustrialEnergyManagement

THERE’S WIDESPREAD EVIDENCE—in the form of numerous analyst reports, articles, and case studies—that industrial companies have made great strides at be-coming more energy ef� cient in recent years.

There’s also ample evidence that there’s still much room for improvement.

The manner in which most manufacturers approach energy management remains the greatest barrier to maxi-mizing energy ef� ciency. The typical approach is to launch one or more small projects that produce a quick—and sometimes even substantial—return on a relatively small investment.

However, once these quick-ROI projects are complet-ed, manufacturers often have trouble � nding additional ways of improving energy ef� ciency.

Often, this is because management doesn’t believe en-ergy management projects can have the same impact on the corporate bottom line as � nely tuned production pro-cesses or well-orchestrated customer acquisition strategies.

This belief also stems from the way most industrial companies approach energy management. Experience has shown that energy performance gains from various one-off energy management projects do not deliver sus-tained energy performance improvements, particularly if those projects are not monitored and adjusted in a con-tinuous manner.

To ensure sustained energy performance gains, energy should not be considered a � xed operational expense. It must be managed just as carefully as production, quality, and safety. To do so requires the collecting of quanti� able energy performance data.

In a 2012 global survey conducted by Deloitte LLP, only 12% of chief � nancial of� cers chose the word “excel-lent” when asked to rate the quality of the sustainability data they normally receive. Industrial companies could bene� t from the implementation of data-driven business practices that will result in continual energy performance improvements.

Key energy-performance indicatorsThe best approach to reducing your energy ex-

pense and use is to take a holistic view of your energy portfolio. This is typically best done by having an independent energy-engineering firm review your en-ergy portfolio. The energy-engineering firm will want to review all of your facilities and determine the key

New approaches toasset management yieldbig energy savingsIntelligent use of control systems can maximize the energy ef� ciency of industrial equipment by, among other things, making sure equipment runs only when needed to support plant operations.

All graphics courtesy: Kaeser Compressors


energy performance indicators (KEPIs) that drive en-ergy use. These KEPIs may be different at each facility depending on what industrial process is performed at each facility.

Each facility should have accurate energy cost and use data for each commodity that is utilized at the facility. This information will determine which fa-cility should be addressed first. Typically, one would start where both use and cost are the highest, which leads to energy projects that will yield the largest sav-ing opportunities in the least amount of time.

Once a facility has been identified as a viable can-didate for an energy management project, the follow-ing steps can be taken:

� A preliminary facility assessment to determine en-ergy-saving opportunities

� Energy project development with associated return on investment calculations

� Project approval and funding� Project implementation� Project measurement and veri� cation.

The controls arena offers many opportunities for reducing energy consumption in industrial facilities. These opportunities cover typical major pieces of equip-ment that exist in various industrial environments.

A master system controller can be used to stage multiple compressors in complex systems. Strategic pressure sensors are deployed in the distribution head-ers and used to provide feedback to the control system. The pressure readings, along with the rate of change of the pressure readings, are used to select which compres-

sors should run to meet the load and, in some cases, what the loading should be on the compressors.

The same concept of properly controlling multiple air compressors can be carried over to other compres-sor applications. These include chillers and refrigeration compressors. In all of these cases, a master system controller can maxi-mize the ef� ciency of the units by minimizing the number of partially loaded compressors.

Holistic view to energy management

Industrial companies should be at the forefront of the energy ef� -ciency movement, since this sector outpaces most others when it comes to energy consumption. Motors con-sume roughly 65% of industrial elec-tricity in the U.S., yet only 10% of these applications have an ef� cient method of keeping motor speeds in sync with process demand. In the production environment, there are signi� cant savings and bene� ts to be gained through effective energy man-agement of motors and production equipment.

Understanding the facility’s total energy usage over time—knowing why energy is used and how that con-sumption impacts overall operating costs—is critical to implementing a plan that will result in true cost savings. Energy improvement initiatives, when properly execut-ed, can easily yield a 15% reduction in use.

