Automation2021 June Iiot Industry40

VOLUME 3
IIoT & Industry 4.0

▶ IIoT and Sensing on the Edge
▶ Robotics Integrator Uses 3D
Printing
▶ Single-pair Ethernet: The
Infrastructure for IIoT
▶ Bringing Your Factory to the
Edge in 2021
▶ How to Make a Battery
Smaller and Less Expensive
▶ Minimizing HMI/SCADA
System Security Gaps
A subsidiary of the International

Society of Automation
Introduction
AUTOMATION 2021 VOL 3 SPONSORS
IIoT & Industry 4.0: Fueling Post-Pandemic Prosperity

As the global economy continues to rebound following
pandemic-related shutdowns and disruptions, signs are good
that many manufacturing businesses, and those who supply and
support them, are on a path toward a bright future. According
to a recent McKinsey briefing, the future holds “a possible new
age of global prosperity, with high rates of economic growth
and surging healthcare innovation.” In the postpandemic era,
says the brief, much is possible: “Just with the technology that
is currently available—no unheard-of breakthrough required—
it’s possible to achieve 3 to 4 percent global economic growth
each year for a decade.” What’s available now to manufacturers
includes Industry 4.0 technologies such as Industrial Internet
of Things (IIoT) devices, edge computing, robotics, and 3D
printing. Smaller batteries, single-pair Ethernet, and open
communications standards support communication and
integration, enabling secure use of IIoT, HMI/SCADA, and other
systems.
All that and more is what you’ll find in this edition of

AUTOMATION 2021. May automation continue to enhance your
business’s success and allow it to prosper today and in the future.
Renee Bassett
Chief Editor
About AUTOMATION 2021

The AUTOMATION 2021 ebook series covers Industry 4.0, smart manufacturing, IIoT, cybersecurity, connectivity, machine and
process control and more for industrial automation, process control and instrumentation professionals. To subscribe to ebooks and
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Table of Contents
AUTOMATION 2021 VOL 3
IIoT & INDUSTRY 4.0
Page 6 IIoT and Sensing on the Edge

By Ryan Williams, Endress+Hauser
Modern instrumentation provides plenty of information—

here’s how to get it into IIoT software.
Case study: Robotics Integrator Discovers

Page 15
Binder Jet 3D Printing for Automotive
End-of-Arm Tooling
By Andrew Klein, ExOne
Metal 3D printing provided weight and cost savings over

machined alternatives for a FANUC robotics systems
integrator.
Bringing Your Factory to the Edge in 2021

Page 22
By Mark Russell, Allied Electronics
Use existing field devices, network connections, and

controllers to build an edge-connected system that
harnesses the full power of factory data.
How to Make your Battery Smaller and

Page 32
Less Expensive
By Sol Jacobs, Tadiran Batteries
Understanding your application can help miniaturize your

battery-powered solution.
Single-pair Ethernet: The Infrastructure for

Page 40
IIoT
By Matthias Fritsche, Jonas Diekmann, and Rainer Schmidt,
HARTING
SPE enables IT and automation to walk hand in hand.
A subsidiary of the International 3

Table of Contents
IIoT & INDUSTRY 4.0
Understanding and Minimizing HMI/SCADA

Page 61
By Gimmi Filice, GE Digital
Know where vulnerabilities lie and the steps needed to

secure interfaces and monitoring systems.
Page 75 Connecting the Factories of Tomorrow—

Today
By Sandro Quintero and Tom Worsnopp, Festo
Current technologies are enhancing our connectivity today,

and bringing us closer to seamless connectivity tomorrow.
Improving Operations with Localization

Page 83
Solutions
By Jeff Graupmann, SICK
Increasing efficiency using real-time, tag-based localization

solutions.
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By Ryan Williams, Endress+Hauser
Smart instruments have been available Modern instrumentation

since the mid-1980s when 4–20 mA HART
devices entered the market, quickly followed provides plenty of
by fieldbus-based devices. These digital information—here’s
communication technologies made it possible
for instruments to provide more than just a how to get it into IIoT
process signal. Using digital interfaces, these software.
devices could now send status, diagnostics,
and other information.
Endress+Hauser estimates that of its 40 million process instruments

installed worldwide, 90 percent are digital, smart devices. These smart
instruments provide an incredible amount of information at “the edge”
that is of immense benefit to a wide range of host systems and Industrial
Internet of Things (IIoT) applications, such as maintenance management,
asset management, inventory control, manufacturing execution systems,
and enterprise resource planning. But one major problem facing
industrial plants is: How do we manage all this data?

