Controller strategies 2020 and beyond Benefit from wider wireless networks Help for critical sensor application designs 3: 3-D trends enhance productivity, Q&A Think again: What can hot topics teach us? 2 (ST, iy 7 CFE Media & mec ooe Vy CFE media www.controleng.comThe sign of reliability For more than 100 years, ABB has developed a reputation for marketing, designing and manufacturing the most reliable industrial electric motors available. Azima, Inc. confirmed this in their Reliability Rating Report in which they stated that “ABB produces the majority of models scoring highest for reliability in 2018. When reliability counts, look for the sign of reliability from ABB. waste ABB input #18 at wwn-contoleng.comvinformationSafer design oe faster installation pos Easy to remove, quick to install, and highly reliable in the harshest environments, ABB's new Dodge® Safety Mount spherical roller bearing is ideally suited for a variety of demanding industrial applications. This innovative solution combines the advantages you rely on in today's Dodge Imperial bearings with features that improve the safety and productivity of your operation, Safe. Fast. Reliable. ao. AbD Input 119 at worn controleng com/nformationMost PLCs will do, but only some will Domoref Starting at $197.00 (expui-10An.0) with FREE Software The Do-more! BRX PLC series is loaded with hardware and software features that provide an extensive toolbox to satisfy even the most demanding projects. + Four form factors to choose from +Seria/Ethernet comm ports included on most ‘models (with suppor for Modbus ATU/TCP, ‘ASC Elheriet/P, MQTT and HTTP) = Built-in discrete, analog and high-speed /O with advanced mation control «Internal RAM and microSD data logging + Free PLC programming software with over 200 easy-lo-use instructions, integrated video help, andaa convenient project simulator Check out what’s new: NEW! Temperature combination modules combine RTD or theemecouple inputs with current outputs for monitoring and control from the same module! + NEW! Two high-speed I/O expansion modules (Bx-HSIO1 and 2) and a serial communications module (8X-SERIO) have been added, giving BRX PLCs even mare motion and communication capabilities “NEW! High-density 16-channe! analog input modules and space-saving combination analog in/out modules ‘NEW! JSON PARSE/BUILD instructions, along with the HTTP pretocel addition, enable communication between BAX PLCs Sand datarich web servers, NEW! The DMXS12 protocol allows BAX PLCs, using the BX-SERIO module, tocontrolstage/theater lighting and effects www.BRXPLC.com 1-800-633-0405 ‘the #valusinautomation| input #1 at wwrwcontroleng comv/informationSwitch on Over for Value AutomationDirect has great deals on limit switches! ——_ Low-cost Switches We have a vast inventory of limit switch options to choose from. You can always trust AutomationDirect for dependable presence sensing solutions at affordable prices! Plastic Compact Limit Switches Starting at $15.00 + Compact size wih standard 25 mm hole spacing +1NO.and1NC contacto all units + Precision Limit Switches _« Double Insulated Plastic ita il Tn ba pwn ue Compact Limit Switches EC Limit Switches disconnect right ext) Heavy Duty Metal IEC Pane ipa Liat Sai - Double insulated plastic housings Limit Switches = Preumatic Limit Switehes + 1P67 dustproof/waterresistant Compact Limit Switches with Halogen-free Cable Starting at $24.00 + Compactsize with standard 25 mm hole spacing +11NO.and 1 NC. contact on all units + Amhalogen-ree cable + Die-cast metal housings EalonNEMA Heavy Duty Metal Precision LimitSwitches IECLimit Switches _Limit Switches + IP67 dustproot/water-resistant Research, price, buy at: www.automationdirect.com/limit-switch woes Seoeeeee 1-800-633-0405 the fivaivein automaton Input #2 at waw.controleng.convinformationNeed experience? Ce Cana acc Cerner uel Solution: If you have new engineers, race mutee Meck an tense asia) to quickly and easily perform complex automation. No experience needed! - ate utes ee ieate as om can provide a complete package, including project planning, software, components, commissioning, and worldwide support. Ea Nees! «eS EURODRIVE Pe eR een d Se ee DE ealRee: The Unlimited SCADA Platform of the Future is Here foramited er Pat Pn ee Bren creVol, 67 Number 1 CONTRO! ENGINEERING ANSWERS 24| Many-core technology fils in the blanks for advanced machine control 26| Smart factory controllers bring security and connectivity COVER: Corittzed 28| Modern controllers ease upgrades oes 30| Answers on factory controller upgrades across 2 prodution ine provide 32| Real-time monitoring and control for a signticant value for menuacturers and machine water, wastewater operation boulders. Courtesy: Bock A.tomation 34| Using energy harvesting, radio technologies to power wireless sensors INSIGHTS 35| Industrial wireless selection and imple- 4| Research from Control Engineering mentation 6| International: Automation approaches 38| Critical sensor applications: Diagnostics to use when market growth slows ‘or redundancy? 8| International: The future of design and 39| Additive manufacturing: Prototyping manufacturing reimagined 12| Technology Update: Not all IloT 41| System integrator helps customer with platforms are created equal 3D printing 18| Application Update: Machine retrofit: . : See webcasts, including - Advanced process control: Network, virtualization Past, present and future. www.controleng.com/webcasts www.controleng.com/webcasts/past NEWS 19| PLCs evolve, Offline robotic pro- INSIDE PROCESS gramming, Advanced manufacturing ae programming, Temperature sensors. hacked, Headlines Online, Correction P1| Get flow measurement right the first time P4| Subscription software drives digital 22| Think Again: How clear is your 2020? transformation comme NNER cSt, vo Na, GS DSA pane 1x pr ye: Mey bce LE 910d Party Sate omer Gr LEE eh Cee Pte Se Rote CUED et HO. AGREEING nigh 220 Fea iA sees ONTO. EMEDIA oseres ea CTE Me LE et te Pe dea psae af ees ov. 1 ado mag ssn ears emote! 310 iin Poy. 8 Domes Ge, Ss. Tepe TO [Ea sunenc redacted aes anes CON GMELIN 310 gan aay. Sat 2 nee ts, alate Mal Apron No 489. tim oar Caan ers 310 an oy, Sal #25 Dem s,s. Ema eo erCerods om Ayre ee an las A. ‘Cnn, Sy fc OS START aed coy Sp he ween nape can a rao tg ep ra 60 Fens sre mals OTA CED, ony Sa ow ne Ss ad UA he Ls ela sey Sey 0) cya caged yo crs a aod ue ue ahs es on mice aa yee aa 6 January 2020 + 3 wow contrlong. com CONTROL ENGIINSIGHTS. RESEARCH 2019 CAREER & SALARY STUDY: Learning about the automation engineer he Control Engineering 2019 Career & Salary Study took a deep dive into the earnings of today’s automation engineering professionals (see the report from May 2019). Below are background information findings from this study as they relate to these professionals: 1. Experience: The average auto: mation engineering professional has worked in their industry for 2 has worked for their current employer for 16 years, and is 54 years old; only e of 40 and 25% are 14% are under the in their 60s 2. Education: Fourteen percent of automation engineering profession als have earned an associate’s degree as their highest form of education; 47% have achieved their bachelor’s degree, 16% havea master’s degree, and 3% have a doctoral degree. The top disciplines studied by these professionals are elect cal or electronic engineering (49%), con- trols engineering (259%) and 1 engineering (25 3. Management role: schanical Automation engineering professionals reported an average of 374 employees at their loca- tion, with 41% claiming fewer than 100, and 17% stating 1,000 or more, Fifty- cight percent of these professionals are responsible for managing or supervis- ing one or more employees; the average number of employees managed/super- vised is 10, 4, Attitude: When asked how they feel about their current job, 48% of auto: mation engineering professionals said they love going to work