IEM3

KEY CONCEPTS:� The manner in which manufactur-ers approach energy management remains the greatest barrier to maximizing energy ef� ciency.� Energy performance gains from various one-off energy management projects do not deliver sustained energy performance improvements, particularly if those projects are not continuously monitored and adjusted. � A holistic, enterprise-wide energy management strategy views energy as an input to production along with materials and labor. The goal is to optimize energy use throughout the production environment while mini-mizing energy costs and waste.

Optimized compressed air system: This diagram depicts multiple compressors controlled by a system controller, followed by clean-air treatment and a storage air receiver with a � ow controller. This setup ensures optimal use of energy.

Courtesy of Kaeser Compressors

A holistic, enterprise-wide strategy approaches en-ergy as a manageable asset to help offset future en-ergy price increases. This approach views energy as an input to production along with materials and labor. The objective of such a strategy is to maintain opti-mum energy procurement and utilization throughout the production environment while minimizing energy costs and waste. However, it is impossible to manage what is not measured.

Using meters, sensors, programmable logic con-trollers (PLC), intelligent motor controllers, and power monitors connected through energy manage-ment software tools, manufacturers are able to inte-grate energy metrics into production operations by capturing and analyzing energy data to make strate-gic energy decisions. Typically, metering starts with the main, then at each switch gear, and then at each high-value asset.

In a case study reported by Rockwell Automation, a North American packaging company used plant � oor energy consumption data to determine that a piece of equipment was using an excessive amount of energy during the � rst shift. The company rescheduled pro-duction on that piece of equipment to the second shift

and saved $66,000 in one year due to a reduction in peak demand charges.

Using the proper controls and techniques allows a facility to save energy and money. The key is to work with quali� ed personnel, either internal or external, that know the proper systems and requirements of both control systems and the processes that they are to con-trol for optimal performance and ef� ciency.

SUPPLEMENT TO CONTROL ENGINEERING

IEM4

Operating cost savings: This graph shows the savings associated with operating � ve 200 cfm compressors with a computer-based controller versus a single 1,000 cfm compressor.

Paolo Baldisserotto, PE, CEM, is a principal engineer for E4E Solutions, an Atlanta-based energy-engineering � rm. He has s performed energy au-dits at more than 200 industrial and commercial facilities, identifying en-ergy and cost savings opportunities in utility systems including chilled water, steam, refrigeration, lighting, HVAC, compressed air, and pumping systems.

Brent W. Stromwall, PE, PMP, is managing partner and vice president of busi-ness development at Polytron Inc., an integration and engineering consulting � rm based in Duluth, Ga. He has more than 20 years’ experience with foods, beverages, pharmaceutical, and consumer products packaging, process, and material handling systems.

Operating cost savings: This graph shows the savings

CONSIDER THIS� If you’re constantly hitting the wall in terms of how much perfor-mance improvement you can get from your energy management projects, isn’t it time to adopt a different approach?

GO ONLINE� For more information, go to www.polytron.com,www.E4solutions.com, or www.kaesercompressors.com



Technical management of plant and equip-ment can be a highly complex and expensive business, especially if that equipment is scattered across the globe. That is why manufacturers and maintenance providers have, for several years, been on the lookout for ways to manage machinery remotely. One of the � rst ways was to use serial interfaces. For more than 25 years they have been incorporated in different devices—from elevators to medical instruments to heating, ventilation, and air conditioning systems. Technicians were able to access machines, albeit only on-site to begin with. To facilitate remote access, circuit-switched networks gradually came into use, but most companies chose not to make use of this option because of the low bit rates and high costs.

Machine-to-machine (M2M) solutions now provide a better alternative. They are much less expensive, run at higher bit rates, and enable maintenance personnel to access plant and equipment remotely via their tried and tested software. A mobile network-based terminal is connected to the serial interface. The device lengthens the serial interface by es-tablishing a secure con-nection via an encrypted tunnel to a server in the corporate network or to a mobile terminal device. Authenticated users can

Remote machine managementpromises numerous operationalimprovements, including moreenergy ef� ciencyWhile smart factories in which every step in the value chain is automatically tracked and recorded may still be a distant prospect, technology that allows remote management of atleast of some plant equipment is becoming mainstream.

