2018’s hot topics 12 | Controllers 27 | Programming help 30 STU 2019 ME@) . Bsn Fee Covering ee ras and automation systems worldwide CFE media DelisProd uctivity‘ioc ooo: Value Leader - CPU only $171.00! $258.00 CPU with 5 built-in co The Productivity1000 series PLC is the super compact yet highly The Productivity2000 PLC is where capable member of our Productivity controller family. Housed in a _designed to provide advanced featu smaller, slimmer design, this controller delivers the space and budget _ lowest cost of ownership in its class. savings your project needs, options, free software, free support 2 offer, it really does stand above the «: Etachias areata kaa) een Starter Kit Chieg $295.00 Pr We've bundled everything you need to get started in our low-cost Starter Kit. Kit includes: += Productivity1000 CPU Terminal blocks ro +8-point simulator «Battery input module Power and +8-point discrete ‘communication output module connectors 5 Power supply + Screwdriver 5 *ZPLink pre-wired « Documentation & 5 Cableandmodule software USB i FREE 30-day online «Programming cable training certificate nserts foreach + TT0VACpowercord “hardware item Data storage card Productivity Suite provides a powerful, user-friendly way to program any one of the Productivity family controllers and best of all it’s FREE. This tag name based software features many advanced easy-to-use instructions, hardware auto-discovery, web server/mobile access and many other features you'll love! Input #2 at www.controleng.com/informationmm ports value meets power. This controller was es at an extremely affordable price and Considering the memory, performance, nd everything else this controller has to smpetition. Expansive I/O and 7 built-in comm ports The Productivity3000 controller is a communications powerhouse with numerous networking options built in. I's also the VO leader of the group with over 59,000 1/0 points possible through local and remote expansion. ll EtherNet/IP - the #1 value in automationa RA i, ain Increase your Productivity’ in more ways than one. renee P3-550E CPU Productivity:.:.:. All this and more... for less! The Productivity Series of controllers provides a peered scalable controls solution with three low-cost, Custom memory allocation hardware platforms and one FREE, powerful + Scalable system with up to 59,840 programming package. Write a program in one VO points possible ni r hi + Multiple built-in communication Sonprol efaiiel “asl Pore fo another 0 TaN: options with Modbus, ASCIl and matter the application, big or small, Productivity has EtherNey/IP" support the I/O, communications and affordability you need. Wik cae msotasea «Built-in datalogging up to 32GB cay. snePi petmetSy, ine Plcy, «Real-time data displays eo ‘, oe e Fi You input #1 at www-controleng.com/informationQuality SENSORS at SENSIBLE prices. Photoelectric Sensors We've got the high-quality, industrial photoelectric sensors you need at the low cost you're looking for. Our vast selection of photo eyes and photoelectric switches is constantly growing and includes many sensing options and ranges, sizes, body styles, etc. Allat prices you won't find anywhere else. _ + Diffuse + Difuse wth beekground ma suppression + Relroreflective + Through-beam Fork Sensors Starting at $87.00 Psut-0F-19 Fork sensors (also called slot sensors or “U" sensors) offered with visible red light and laser (Class 1) light to detect very small objects. 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CODESYS e 2"PAC Control 2 ICC) Java = = ® python Lins, IEC 61131-3 = Custom Flowchart groov EPIC is the world's first Edge Programmable Industrial Controller designed for today’s—and tomorrow's—automation and lloT applications. And the “P* in EPIC means you can choose how you want to program it. FIPPAAT + Develop and run IEC 61131-3 compliant programs—including ladder logle—wit Input #4at www controlengconvinformationEZAutomation ile 12 Borne) NO Ch 74) Be aac LU Bringing Manufacturing Back to U.S. li VA Touch EZ12 Series EZ to Mount...EZ to Program...EZ tcPraia at Bete EZMount system Deeley meer le uird-le eM ere ga td Sd x Z Packaging EZ Connectivity nerNewlP US-Based Tech Sunne PELfenstors toring sohwsrs Eormsiston red nd miksow sonnet ‘hover ana astra Upset, S48 Ins tramp Cam's bah mS 278 Ince le = Tr Seen Neworing TS tone he Rose Aare al herr des Gn eer aang, Seo a se are a ue, pags M8. INSIGHTS 5| PLC research results from Control Engineering 6| Legalities: Negotiate better payment terms 8| Technology Update: Digitalization and innovation NEWS 10| Industrial internet groups to col- laborate on cloud computing, IloT research; Manufacturer to realign around digital industries; Online headlines k Again: Hot topics in Control Engineering for 2018 ANSWERS 14| Industrial networking and the lloT 16| Future of lloT software in manufacturing 20| MQTT's role as an loT message transport 12 CONTROL ** ENGINEERING 22| 24| 25| 27| 30| 33| 34| JANUARY 2019 Industrial network communications Industrial Ethernet, smarter machines Software unlocks protocol diagnostics Industrial controller selection advice Automation programming advances enhance communication, programming ‘Shaft encoders vs. bearingless encoders System integration in the automotive industry INSIDE PROCESS P1|_ Verifying primary and secondary flow measurement performance P7| Lessons learned: Startup, shutdown incidents INNOVATIONS 58 | 64| NEW PRODUCTS FOR ENGINEERS ‘Stepper motor for hazardous locations; Non- contact magnetic measuring system; LVDTs; Three-phase ac motors; Al controller extends ‘equipment life; CNC for machine tools; Cyber risk management BACK TO BASICS Programming, collaborative robots ONLINE ‘* More networking software: OPC UA, MTConnect, EtherNet/IP from ODVA, and CC-Link. * Smarter robot grasping: sensors, software, cloud como NNER cst, vo. RS ZS pane 1p yo: MeO Me L910 Md Party, Sat #25 omer rt SI eee Cg Plt Se Roe CevCD ea ONTO ENGHEEING eri 210 Teka Ah enced CONTROL DEMEEING sade CTE Me LE el a te Pe dea psa at eae ov I a ado alg rs ese mie! 210 fin Po, 8 Dm Ge, Ss. Ten 37-70 [ul sanene credo one et aes canes CON GMELIN 070 gan aay. Sal 2 ewes Gees, alate Mal Agee No 49. tm unabr Caan srs 310 yap ok, Slt #25 Dems oI. Ema ctomre erCerods bm Ayer ace an as A. ‘Sr, Cane, 0 fe OS STAB anand coy SU he swe ene nape cans a rao geese ae 608 sr. ne aes sr mals OR EMEP Ma ony Sa om ne Ss Pa We UA he Last ene ey Sebi) cya ag ee os cs be a aod oe ua ox eon mice aa ny oe a conraot enanecans January 2019 ¢ 3When YoujNeedito Pass|/HART Data, Get a Little|SUper Hero HART® data is extremely useful but when y have to isolate your loops in order to share key process signals or keep your systems safe from power issues, HART data can be stripped off and blocked by most isolators. This prevents your critical HART data from reaching your to asset management systems, programming devices or host systems, HART Isolators from Moore Industries can save the day. With built-in HART pass-through technology you can rest assured that when your loops use HART transmitters, critical and valuable HART diagnostic, process, and calibration information can be read on either side of the Moore Industries HART Isolators. [ll moore cog INDUSTRIES BSN HART Isolators from Moore Industries CallB00-999-2900 Domand Moore Roliility or visit worming. com/HART Isolators Ingut #5 at wurcontrolengconvinformationAttitude towards job Works tolerable Actively butopen to other searching opportunities foranother . job 2% z ie Works going okay, glad to to work have a job every day Figure 1: 46% of end users enjoy their jobs and look forward to Pe eek cr pee ee ccae ing, Source: Control Engineering 2018 Career & Salary Study Sey eee eer ee ae per drive controller products as pee ect nae eae a ee teu Six in 10 .... are not bound to existing purchase See nae SCADA software or hardware. Cer HMI Software & Hardware Study CT eee See ec es provided by their industrial con- Re eee Control Engineering 2018 Program- De eg Dec) Cee ee ne eee eed es ee eee wn controlong,com INSIGHTS. RESEARCH 2018 PROGRAMMABLE CONTROLLERS STUDY Industrial controller features espondents to the Control Engi- neering 2018 Programmable Controller Software & Hardware Study provided their insights fon important capabilities of industrial controllers: + Software functions: Programmable logic controller (PLC) programming tops the list of controller software features that end users need at 87%, followed by human- ‘machine interface (HMI) development (7286) and remote monitoring (70%). + Controller features: Seventy-seven percent of industrial controllers have pro: portional-integral-derivative (PLD) control, and 61% can communicate with devices or systems outside of the control loop. + Networking: Thirty-seven percent of end users’ controllers interface with PLCs, 21% with a distributed control systems (DCS), 12% with programmable auto: ‘mation controllers (PACS), and 11% with industrial PCs; 18% stand alone. + Communications: The top commu nications protocols used by controllers are 4-20 mA/0-10 V de (76%), Ethernet (73%), RS-232/RS-485 (61%), and Modbus TCP (55%). Forty-five percent of end users controllers use the OPC Unified Architec~ ture machine-to-machine communication protocol, and 25% use another communi- ‘cations software/method from OPC Foun dation. Fight-two percent of end users employ Ethernet, TCP/IP in their control- ler hardware, + Programming: The majority of end users (849%) use or expect to use ladder dia grams over the next 12 months, while 639% Use/expect to use function block diagrams and 38% use/expect to use sequential func- tion charts and/or structured text. + Integration: Sixty-six percent of end tusers use controller software that is com: patible with prior versions of the platform and 43% use a controller software that eas- ily integrates data from other systems. e« ‘additional findings 2! snwecontroleng.conv2018- programmable Ccontrolers-study. Amanda Peliocione: Is the research director at OFE Meda, ‘apelicconedictomedia.com, Top 10 controller software programming, setup functions Ladder logic Function blocks FullIEC 61131-3 language support Funetion/code libraries, object-oriented code Client-server capabilty Structured toxt ‘Automated t9gging Sequential function charts Simulation capabilities Custom programming tools Figure 2: End users most often use controller software featuring ladder logic, function blocks, and full IEC 61131-3 language support. Source: Control Engi- neering 6 January 2019 «5INSIGHTS. LEGALITIES FOR AUTOMATION AND INTEGRATION Brian Clifford, Faegre Baker Daniels Negotiate better payment terms Payment cycle provisions are common in automation and integration contracts. Four strategies can help a company's cash flow. Invoice the costs for expensive third-party equipment separately. 5 More UW INSIGHTS he right contract clauses can improve a company’s cash flow—whether you are ‘making or receiving payments. “Payment, cycle” provisions are common in auto- ‘mation and integration contracts. As you are likely seeing in the market, the historic “net 30” terms in commercial agreements are becoming harder to obtain. Companies making payments for completed services and deliverables are pushing for longer dead- lines, as long as 90 or more days from invoicing. Like using a credit card (and paying it off month- |y), companies are buying automation services and products and. are essentially obtaining short-term, interest-free loans from vendors for projects, Sometimes, long payment cycles are an indica- tion a purchaser is experiencing financial difficulties. ‘Other times, such cycles are a function of burdensome internal approval processes or a company knowing it can use its leverage to obtain very favorable payment deadlines. Sometimes, it’s both scenarios. Ifyou are the seller, four strategies can be used to «get paid for completed work as quickly as possible: ‘1. Negotiate shorter payment deadlines ‘The most straightforward method to get paid faster, of course, is to shorten the payment dead- lines. Often, customers are willing to consid er reducing particularly long payment cycles if the issue is presented to them in the right way. You can explain that you are unable to Cchusctymeemttes —_obiain corresponding payment cycle terms ee pementte™® from your own vendors, meaning you would ‘can improve how payments improve cash flow. ‘Shorter payment deacines ‘can improve cash flow. Expensive equipment might be invoiced separately. CONSIDER THIS How is your auiomation- industry company aiming improve cash tow? lfreading trom the digital ‘edition, cick on the headline for more resources. For other ‘enginsering-reated legal issues, search “Faegre” at ‘ww cantrolang com. 6 © January 2019 have to “come out of pocket” for the project, for long periods of time. Many customers are sensitive to this cash-flow problem. 