every day; 40% are content and glad to have a job; 10% find their job tolerable, but are open to new opportunities; and 2% are actively seeking new positions. ee At www.controleng.com/research find ‘more, Amanda Pelliccione isthe research director at CFE Media and Technology. More 1 Engineering research this page are avaiable oni ONLINE TRAINING at worw.co nentioned Average compensation by highest level of education Wi Average bate annual salary Bachelor's Trade/technical Dual bachelor's Some colege ° soo S100 Average non-salary compensation sisog00 $2000 $250,000 With almost half of automation engineering professionals having achieved a bachelor’s degree as the highest level of education, those respondents’ aver- age total take-home pay in 2018 was $115,793. Source: Control Engineering 4 © January 2020 cone0. Purchasing servo/ stepper drive products Separate Six in 10 engineers prefer to pur chase servo and/or stepper drive Pee ee eee Nee ee ee ered Motor Drives Study Ly eer Dene her a peer ee ey responsible. Source: Control Engi- ea erected Ula) eee ee ees pee eae Source: Control Engineering 2018 ees erin LW Ce ag receiving a yearly bonus based on their personal performance. Source: Control Engineering 2019 Career & Salary Study Uc) eee eo eee tee eee sed Ree eeeINSIGHTS. INTERNATIONAL Stone Engineering China Automation as market growth slows Fast-growing areas for automation, according to analysts, include edge computing, cloud computing, data analysis, machine learning and industrial network security INSIGHTS come global markets are slowing growth, which isa challenge for automation indus- tries in every region, Trade friction and an unstable geopolitical environment also are affecting industries in some impor- tant areas. Where can automation enterprises find ‘opportunities amid challenges? In October 2019, ARC Advisory Group released a list ofthe top 50 global and North American auto- ‘mation companies of 2018, At the same time, analysts pointed out that with slower growth in some global ‘markets, automation companies still have opportuni- tiesto grow against the trend. Compared with the rankings of last year, the positions of some leading automation vendors have remained mostly unchanged. but there are also many new suppliers parachuting into the industrial automation market from infor- ‘ation technology (IT), Industrial Internet of Things (IfoT) and cybersecurity markets. KEYWORDS: Automation ane ‘These suppliers include companies providing See edge computing, cloud computing, data anal- Emerging automation ysis, machine learning and industrial network technologies hove doublo- Security. Despite the sluggish development of festo.us/eaINSIGHTS. TECHNOLOGY UPDATE but also from a device management and support perspective. Platform security is a factor which is ‘easily overlooked. Security is applicable across the various layers. It is important that any device connected to the platform should be authenticated and the commma- nication channel ideally should be encrypt- ced. The platform should be able to securely Rugged P The MAQ®20 store the data and allow access to the data and dashboards based on grouped user rights, such as administrative rights, write- ‘back, read-only, and which sets of data that will be visible to which group, ‘The last big consideration is the tools and ability to integrate and handle data, both from bottom (level 2) to top (evel 8) also called north-bound integration and recision Industrial Data Acquisition & Control System Signal Integrity, Compact Design 2 Software Packages th RoDAQ? Shapo Unlimited Loops with IPEmotion + -40°C to +85°C Operating ‘Temperature Input 9 atwwrcontoleng for DAQ or T&M QDATAFORTH” Instrument Class® Signal Solutions dataforth.com * 800-444-7644 sconvinformation 6 When selecting an IloT platform it is very impor- tant to ensure the plat- form fits specific long- and short-term needs. 5 top (level 8) to bottom (level 2) also called south-bound integration. This is very important as some vendors are very good at north-bound integration but struggle with south-bound integration. Especially for lloT, the ability to send information down to instruments is very important as pure reporting within a paced envionment will be inadequate. Look specifically at the drivers or proto- cols supported by the platform and ensure that it supports LIoT protocols. such as OPC, fieldbus, Profibus, etc, for south- bound integration and have adequate APIs, ete, for north-bound integration ‘Again, access to the data should be secure, authenticated and tracked. ‘When selecting an IloT platform it is very important to work through the var- ious factors to ensure the platform fits your specific long- and short-term needs HloT platform functionality Looking at the full stack of HoT, a number of functions need to be avail- able in the HoT platform to ease the implementation and reduce the number of vendors involved in an UT solation. The platform needs a front end or user interface development environment that is user friendly and easy to use. It must make provision for and enable the han- dling of a variety of communication pro- tocols, both northbound and southbound. 1 needs a user interface that enables device management, device status moni- toring and device grouping. The platform needs to provide a data storage environ- ment that i scalable and secure, but allows casy data acess and retrieval. Italso needs to provide tools for the easy development of dashboards for live values and trending as ukimately, ths is the view the custom erneeds to make better business decisions. 14 © January 2020fe => SUNNEN ie on SV-30 Ch — Ve — omg i GRAYBAR KNOWS TPL ORS ted PAV Seda wal LUM Leu) —S —= Ba £INSIGHTS. TECHNOLOGY UPDATE Although multi-tenancy (one plat- form for multiple and separated users) is not required by all users, it may be that a company wants to segregate data with- in a platform so that not all data are vis- ible to all users and each user company can have their own branding and “look and fee!” When used specifically in the MoT environment, workflow manage- ment, notifications, and alarming are very important to inform plant opera- tors, supervisors and managers when things do not go as planned. ‘Tools need to be available to enable advanced data analytics, such as machine learning (ML), advanced pat- tern recognition (APR), artificial intel- ligence (A1), robotic process automation (RPA) acoustic analysis and facial and image recognition. Ultimately, these tools will increase the efficiency and effectiveness of businesses when applied correctly. If the platform does not have these tools (and very few do), then at least the data should be available and easi- ly extracted via standard tools and pro- tocols into other applications that have these tools available. ‘The platform needs to be flexible regarding where it will be hosted, espe- cially for TloT as a hybrid model will probably be the most effective, specifi- cally for real-time process industries. The availability of after-sales and plat- form back-end administration support is also very important for a long-term sus- ble solution. Evaluate, for today and beyond Not all platforms are created equal ‘To get the best HoT platform, companies need to take the time to evaluate the ven- dors. Look under the hood and ask the vendor to explain how the vendor incor- porates the various consideration fac- tors. Look at all eight layers, determine what is part of the platform and what is “bought-in’ third-party functionality ind the best fit to solve the current and future business problems. ew Gerhard Greeff, MESA EMEA Board ‘Member. This article originally appeared on MESA International’ blog. MESA International is a CFE Media content part- ner. Edited by Chris Vavra, production edi- tor, Control Engineering, CFE Media and Technology, cvavra@efemedia.com. More INSIGHTS KEYWORDS: loT platforms, MESA Defining HoT architectures