IEM5

This is the type of data that can be viewed through a dashboard connected to a system performing remote machine management. Users can set the parameters to be monitored based on their individual needs or preferences. All graphics courtesy: Deutsche Telekom


IEM6

thereby access the machine from anywhere.

Mobile network-based controllersFor plant and equipment that is not Internet-enabled,

there is another networking option—an off-the-shelf so-lution that any quali� ed electrician can set up. The � rst step is connecting a mobile network-based controller to enable data and instructions from and for the machine to be transmitted, received, and passed on. Once a tech-

nician connects the control-ler’s standard ports with the machine’s interfaces, man-agement software embedded in the controller can be used to con� gure the operating parameters to be recorded.

Communication with terminal devices such as PCs, tablets, smartphones, or a server is via the mo-bile network. By means of

authentication the management software ensures that only authorized users can start or stop processes or adjust settings. The software also provides various con� guration options. If a speci� c threshold level is exceeded or not reached, the software alerts mainte-nance personnel automatically by e-mail or text mes-sage. This function enables � eld service to take place almost immediately.

Remote access for process optimization The advantages of remote management solutions

of this kind are self-evident. Maintenance personnel no longer need to be called out to diagnose problems or change machine settings. The system monitors speci� c parameters itself and alerts maintenance personnel if on-site intervention is required. Information supplied in the course of this process assists the � eld service techni-cian, especially in the case of unscheduled disruptions that require swift responses and decisions. The more details are known, the faster and more precisely the maintenance personnel can respond. They then know, for example, which tools and spare parts they will need for the repair or which operating parameters will need to be recalibrated.

Continuous monitoring of specific parameters promises further potential, especially when it comes

Data logger: Remote monitoring systems can log data on various parameters—such as temperature and current—in near real-time. Deviations from prede� ned ranges of any monitored parameter can trigger a signal that corrective action should be taken.

KEY CONCEPTS� New technologies are emerging to enable true remote equipment management.

� Remote machine management offers numerous advantages, starting with near immediate problem diagnosis, which lets � eld technicians know exactly what action they need to take upon arriving at the site.

� With a remote machine management system in place, an enterprise can reduce energy consumption as much as 10%.

thereby access the machine from anywhere.

to energy efficiency. Industrial companies, for exam-ple, suffer because a large part of their compressed air does not arrive where it is needed. Monitoring flow speed and volume flowrate by sensors, the system is able to note even the smallest leaks and inform the technicians about the affected spot. With such sys-tems in place, an enterprise can reap a 6% to 10% reduction in energy consumption.

Wear and tear of critical components can also affect energy efficiency. It is therefore even more important to have sensors continuously monitor-ing machine components. The system notifies the maintenance team as soon as pre-defined limits are exceeded or not reached. If a sufficiently large buffer is included when defining these limits, the part can be replaced outside of operating hours. Evaluating operating data thereby not only avoids wear-related energy losses but also makes proactive maintenance possible. Indeed, if the product and its surroundings are measured and evaluated continuously, its devel-opment process can be influenced fundamentally.

This new knowledge is reflected in the offerings of manufacturers and service providers. Proactive ser-vices could, for example, be incorporated in service level agreements. If, say, a connected street lamp on the company’s premises breaks down, the incident must not first be discovered and reported. Instead, the lighting system diagnoses the street lamp’s break-down, notifies the workshop immediately, and docu-ments how long it takes to repair.

Off-the-shelf solutions spur the marketConnected solutions do, however, require seam-

less interaction of several components and services. They do, after all, consist of complex embedded sys-tems or externally connected communication units and depend on either a reliable fixed-line connection or a highly available mobile network. In most cases a cloud-based management software platform also is required and must be integrated into the company’s IT landscape. Until recently, users wishing to adopt these connected solutions had to sign separate con-tracts with multiple vendors—hardware and software suppliers, and a mobile network operator.

