EZAutomation.

net
EZ is Better! Look inside
Pg. 9
HMIs, PLCs, Marquees, Panel PC, Software & more

Exceptionally Innovative
Top
Quality

PROUDLY
MADE Factory
IN THE
USA Direct
SINCE 1968

Great
Prices

Since
1968

!
w
no
ts
ar
st
n
io
at
iz
al
su
vi
of
re
tu
fu

See page
e

www.controleng.com
Th

23 for
details.
 DISPLAY YOUR WAY
Large, small, or no screen at all, the C-more Headless HMI lets you decide

Headless HMI
With the C-more headless HMI, you can display your factory
floor data how and where you choose. The EA9-RHMI has all
the powerful functionality of the C-more Touch Panel HMIs,
but without display size restrictions. This HDMI-enabled device
works with televisions, monitors, projectors, and most any
other HDMI display device or use the C-more Remote HMI
mobile app and/or the embedded Web Server if you prefer no
local display at all. The choice is yours!

C-more
Headless HMI
priced at:
$399.00
(EA9-RHMI)

Now with FREE

Features include:
• HDMI Video/Audio output with multiple resolutions
software!
• VGA 640x480, SD 720x480, XGA 1024x768, HD 1280x720 C-more HMI design software
• Compatible with ELO Resistive Touch screens can now be downloaded
• Multiple connections free-of-charge. Get started
• Ethernet and RS-232/422/485 serial ports support on your project today or
programming and device connections take it for a test drive.
• USB-B port for programming, monitoring and configuration
• USB-A port for USB HID devices such as pen drives, touch Download as often as
screen displays, keyboard, mouse and bar-code scanners you need. No license or
• SD card slot for log files, project memory or graphic media key needed.
• Get control on-the-go with the C-more Remote HMI mobile app
and embedded Web Server Get your copy now at:
• 82MB of user memory www.go2adc.com/cmoresw

Research, price, buy at: www.automationdirect.com/cmore

Order Today, Ships Fast!

* See our Web site for details and restrictions. © Copyright 2020 AutomationDirect, Cumming, GA USA. All rights reserved. 1-800-633-0405 the #1 value in automation

input #1 at www.controleng.com/information
 Automate the easy way
with CLICK PLCs

STAND-ALONE PLC
W/ BUILT-IN I/O
starting at:

$69.00
(C0-00DD1-D)

CUSTOMER REVIEWS:
“Very easy to use and interactive
little PLC. Love that modules can be
added to create exquisite systems.
Cannot be beaten for the price. Programing
Automation is easy and affordable... is easier than Micrologix and it is free.”
Joshua in LAKE LYNN, PA
...when using a controller designed that way. The CLICK PLC
family provides the right amount of control for small systems “Super easy to use. Ethernet setup is
and beginner projects without unnecessary cost and complexity. simple. Easy to integrate with C-more
products.... you will look like an expert...”
Low-cost hardware and FREE low-learning-curve software make Tim in LAKEWOOD, NJ
CLICK the go-to choice for simple control.
• Multiple stand-alone PLC units available with different I/O configurations “The C0-04RTD module makes the job as
(relay, analog, AC or DC discrete I/O) easy as it could possibly be. Just connect
your sensors to the inputs, and point your
• Support for Modbus RTU, ASCII, Modbus TCP and EtherNet/IP logic or HMI objects to the appropriate
communication protocols registers, and the temperatures are there.
• All CLICK PLC units use our FREE programming software with a simple No scaling or anything else. It’s done.”
but practical instruction set Brian in TACOMA, WA
• Easy, streamlined PID gets your process under control in record time
(Ethernet PLC units only) “Very easy to use, powerful for the price...
Programming is easy, intuitive, and help
• Easily expand your CLICK PLC with snap-on I/O modules for up to an menu well done.”
additional 128 discrete or 48 analog I/O points Sylvain in JOLY, QC
• NEW! High current relay output modules allow up to 10A per point
and an input simulator module provides 8 toggle switches to
simulate input devices

www.CLICKPLCs.com

Order Today, Ships Fast!

* See our Web site for details and restrictions. © Copyright 2020 AutomationDirect, Cumming, GA USA. All rights reserved. 1-800-633-0405 the #1 value in automation

input #2 at www.controleng.com/information
Drive Pre-Wired &
Programmed
Designed to run IP54 Rated Drive & motor
out of the box with conformal coated
drive components

IE5 Efficiency Guaranteed -

Ferrite assisted
synchronous reluctance
rotor (FASR)

—
Plug and play
Eliminate wiring, reduce time

Upgrade to ABB’s new Baldor-Reliance® ultra-premium EC Titanium™ integrated motor

drive, and enjoy easy startup with our pre-programmed plug and play design.

• Eliminate expensive wiring and reduce installation time

• Reduce personnel risks and access hazards
• Integrated motor and drive designed to achieve IE5 efficiency levels
• Save up to 40% in energy costs with variable speed control

Efficient. Innovative. Simple.

baldor.abb.com/ec-titanium
input #3 at www.controleng.com/information
 Vol. 67
Number 8

AUGUST 2020
ANSWERS
16 | How edge computing will unleash IIoT

18 | Embedded HMIs excel in automation

applications
22 | Augmented reality
tools: A digital bridge
for the skill gap
26 | What industrial wireless
network should I use?

16 30 | 5G wireless for indus-

trial use: Six answers
COVER: Many manufacturers use edge computing to become more
efficient and productive; the Industrial Internet of Things (IIoT) can help 32 | How to build a system
make the data smarter. Courtesy: ABB
integration business p.22
case for automation, controls
INSIGHTS
6 | Technology Update: Integrated design
software lower costs, adds flexibility
8 | Technology Update: COVID-19 accelerates
digital transformation
10 | Technology Update: Automation helps
with COVID-19, energy efficiency, robot-
ics, non-contact motion control, STEM

NEWS
p.M3
12 | COVID-19 developments and effects INSIDE MACHINES
on engineers from the industry:
M1 | Cost-effective position control boosts
Flexible and anlytical; reusable PPE;
stepper motor performance
Students innovate pandemic solu-
tions for workers; Headlines online M3 | Connect automation to the power
of predictive maintenance
14 | Think Again: Hot topics in M5 | Which IEC 61131-3 programming
Control Engineering language is best? Part 2

CONTROL ENGINEERING (ISSN 0010-8049, Vol. 67, No. 8, GST #123397457) is published 12x per year, Monthly by CFE Media and Technology, LLC, 3010 Highland Parkway, Suite #325 Downers Grove, IL 60515. Jim
Langhenry, Group Publisher/Co-Founder; Steve Rourke CEO/COO/Co-Founder. CONTROL ENGINEERING copyright 2020 by CFE Media and Technology, LLC. All rights reserved. CONTROL ENGINEERING is a registered trademark
of CFE Media and Technology, LLC used under license. Periodicals postage paid at Downers Grove, IL 60515 and additional mailing offices. Circulation records are maintained at 3010 Highland Parkway, Suite #325 Downers
Grove, IL 60515. Telephone: 630/571-4070. E-mail: ctle@omeda.com. Postmaster: send address changes to CONTROL ENGINEERING, PO Box 348, Lincolnshire, IL 60069. Publications Mail Agreement No. 40685520.
Return undeliverable Canadian addresses to: PO Box 348, Lincolnshire, IL 60069. Email: ctle@omeda.com. Rates for nonqualified subscriptions, including all issues: USA, $165/yr; Canada/Mexico, $200/yr (includes 7%
GST, GST#123397457); International air delivery $350/yr. Except for special issues where price changes are indicated, single copies are available for $30 US and $35 foreign. Please address all subscription mail to CONTROL
ENGINEERING, PO Box 348, Lincolnshire, IL 60069. Printed in the USA. CFE Media and Technology, 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.

www.controleng.com control engineering August 2020 • 3

input #4 at www.controleng.com/information
 AUGUST 2020

INNOVATIONS
NEW PRODUCTS FOR ENGINEERS
61 | Plant process management software;
Digital commissioning and turnover package;
COVID-19 safety labels and signs; Customized LVDT
position sensors; Inductive position sensor
See more New Products for Engineers at
www.controleng.com/NPE. Control Engineering eBook
series: Robotics eBook
Summer Edition
BACK TO BASICS Robotics are one
62 | Secure remote access to survive and thrive of the fastest-
growing industries
Secure remote access (SRA) is being used to help companies survive
and their impact
and thrive during the COVID-19 pandemic, but there are some new
can be felt on
challenges that need to be considered. See 10 remote access best
many manufacturing floors. There’s
practices.
more to the robot, however, than
what you see on the plant floor.
ONLINE EXCLUSIVES: Click on the headlines This helpful eBook from Control
Engineering and Universal Robots
Extending TSN capabilities over 5G includes articles on robots fighting
and other wireless networks COVID-19, mitigating potential
Time-sensitive networking (TSN) has gained more attention from  manu- robot hazards and more.
facturers as capabilities like 5G become more accessible. Benefits  include Learn more and register
faster communications, better mobility and high reliability. to download at
Dave Cavalcanti, Intel; Stephen Bush, GE; Alon Regev, Keysight Technologies www.controleng.com/ebooks/.

Robotic software improves robot health

Industrial robotic software, industrial networks and cloud-based tech- Oil & Gas Engineering helps
nologies are helping to improve industrial robotic health, improve maximize uptime and increase
robotic uptime and better manage robotic assets. productivity through the use of
Mark T. Hoske, Control Engineering industry best practices and new
innovations, increase efficiency
NEWSLETTER: Safety & Cybersecurity from the wellhead to the refinery
by implementing
• Separating process control and safety systems automation and
• Safety over EtherCAT conformance test ben- monitoring strate-
efits gies, and main-
• Cybersecurity requires asset updates tain and improve
safety for workers
• Researchers develop method to recycle PPE
and the work
using radiation
environment.
• Phishing heads COVID-19 themed attacks. Read the digital
Keep up with emerging trends: subscribe. edition at
www.controleng.com/newsletters. www.oilandgaseng.com.

controleng.com provides new, relevant automation, controls, and instrumentation content daily, access to
databases for new products and system integrators, and online training.

www.controleng.com control engineering August 2020 • 5

INSIGHTS
TECHNOLOGY UPDATE: PLM SOFTWARE
Mark T. Hoske, Control Engineering

Integrated design software

Product lifecycle management software (PLM) and service lifecycle management software enable
digital twins, digitalization, automation design and plant design. See five digital twin attributes.

S
oftware can help with the collaboration
of applications, Industrial Internet of
Things (IIoT) and analytics, operations,
manufacturing, simulation, electron-
ics and mechanical aspects of design,
according to Siemens Digital Industries Software.
Product lifecycle management (PLM) soft-
ware also improves the design process by infer-
ring part relationships on the fly, improves design
innovation during rapid-response development,
speeds digital twin development and mainte-
nance, uses artificial intelligence (AI) for gen-
erative material design to optimize component
performance, helps with digital transformation
electronic and digital designs.
adaptable and modern tools, and a flexible open
collaborative ecosystem.
Design software is helping to lower risk in
restarting manufacturing with new laws and rules
for a safe work environment.
Stuart McCutcheon, global VP of global sales and
customer success, Siemens Digital Industries Soft-
ware, said digital twins create faster time to market,
drive innovation, provide an adaptive response to
demand as signals change, extract value from moun-
tains of data and unite engineering disciplines from
across the lifecycle driving to a common business
goal. Digital twins also create the ability to be proac-
tive to events while optimizing quality and produc-
tivity, and delivering new business models.

M More
INSIGHTS
KEYWORDS: Product
lifecycle management
PLM software helps
integrate, eliminates waste
and increases innovation.
Digital twins simulate and
model PLM.
CONSIDER THIS
What benefits can you get
by integrating PLM and digital
twins?
ONLINE
See more tips, images online.
PLM design collaboration
Collaborative PLM design software has
been helping in a diversity of industries,
including with COVID-19 vaccination
development, said Tony Hemmelgarn, pres-
ident and CEO of Siemens Digital Industries
Software. Time to produce an experimen-
tal vaccine decreased from months or years
to 42 days through use of a digital design
architecture, he noted during the June Sie-
mens Digital Industries Software’s virtual
2020 Media & Analyst Conference.
Time savings result from development of
a comprehensive and actionable digital twin
that speed design iterations; personalized
Five attributes of a digital twin
What is a digital twin? Beyond a virtual represen-
tation of a physical object that evolves with the life-
cycle of physical objects, McCutcheon said, a digital
twin also is:
1. A precise virtual representation of a physical
product or process.
2. Used across its lifecycle to simulate, predict
and optimize product and production systems.
3. Made of multiple representation of models for
different aspects of physical behavior.
4. An evolving object with a lifecycle that needs
to be managed from concept, development,
verification, manufacturing, sales and support.
5. Closed-loop digital twin provides for bi-direc-
tional connectivity between the physical asset
and the virtual representation.

Digitalization notes
Integration of software tools are
helping with the following. (See
more details and benefits online.)
1. Electric-powered airplanes
2. Commercial supersonic aircraft
3. Wind power energy services
4. Rapid-start car company
5. Filling and packaging machinery
manufacturer. ce

Mark T. Hoske is content manager,

Siemens Teamcenter and MindSphere and Xcelerator software products create a Control Engineering, CFE Media and
closed-loop digital twin across the lifecycle to correlate real-world behavior with the Technology, mhoske@cfemedia.com.
digital twin to optimize product design. Courtesy: Siemens Digital Industries Software

6 • August 2020 control engineering www.controleng.com

 The Plant Floor in Your Pocket
Get an overview of your process at a glance.
Control your SCADA with a swipe.

See the live demo now.

Scan this QR code with your phone
or visit demo.ia.io/engineering
input #5 at www.controleng.com/information
INSIGHTS
TECHNOLOGY UPDATE
Sean Callahan, Kepware

COVID-19, digital transformation

Industrial organizations are realizing digital transformation value during the COVID-19 pandemic.

H
ow is COVID-19 affecting digital
transformation? Control Engineer-
ing had questions for software con-
nectivity company PTC about how
the COVID-19 pandemic was chang-
ing digital transformation. Sean Callahan, senior
director, strategic marketing for Kepware, part of
PTC, provided answers about digital transformation
value, enterprise-wide connectivity and Industrial
Internet of Things (IIoT) proof of value.
QUESTION: How has COVID-19 impacted
marketplaces, industries, and/or supply chains?
Callahan: COVID-19 has been a catalyst for com-
panies accelerating their digital transformation jour-
neys. Industrial organizations have now seen firsthand
the value that digital transformation brings when deal-
ing with crisis situations, or when they need to rapidly
make shifts in production, and are responding.
Many organizations that did not undertake major
digital transformation efforts ahead of the pandem-
ic were more negatively impacted as a result. We
have found that they are now evaluating and mak-
ing plans to quickly implement transformative tech-
nologies in the future such as the Industrial IoT and
and transfer knowledge – to employees, customers,
and other manufacturers.
Q: How will engineering teams evolve in the
coming months, using communications and pro-
ductivity tools to drive efficiencies?
Callahan: As organizations look to gain efficien-
cies, we are seeing teams from OT and IT [operation-
al technology and information technology] groups
work together more strategically, driving industri-
al IoT initiatives together to realize tangible busi-
ness outcomes for both groups. We are also seeing a
shift from a focus on “proof of concept” implemen-
tations to a focus on “proof of value.” Proof of con-
cept implementations were typically deployed in an
area of the shop floor that was less risky to test new
technology on – but the problem was that with these
low-risk, low-priority pilots, companies could not see
the value that would be realized by scaling these to
more impactful areas of the business. By shifting to
a proof of value implementation, they are targeting
the areas of the business where they can realize the
largest impact and value. To do this successfully, they
are looking for solutions they can get running quick-
ly without disrupting the manufacturing process in

M More
INSIGHTS
KEYWORDS: COVID-19, digital
transformation, IIoT
Digital transformation and Industrial
Internet of Things tools help industrial
connectivity during the COVID-19
pandemic.
Two goals of digitalization are
enabling remote work and remote
service.
Industrial connectivity tools can
connect existing assets without
replacing machines.
CONSIDER THIS
If COVID-19 isn’t accelerating your
digital transformation, what about
your competitors?
ONLINE
If reading from the digital edition,
click on the headline for answers
on the 1-3 year outlook, more
details about growth, and a large
graphic about connectivity and
communications tools.
www.controleng.com/magazine
augmented reality (AR). Demand for
these technologies, as well as critical
foundational technologies like enter-
prise-wide connectivity, continues to
grow as organizations evaluate how
they’ll position themselves to thrive
post-crisis.
Q: How will COVID-19 shape
technologies, systems, people, train-
ing, processes and quality control?
Callahan: The most tangible exam-
ple of COVID-19 disrupting products,
processes, and people is with training
and digital work instructions. Facing
rapid changes in demand, new social
distancing measures, and the rise of
remote work, industrial organizations
needed new approaches to onboard-
ing, training, upskilling, and reskilling
that worked within the new normal
they were facing. To maintain business
continuity and help their employees
navigate these challenges, manufac-
tures are now leveraging AR to capture
the critical areas targeted for these high-value pilots.
Industrial connectivity tools provide the ability to
connect existing assets without replacing machines,
enabling industrial organizations to demonstrate
real proof of value without disrupting production on
their most critical lines.
Q: How will engineers help growth return?
Callahan: We are seeing that manufacturing engi-
neers are using this time to research, design, imple-
ment, and empower digital transformation strategies
in their organizations. We are also seeing their orga-
nizations make commitments with global systems
integrators and consultants to ensure they lock up
the best resources for enabling digital transforma-
tion as soon as the economy reopens. In supporting
the broader digital transformation economy, as well
as strengthening their own businesses, manufactur-
ers are leading the way to helping us return to a peri-
od of economic growth.
Sean Callahan is senior director, strategic marketing
for Kepware. Edited by Mark T. Hoske, content man-
ager, Control Engineering, CFE Media and Technol-
ogy, mhoske@cfemedia.com.