Factors to consider wien selecting a platform oT platform functionality, CONSIDER THIS ‘What lloT advantages wil you adopt? ONLINE reading from tho digital edition, eck on the headline for more oT resources, Aso see: wwwz.conttoleng.com/magazine vwww:controleng.com/webcasts wmwcontroleng.con/research ww controlang.com/ebooks wmwmesa.org Continued from p.8 PAZZINI: The challenge is, how ‘much can the infrastructure ease the adoption of cloud technologies in man- ufacturing? At the moment, eustom- ers are pretty skeptical because the MOM system is a business-critical sys- tem. Deploying a system in the cloud requires very strong and reliable IT infrastructure. Use of 5G technologies in manufacturing requires creating a strong web-based cloud infrastructure with the same level of reliability as an ‘on-premise platform. CEP: We see the cloud becoming ‘extremely important across many indus- tries, particularly in manufacturing. Is there a preferred cloud platform? PAZZINI: It depends on the region. In Western countries, we see Amazon as a major player with large adoption by manufacturers, China i quite reluctant to implement AWS (Amazon Web Servic- es) due to the need for greater data con- trol. From our view, Amazon probably is the first choice of manufacturers for cloud platforms that customers are adopting. 16 + January 2020 I think it seems more medium-sized ‘businesses will endorse the cloud quick- er than the large corporations because the large corporations at the moment do not sce a big advantage in reducing some operational costs from redesign- ing their IT infrastructure. They have available big data centers and teams established, so it's just fine for them to add one more system, for example, not the whole MOM system. We see large corporations adopting only pieces of the MOM system, and not mission-critical applications. Small and medium com- panies might have challenges in adopt- ing MOM, but I see small and medium businesses adopting the whole system from the ground up. which is why I think that they will probably be the trendsetters for MOM adaptation CEP: Central and Eastern European ‘manufacturing markets have an edu- cated labor force at lower cost than other areas of Europe, but without enough labor, automation is consid- ered. How can automation continue to help manufacturing? ‘CONTROL ENGINEERING PAZZINI: Repetitive manufactur- ing processes can be highly automated. The number of people on the shop floor is proportional to the complexity of the goods being produced. In aerospace, I don't sec fully automated manufacturing happening in the short term. For com- plex products, humans will still play an important part in production. As new industries emerge (like rockets), many engineers and production people will be needed to produce them. CEP: So, you're optimistic about the future? PAZZINI: Absolutely. 1 think our vision is well appreciated by customers, but we have challenges because our cus- tomers are always raising the bar. Once they buy the whole portfolio they really expect a lot. Such interactions facilitate product innovation. e& Michael Majehrzak is with Control Engi- neering Poland. Edited by Mark T: Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com. nw controlang comCourtesy of GLFLEX® SERVO FD 7FTC Countdown to the New Year and count on LAPP's new OLFLEX® SERVO FD 7FIC. The single-cable solution for servo applications that goes from cable tray to cable track, saving conduit costs. Servo motors often ‘operate in harsh conditions — robust oll, mechanical and flame resistant ‘encoderfeedback cables like LAPP’s new OLFLEX® SERVO FD 7FIC are vital. This continuous flex cable is rated CF-02 by LAPP's UL-Verified Continuous Flex Test Method, and XLPE (Plus) insulation provides low capacitance for long cable runs. Count-on LAPP cables to keep your factory up and running ...the ball does.INSIGHTS. APPLICATION UPDATE Jeorg Hecke, SEH Retrofit: Network, virtualization An industrial conveyor manufacturer needed to put computer-aided design (CAD) software into the cloud, eliminate outdated Microsoft Windows 7 PC software, and keep a steel cutter with RS-232 communications connected to receive CAD outputs. See two virtualization obstacles i More INSIGHTS KEYWORDS: Retrofit, Virtualization, network ‘manufacturer of bulk-material convey- or for heavy industry, Loibl Forderan- lagen Gmblt, also produces equipment as bucket, pipe, and crop conveyors, as part of a larger contract to engineer, plan, service and modernize industrial plants. To design and create such machinery, the 140-employee company, based in Straubing, Ger- ‘many, used a Messer Group steel-cutting machine. In a modernization effort. Loibl engineers set out to virtualize and encloud the on-site, Microsoft Windows 7 PC that ran the steel-cutting machine's design software. The computer-aided design (CAD) program helped Loibl engineers design ‘metal parts and the cutting layouts (“nesting”) to deliver the most parts in the least material. The software output directs the computer numerical control (CNC) thermal cutter. ‘Two virtualization obstacles ‘Two obstacles to the virtualization effort were ‘common, though not often seen, together. 1. The CAD-running PC had communicated with the steel-cutting machine’ control unit over an RS-232, short-range serial interface, requiring the computer to reside in close physical prox- {mity to the machine (rather than blocks or miles away in a data center), 2. Like many industry-specifie design oorade programs, the CAD software license rested in ‘Steel cutting mactine a physical USB dongle, inserted in the same needed a software update ‘PC. The planned virtual computers, by def- Connected network co _inition, would not have physical USB ports. required an update, New devices hloed with CAD sofware integration What outdated operating systems add risk to your inetallaions? Replacing the RS-232 interfaces of the cutting system was not an option. (See “Before Virtualization,” top of diagram, with this story online). Baycix, an IT systems and service provider, resolved the challenges by preserving existing machinery and control unit by converting the serial data to USB, and using rail-mounted serial-to-USB converter. lfreading from the digital cedtion, cick on the headline for more images and information vwrcontolng.convragazne See related Now Products for Engineers products at ‘wuew.controlang,com/NPE ws January 2020 Double-duty device ‘A separate device server encapsulates USB data for transport over Intranet and unpacks it at the receiving point. The con- versions occur in the shop-floor control cab- inct, and the virtualized CAD-running PC, ‘CONTROL ENGINEERING BayCIX, an IT systems and service provider in Landshut, Germany, suggested that Loibl Férderanlagen used SEH Technology devices to ‘communicate to a Messer steel-cutting machine and eliminate outdated PC-based operating system software with a virtualization design. Courtesy: SEH Computertechnik GmbH with updated operating system, communicates over the network with the cutting machine. Because the added device server has two USB ports, it can per- form double duty. It accepts the USB dongle on behalf of the (now virtual) PC and sequentially ‘extends the license to anyone accessing the software across the intranet. In so doing, it remains within the license's one-user limits The BayCIX December 2018 test ran for six weeks, beginning with cloud migration of the CAD software and installation of the serial-to-USB con- verter and USB device server. Now, the virtual PC communicates with the device server to access the USB license dongle and send its command file to the metal-cutting machine across the network over IP. Both devices were installed on DIN rails inside the control cabinet. Operators were relieved to retire the computer and migrate updated software to the cloud, without changing or reconfiguring the serial- baseel machine. Hermann Lehner, operations manager at Loibl, said, “We value the stability and flexibility of the entire system. Its convenient to be able to configure settings with RS-232, which is easy to use despite its age, thanks to” the new devices. e@ Jeorg Hecke is head of product management, SEH Computertechnik GmbH. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com. nw controlang comINSIGHTS. NEWS PLCs evolve, After two years of strong expansion, programmable logic controller (PLC) market revenue growth is set t0 slow to nearly zero in 2019 due to weak demand from downstream industries, according to IHS Markit | Technology. Global PLC market revenue is set to rise by less than 1% in 2019 from $9.5 bil- Jion in 2018, said IHS Markit | Technology. ‘This follows a recent peak of 12% growth in 2017, and a 9% expansion in 2018. “The PLC market has gone into a slump in 2019 as demand from industries including automotive, semiconductor, electronics and machine tools has decel- crated,” said Daisuke Muto, senior analyst, ‘manufacturing technology, for IHS Markit ‘Diaiol ealion? Click on headings for more dati See news dally ai www.controleng.com add functions, efficiency | Technology. “This trend started in the first-quarter 2018, and now has gained ‘momentum this year. However, growth is expected to rebound slightly in the com- ing years, stabilizing market condition ‘Transformative technologies Long-term market stability is being driven “by transformative technologies applied to industrial sectors. Technology advances like the cloud, artificial intel- ligence (AI), and new communications approaches have significantly effected PLC products in recent years, allowing these devices to diversify al automation control systems. TToday’s PLCs support multiple fanc- in industri Offline robotic programming benefits tutomation speeds up manufacturing and production schedules; howev- [ \ cr, operators can see those gains dwindle when factoring in robotic pro- gramming time. Fortunately, engineers have found a solution with ofine programming (OLPI, which reduces initial setup time, programming time, and ‘changeover and alteration time. Offine programming tools provide operators with simulation software to cre- ate a digital representation of their production environment. This allows them to know how the robots will perform within the simulated environment. Thanks to offiine programming, integrators of robotic systems have been able to imple- ‘ment automation in markets that don't have room for the downtime associated with traditional programming methods. CLP can reduce the time it would take to train a robot point-by-point. Opera- tors can more efficiently create programs and updates to ther simulated produc- tion line as their real-world robots keep hurnming along. OLP not only saves money by keeping the physical robots running, but changes to their programming can be implemented faster, doubling down on the benefits. Offline programming software isnt just a robot simulator. It helps programmers and operators test updates and predict how their production line willbe affected by changes to their automation system. A significant benefit is that robot opers- ‘ors don't have to be highly skilled in programming to use it ‘The costs to implement offline programming can be gained beck through pro- {duction and programming efficiency, making it cost effective for manufacturers. Since OLP software can be leveraged for nearly any application, the software helps production managers plan updates and make changes that can be imple- mented without extensive, #f any, real-world testing, Five ways robotic offiine programming helps {All the benefits of robotic offline programming make OLP applicable for near- ly any robotic integration. Some facilities, however, will reap the benefits quicker than others. OLP can help manufacturers accomplish the following: 1) Shorten startup times; 2) Tweak programs quickly; 3) Program heavy tasks faster; 4) Reduce downtime; 5) Reduce robotic changeover tims ‘This article originally appeared on the Robotics Online Blog. Robotic Indus- tries Association (RIA) is a part of the Association for Advancing Automation (A3), a CFE Media content partner. CONTROL ENGINEERING January 2020 * tionalities, such as inspections, robotic ‘guidance/positioning and high-precision ‘quality control/sorting. AT technologies ‘can be deployed at the edge, the near-edge ‘or in the cloud. With increasing comput- ing power, PLCs represent the ideal equip- ment to run the appropriate AL algorithms ‘or work as part of Al-based cloud software. Rather than being part ofa cloud solu- tion, an Al algorithm can be embedded in separate models that can fit inside PLCs or integrated into the PLC hardware. By “learning” an application running on PLCs, AI algorithms can help build a model oft automatically. The models ean ‘guide robot systems, perform visual qual- ity checks in production plants, reduce time for developing programs, or handle several key steps in a data-driven decision process for predictive maintenance. ‘Through new communication tech- nologies, PLCs can communicate with the cloud, without gateways or host comput- cers. They are customizable for retrofit proj- fects to upgrade legacy production lines and enable connectivity. Additionally, they reduce machine builders time-to-market. Increasingly, advanced PLCs are now designed with multi-core processors, ‘enabling end users to install more applica- tions. PLC manufacturers also are invest- ing in edge computing, enabling PLCs to process data in real-time and streamline the amount of data sent to the cloud. The core of the issue ‘The stage appears to be set for higher productivity and enhanced efficiency in the manufacturing industry. A substantial amount of effort and time will be required. before the next-generation PLCs are reality. “Due to the complex application envi- ronment, diversified production process- es and strict requirements for reliabi and stability, it will ake afew years before PLCs integrated with AI technologies are ready for mass production” Muto suid. ‘The PLCs Report ~ 2019 from HS Markit covers the global PLC market, including all regions, sub-regions, and segments of ‘countries Edited by Mark T: Hoske, content man- ‘ager, Control Engineering, CFE Media ‘and Technology mhoske@efemedia.com 9INSIGHTS. NEWS Program for advanced manufacturing ‘A robotics program led by Worcester Polytechnic Institute (WI) will help pre- pare the next generation of advanced man- facturing employees with the skills they need through summer and. after-school programs, giving them hands-on experi- ‘ence and taining in collaborative robotics. The program, geared for middle and high school students, integrates the fields of robotics, engineering and manufacturing with the cutting-edge work being done in the WPI Manufacturing Engineering Labs. Torbjorn Bergstrom, director of the Haas ‘Technical Education Center, said the program will provide opportunities for two- and four-year college students to assist as program instructors. The pro- ‘gram debuted this fll, and will run in the spring semester as well with afterschool programs, and will continue next sum- set with the release of the CoBot for Kids program at WPTS Launch camp. ‘The project combines a Massachu- setts Manufacturing Innovation Initiative (M212) grant for $82,000 that funds the two collaborative robots for the program; an Advanced Robotics for Manufacturing Institute grant for $100,000, and $120,000 in funding from WPL Bergstrom was inspired by an earl er program where WPI trained over 400 displaced workers as computer numeri- cally controlled (CNC) operators and put them back to work. That program was a hhuge benefit to WPI undergraduate stu- dents who taught the technology to the displaced workers, he added. “The students are the ones most easily able to do that, and they gain experience when they are hired as engineers to train people