It’s much simpler now, as telecommunications companies and global IT service providers have be-gun bundling all of the components and competences required for these solutions. The aim is to offer small and midrange enterprises, in particular, a full-service solution from a single source.

Some of these solutions can be purchased at a fixed price per machine, eliminating the costly up-

front investment that has discouraged many manufac-turers from entering the world of connected produc-tion. Indeed, full-service packages of this kind will spur the market on. In the long term, they will lead

to remote management of nearly every aspect of a manufacturing plant’s equipment. Service providers will derive special benefit from being able to offer their customers significantly improved service that also lowers their operating costs.


IEM7

Jürgen Hase is the vice president of the M2M Competence Center at Deutsche Telekom AG. He joined Deutsche Telekom AG in 2011 as head of the M2M Competence Center and has been in the telecommunications industry for more than 20 years. He is also Chairman of the M2M Alliance.

Continuous monitoring of speci� c parameters helpsavoid wear and tear on equipment that eventually willlead to energy leakage.

Power tracking: Remote monitoring systems can compare actual power use versus expected power use in a facility. This data allows for optimizing power use to meet production needs.

CONSIDER THISIn addition to contributing to energy savings, remote machine management makes it easier to practice proactive maintenance. That allows for replacing parts at the � rst signs of wear. This means parts can be replaced without interrupting production, and without causing damage that ultimately shortens equipment life.


IEM8 IndustrialEnergyManagement

SINCE 2009, the SunSpec Alliance has been helping solar power make the transition from “alternative energy” to a steady source of fuel for the electric power grid.

The alliance’s initial goal was developing standards to make it easier for solar plant equipment from different manufacturers to work together, thus smoothing the path for wider production and distribution of solar power.

Now, with nearly a dozen equipment-related stan-dards in place—and widely adopted across the industry—the alliance has expanded its mission to include boosting another area that’s critical to bringing solar energy into the mainstream: the � nancing of solar power plants.

“Financing and customer acquisition represent the

two highest costs associated with solar power develop-ment,” said Tom Tansy, chairman of the SunSpec Alli-ance, which counts more than 60 companies engaged in some aspect of solar power development among its membership. “There’s a lot of inef� ciency that can be removed from the � nancing process.”

Not surprisingly, the SunSpec Alliance advocates streamlining the solar plant � nancing process by creat-ing a standard method for carrying out such transactions. The speci� c approach SunSpec supports involves pack-aging the assets that solar plants represent into � nancial instruments that can be sold to investors on the open market much like corporate bonds.

So far, only one deal of this type has been completed, but much of the industry appears to be coalescing around the concept, which in � nance circles is known as secu-ritization.

Solar power developers like the idea for two reasons:� It promises to greatly expand the potential sources

of capital for building solar power plants.� It would signi� cantly reduce the cost of acquiring

capital, which should in turn lead to cheaper pow-er and more customers.

However, Tansy argues that neither of those scenari-os can play out without a set of standards governing the securitization process, which is why SunSpec was asked to play role.

The idea for securitizing solar power assets origi-nated with the National Renewable Energy Laboratory (NREL), a Golden, Colo.-based arm of the U.S. Dept. of Energy.

Attacking high capital costsNERL convened a working group with more than

New � nancing method could secure the solarindustry’s futureBundling solar assets into marketable securities promisesto lower project � nancing costs, leading to cheaper powerand faster industry growth.

Performance data: Actual data from working solar plants, like this one at the Brea, Calif., headquarters of Moxa, an automation equipment supplier, feeds the Open Solar Performance and Reliability Clearinghouse database supporting a new movement to securitize solar power assets. Courtesy: Moxa


100 members from the solar power, legal, and � nancial sectors to develop ideas for spurring investment in solar energy. This group launched a project called Solar Ac-cess Public to Capital (SAPC), which ultimately began the movement toward turning solar power assets into mar-ketable securities.