If a single smart instrument, such as a Coriolis meter, can provide a

few dozen items of status and diagnostic information, and a plant has
several thousand similar instruments (figure 1), the host systems have
to deal with huge amounts of data arriving in real time.
Because of the immense amount of data, and the problems

involved in managing it, Endress+Hauser estimates that 97 percent
of the data is not being used. Instead, automation systems use the
flow, pressure, temperature, level, and other data needed to control
the process, and ignore or discard the status, diagnostic, and other
data.
Figure 1. A process plant may have

thousands of smart instruments, all
providing status and diagnostic data
needed by IIoT software.

Major instrument manufacturers are well aware of the problem,

and several are now providing solutions to acquire data from the
edge and provide it to specialized IIoT software—all without affecting
or involving the automation system. This article explains how these
concepts work.
Handling massive amounts of data

As noted above, a smart instrument generates a great deal of status,
diagnostic, and other information. An Endress+Hauser Proline®
flowmeter, for example, can detect entrained air, vibration (which could
be caused by pump cavitation), coating, corrosion, and inhomogeneous
or unsuitable media. The flowmeter can detect 125 different problems.
When process conditions warrant a notification (figure 2), the
flowmeter will generate an event message.
While the automation system is mostly interested in flow values

and alarms, IIoT software wants to know about the warnings shown in
figure 2, as well as diagnostics and other data.
Many smart instruments have diagnostics to indicate problems

with electronics or subcomponents. For example, Proline Coriolis
flowmeters can monitor oscillation damping and frequency,
Error code Error Actions Alarm type

843 Process limit Check process conditions Alarm
962 Partially filled pipe Check for gas in process Warning

Adjust detection limits
910 Tubes not oscillating Check input configuration Alarm

Check external device or process conditions
912 Medium inhomogeneous Check process condition Warning

Increase system pressure
913 Medium unsuitable Check process conditions Alarm

Check sensor
948 Oscillation damping too high Check process conditions Warning
Figure 2. Typical errors that can be generated by an Endress+Hauser Proline flowmeter.

temperature, signal asymmetry, exciter current, carrier pipe

temperature, frequency fluctuation, and other parameters. Changes in
these parameters can indicate potential problems.
Every instrument manufacturer’s diagnostics differ, but each

typically monitors internal parameters, observes changes, and
diagnoses problems. Any further analysis must be done by IIoT
maintenance software, which means status and diagnostic data needs
to be transmitted to this software.
In many cases, this is accomplished by the automation system,

which periodically asks each instrument for the data, then stores
it in an online database, such as a process historian. Maintenance
management software accesses what it needs from the historian and
performs its analysis.
This type of solution presents problems. Networks can be unduly

burdened with data transmissions, historians can become bloated, and
there can be lags between data collection and recognition by the IIoT
software.
Rather than use a historian, all edge data

is provided to IIoT software via the cloud,
bypassing the automation system.
Data is collected only periodically because the automation system

cannot deal with the massive amount of status and diagnostic data
from hundreds or thousands of instruments. The data is stored in a
database, which has to be accessed from the maintenance software,
adding even more delays.
A better solution—now being offered by several major instrument

manufacturers—is to provide all the data available at the edge to
IIoT software via the cloud, thus bypassing the automation system
completely.