8 • August 2020 control engineering www.controleng.com

 Unpredictable
Supply and Price Did you know AutomationDirect.com sells
o to products that are mostly manufactured in
Say N
China China, home of Corona pandemic

re
mINoCHINA
C-MADE

It is high time to switch to...

®

LED
backlight EZTouch is Better
400 nits,
75K hrs. and Made in America
@ 55°C

Supply Chain Security PROUDLY Predictable & Stable

Same day Shipping MADE Product Supply No Virus!

Exceptionally
IN THE
USA
SINCE 1968
Top Quality
Innovative Products

FactoryDirect Great
Design & Mfg. of Top Quality
@Great Prices Prices
Automation Products Free Tech/App Support
Since 1968

Free Factory Support from Machine Development to Mass Production

HMIs, PLCs, HMI+PLC Combo, Remote Industrial
I/O, Industrial message displays, DIN mount power
supplies, Soft HMIs, SCADA, Panel PCs, Software
Products, Time Delay Relays, Proximity Switches and
many more
input #6 at www.controleng.com/information

Check out our

Great Starter Kits

1-877-774-3279 * All product names, and registered trademarks are the property of their respective manufacturers or
legal holders. EZAutomation disclaims any proprietary interest in the marks or names of others.
EZ is Better!
INSIGHTS For 2020, Festo Bionic developed an
autonomous flock of flying robotic
TECHNOLOGY UPDATE birds using an indoor global position-
ing system to adjust as needed, said
Mark T. Hoske, Control Engineering Karoline von Häfen, Festo head of
bionic projects. Images courtesy: Festo

COVID-19, efficiency, robotics,

non-contact motion control, STEM
Automation innovation is helping with pandemic response, energy efficiency, robotics, non-contact
motion control, training and science, technology, engineering and math (STEM) excitement.

E
lectric, pneumatic and process automation
help interconnect engineering-related
workers during the COVID-19 pandem-
ic; Industry 4.0 and Industrial Internet of
Things (IIoT) support and enable opti-
mized automation architectures; bionics (robotics
mimicking nature) inspire future engineers in sci-
ence, technology, engineering, and math (STEM)
and offer innovation to integrate into operations;
training courses and automation modules help stu-
dents and teachers; contactless motion control uses
superconductivity. These were among innovations
demonstrated by Festo in several online events in
July leading up to a planned Festo North Ameri-
can online tradeshow Aug. 5 and 6, expected to be
archived until Sept. 5 The pandemic cancelled Han-
nover Fair, IMTS and other shows and conferences, so
Festo is sharing exhibits and trends online.
COVID-19, digitalization
Dr. Frank Melzer, member of
the Festo management board, prod-
uct and technology management,
said COVID-19 has brought many
changes to private and professional
lives globally. Melzer said Festo had
a solid digital infrastructure and bol-
stered cybersecurity with installa-
tion of 6,000 virtual private network
(VPN) nodes in one day. The com-
pany continued production espe-
cially for critical industries under
sanitary conditions. Rapid engineer-
ing projects including face masks
and emergency respirators in four
Marcus Stemler, Festo product weeks; parts are available to others.
manager, digital pneumatics, Festo is among companies on Ger-
said digital pneumatic valves
can reduce related energy con-
sumption up to 60% or more
many’s Industrie 4.0 committee (with
150 companies and 600 participants),
working on a future industrial frame-
energy savings can result, for work. It’s important that systems can
instance, in loading tires into a talk to each other to create efficiency
curing press, controlled by Festo with digital interoperability.
Motion Terminal, said to be the Dr. Ansgar Kriwet, Festo member
first digitalized pneumatic valve of the management board, sales, said
terminal. the Hannover Fair theme this year
would have been industrial transformation, and the
coronavirus crisis shows the need for industrial trans-
formation. This includes more home offices, higher
data bandwidth and cybersecurity, safety distancing
with high production efficiency and reliability. Better
machine control with sensors enables more mobility.
Dr. Hans Jörg Stotz, member of the management
board of Festo Didactic SE, said industries need to
bring digital competence to more applications with
Industry 4.0 training covering technologies, business
models and life-long learning. Applications include
cyber-physical factories, module-based factories, and
learning centers that do not disrupt production.
Karoline von Häfen, Festo head of bionic projects,
showed a soft robotic hand and a wrist for 12 degrees
of freedom. The glove for the robotic hand has 113
tactile force sensors; a haptic glove can allow a human
to feel what the robot feels, she said. At the wrist, a
camera offers visual object recognition with artificial
intelligence (AI) to improve learning; the robotic hand
and wrist are mounted on a robot that balances and
travels on a ball. For balance, a neural network system
stabilizes while the robot rolls with an on-board ener-
gy supply. Humans and robots are changing to work
together in workspaces, von Häfen said.
Michael Schöttner, Festo head of SupraMo-
tion, demonstrated commercialized Festo contact-
less motion control using superconductivity. The
low-power system provides automated friction-free
wireless movement, advantageous in many medical,
biomedical, or pharmaceutical applications. It uses
permanent magnets and superconductive cooling for
precision movements. ce
Mark T. Hoske is content manager, Control Engi-
neering, CFE Media, mhoske@cfemedia.com.
M More
INSIGHTS
KEYWORDS: Motion control, robotics, pneumatics
COVID-19 has increased digitalization efforts.
Automation, bionics (lifelike robotics) and education
modules, can help STEM efforts.
Non-contact motion control is commercialized.
ONLINE: More photos and details with this web article.

10 • August 2020 control engineering www.controleng.com

 Are you into belts and
Mounting
chains..?
No..? Then you need our patented TorqLOC®. Its
keyless hollow shaft and taper bushing eliminate
inefficient belts, chains, and sprockets to reduce
costs and to enhance system safety.

TorqLOC® contains a large air gap for easy mounting.

So, no more keys, tight tolerances, or fretting! Plus,
the same bolts used for tightening are also used for
Removal
easy removal.

Need retrofit? No problem. TorqLOC® even mounts

onto an existing shaft that has a keyway.

TorqLOC®
Mounting System

seweurodrive.com / 864-439-7537

input #7 at www.controleng.com/information
INSIGHTS
NEWS

COVID-19 developments and

effects on engineers from the industry
The COVID-19 pandemic continues
to affect engineers in many profound
ways. Social distancing, remote work-
ing and many other changes are forc-
ing a new normal in our society. While
engineers work to adjust to this and what
this means for the future, many contin-
ue to find ways to help out and make
work safer during the pandemic. Here
are some notable highlights featured
on the Control Engineering website and
e-newsletters during the month of July. If
reading the digital edition, click on the
headlines to read the full story.
Reusable PPE for workers
Manufacturers looking to
be more flexible, analytical
in wake of COVID-19
Relayr, a global Industrial Internet of
Things (IIoT) company, surveyed more
than 200 leaders in the U.S. and German
manufacturing industries.
Topics ranged from how the crisis
affects their operations and how they’re
dealing with challenges presented by the
pandemic to their assessment of future
economic development.
Their six key findings from the sur-
vey were:
1. U.S. companies have been hit hard
by the crisis: Two-thirds cited a negative
impact on their business.
2. Investment behavior is curtailed:
Half of the surveyed companies expect-
ed lower investments in 2020.
3. Flexibility is the new mantra:
Almost 60% cited “increased flexibil-
ity” as the thing they want to improve
most on.
4. Equipment-as-a-service (EaaS)
models are becoming increasingly popu-
lar: This is beneficial for the supply and
demand sides in the current crisis.
5. Predictive analytics, IIoT use is
rising: U.S. companies are using predic-
tive analytics more; German manufac-
turers are using a mix of IIoT and AI.

A
study conducted by Georgia Tech researchers shows that ozone gas, 6. Easing of lockdown measures
a highly reactive chemical composed of three oxygen atoms, could shows positive effects: Since some
provide a safe means for disinfecting certain types of personal pro- restrictions have lifted, demand has
tective equipment (PPE) that are in high demand for shielding healthcare increased. ce
personnel from COVID-19.
The researchers, using two pathogens similar to the novel coronavirus, - Edited from a relayr press release by
the study found that ozone can inactivate viruses on items such as Tyvek CFE Media.
gowns, polycarbonate face shields, goggles, and respirator masks without
damaging them — as long as they don’t include stapled-on elastic straps.
The study found that the consistency and effectiveness of the ozone treat- Headlines
ment depended on maintaining relative humidity of at least 50% in chambers
used for disinfection. online
- John Toon, Georgia Institute for Technology Top five Control Engineering articles
Articles about returning to the office after
COVID-19, automation design software,
cloud efficiency, learning ladder logic and
more were Control Engineering’s five most
Health students use COVID-19 clicked articles from July 13-19, 2020.

pandemic to innovate solutions Laser inversion enables

multi-materials 3D printing

S
tudents and staff at Rice University, the Malawi University of Science Columbia university researchers develop
and Technology (MUST) and the University of Malawi, The Polytechnic technique enabling printing of circuit boards,
(Poly) gathered virtually for six weeks to iterate on creative devices that electromechanical components and robots.
address the COVID-19 pandemic. Ideas had been prototyped by students in Space-rate force/torque sensor devel-
Africa at Rice 360˚’s partner design studios in Malawi and Tanzania earlier. oped for Mars 2020 Rover
Plans were revealed at the institute’s annual intern showcase July 16, a vir- ATI Industrial Automation and NASA’s Jet Pro-
tual event this year, with participants joining the Zoom session from around pulsion Laboratories (JPL) developed a cus-
the world. Three of six proposals were presented at the showcase by 13 tom force/torque sensor for Perseverance, the
undergraduate interns and eight teaching assistants from Rice and Malawi. All Mars 2020 Rover project. See video online.
were the focus of videos the multidisciplinary teams were required to produce.
Graphene shield improves
Presentations included a mask-disinfecting system, a walk-through decontami- wastewater protection
nation unit and a “distancing” box for medical staff during patient intubation. Rice University researchers found that a
- Mike Williams, Rice University shield of graphene helps particles destroy
superbugs in wastewater treatment plants.

12 • August 2020 control engineering www.controleng.com

 We see plant operators ready for
problems without ever
experiencing one.
Emerson introduces Mimic Train – a revolution in training
simulation that gives plant operators dynamic, hands-on
experience for unplanned events. Mimic Train is the most flexible
operator training system available, customized to the needs of your
plant and process. And it is cloud ready, scalable, and seamlessly
integrates with DeltaV and other control systems.

To see how Mimic Train can revolutionize your training, go to

Emerson.com/WeSeeConfidentOperators

input #8 at www.controleng.com/information

The Emerson logo is a trademark and a service mark of Emerson Electric Co. © 2020 Emerson Electric Co.
INSIGHTS
THINK AGAIN
Hot topics in
Control Engineering
Research: For 2021, programmable logic controllers (PLCs), control
system integration, instrumentation, industrial wireless, industrial
PCs, industrial Ethernet and advanced process control are among
hot topics; 18 topics are in the top 10; 62 are in the top 20.
B
readth of automation
engineering knowl-
edge matters. Control
Engineering subscrib-
ers want to learn about an
amazingly wide array of top-
ics in automation, controls,
and instrumentation. To help
prioritize Control Engineer- Mark T. Hoske,
ing’s 2021 editorial calendar, Content Manager
a survey asked subscribers
to check off the most impor-
tant topical areas of coverage. (Thanks
to those who participated.) The diverse
M More
INSIGHTS
KEYWORDS: Control Engineering
2021 hot topics
Top 5 contains seven topics.
Top 10 has 18 topics.
Top 20 has 62 topics.
CONSIDER THIS
Contribute to industry knowledge and learn
from your peers at www.controleng.com.
ONLINE
See some write-in comments with this
article online at www.controleng.com.
Share your knowledge at:
www.controleng.com/2020articles
www.controleng.com/contribute
EXTRA THOUGHT
The research demonstrates what I’ve heard
consistently from subscribers in one form
or another since I joined the team in 1994:
Sometimes I don’t know what I need to
know until I read it in Control Engineering.
Write-in comments from the Control
Engineering subscriber survey on 2021
editorial topics included:
• All topics related to industrial automation.
• I appreciate every topic you share.
• Keep it up!
• Try your best. Stay safe. Enjoy your life.
14 • August 2020 control engineering
topical ranking follows, as
respondents stuffed 18 areas
of coverage into the top 10 and
an incredible 62 topics into the
top 20.
18 top 10 Control
Engineering topics
1. Programmable logic
controllers (PLCs)
2. Control system
integration
3. Instrumentation, industrial wire-
less - tie
4. Industrial PCs, industrial Ether-
net - tie
5. Proportional integral derivative
and advanced process control
6. Loop control
7. Energy efficiency, drives, machine
control, artificial intelligence/
machine learning (AI/ML) - tie
8. Process control, motors - tie
9. Process sensors
10. Supervisory control and data
acquisition (SCADA), power sup-
plies, COVID-19-related engineer-
ing topics - tie
62 top 20 topics: Long tail
of engineering interest
If you thought Control Engineering
subscriber interests in automation, con-
trols, and instrumentation might narrow
after that, think again. Topics broadened
considerably. To get through the top 20,
when accounting for ties, subscribers
ranked another 44 topics.
The 2021 editorial calendar will
be available soon, reflecting that wide
breadth of interests, but before plan-
ning for 2021, please consider sharing
your expertise with peers through 2020.
Thank you to those who have. ce
®
3010 Highland Parkway, Suite 325, Downers Grove,
IL 60515. 630-571-4070, Fax 630-214-4504
Content Specialists/Editorial
Mark T. Hoske, Content Manager
630-571-4070, x2227, MHoske@CFEMedia.com
Jack Smith, Content Manager
630-571-4070, x2230, JSmith@CFEMedia.com
Kevin Parker, Senior Contributing Editor, IIoT, OGE
630-571-4070, x2228, KParker@CFEMedia.com
Emily Guenther, Director of Interactive Media
630-571-4070, x2229, eguenther@CFEMedia.com
Amanda Pelliccione, Director of Research
978-302-3463, APelliccione@CFEMedia.com
Chris Vavra, Associate Editor
CVavra@CFEMedia.com
Contributing Content Specialists
Suzanne Gill, Control Engineering Europe
suzanne.gill@imlgroup.co.uk
Ekaterina Kosareva, Control Engineering Russia
ekaterina.kosareva@fsmedia.ru
Agata Abramczyk, Control Engineering Poland
agata.abramczyk@trademedia.pl
Lukáš Smelík, Control Engineering Czech Republic
lukas.smelik@trademedia.cz
Aileen Jin, Control Engineering China
aileenjin@cechina.cn
Editorial Advisory Board
www.controleng.com/EAB
Doug Bell, president, InterConnecting Automation,
www.interconnectingautomation.com
David Bishop, president and a founder
Matrix Technologies, www.matrixti.com
Daniel E. Capano, senior project manager, Gannett Fleming
Engineers and Architects, www.gannettfleming.com
Frank Lamb, founder and owner
Automation Consulting LLC, www.automationllc.com
Joe Martin, president and founder
Martin Control Systems, www.martincsi.com
Rick Pierro, president and co-founder
Superior Controls, www.superiorcontrols.com
Mark Voigtmann, partner, automation practice lead
Faegre Baker Daniels, www.FaegreBD.com
CFE Media and Technology
Contributor Guidelines Overview
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.
* Content should focus on helping engineers solve
problems. Articles that are commercial or are critical
of other products or organizations will be rejected.
(Technology discussions and comparative tables may
be accepted if non-promotional and if contributor
corroborates information with sources cited.)
* If the content meets criteria noted in guidelines,
expect to see it first on our Websites. Content for our
e-newsletters comes from content already available on
our Websites. All content for print also will be online.
All content that appears in our print magazines will
appear as space permits, and we will indicate in print
if more content from that article is available online.
* Deadlines for feature articles intended for the print
magazines are at least two months in advance of the
publication date. Again, it is best to discuss all feature
articles with the appropriate content manager prior to
submission.
Learn more at: www.controleng.com/contribute
www.controleng.com
 ACCELERATE

“
YOUR DIGITAL
TRANSFORMATION
What you’re doing now are the
early steps in a journey to get
JOURNEY
to where you’re ultimately going,
which is Edge Computing.
- Jason Andersen,
Leverage Edge Computing to
vice president, strategy
and business line management
ensure you are operating at
Stratus Technologies

peak performance.