The movement is needed, according to Tansy, be-cause there are not many places for solar developers to turn to for capital, and when they do � nd willing inves-tors, the price of obtaining that capital tends to be high.

“We were asked to participate because we have pub-lished all of these information standards related to solar,” Tansy explained. “For example, we have standards that describe logically how inverters, meters, and other de-vices should � t in and interact in solar plants.”

De� ning standardsThe process starts by de� ning exactly what investors

are buying when they purchase a solar-based security. They are buying into the revenue stream generated by a group of solar power plants.

The revenue is generated via contracts the plant op-erators sign with the individuals who will consume the energy generated by the plant. These contracts, called power purchase agreements, or PPAs, usually are long-term agreements, obligating the consuming party to make monthly payments for 10 to 20 years.

Such long-term revenue streams clearly are attrac-tive to investors; however, they still typically want some assurance that the stream won’t be interrupted either by nonpayment on the consumers’ part or because of failure of the power plants.

To provide that assurance, SunSpec created the Open Solar Performance and Reliability Clearinghouse (oSPARC) database. Tansy describes it as an actuari-al database that takes daily reports from solar power plants scattered around across the country and gleans the data for key indicators about their performance. “These types of databases are common across all sorts of asset classes that are securitized,” Tansy said. What makes solar somewhat different is that it’s an opera-tional asset. It generates value by what it puts out, whereas most of the other assets are more passive.”

SunSpec gets plant operators to contribute to its

database by giving them information they can use to benchmark their own plants’ performance against their peers.

“Currently, the solar business is a good business, with relatively high profit margins. So, most compa-nies feel like they’re doing well,” Tansy said. “But they don’t know, on a national basis, if they’re over performing, underperforming, or leaving money on the table. This benchmarking gives them that type of information.”

When it’s time to make an asset sale, the parties selling the associated securities, typically an invest-ment bank, can also use a secure link to tap into the database and run queries on the performance of assets similar to those they wish to package in a deal. They can then pass that information to potential investors who will use it to make a decision about purchasing the securities.

IEM9

GO ONLINE: � For more information, visit www.sunspec.org, www.nrel.gov, www.solarcity.com, and www.moxa.com.

CONSIDER THIS:� In a pilot project, Solar City, a leading developer of solar systems, shaved two percentage points off its borrowing costs by issuing securities backed by power purchase agreements. That could translate into a 50-cent-per-watt reduction in the cost of producing energy.

Solar growth: Though solar power has shown substantial growth in recent years, it will have to sustain an annual growth rate of 25% to achieve the DOE’s goal of solar meeting 14% of the country’s electricity needs by 2030. Securitizing solar assets could help the industry meet that pace. Courtesy: National Renewable Energy Laboratory

Solar growth: Though solar power has shown substantial

2000 20020 2004 2006 2008 2010 2012

100,000

80,000

60,000

40,000

20,000

0

Non-Residential

Residential

KEY CONCEPTS� A limited number of � nancing sources has slowed the growth of solar power plant development.� The solar industry is coalescing around the idea of bundling power purchase agreements into � nancial instruments that can be sold to investors, much like corporate bonds. This is a means of raising capital for new plant development.� The SunSpec Alliance, the primary developer of technical standards for the solar industry is now working to standardize the solar securitization process.

Sidney Hill, Jr., is a CFE Media contributing content specialist.Send comments to [email protected].

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The Anybus CompactCom 40-series from HMS Industrial Networks allows fast and accu-rate communication between the host device and Powerlink. The CompactCom 40-series Powerlink products come in three formats—chip, brick and module—and are all equipped with the same soft-ware interface from the host device.