Connecting at the edge

The more than 30 million digital instruments currently installed
worldwide communicate with their automation systems via different
interfaces, including Profibus®, 4–20 mA HART, WirelessHART™, and
EtherNet/IP™. However, many eventually connect to an Ethernet-based
network (figure 3), where the data can be acquired by a specialized
“edge device.”
The edge device is programmed to extract instrument data from

the network and transmit it to IIoT software in the cloud. An edge device
can also be installed on a smaller system, such as a pumping station,
that may or may not be connected to a plant’s Ethernet network, or to
instruments that are connected to an older, non-Ethernet system. In
that case, each instrument is wired to a nearby “edge gateway” device
that collects data from devices and transmits it to the cloud.
Figure 3. An edge device (upper right) takes instrument data from the plant’s Ethernet network and sends it
to Endress+Hauser Netilion IIoT software in the cloud.

Once the instruments are connected to an Ethernet-based

network that is ready for IoT connection, the appropriate edge device
is selected. Various edge devices are available from instrument
manufacturers to handle expected data rates.
For example, Endress+Hauser has multiple approaches to selecting

the right edge device for the right quantity of instruments transmitting
information to the cloud. At a site where there are hundreds of
instruments, the edge device has high-speed data acquisition to push
the information to the IoT cloud. Conversely, Endress+Hauser also offers
instrument-based edge devices that run at basic speed, transmitting
small amounts of information to the IoT cloud.
All data transmission is one way from the device to the cloud.
Cybersecurity is deployed within data transmission, edge devices, and
cloud services connectivity.
Inside the cloud

Major instrument manufacturers provide software that uses data from
the edge to diagnose problems, schedule maintenance activities,
analyze processes, predict problems, and so on. Using Endress+Hauser
as an example, cloud software consists of several components:
Instrument diagnostics – Software built into modern instruments

monitors device status and process conditions, and provides data
needed for further analysis. Endress+Hauser embeds Heartbeat
Technology® into its instruments to give status and diagnostic
information, and to perform vital functions, such as condition
monitoring and in-situ verification.
During verification, the current conditions of various parameters

are compared with their reference values, thereby determining the
device status. Heartbeat Technology produces a “pass” or a “fail”
statement based on the tests, which are performed by traceable and
redundant internal references. The individual tests and results are
automatically recorded and used to print a verification report.

Cloud connection – Software and hardware are needed to extract

data from the plant’s Ethernet network or from individual devices and
to transmit it to the cloud-based software. At Endress+Hauser, this is
accomplished with Netilion Connect, which consists of edge devices
that acquire the data, a cloud platform that hosts the IIoT software, and
an application programmable interface (API).
The API provides a simplified way to connect cloud-to-cloud or

cloud-to-apps. Companies can use IoT in an efficient way without the
complexity of IT computer science.
The API provides a simplified way to connect

cloud-to-cloud or cloud-to-apps.
Netilion is Endress+Hauser’s brand name for its IoT ecosystem.

The ecosystem is based on an open source technology platform that is
common in our industry and—like other vendor’s ecosystems—offers
these functions:
Analytical software – Analytics process data generated by

Heartbeat Technology to assess instrument health, analyze and predict
problems, schedule maintenance, etc.
Process health – Health software analyzes instrumentation at the

edge to determine if the process is getting more difficult to control, if
external influences are having a detrimental effect on performance,
or if changes need to be made. For example, Netilion Smart System
for Surface Water can be used by water treatment plants to monitor
incoming surface water. The system monitors conductivity, pH,
dissolved oxygen, and other parameters, and issues warnings to
operators.
Equipment documentation – Maintenance technicians need

access to equipment manuals, troubleshooting instructions, and
other materials describing each instrument. Library software logs in all
pertinent information and makes it available to technicians on request.