Learn the 10 Best Practices

DOWNLOAD
for Edge Computing at
stratus.com/edgebestpractices
YOUR FREE COPY

TODAY!
Stratus.com/TrendReport

input #9 at www.controleng.com/information
ANSWERS
COVER STORY
Christian Johansson, ABB
How edge computing
will unleash IIoT potential
Combining the potential of Industrial Internet of Things (IIoT) devices with the processing
power of edge computing, automation solutions and analytics is giving manufacturing production
data more value. See five ways to make edge IIoT deployment more effective.
T
he Internet of Things (IoT) is present as
refrigerators order food deliveries and
autonomous vehicles schedule their own
service, examples of computing decisions
on the edge of the process and internet.
Manufacturing industries have taken a little longer to
implement the Industrial Internet of Things (IIoT),
but it is now making up for lost time, with significant
technology developments, including edge computing.
A major challenge industrial companies face is
how to make the best use of the data gathered from
IIoT-type devices and control systems in production
processes. Unleashing data value can be hampered
by a lack of the processing power needed to make the
most of the industrial data and convert it into useable
knowledge. Edge computing can move computing
power and data storage closer to where needed, deliv-
ering benefits including faster processing, improved
security and optimizing available bandwidth.
Manufacturer benefits
Edge computing and industrial analytics’ biggest
benefit for manufacturers is the
ability to use industrial data to
optimize production processes.
Companies have used edge com-
puting and industrial analytics
to help plants achieve accurate
and efficient production – they
are now looking at optimizing
it through low cost sensing, data
analytics and machine learning
(ML) to add efficiencies.
Putting computing power
near to devices it serves pro-
duces enhances speed by reduc-
ing latency, the time needed
Edge computing and the cloud are for data to travel from source
valuable for manufacturers, but they to destination. Latency can be
have different benefits. Edge com- greatly reduced by edge com-
puting is better for real-time needs; puting compared to sending it
cloud is better for long-term proj- to the cloud.
ects. Images courtesy: ABB These gains depend on
16 • August 2020 control engineering
the use case – if an application is trying to control
or interact with actuators and motors and the pro-
cess, then real-time control is needed. If long-term
process optimization based on the deep analysis of
trends is needed, the cloud is the better alternative
because it isn’t time critical.
One major benefit of combining the cloud with
edge computing is the ability to use the cloud to train
models using data from IIoT devices. These models
can then be executed at the edge, allowing devices to
respond more appropriately to changes.
Cloud connections can represent a security risk.
Cybersecurity needs to be top of mind when select-
ing edge computers. Automation vendors can sup-
ply systems that incorporate end-to-end security built
on application expertise. Edge computing also allows
more scalability as the business grows and produc-
tion plants expand. With a scalable range of comput-
ing devices, installations easily can expand for greater
volumes of data and more applications.
Choose an edge computing use case
Many potential edge computing customers are
exploring what’s possible and seeking the right use
case that will help their operations. Many industrial
users have increased efficiency with automation sys-
tems. To add extra percentages of efficiency, what’s
added should not compromise what exists now. That
difference can be found in IIoT and edge computing.
Using the edge for computing and as a gateway
to the cloud offers the potential to support many use
cases of varied complexities, from a self-contained
process to a set up involving multiple sites. A large
mining company wanted to compare operational
excellence, safety incidents and maintenance statistics
across its mines, treating them as fleet assets. When
operating multiple sites with the need to optimize
operations in different ways or optimize the value
chain across different factories or the transfer of goods
between factories and sites, then look at the cloud.
When it comes to artificial intelligence (AI) pro-
cessing of IIoT data, some vendors are driving AI
and ML technologies from the cloud, while others
www.controleng.com
are building from the edge. In between is federated
learning, a combination of smaller applications and
the ability to learn and optimize by learning from
a fleet of machines. The right choice depends on
what the company is aiming for – edge and cloud are
equally important depending on the use case.
An integrated system benefits from digital tech-
nology data, edge computing’s fast processing and the
cloud’s deep analysis and learning capabilities.
Improve edge IIoT in five ways
In the future, the most successful businesses will
be those that deploy an effective site, edge and cloud
strategy that can drive value by turning their collect-
ed data into useful information quickly, efficiently
and cost effectively and share it across the enterprise
wherever and whenever it is needed.
Consider these five recommendations that can
help to achieve these aims and ensure that expecta-
tions on return on investment are met.
1. Start with the edge computing use case
When starting an edge deployment, consider
where the industrial data comes from (such as intel-
ligent devices and/or control systems), connectivity
capabilities and how much processing will need to
be done at the edge versus how much can be done
through the cloud. This ensures applications using
real-time control data are hosted near the source
where data is processed quickly. This reduces laten-
cy and offering the best possible response times
while other analytics are done in the cloud and easily
shared between sites.
2. Keep edge computing simple
The great thing with edge computing is its scal-
ability, with elements such as new edge nodes or
devices that can be added later down the line if nec-
essary. Achieving this should be made as easy as
possible by choosing solutions that allow easy con-
nectivity between devices and systems and seamless-
ly bridge information technology (IT) and operations
technology (OT) functions to give a greater insight
into the data. Fast deployment of new value adding
applications should also be easy.
When it comes to selecting the appropriate tech-
nologies for an edge IIoT project, it pays to opt for
solutions that are already pre-validated and proven to
work together. Taking this approach will help ensure
the edge IIoT solution can be deployed and/or scaled
up quickly with a minimal risk of potential errors
caused by untested or non-compatible technologies.
3. Difference between the edge and the cloud
Both edge computing and the cloud serve dif-
ferent purposes, with neither being more dominant
than the other. Consider the use case characteristics
and how the data will be used to guide the choice.
The key differences between edge and cloud
include bandwidth, latency and network availability.
The main reasons for choosing edge computing over
cloud computing are performance related. Edge com-
puting is ideal for real-time applications where a fast
www.controleng.com
COVER: Edge computing has already been used by many manufac-
turers to become more efficient and productive, but the Industrial
Internet of Things (IIoT) can help make the data smarter.
response is needed. The cloud better fits applications
calling for centralized collection and analysis of com-
plex data where time is less critical.
4. Consider security and integrity
Data, which serves as a company’s collection of
know-how, ideas and operations, is the most valuable
asset and needs to be protected. In designing an edge
IIoT solution, and choosing the right partner to help
deliver it, cybersecurity and data privacy must be the
top priority. Security should extend to all levels, pro-
viding robust protection from cyber infiltration and
unauthorized access and ensuring plant integrity and
confidentiality through inherent security features. The
cybersecurity provider also should help maintain data
confidentiality, providing full transparency on how it’s
used and stored and ensuring nothing is disclosed to a
third party without prior consent.
Ensure the edge computing provider
can guarantee continued protection against M More
INSIGHTS
potential security issues by evolving soft- KEYWORDS: edge computing,
ware and hardware so products keep pace Industrial Internet of Things, IIoT
with cybersecurity standards. Edge computing and the cloud
5. Pick an edge computing partner can be combined to improve data
Finding the right edge computing ven- speed and value.
dor or partner can be key to determining Edge computing is better for
the success of an edge IIoT deployment. applications where data is needed
immediately; the cloud fits long-
Look for an established portfolio of prod- term applications.
ucts and applications that can be integrat- Consider cybersecurity in edge
ed. The vendor or partner also should be computing implementations.
able to demonstrate a good track history
ONLINE
in deploying and supporting solutions in
Read this article at
industries and applications that are either www.controleng.com for more on
the same or similar to yours. ce edge computing and the cloud.
www.controleng.com/control-
Christian Johansson, global product man- systems/embedded-systems-
ager - digital for ABB Process Control Plat- edge-computing
form. Edited by Chris Vavra, associate CONSIDER THIS
editor, Control Engineering, CFE Media How can edge computing and
and Technology, cvavra@cfemedia.com. cloud help your applications?
control engineering August 2020 • 17
ANSWERS
HUMAN-MACHINE INTERFACES
Bill Dehner, AutomationDirect
Embedded HMIs excel in
automation applications
Delivering the right human-machine interface (HMI) experience is
critical whenever people need to interact with automation.
T
he ways we interact with our phones,
vehicles, and automation systems have
been generalized as human-machine
interfaces (HMIs). Using a car, for exam-
ple, HMIs have progressed over the years
from mechanical (manual transmission stick shift),
to electrical (headlight switch), to digital (touch-
screen navigation controls). Digital systems appear
to be the highest evolution of the HMI, and there are
a few ways to implement these types of interfaces.
For today’s industrial automation systems,
users generally have two options for digital HMIs
installed on the plant floor. They can select dedicat-
ed HMIs, also known as embedded HMIs, built for
purpose. Or, they can choose standard or industri-
al PCs (IPCs) running more general operating sys-
tems (OSs) and IPC-based HMI applications.
Because PCs are so common, many might think
an IPC solution is the best choice because embed-
ded HMIs were less capable than IPC-based HMIs.
However, embedded HMIs can perform
nearly all the same functions of an IPC
HMI, with a lower net operating cost,
smaller form factor and easier main-
tainability. Following are some points
to consider when deciding between an
embedded or an IPC-based HMI.
HMI evolution
The first automation HMIs were
simple and physical pilot devices such
as pushbuttons, switches, lights and
needle gauges. These allowed operators
to initiate inputs to automation systems
Figure 1: Digital HMIs, such as this
AutomationDirect C-more embed-
ded HMI, consume less installation
space that physical pilot devices
and provide a better developer
and end-user interface experience.
Courtesy: AutomationDirect
18 • August 2020 control engineering
and obtain output indications of status. Some devic-
es, such as selector switches, provided input and out-
put capability. Many users appreciated the immediate
response and tactile feedback of these panel-mount-
ed devices serving as human-machine interfaces.
Digital HMIs were a great advance. Users could
pack a far greater density of controls and indicators
into one interface display, taking up only a modest
footprint. The configuration could be updated via
software and it was far easier than reworking and
rewiring a physical control panel (Figure 1).
Early digital HMIs were mission-specific
embedded systems only capable of the specific and
limited operations technology (OT) tasks they were
designed to perform, making them highly efficient
and lightweight from a computing standpoint.
As PCs – and later IPCs and then mobile devic-
es – became available with general-purpose infor-
mation technology (IT) OSs, suppliers created HMI
software to run on these systems. IPC-based HMIs
quickly overtook embedded HMIs in performance,
capabilities, and look-and-feel. However, these fea-
tures came at a price.
Reasons to use IPC-based HMIs
PCs and their ruggedized IPC counterparts
gained functionality and lowered costs due to
mass commercial adoption. Major benefits of PCs
employed as HMIs include:
• Rapidly updated high-performance processors
• Generous memory
• Large storage
• Numerous wired and wireless connectivity
options
• Repairable component-based designs
• Capability to host higher-level functionality
software, such as databases and analytics
• OT personnel could choose from many HMI
software packages
• Improved integration with IT systems.
So what is not to love about the comprehen-
www.controleng.com
Looking for industrial automation
components fast?

All items shown

on our webshop
ship the same day
you place your order!

you place your order!

ship the same day
on ouratwebshop
Strong brands available www.automation24.com
www.automation

www.automation24.com
24 – your online supplier for automation technology
AHU
LQTAU QUAQUQAUA EPTEIPOTENIPOTNEIOTIEOPNETPIO
PN TINON EY EBYEBY BEY BEYEBY B
H QHUQ
IG IG IG IIG
LIA
H T ILGITHIGLHIT LITLIT XC XC XC XAC AXCAXC A A A ONONONACOANC AOCNOANC ACAC
PPLIPCPALPICPALICPAPLICAPPLPICPALITCI ATI
E A E A E ATI E TAI TIE A ETAI 2 2 2 2 22
$$$$$$
M
M
M
M
M
M

90909090 9090
K
K
K
K
K
K
E
E
E
E
E
E

L
L
L
L
L
L
H
H
H
H
H
H

YEAR
YEAR
YEAR YEAR
YEAR
YEAR
Y
Y
Y
Y
Y
Y

FRE
FRE
FRE

FRE
FRE
FRE

ON
ON
ON

ON
ON
ON

PIN GINGING ING INGING

SHPIPSPHIPPSHSIPHPIPP
IP
INININ
STOCK
IN
STOCK
STOCK STOCK
ININSTOCK
STOCK DAYS
DAYS
DAYS DAYS
DAYS
DAYS
SHIP
SH
100 %
100 %
100 %

100 %
100 %
100 %
100 %
100 %

100 %
100 %
100 %
100 %

P R P R P R P RS PSRPSR S S S S U S U S U TS UT STUS UT T T G U G U G U G UE GE UGEU E O VO VO V O0 V5 0 O O

O DOUDO UTD
CUTDCO C TUOCDOTUDCUTC T P R IP R PINCRGIINCPG P NPIGR N GN G P PPOPRPOPROPRP OPRPPOPRO R E ENRTAEARNATNE ET E E 5 0V$E5VR0E$R5$05 0
CI IRNI CGI R CI CI A RA ARNAATRENATANRTA A E R E$R5E$R $E R

$
O D UC TS CI
PRI N G P P O RT A R A NTE
OV
ER $ 50
PR SU GU E

IN STOCK DAYS
YEAR 90
% 001

% 001

SHIPP
ING
IG XC 2
F

NO

EA
H QUALIT PPLICATI ON
ER

EPTIONA EY BAC
Questions about your application? Require support before, during and after your order?
H

M
L

We can help! You can reach our support team Monday through Friday from 8 am – 6 pm EST.

800-250-6772 (free) or 610-981-2900 mail@automation24.com www.automation24.com

input #10 at www.controleng.com/information
ANSWERS
HUMAN-MACHINE INTERFACES
industrial use. IPCs are built for the target environ-
ment, but this specialization means the hardware is
more expensive than office-grade PCs.
tem, which users must carefully manage and update.
Embedded HMIs are not immune from the need for
M More
ANSWERS
KEYWORDS: Human-
machine interface, HMI,
embedded PC
Industrial PCs (IPCs) are
used by many on the plant
floor, but embedded HMIs
can do many of the same
things.
Embedded HMIs are seen
as the best technical choice
for local displays out on the
factory floor; industrial PC
(IPC)-based HMIs may be
perceived as a better fit for
larger applications.
ONLINE
See more articles
from the author, a mobile
HMI photo, and more about
remote connections.
www.controleng.com/
info-management/hmi-oi
CONSIDER THIS
What benefits could
embedded HMIs bring?
20 • August 2020
Figure 2: Ready to work
almost right out of the
box, embedded HMIs are
designed with robust and
compact form factors, reduc-
ing overall costs. Courtesy:
AutomationDirect
sive flexibility of an IPC-based
HMI? In most cases, especial-
ly for mid-sized equipment or
smaller machines, the overall
lifecycle cost for using an IPC
HMI exceeds an embedded
HMI’s cost. In many situations,
IPCs are too feature-rich for an
industrial HMI’s job, driving
up costs and complexity.
Complications manifest
themselves in hardware, OS
and software management.
PC-based hardware is mod-
ular and economical, but not
well suited to the rigors of
Another part of the problem is the operating sys-
performance and security updates, but PC-
based platforms are more vulnerable and must
get frequent cybersecurity updates.
A benefit of IPC HMIs is users can choose
from dozens of HMI applications, suites and
related software products like historians,
reporting packages and more. Users can cre-
ate their own custom-coded applications. The
diversity of software options places a burden on
the end user to confirm interoperability, keep
up on licensing costs and requirements and
update the software. An IPC can form the basis
for an attractive HMI. It may run for years as
it was installed, but it is more likely to require
ongoing support and updates.
Users also must consider their display
needs. Many IPCs are standalone boxes need-
ing a separate panel-mount display. While this
means users can mix and match the exact parts
they want, it creates more effort on the installa-
tion side. Maintaining a consistent panel cutout
size for the display is a great concern for future
maintainability of any HMI.
For these and other reasons, those consid-
ering an IPC HMI should look at embedded
HMI options.
control engineering
Embedded HMI functionality
The size of the application in terms of tag count
and number of displays needed can be a major fac-
tor when determining the best type of HMI. For
many types of equipment and processes that are
mid-size and below, an embedded HMI offers the
right level of functionality.
While embedded HMIs may use some commer-
cially-based computing elements, their hardware
design is tailored for the role with accommodations
for the temperature and other environmental fac-
tors associated with industrial applications. Instead
of using a resource-hungry general-purpose OS, an
embedded OS only needs to host the HMI functional-
ity, which requires less processing power and memory.
Embedded HMIs are often ready to work right
out of the box. Their all-in-one touch screen form
factor is easy to work with, presents fewer points of
failure than an IPC-based HMI assembly, and lends
itself to maintaining a spare on the shelf. They can
be quickly deployed, whether for a new project or
replacing a unit for an existing system (Figure 2).
Embedded HMIs also can make good economic
sense from several standpoints:
• Dedicated, sometimes free, PC-based software
development environments are easier to set up
• Runtime software included
• Complete product pricing typically less than
an IPC plus software licensing
• Compact and robust design is better for
installation and maintenance
• Standalone configurations are less likely to
need system updates
• Faster to replace an entire unit than for an
IPC-based solution.
HMI platforms used to compete based on
detailed feature sets. Maturity of today’s HMIs
include a lot of crossover functionality between
IPC-based and embedded HMIs. Both types can:
• Communicate with many types of target
devices
• Support a variety of industrial protocols
• Are configured with tags
• Provide a rich variety of graphical objects
• Offer animation options.
In some cases, that maturity has led to simpli-
fication. Simplified high-performance HMI design
principles have replaced excessive animation associ-
ated with older HMI designs. ce
Bill Dehner, technical marketing manager, Automa-
tionDirect. Edited by Chris Vavra, associate editor, Con-
trol Engineering, CFE Media, cvavra@cfemedia.com.
www.controleng.com
input #11 at www.controleng.com/information
ANSWERS
AUGMENTED REALITY
Anna Velena and Vineesh Kapoor, Emerson
Augmented reality tools:
A digital bridge for the skill gap
Augmented reality (AR) is changing how manufacturers work in the field. See
three benefits of augmented reality and three examples of how AR helps users.
A
s a new generation of technicians begins
to step up, plant management can no
longer rely on workers’ long-nurtured
abilities to detect sights and sounds in
the field. Those skills will come with
time, but to accomplish continual improvements to
safety, productivity and efficiency, organizations need
to provide field technicians with tools such as aug-
mented reality (AR) to bridge the gap and accelerate
skill development. AR is already moving beyond the
buzz and delivering value to organizations. The differ-
ence between flashy digital transformation technology
and practical value to business is in the strategy.
Prepare a strategy to get the most practical value
from AR technology. Adopters should look for AR
22 • August 2020 control engineering
solutions that integrate with existing plant and oper-
ations technology (OT) systems that provide three
key benefits: situational awareness, IoT data integra-
tion and live remote assistance. Building a strategy
around these elements helps organizations implement
with ease and achieve fast return on investment (ROI)
through practical AR applications to their operations.
Two issues that vex new and incumbent workers in
the field are knowing where to find devices and iden-
tify the correct assets when they have made it to the
right location. Industrial sites can easily have thou-
sands of devices scattered across large areas in the
field. Further complicating asset identification, some-
times a facility can have similar devices adjacent to
each other, making it possible for an inexperienced
technician to disable the wrong device by accident.
AR helps field workers build the situational aware-
ness they need to quickly locate malfunctioning devic-
es to resolve issues. Advanced AR technology includes
functionality that helps operations and maintenance
personnel visually map elements in the plant so that
they can locate, identify and resolve problems.
Navigation tools built into AR help users locate
assets. Using their mobile devices, plant personnel can
view assets in the field and see overlays that identify
assets by name and provide an intuitive health status.
AR situational awareness, processing
One chemical manufacturer in North America
has a large manufacturing site with numerous facili-
ties – many of them adjacent to one another.
Contracted instrumentation and engineering
(I&E) technicians often don’t know the layout of the
facility they are working in, so every time they visit,
they are chaperoned by a plant employee to make
sure they work on the correct equipment.
To reduce the time personnel must spend chaper-
oning I&E technicians, the organization is implement-
Figure 1: AR tools provide new and incumbent
field technicians with situational awareness,
helping quickly locate needed assets and pro-
viding tools to work more efficiently once they
arrive. Images courtesy: Emerson
www.controleng.com
 Learn
more

The future of visualization

starts now!
SIMATIC WinCC Unified is a new visualization system you can
use to overcome the challenges of digitalization in mechanical
engineering and plant construction. It offers proven engineering
in the TIA Portal and the latest web technology, so you can
implement your ideas the way you imagine them.