Process data latency is less than 15µs, and it allows up to 1500 bytes of process data in each direction. The CompactCom 40-series has a re-sponse time of 1µs (time from Poll Request to Poll Response) and a synchronization jitter of 1µs.HMS Industrial Networkswww.hms-networks.com Input #200 at www.controleng.com/information

ETEL’s TML and TMM series of cageless, high-peak torque motors use direct drive ETEL’s TML and TMM series of cageless, high-peak torque motors use direct drive technology and have a low weight pack-age with diverse and easy-to-utilize mounting options. They can be used for any application with low continuous torque requirements, while still providing the same peak torque with up to 5000 Nm and reach-ing speeds of up to 2100 rpm. The TML’s lugs are located along its outer diameter, which provides an easy mounting method. The TMM is even lighter and is designed to be directly glued into the machine structure. The TML/TMM both come in multiple standard sizes, provid-ing more performance variations.ETEL S.A.www.etelusa.com Input #203 at www.controleng.com/information

Fluke’s 1623-2 and 1625-2 Earth Ground Testers come with features and accessories designed to speed verifi ca-tion of a reliable connection to earth for grounded electrical systems, helping solve power quality problems and lowering the risk of shock to users.

They perform all four types of earth ground measure-ments: 3- and 4-pole fall-of-potential, 4-pole soil resistivity, selective testing, and stakeless testing. The advanced testers feature USB connectivity for easy storage of up to 1,500 records with time stamp and fast measurement download, eliminating the need for manual data transfer.Fluke Corp.www.fl uke.com Input #201 at www.controleng.com/information

Wago Corporation’s 750-658 I/O module links CAN fi eld devices to the 750 Series Wago I/O system. The CAN Gateway module can be used with 750 Series PLCs or couplers, providing a gateway between a CAN network and other fi eldbuses (Ethernet or Profi bus), leveraging the fl exibility of the fi eldbus independent Wago I/O sys-tem. The 750-658 supports CAN Layer 2, making it extremely fl exible at the fi eld level. The module can be integrated into a CANopen, SAE-J1939, or DeviceNet network by using CoDeSys function blocks. The 750-658 has GL marine and UL508 certifi cations.Wago Corporationwww.wago.us Input #202 at www.controleng.com/information

Ethernet connectivity for industrial devices

Cageless, high-peak torque motor

Ground testers for quick electricalequipment verification

CAN gateway IO module

PRODUCTSPRODUCTS& software

Industrial media converter allows Ethernet over A-B Remote IO

Industrial Media Con-verter by ProSoft Technol-ogy is designed to help companies upgrade control system communications with minimal downtime. Once the converters are in-stalled, companies can run Allen-Bradley Remote I/O (from Rockwell Automa-tion) and EtherNet/IP (an ODVA Ethernet protocol) data simultaneously on the same cable. This will allow upgrade of individual nodes at a pace that makes sense for the application.

The Ethernet to Belden Blue Hose Indus-trial Media Converters units are plug and play with no confi guration needed. The converters offer 57.6 and 115.2 K communication rates and a maximum distance of 1,300 ft with simultaneous Ethernet and A-B Remote I/O data. Repeaters are available for networks with distances up to 10,000 ft.

The converters are the latest example of phased migration solutions from ProSoft Technology, the company said, providing the freedom to complete necessary upgrades on schedules that make the best business sense.ProSoft Technologywww.prosoft-technology.comInput #204 at www.controleng.com/information

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Input #100 at www.controleng.com/information



Texas Instru-ments’ SN74LV1T family is designed to fully integrate logic gate and up/

down translation functionality operating from a single power supply. The SN74LV1T family also offers an operating voltage range, from 1.8 to 5 V, and has an extended temperature range from -40 to 125 C. Because of this, it can also be used in industrial and telecom-munications applications as a logic gate, translator, or both. This eliminates the need for multiple logic ICs and eases procurement management. The SN74LV1T family is avail-able in nine logic gates, as well as several buffer functions. Texas Instrumentswww.ti.com Input #205 at www.controleng.com/information