2. Carve-out portions of the contract amount Ifa customer is unwilling to shorten the payment deadline in general, you may want to ‘consider “carving-out” certain portions of the contract amount for a shorter payment cycle, For example, if you are required to provide an expensive piece of third-party hardware or equipment for the project, you may be able to geta customer to agree to have the costs forthe item separately invoiced on payment terms that are within the deadline established to CONTROL ENGINEERING by your agreement with the third-party vendor. This can prevent you from being “caught in between’ two large corporations using their market share to obtain unreasonably favorable payment cycles. 3. Insert a down payment ‘or mobilization fee Ifyou know long payment cycles wile required, you may want to“ront-load” your fes in the agree- ment, You can ue this up-front payment to keep your out-of-pocket expenses toa minimum as work progresses Sach terms also decrease risk af non-pay- tment for work already completed, but not yet billed or paid. However, you should be careful not to mis- represen such early payments 4. Invoice more often ‘Another effective strategy in mitigating the risk of long payment cycles is to invoice more frequently. Instead of your usual monthly invoices, will a cus- tomer accept weekly or bi-weekly invoices? While the deadline for your receipt of payment on each of these invoices may still be set out far in advance, tore frequent invoicing wll increase cash flows for ‘the project and decrease the amount of payments outstanding at any point in time. If you are the purchaser, you can flip these strate- gies around, For example, you could propose a short- cer payment cycle for services (in recognition of the employee salary payment cycle), but only permit invoicing for equipment once it has been delivered and passed a site acceptance test (SAT), It also might be possible to withhold a certain portion of the contract price until after final aceep- tance of the entire system and a successful start-up period. Invoicing also could be set on a longer cycle through the use of a milestone billing provision Regardless of which side ofthe payment cycle you are on, you may be able to ensure a steadier cash flow for your next project by using these contract negotia- tion techniques. e Brian Clifford is a partner in the automation and robotics practice of Faegre Baker Daniels, a law firm in the US., UX. and China. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, mhoske@efemedia.com. nw controlang comrN ALLIED ELECTRONICS © AUTOMATION Automation & Control Freak? Same here. We carry more automation & control brand names than any other distributor in North America. It’s true — we checked. input #6 at www.controleng convinformation iedelec.com @ 1.800.433.5700INSIGHTS. TECHNOLOGY UPDATE INDUSTRIE 4.0 Jonathan Wilkins, £U Automation Digitalization and innovation driving manufacturing’s future Manufacturing is in the midst of the fourth industrial revolution—known as Industrie 4.0.— and constant plant-floor changes are forcing companies to keep up with the rapid pace or risk getting lost and falling behind Book by EU Automa- tion has more about Industrie 4.0. Cour- tesy: EU Automation Ua More INSIGHTS KEYWORDS: Industrie 40, digitalization, robots Digitalization is key part ofthe fourth industrial revolution. In this new manufacturing fenwrcarment, the robots role has changed and become more colaborative, Digitalization offers 2 ‘Feat deal of potential, but ‘Companies have 1 recognize that and enact policies to he fourth industrial evolution, aso called Industrie 40, is underway. It revolves around the rise of the Industrial Inter- net of Things (LloT) and its ability to con- nect to seemingly everything, including innovations such as additive manufacturing, collab- orative robots, artificial intelligence, and augmented and virtual reality (AR/VR). Industrial revolutions themselves are nothing new, but the pace at which they're occurring is remarkable. The pace of change in ancient societies was on a scale of hundreds or thou- sands of years. In contrast, the industrial revolutions ‘of the 18thand 19th centuries shortened the time span between successive revolutions to less than a hundred years. Depending on the source, the third industrial revolution lasted from 1980 to the Great Recession. Despite innovations being more readily available than ever, countries are at different points on the jour- ney to dgitalize. There isa disparity between the rates of adoption of new technologies, awareness about what the fourth industrial revolution offers, and a cohesive leadership intended to drive change initiatives. This has resulted in a fragmented system, with the con- cept of industrial digitalization, or Industrie 40, referred to by various names including Society 5.0, Smart Industry, Manufacturing USA, and Made in China 2025. ‘While the names and concepts differ, the core principles are largely the same. Countries and companies seek to enhance connectivity ‘on the manufacturing floor to provide better, faster, and accurate data to make manufactur- realize ing operations safer and more productive eee Robots and Industrie 4.0 dodocmerte Gilt ean ‘Manufacturing has turned to robots to Industrie 4.02 handle many of the dirty, dull, and dangerous a (the three Ds") tasks on the plant floor. While Leam more about Industrie. 4. at ww controleng.com under the loT and industre 4.0 topic. January 2019 robots used to be confined to a fixed area— preferably behind a mesh cage—they are start- ing to work alongside humans in day-to-day operations. Collaborative robots are among. CONTROL ENGINEERING the manufacturing innovations. Nigel Smith, CEO of TM Robotics, has seen the challenges and the possibilities robots ean bring in this, ‘new manufacturing environment. “Robots have dominated automotive applications fora long time?’ he said, “In the last few years, howev- er, we've seen robots being used in inereasingly varied sectors, from food and pharmaceutical to medical and. plastics manufacturing” In addition to new applications, robots have become more reliable, Smith said, thanks to manufac turers shifting from hydraulics to electrical actuation, Remote monitoring helps users gain more insights to prevent potential mechanical or control issues. Interfacing and connectivity have improved. Con- necting a peripheral device such asa vision system to-a robot can be done easily, which makes processes such. as inspection and conveyor tracking smoother. ven with these improvements, Smith pointed out ‘here s still big fundamental challenge manufactur- ers face atthe beginning ofthe process. “A challenge that continues to affect many busi- nesses is choosing the right robot” he said. “Because robots are becoming easier to use and maintain, cheaper, more efficient and easly deployable, [there are more options This makes it even more important that engineers choose one with the right blend of fea- tures to match the needs ofthe application” ‘The manufacturing industry has progressed since the term Industrie 40 was introduced. Some technolo- gies in operation were just ideas then. Robots were stil in cages. Workers, while operating in a more interac- tive environment, didnt have nearly as many choices as they do now with digitalization. Digitalization has the potential to transform the ‘manufacturing industry, but companies need to ‘embrace new technology to benefit. Even making small changes can have a huge impact on operations, staff and producti Jonathan Wilkins, marketing director, EU Automation. Edited by Chris Vavra, production editor, Control Engi- neering, CFE Media, chavra@cfemedia.com. nw controlang com© One stop. Smart shop. Avutomatione4 YOU DESERVE automation excellence queens ig _® www.automation24.com/siemens Now available | — — aes LOGO! Logic motiules = BS ae es ee Pile nes y — = Cees Aad =} cee O elt YOU DESERVE fast delivery — all products in stock at our warehouse Par Bee MAT ge san eaat Ci Large selection eee’ rec Ce Oe tac with tech support pricing Sua @ c=ewore siemens Moma GPRUTSCH Weldmiller3E microrone Nee Ret ea en kOe on er see el aT Speirs teed elie MOR TC LMC ene MO Rann ena +1 610-981-2900 Dre a SedINSIGHTS. NEWS Industrial Internet groups to collaborate on cloud computing, IloT research The Industrial Internet Consortium (IIc), a CFE Media content partner, and the OpenFog Consortium are merging to bring research and best practices promul- gation around cloud and fog comput 5G cellular communications, and artificial intelligence (Al) under one organization. ‘The two groups announced Dec. 18, 2018, they would combine their organizations under the LIC name and would collabo- rate on a more holistic approach to fur- thering the use of the Industrial Internet of Things (IloT). “The Industrial Internet Consortium, ‘now incorporating OpenFog, will be the single largest organization focused on ToT, AI, fog, and edge computing in the world. Between both of our organizations we have a remarkable global presence with members in more than 30 countries?” said IC president Bill Hoffman, “This agreement will help accelerate the adop- tion ofthe IloT, fog, and edge computing” ‘Cloud computing transmits and stores information through data centers to pro- vide greater computing capacity. Fog com- puting, also known as edge computing, allows for such calculations to be done at servers on a plants premises. “Were excited by the growth and advancement of fog technologies—from a technology, standards, and general aware- ness standpoint—since our launch nearly three years ago. said Matt Vasey, Open- Fog chairman and president, and director, Aland lo business development, Micro- soft. “During that time, it has increasingly become apparent that we share so much synergy with the efforts of the TIC that it just made sense to bring the two consor- tia together. The resulting combination of memberships, resources, and shared Manufacturer to rea around digital industries four business units and sell its power grids business to Hitachi for $11 / BB announced the company will reorganize its global organization into bilion as part of the streamlining effort. The reorganization, scheduled to take effect April 1, will create four bust ness units that company officials said would better position ABB to meet the customer needs in a changing digital landscape. "To support our customers in a world of unprecedented technological change and digitalization, we must focus, simplify, and shape our business for leadership. Today's actions will create a new ABB, a leader focused in digital industries,” said ABB CEO Urrch Spiesshofer ‘ABB will organize itself into four business units: electrification, automation, robotics & diserete automation, and motion, "Our four newly shaped businesses, each a global leader, will be well- aligned to the way our customers operate and focus stronger on emerging technologies such as artificial intelligence,” said Spiesshofer. “The continued simplification of our business model and structure will be a catalyst for growth and efficiency.” By streamlining the organization, eliminating regional executive commit- ‘tees, and reallocating resources, ABB officials said the company expects to reduce costs by about $500 million annually and expects to grow to a $550 billion business by 2025, an increase of $140 billion from today's revenues. ©@ Bob Vavra, content manager, CFE Media, bvavra@cfemedia.com. dustrial 10. + January 2019 conrpot enineraInG knowledge will only further the growth of the technologies, including fog, that will support IIoT ecosystems” In a press release announcing the merger, IC officials quoted Christian Renaud, research vice president for Inter- net of Things (IoT) at 451 Research as saying, “Both organizations have been advancing the Ilo, fog, and edge comput- ing, and their members represent the best and the brightest in their fields. It makes sense to merge their expertise and work streams to continue providing the LloT, fog, and edge guidance that the industry needs?” The IIC’s overall goal isto help deliver a secure and connected infrastructure for ‘manufacturers using the cloud computing technology to improve operations. ce Bob Vavra, content manager, CFE Media, byavragecfemedia.com. Headlines online Top 5 Control Engineering articles Dec. 3-8, 2018 ‘ticles on process tuning, Engineers Choice fnaliss, process simulation, imple- menting a linear motion application. geting stronger process readings, and AR and VR. ‘were the most-viewed from Dec. 3-8, 2018, Researchers use thermal transistor to protect electronic devices from overheating A Stanford-ed engineering team developed a way to manage heat produced by elec- ‘wonie devices witha thermal transistor. The next era of global manufacturing |With technology and information, manufac- turers change how they do business as glo- balization changes the nature of business. Hannover Fairs USA new trade event Digital industry USA (DIGAN USA) wil high- light digital manufacturing Sept. 10-12, in Louisvile Engineer lights up the town Caleb Oito used his engineering back- ‘ground and love of holiday tradition to set up ‘a musical ight display. See video online. nw controlang comOTS CMe RT ey PETE MET ee MEU ey OTH Cm CR CTL 1.800.344.4539 ( Diegi-K. By AIL f rm) ecraomes GZ PteINSIGHTS. THINK AGAIN Hot topics in Control Engineering for 2018 Engineering salaries and career tips, neural network advances, ladder logic, cybersecurity, and autotuning were among top articles posted on the Control Engineering website in 2018. ‘ot Control Engineering topics posted in 2018 include engi- neering salaries and career tips, neural network advances, lad- der logic future role in automation, indus- trial control system cybersecurity, and proportional-integral-deriva- tive (PID) controllers autotun- ing control, as identified by the most visited Control Engineering articles during 2018. Think again about upeom- ing topics at www.controleng. com/2)19articles and contrib- tte your expertise to next yea's hot topics. Especially of interest will be September, Control Engi- neering’s 65th anniversary, look- ing at how the past continues to influence where were headed. Top 10 Control Engineeri articles posted inate ‘The articles posted during 2018 at www. controleng.com with the most clicks during 2018 follow. This metric obviously favors those posted earlier in the year. At the bot: tom ofthis article online, lnk to the top art cle rankings for articles posted later in 2018 1. Controt Engineering Salary and Career Survey, 2018; May 15 Career Update 2018: Engineers ae get- ting paid more and a greater percentage expect to get increases in 2018, but the technical challenge and a general feeling of accomplishment remains the highest fac- tors for job satisfaction. mM More INSIGHTS reading trom the itl ection ‘war contrsieng comfmagazine cick on the headine op covers of 2018 and top 1 arices in 2018 posted prior to 2018 representing strong set of tutorials about Contra! Engneerng tops. With nis article toning, Inicto each arte referenced. 