Join the WinCC Unified community to be one of the first to learn

© Siemens Industry, Inc.

how to turn visualization of the future into reality.

usa.siemens.com/wincc-unified

input #12 at www.controleng.com/information

ANSWERS
AUGMENTED REALITY

ing AR technology. This allows the I&E technicians to
use AR technology to find a landmark such as a com-
mand center or a skid unit, and then quickly identify
the right assets through an overlay on a mobile device.
AR IIoT data integration
For AR to deliver the most value to operations,
the technology must be integrated with OT data sys-
tems such as an asset performance platform. However,
manually engineering that integration can be expen-
sive. Organizations should prioritize solutions with
native integration that eases implementation. Other-
wise, they risk spending more than the
Asia has decades of plant knowledge stranded in
the brains of an ever-diminishing number of expe-
rienced technicians and engineers. The reliabil-
ity team wants to capture this knowledge to help
upskill future generations of workers at the plant.
To build the database necessary to preserve knowl-
edge, the reliability team will capture the methods of
experienced personnel in the AR system and tie them
to the assets they impact. Newer technicians will have
fast access to that knowledge directly from the field.
The captured knowledge will serve as a powerful
tool in the field as well as a learning platform to help
improve the skillset of inexperienced personnel.

M More
ANSWERS
KEYWORDS: augmented reality,
Industrial IoT, skills gap
Augmented reality (AR) technology
can help younger workers learn skills
from older workers.
For AR to deliver the most value,
the technology must be integrated
with operations technology (OT)
data systems such as an asset
performance platform.
AR can cut costs and safety risks and
improve collaboration and training.
ONLINE
With this article online see
another photo and more text.
Search “augmented reality” at
www.controleng.com for more on
augmented reality.
CONSIDER THIS
What plant applications would
benefit most from augmented reality?
technology costs just to implement it.
Integration provides field workers
with instant IoT data relevant to a spe-
cific asset. Using a mobile device, users
can tap the asset to bring up its entire
catalog of asset and process data, doc-
umentation, and maintenance history.
With immediate access to relevant
asset data, field operators and techni-
cians avoid the need to make multiple
trips back and forth to the mainte-
nance staging area. Assets are fixed
efficiently, reducing outage lengths and
simplifying routine maintenance.
AR tools also help level the playing
field for less experienced technicians
by ensuring they have all tools need-
ed for fast troubleshooting and main-
tenance – including history of work
on the asset, notorious problems, and
notes left by previous technicians.
A natural gas organization in
AR also gives field technicians immediate access
to a knowledge library containing tools they need to
perform maintenance. Currently, technicians print
manuals and loop diagrams to take to the site. If
they arrive and discover they have the wrong mate-
rials, they need to go back. With AR, technicians
know they always can access the right documen-
tation – loop diagrams, datasheets, manuals, plant
diagrams, and more – on the mobile device.
AR live remote assistance
Even when equipped with the right tools and
resources, technicians can run into problems in the
field they don’t know how to fix. When an assigned
technician can’t figure out what is wrong, they often
escalate the issue to more experienced personnel.
experienced technicians and engineers are in high
demand and waiting for them to travel to site often
can cause extended delays.
A more efficient solution is to remove the need for
experts to travel to site. AR enables multiple techni-
cians to work together from anywhere to resolve the
problem more quickly. Experts can use AR tools to see
what the field technician is seeing and share live on-
screen annotations, provide voice and text assistance,
and link to additional resources. When experts are
available faster and have more tools to help fix prob-
lems in the field, asset downtime is reduced, leading to
fast return on investment for the AR system.
At the natural gas facility in Asia, technicians cur-
rently use a phone or a chat app to communicate
with experts from the field. If a problem occurs late
at night, this means waking up the expert on call and
having them search the internet for a manual to pro-
vide guidance over the phone. With AR, experts
can avoid site trips. The experts have remote assis-
tance tools and documentation available in exist-
ing mobile devices to point a field technician in the
right direction. ce

Anna Velena, product manager for software inter-

faces; Vineesh Kapoor, director of Plantweb product
Figure 2: AR collaboration tools allow experts to see a field techni- management, Emerson. Edited by Chris Vavra, asso-
cian’s display, making it easier to remotely guide field technicians ciate editor, Control Engineering, CFE Media and
with step-by-step instructions and on-screen annotations. Technology, cvavra@cfemedia.com.

24 • August 2020 control engineering www.controleng.com

 UNWANTED INVENTORY
TAKING UP VALUABLE SPACE?

Sell us your unwanted

industrial automation product.

Radwell.com - 800.884.5500 - sellto@radwell.com

input #13 at www.controleng.com/information

Radwell_Asset_7x10_2020.indd 1 6/1/2020 1:30:24 PM
ANSWERS
WIRELESS
Ford Cheeseman, Siemens

What industrial wireless

network should I use?
Are your industrial wireless local area networks up to date? Industrial
communications are taking another leap forward with IEEE 802.11ax and 5G
wireless technologies. Evaluate industrial wireless LAN (iWLAN) technologies.

T
he steady evolution of fast, determin-
istic and reliable wireless networks in
industrial environments has been a
critical driver behind the realization
of Industry 4.0 and Industrial Inter-
net of Things (IIoT) concepts over the past decade.
Industrial communications are taking another leap
forward with IEEE 802.11ax and 5G wireless tech-
nologies available for industrial environments.
That’s why it’s a good time to evaluate the status
of industrial wireless LAN (iWLAN) technologies
supporting production plants and their associated
logistics and warehouse facilities. [LAN stands for
local area network.]
Industrial engineers working in operations tech-
nology (OT) environments should work together
with their enterprise information technology (IT)
counterparts to develop wireless mod-
Closing wireless latency gaps, real-time
The biggest shortcoming was data transmis-
sion latency – mostly from data collisions within
the iWLAN’s shared medium that require data to
be retransmitted. Too many retransmissions of the
same message can cause an expiration of watchdog
timers that monitor the response time of control
and safety data traffic between sensors and pro-
grammable logic controllers (PLCs), leading to nui-
sance faults that can disrupt production.
It can be especially problematic when roam-
ing is involved. That’s because the moving client is
transitioning its wireless communications from one
access point (AP) to the next. The time required to
re-associate to the new AP, which can be even lon-
ger if it must go through an AP controller, can also
lead to communication faults that compromise the
effectiveness of control and safety systems. These

M More
ANSWERS
KEYWORDS
Industrial wireless, 5G, IEEE
802.11 wireless
Closing wireless latency gaps
can achieve real-time wireless
communications.
Industrial wireless is more than
hotspots.
IEEE 802.11ax and 5G boost
future network communication
options.
CONSIDER THIS
Where do you need real-
time industrial wireless
communications?
ONLINE
If reading from the digital
edition, click on the headline for
more resources.
www.controleng.com/magazine
www.controleng.com/
networking-and-security/
wireless/
ernization roadmaps to ensure max-
imum performance, reliability, and
security in coming years. The collabora-
tion between OT and IT teams is critical
because data can be used differently in
industrial environments than enterprise
ones. This primer on industrial wireless
communications intends to help OT and
IT professionals better collaborate on
those roadmaps.
It’s been more than 20 years since
the IEEE first ratified the original IEEE
802.11 wireless standard, with IEEE
802.11a,b, and g versions quickly fol-
lowing, all mostly designed for office
and home applications under the “Wi-
Fi” trade name. Although some plant
engineers may have trialed these ver-
sions in industrial applications – most-
ly with hopes of reducing cabling costs
and gaining floorplan configuration
flexibility – the deterministic inade-
quacies of these early Wi-Fi versions
became apparent in OT networks.
delays may even influence controls engineers to
increase their watchdog timers to accommodate the
longer latency, sacrificing their control and safety
standards to keep production running.
The introduction of IEEE 802.11n in 2009 and
IEEE 802.11ac in 2014 helped changed this. Trans-
mission speeds of each increase by orders of mag-
nitude over their previous standards and specific
technology developments helped ensure greater
determinism for OT applications—with latencies as
low as 17 milliseconds.
Such technology reduces, fixes and distributes
even the polling cycles among clients enough to
minimize latencies and allow for much faster roam-
ing times. A variation of this protocol was devel-
oped especially for continuously moving nodes like
those aboard automated guided vehicles (AGVs)
and cranes, to further boost performance and
reduce roaming times to under 50 ms.
Industrial WLANs are not just hotspots
Establishing iWLANs takes more tech-savvy than
setting up Wi-Fi in a home, office or café. Hotels, air-
ports and municipalities may be more complex under-

26 • August 2020 control engineering www.controleng.com

input #14 at www.controleng.com/information
ANSWERS
WIRELESS
takings because of their scale, but in a production
plant wireless connectivity must meet much more rig-
orous demands. Here are two other differences:
• Fail-safe reliability: Data loss or corruption
during transmission in non-industrial environ-
ments isn’t always critical since the data can
often be retransmitted without any detectable
impact by the recipient. In industrial environ-
ments, however, failed data transmissions can
compromise process and safety controls, leading
to plant downtime, quality issues and injuries.
• Radio interference, attenuation, and reflec-
tion: Non-industrial environments tend to lack
the different sources of radio frequency (RF)
interference, reflective objects, and attenua-
tion that industrial environments have: large,
odd-shaped metal machinery, ductwork, metal
decking, and aluminum rolling doors can
reflect RF waves; thick concrete walls or mate-
rials stored in warehouse racks that can block
them; and a range of other sources of radio sig-
naling – RFID, neighboring industrial WLANs
and office WLANs, to name a few.
IEEE 802.11ax and 5G options
Given the growth in IoT and IIoT device num-
bers and density, IEEE 802.11ax shifts the Wi-Fi par-
adigm from theoretical peak data speeds to overall
network capacity. To be sure, IEEE 802.11ax increas-
es speeds from IEEE 802.11ac up to 10 Gbps, a 37%
boost. Using an orthogonal frequency-division mul-
tiple access (OFDMA), which was borrowed from
4G LTE technology, the IEEE 802.11ax standard
improves spectral efficiencies enough to support
the communications of a million devices per square
kilometer.
Industrial 5G
is another animal
Wireless connections are ideal for applications where it would be too
complex or even impossible to lay cables. The Siemens Scalance W
line provides flexibility and fail-safe communications without a wired
connection. Courtesy: Siemens
28 • August 2020 control engineering
entirely. It opens the door to the comprehensive,
wireless networking of all kinds of new applications
in production, maintenance, and logistics. High
data rates, reliable and powerful broadband trans-
mission, and ultra-short latencies will boost effi-
ciency and flexibility in industrial value creation,
although all of these benefits will not be available
simultaneously.
Industrial 5G raises a lot of questions on how
the new communication standard can be best
implemented. Some automation companies have
5G research teams working with standards bod-
ies to bring customers 5G when it’s ready for full
deployment in industrial environments. In the
meantime, sticking with IEEE 802.11 Wi-Fi stan-
dards, particularly IEEE 802.11n, ac and ax, is rec-
ommended, depending on the wireless industrial
application.
Time to update industrial WLANs?
Many iWLANs in use today may have been
deployed with IEEE 802.11a, b, g or n technolo-
gy that is in some cases now a decade old. Plant
engineers should consider evaluating their cur-
rent networks for modernization – or at least a
modernization roadmap – in concert with indus-
trial networking experts and their enterprise IT
counterparts.
While 5G and IEEE 802.11ax are the future direc-
tions of wireless, IEEE 802.11ac and IEEE 802.11n
are capable today of providing the fast throughput
and low latencies industrial applications require.
For example, IEEE 802.11ac can provide the
throughput needed for video applications, while
IEEE 802.11n is valuable for industrial MIMO (mul-
tiple input, multiple output) applications. The latter
can support mobile automated guide vehicles and
overhead cranes by helping to deal with ever-chang-
ing RF reflections as one moves through a plant.
In addition, where deterministic communi-
cations such as control traffic and safety must be
prioritized, iWLANs can be optimized using tech-
nology that adds determinism to industrial wire-
less communications.
Low latencies can improve edge computing
performance, workers assisted by virtual and aug-
mented reality (VR/AR) technologies, provide
greater mobility in plant equipment, machines,
autonomous machines and logistics.
Of course, the greater sophistication of these
applications will require more sophisticated RF
engineering, making careful site surveys and other
best practices critical to successful deployments. ce
Ford Cheeseman is automation networking con-
sultant, Siemens. Edited by Mark T. Hoske, content
manager, Control Engineering, CFE Media and
Technology, mhoske@cfemedia.com.
www.controleng.com
Calling all system integrators...

Control Engineering and

Plant Engineering’s annual
System Integrator of the Year Awards

Entries are due September 4, 2020

Who should enter?

If you’re a system integrator with demonstrable industry success, Control Engineering and
Plant Engineering urge you to enter the 2021 System Integrator of the Year competition.
Past System Integrator of the Year winners—Class of 2020, Class of 2019, and Class of
2018—are not eligible to enter the 2021 System Integrator of the Year program.

What’s in it for the winners?

The chosen System Integrator of the Year winners will receive worldwide recognition from
Control Engineering and Plant Engineering. The winners also will be featured as the cover
story of the Global System Integrator Report, distributed in December 2020.

How will the competition be judged?

Control Engineering and Plant Engineering’s panel of judges
will conscientiously evaluate all entries. Three general
criteria will be considered for the selection of
the System Integrator of the Year:
• Business skills
• Technical competence
• Customer satisfaction

Questions?
Contact Tom Magna
System Integrator
Marketing Consultant
CFE Media
tmagna@cfemedia.com

For more information on how to enter and proper criteria, visit:

www.controleng.com/events-and-awards/system-integrator-of-the-year-program
ANSWERS
5G WIRELESS
Daniel Quant, MultiTech Systems Inc.

Six answers about 5G wireless

Industrial communications is adding 5G to wireless protocols to use.

I
ndustrial applications will benefit from 5G 2. What are 5G’s main benefits?
wireless technologies. See answers about 5G
wireless from Daniel Quant, vice president,
strategic development, MultiTech Systems Inc.
1. What’s 5G’s rollout status?
Quant: More than 50 operators in more than 30
countries have launched one or more 3GPP 5G com-
mercial service, about 8 to 10% of 4G-LTE network
operators. Initial focus was on consumers and com-
mercial enterprises requiring faster and lower laten-
cy wireless connectivity, mobile to smartphones or
fixed to commercial and residential buildings (3GPP
5G-NR [New Radio] Release 15 – Enhanced Mobile
broadband). [3GPP is the 3rd Generation Partnership
Project.] More than 10 million handsets have shipped
globally, with a few million more customer premise
equipment (CPE) devices connecting outside or inside
of buildings to 5G fixed wireless access services. South
Korea, USA and China lead new service deployments.
Quant: Enhanced broadband data speeds, esti-
mated at well over 1 Gbps, lower latencies – for
most at less than 10 ms and targeted at sub 1 ms
with ultra-reliable connectivity for industrial mis-
sion critical assets (3GPP release 16, released in June
2020). Far higher density of low power lower bit rate
machine connections, many running on batteries for
years, often referred to as massive machine connec-
tivity (3GPP release 17 expected by 2022)
3. What will be the top 5G applications?
Quant: I think industrial transformation (well
behind the digital transformation of most smartphone
consumers) is the 5G game changer. Connecting
machines and workers for greater process efficiency
and improved data-driven decision making. Much
of this will be privately deployed by industrial enter-
prises, such as oil and gas, utilities, real estate owners,
transportation and other industries for improved net-

Rugged Stainless Steel Enclosures

Extensive stainless steel offering
has been expanded.
New HWSSHK Series:
• Durable 14 gauge 304 or 316L stainless
steel construction
• Heavy duty 316 SS piano hinges and
padlockable handles
• UL/CSA Type 4X approved
• Painted steel version available

Trust your next project to

Hammond enclosures.
Quality Products. Service Excellence.
Visit hammondmfg.com to learn more.

hammondmfg.com | (716)630-7030 | sales@hammfg.com

input #15 at www.controleng.com/information

 More agile business models and net-
work architectures enable enterprises to
capitalize a converged wireless private
5G network with edge intelligence for
improved security, greater performance,
faster decision making along with
reduced bandwidth, cloud compute and
storage costs. 5G wireless standards
efforts are helping. QAM is quadrature
amplitude modulation. MIMO is multiple
input and multiple output. Courtesy:
MultiTech Systems Inc.

work performance targeting sub-millisecond ultra-
reliable connectivity for mission-critical assets and
services vs. large scale deployments of low-power-con-
strained devices, such as sensors and actuators.
milli-wave spectrum are being rolled out, improving
access to more spectrum bandwidth and
increasing data performance.

6. What else can you add?

4. What are 5G adoption challenges?
Quant: Thousands of sensors require low bit
rate long battery life often in difficult to reach plac-
es sharing 5G-NR resources with enhanced broad-
band and sub-millisecond latency time-series
networks for mission-critical control automation.
Who will manage these new networks?
5. What 5G developments are near?
Quant: Improved data speed and reduced latency
target consumers. Early 5G-NR networks gain matu-
rity. Dynamic spectrum sharing and mid-band and
Quant: 3GPP 5G new radio is a stan-
dards-driven process and will be for years.
Industrial enterprises have the most 5G
benefits to gain and are joining 3GPP stake
holders with data transformation needs for
upcoming releases and work items. ce
Daniel Quant is vice president, strate-
gic development, MultiTech Systems Inc.
Edited by Mark T. Hoske, content manag-
er, Control Engineering, CFE Media and
Technology, mhoske@cfemedia.com.
M More
ANSWERS
KEYWORDS: Industrial wireless,
5G for industry
Industry will use 5G wireless
technologies.
5G wireless services are
ramping up, and applications
offer industry benefits.
CONSIDER THIS
Are you developing or using 5G
industrial wireless applications?
ONLINE
Click on the headline for more
on each point and related links.