on this technology? he said. “It gives ‘our students abig benefit tobe able to train people on this when they go into the work- place. It helps WPI make better engincers, and the middle and high school students get excited about tech careers inthis area” Creating a pipeline Bergstrom said robotics technology also helps promote manufacturing, both in the region and nationwide. “Any manufacturer that is not able to understand technology is going to fail” he said. “Its going to be much easier for Mas- sachusets to attract manufacturing ifthe talent pool understands the technology. WPLis priming the pump” Nationwide, manufacturing represents ‘more than 50% of the gross GDP, he says, including direct manufacturing jobs, peo- ple who work in retail sales selling what is ‘made, investors, and vendors. “Without manufacturing, local people ‘wouldn't have those jobs,” he said. “Manu- facturing creates new wealth; we want . it here instead of outsourcing it offshore” Robotics and STEM Tn 2008, WPI expanded to include robot programming for grades 4-12, “Since the inception ofthese programs, the demand for these types of programs hhas consistently and significantly outpaced the number of spots we have available” said Sue Sontgerath, director of Pre-collegiate Outreach Programs (POP) at WPI, “This grant will serve to integrate the concepts of robotics and manufacturing for middle and high school students. From that perspec- tive, weare excited to beable to offer a new and unique option for participants” Temperature sensors can be remotely targeted and hacked ing incubator temper atures to safeguarding chemical reactions in indus- ‘try rely on realtime monitoring and control from ritical processes from mai ‘temperature sensors to stay safe and accurate. The devic- es ensure that these systems make proper adjustments to, their sensitive environments, keeping infants healthy and, industrial processes safe for the surrounding area. ‘research team led by Prof. Kevin Fu at the University of Michigan and Prof. Xiali Hei lab from the University of Louisiana at Lafayette has demonstrated that these tem- perature control systems, particularly in sensitive devices, like infant incubators or industrial thermal chambers, can, be remotely manipulated using electromagnetic waves. The vulnerability results from the weakness of analog sensing components. The attack exploits an unintended, rectification effect in amplifiers and can be induced by injecting electromagnetic interference at a certain wave- length through the temperature sensors. The researchers, led by Sara Rampazzi from the University of Michigan and, Yazhou Tu from the University of Louisiana at Lafayette, demonstrated an adversary could remotely manipulate ‘the temperature sensor measurements without tamper- ing with the targeted system or triggering automatic tem- perature alarms. From meters away or an adjacent room, an attacker could trick the intemal control system of an. 20 + January 2020 conrpot enaineraInG igan and University of Louisiana at Lafayette researchers remotely manipulated tempera ture control systems. Courtesy: University of Michigan infant incubator to heat or cool to unsafe temperatures. ‘Analog temperature sensors, such as thermocouples, NTC. thermistors, and resistance temperature detectors (RTDs), are susceptible. The authors described how to defend, against the attack, proposing a prototype of an analog ‘anomaly detector that can identify malicious interference in the vulnerable frequency range. When interference is, detected, signal information can be used by the system. software to estimate the sensor data reliability, Tu said. Steve Crang, University of Michigan. Edited by Chris Vavra, associate editor, Control Engineering, CFE Medi and Technology, cvavra@cfemedia.com. nw controlang comSontgerath said that offering the pro- gram free to participants also aligns with the POP mission, “WPI’s Office of Pre-collegiate Out. reach Programs provides high-quality STEM programming to K-12 youth and their families—with a special emphasis on broadening access and increasing interest in these fields among groups historically underrepresented in STEM she said. “We provide collaborative, project- or inquiry- based enrichment experiences that inspire exploration and discovery, while estab- lishing a pathway into STEM disciplines. Robotics is an especially valuable way for kids to explore and discover a pas sion for STEM because of its interdisc. plinary nature, Sontgerath said. Through robotics, program participants explore concepts from mechanical engineering, physics, electrical engineering and com- puter science, Paula Owen, Worcester Polytechnic Insti- tute (PD. Edited by Chris Vavra, asso- ciate editor, Control Engineering, CFE ‘Media and Technology, cvavra@cfemedia Digital editon? Click on headlines for more dati See news daly ot www.contoleng,com Headlines online Top 5 Control Engineering articles Decomber 9-15 ‘ticles about the System Integrator Giants, SIY winners, collaborative robot use cases, digi ‘al twins, and industrial itualzation were the most-viewed storia for the week Aqueous Lithium-ion battery improves safety ‘Ateam of engineers at Rensselaer Polytechnic institute (RP!) have found using aqueous ‘electrolytes instead ofthe typical organic electrolyte fora lithium-ion battery doesn't reduce ower or overall performance, Researchers develop coating that uses thermal trickery for detection University of Wisconsin-Madison researchers have built @ coating designed to break the relationship between temperature and thermal radiation, which could have an impact on infrared cameras used for vision applications, University recolves grant to construct high-performance computing cluster. Clarkson University received a National Science Foundation (NSF) grant fo construct a new high-performance computing cluster to support data and computationally intensive projects, Leveraging augmented reality wearables on the plant floor ‘Augmented reality (AR) wearable technology can provide workers and companies reabtime information about conditions on the plant floor to make everyone safer Cae ees (On page 34 ofthe 2020 Global System Integrator Report, the listing for E-Technolagies Group inc., West Chester, Ohio, was shown incorrect. The listing should have been shown as E- Technologies Group Inc. (E-Technologies, Glenmount Global Solutions, Superior Con twos, Banks Integration), See the corrected ist‘at ww.controleng comigiants Oster AZ Series ial Now With Rock & Pion Systm Compact Bac Cylinders Rotor Aetuctors Open loop performance. Closed loop control. EtherNet/IP_ Orientalmotor input #12 at wwn.contoleng.comiinformation tae ong ie 0,INSIGHTS. THINK AGAIN How clear is your 2020? Did you have 2020 vision? Predictions of automation, controls, and instrumentation for 2020 were spot on. Are you making these changes quickly enough to stay competitive? hat will automation, con- trols, and instrumentation Took like in 2020? That was the question repre- sentatives of the System Integrator of the Year (SIY) winners answered five years ago. Looking around, fd say those 2020 Visions were clear. T worry some technology users aren't moving quickly enough with upgrades and new installations and are putting their organiza- tions at risk with hesitation, (With this article online, see connectivity, network security, network ‘upgrades, more intuitive human-machine interfaces (HMIs), safety, predictive ana- Iytics and upgrades. + Malisko Engineering explained how connectivity, modularity, and predictive support will help. Stephen J. Malyzsko, president and CEO of Malisko Engineering, offered advice on connectivity, modular manufac- turing, system support, built-in security, technology shift, and collaboration Tinks more 2020 predictions.) Why hesitate? vet Henke WHY. does anyone void 2018's view of 2020 MKT Hote ois automation, controls ‘Looking back at 20155 view Manager and