12 + January 2019 2. Processing a neural network's mind and its ability to process language; Jan.7 “MIT researchers have developed a tech- nique illuminates the inner workings of artificial intelligence systems that process language, which could improve overall efficiency for machines. = 3. Ladder logic’ future role in ‘automation; July 3 Review nine considerations ‘when selecting @ programming language. 4. Understanding industrial control systems security basies; April 6 Its critical to implement an in-depth cybersecurity plan to reduced risk to industrial control systems (ICSs). 5. Prosand cons autotuning control: Part 1; June 1 TD controllers that can automaticaly jasc thee owa taming parame ame ood but face challenges 6. Ladder Logic: Fault detection and messages; Feb, 22 7. Comparing ladder logic and object- oriented programming; July 12 8. Implementing a cybersecurity strate sy for cloud-based SCADA; Aug. 14 9. Three major VED trends; Jan. 4 10. Process control sensor types and applications; Mar. 4. ce Traffic ranking based on www.controleng com analytics performed by Chris Vavra, production editor, Control Engineering, cvavra@cfemedia.com. ‘CONTROL ENGINEERING [ROL E EERING. S010 Higa Para, Sut 325, Downer Gove, ICecst 690-571-070, ax 90. 2144504 Content Specialists/Editorial Mark Has, ora Haag (Susie sos? MtnaecroMctacon ace Sit Cote Marae ‘soso 1250, ssmt2CFEMea com Kev Pare So Cog Eo, oT OO (Soares anderen com ty Gums osc Canara (ior 701228, epothreOrEos com ‘Amanda Plicions, Det ofeach ow ion, psi rt a tndoy Frank Lamb, ta one ‘damatan Com 10 rata on Matin etna er ‘User Gael Sema rari com ek Pwo, pio arco‘ Serer Coens mumaiperovaredcon Mark oitnann, pars aon ace ad Fe tera afaegeo sr CFE Media Contributor Guidelines Overview Conte Fo ng Thal a CFE da ‘Senator anturar CFE Meas a t= (Sher comanbatralccseiedpote ‘raring, Mol co ose mtr oto. 00 ‘Sumatran neve ‘tos med abo he ri ck tamer mcoonncomlecnrite ete {Decor pes neces recs, repos ‘pophon one aes a we foes ad one ra * Corres oa rhb egress poviers denote comme race ‘Soou peer opto mb eee (tet ces lect ese ecstorproreenal an eur ‘incor romeo wh ees ce) +h crenl mets cra een gain ‘tpt ane ren Wt Sora cu Sete res calomel ay mens Sean Mt wor ‘A corr at opens er Dt rogcres ‘Sear supmapioni we wou cee prt “uae ui aan ee win Se Aun Tb soemea re whi epee ons manage Tet er ely cernsBaNihi))> i Shed a Makes no cents! Pe aie a anneal PU era ode ewan Rea Soho aurea < . Why gain 2-3% energy savings with a more efficient motor and then lose 50% or more through the worm gear? Solution: Use a helical-bevel gearmotor from SEW-EURODRIVE and obtain 96% — efficiency. Now that makes a lot of cents! EURODRIVE seweurodrive.com | 864-439-7537 ero CeANSWERS. COVER STORY: NETWORKING SOFTWARE Dr. Michael Hilgner, TE Conn: The sign ty Germany Gi iC working groups ificance of industrial networking for the IIoT The Industrial Internet Consortium (IIC) focuses on the role of the Industrial Internet of Things (IloT) in industrial networking ANSWERS KEYWORD: Industrial Internet of Things (lloT) dustrial networking connects devices and systems and is ertical to the Industrial Inter- net of Things (IloT). Application and deploy- ment considerations—along with existing and emerging technology options—adds complexity to network planning and technology selection according to the Industrial Internet Con- sortium (IIC) white paper “Industrial Networking Enabling HoT Communication.” When trying to understand and resolve net- ‘working issues, consider: 4, Future HoT scenarios high-level deserip- tions of requirements and design consider- ations can vary by industry. 2. Various standards can apply and help. 3. The IICis developing a technical document, the Industrial Internet Networking Framework (INF). The core element of the document will be a conceptual toolbox designed to provide guidance for selecting the appropriate network infrastructure HoT s roe in industrial networking, ‘The Industrial Internet ‘Consortium (IC) is developing a technical dacument to provide guidance for selecting the appropriate network infrastructure. ‘There is demand for strearined semantics to help with operations technotogy/ntormation technology (OTM integration CONSIDER THIS ‘Are you aware of the proper network architecture for an Industrial Internet Networking Framework (INF)? ONLINE ‘See lIC's white paper, “industrial Networking Enabling lloT Communication,” for mors information. 14 January 2019 ‘The Networking Task Group (NTG), a sub-group under the 1IC’s ‘Technology Working Group, is responsible for the three lower lay- crs of the Industrial Internet Com- munication Stack as defined in the Industrial Internet Connectivity Framework (IICF), which are iden- tical to the lower three layers of the OSI model: Physical layer, (data) link layer, and network layer. In industrial automation, these layers are impacted by the transition from traditional field buses to Ether- net-based protocols. Such industri- al Ethernet technologies are defined by international user groups such as ‘CONTROL ENGINEERING Profibus Profinet International, ODVA (EtherNet/ IP), the EtherCAT Technology Group, the Ethernet Powerlink Standardization Group and the CC-Link Partner Association (CLPA). Some technologies use standard Ethernet without modifications to layers 1 and 2 of the foundational IEBE 802.3 stan- dard, whereas others define deviations in the data link layer. These Institute of Blectrical and Blectron- ics Engineers (IEEE) standards define the physi- ‘al layer and data link layer’s media access control (MAC) of wired Ethernet. A set of common and technology-specific definitions is made available through the International Electrotechnical Com- mission (IEC) 61158 and IEC 61784-5 series. Companies implementing software stacks for these technologies or gateways to exchange data between them or between industrial Ethernet net- work and fieldbus segments need to follow the def- initions by the user groups—especially those for the application layer. The emergence of the IloT and the possibility to perform advanced analytics in higher-level IT systems have led the demand for interfaces providing access to additional data. Fur- thermore, for the sake of quick and reliable oper- ational technology/information technology (OT/ IT) integration, there isa request for standardized semantics, which is often implemented through an additional “user layer” performing the conversion toa rich data model. ce Dr. Michael Hilgner, manager consortia and stan- dards, TE Connectivity Germany GmbH, works on international standardization activites and indus- trial user groups in the areas of industrial networks, fieldbuses and cabling systems. For the Industri- ‘al Internet Consortium (IIC), a CFE Media content ‘partner he leads the smart manufacturing connectiv- ity for Brownfield Sensors Testbed, and contributes to several Industrie 4.0 working groups. Edited by Emily Guenther, associate content manager, Conteol Engineering, CFE Media, eguenther@cfemedia.com. nw controlang comcoos elementiu 3M G7 BELDEN E.1n ay wreysicut een ‘S\Meesocre molex mutticomp Breese! —Teltronix: «TEMA input #10 at worn.contoleng.comvinformationANSWERS. COVER STORY: NETWORKING SOFTWARE Stan Schneider, PhD, Real-Time Innovations (RTI) and vice president, IC The future of HoT software in manufacturing A guide to understanding and using data distribution service (DDS), time-sensitive networking (TSN), and OPC Unified Architecture (OPC UA) for advanced manufacturing applications he top Industrial Internet of Things (Ilo) connectivity framework stan- dards are OPC Foundation’s OPC Unified Architecture (OPC UA) and Object Management Group's (OMG) Data Distribution Service (DDS). Both are gaining widespread adoption in industrial systems, though not in the same sectors. Each differ from many of today’s discrete auto- ‘mation systems, which use a simple architecture. A programmable logic controller (PLC) con- neets devices over a fieldbus. The PLC controls the devices and manages upstream. connections to higher-level software such as human-machine interfaces (HMIs) and data historians. Factory-floor software is straightforward. It reads sensors, executes logic, and drives actuators, thereby implementing a repetitive operation. The factory has a series of workcells, each with a few dozen devices. Why designs are changing ‘The traditional PLC and HIMI design served well forthe last three decades. However, it may not survive the next one. Why? Processor speeds and easy inter- connectivity offer more capable compute resources. ‘The PLC-centric workcell design can build reliable systems that endlessly repeat an operation. They arent truly “smart” though. They dont adapt well to change. They cant take advantage ofthe explosion in compute and networking capacity. In short, they dont provide a path to intelligent, but more complex, software. The HoT has the potential to transform industri- al systems. To do that, it must share data across the ‘workcell factory, and front office. OF course, its not that simple. Pervasive data use requires a new archi- tecture and new approach to connectivity OPC UA and DDS solve different prob- lems. Hardware engineers use OPC UA because it makes device connections simple. System archi- tects use DDS because it spans system layers with a system-wide client/server network Figure 1: Locally-connected pubsub device networks. OPC UA client/server uses a client/server pattern to connect workcells to human-machine interfaces (HMIs) and historians. When the OPC. UA pubsub specification is used, devices and programmable logic controllers (PLCs) publish or subscribe to simple numeric data types and communicate over local connections, with time-sensi- tive networking (TSN) replacing a fieldbus in workcells. All graphics courtesy: Industrial Internet Consortium (IC) 16 © January 2019 contro. enaInezaING nw controlang comconsistent model. DDS and OPC UA are different, but it not a matter of choosing the right one; they do not compete. In fact, there is growing appreciation for how they can work together to build a powerful industrial com- ‘munication architecture in the future. The real chal- lenge is deciding which problem needs to be solved. ‘That makes it critical to understand what OPC UA and DDS can do. Its important to identify when to use DDS alone, when to use OPC UA alone, and when to use a combination of both frameworks. OPC UA and TSN connect crete manufacturing sector, OPC UA and ive networking (TSN) offera potential path to resolving the “fieldbus wars” OPC UA is useful for integrating dedicated devices, such as conveyor belts, sensors, repetitive robots, and drives into a workcell. It can connect workcells to software like HMIs and his- torians. It does this by modeling devices and allow- ing factory technicians and manufacturing engineers to coordinate these devices through a PLC controller (Gee Figure 1). ‘Workeells arent so much programmed as they are configured. Manufacturing engineers or techni use palette of devices to implementa function in the cell. The devices come with standard models so the factory isnt locked to one vendor. OPC UA systems are compositions of devices and existing modules such as data historians and HMils. This design makes iteasy to assemble workcells of devices with litle soft- ware effort OPC UA connects