Finally, an I/O solution we

can milk for all it’s worth.
Sealevel is an American-owned designer and manufacturer of critical The SeaLINK® 2402 USB
communication products, I/O and industrial computers. With more than serial I/O adapter provides
30 years of experience and over 250 standard products, our forte is using USB connectivity to legacy or
non-USB compliant devices.
in-house engineering to create custom adaptations for our partners,
precisely matching their application requirements.

Industrial automation. It’s where Sealevel got its start. Let’s start something together. SEALEVEL.COM

input #16 at www.controleng.com/information

ANSWERS
SYSTEM INTEGRATION PRIORITIES
Ryan Courtney, MEM, PMP, Matrix Technologies Inc.

How to build a system

integration business case
for automation, controls
When starting any system integration project, consider four fundamental
components to business case development: business needs, situational
analysis, recommendation and evaluation to create due diligence
for project management.

P
roblems are the driving force behind
automation and operational technology
engineering projects. Company leader-
ship recognizes this need and relies heav-
ily upon cross-functional teams to study
feasibility and determine if a business case can be
developed for system integration projects as part of
effective project management.
Management uses a business case to quantita-
tively and qualitatively determine the economic
feasibility of a system integration effort current-
ly lacking in definition. The business case is a key
input to the project charter and will be a living doc-
ument throughout the life of the system integration
project that serves as a litmus test against the engi-
neering project objectives.
Within the initiation phase of any system inte-
gration project, four fundamental components to
business case development need to be considered:
business needs, situational analysis, recommen-
dation and evaluation on the way to creating due
diligence.
1. Determine business needs
for a system integration project
Determining business needs is an important
first step in the process of developing a solid busi-
ness case for an industrial system integration proj-
ect. Accomplish this by assessing needs, identifying
stakeholders and identifying scope.
A needs assessment is a data collection process
that identifies business needs versus wants and cor-
responds to the gaps between the current situation
and the desired outcome. This manner of data col-
lection involves understanding regulatory require-
ments, surveying stakeholders and analyzing
historical data, as well as an important component
Don’t press your luck by starting a major sys-
tem integration project without considering
business needs, situational analysis, recom-
mendation, and evaluation, according to Ryan
Courtney, MEM, PMP, project manager, Matrix
Technologies Inc. Courtesy: Mark T. Hoske,
CFE Media and Technology
of listening to the customers involved in the project.
Stakeholder identification is a process of engag-
ing all key decision-making personnel to collabo-
rate on determining the business need. Stakeholders
often represent operations, maintenance, engineer-
ing, procurement, and environmental health and
safety, in addition to a representative or champi-
on from the steering committee or leadership. The
challenge in stakeholder identification is ensuring
all key personnel are appropriately represented and
engaged early on in the system integration engi-
neering project. Failing to involve all the proper
stakeholders early on in initiation can lead to over-
sights and misalignments later in the project effort.
Identify scope by determining what work is
required to achieve the desired business outcome

32 • August 2020 control engineering www.controleng.com

or objective for the system integration project.
Scope identification relies upon stakeholder iden-
tification to make certain there is early alignment
with the business functions the project effort will
impact.
2. Analyze the situation for the
industrial system integration project
Situational analysis is important for an organiza-
tion to recognize their objectives, goals and strate-
gies. Determine root causes of the problem or the
conditions to leverage in the case of an opportunity.
Consider conducting a gap analysis on the identi-
fied business need versus the current organizational
capabilities.
Discuss and capture the known risks, which, at
this point in the process, may be at a high level and
highlight factors that are critical to success of the
effort, especially those quick wins and low-hanging
fruits. Determine the decision-making criteria you
will use to assess the course of action through the
life of the system integration project effort.
Through situational analysis, classify identified
components as being required, desired or option-
al. This further qualifies needs versus wants and is
essential to the business case’s objectivity. Take the
time and identify options during situational analy-
sis. This ensures the business leadership you have
considered and vetted all avenues to determine
the best course of action relative to an investment.
Further classify options as doing nothing, doing
the minimum or going beyond the minimum to
address the problem or opportunity.
3. Recommend options with risks,
assumptions, constraints, and
interdependencies
The recommendation section of the business
case is often synonymous with the conclusion. It
states to the business the most feasible option to
progress with. A recommendation of an option
includes a summary of the results compiled in addi-
tion to the risks, assumptions, constraints and inter-
dependencies associated with the chosen option.
The recommendation should highlight the suc-
cess criteria used to measure the outcome of the
option pursued. Depending upon the nature of the
business case and organizational requirements, con-
sider including high level milestone schedule as well
as a RACI (Responsible/Accountable/Consulted/
Informed) chart accentuating roles and responsibil-
ities as part of the recommendation.
4. Evaluate the success of the
system integration project
Finally, consider the evaluation part of the busi-
ness case. The evaluation section determines the
measure of success during the course of the proj-
ect effort, handoff between project and operations
and the operational impacts beyond implementa-
www.controleng.com
tion. This statement and supporting information
outline how you will measure the long- and short-
term benefits of the project deliverables.
Justifying a system integration
project with due diligence
By following the steps identified above, a team
can ensure it has performed due diligence in devel-
oping the business case for a system integration,
operational technology project. Moreover, company
leadership can be assured the business case is objec-
tive in nature, watertight and aligns with organiza-
tional goals, objectives and strategies.
‘
Failing to involve all the proper stakeholders
early in system integration project initiation
can lead to oversights and misalignments
’
later in the project.
The more objective, concise and data-driv-
en the business case is for the system integration
project, the more efficient the process will be to
determining the payback of an investment, wheth-
er it be return on investment, net present value or
other financial efficiency metric. The culmination
of these components in a solid business case will
allow for leadership to render a “go/no-go” deci-
sion effective. ce
Ryan Courtney, MEM, PMP, is project manager,
Matrix Technologies Inc. Edited by Mark T. Hoske,
content manager, Control Engineering, CFE Media
and Technologies, mhoske@cfemedia.com. This was
adapted with permission from a Matrix Technologies
blog post on building a business case.
M More
ANSWERS
KEYWORDS: System integration project management
Justifying an industrial system integration project
requires due diligence.
Develop a business case as part of the system
integration project.
System integration project management should begin
with considering business needs, situational analysis,
recommendation and evaluation.
CONSIDER THIS
As you prioritize for 2021, will you incorporate system
integration project management into planning?
ONLINE
If reading from the digital edition, click on the headline
for more resources. www.controleng.com/magazine
www.controleng.com/Global-SI-Database
control engineering August 2020 • 33
ANSWERS
INSIDE MACHINES
Jim Stevens, Posital Inc.

Cost-effective position
control for stepper motors
Kit-based absolute encoders (position sensors) can make stepper motors
a lower-cost option to servo motors for motion control applications.

L
ow-cost stepper motors are an attrac-
tive alternative to high-end servomotors
for many motion control applications in
industrial machines. This has been made
possible by a new generation of kit encod-
ers (modular position sensors) that can be added
to standard motors, providing accurate and reliable
closed-loop position control. As well as providing
absolute position measurements, these new sensors
offer self-powered, maintenance-free multi-turn
functionality.
Stepper motors are simple brushless dc motors
the rotor moves forward by a clearly defined step
or angular offset. Up to 200 steps per revolution are
common, although motors with 400 or more steps
also are available. A resolution of less than 0.1 degrees
can be achieved by micro-step operation. The step
accuracy is usually in the range of a few percent.
Position sensor closes the control loop
Basic stepper motors operate as part of an open-
loop control system. If a motor fails to move as
requested (due to unexpected mechanical resistance),
there will be a discrepancy between what the control

M More
ANSWERS
KEYWORDS: Position control,
encoders, motion control
Stepper motors and encoders
provide closed-loop control.
Absolute encoders provide
reliable position capabilities to
stepper motors.
CONSIDER THIS
Where could you use lower cost
rotational position control?
ONLINE
See: Kit encoders with magnet
absolute encoders.
stepper motor’s housing, with a rotating
magnet assembly attached to the shaft.
used in a wide range of applications,
such as small tools, appliances, printers
and vehicles. In the industrial arena, they
have been used for positioning tasks in
machines or high-speed pick-and-place
processes.
Compared to servomotors, which
are designed for precision motion con-
trol, stepper motors are simpler devices.
They also are much less expensive, aver-
aging one tenth the cost of servomotors.
With stepper motors, control is achieved
through incremental rotation of the elec-
tromagnetic field generated by the motor’s
stator coils. With each controller pulse,
Stepper kit exploded
view shows how magnetic
kit encoders can be mounted on a
Courtesy: Posital Inc.
system “thinks” is the position of a mechanical com-
ponent and the actual position, resulting in a loss of
accuracy. This shortcoming can be overcome by add-
ing an encoder (rotation sensor) that can confirm if
each step motion has been completed.
Incremental encoders provide simple pulse sig-
nals with each completed rotation step and are ideal
for speed control. However, absolute encoders can
be a better choice for position control tasks.
With incremental encoders, if the control system
needs to determine the absolute rotary position of
the motor’s shaft, it must keep an accurate count of
the number of steps that have been completed. If
this count is lost or corrupted – such as from to a
power interruption – position knowledge is lost. In
this case, it is often necessary to “re-home” the sys-
tem by returning the machinery to a known start-
ing position and re-starting the step count.
By contrast, absolute encoders measure rotation
angles directly and can report complete position data,
including the number of complete rotations. This
information can be retrieved by the controller at any
time so production can resume immediately with
minimal loss of time and materials.
Stepper motors with built-in position sensors are a
useful alternative option for positioning tasks in man-
ufacturing equipment, packaging machinery, robots
and other applications where a reliable, cost-efficient
drive mechanism is needed. ce
Jim Stevens is product specialist, Posital Inc. Edit-
ed by Mark T. Hoske, content manager, Con-
trol Engineering, CFE Media and Technology,
mhoske@cfemedia.com.

M1 • August 2020 control engineering www.controleng.com

 S THE
THING
PREROSUP2PLY
POW
N N OT DO:
CA

DOESN’T PACK
YOUR BAG –
BUT SAVES
VALUABLE
CABINET SPACE!
Learn what reducing your panel size can do for you.

www.wago.com/us/
www.wago.com/us/planning-pro2

input #17 at www.controleng.com/information

ANSWERS
INSIDE MACHINES, DISTRIBUTION CENTERS
Eric Rice, Honeywell Intelligrated
Connect automation
to predictive maintenance
Leveraging operational data already in control systems can drive distribution
center (DC) performance and maintenance improvements.
I
ndustry 4.0, Industrial Internet of Things
(IIoT) and digital transformation efforts are
helping material handling companies recog-
nize the need to make a fundamental shift in
how distribution and fulfillment (D&F) opera-
tions are run. In fact, 70% of material handling exec-
utives consider Industry 4.0 a top priority.
While the potential benefits of IIoT technologies
are well-known in other industries, the D&F sector
has relatively slow adoption rates. A recent study said
only 2% of executives identified supply chain perfor-
mance as a focus of their digital strategies. This trend
suggests IIoT’s importance may be misunderstood
and/or its potential benefits difficult to measure.
In the energy sector, IIoT’s transformative oper-
ational impacts were proven a decade ago. A 2010
Department of Energy study of operations, mainte-
nance and energy professionals revealed the average
savings from an IIoT-driven predictive maintenance
operation delivered a 1,000% return on investment
(ROI), including the following key performance
indicators (KPIs):
Figure 1: When it comes to maintenance operations, limiting the
duration of downtime is a top priority. Market growth paired with a
declining technician workforce will dictate the need for more predic-
tive automation. As a result, enterprise and DC operators will need
the insights to implement smarter processes and achieve more reli-
able equipment operation. Images courtesy: Honeywell Intelligrated
M3 • August 2020 control engineering
• 25 to 30% reduction in maintenance costs
• 70 to 75% elimination of equipment
breakdowns
• 35 to 40% decrease in downtime
• 20 to 25% increase in production.
The building automation sector has been deploy-
ing IIoT best practices for more than a decade. Other
industrial sectors, like the oil and gas industry, also
have willingly embraced the power of operational
data to help predictive maintenance. Despite the dif-
ferences between these sectors and D&F, they share
similar business objectives and KPIs – and the same
potentially transformative benefits.
Automated devices and systems
The D&F industry has unique complexities, bar-
riers to adoption and opportunity costs for automa-
tion devices and systems. Because no two operations
are alike, it can be difficult to approach implementa-
tion from a “standard” perspective. The ever-present
risk of disrupting operations in a hyper-competitive,
e-commerce fulfillment sector also may be a deterrent.
The proliferation of warehouse software, manage-
ment systems and automation technologies can pres-
ent compatibility challenges when integrating existing
assets into a connected infrastructure. For most com-
panies, the absence of a viable change management
strategy prevents them from achieving fundamental
progress and affecting the required organizational
shift needed to embrace a data-driven enterprise.
The risks of doing nothing and not making a digi-
tal transformation, may be greater, given the acceler-
ation automation can provide. Increasing digitization
of operations, business transactions and customer
interactions say IIoT infrastructures can:
• Address e-commerce pressures
• Ensure customer service level agreements
(SLAs) are met
• Shorten order cycle times and delivery windows.
In a world where reliable, consistent uptime is a
differentiator, skilled service technicians for automa-
tion, devices and systems are vital to an operation’s
success. But as a generation of service veterans nears
www.controleng.com
retirement, there are few qualified technicians poised
to replace them. This trend is creating a significant
knowledge and service gap that presents a long-term
threat to many operations. DC operators are now in a
race to improve training processes, recruit new candi-
dates and get them up to speed on increasingly inte-
grated automated systems.
Effective digital transformation
The most common barriers to successful IIoT
adoption can be traced to three primary causes:
1. Lack of understanding of the technology
landscape and its effects on your business
2. Lack of adequate talent to effectively imple-
ment and use the technology
3. Lack of a clear business case to justify the
investment.
3 steps for smart digital transformation
1. Create a strong business case for digital
transformation. IIoT adoption leaders were 75%
more likely than IIoT laggards to cite the prepara-
tion of a strong business case or clearly articulated
vision for value creation as key factors in their IIoT
programs’ success.
2. Start small and clearly define the scope for
digital transformation.
• Digital transformation is an iterative process.
• Choose a key area of operations for many stake-
holders and establish time-bound parameters.
• Create an actionable business plan with goals
for achieving a specific financial outcome.
3. Build a competent and capable IIoT inno-
vation team for digital transformation.
• Visionary: Establishes the vision and provides
clear direction
• Motivator: Engages the team with a common
goal and coaches others along the way
• Executor: Brings necessary resources and capa-
bilities to drive change through an organization.
Cost of facility downtime
Up to 80% of businesses are unable to accurate-
ly estimate downtime rates. Many underestimate
downtime costs by 200 to 300%. The following fac-
tors are often ignored when calculating downtime:
• Lost production
• Recovery costs
• Wasted labor/productivity
• Missed customer SLAs
• Depleted inventories
• Mechanical equipment/system stress
• Disruption to innovation
• Loss of brand loyalty/customer trust.
Use control system data
For those who are new to using their data, a good
place to start is tapping into the vast amounts of
www.controleng.com
Figure 2: New technologies can give service teams remote eyes in
the field, allowing diagnoses of problems that staff may not have the
knowledge or expertise to address.
available data from their machine control systems.
It’s estimated there are hundreds of thousands of data
points that can be accessed from a control system,
but this data is often underused. Some operators pull
data from programmable logic controllers (PLCs)
periodically throughout a day or shift. However,
PLCs are only capable of storing limited amounts of
data, which means this information alone is transient
and offers no trending information or insights for
predictive maintenance. About a quarter
of the extracted data has value.
To extract value from control system
data, operators need software and analyt-
M More
ANSWERS
KEYWORDS: Digital
ics tools to make sense of it. By continu- transformation, predictive
ally aggregating and interpreting this data, maintenance, automation
these tools filter out the noise to deliver U.S. Department of Energy
historical trends and actionable insights said IIoT-driven predictive
that provide operational value. Analy- maintenance operation delivered
a 1,000% ROI.
sis of conveyor run statuses can help DC
Automation help distribution and
operators evaluate KPIs such as read rates, fulfillment.
throughput, flow balance through merges Smart glasses allow a
and conveyor jams. Armed with this data, technician to share live audio/
operators can address a variety of issues video with OEM experts.
that impact performance. CONSIDER THIS
By connecting control system data to How’s your digital transformation
software with alarm management capa- going? Better than competitors?
bilities, operators see real-time dashboards
ONLINE
and receive needed notifications. ce
Read this online for:
- Augmented reality photo
Eric Rice is principal product marketing - Condition systems, motors
manager, Honeywell Intelligrated. Edited by - Integrate predictive capabilities
Mark T. Hoske, content manager, Control into maintenance
Engineering, CFE Media and Technology, - Prepare for a more connected
mhoske@cfemedia.com. automation future.
control engineeering August 2020 • M4
ANSWERS
INSIDE MACHINES: PROGRAMMING
Gary L. Pratt, P.E., ControlSphere Engineering

Which IEC 61131-3 programming

language is best? Part 2
With many programmable logic controller (PLC) programming languages and
standards from which to choose, select the best language for specific automa-
tion and controls applications. Part 2 focuses on function block diagram (FBD),
continuous function chart (CFC) and structured text (ST).