instrumentation? of 2020.. + Maverick Technologies suggested that greater automation value in automation would come from being more connect- ed, collaborative, and secure. Paul Gales- ki, CEO, Maverick Technologies, discussed advances in automation, networking, new people, collaboration and cybersecurity. + Polytron saw engagement in the digi- tal era of manufacturing. Brent Stromwall, PE, PMP, and vice president of Polytron Inc, said manufacturers should provide more precise and advanced access to tech~ nical and reference materials. Bight tech- nology predictions covered sustainability, More INSIGHTS KEYWORDS: 2020 predictions, upgrades Predictions of 2020 technologies Implementations might be behing. Collaborate to upgrade soon. CONSIDER THIS ‘As CFE Media and Technology celebrates its 10th anniversary, get advice about factory controler upgrades in January 2020 Contr Engineering anc on process contro! upgrades in February, ONLINE ‘See advice from other system integrators at ‘wan controteng convS¥ 22 + January 2020 + Change ischallengings why change what’ working? + We have alot on our plates, and cannot adequately evaluate or ‘migrate to the next generation of technologies. + IF just keep this running for anoth- cr few years, I can retire and leave the upgrade to someone else. + Ifwe wait afew more years, can install what I want and not what the elders think we need. Any ofthat sound familiar? Step up and think again about upgrades before more retirees walk out the door. Work with the next generation of control and automation experts at your location to upgrade before you go. They'll be glad for your insights. ‘And you, the next generation of auto- ‘mation and control experts: Dont let that domain knowledge walk out the door without capturing the best and letting go ofthe rest. Everyone: Collaborate with experts; donit let another year pass without the competitive advantages from new designs, technologies and implementations. Get help and advice from system integrators to move quickly with confidence. e ‘CONTROL ENGINEERING [ROL E EERING ‘S010 Higa Para, Sut 325, Downer Gove, ILeost 620-571-470, Fax 530-214-504 ‘Content Specialists/ Editorial Mark Ha, ara aay (Sosriaovescss? MiaaecrOMctacon ace Si Coe Marae ‘ios aro 12230, samteecFEveacon Kev Pane Sr Cot Eo, oT, OE (Sossrivo x28 arden com ty anther reco eect (ost 12208, epothrSOFEVos com ‘Amanda Plicions Dect of Feosch ‘fear uma swansea rece com he aa esac ter ‘Glows som ‘Contributing Content Specialists Suzan i Canta Ean Eoco Reeotempmpeauk tan Kosnea, Cael gra st ‘Saenatoernedenaass ‘thorny, Coree Engroama Pa ‘Siisabraneyediaderecat Luk Smet, Catal Engine eet Pape oeonaeedenegn ‘Aue Jn, Con Engrs Cane Beevaceceen Editorial Advisory Board eenteanralng cana ovg Bl eet erComin anston ‘Simerstscnanenson am owl ition, si art a nd (Sia aomwgen wma Frank amb ton ona ‘Adamson Com 1 rant onan ete a er ison Goel Speman com ek Pwo, pesto acon ‘Speer Cres mun pencerece co Mark tna pus, atoen acess Fe eters faegn (CFE Media Contributor Guidelines Overview Contest Fo egnerTha ha CFE a ‘Stns andra GFE Meds a beak Seer whee ace ‘Song Wl a ton rt oro ‘Sanat ann newts ap ‘tos Flomed abot he rica cn otamn sore cong coment lee {Decbnt peor kes rec, repos ed ne te i a te * Corse oa hg egressS Newark 3M G7 Aire BELDEN ETN =a west Ou. ‘mero — molex _mutifeomp Beospvery ri Tektronix TENMA SgANSWERS. COVER STORY: FACTORY CONTROLLERS Eric Reiner, &: Many-core technology helps advanced machine control As machines incorporate more complex components and software, many-core industrial PCs (IPCs) offer processing and core isolation to realize smart factory and Industry 4.0 concepts. How many cores do applications need? hen many-core technology _ interfaces (Ols) with voice commands, mobile human- became available for industrial machine interfaces (HMIs) and machine learning ‘machinery, engineers had ques- (ML). These continue to fil in the blanks and justify tions. “What can you do with all the integration of many-core technology. of that processing power?” some PLCs and programmable automation controllers ‘wanted to know. “When would you need it2” others (PACs) have not kept pace with the massive influx of asked. At the time, running a programmable logic data, Multi-vendor, distributed control architectures, controller (PLC) program in PC-based automation have not always proven effective due to the “hand- software required one core. Even with HMI and a few shakes” required to make the systems work togeth- extra programs, industrial servers with dual 16-core er. Advanced machines require advanced controls. processors appeared excessive. Blanks were builtin for PC-based contol has proven its capabilities for many future programs, but engineers werertt sure how to fill years, but these abilities have grown through the intro- them. Production machinery isnot what it was duction many-core CPUs. Multi-core industrial PCs Constant advances in automation technology (AT), (IPCs) meet most machine control needs, but a rapid ‘combined with the greater convergence of AT, oper- increase in requirements and opportunity to gain an ations technology (OT) and information technology advantage makes a convincing case to explore many- (T1),have created more efficent, reliable and complex core options for upgrades and future machine designs. machines. The data acquisition and responsiveness necessary for smatt factory and Industry 4.0 concepts What are many-core IPCs? also have led to significant changes. ‘The key difference between many-core and muiti- Systems that once used a few PLCs, stepper motors core control is not so much the number of processor and a basic fieldbus, for example, have received major cores as it is the actual processor structure. Many- updates in motion control with robotics and mecha- core builds on high-performance computing (HPC) tronic Iinear transport systems (LTS), EtherCAT principles by using embedded processors optimized communication, machine vision systems, operator for greater parallelism and throughput. Parallel data stream processing on a large scale means lower power consumption for concurrent completion of tasks due to the tasks’ spatial layout. Many-core also relies on. enhanced thread synchronization to resolve data bot- tleneck issues seen in most low-range CPUs In most applications, multi-core technology simul- taneously can do numerous complex tasks with ease when paired with suitable automation software for standard machine control logic and advanced fune- tions. Many-core CPUs are engineered to extend this ability to taxing applications with the same high scal- ability and flexibility. As a result, many-core control principles could extend to a range of devices from DIN rail-mountable embedded PCs with quad-core processors as easily as they do to industrial servers Many-core principles even extend to DIN rail-mountable machine with dual 20-core Intel Xeon boards and beyond. No controllers, such as this Beckhoff CX2042 Embedded PC. Images matter the size,a key strength of the technology is use courtesy: Beckhoff Automation of PC-based automation software for core isolation. 