Rhino PSB series DIN rail mount single-phase and three-phase input power supplies have IP20-rated terminals, offering high perfor-mance and reliability. The series features rugged plastic or aluminum housings and output status LED indicators as well as overload, over-voltage, and thermal protection. Five models are approved for Class I, Div. 2 hazardous locations and one unit is UL 1310 recognized (NEC Class 2). DIN Rail mount 12, 24, and 48 V dc output, as well as 85-264 V ac/ 120-375 V dc single-phase input voltage power supplies are available. Three-phase, 320-600 V ac input versions are available with 24 V dc outputs from 60 to 960 W. AutomationDirectwww.automationdirect.com Input #206 at www.controleng.com/information

Integrated logic gate device

DC power supply line in plasticor aluminum housings

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Content For Engineers. That’s what CFE Media stands for, and what CFE Media is all about – engineers sharing with their peers. We welcome content submissions for all interested parties in engineering. We will use those materials online, on our website, in print and in newsletters to keep engineers informed about the products, solutions and industry trends.

www.controleng.com/contribute explains how to submit press releases, products, images and graphics, bylined feature articles, case studies, white papers, and other media.

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ABB Inc - Safety Systems. . . . 19. . . . . . . . . . 13 . . . www.abb.com/highintegritysafety

Allied Electronics . . . . . . . . . . 11 . . . . . . . . . . 8 . . . www.alliedelec.com

Antaira Technologies LLC . . . . 25. . . . . . . . . . 18 . . . www.antaira.com

AutomationDirect . . . . . . . . . . C2, 1,

. . . . . . . . . . . . . . . . . . . . . . . . . 16A-16D . . . 1, 2 . . www.automationdirect.com

AVG . . . . . . . . . . . . . . . . . . . . . BB . . . . . . . . . . . . . . www.EZAutomation.net

Baldor Electric Company . . . . 13. . . . . . . . . . 9 . . . www.baldor.com

Coming Soon…a databaselike none other... . . . . . . . . . . . 29

Control Engineering2014 Cyber Security Research . 92. . . . . . . . . . . . . . . www.controleng.com/2014CyberSecurity

Control EngineeringE-Newsletters . . . . . . . . . . . . . 46. . . . . . . . . . . . . . . www.controleng.com/newsletters

Dataforth Corp . . . . . . . . . . . . 24, 26. . . . . 17, 19. . www.dataforth.com

EnclosureHub . . . . . . . . . . . . . 32. . . . . . . . . .22 . . . www.enclosurehub.com

Honeywell Inc . . . . . . . . . . . . . 4. . . . . . . . . . . 4 . . . www.honeywellprocess.com

IANA at IMTS 2014 . . . . . . . . . 35, 41. . . . . . .24 . . . www.ia-na.com

ITSENCLOSURES . . . . . . . . . . 15. . . . . . . . . . 10 . . . www.itsenclosures.com

Kepware Technologies . . . . . . 33. . . . . . . . . .23 . . . WWW.KEPWARE.COM

Let’s Connect Socially…. . . . . 92. . . . . . . . . . . . . . . www.contoleng.com/connect/twitter-facebook-linkedin.html

Moore Industries - Intl. Inc . . . 27. . . . . . . . . .20 . . . www.miinet.com

Moxa Technologies . . . . . . . . . 3. . . . . . . . . . . 3 . . . www.moxa.com

National Instruments . . . . . . . 7. . . . . . . . . . . 5 . . . www.ni.com

Nexcom . . . . . . . . . . . . . . . . . . 28. . . . . . . . . .21 . . . www.nexcom.com

Omega Engineering Inc . . . . . 23. . . . . . . . . . 16 . . . www.omega.com

OPTO 22. . . . . . . . . . . . . . . . . . 9. . . . . . . . . . . 6 . . . www.opto22.com

Sealevel Systems Inc . . . . . . . 18. . . . . . . . . . 12 . . . www.sealevel.com

SEW-EURODRIVE, Inc. . . . . . . C4 . . . . . . . . .33 . . . www.seweurodrive.com

Siemens Industry Inc . . . . . . . C1, 10, 21. . . 7, 14 . . www.sea.siemens.com

Teledyne DALSA . . . . . . . . . . . 22. . . . . . . . . . 15 . . . www.teledynedalsa.com