M
any programming language
choices exist for programma-
ble logic controllers (PLCs), and
the IEC 61131-3 Programming
Languages standard has several
options. It’s more efficient and effective to use the
strength of each rather than learn the tricks and
workarounds required to force-fit one language to
all applications. The programmer should select the
best language for the application.
Programming languages:
LD, SFC, FBD, CFC and ST
“Which IEC 61131-3 programming language is
best? Part 1” discussed the strengths and best appli-
cations for each language, has a graphic showing all
five languages, and provides details on ladder dia-
gram (LD) and sequential function chart (SFC).
“Which IEC 61131-3 programming language is
best? Part 2” (this article) discusses function block
diagram (FBD), continuous function chart (CFC),
structured text (ST) and how they can be mixed
and matched for optimal results.
Function block diagram (FBD) and
continuous function chart (CFC)
Function block diagram (FBD) is a graphi-
cal language which appeals to engineers’ affinity
for graphical information. The Codesys integrat-
ed development environment (IDE), from Codesys
GmbH (previously called 3S-Smart Software Solu-
tions), offers two flavors of FBD, the traditional IEC
61131-3 FBD and the similar but more flexible con-
tinuous function chart (CFC) which is not formally
part of IEC 61131-3. CFC is a super-set of FBD and
has two areas of strength:

Figure 1: An example of a block-based programming design is show in Codesys continuous function chart language
programing from Codesys GmbH. Courtesy: ControlSphere Engineering.

M5 • August 2020 control engineering www.controleng.com

Figure 2: Structure pins enhance readability of diagrams by reducing unnecessary
detail and clutter. Courtesy: ControlSphere Engineering.
1. Block-based functional programming
(performing Boolean and mathematical
operations)
2. Hierarchical designs (calling other functions
and function blocks).
Block-based programming with CFC
Block-based designs consist of assemblies of pre-
defined functionality which are wired together to
carryout Boolean logic, mathematical calculations,
or a combination of the two as shown in Figure 1.
CFC block programming is excellent when the out-
puts are strictly a function of the current inputs (in
other words, when there are no state variables such
as Boolean feedback, set/reset coils, or flags). When
there is a combination of state-less and state-based
functionality, use a combination of CFC and SFC.
Because connectivity is represented with lines
between the function blocks, it is easy to under-
stand the flow of information and how the informa-
tion is modified along its path. If the functionality
begins to become complex, it should be split into
smaller, more manageable sub-blocks as described
in hierarchical designs below. If there are a signif-
icant number of connections between blocks, the
lines can be consolidated into pins that are declared
as a data structure type as shown in Figure 2.
Three advantages of structured pins
Structure pins have three advantages:
1. They remove unnecessary detail from this
level of the design hierarchy so that the for-
est isn’t lost in the trees (to paraphrase the
saying).
2. Keeps the block size small so that
the overall flow of information can
be viewed on one page
3. Allows information to flow
upstream and downstream (to
further reduce the unnecessary
detail).
For PLC programmers who have
used LD to perform block-based or
hierarchical functionality, CFC pro-
vides a more concise and flexible
approach. CFC is quicker to develop
and much more understandable for
future engineers who will be called
to maintain or enhance the code. See
the online version of this article for a
graphic showing the implementation of
structured pins.
Hierarchical designs with CFC
Hierarchical design is the practice of
creating a design from building blocks,
which are built from simpler build-
ing block, which are built from sim-
pler building blocks and so on. Small
building blocks have many advantages
over the traditional large flat designs,
including being easier to:
1. Specify
2. Create
3. Test and perfect
4. Understand and maintain
5. Be much more likely to be reused.
M More
ANSWERS
KEYWORDS: IEC 61131-3
Programming Languages, FBD,
CFC and ST
Function block diagram (FBD) is a
graphical language.
Continuous function chart (CFC)
programming, a super-set of FBD, is
a similar but more flexible extension
to IEC 61131-3.
Structured text (ST) is based on the
Pascal programming language and is
similar to Visual Basic.
CONSIDER THIS
Use the right IEC 61131-3
programming language for the
application.
ONLINE
If reading from the digital edition,
click on the headline links to
referenced articles and resources.
www.controleng.com/magazine
www.controleng.com/
control-systems/plcs-pacs
For more, see:
–Video demonstration of each
language and configuration from a
csv file.
–Object Oriented Industrial
Programming (OOIP) article.
–More programming downloads
from Object Oriented Industrial
Programming Foundation.
www.ooip-foundation.org
–Codesys integrated development
environment (IDE) from Codesys
GmbH, used for examples in this
article can be downloaded at
no charge, including a software-
based PLC that will run for 2 hours
between resets.

www.controleng.com control engineeering August 2020 • M6

ANSWERS
INSIDE MACHINES: PROGRAMMING
Figure 3: Hierarchical design is implemented here in continuous function chart (CFC) graphical programming. Courtesy:
Marine Hydraulic Consultancy.
The building block technique is easier to
design and understand because it enables and
encourages the practice of maintaining a con-
sistent level of detail at each level of the hierar-
chy. In this way, upper levels of the design are not
cluttered with confusing and unnecessary detail
that is important at the lower levels of the design.
The analogy is an automobile engine which has a
starter, which has an armature, which is wound
with copper wire, which is extruded from cop-
per, which is mined throughout the world. The
automobile designer doesn’t need to be an expert
or be concerned with how the copper in the
engine is mined. This level of detail is left to the
lowest levels of the design, where that detail is
important. Hierarchical CFC designs should be
designed with a consistent level of detail on each
level of the hierarchy.
Two downfalls of using LD
as a building-block language
This reveals the downfall of the traditional
method of using LD as a building-block language.
Specifically:
1. The low density of information requires
LD designs to be spread-out over dozens of
pages, making it difficult or impossible to see
and understand the big picture.
2. High-level details and low-level details are
intermingled on the same level leading to
clutter, which makes the design difficult to
understand and maintain.
M7 • August 2020 control engineering
Hierarchical design in CFC using structure-pins
solves both of these problems, while maintaining
the graphical nature of LD. It’s a no-compromise
solution with the best of both worlds.
Benefits of using CFC
and hierarchical design
Hierarchical design is a key feature of object-
oriented industrial programming (OOIP). Figure
3 shows an OOIP design of a control system for a
racing sailboat. The top-level of the design shows
the boat control consists of inputs and outputs
(I/O), services, winches, cylinders, and hydrau-
lics. Double-clicking any of those blocks reveals
the next level of detail such as the overview of the
cylinders and the hydraulic system. Further dou-
ble-clicking on any blocks in those reveal progres-
sively further levels of details, each implemented
in the best language for the job. Notice the care-
ful attention to keeping the CFCs one page and of
consistent levels of detail so the functionality is
easily understood at each level. These objects are
then configured with a .CSV file as shown in the
OOIP article and video referenced in the “More
Answers” box on the prior page.
With the ability to place and configure user-
defined blocks, CFC programming begins to
closely resemble programming/configuring for
a distributed control system (DCS), except with
IEC 61131-3, the programmer is in control of
the underlying blocks. If a block needs a minor
enhancement, the programmer has the power to
do this without the expense and time required to
involve the DCS vendor.
www.controleng.com
 A complete hierarchical PLC design
can be thought of as a tree with hier-
archical CFC making up the trunk
and branches (the block diagram); and
block-based CFC, SFC, LD, and ST fill-
ing in the detailed functional design at
the leaves of the tree. Together, the IEC
61131-3 language forms a team that is
more powerful than any of its individ-
ual parts.
effective industrial controls programs, it
is important to have the right languag-
es and know how to use those languages
effectively.
IEC 61131-3 provides the languag-
es, and this article has provided guid-
ance on their effective use. Use the tips
on LD, SFC, FBD, CFC and ST in this
two-part series to go forth and program
effectively with IEC 61131-3 Program-
ming Languages. ce
Gary L. Pratt, P.E. is president of Con-
trolSphere Engineering. Edited by Mark
T. Hoske, content manager, Control Engi-
neering, CFE Media and Technology,
mhoske@cfemedia.com

What operations should

be programmed with
structured text?
While LD, SFC, and FBD/CFC are
KNOW THIS FEELING?
great tools for their purposes, there are
some operations that do not lend them-
selves to graphical languages.
Some operations that favor use of ST
programming include:
1. Iterative operations such as For,
While, and Repeat
Then stop using complicated controllers for precision motion.
You shouldn’t need a master’s in digital signal processing (DSP)
controls to program your controller.
With Automation1, you can now reduce your set up time —
in many cases, from days down to minutes — thanks to a
user-friendly, intuitive interface and machine setup wizard.
Automation1 is the easiest,
fastest and most precise motion
controller available.

2. Complex conditionals and selec-

tions such
as IF-THEN, and CASE

3. Bit manipulations such as bitwise-

AND, Shift, Rotate

4. Text string manipulation

5. State machines with unusual

requirements or complexity

6. Pure object-oriented programming

(calling methods, setting proper-
ties, etc.)

There are many good tutorials avail-

able for engineers transitioning from
other text-based languages to ST. A Visu-
al Basic tutorial is a good starting point
for those completely new to text-based
languages. While structured text is based
on the Pascal programming language, it
has enough similarities to VB to make
use of the more widely available VB
tutorials.

Know programming vocabulary

for best results
To be able to communicate effective-
ly in the English language it’s impor-
tant to have the right vocabulary and to See how we make
know how to use that vocabulary effec- your motion easier.
tively. Similarly, to be able to create

August 2020 • M8 input #18 at www.controleng.com/information

AT0520A-CSG
Education and personal development are vital to the advancement
of the engineering community. We invite you to explore and
utilize the educational efforts of the following companies
participating in our annual Educating Engineers program:

ABB Motors and Mechanical EZ Automation

Acromag Hammond Manufacturing

AutomationDirect HELUKABEL USA, Inc.

Beckhoff Automation Lenze Americas

Cimon Radwell

Contemporary Controls SEW Eurodrive Inc.

Dataforth Siemens Digital Factory

Digi-Key Electronics Stratus Technologies

Emerson WAGO Corporation

EPRI
 I n this 2020 ABB webinar series, our experts are
providing practical solutions to everyday challenges
faced by operators and facility owners alike.

On-Demand Now
Do your bearings or gear reducers tell you how they are feeling? If not, learn how they can in
“Condition monitoring for mechanical power transmission,” an on-demand webinar available now.

Changes in temperature and vibration can indicate potential problems in mounted bearings and gear
reducers, yet if the health of these products is overlooked, problems are unnoticed until failure occurs.
Listen as we discuss “traditional” equipment maintenance and how the installation of smart sensors will
increase plant safety and productivity while decreasing maintenance and unplanned downtime.

By the end of the session, you will understand how safe your data is and how it can make your operation
safer, more predictive and efficient. You will also have a better understanding of the products that can
be monitored with this technology.

Watch on August 10
As variable frequency drives (VFDs) are being adopted in more and more industrial applications,
something to consider is that the motors they are driving need to be carefully selected. The improper
selection of motors can lead to unsatisfactory reliability and longevity. The August 10 session titled
“Tips to extend motor life when driven by variable frequency drives” will provide tips for proper
motor selection to ensure reliability when powered by a VFD.

After the session, you should understand the importance of shaft current mitigation, insulation systems,
Corona prevention, speed turndowns, and effective heat dissipation.

baldor.abb.com
479.646.4711
input #21 at www.controleng.com/information
A utomationDirect
provides free online
PLC training to anyone
and everyone with
no purchase necessary.

As the world around us becomes

more and more automated, an
understanding of electrical control
systems becomes more and more
vital. Because of this, the demand
A wide variety of free training videos
for training in industrial controls has
can be found at automationdirect.com.
grown exponentially over the years.

Luckily, AutomationDirect has
decided to meet this growing
demand head-on by offering
absolutely FREE online PLC
training – no purchase necessary!
This online video training course
encompasses various levels of
training from entry level program-
ming to advanced PLC functions,
and is available 24/7/365 so you
can learn at your pace and at
your convenience. Some of the
general topics covered include:
• Logic circuits
• Basic switches
• Sinking and sourcing
• PLC scan time
• I/O fundamentals
• PLC memory addressing
Also available are over 200 training videos specifically covering
AutomationDirect PLCs and include topics on how to use their rung
editors, logic instructions, internal control relays, subroutines,
communication, data view windows and many other functions.
• CLICK PLC Family Video Library (64 videos)
• Do-more\BRX PLC Family Video Library (115 videos)
• Productivity PLC Family Video Library (62 videos)
This training is provided by AutomationDirect’s education and its training
partner Interconnecting Automation who has been training automation
professionals for more than 20 years.
Interconnecting Automation’s instructors pride themselves on providing a
“no hype”, “no sales pitch” type of instruction and aim to thoroughly help
others learn about PLC products so they are ready to use these products
to their fullest potential.
To get unlimited access to the FREE online PLC training or to learn
more about what is provided, we invite you to head on over to
www.automationdirect.com/plc-training.

input #22 at www.controleng.com/information

T echnical resources
you need from an
automation vendor you
can depend on

The Beckhoff team works hard to

design and deliver the most advanced
automation and controls technologies
available. Of course, that is only half
the battle as offering best-in-class
education and training is also crucially
important. A wide range of online
resources are available 24/7/365 from
Beckhoff for engineers:

E-Learning Portal - Beckhoff USA is pleased to announce the launch of an e-learning portal with a range
of presentations on topics related to industrial automation – and you’re invited to join! These useful educational
resources are free and open to engineers located in the U.S. Multiple classes are available, including topics
from all Beckhoff product families: automation software, industrial PCs, I/O and drive technology.

Each presentation is followed by a quiz to reinforce the topics covered and gauge what you’ve learned. No
Beckhoff hardware is required to participate, but there are modules that permit students to use their own
Beckhoff equipment during the training.

Register for an account at learn.beckhoffus.com and start learning today!

Educational Webinars - Pressed for time? Beckhoff offers many webinars throughout the year on a wide
range of interesting topics, particularly automation and controls programming, industrial Ethernet applications,
tips for designing world-class motion control architectures and much more.

Visit www.beckhoff.com/webinar to learn more. Don’t forget to visit the webinar archive to view the complete
history of Beckhoff webinars anytime.

TwinCAT Engineering Environment - Programmers and engineers can download the base engineering
module of TwinCAT 3, the leading PC-based automation software at no charge from Beckhoff (TE1000).

Visit www.beckhoff.com/twincat3 to quickly download and install TwinCAT 3 on your programming and
development PC today!

For more information:

www.beckhoffautomation.com
input #23 at www.controleng.com/information
T he Future
of Automation Starts
with CIMON

In the Industry 4.0 era,

automation is evolving at a CIMON will soon
be offering free
rapid pace. As the demand for hands-on training
automation grows, so does the with their hardware.
competition. CIMON offers free
and unlimited resources for
learning and advancing with the
latest automation technology.

Free HMI, PLC, and SCADA Software Webinars

All of CIMON’s product software is absolutely free to
download. Simply create an account on the CIMON
website and visit https://www.cimon.com/customer-
support/download/ to download the HMI, PLC, and
SCADA software. Updates are free, as well, and so is
CIMON customer support.
Online Training
CIMON offers an array of free online training courses
dealing with all of their products and software.
Reserve your spot for a live training session by
visiting www.cimon.com/book-your-cimon-training/
and selecting a date that works for you.
Some common training topics include the following:
• Tags and database
• Switches and lamps
• Scripting and Syntax
• Trend graphs and reporting
• Data logging
• Security
• Troubleshooting
• Free simulator setup
If you can’t make it for a live training session, there
are also free webinars for your convenience. Visit
www.cimon.com/videos-webinars-tutorials/ to
become familiar with CIMON hardware and software.
In-person Training
CIMON’s in-person training is still being set up at
their newest U.S. location, but when it is complete,
they will be offering free hands-on training with their
hardware. Experience PID control, servo operation,
and HMI communications with the CIMON PLC CM1
and CM3 series.
For more information about CIMON products and
training, get in touch with their support staff!
+1 800 300 9916 • support@cimoninc.com
www.cimon.com

input #24 at www.controleng.com/information

D igi-Key Electronics
offers automation
and control products and
solutions to meet the
manufacturing demands
of today and requirements
for the future.

From robotics and safety to

controls and relays, Digi-Key
enables engineers to design easier
and operators to work smarter.

Robots can reduce human error, increase
productivity, and improve the overall automation
process. Digi-Key’s educational robotics kits and
industrial robotics include a variety of robotics and
accessories for a host of applications.
Machine safety and the use of safeguarding
equipment protects a company’s most important
asset - its people. From the production line to
shipping and pumping to drilling, each type of
machine creates unique hazards in the workplace.
Learn more about area scanners and light curtains
that protect personnel from getting too close and
door interlocks that prevent unauthorized entry into
hazardous areas.
Turn information into action with controls and relays
that manipulate values to ensure your automated
cell works exactly as you intended. PLCs and smart
relays monitor your devices for ease of mind and
improve efficiency by observing patterns and
modifying accordingly.
Digi-Key offers a wide variety of online resources
to empower your success, including:
• Design & Integration Services - Access a
network of experienced system integrators to
develop automation solutions from concept to
commissioning, testing, and beyond
• Interactive Product Selectors – Use the visual
product selectors to navigate to the automation
products you need
• Blogs – Learn something new today!
• Articles & White Papers – Discover the latest
technology news, product information, and
supplier updates
• 3D CAD Models, Datasheets, & Technical
Manuals – Take your design to the next level

sales@digikey.com • 1-800-344-4539 • www.digikey.com

input #25 at www.controleng.com/information

C ultivate a “future
proof” workforce that
can sustain profitability in
any market.

As automation technology continues

to revolutionize the industry,
organizations risk falling behind if
they don’t adapt to the changes.
When personnel are overwhelmed
with data, and their work processes
haven’t evolved along with the
technology, it can be difficult for
them to turn investments into real,
quantifiable results. Emerson’s Educational Services offer innovative, scalable, and customizable training
solutions that enable you to use workforce development as a strategic lever for sustaining growth in highly
competitive industries. With hundreds of available courses and a range of content delivery methods, from
on-site and hands-on to virtual and self-paced, you’ll be able to accommodate different learning styles and
find solutions that match your training budget.

Learn online and bring the experts to you.

Working alongside Emerson trainers, provide your team with full access to software and control systems
without the need to travel. Choose an online option that works best for your business needs. Emerson offers
online self-led eCourses, and virtual instructor-led courses through our virtual classroom.