24 + January 2020 conrpot enaineraInG veo conteleng comWith CPU options up to dual Intel Xeon with 20 cores each, the Beckhoff C4670 Control Cabinet Industrial server uses core isolation to run a range of processes and programs concurrently in ‘TwinCAT 3 automation software, including PLC, HMI, machine learning and vision. Advanced control: How many cores? IPC software with core isolation allows engi- neers to dedicate specific tasks to individual cores or clusters in software. The processor's memory affin- ity leads to faster processing times. with task data cached in specific locations for higher performance Demanding programs, such as integrated ML or real- time simulation with MatlabySimulink from The ‘MathWorks, cam take up multiple cores located near each other and run concurrently with similar tasks. ‘This is true for advanced motion control archi- tectures, such as [TSs and planar motor systems with levitating movers, which require dedicated neural net- ‘works. Multiple cores could be required for sophisti- cated analytics and oscilloscope software, especially with the quantity of data available through Gigabit Ethernet and 10 Gbit/s communication speeds. IPC selection also depends on the number of tasks and systems supported as well as the cores available, rather than the highest clock speed. Dura- bility also is a concern for production environments. For production environments, durability also is a concern. Its important, then, to choose vendors that provide scalable products in rugged form factors. On the lower range of many-core controllers, some vendors supply PC-based controllers in stan- dard, DIN rail-mountable form factors. Some embed- ded PCs offer four to 12 2.2 GHz processors. 8 to 64 GB DDR4 RAM and operating temperature ranges of -25 to 500°C, On the higher end, few industrial serv cershave dual processors featuring six to 20 cores, with clock rates varying based on core count. These can offer hard drive capacities from 240 GB SSD up to 4 TB, 1,024 GB of DDR4 RAM and a working range of 0 0 50°C. Scalability is very important; not every appli- cation calls for 40 cores of processing power, but some could require more than four cores. ‘The benefits of centralized control systems are within reach with many-core IPCs. Many-core machine controllers create a multitasking device by consolidating all tasks while limiting hardware, minimizing footprint and increasing overall per- wow contrlong. com COVER: Centralized control systems that run ny machines and programs across a production line provide significant value for manu- facturers and machine builder OEMs. formance. This isa large improvement from previ- ous systems that divided processes between various PLCs, motion controllers and network PCs, which created communication delays ‘While the IPCs also can connect to the cloud their storage capacity and ability to run numerous pro- ‘grams on the device make the controllers more self- suflicient, benefitting manufacturers and machine builder original equipment manufacturers (OEMs) across many industries. Some OEMs may choose to develop intellectual property to handle advanced ‘machine learning and artificial intelligence (AI) by ‘running their proprietary software on the many-core device. Manufacturers also may be wary of the cloud if their machines process volatile compounds. Even without an internet connection, engineers have access to a more efficient platform for {implementing Industry 40 and smart fac- tory concepts. ‘The controller software has a erucial {impact on overall performance gains and capabilities. With multi- and many-core architectures, OEMs and manufacturers can face many new challenges because the PC-based controllers evolved and expanded capabilities over time. Soft- ‘ware that is as advanced should be tested and proven to adapt to these challenges. ‘The processing power contemporary ‘machine architectures require has caught some vendors off guard, even as many advanced machines and systems show the value of many-core technology. 26 Eric Reiner, IPC product specialist, Beckhoff Automation. Edited by Chris Vavra, associate editor, Control Engi- neering, CFE Media and Technology, evavra@cfemedia.com. "1 More ANSWERS. KEYWORDS: industrial PCs, many- ccore technology, Industry 40 Many-core technology options ‘can halp companies keep up vith ‘upgrades and future machine designs for industrial PCs (PCs). ‘Many-core CPUs are engineered to extend ths abilty to the most tang ‘applications with the same high scalabilty and fexibilty ‘Many-core PCs can consolidate operations and streamine data ‘management ONLINE Read additional articles trom the ‘author at www. controleng.com on topies such as mutt-touch HMI hharcware and edge computing, CONSIDER THIS. What benefits could your company receive from many-core technology ‘and where would ft help the most? conrro. ensnecins January 2020 © 25ANSWERS. COVER STORY: ADVANCED CONTROLLERS Josh Eastburn, Opto 22 Control, security, connectivity Powerful edge controllers are replacing PCs on the factory floor and going where PCs can't, providing a variety of “apps” for every task. 26 January 2020 hile smartphones have replaced the prior generation of consumer devices in many daily tasks, edge programmable industrial control- lers (EPICs) are replacing PCs, servers, and legacy hardware in the factory environ- ment. Edge controllers are designed to increase the ffciency of existing automation systems, while redue~ ing complexity and cost of ownership. What is edge computing again? alge computing isthe trend of increasing process- ing power and storage in devices that reside close to ‘where real-time data is generated by sensors, equip- ‘ment, and users. or control systems, edge controllers bring general-purpose computing power, connectivi- ty, data processing, and storage to the process level in a ‘compact, industrial form factor, along with input/out- put (V/O), real-time control and visualization options. Like a smartphone, a modern controller is chang {ng the traditional architecture ina platform for inno- vative software at the edge, where data is generated. User management, networking, security, and hardware interfaces are integrated, ereating an ecosystem of applications and tools users can work within to deliver a richer functionality to the process than previously possible. One controller can handle more automation functions including those that traditionally required a PC or other dedicated equipment. ‘On-board OPC and more Integrating multi-vendor programmable logic controllers (PLCs) or aggregating data from hetero- geneous devices might be handled using a dedicated OPC server. It could be hosted on anything from a cconsumer-grade laptop on a shel, toa rack-mounted server, to a virtual machine (VM) in an information technology (IT)-managed infrastructure. Regardless, this dependence on PCs requires additional licensing costs and management overhead. TT management complexity, in particular is a thorn for factory automation. Every new PC requires configuration, user access controls, antivirus, driv cer and operating system updates, and so on, which invite potential disruptions to production due to maintenance or unexpected downtime. Each of these ‘components may introduce more costs in the form of licensing and long-term support agreements. System. ‘CONTROL ENGINEERING ‘ownership also can become contentious when main- tenance procedures dor't integrate well with any par- ticular groups operations. Unlike legacy PLCs, edge controllers can provide a complete connectivity solution, including acting as OPC oF messaging queuing telemetry transport (MOTT) servers. Unlike PC-based solutions, edge controllers require little IT involvement, because they're built for industrial environments and. are secure out of the box. This shifts the burden away from IT and allows operations and engineering to fully control the automation. Costs vary based upon the specifi application, but are often lower because ‘of reduced hardware and software licensing When PCs are removed from the communication infrastructure, the architectures overall compleaity is reduced. Fewer interconnections ae required, and ‘control and communication can be managed together. Benefits of databases at the edge Database servers are another common feature of the factory environment because of the way they make it possible to store, combine, share and protect process data. In the age of Big Data, cloud analy machine learning, and the Internet of Things (IoT), database servers are becoming more important since data is more prolific and complex. The tradeoff isan increased burden on central servers, There is more network traffic, and data originates from many devie- «sin different