workcell data to systemwide data by changing the communication pattern from pubsub to client/server (request/reply). To receive data, an application or higher-level client has to dis- cover and connect to the server. This architec~ ture is not designed to enable programming teams. For instance, translating pubsub and client/server presents an inconsistent programming model across levels. And it doesnt let teams pre-define new software interfaces or shared data types. Without these, OPC UA doestit provide one source of “system truth” for systemwide software. ‘OPC UA is optimal for integrating devices into a ‘workcell although OPC UA can frustrate teams trying to build complex system software. DDS enables system software DDS, on the other hand, targets teams build- ing distributed software applications. The first DDS application was feedback control over Ethernet for intelligent robotics. DDS then spread into software {intensive distributed applications such as autonomous vehicles and Navy combat system management. Its fundamental purpose is combining soft- ‘ware applications into a complex system-of-systems with one consistent model. Most DDS systems com- bine “functional” artificial intelligence with 10 to 50 applications and devices, but some DDS systems are comprised of hundreds of thousands of devices and applications, which are written by thousands of programmers The key to understanding DDS is to realize dis- tributed systems are fundamentally parallel, and the system architecture must match that realty. This isn't new: the heart of a current distributed control sys- tem (DCS) is a control execution engine that man- ages timeslices and control loops. All data is stored in “sandbox RAM" so processes can access any data without unwanted interaction, The DCS provides an environment to combine function blocks into parallel, deterministic feedback loops in one box. DDS takes that same concept and distributes it, DDS implements a data-centrie shared “glob- al data space” This means all data appears as if it lives inside every device and algorithm. This is, of course, an illusion—all data canit be everywhere. More WAN SWers KEYWORDS: Data Distribution Service (ODS), OPC Unified Architecture (UA) When to use OPC UA, and DOS frameworks When to use 2 ‘combination of both standard frameworks Defining how DDS and (OPC UA can help. CONSIDER THIS What framework would be the best ft for your manufacturing operations? ONLINE For more information (on OPC UA and DDS, go online at \wr.controleng.com. \wnwiconsortiu,ora/ CF, Industrial loT System iabile and Web User interfaces: sm ce 22 1,7 Connect Cove dnp Stars HITPREST) Devices Gateway ‘Manufacturing Workcells OPC-UA ‘oPc-us.o0s Figure 2: The IIC’s Industrial Internet Connectivity Framework (IICF) is the industry's most comprehensive analysis of connectivity technologies. It includes detailed assessments for the most common IloT technologies, including OPC. UA and DDS. It also proposes an architecture for using them together. conrmox eneneeenc January 2019 + 17At 3:25 a.m. a problem et Runa aca PLANTREPLAY saw it. rae ae Le REPLAY lets operators, managers and plant engineers go to any HMI client and last week, last month... or earlier this morning. Module for Ignition SCADA Run license $1000 Available to all sites and Ignition Integrators Proven installs in the US, Europe and Asia Systems from 1000 to 500,000 tags REPLAY the missing piece to ukimate SCADA TAMAKI CONTROL Visit PlantReplay.com Se oR US Ue ees ee eat) DDS works by keeping track of which application needs what data and when, and then delivers it. Asa result, data an applica: tion needs is present in local memory on time, The essence of data centriciy is instant local access to anything by every device and every algorithm, at every level, in the same way, at any time. Its best to think of itas.a distributed shared memory, similar to the DCS sandbox RAM. There are no servers or objects or special locations. Its a parallel software architecture across the system, “DDS is about data centrcity, not pat terns. While most standards use pubsub, the standard also specifies requests/replies and some vendors support queuing. Appli- cations interact in many ways, but only with the shared distributed memory, not with each other directly. DDS also defines system interfaces (datatypes) and qu of service (QoS) flow contro. I integrates ‘modules with a transparent and consistent systemwide architecture thats independent ofppatterns. Ths isthe connectivity analog to data-centric system “truth” databases use to power the enterprise. However, DDS doestit model devic- cs. Factory engineers and technicians cant combine devices into. workcells without writing code, Should you use OPC UA, or DDS, or both? Manufacturing systems compete on the same bass they have for decades: reli ability, production rates, or implementa- tion cost. If you believe software can be bought and remain competitive, you dont Table: OPC UA and DDS hhave to change. If, on the other hand, you see a future where the best software wins, you will need a different path to keep up (see Figure 2), A system may also need to be built from interoperable devices. Fortunately, this doesn't have to be an all-or-nothing decision; DDS, OPC UA, and TSN can work together. The Object Management Group (OMG), the parent organization for the Industrial Internet Consortium (IIC), recently approved a standard to integrate DDS with OPC UA. OMG and OPC Foundation are working on stan- dards to use TSN with DDS and OPC UA. DDS vendors are working on config- uration tools. TIC developed an integrated archi- tecture and has several testbeds using OPC UA in manufacturing applications and DDS in applications such as electric power and health care. Some use OPC UA and DDS. Combining the flexibility of interchangeable devices with a power- ful software development environment is not too far off ‘Many people have difficulty defining what these technologies do. To stay com: petitive in the future, its vital to research and ask questions to ensure the right platform, or the right combination, is chosen. €« Stan Schneider, PhD, is vice chair of the Industrial Internet Consortium (IC), a CFE Media content partner, and is CEO of Real-Time Innovations (RTL). Edited by Emily Guenther, associate content man. ‘ager, Control Engineering, CFE Media, eguenther@cfemedia.com. Integration usere | Enginerstechnicians Opposite (bject-Overted Data-Centre Opposite Primary markets Manutaturin Tenenreton. matical paves, | oppoche lanutactring robo8cs, defense, autcnomy | _OPPOS System data modal | Nore(@ynaricat | cundomontat integration pot | Opposite Vendor device support Extensive None Opposite Data model Hierarchical elational Opposite Data sharing model Variables GAUDmanagedtypes | Opposite Sends data Yes Yes ‘Sear DDS and OPC UA are nearly opposites. DDS is widely deployed in industries that need sophisticated distributed software. OPC UA targets manufacturing, ‘where device interoperability matters mor 18 + January 2019 CONTROL EneTC ey ae ea tesa CC-Link IE TSN - Accelerate smart factory construction with TSN technology CC-Link Partner Association (CLPA) ‘The CCLink Partner Association (CLPA) has created a new industrial open. network specification “CC Link I TSN" as the next generation CC-Link IE network. The first to offer a TSN network specification. (CC-Link IE was introduced in 2007 as the first industrial open networkin the industry based on 1 Gbps Ethernet. CCLink IEis available in several different types. "CC-Link IE Control’isa trunk network that connects controllers within a factory, while "CC-Link IE Field” covers general input/output control, connecting controllers with a wide variety of field devices. Functionality and scope have also been expanded with *CC-Link IE Field Motion” (for motion es control) and “CC-Link IE Safety" (for safety control) (GGE-LINkIE TSN, Functionality The newly established CC-Link IETSN specification is the first to combine gigabit Ethemet bandwidth with Time Sensitive Networking (TSN). TSN isan addition to the IEEE Ethernet related standards and is starting to become popular for industrial networks. TSN's key benefit is that it allows the combining of real-time control communication with non-real time information communication while maintaining deterministic performance. Ths is not possible with conventional general purpose industrial Ethernet. CCLink IETSN adds TSN to increase openness while se De further strengthening performance and functionality. Italso supports more development methods, System size enabling easier implementation on a wider range of equipment and increasing the number of compatible products and is expected to accelerate the construction of smart factories using the IlcT. Download the paper at: am.cc-link.org/en/downloads/TSN_WP/TSN_WP.html Infoacctnkamercaong-amccsiniors CC-LINKIE TSN Input #12 at wecontroleng.comvinformationANSWERS. COVER STORY: NETWORKING SOFTWARE Arlen Nipper, Cirrus Link Solutions MOTT?’s role as an IoT message transport Message queuing telemetry transport’s (MQTT) role as an Internet of Things (loT) message transport began as an industrial communicator for a pipeline supervisory control and data acquisition (SCADA) system. essage queuing telemetry transport (MQTT) has emerged as one of the dominant loT message trans- pports across multiple industries in the last five years. Considering that most cloud services provide native MQTT capabili- ties, more device manufacturers, software, and ser- vices are implementing MQTT-based products. The genesis of MOTT Adoption of MQTT by Facebook, cloud ser- vice providers, and many others in the information technology (IT) space might lead one to think that MQTT was invented targeting IT solutions, but the genesis of MQTT was driven by an industrial com- ‘munication problem. In 1997, Phillips 66 had installed one of the first transmission contzol protocol/internet protocol (TCP) IP)-based very-small-aperture-terminal (VSAT) sys- tems in the market for use in its pipetine superviso- ry control and data acquisition (SCADA) system. Numerous challenges needed to be addressed to use Pept vend prota pest Elo Messaging standards What messaging protocol(s) de you use for your loT solution? marr HTTP Websockets HTTP ‘comp AMAP (09 andor 1.0) lerhouse /propetany (Other plea speci) Dont now Dos. xMeP None 10% 10% 20% 0h SOHO this network infrastructure effectively. Pll/response protocols were the norm for any SCADA system implementation until this system was implemented. However, due tothe propagation delays inherent to VSAT communications, and the cost associated with, continuously polling for process variables that may not have changed, Phillips was looking fora better way to optimize its network infrastructure. By this time, information technology (IT) departments used message-oriented middleware (MOM) software to decouple applications from each other. They were efficient infrastructures that used message brokers to ensure applications that “published” information could be connected to applications that “subscribed” to that information. Information could be published on an exception basis to any application that had interest and was subscribed to that information. ‘The idea was to use this same typeof infrastructure fora real-time SCADA system. The only problem was that MOM products on the market at that time werentt appropriate for use in the SCADA environment ‘Based on these requirements, a project was start- ced to develop a MOM specification that would be appropriate for use in these types of industrial envi- ronments. This ultimately led to the design of MQT'. The original design goals of MQTT were that it would be simple efficient, stateful, and open. ‘Simple. When MQTT first was being developed, the hardware platforms available on the market for remote edge computing were minimal; 8-bit micro- processors with 64 KB of memory were the norm. ‘MQTT had to be simple to implement with minimal computing resources. Even in 2018, Arduino micro- controllers can provide complete MQTT communi- cation stacks. Efficient. Early VSAT system providers charged for every byte of information sent and received. The MOTT transport had to provide minimal overhead Figure 1: According to a survey by the Eclipse Foundation, message on the network. Once an MQTT session is estab- ‘queuing telemetry transport (MOTT) is the most-used messaging pro- lished, there is only a 2-byte overhead in messages tocol for an loT solution. All graphics courtesy: Eclipse Foundation Inc. being published. 