Getting started
Implementing a system like Netilion might appear challenging, but
several factors help simplify the effort. First, few plants are exclusive to a
single instrument vendor. All this instrumentation has to be identified
and entered into the system, along with their manuals, error codes,
diagnostic information, etc. This is normally done during an installed
base analysis.
Fortunately, modern instruments typically are identified with bar

codes or labels that can be scanned to identify the vendor and product.
Then, the necessary data can easily be downloaded from the vendor’s
website.
Second, there is no need to implement a plantwide system right

away. Most vendors have a “startup kit” that allows a plant to try out
the concept. For example, Endress+Hauser offers a free trial version for
up to 15 assets with a typical plant introductory IoT package that can
connect up to 500 instruments to its cloud software.
Modern instruments provide a wealth of information about their

health and the process they are monitoring, but few plants use all that
data. Today, major instrument manufacturers are providing hardware
and software solutions that bring all the data available at the edge to
IIoT software for analysis and corrective actions.
ABOUT THE AUTHOR

Ryan Williams is the national product manager for services
and solutions at Endress+Hauser. Williams graduated from
Purdue University in 2005 with a degree in electrical & computer
engineering technology. He came to Endress+Hauser with more
than 14 years of experience at Rockwell Automation and has
been with the Endress+Hauser since 2018.

NEW
Casey
Stud
Binder Jet 3D Printed EOAT Solution

Durable, Lightweight, and Affordable Automotive Tooling
Robotic EOAT binder jet 3D printed in 17-4PH to MIM

� Unique lightweight design only possible with additive,
�
MPIF Standard 35 reduced the overall payload to help extend the life of
One-fourth the cost of DMLS, binder jet production
� the robot
was also faster than other additive manufacturing The ExOne family of production metal 3D printers
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and traditional methods can process 20+ metals and ceramics
READ THE CASE STUDY

exone.com/EOAT
Pictured left to right: InnoventPro™, X1 25Pro®, X1 160Pro™ and X1D1 automated guided vehicle.
Case Study: Robotics Integrator

Discovers Binder Jet 3D Printing for
Automotive End-of-Arm Tooling
Metal 3D printing provided

weight and cost savings over
machined alternatives
for a FANUC robotics systems
integrator in need of an
end-of-arm tooling solution.
By Andrew Klein, ExOne
Allegheny Electric Service—a control systems

design and industrial automation provider for
the powder metal, lumber, and metal stamping
industries—was asked to create durable and
The complex part designed in
lightweight end-of-arm tooling (EOAT) for an Solid Edge and 3D printed with
automotive manufacturer’s robotic inspection binder jetting technology enables
two tools to sit on the end of a
process. A six-axis FANUC robot needed to pick up
robot arm at a 90-degree angle
and place six different parts of varying weights up to each other. They must hold
to 2.5 pounds, for serial inspection running nonstop a variety of weights for a high-
volume precision inspection
across three shifts. The number of parts being
application.
inspected annually in this factory environment
ranges from 50,000 for the lowest-volume piece to

500,000 parts for the highest volume. A 3D-printed piece was part of
an assembly that needed to attach to two other EOAT pieces that, in
turn, needed to sit 90 degrees to one another for a variety of different
inspection techniques.
Oftentimes, an Allegheny Electric EOAT solution would be 3D

printed in plastic or carbon-fiber-reinforced plastic, or it would be
machined in a strong, lightweight material such as aluminum, said Jake
Shannon, design engineer at Allegheny Electric.
Although an initial prototype was originally 3D printed in a carbon-

reinforced plastic, the weight requirements and processing volumes for
the project eliminated this material from consideration due to a lack of
durability. It just did not have the rigidity and strength for the biggest
parts. Additionally, machining the desired functionality,
even in lightweight aluminum, would have produced an
EOAT part at the upper edge of weight for the FANUC
robot arm being used. This was also not considered
desirable.
The technology partners

Allegheny Electric wanted to explore whether metal 3D
printing could offer weight and cost savings through
new design options, so they approached FreeFORM
Technologies about both laser powder bed fusion—
specifically, direct metal laser sintering (DMLS) and binder
jet 3D printing.
Using 50 micron layers of

FreeFORM is a first-of-its-kind metal binder jet 3D
standard MIM powders, the ExOne
printing contract manufacturer. It was founded in 2020 by Innovent+ metal 3D printer took
a group of engineers who bring a diverse outlook to metals less than a day to produce the
final EOAT part.
manufacturing and a desire to be the benchmark for additive
manufacturing. FreeFORM uses technology from ExOne, a
pioneer in binder jet 3D printing technology. Since 1995, ExOne’s 3D
printing systems have been quickly transforming powdered materials—
including metals, ceramics, composites, and sand—into precision parts,
metal casting molds and cores, and innovative tooling solutions.