formats. Extra work to normalize data includes processing and sequencing so database sche- mas dorit become complicated and inefficient. Edge computing techniques were first developed to address problems like these on the global internet, by decentralizing resources and moving them closer to the requested geographic areas. Edge controllers can do the same thing for factory networks. With an edge controllers ability to run custom applications — in addition to basic control — its possible to have a data- base server running locally The edge controller can store and pre-process data, respond to local requests, and forward normal- ined data to central storage. This reduces the demand on central networks and servers. It also improves responsiveness and flexibility at the process level compared to using flat-file storage. Store-and-for- ward techniques also ean be used to buildin faut tol erance where network stability isan issue. nw controlang comMany potential applications are available, such as data logging and historization. Process data is much _more usable when stored in a database, because of the built-in query logic and available administration tools. Users can turn a simple archive of process values and events for a given piece of equipment into a report system to reduce local downtime or increase overall equipment effectiveness (OEE). The system that can be queried directly or replicated to central storage. Programming improvements A local database also could be used as a task scheduler across one or more process areas. Building this kind of logic using process control languages can be cumbersome and inflexible. Database systems and. high-level programming languages are better able to create and manage time-based event mechanisms ‘An advanced example, combining storage and scheduling needs, is batch and recipe management ‘Many recipes can be stored ina database and modified ‘without needing to download new control code, with recipe execution triggered by operators or scheduled to run at particular times. The quality of open-source databases makes it possible to deliver functionality like this on an edge controller even for smaller facilities or low-cost applications without setting up a host PC. ‘Database connectivity can work in the other direc- tion, as well, since edge controllers can establish their ‘own connections to external on-premises or cloud- hosted databases. Ifthe recipe database from the pre- vious example were moved to cloud storage, it could be shared with controllers across many sites. Fach edge controller could establish its own connection and request parameters as needed, while allowing for consistent recipe management across all equipment (Ora combined approach could be used, with the edge controllers housing local replicas ofthe master data- base. In either case, this model can be achieved while reducing dependence on factory floor PCs. Security by design Connectivity is a principal driver of the devel- ‘opments in controller technology. Bdge controllers, are designed to support the increasing convergence between information technology (IT) and opera- tions technology (OT), as in the examples for OPC communication and data storage and processing. Cybersecurity is also a key driver in this increasing- ly connected world. Edge controllers address mod- ern security through design and operationally, by the way they simplify control system architectures. Edge controllers embed enterprise-grade securi ty standards. They require user authentication and support multiple access levels, Since they are net- work-oriented, they include standard networking protections, such as internal firewalls for blocking unsolicited requests, multiple Ethernet interfaces for segregating trusted and untrusted traffic, and SSL/TLS encryption and certification. By contrast, the typical factory supervisory control wow contrlong. com Edge Programmable Industrial Controller (EPIC) It's a controller... oe S*PAC Control copEsys and HMI ied Ske --and dev platform antoneeiy —— suite and VPN client = { @ opeNven ..and OPC server .and MQTT client tgniioa/ Bas and data acquisition (SCADA) architecture involves ‘many point-to-point connections, using unsecured application- and device-specific communication pro- tocols. As these networks grow, potential attack vee~ tors multiply. Maintaining a secure fabric in these types of systems requires heavy IT involvement and increased infrastructure, This also means spending a lot of time getting approvals for network addresses, ports, LAN management and general operations. Edge controllers absorb the job of legacy hardware, flatten architecture, and reduce the overall attack sur- Edge programmable industrial controllers (EPIC) like Opto 22's groov EPIC provide a secure platform for running many kinds of industrial applica- tions. Using secure shell (SSH) access, users can install enter. prise-class database face while adding a strong layer of security: Rather systems, and a wide than requiring either a rip-and-replace approach or variety of other appli- heavier infrastructure to secure automation, a net- ations, on the factory ‘work of edge controllers can sit between unsecured controller. Courtesy: and even disparate network segments (separated phys- Opto 22 {cally or by subnets, VLANs, or firewalls for example), establishing a secure, cohesive internal network that can be managed more effectively. There's an app for that Smart edge devices do the same for industries as for consumers: Bring flexible functionality where most needed. Edge controllers can be used for basic con- ‘roland have the horsepower to run many “ap aneginsr ight wat atthe wos VN Move cess level. Edge controllers can revital- ANSWERS ize and simplify existing factory control yeywoRns: Eage co . systems and infrastructure and provide a platform for mobile visualization, text and email alarm notification, integration with [MES and IoT systems, or developing cus- tom applications ‘There are limits, Edge control- Jers require resource management, and advanced functionality requires an under- standing of security and administration. But the result can simplify and improve the system architecture. ew Josh Eastburn is director of techni- cal marketing, Opto 22. Edited by Chris Vavra, associate editor, Control Engi- neering, CFE Media and Technology, evavra@efemedia.com. conTROL enainecnn January 2020 Internet of things, mobility Edge computing s the trend of inoreasing processing power and storage in devices that reside cose to whore realtime data te generated by sensors, equipment, and users. Edge controllers can improve ‘connectivity and require litle or no Tiwolvement, ‘Smart edge devices bring flexible functionality where most nosed. ONLINE Read this article online at \wsrw.contoleng,com for addtional Stories rom the author. CONSIDER THIS ‘What benefits can oxga contrliors bring to your fly? aANSWERS. COVER STORY: CONTROLLER ADVANCES Vibhoosh Gupta, Emerson Modern controllers, upgrades Legacy industrial automation systems must be replaced or upgraded. See four challenges and five benefits of upgrades using modern controllers. uch ofthe consumer world is com- fortable with frequent upgrades of their mobile electronics and asso- ciated apps. Even for some more ‘expensive consumer goods such as big-screen TVs, the cheapest and easiest path for- ‘ward is discarding the problem item and buying a new one. However, the case is much different for industrial automated machinery and systems. Industrial equipment can run for decades. Many ‘mechanical elements can be rebuilt or replaced with litle difficulty. The related automation system hard- ‘ware and software can become difficult to maintain, resulting in increased unplanned downtime. When, or before, automation systems become lunsupportable, users are faced with ripping and replacing or upgrading and integrating a new auto- mation system. Both modernization options can be