20 + January 2019 contro. enainesana vw controleng.comMessaging standards — trends & ee Ft £ of oe “ & mz016 2017 zor Stateful. fa user is providing infrastructure for mission critical, real-time infrastructure then the “state” of the MQTT TCP/IP connection is critical MQTT provides a mechanism called “continuous session awareness” that informs all clients that care about the real-time state information of the MQTT connections, Open. In the late 19905 SCADA/DCS/Teleme- {ry products were based mainly on proprietary lega- «y Poll/Response protocols. For MQTT to be usefal to the industry asa whole it was understood that whe ‘was released, it needed to be an open specification that anyone could implement for fre. Even with those criteria, it would be easy to assume few important aspects ae left out, including: Security. A lot of people note the MQTT specifi- cation does not define any security. This is because the MQTT specification in based on top of TCP/IP. It always was envisaged that the latest TCP/IP secu- rity practices would be applicable to an MQTT infra- structure. This ranges from private networks where security isnt even required, to full transport layer security (TLS) certificates being used for connections. Since MQTT isa remote-originated connection, edge devices and clients dont even have to have any TCP/ IP ports open, which isa huge reduction in the overall cybersecurity footprint. Payload data format. MQTT is data agnostic ‘when it comes to the information contained in an MITT payload. It can be a binary message from a programmable logic controller (PLC), a JPEG image, an extensible markup language (XML) document or a JavaScript object notation (JSON) string, MQTT leaves the encoding and interpretation ofthe payload to the software provider. Industrial-strength MOTT ‘As Internet of Things (IoT) solutions using MQTT started to migrate to more mission- critical Industrial loT (HoT) implementations. the ‘market needed a specification that would allow MOQTT:based vendors easy interoperability. Although the MQTT specification does not dictate any mes- sage topic namespace or data representation, one was needed for the IloT space. The Sparkplug specifica- tion does that for the Ilo market. “The Sparkplug specification was developed to help define how best to get started using MQTT ina mis- sion-critical, real-time application. The Sparkplug specification defines: 4..Awell-known MQTT topic namespace so publishers and subscribers of information can know the topic namespace in advance for interoperability 2. Abinary payload optimized for industrial process variables. The Sparkphug specifica- tion acknowledges that industrial inrastruc- tures dost have unlimited bandwidth and must work well over VSAT, radio, and cellular infrastructures. ‘3. How the “state” management in MQTT works and how to effectively use tin SCADA, dis- tributed control system (DCS), and industri al control system (ICS) solutions to know the state ofall MQTT clients in realtime. The Sparkplug specification and all of the ref- erence implementation code written in C, Java, JavaScript, Python, and Node Red have been con- tributed to the Eclipse Foundation and to an open source project. 8 Arlen Nipper is president/CTO, Cirrus Link Solu- tions. Edited by Chris Vavra, production editor, Con- ‘rol Engineering, CFE Media, cvavragcfemedia.com. Figure 2: According toa survey by the Eclipse Foundation, MATT is trending up since 2016 to over 62% use as a messag- ing standard. More WV ANSWERS KEYWORDS: Internet of MOTT began as 2 ‘communication protecol Used by Phiss 66 to ‘operate in tough industrial ‘onciions, MOTT’ usefuiness toengineers and rmanulacturers stems from ace of use MQTT has been enianced to work inthe Indust Intemet of Things jloT) era, CONSIDER THIS For what applications do ‘could you use MATT? ONLINE Read this story onine at wonw-controleng, com for ‘more information about the author and related stores ‘about MOTT. covrmot eneneeeenc January 2019 + 21ANSWERS. COVER STORY: NETWORKING SOFTWARE Michael Bowne, P Nor Improving industrial network communications Selecting a Profinet interface may enhance industrial network communication for devices. LY 2 ANSWERS KEYWORDS: Profinet, time- ‘sensitive networking (TSN) Conformance classes for ‘autornation systems How to implement Prctinet features ‘The benefits of time-sensitive networking (TSN) and Profinet. ‘CONSIDER THIS How can Profinet Ethernet ‘enhance communications for your operation? ONLINE Read more online about how to implement Profinet features at ‘wa cantrolang, com. January 2019 nntegrating an industrial communication inter- face into an automation device begins with gathering information to determine the indus- trial network's functionality along with famil- iarization about the task at hand. Development tends to be faster for new devices if the wheel isn't reinvented each time. Depending on the functionality required (con- formance class), itis essential to select the suit- able type of implementation for each individual case. The available development capacity, company expertise, expected costs to produce the interface, and the time to market also play a large role. A variety of starter kits and evaluation boards are available for most implementations. These sets ‘enable a quick introduction to development activ ities and often contain a complete development environment, as well. Sample programs and circuits and block diagrams ean be especially helpful. The development packages also include the certifiable Profinet stack of the corresponding provider and detailed documentation. The plan of action and expenditure required for hardware and software design depend heavily fon the selected implementation meth- od. Here, a device manufacturer can carry out the development work inde- pendently or work collaboratively with a development or technology partner. Independent development requires well- grounded Profinet expertise and one’s ‘own hardware and software development To unburden an automation device ‘manufacturer's development resourc- es, PL member companies can provide complete development packages, ready- to-install Profinet communication mod- ules, and a host of development services. ‘These give the device manufacturer the support needed from the design phase to hardware and software development to certification ‘CONTROL ENGINEERING Real-time requirements IEEE 802.3-Standard for Ethernet is designed to ensure problem-free communication between Profinet automation devices and among Profinet automation devices and other standard Ethernet devices. For applications with stringent real-time requirements, Profinet offers mechanisms that ‘enable standard and real-time communication to coexist in parallel. Communication with Profinet can be scaled using three performance levels that build on each other: 1. The transmission of engineering data and non-time-critical data occurs over transmis- sion control protocol/internet protocol (TCP/ IP). This standard communication is possible between all automation devices. 2. The real-time (RT) channel is available for the transmission of process data 3. For sochronous applications like motion con- tro, ochronous real-time (IR) communica- tion is used. This enables a clock rate of < 1 ms ‘The IRT capability is based on hardware support i the device, which means special application-specific integrated circuit (ASICS), microcontrollers, and field programmable gate arrays (FPGAs) must be used for this purpose. Commercial-switch ASICs without IRT hardware support are suitable for implementing an automation device with RT capabilites only. Devices with RT communication can be developed based on standard Ethernet components and a Profinet soft- ware stack. Profinet conformance classes ‘To meet the different requirements of automation systems, three conformance classes that build upon ‘one another are defined for Profinet. Each class has a functional scope determined for the typical area of application. The device manufacturer must consider nw controlang comthe required conformance class before selecting an implementation option for the Profinet device inter- face because the type of interface implementation affects the conformance clas that can be achieved, ‘The key functions ofthe three conformance classes and their advantages are described below: + CC-A: Using the infrastructure of an existing Ethernet network, including integration of basic Profi- net functions. Al information technology (IT) servic~ cs can be used without restriction. Typical application «examples are found in building automation and pro- cess automation, + CC-B: The functional seope of CC-B comprises the functions of CC-A. plus it supports user-friendly device replacement without needing an engineering tool. Simple network management protocol (SNMP) supports extended device diagnostics of network fune~ tions such as port status messages. To increase data reliability, a performance-adapted media redundan- Cy protocol is available as an option. All IT services can be used without restriction. Typical applications can be found in automation systems with higher-level ‘machine control with a deterministic, but not isochro- nous, data cycle. The vast majority of Profinet devices, fall into this category. + CC-C: The functional scope of CC-C comprises all the functions of CC-B. It also supports high-pre- cision and deterministic data transmission, inelud- ing isochronous applications. The integrated optional ‘media redundancy enables smooth switchover of the WO data trafic if fault occurs. AULIT services can be used without restriction. Typical applications are in the field of motion control, ‘Once a device manufacturer has decided what Pro- finet features they need to implement on a product, the next question is how to implement those features. ‘There are three options: + Drop an ASIC onto the printed circuit board (PCB) to handle Profinet communications. Ifthe real estate is available on the PCB fora chip, this might be feasible. + Plug a module into a slot on the device PCB. Unlike ASICs, a module can deliver the network requirements with physical cable connectors, magnet- ics, PHYs (physical layer circuits for the physical layer of the OSI model), an integrated Ethernet switch, and. a chip to handle the Profinet stack. There is a range of backplane connections available-everything from dual-port memory to SPI to the compact flash (CF) card interface. wn controlong,com + Buy a software stack and implement it on the application processor. Software stacks are one of the ‘most common Profinet implementations-theyire the ‘most cost-effective way to implement the protocol in volume. However, they're also the most complex way to implement Profinet. Stacks touch a lot of peripher- al software pieces such as the operating system, the IP stack, the nonvolatile RAM, and so on. TSN and Profinet ‘Time-sensitive networking (TSN) is a promising technology and offers alot of potential for Profinet. "TSN aims to combine the wide range of IT networks With the robustness and determinism of automation networks. In short: hard real-time via standard IT networks. This doesnit signal a revolution for Profi- net Rather, it represents a Visionary architecture upon which Profinet is building. ‘TSN offers Profinet a new layer 2 in the ISO/OSI ‘model. It corresponds to today’s RT and IRT technol gies. This makes it clear TSN will not replace RT or IRT in the coming years. san additional option with a number of potential benefits. Today's manufacturers that are providing solutions with RT and IRT will be able to continue providing them in the future. Users employing RT or IRT to operate their systems can be sure that they are using a sustainable technology. ‘TSN offers the possibility to also achieve this with standard chip-sets because TSN is based on open standards, which is supported by many semiconduc- tor vendors. Everything else about Profinet remains _unchanged-especially services such as diagnosis, con- figuration, alarms, etc. Ths will make it easy for users and device manufacturers to use TSN in the future. ‘They can build on existing knowledge and continue using the applications they have developed. ©@ Michael Bowne, executive director, PI North Amer- ica. Edited by Emily Guenther, associate con- tent manager, Control Engineering, CFE Media, eguenther@cfemedia.com. conTROL ENcineEEANG January 2019 * TSN services inte- grate seamlessly into the Profinet architec- ‘ture. They reside at Layer 2 of the ISO/ (OSI Model, maintain- ing existing upper level PROFINET func- tionality. Courtesy: North America BANSWERS. COVER STORY: NETWORK SOFTWARE APPLICATION Michael Bowne, Pi North Ar Smarter machines Machine builder uses industrial Ethernet for remote monitoring and diagnostic services. Hugo Benzing LLC uses Ecoclean’s new remote sup- port capability at ‘a fastener plant, with Profinet and ‘a TosiBox VPN router. Courtesy: PI North America dustrial Internet of Things (Ilo) concepts are inspiring new business models for manu- facturing, Manufacturers are asking equipment makers to find new ways to help them improve machine reliability and production uptime. Ecodean Inc., a maker of industrial and automotive leaning machines, now provides remote monitoring and diagnostic services on dashboards by using Pro- finet networks. Eooclean machines are a part of the quality control for manufacturers, Reliability is critical POW aera be fd Ean any Me < provduction tins, making tat process en ANSWERS cial in overall plant production” said Aaron Kerwonos: Zaremibsk, controls engineer for Eeoclean Industl Ethernet, Profit Ecoceas technical