The virtual classroom platform allows students the ability to engage with peers and industry experts at a place
and time that work for them. In addition to hands-on demo sessions, the virtual classroom offers theoretical
training in several courses and webinars covering field instrumentation, measurement, final control, process
control, safety systems, reliability, digital solutions, and more.

Emerson’s Educational Services can help you develop the strategies to arm your workers with the practical
knowledge and skills they need and to provide your business with a strong foundation of expertise.
Emerson Automation Solutions is accredited by the International Association for Continuing Education and
Training (IACET) and is accredited to issue the IACET CEU.

To learn more or to find training,

visit Emerson.com/education
input #26 at www.controleng.com/information
iI nterested in a
quick way to improve
process productivity?
Squash Your Power
Quality Downtime!
Lightning, storms, fallen trees or
tree limbs, animals—these and more
cause power quality issues—and
process downtime. But we can help
you keep your “Uptime Up!”
EPRI’s Power Quality Services Team
specializes in helping industrial and
commercial enterprises make their
important processes more resilient
in the face of common power
quality (PQ) phenomena, especially
as more sophisticated control
systems appear in their manufactur-
ing systems.
With more than 300 PQ Site
Assessments completed to date,
plus thousands of laboratory tests
and years of applied R&D, our team
can quickly identify the unique
issues and solutions for your
individual facility.
Our team can prescribe the most
cost-effective and relevant mitigation
and control system design tech-
niques to reduce process and
machine sensitivity to PQ events,
often without requiring battery-
based solutions.
EPRI’s PQ Services include:
• Industrial facility assessments,
testing, design consulting,
training in power quality, process
control sensitivity to PQ, and
mitigation methods—all turbo
charged by our unique Power
Quality Investigator (PQI)
expert tool.
• Direct engagement with plant
management, engineers, main-
tenance, and process operators
to understand shutdown issues
and their relation to PQ at the
facility as revealed by available
PQ event data at the site.
PQServices@epri.com • MyPQ.epri.com
input #27 at www.controleng.com/information
• Expert analysis of available
shutdown logs and process
control drawings identifying
specific component sensitivities
as well as mitigation options.
• Testing of control component,
machine or process PQ
susceptibility, or compliance to
standards, such as SEMI F47 and
IEEE 1668, including verification
of mitigation strategies.
• Comprehensive PQ
recommendations including
economic analysis.
Put our decades of experience
investigating and solving industrial
PQ issues to work for you. Learn
more about EPRI’s capabilities and
how we can help your organization
keep your “Uptime Up!”
 N ot every HMI/PLC
Programming Software
is the same! Read below:
10 minute screen design,
on-line edit, drag-n-drop
PLC software.

Most suppliers of HMIs and PLCs claim

that their software is easy to learn and
easy to use. The real test comes in
when you actually get to do it.

We introduced EZTouch in 2001 with a simple aim for a new user to learn the software from scratch
in less than an hour and create a fairly complex screen in 10 minutes or less. No going to a school
like Rockwell requires, nor spending endless hours reading manuals. We created a simple design
interface to add pre-built objects to a screen. You have a quick selection on which EZTouch panel,
what PLC protocol among hundreds including DH+/RIO, and you start placing the objects on the
screen. There is an extensive symbol library to pick objects from. You can also simulate your HMI
screens on the computer itself!

A recent study of plant users of HMIs found that a typical user makes changes to the HMI screens at
least 6 times during the first three months. EZTouch patented on-line edit allows screen modification
without shutting the machine down. Changes are made on the fly. This feature is enhanced by our
new miniWIFI, allowing you to program up to 50 feet away and with no cables.

EZPLC offers a similar free-flowing drag-n-drop programming software. No restrictions, just draw
the ladder. Try inserting an e-stop contact in an existing rung in any other PLC programming
software and you will quickly find out that not every programming software is the same. In addition,
our integrated software with no annual fees with free life time upgrades, is common to all our HMIs,
PLCs and EZTouchPLCs.

Order your FREE KTD (Knowledge Treasure Drive) to see live examples. www.ezautomation.com.

sales@ezautomation.net • 1-877-774-3279 • www.EZAutomation.net

input #28 at www.controleng.com/information
E nclosure Quality
Supported by
Superior Service

Hammond Manufacturing offers a

broad range of industrial and
commercial electrical enclosures.
Their focus on providing industry
leading service to support their
quality enclosures includes extensive
inventory for immediate delivery, coast-
to-coast field sales support and an easy to use
enclosure website, www.hammondmfg.com.
Polycarbonate Watertight Enclosures
Hammond Manufacturing offers several series
of watertight polycarbonate and ABS plastic
enclosures available from stock. Ideally suited
for mounting printed circuit boards or DIN rail
mounted components, with several series offering
optional subpanels.
Gasketed lids with two piece “tongue & groove”
construction provide protection against access
of oil, dust and water. Polycarbonate versions
are cUL and UL508A listed and are designed to
meet NEMA Type 4, 4X, 6, 6P, 12 & 13 ratings –
exceeding IP ratings up to and including IP68.
Replaceable gasket is one piece made from high
temperature, U.L. listed silicone.
Optional mounting accessories include external
feet, as well as pole mounting brackets. There are
Quickly find the right enclosure at hammondmfg.com
modifications also available to customize any
enclosure with holes, cutouts and screen printing.
For CAD files and detailed specifications visit:
hammfg.com/electronics/small-case/industrial.
Is Finding the Right Enclosure a Challenge?
With a variety of materials as well as hundreds of
sizes, how can you quickly find the right enclosure
for your need? Hammond Manufacturing’s web
site – www.hammfg.com/electrical provides the
tools needed to help.
Hammond’s site has a built in search function
which quickly allows for a search by size. Once
size has been specified, additional criteria like
material, NEMA Rating and specific features can
further refine the list of options. No more poking
through page after page based on generic
descriptions or pictures — the site is extremely
intuitive and user-friendly.

sales@hammfg.com • 716-630-7030
www.hammondmfg.com
input #29 at www.controleng.com/information
H ELUKABEL
Introduces ISOBUS
Hybrid Cable for
Agriculture Industry

HELUKABEL, one of the

leading global manufacturers
and suppliers of cable, wires
and accessories, has introduced
the ISOBUS PUR hybrid power and data cable for use in the agriculture industry. This cable connects
tractors, combines, sprayers and other farm vehicles to their implements at the front or rear of
the machine.

The ISOBUS PUR is built to the worldwide ISO 11783 standard that governs the communication between
agriculture machinery, mainly tractors and implements. ISOBUS areas of application include: wheel
sensors, auto steer and turnaround, GPS navigation, row guidance, equipment monitoring and sensors,
video input, as well as fleet management to name a few.

The PUR-jacketed hybrid cable can operate in environments ranging in temperature from -40°F to
+185°F (-40°C to +85°C), application dependent. Additionally, the ISOBUS PUR’s rugged outer jacket
can withstand oil, abrasion, UV rays, microbes, and is flame retardant.

HELUKABEL currently offers three configurations for agriculture OEMs, but can also provide additional
custom constructions upon request. The three standard configurations are:
• PN: 17001249 – 2xAWG10 + 2xAWG14 + 1x4xAWG20 (2x6 mm2 + 2x2.5 mm2 + 1x4x0.5 mm2)
• PN: 17001250 – 2xAWG8 + 2xAWG14 + 1x4xAWG20 (2x10 mm2 + 2x2.5 mm2 + 1x4x0.5 mm2)
• PN: 17001251 – 2xAWG6 + 2xAWG14 + 1x4xAWG20 (2x16 mm2 + 2x2.5 mm2 + 1x4x0.5 mm2)

Visit www.helukabel.com/us/products/data-network-bus-technology/isobus-pur.html
to learn more about the ISOBUS PUR.

(847) 930-5118 • sales@helukabel.com • www.helukabel.com

input #30 at www.controleng.com/information

T he best machines and production
facilities around the world use Lenze

Lenze offers a comprehensive, future-proof portfolio

that covers the control level, the field level, and
the electromechanics, and ensures standardized
data communication right up to the cloud level.
Our solutions enable you to meet all your machine
development requirements easily and efficiently, with
the greatest possible flexibility. You can rely on:

• Scalable hardware in a comprehensive and open

automation platform
• Modular software for efficient software engineering
• Open networking thanks to the use of
market standards
• Solutions that meet the requirements
of digitalization
• A thorough understanding of your machine from
experienced experts in your sector
Our newest portfolio additions:
The i950 Servo Inverter is a match for any operational
scenario thanks to three different modes of operation.
It can be freely programmed or serve as an actuating
drive under a CiA402 motion control, but the most
common mode of operation is via parameterization
using preconfigured technology applications.
Lenze’s X4 Remote, offers an integrated and ready-
to-use solution for cloud-based remote services. Easily
set up and configured, machine manufacturers can
confidently offer reduced downtime and increased
productivity, making their machine fit for the future.
Our new i550 protec Frequency Inverter,
well-protected with IP66 (NEMA 4X), conquers a
wide range of decentralized drive tasks. It is an
exceptionally compact device with a design
that ensures maximum protection against adverse
environmental conditions such as high temperatures,
dust, dirt or water jets during cleaning operations.
The Lenze Smart Motor works without contactor
or starter, fixed speeds can be set at will, and there
are many integrated functions for material handling
applications. It meets the strictest energy efficiency
requirements and can be operated very conveniently
using a smartphone.

info.us@lenze.com
800-217-9100, 508-278-9100
www.Lenze.com

input #31 at www.controleng.com/information

N eed to Liquidate your
Inventory Quickly
and Professionally?
Radwell International’s Asset
Recovery program is an
exceptional resource for your
company. We offer cash for parts
and products you don’t need. In
many cases, selling your excess
inventory to Radwell gives you the
opportunity of adding dollars to
your bottom line.
With extensive knowledge,
Radwell stocks and sells new
and certified preowned industrial
automation, MRO, pneumatic,
motion, electronic, hydraulic,
HVAC, and electrical control
equipment for plant floor and
facilities maintenance machinery.
The process is easy. Gather all
your inventory, box it, and then
call Radwell for free pick-up.
Need more information?
Radwell has highly trained and
To learn more about Radwell International’s Asset Recovery Program visit https://info.radwell.com/en/asset-recovery-program
experienced asset recovery
and surplus team members ready
to help.
It is important to note that any
equipment being sold to or
sourced by Radwell International
must meet the highest standards
of functionality and use. However,
not all equipment sold to Radwell
via the Asset Recovery program
has to be brand-new.
Radwell has a team of in-house
engineers and technicians who
can refurbish equipment to a
like-new state, granting it the
Radwell Certified PreOwned
stamp of approval, which comes
with Radwell’s Two-year warranty.
input #32 at www.controleng.com/information
Radwell has highly trained
and experienced asset
recovery and surplus team
members ready to help you
make your business thrive.
The types of equipment
Radwell most often purchases
and upcycles include industrial
automation equipment, PLCs,
drives, motors, electronic
parts, circuit boards, meters,
ensors, and all types of
industrial controls.
However, if your company has
other types of surplus inventory
that you’re looking to offload,
please feel free to contact us at
800-884-5500 ext. 824.
W ant to learn about
engineering topics
pertaining to gearmotors?
We have the information
at your fingertips!

Tired of looking up multiple

sources for answers to common
engineering questions about gear
units or gearmotors? We have
the solution.

SEW-EURODRIVE’s online
Technical Notes can be a real
life-saver when you need answers.
Technical Notes provide quick
access to many engineering
topics such as how to properly
mount a torque arm, how to
determine and design for inertia,
or how to properly design your
machine to use a hollow shaft
gear unit.
Need answers on how the speed,
mounting position, environment,
and duty cycle can affect the
thermal rating of a gear unit and
how to protect against too much
heat? That’s one of many in-depth
documents you can find by
visiting www.seweurodrive.com
and clicking Technical Notes.
Whitepaper
Our technical white paper, Maximizing Gearmotor Speed Range
shows you how to operate VFDs above 60Hz to widen speed range,
improve stability and reduce cost.
In this white paper, you’ll learn why it can be a good idea to operate
gearmotors above 60Hz. Through a common example, we will show
you how to select the proper gearmotor that will significantly enhance
performance in the following ways:
• Increase stability by reducing inertia mismatch
• Widen the available speed range
• Eliminate a costly ventilator fan at low speed
• Eliminate motor overheating at low speed
• Enable the use of a smaller motor
Visit www.sewwhitepapers.com/vfd to download the PDF.

mktg@seweurodrive.com
864-439-7537
www.seweurodrive.com

input #33 at www.controleng.com/information

M aker of prefab
pharmaceutical
clean rooms (POD)
standardizes on
Siemens technologies
with huge cost, time
and space savings
By standardizing on Siemens
automation, controls, and building
management system components,
G-CON Manufacturing cut its
prefab cleanrooms’ component
costs by as much as 75 percent,
programming time by 80 percent,
and mechanical space requirements
by 30 percent — all while ensuring
greater lab reliability, availability and
utilization for its customers.
When Patrick Dorman, G-CON’s
automation and electrical engineer-
ing manager, joined the company
in 2018, he saw lots of opportunities
to improve the PODs, especially
the automation and controls for
each one’s building management
system (BMS) and environmental
monitoring system (EMS). These
are the most important systems in a
POD and contained in each POD’s
mechanical space.
With G-CON management’s
support, Dorman made the strategic
decision to bring the design and
fa.marketing.us@siemens.com • 1-800-241-4453
engineering of the BMS/EMS
automation and controls in-house
and combine them to manage
both systems. In addition, he chose
to standardize on the Siemens
SIMATIC Totally Integrated
Automation (TIA) portfolio of highly
integrated components, program-
ming them all using the SIMATIC
TIA Portal, a common software
engineering and programming
framework with point-and-click
ease-of-use. Both decisions would
greatly simplify procurement,
fabrication, support, and service,
saving G-CON weeks, if not
months, rework by a third-party,
and associated costs.
The combination of Siemens TIA
components and the TIA Portal
enhances interoperability and
scalability, both big benefits of
standardization. G-CON’s PODs
usa.siemens.com/automation
input #34 at www.controleng.com/information
provide easy traceability and audit
trails of their BMS/EMS systems for
Title 21 CFR Part 11 compliance
and similar regulations in the EU
and other world regions. This saves
customers time and labor by not
having to log system data manually.
For G-CON customers, the
company’s standardization on
Siemens components means
greater reliability and availability as
well as asset utilization. Reliability
and availability of G-CON PODs to
a customer’s process is critical both
in terms of cost and life-or-death
outcomes, according to Backstrom.
Lowering cost was a primary
objective for G-CON and
Siemens delivered.
B ecome an Edge Computing
Expert with Stratus
Educational Services

Whether you are a Stratus customer or

partner, or simply looking to gain expertise in
Edge Computing, we can help. Stratus offers
a variety of learning opportunities to enable
you to become an expert in configuring your
Edge Computing environment to prevent
downtime of critical systems and applications.
Stratus offers instructor-
With 40 years’ experience across numerous industries, we are ready to led courses as well as
online self-paced classes.
pass along our expertise and help you make the best of your resources.

Stratus offers instructor-led courses as well as online self-paced classes. In-person classes offer an
opportunity for face-to-face discussion and Q and A, while our self-paced classes have been created in
a format to allow more flexibility on the part of the students. They have also been created in a modular
fashion to provide the ability for the students to upgrade their knowledge without having to review or
retake materials they have already learned.

We also offer the Stratus Always-On Certified Professionals Program, a global certification program
designed to help you maintain 99.999% availability. Successful completion of the program validates
technical knowledge in implementing and supporting continuously available Stratus ftServer®-based
solutions. The objective of the program is to effectively set and validate high standards of excellence in
the support of Stratus solutions by using certification testing to measure skills, experience, and the
degree of specialized knowledge candidates have gained. The requirements for certification are
consistent worldwide.

For more information on the Stratus Education Services currently available, and information on
registration and costs, please visit https://stratus.com/education/.

Stratus Technologies
5 Mill and Main, Maynard, MA 01754
978-461-7000 • www.stratus.com

input #35 at www.controleng.com/information

 W AGO is adapting
to New Training
Methods in 2020
During this unprecedented time,
we are currently unable to provide
the quality face-to-face learning
opportunities you have come to
expect from our expert training team.
Currently we are not offering free training classes at
WAGO. Go to www.wago.com/us/learning-opportunities
to see when they may become available again.
To help fill this void, we have expanded our online
training options to include a series of free webinars that
may be accessed entirely remotely (in addition to our
eLearning modules and YouTube channel). Read more
details below:
On Demand Webinars for Instant Learning
If you are interested in learning new automation skills,
check out our on demand webinar portal — available
now. Learn at your own pace and choose from a
multitude of topics like:
· Cybersecurity
· Advanced power supply features
· IIoT: Node Red and Linux
· Electronic circuit breakers
· IIoT: Edge computing
· And more!
input #36 at www.controleng.com/information
WAGO’s Free webinars may be
remotely accessed at any time
for your convenience
Our experts will teach you how to use specific
products for certain applications through hands-on
demonstrations. Also, watch for upcoming live
webinars each month to further broaden your skillset.
See the complete list of topics to start watching right
away: www.wago.com/us/ondemand-webinars.
eLearning Modules
Customers can improve their understanding of
our product solutions through eLearning modules
available online (www.wago.us/elearning) covering
topics such as Ethernet, power measurement,
Bluetooth, and more.
YouTube
The WAGO YouTube channel covers a wide variety of
how to videos, product demonstration videos, and
product overview videos. Visit our YouTube channel at
www.youtube.com/wagocorp.
WAGO Corporation
Info.us@wago.com
1-800-DIN-RAIL (346-7245)
www.wago.us
 Acromag Supports Engineers from the Beginning
of their Education through their Career
Acromag has been designing and manufacturing industrial
I/O for over 60 years. Acromag’s founder believed in helping
the next generation of engineers and bestowed to the
University of Michigan a scholarship. This scholarship is
awarded on the basis of academic merit to students pursuing
engineering degrees.

Engineers are encouraged to visit our website to download

industry related application notes and white papers.