Turck Inc. . . . . . . . . . . . . . . . . . 16. . . . . . . . . . 11 . . . www.turck.com

Yaskawa America, Inc. . . . . . . C3 . . . . . . . . .32 . . . www.yaskawa.com

Industrial Energy Management

American IndustrialSystems (AIS) . . . . . . . . . . . . . IEM1 . . . . . . .30 . . . www.aispro.com

Otek Corporation . . . . . . . . . . IEM4 . . . . . . .31 . . . WWW.OTEKCORP.COM

Inside Machines

Aerotech Inc . . . . . . . . . . . . . . M10 . . . . . . . .29 . . . www.aerotech.com

Banner Engineering Corp. . . . M3 . . . . . . . . .25 . . . www.bannerengineering.com

Beckhoff Automation LLC. . . . M7 . . . . . . . . .27 . . . www.beckhoff.com

Red Lion Controls . . . . . . . . . . M9 . . . . . . . . .28 . . . http://better.redlion.net

WAGO Corp. . . . . . . . . . . . . . . M5 . . . . . . . . .26 . . . www.wago.us

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‘ The goal in quality

management should be to

control the process, and then

keep it in control; small and

often frequent adjustments

should be made before the

process gets out of hand.’

Rapid and effective testing isn’t neces-sarily a new idea. It’s practical com-mon sense, can have a huge impact on manufacturing quality, and can

improve quality management on the shop floor.

From the lab to the operatorFor many companies, the lab controls the

entire testing process. It collects samples from the shop floor, runs the tests, and eventually gives the test results to the shop floor.

In some cases, these pro-cesses waste valuable time. Often the lab causes long delays in relaying feedback to the shop. If something needs to be adjusted, it could be a long time before those adjustments are made, and it’s possible that a prod-uct won’t be manufactured to certain specifications because of the delay. Delay is time, and time is money.

Instead of the norm, con-sider a testing process that puts the operator in charge

of quality management. The reasoning is sim-ple: The operator is in charge of making the product; the operator is closest to the manu-facturing process and truly understands what’s going on. As such, the operator—not the lab—should be in charge of quality tests. After all, it’s the operator who needs the information to make the appropriate changes in response to

the results. The major benefit:

The tests are performed more efficiently and quickly. Another ben-efit is that feedback is promptly delivered to

the manufacturing processes. So if things need to be changed, operators can make swift adjustments.

Small and frequent adjustmentsInstead of focusing on quality, labs often

adjust the manufacturing process as if they are meeting quotas. Instead of making sure the pro-cess is in control, they make adjustments, trying to hit a target number. This practice is typically fraught with process overcorrection, delaying time and again wasting money. Such quotas also result in over-testing. Manufacturers shouldn’t run tests just to run tests.

Instead, the goal in quality management should be to control the process, and then keep it in control. Small and often frequent adjust-ments should be made before the process gets out of hand. Managers also should look to achieve testing rationalization. That is, run only the tests that make sense. Run the tests that are the true indicators of what’s happening on the shop floor.

There are many ways to do this using sta-tistical methods and a variety of other tech-niques, but the idea is the same—make small adjustments and keep the process in control all the way.

Empower the shop floorWhen labs are in control, shop-floor employees

often don’t share the manufacturing knowledge that lab employees do.

Breaking this paradigm means expanding the knowledge about the manufacturing process and getting the appropriate information out of the lab and on to the shop floor. It means better educating operators. ce

- John Clemons, director of manufacturing IT, Maverick Technologies. Edited by Jordan Schultz, associate content manager, Control Engineering.

BASICSBASICS

Ideas for quality management

back to

Manufacturing quality tests in the lab can take time, causing a delay in production.Consider rapid testing with operators to deliver prompt feedback and make necessary adjustments sooner.

Check out more industry advice from Maverick:www.controleng.com/blogs/real-world-engineering

Read more Control Engineering blogs:www.controleng.com/blogs

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