support. involves Machine builders want 10 ‘expand servogs, Industrial Ethemet networks such as Profinet ean hl. Monitoring and diagnesties improve uptime. CONSIDER THIS 's your plant-floor network hindering productity? reading trom the digital tediion, cick on the heacline for more, including & ‘decussion of local versus cloud" orfind it onine, WoT webcasts are avaiable ‘wu controlang com! webcasts 2s January 2019 three tiers of service, beginning with remote diagnostics of the programmable logic con- trollers (PLCs), human-machine interfaces (HMI), robots, drives, and other compo- nents that control the cleaning machines. Online troubleshooting, modifying param- eters for process control, software upgrades, and adjustments to the PLC code can be hhandled remotely. Statistical data from the machines also can be logged onto a server and then used to identify trends and make preventive decisions for maintenance prior toany equipment failure. A third service level enables compiled information to be displayed for the customer in realtime on a dashboard interface showing pertinent machine data graphically ‘CONTROL ENGINEERING “Our primary goal was to maximize uptime and ‘customer satisfaction, as wel as to identify opportu nities for continuous improvement for current and future equipment” Zarembski said. He wrote the algo- rithms that evaluate machine performance and guide the company’s service technicians in troubleshooting. and technical assistance work. First installation with services ago Benzing LLC manufactures fasteners for the automobile, aerospace, fine mechanical, and electri- cal industries. The fist installation of Ecoclean’s new remote support capability was at the Hugo Benzing manufacturing facility in New Hudson, Mich. The plant has a Profinet network, which allowed Eeoclean technicians to remotely connect to the network and clean machines using a self-contained and secure vir- tual private network (VPN) router. “This was a perfect example of streamlined inte- gration for remote diagnostics? Zarembski said. “With the Profinet architecture and (the router manufactur- er], we had a secure VPN connected to the network in ‘minutes, and it required minimal interaction withthe customer's information technology (IT) department. It uses a non-IP protocol on top of the Profinet Ethernet. layer, making the remote connection implementation easy and secure” Although it would have been possible to connect to the Internet in other ways to provide support, accord ing to Zarembski, using the Profinet protocol helped. with processing of safety signals. The installed devic- es had embedded hardware configurations, dedicated diagnostic signals, and priority settings fr safety: Such options are crucial when making a safe fast, and reli able system, Systems built on this framework are easly upsized without impacting functionality. Forolder machines with Profibus protocol, a proxy translates Profibus into Profinet, allowing remote ser- vice capability. This also works with other protocols that can interface with Profinet via proxy. ‘Zarembski said Ecoclean intends to embed this remote service capability, making the hardware stan- dard and the service contract an option for customers that require high uptime through preventive mainte- nance and statistical analysis. ew ‘Michael Bowne is executive director, PI North Amer- ‘ca, the organization for Profinet, Profibus, and other networking technologies. Edited by Mark . Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com. nw controlang comANSWERS. COVER STORY: NETWORKING SOFTWARE Robert Trask, PE, EtherCAT Technology Group Software unlocks EtherCAT Ethernet protocol diagnostics Through a vendor-independent diagnosis interface, an EtherCAT master can provide detailed slave diagnostic information and network health status via human-machine interfaces (HMIs) or third-party tools. ppecifcation of a vendor-independent diag- nosis interface for the EtherCAT Ethernet protocol was among the announcements the EtherCAT Technology Group (ETG) made at SPS IPC Drives 2018. This interface will help EtherCAT vendors gather and analyze data to deter- ‘mine internal or external issues affecting components throughout an BtherCAT network. This specification, known as ETG.1510, “Profile for Master Diagnosis Interface” will provide an accessible upgrade to allow easy access to the network’ health status. FtherCAT can support 65,535 deviees in real time fon one network. It also has a range of cyclic and acy- clic diagnostic information for rapid reactions to errors and in-depth analysis for intermittent issues. ‘The interface will provide a master-based soft- ‘ware so all network users can use this data. Asa result, plants can expect to improve machine performance and increase uptime through the diagnostic inter- face without having to implement any changes to the slave or EtherCAT slave controller (ESC) hardware. To understand the value ofa diagnostic interface, itis important to know what kinds of built-in diagnostics EtherCAT offers. New diagnosis interface plan ‘More than 200 approved EtherCAT masters range from traditional programmable logic controllers (PLCs) to PC-based software. Many call the diagnostic information quit easily but not all One consideration is EtherCAT network diagnostics are found in three locations: the slave registers, the DS402 CAN protocol over EtherCAT (CoE) and in the cyclic process data with the working counter (WKC) concept. ‘The issue isnot the amount of network data avail able; EtherCAT is already very good at locating errors with precision such as including loose connectors, incorrect cabling order, damaged cables, unintend- cd effects on slaves, EMC interference and bit errors, among others. ‘The new diagnostic interface will not change this ‘existing capacity, but will instead act like a dragnet, oe Diagnose ae integrating all information. The interface will gather errors created by hardware and software to assess the network's health status. It will also maintain a mini- ‘mal filesize so it can be used on any EtherCAT con- troller—even compact embedded devices with limited ‘memory. "The diagnostic interface’s access mechanism will provide diagnostic information from the FtherCAT slaves based on the existing EtherCAT master object dictionary and mailbox gateway functionality. ‘The interface runs in the background and enables the master to casta wide net to pullin al ofthe diag- nostic data stored in the subordinate devices. The vendor-independent design will also allow any mas- ter implementation to use third-party analysis tools in conjunction with ETG.1510. Different network diagnostic variants ‘With the interface in place, engineers will have access to a range of diagnostics. These rely heavi- ly on the WKC, which is a 16-bit field at the end of each datagram. The EtherCAT slaves increment the read and/or write commands for each WKC. "The master then compares the datagram against the expected value, discarding any bad frames and for- ‘warding all good frames to the control application. conTROL ENcineEEANG January 2019 * Figure 1: The new ETG diagnosis inter. face enables vendor- independent access to EtherCAT diagnostic data. It allows users to troubleshoot or improve machine performance whether ‘they are using a PC- based controller or traditional progr: mable logic controller (PLC) as the EtherCAT master. All graphics courtesy: EtherCAT Technology Group 25ANSWERS. COVER STORY: NETWORKING SOFTWARE Figure 2: Both hardware and software diagnostics are available ing cyclic and acyclic information. The new diagnosis interface software gathers disparate information in one through EtherCAl location. ein 33038 Figure 3: When the working counter (WKC) value returning to the EtherCAT master does not match the expected valu in the datagram are discarded, and a counter is incremented. Other variants of FtherCAT network diagnostics reported by the interface include: + Lost link errors: When a component that is physically attached to a slave disappears, the slave signifies internally that it has lost a physi- cal connection to the next slave + Invalid frame errors (CRC): Each frame is ‘mathematically checked and bad frames are counted and discarded. + Physical layer errors: Similarly, this detects frame corruption and increments a counter. Physical layer errors are different from CRC errors, and the ratio of the erors is important in diagnosing intermittent errors from noise. + State machine errors: This occurs when an 26 + January 2019 conrRot encInerRING EtherCAT slave's internal state differs from the state commanded by the master. + Product vision serial number errors: These often happen when the network topology does not match with the one expected by the mas- ter or when slave devices were connected in an incorrect order. ‘These mechanisms add analysis and comparison capabilities, such as examining invalid frame against. lost link counters and vice versa, for cyclic and acyclic diagnostics. While cyclic synchronous diagnosis for hardware and software relies on WKCs, acyclic hard- ‘ware diagnosis involves link lost counters and inval- id frame counters. Acyclic software diagnosis also involves state machine errors. EtherCAT slaves incor- porate all diagnostic mechanisms at the chip level, and as a result, they will remain available on legacy and future components. Masters, network architectures ‘The diagnostic interface unlocks a wealth of Ether- CAT topology information, providing. significant advantages for end users, vendors of master compo- nents, and diagnostic tool suppliers. With this data, ‘engineers will be able to conduct rapid troubleshoot ing and pinpoint where errors occurred. For exam- pile, a slave that might have seemed to operate without issue could require service, repair, or replacement because it is storing 400 link lost counters. Without the ETG.1510 specification, masters that were not equipped to gather this information would require new code. However, the specification also will ‘enhance masters that could access the data by auto- matically locating it on the master. It also will make it ‘easier to access data with third-party diagnostic tools and HIMIs. In general, the software interface will ben- fit all EtherCAT system architectures and master implementations. ce Robert Trask, PE, North American representative, EtherCAT Technology Group. Edited by Emily Guen- ther, associate content manager, Control Engineer- ing, CFE Media, eguenther@cfemedia.com. iyi More ANSWERS KEYWORDS: EtherCAT, industrial Ethernet ‘The benefits of te ETG.1510 specication ‘The range of diagnostics wth ETG. 1510. ‘CONSIDER THIS How will you bereft rom the new data/dagnostios due to the new specication? ‘ONLINE Read more about the ETG.1510 speciicaton onine at wiv contreleng.com. nw controlang comANSWERS. FACTORY AUTOMAT Winn Pauilk, Aut ION CONT ROLLERS Industrial controller selection: Look beyond the basics When specifying controllers for industrial automation applications, consider capabilities such as data handling, communications, and high-speed control ost industrial controllers, such as programmable logic controllers (PLCs) and programmable auto- ‘mation controllers (PACs), can handle basic functions like real- time control of discrete and analog input/output (1/0) connections. In fact, this type of functional ity isa given with most controllers, with the main concern being the capacity to handle the required number of I/O points, which is normally easy to ascertain, When specifying industrial controllers, con- cerns often turn to other capabilities such as data handling, communications, and high-speed con- trol. Identifying functions required to select and implement controllers and knowledge of how functions improve designs can help. Data handling functionality Modern controllers with advanced tag: name- based programming have a variety of data handling capabilities including built-in data logging. Some advanced controllers also can also interact with standard databases in enterprise-level systems such as an enterprise resource planning (ERP) system. Logging data directly to a USB storage device connected to the controller is an important fea- ture and often a requirement in many applications. Controllers with data logger features often support a formatted USB pen drive or MicroSD eard, each with up to 32 GB of storage. Data logging is typically event-based or sched- led. Events are triggered by status changes such as an edge transition of a Boolean tag. Scheduled data logging is configured to occur at regular intervals. such as every minute, hour, day, or month, ‘The number of tags that can be logged is often limited, but at least 50 tag values should be stored for every scheduled or triggered event. System errors should also be stored with the time and date of the error or event included. The log file name should be configurable or automatically generated depending on user preference Beyond local dat logging, some contrllers can communicate wth information technology (1) pYP MCLE satrprine systems, One example san OPC server ANSWERS Sumsced G