Technical support is available from the factory from a team of

experienced application engineers to help you find the best sales@acromag.com • 877-295-7057
solution or to troubleshoot your system. www.acromag.com

input #37 at www.controleng.com/information

ce202008_eduEngHLF_acromag.indd 1 7/7/2020 10:07:02 AM

EIGR-C3 Gigabit Cellular Router Available

The Contemporary Controls EIGR Series IP routers allow you to create subnets to
separate your IT and OT infrastructure. VPN models allow remote access to devices
at the job site for easy troubleshooting and commissioning. The EIGR Gigabit routers
allows for higher speeds and data throughput while supporting OpenVPN client/server
functionality for worry-free communications. The EIGR line is being expanded with
the introduction of a 4G LTE cellular router that has been certified and approved for
use on Verizon networks.

We are now shipping the EIGR-C3 VPN Router which allows for cellular, secure VPN
connection to remote sites where wired connection is not an option. Multiple cellular
data service options are available for purchase from us for convenient and quick
device commissioning.

info@ccontrols.com • Tel: +1 630 963 7070

www.ccontrols.com

input #38 at www.controleng.com/information

cse202008_eduEngHLF_contmpCtrls.indd 1 7/8/2020 5:16:46 PM
 Dataforth: The Industry Leader in Signal Conditioning,
Data Acquisition & Control
Founded in 1984, Dataforth’s ongoing commitment has been to
incorporate leading-edge technology into the design, development,
and manufacture of top quality, affordable Industrial Electronics.
Today, Dataforth’s 2,000+ made-in-the-USA products all ensure
rugged signal and data integrity, wide spectrum accuracy, and
unrivaled reliability for wide-ranging applications.
Key Dataforth signal conditioning modules and data acquisition systems
Unmatched Isolated Signal Conditioning Exceptional Data Acquisition & Control
Dataforth’s online library includes Application
• SCM5B Analog Modules • MAQ®20
Notes, Tech Notes, and User Manuals, along
• SCM7B Process Control Modules • 8B isoLynx® SLX300
with real-time demos, a MAQ20 webinar, and
• Miniature SensorLex 8B Analog Modules
®
• SCM5B isoLynx® SLX200
the Full-Line Product Catalog.
• DSCA DIN Modules • DAQ System Builder

Other product lines include dedicated DAQ software; isolated

digital I/O modules, loop isolators and transmitters, and data
communication drivers and converters. sales@dataforth.com • 800-444-7644 • dataforth.com
input #39 at www.controleng.com/information
ce202008_eduEngHLF_dataforth.indd 1 7/7/2020 9:44:51 AM

PRODUCT & LITERATURE SHOWCASE

The Unlimited SCADA Platform

of the Future is Here

• Unlimited high-performance tags

• Instant web-deployment
• Build pure-web applications

Ignition 8 will revolutionize the way

you control your industrial processes.

Input #100 at www.controleng.com/information

eNewsletters
Subscribe today by visiting: Discover more at:
www.controleng.com/newsletters inductiveautomation.com/ignition

Input #101 at controlengineering.hotims.com

60 • August 2020 control engineering

INNOVATIONS See more New Products for Engineers.
www.controleng.com/NPE PE
NEW PRODUCTS FOR ENGINEERS

Plant process management software for shift handover

Shiftconnector software from Eschbach is plant process management software that tracks and man-
ages all important information that is needed at the time of the shift handover. It has a 360°-over-
view of all events and change. All information known is captured, stored and auditable and makes
shift changes easy and efficient. The data in Shiftconnector can be analyzed to find optimization
potential and sources of error, leading to improved business processes. It provides visual presenta-
tion of data and performance figures, filters and search functions that highlight errors and faults. It
also can communicate, control and determine the benefit of improvement initiatives.
Eschbach, www.eschbach.com Input #200 at www.controleng.com/information

Digital commissioning and COVID-19 safety

turnover package labels and signs
Endress+Hauser expands end users’ digital expe- Clarion Safety Systems has expanded its
rience on instrument projects with their digital safety product line to offer a full portfo-
commissioning application and Netilion proj- lio of COVID-19 safety products. These
ects digital turnover package. These capabilities visual safety solutions are designed to
are designed to empower the plant startup team help businesses to keep employees, visi-
by mitigating project risks and tracking prog- tors and customers safe by supporting
ress in real time. Users can see project work progress across the field devices startup social distancing policies, reminding
phases in real-time and can flag any potential issues on the commissioning app. The of hygiene protocols and reinforcing
web-based application workflow is tailor built to field technician and project man- personal protective equipment (PPE)
ager user’s needs for greater productivity. Netilion Library helps users organize asset requirements. The COVID-19 safety
records, drawings, pictures, files, and turnover package documents. It is a file-shar- label and sign products include signs
ing and data management service for the complete life cycle of an instrument. This on washing your
saves significant time when carrying out maintenance or engineering activities since hands, virus pre-
the often-tedious search for information is eliminated. tention tips, virus
Endress+Hauser, www.us.endress.com Input #201 at www.controleng.com/information symptom aware-
ness, social dis-
tancing notices,
Inductive position sensor has stray field immunity and floor mark-
Renesas Electronics Corp.’s magnet-free IPS2200 inductive position sensor features ers to tell work-
high accuracy and speed, total stray field immunity and efficient motor integra- ers where to stand. These are signs with
tion in a thin and lightweight form factor. The sensor is ideal for use as an abso- complaint with OSHA regulations and
lute position sensor in a wide range of industrial, medical, and robot applications. also use the latest American National
The sensor allows customers to cost-effectively tailor sensor design for Standards Institute (ANSI) and Inter-
their applications and maximize the performance of the sensor’s national Organization for Standardiza-
accuracy. It is designed around the motor, allowing customers to tion (ISO) warnings technology to more
match the number of sectors to pole pairs of the motor to maxi- effectively create awareness and explain
mize accuracy, accommodating both off-axis (through shaft and hazards specific to the issue at hand.
side shaft) and on-axis positioning. Clarion Safety Systems
Renesas Electric Corp., www.renesas.com www.clarionsafety.com
Input #202 at www.controleng.com/information Input #203 at www.controleng.com/information

Customized LVDT position sensors fit many applications

NewTek Sensor Solution is providing custom LVDT position sensors in short timelines in meeting unique
and demanding position measurement requirements for applications in a range of industries including
oil and gas, packaging, manufacturing and power generation. The most popular sensor modifi-
cations include custom mounting brackets, specific electrical output requirements, ratio-
metric (difference/sum) output, high stroke to length ratios, high temperature exposure,
radiation and submersion resistance as well as custom signal conditioning. These sen-
sors can be used for many different applications as users deal with supply chain issues
due to the COVID-19 pandemic.
NewTek Sensor Solutions, www.newteksensors.com
Input #204 at www.controleng.com/information

www.controleng.com control engineering August 2020 • 61

INNOVATIONS
BACK TO BASICS: REMOTE ACCESS
John Almlof, Nozomi Networks

Secure remote access to thrive

Secure remote access (SRA) helps companies survive and thrive during the COVID-19 pandemic.
Some new challenges need to be considered. See 10 remote access best practices.

A
s the world sorts itself out during and
post-pandemic, one thing is certain –
remote working is here to stay. For-
tunately, technology can provide the
visibility needed to secure operation-
al access, whether employees are working from the
office or at home. While this level of flexibility hasn’t
been so readily embraced in the past, secure remote
access (SRA) is now being widely used to help com-
panies survive and thrive.
For example, a 70-year old plant engineer was
considered high risk due to a medical condition, and
needed to self-isolate. The company he worked for had
to provide secure remote access for him, so he could
get “inside” their facility to manage their critical assets.
The challenge was by enabling remote access to
critical operations assets, the company significant-
ly expanded its attack surface. According to research
from NordVPN, 62% of employees are now vulnerable
to cyberattacks, thanks to the use of personal comput-
ers for remote work during the COVID-19 pandemic.
Another survey found COVID-19-related phish-
ing emails are on the rise, with many embedding
different malware strains as attachments. Agent-
Tesla (45%), NetWire (30%), and
sible remotely,” Bill Johnson said. “Historically,
SCADA technologies and OT technologies haven’t
been connected to a network that could be remote-
ly accessed. So, consequently, some organizations
default to ‘security by obscurity.’ But the COVID-
19 pandemic has forced companies to re-think both
people and processes.”
While it might be preferable for employees to be
physically present, secure remote access technol-
ogy allows organizations to manage remote access
to critical systems in a responsible, secure way, pro-
viding situational awareness and auditability to see
who is touching the business infrastructure.
10 secure remote access tips
To help ensure secure operating practices, Bill
Johnson and Pam Johnson listed best practices that
companies and employees could follow:
Companies should:
1. Protect everything with firewalls, VPNs and
two-factor authentication (basically zero trust)
2. Monitor remote access connections to see how
remote systems interact with the network
3. Ensure standards and policies in place include

M More
INNOVATIONS
MORE INNOVATIONS: Keywords:
remote networks, remote security,
COVID-19
The COVID-19 pandemic is forcing
more workers to operate remotely,
which brings new challenges for
companies.
Cybersecurity, in particular, is playing
a larger role as more people work from
home.
Remote access should be protected
with firewalls and companies and
employees need to follow standard
best practices.
ONLINE
Read more articles about wireless
networks in the “wireless” sub-channel
page under networking and security at
www.controleng.com.
CONSIDER THIS
What challenges does your company
face with remote networks and how are
you overcoming them?
LokiBot (8%) were the most active-
ly exploited malware families, said
researchers at Singapore-based
Group-IB’s Computer Emergen-
cy Response Team’s (CERT-GIB).
With some minor differences, the
goal of all these malware sam-
ples is to harvest user credentials
from browsers, mail clients and file
transfer protocol (FTP) clients, as
well as capture screenshots, and
secretly track user behavior and
send it to cybercriminals’ com-
mand and control centers.
Security was always thought
of as a collection of people, pro-
cesses and technology, but the lat-
ter is now playing a bigger role in
allowing businesses to operate via
remote access.
“I’ve found that people were
often the inhibitor to technolo-
gy, in that they simply didn’t want
to allow technology to be acces-
rules for secure servers, and server settings
4. Consistently make sure settings haven’t
changed
5. Evaluate how those servers are configured,
what software is on them and what version it is, and
all automation behind the scenes
6. Apply patches remotely if it is possible to do
so securely
7. Incorporate a regular password update pro-
cess, through automation
8. Keep a log of configuration or firmware
changes, what was done and by whom.
Employees should:
1. During remote access, double check the loca-
tion you’re going to visit before going there
2. Don’t click on unknown links and files. ce
John Almlof is director strategic alliances and busi-
ness development – Americas at Nozomi Networks.
This article originally appeared on ISSSource’s website.
ISSSource is a CFE Media content partner. Edited by
Chris Vavra, associate editor, Control Engineering,
CFE Media and Technology, cvavra@cfemedia.com.

62 • August 2020 control engineering www.controleng.com

EDUCATION for ENGINEERS

August 18, 2020

11AM PT | 1PM CT | 2PM ET

Learn how to leverage

intelligent circuit
protection
SUMMER EDITION
Big thinking on
miniature circuit Attendees are eligible for a certificate
Motors & Drives breakers of completion.

Sponsored by
Sponsored by
Sponsored by

www.controleng.com/webcasts | www.controleng.com/research | www.controleng.com/ebooks | cfeedu.cfemedia.com

August 12, 2020

11AM PT | 1PM CT | 2PM ET

ONLINE COURSE:
IIoT Series: Part 4: Avoiding Profit Killers
Machine Learning in Manufacturing
Maintenance and SPRING EDITION
Operations
SCADA & HMI
One (1) certified professional Attendees are eligible for a
development hour (PDH) available certificate of completion. Sponsored by
for all attendees.
Sponsored by

Course runs until January 27, 2021

www.controleng.com CONTROL ENGINEERING August 2020 • 63

 Advertising Sales Offices
ContentStream
Patrick Lynch,
Director of Content Marketing Solutions
630-571-4070 x2210
PLynch@CFEMedia.com

ad index
AR, IL, IN, IA, KS, KY, LA, MN, MO,
MS, NE, ND, OK, OH, SD, TX, WI,
Central Canada
Company Page# RSN Web Robert Levinger
630-571-4070 x2218
RLevinger@cfetechnology.com
ABB Motors & Mechanical . . . . . . .2 . . . . . . . . . . 3 . . . . . . . .http://baldor .abb .com/ec-titanium

Automation24 . . . . . . . . . . . . . . . . .19 . . . . . . . . 10 . . . . . . .www .automation24 .com AK, AZ, CA, CO, HI, ID, MT,
NV, NM, OR, UT, WA, WY,
Western Canada
AutomationDirect . . . . . . . . . . . . . .C2, 1 . . . . . . 1, 2 . . . . . . .www .automationdirect .com
Aaron Maassen
816-797-9969
Beckhoff Automation LLC . . . . . . . .21 . . . . . . . . .11 . . . . . . .www .beckhoff .com AMaassen@CFEMedia.com

CALLING ALL SYSTEM

INTEGRATORS… . . . . . . . . . . . . . . .29 . . . . . . . . . . . . . . . . . .www .controleng .com/SIYApplication CT, DE, MD, ME, MA, NC,
NH, NY, NJ, PA, RI, SC, VA,
CIMON . . . . . . . . . . . . . . . . . . . . . . .27 . . . . . . . . 14 . . . . . . .www .Cimon .com VT, WV, DC, Eastern Canada
Julie Timbol
Digi-Key ELECTRONICS . . . . . . . . .4 . . . . . . . . . . 4 . . . . . . . .WWW .DIGIKEY .COM
(978) 929-9495
JTimbol@CFEMedia.com
Emerson Automation Solutions . .13 . . . . . . . . . 8 . . . . . . . .www .emerson .com/weseeconfidentoperators

EZAutomation . . . . . . . . . . . . . . . . .C1, 9 . . . . . . . 6 . . . . . . . .www .EZAutomation .net Publication Services

Jim Langhenry, Co-Founder/Publisher, CFE Media
JLanghenry@CFEMedia.com
HAMMOND MANUFACTURING . .30 . . . . . . . . 15 . . . . . . .www .hammondmfg .com
Steve Rourke, Co-Founder, CFE Media
SRourke@CFEMedia.com
Inductive Automation . . . . . . . . . . .7 . . . . . . . . . . 5 . . . . . . . .www .inductiveautomation .com
Courtney Murphy, Marketing Services Manager
630-229-3057 CMurphy@cfemedia.com
RADWELL
INTERNATIONAL, INC . . . . . . . . . .25 . . . . . . . . 13 . . . . . . .www .Radwell .com McKenzie Burns, Marketing and Events Manager
mburns@cfemedia.com

Red Lion Controls . . . . . . . . . . . . . .Bellyband . . . . . . . . . . .www .redlion .net Brian Gross, Marketing Consultant, Global SI Database
630-571-4070, x2217, BGross@CFEMedia.com

Sealevel Systems Inc . . . . . . . . . . .31 . . . . . . . . 16 . . . . . . .www .sealevel .com Michael Smith, Creative Director
630-779-8910, MSmith@CFEMedia.com

Paul Brouch, Director of Operations

SEW-EURODRIVE, Inc . . . . . . . . . . .11, C4 . . . . .7, 20 . . . . . .www .seweurodrive .com PBrouch@CFEMedia.com

Michael Rotz, Print Production Manager

Siemens . . . . . . . . . . . . . . . . . . . . . .23 . . . . . . . . 12 . . . . . . .www .siemens .com/wincc-unified 717-766-0211 x4207, Fax: 717-506-7238
mike.rotz@frycomm.com

Stratus . . . . . . . . . . . . . . . . . . . . . .15 . . . . . . . . . 9 . . . . . . . .www .stratus .com Maria Bartell, Account Director, Infogroup Targeting Solutions
847-378-2275, maria.bartell@infogroup.com

Yaskawa America, Inc . . . . . . . . . . .C3 . . . . . . . . 19 . . . . . . .www .yaskawa .com Rick Ellis, Audience Management Director
303-246-1250, REllis@CFEMedia.com

Letters to the editor: Please e-mail us your opinions to

MHoske@CFEMedia.com or fax 630-214-4504. Letters should
Inside Machines include name, company, and address, and may be edited.

Information: For a Media Kit or Editorial Calendar,

Aerotech Inc . . . . . . . . . . . . . . . . . .M8 . . . . . . . 18 . . . . . . .www .aerotech .com go to www.controleng.com/mediainfo.
Marketing consultants: See ad index.
WAGO Corp . . . . . . . . . . . . . . . . . . .M2 . . . . . . . 17 . . . . . . .www .wago .us Custom reprints, electronic: Shelby Pelon,
Wright’s Media, 281-419-5725 x138,
cfemedia@wrightsmedia.com

REQUEST MORE INFORMATION about products and advertisers in this issue by using
the http://controleng.com/information link and reader service number located near each.
If you’re reading the digital edition, the link will be live. When you contact a company
and
directly, please let them know you read about them in Control Engineering. Technology TM

64 • August 2020 control engineering www.controleng.com

Connect to Easy
Cut Down Commissioning Time with Yaskawa
HMIs and Controllers

NEW!

Panel PC

smartPanel

Get intelligent system monitoring by integrating Yaskawa’s

Panel PCs or smartPanels into your operations.
We now offer our smartPanels and Panel PCs to communicate directly to Yaskawa controllers.
This makes commissioning easier and operations more productive.

Want easier and better system performance? Get in touch with Yaskawa today.

Yaskawa America, Inc. Drives & Motion Division 1-800-YASKAWA yaskawa.com For more info: http: https://go.yaskawa-america.com/yai1397

input #19 at www.controleng.com/information

 Fed up?
Problem: You want to use the latest
automation technology. However, the
complexity is overwhelming.

Solution: MOVIKIT® software modules! They

empower you to perform complex automation
tasks easily and without experience. No more
long hours. No more complex programming.

Positioning? Synchronization? Torque

sharing? Winders? Yes, and even more!

Simple is good...

seweurodrive.com / 864-439-7537

input #20 at www.controleng.com/information