thesmccicn Wealom ctr: Retemcraciay ts clot se-tar att gin coamslecy on Ths senate mune plant Ge al secre cd, delete, sd npdats| Conor aloobon requires specic knowledge Controllers help with data handing, communications High-speed motion Controls a factory ‘controlar function, CONSIDER THIS Existing controllers may wor ne, but what commpettieness is lost \whout modern functionality? ONLINE See research and 2 Digital Fport on PLCs at data records in a standard database. This is done by supporting connections to a database compat ible with Microsoft Access, a structured query language (SQL) server. or an open database con- nectivity (ODBC). Several software tools on the market allow a user to set up a connection between an IT enterprise sys- tem and a PLC to allow data to be collected from the PLC and saved in a database. Configuration effort for these servers is often minimal, and the user can choose to collect only the data they need for their process. These database capabilities provide practical applications for tracking material movements and production metrics. The controller performing the actual production tasks can track plant-floor 9 \wne.controleng.com/ research, wwwa:controleng, comPDightalRepors Lp messes Figure 1: Productivity relies on data collection. The communication and data handling capabilities of this AutomationDirect Productivity Series controller enables connection to many different devices. All figures courtesy: AutomationDirect, conrmox eneneeenvc January 2019 + 27ANSWERS. FACTORY AUTOMATION CONTROLLERS fi aa Secure oa] ei, areca GISIERED eo 6 0 6's Ne access OSE “Sih Figure 2: Get remote data from the controller. Some modern control- lers, such as this Productivity3000 from AutomationDirect, include up to seven built-in communication ports, a critical capability for ‘connection to both devices on the plant floor and to enterprise level business networks. progress to make sure manufacturing time is opti- ‘ized. It also can track consumption of materials. This information ean be used to adjust inventory to ‘ensure materials are available when needed. These capabilities also can be used to track the status of the product from start to finish by logging production data as the part or product is manufac- tured. The status of the final product is saved, and the database's built-in date/time stamping features. can be used to satisfy quality assurance or audit requirements. Communications capabilities ‘Another important feature to consider when selecting an automation controller is commu- nication capability. Multiple Ethernet and. serial Be January 2019 conTRoL ENGINEERING communication ports should be available to provide easy integration with human-machine interfaces (HMI), motor drives, and other devices (Figure 1), ‘These high-speed Ethernet ports also can be used for peer-to-peer (P2P) or business system net- working, This is where support for the FtherNev/IP (ODVA) and Modbus TCP/IP Ethernet protocols is important. "Diher communication ports shouldbe provided for USB in/USB out, Mini USB, MicroSD, Remote WO, RS-232, and RS-485 connectivity ‘These connections enable simple programming access, connection to high-speed devices such as drives, and HMI integration for operator monitor- ing. They also enable outgoing email, scanner/cli- ent, and adapter/server connections —along with other communication funetions for remote access. Remote monitoring apps are available to allow users to connect to controllers using Wi-Fi (IEEE 802.11x wireless) or cellular network connections. ‘The remote user can monitor the local controller via user tags configured for remote access inside the tag database ‘Modern controllers should have builtin security whereby remote functions must be enabled in the hardware configuration related to remote access, with each tag in the database selected to enable remote access to it. Also, as is true for any device that can be accessed from the internet, itis highly recommended a firewall be used for security pur- poses. Even though the remote access feature for a controller can and should be configured with pass- word protection, a secure and encrypted! VPN con- nection is best practice due to internet security risks (Figure 2), ‘Another protection feature related to remote controller access is the separation of accounts and IP addresses configured to allow the upload, download, or edit of a program by users given a remote access connection. One account should not permit both remote monitoring and program modifications. The controller should support remote moni- toring apps and include the necessary security. Authorized users should be able to connect their smartphone or tablet to the controller for remote monitoring in real time with a Wi-Fi or cellular ‘connection. ‘Additional web server functionality in a control- ler allows remote troubleshooting of issues through system tags, error logs, and event history—and allows remote users to examine data files logged to a controller's thumb drive or MicroSD card. High-speed control “Another feature driving the selection of a mod- ern controller is the ability to control motion and other high-speed applications. High-speed 1/0 is nw controlang comjes are expanding, such as those with this Produc- tivity2000 from AutomationDirect. Features such as data handling, communica- tion, and high-speed control should be considered during the sele to improve designs. needed to perform these functions, along with a powerful processor and the ability to prioritize high-speed tasks. While some controllers offer coor- dination among many motion axes, even coordinated motion between two axes typically requires special hardware and built-in controller functionality. To start, a high-speed output (HSO) mod ule and high-speed input (HSI) module are required. The HSO module gener- ates pulse and direction commands to command servo drives operating two or more servo motors. These pulse and direction commands can control ty of applications such as cut-to-length, stitching and coordinated x-y axis moves. ‘A registration function also may be available for move commands generat- ed by an TSO module. The registration function can trigger several internal and external position-based events using the ‘modules builtin I/O. An input from a sensor via an HSI module can be used to trigger the starting or stopping of a move, capture encoder feedback posi- tion, or to turn on/off or pulse an output A programmable drum switch (PDS) and programmable limit switch (PLS) offer additional high-speed control capa. bilities, The PDS enables monitoring of several devices, such as encoders, at rates up to 1 MHz. These input signals are CONTROL ENGINEE used to coordinate and control outputs at rates of up tens of thousands of times a second. This type of hardware config- uration provides precise and accurate motion control independent of control- ler scan time, which can vary depending, ‘on processor load. A PLS instruction works like a mechanical rotating cam with limit switches, but the virtual shape of the cams can be controlled in real time. Since this function often runs in conjunction with an HSI, its completely independent of the processor load and related sean time, resulting in accurate and repeat- able timing for high-speed applications, Data logging, communications, motion ‘When selecting PLCs, PACS, and other industrial controllers, users need to think beyond basic control and W/O require- ments. For many applications, control Jers (Figure 3) also need extensive data Jogging and communication capabilities, along with control of high-speed applica- tions such as coordinated motion. ew Winn Paulk is automation controls group product manager, AutomationDirec. Edited by Mark T. Hoske, content man. ager, Control Engineering, CFE Media, mhoske@efemedia.com, ang January 2019 + 29 RESPOND QUICKER Nia) yale 3 NETWORK MONITORING Naat) Sec oo ee rea Seca = Pa eran ca a Cre mT ae eee Me uniaeANSWERS. CONTROLLER PROGRAMMING John Kowal, B&R Industrial Automation Corp. Controller programming Automation software and hardware advances reduce programming tasks and provide more built-in configurability, scalability, background communication ity. among software components, simulation/digital twin capability, and usabi day’ automation hardware and soft- ‘ware can integrate much more than stand-alone machine controls. There is a need to provide an integrated devel- lopment and programming environment that presents itselfin an approachable, cohesive way. Its not enough to pick a programming language ‘nd go-that only viable for straightforward machine applications. Today, machine automation require- ments integrate HTMLS human-machine interfaces (FMI), input/output (1/0), sequential logic, motion and networked safety, robotic and collaborative robot kinematics, vision, safe robotics and motion, condi- tion and energy monitoring, machine-to-machine ‘communications, coordination with multiple produc tion modules and intelligent track systems, edge and Kesto.us/eaINNOVATIONS NEW R ENGI R {{ Stepper motor for hazardous locations, where flammable gases are Applied Motion’s HXS6-100 hazardous location stepper motor is designed for motion contzol in challeng ing environments of oil, gas, printing, and paint finishing applications. I is certified for ATEX and IECEX for Class 1, Zone 1 locations and UL-Listed for Class 1, Division 1, Group C and D locations. Class | haz ardous locations are areas where flammable gases, vapors or liquids are, or may be, present in the air to cause a potential hazard. Zone I defines a hazardous location in which flammable gases, vapors or liquids exist all ofthe time or some of the time. It can run stored programs created with Applied Motion’ Q pro- ‘gramming language, and can connect to multiple external devices or sensors. Applied Motion, wiww.applied-motion.com Input #200 at wine contlan.comfnfermation Non-contact magnetic measuring system Hermetically-sealed, }) Elesals MPI-15 magnetic measuring system is designed to allow pre- spring-loaded LVDTs. Wee 2 machinery processes to a minimum, saving costs, and speeding the of spring-loaded linear variable ¥ whole production cycle. Combined with a magnetic band, itis easy to! gifferential transformers (LVDITS) ol install and features an easy-to-read digital display, enabling operators are designed to provide accurate to accurately read linear or angular displacements. It is made of an ° dimensional feedback for many LCD multifunction display with a built- in magnetic position sensor. When combined with the magnetic band M-Band-10, it provides a complete sys tem to measure linear and angular dis position measurement and quality assurance applications including go/no-go measurements, quality testing, post tion/thickness control and material testing, Designed with a stainless-steel probe assembly and %"-in. diameter her- ‘metically sealed housing, the sensors operate in dirt, water, placement (with a minimum radius of yibmation, and temperature ranges of63 to 220°F with max 6mm). itmum linearity of #0.25% of full-scale output Elesa (UK) Ltd., www.elesa.com NewTek Sensor Solutions, www.newteksensors.com Extensive stainless steel offering has been expanded. New HWSSHK Series: See R CORD Re MSC SC eatt) SCOUTS Cu Ce) Peter lM Ud Ne WNT Le ea) CCRC Ea HAMMOND Bla ai ycm ce) (eae) MANUFACTURING. Hammond enclosures. ee A a hie ASCs K Ro nL hammondmfg.com | (716)630-7030 @hammig.com input #20 at wwrwcontroleng com/infrmationSee mare New Products for Engineers Cast-iron three-phase ac motors )) AulomationDirect’s ronHorse MICP? industrial duty motors are offered in T-Frame (1 to 300 hp) and TC-Frame/C-Face (1 to 30 hp). C-face kits are avalable for motors over 30hp. These motors are available in 1200, 1800, and 3600 RPM and have totally enclosed fan cooled (TEFC) enclosures with a cast iron frame and ribbed design for maximum cooling. The motors feature full length, cast iron mounting feet, a steel fan cover, and a cast iron junction box with a rubber gasket and rubber dust cover. MTCP2 motors have premium quality ball bearings (1 to 75 hp) or roller bearings (100 to 300 hp) with maintenance-free bearings on 10 hp and below. V-ring shaft seals are used on the drive end and oppo: site drive end. The motors are electrical- ly reversible and have Class F winding insulation. AutomationDirect, worwautomationdirect.com Input 42032 wav corrleng.comiforation ® Alcontroller uses machine learning to extend equipment life Omron Automation Americas’ Sysmac AI Controller handles several key steps in the data-driven decision process for predictive maintenance, thereby freeing Up industrial professionals from tedious calculations, analyses, and infrastructure upgrades. It is designed to help manu- facturers reduce the risk of bad parts or equipment damage by detecting issues early and prompting immediate action to resolve them, Customers will be able to take advantage of Omron’ advanced technology and its team of data scientists. to facilitate predictive maintenance rath- er than figuring everything out on their own. The machine learning functionality can identify abnormal machine behavior - without being explicitly programmed to a ee ‘° RENTS Ta Neto 19 ms rN Omron Automation Americas, PATON C7 Tres Input 204 a wv corvleng. conformation January 2019 + 59 ae www.controleng.com/NP4E leh a eo) of Cotte ge eSATA: s5 cet, meee) (425) 745-3229INNOVATIONS —e a 5 wwe n/NPAE oe NEW PRODUCTS FOR ENGINEERS SormrCIeng EOIN «€ CNC system for machine tool applications Bosch Rexroths CNC system MTX with new hardware is designed to achieve even shorter cycle times and better machining quality. With the new XM42 embedded controller, systems with an extremely large number of axes and stations can now be automated efficiently with one central controller. This simplifies project planning and reduces costs and complexity, With the elimination of communication in multi control solutions, performance increases, The CNC system MTX uses open stan- dards and protocols throughout and, with its Open Core Interface, offers machine manufacturers the opportunity to implement their know-how independently and securely. With an interpolation cycle of 250 ss, the MTX from Rexroth sets stan- dards for CNC machining. The cores of the multi-core processor, assigned to the respective tasks, process the CNC, PLC, and communication tasks independently of each other. Bosch Rexroth, wwwzboschrexroth.com Input 205 arn contolang cmintoion ®% Cyber risk management platform, roadmap to improve operations Axio NIST-CSF risk management plat form is designed to establish a baseline for cyber readiness, and provides com- panies a risk reduction roadmap for paseo Ongoing improvement. Axio platform ib enables risk officers and chief informa- tion security officers (CISOs) to achieve and sustain fal visibility into their over- all cyber program maturity through model-driven, on-demand assessments It also helps companies develop a clear action plan and rondmap for imprave- ments. It also can help prioritize actions and investments based on the impact to ee their business, and monitor and report on cyber program maturity as it changes over time Axio Global, wiv axi.com aH gee |e 60 + January 2019 input #22 at wwwcontreleng.com/informationet NAA ceeaucte DC-POWERED SERVO DRIVES Supply voltages from 24 to {60 volts DC. Up to 40 in-Ib peak output torque. ‘Auto-tuning and Safe Torque Off (STO). Pair with J Series Servo Motors. we applied metion com ANALOG & DIGITAL 1/0 RS232 VOLTAGE CURRENT Ss TC, RTD 6036220452 BrinGE Made in USA FREQUENCY Since 1986 pirat www.dghcorp.com/rs232 Want to receive your Control Engineering magazine as a and get our digital edition, in your email in-box. Input 101 atconeiongeerng tts com RUGGED MOBILE HMI CREATE YOUR OWN CUSTOM HMI ZI rocrammasie [9 ivreRrace A teinpicarors [Wf] vourace IZ] EMERGENCYSTOP [¥/] LIVEMAN ZI rrmware> Gf] KeveAo A wane ase (9 orsmtar te now at RAC * con replace end of life & legacy hercware! WWW.2T.COM |CONTACT PRODUCT SALES DRECT 215737194 pu 102 atconvingneatngotina com Handy Guide Compact 110 page, open-flat guide with sensor basics, ATO and EMF tables , measurement tips, materials and wire composition info, and more. Get your now! (lore INDUSTRIES np #108 torreon otr.com Ino 08a contotgherrg hatin com pu 08 at convtngneinghtin com CONTROL ENGINEERING January 2019 *P 62 lg eer m= research 2018 Programmable Controller Software & Hardware Study This study was conducted by Control Engineering to acquire information related to the buying and specifying habits of automation engineering professionals for programmable controller software and hardware. The Contro! Engineering 2018 Programmable Controller Software & Hardware Study Unveiled six key findings regarding what end users expect and how they purchase ‘or specify industrial controller software and hardware, ‘According to data in the 2018 report, the top uses for programmable controller cael software or hardware are discrete and continuous manufacturing (23% primary, 20% secondary) and continuous manufacturing (24% primary, 17% secondary). In addition, in the past 12:months, respondents spent an average of $183,746 on industrial controller hardware and software (an inorease of 17% over 2017 data)—with 26% having spent $200,000 or more, Download the new Programmable Controller Software & Hardware research today! = www.controleng.com/2018-programmable-controllers-study/ ENGINEEI RODUCT & LITERATURE SHOWCASE Eure lise Rela magazine as a digital publication? Fei asa DONIC MA Nele Cnet cou} CRC eee] user-friendly platform, eNewsletters 1g: www.controleng.com/newsletters wwwicontroleng.com * January 2019 conrroL encineseIna nw controlang comAdvertising Sales Offices Contentstream Patrick Lynch, Director of Content Marketing Solutions (630-571-4070 x2210 PLynch@CFEMedia.com AL, FL, GA, MI, TN ‘Aaron Maassen, Classified, Product Mart, ‘Media Showcase (630-571-4070 x2216 ‘AMaassen@CFEMedia.com ‘AR, IL, IN, IA, KS, KY, LA, MN, MO, MS, NE, ND, OK, OH, SD, TX, WI, Central Canada Bailey Rice (630) 871-4070 x2206 BRice@CFEMedia.com AK, AZ, CA, CO, MI, ID, MIT, NV, NM, OR, UT, WA, WY, (858) 270-3753 ISelbert@CFEMedla.com CT, DE, MD, ME, MA, NC, NH, NY, NJ, PA, RI, SC, VA, VT, WY, DC, Eastern Canada Julie Timbot (978) 929-9495 ‘JTimbol@CFEMedia.com international (outside U.S., Canada) ‘Stuart Smith ++44-208 484 5577 stuart.smith@giobalmediasales.co.uk Publication Services in Lapa, Co Fen P CFE Main Sonomecrevecacon ‘Sve Rect, Co face CFE Mas ‘StoumeocrEleds.cm ee Meer Youre ei ase Figisa8 AtrgesrElean etn im, Mains Manger RiimnooorDiaa con Sebniaiannecenecionaasn ctl rath Cnn re ‘Soren wermacreetacon Pa Bote reer pees Metal Rts Pr Posten ae Pereoaet ato Fac TP 56 28 pereesiyconmon ar ras cnr Dinca nag Tar Sine sre mawbetaseiogaen con Fick te Aes Mort Orc Sooo" nemueruasa sn Later ae war Ps al seers 2 toscrStecncam ota Stea50 tes mus (Pilger company aan nama nei, fpowmonvvlngeonmetero. Manat estat So cont pn acto: rc ut, ‘ign nose 297 nmr ordcom CFE media Cn ET CONTROL ENGINEERING ‘Company BSN Allied Electronics ..sccssseseTeseeseeess6s Automation24 AutomationDirect (02,6, 0F6,1....1,2,3. Beckhoff Automation LLC... 60. 2 (CC-Link Partner Association, ....9B.cecs00 12 Control Engineering 2018 Programmable Controllers Research Study 2 Datatorth Corp os eseseseeseee BBeceeeeee ME DigiKoy ELECTRONICS»... 06-1 cossesees8. EZAutomation, Bellyband, Festo Corporation. 5 9 HAMMOND MANUFACTURING... 0.00 0.0+-5B. cesses 20 Maple Systems Inc... 9) a. Moore Industriag Intl In... is Newark 16 0 opto 22. 2 «: PATUITE Bisco SEW-EURODRIVE, tne... 20.18 Coos B24 c coe ‘TAMAKI CONTROL. 18 " ‘Yaskawa Ameria, In. 3 2 Alliod Moulded Produes, Inc 216 Load Controls ne rs. Applied Motion Products......-PBsoosss.- 18 Pe. ”, Fe. \WAGO Corp. 8. ad index cco saw alideloc.com are automation?4.com sv automationdirect.com svar hesthoft.com Anta CC-Link org mcg ont pgm dy saw datatorthcom WoW DIGIKEY.COM - shu £ZAutomation net sv festo.com srw hammondmg.com svawmaplesystams.com sve newark com svar opte22.com svar patite.com saw: sewourodrive.com saw PlantReplay.com saw yaskewa.com _swwaliodmaulded.com aww Appliod-Motion.com \WWW/LOADCONTROLS.COM REQUEST MORE INFORMATION about products and advertisers in this issue by using ‘the htip://controleng.com/information link and reader service number located near each. It you're reading the digital edition, the link will be live, When you contact a company irecty, please let them know you read about them in Control Engineering. conrrou enaneennc January 2019 + 63INNOVATIONS BACK TO BASICS Manan Banerjee, Cross Co. Six ways programming, maintenance help collaborative robots Good programming and maintenance of a collaborative robot can provide manufacturers many benefits such as better return on investment (RO)), lower total cost of ownership (TCO), and more ollaborative robot deployments often have high visibility in all levels of an organization, manufacturing, packaging, or research. What also is highly visible is the process for overcoming the learning ‘curve and the ease with which a robot gets back online if hiccups occur. Easy programming and maintenance ‘help an organization; here are six reasons that empha- size their potential benefits for manufacturers. ‘1. Return on investment (RO!) Implementation times quickly add to the upfront cost of a new robotic implementation. Even if one robot is repurposed as needed, each new application requires some amount of time investment on top of| any needed hardware. Minimizing this time increases the flexibility ofa platform and its ROL 2. Capacity and capability Depending on the scale ofthe operation and asso ciated goals, it is not always feasible for one person to evaluate opportunities and program them all. Low- cing the technical threshold needed to deploy and monitor them makes it much more likely that the WV More INNOVATIONS KEYWORDS: Collaborative robot, ‘eobot, programming Regular maintenance ans good programming can enhance the itespan ‘of a colaborative robot. Immediate benefits incluse improved return on investment (RO) and reduced ‘ountime, Long-term benefits include a happier and more skiled worklere. CONSIDER THIS ‘What long-term benefits derive from regular maintenance and programining ofa collaborative robot? ONLINE Read this story online at ‘wanw.controlang,com for ditional links to stoves about collaborative robots and ther potential Benefits for manufacturers 64 + January 2019 ‘same employee(s) doing the auto- ‘mated tasks also can serve as robot deployers. An easily programmable system can act asa labor multiplier. 3. Workforce elevation tis increasingly common for a manufacturer to have difficulty find- ing employees to do dull, dirty, or dangerous work (“the three Ds”). The historically low unemployment rrate is undoubtedly a good thing for the economy at large, but manufac- turers looking to fill operator pos tions are finding it tough to make laborious jobs appealing with the widespread availability of work. An automation platform with a gen- tle learning curve makes it pos- sible to redefine a traditional line position with greatly reduced extra investment. Strategically assigning unskilled workers to new or varied ‘CONTROL ENGINEERING positions enhances the organization and workers’ skill sets. It can justify pay increases to match the added value of the position and help to increase employee fulfillment. The employee gains added skills, expertise, and job satisfaction; the organization ean be a compet- itive employer and reduce employee turnover. 4. improved downtime and recovery Given enough time, any sophisticated system will need troubleshooting, debugging, or fixing. Produc- tion lass caused by this downtime can detract from ROI and throughput, and often cause intangible draw- backs such as frustrated technicians, It is important that a platform be easily and quickly serviceable and hhavea robust support system to hep the end user. 5. Opportunity cost ‘Time and resources are finite, and each project has an opportunity cost, whether during deployment or servicing. Making programming and support acces- sible minimizes this opportunity cost and further improves the ROL of any particular project. 6. Total cost of ownership (TCO) ‘The cost of training courses (both for program- ming and maintenance) casly can add up to several days and thousands of dollars per trainee. An intui- tively programmable and easily serviceable platform siigates—or may even eliminate—this ramp-up time and can reduce the TCO of the system, An internal robotics integration team with exper- tise in deploying major robotic brands can help. While this may require personnel retraining for the first application, every subsequent project takes less time as the team advances. Internal innovation and exper- tise can provide a competitive advantage by granting the ability to quickly expand capacity and capability in industries where new products get to market regularly. A third-party team also can provide support and integration. Outsourcing expertise avoids shifting focus away from immediate production needs. 8 ‘Manan Banerjee works for Cross Co. This article origi- nally appeared on Cross Co’ blog. Cross Co. is a CFE Media content partner. Edited by Chris Vavra, produc- tion editor, Control Engineering, cvayra@cfemedia.com. nw controlang comAlways the One Choice for All Controling a robot arm, a servo axis, a VFD drive ora custom robotic mechanism is all the same task for an MP330Oiec machine controll. It uses. familar IECB 1131-3 and PLCopen programming to operate them all, and will even allow you to ‘substitute one motion deviee for another without reprogramming. Looking for motion contro that can change and gow as readily as your machines do? Move to the MP3300iec by contacting your Yaskawa representative. input #23 at wiwn.contoleng.comiinformation Yackawa America, Inc. Drvas & Motion Division YASKAWA 1-800-YASKAWA —yaskawa.com Right Move one For mors ino: hip:/ge.yaskawa-amorica conyait242Called SEW Got expert solution Ordered complete package WM) Dinner with family M-F Home on Sat/Sun! Honey, I’m home! 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