Using generative software from Solid Edge, computer-aided

design, and analysis software from Siemens, Allegheny Electric and
FreeFORM collaborated on a new, lightweight design for the project
that could only be produced with 3D printing. The design was quoted
for both DMLS and binder jetting. In binder jet 3D printing, the printer
uses a digital file to quickly inkjet a binder into a thin layer of powder
particles—metal, sand, or ceramic—creating a solid part one layer at a
time. When printing metals with DMLS technology, the final part must
be sintered in order to fuse the particles together into a solid object.
Benefits of binder jetting

FreeFORM estimated that the part would cost $672 to create using
DMLS, before any final finishing, and only $150 to create using the
ExOne Innovent+ binder jet printer owned by FreeFORM. Chris Aiello,
VP of business development at FreeFORM, says that because binder
jetting is so much faster than other metal 3D printing methods,
including DMLS laser powder bed fusion, it has much lower costs that
are more competitive with traditional manufacturing processes. Binder
jetting also provides other benefits:
▶ a sustainable method of manufacturing

that reduces material waste to less than
5 percent
▶ energy savings from consolidating many

assembled parts and processes into one
▶ end-use designs that are 30 to 40 percent

lighter.
Aiello said that the unique lightweight

design generated in this case could not
have been produced without 3D printing
technology. FreeFORM was able to print
FreeFORM 3D printed the part in 17–4 PH
a traditional stainless-steel MIM powder,
stainless steel. A 3D-printed carbon-fiber-
17–4 PH, with a D90 of 22 μm. This material reinforced prototype, shown in black, was not
was desirable because of its durability and rugged enough for use in the final application.

corrosion resistance—an important feature for a part that would be

used in a factory with frequent temperature fluctuations, he added.
Printed on an entry-level Innovent+ printer, the final part

exceeded MPIF standard 35, delivering a hardness of HRC 27 and a
final density of 98 percent. Because that hardness met the customer’s
requirements, additional heat treatment was not required.
“They could have gone with a simpler design in aluminum, but the
part would have actually been heavier to get the same strength as 17–4
PH,” Aiello explained. “By going with this kind of organic generative
design, they were also able to reduce the overall payload on the
machine, so it’s likely going to extend the life of the robot for the
customer.”
In this case, FreeFORM decided

to machine three critical features on
the part for further accuracy. These
included a few holes and one surface for
final flatness. Binder-jetted parts take
to machining just like standard metal
materials, said Aiello, “It’s very similar
to machining-wrought material, and it
looks no different than a machined metal
flat stock part.”
The part as designed had a build

volume of 160 × 65 × 65 mm (6.3 × 2.5 × 2.5
in) and a weight of 95 grams. The initial
printing of the part, using 50 micron
layers of standard MIM powders, took less
than a day of printing on the Innovent+,
a printer that has been on the market
since 2016.
The Innovent+ was not only fast; it

also delivered reliable parts. “The surface
quality is superior to any of the other

printers,” Aiello said. “It’s an easy machine to run. It was great for
this kind of application . . . . The Innovent+ is definitely meeting plus-
or-minus 2.5 to 3 percent accuracy (for first runs), which is the kind of
out-of-the-box performance that the engineering team expects.” The
Innovent+ can dial in even better accuracy (below 1 percent) with two to
three iterations.
The future
Although this project did not have Allegheny Electric Service was eager to
a high-volume part requirement explore whether binder jet 3D printing
for the final EOAT—only four parts was ready to produce affordable parts in
were initially needed—Allegheny unique designs for higher performance in
Electric Service was eager to do its automation applications.
the project to explore whether
binder jet 3D printing was ready
to produce affordable parts in unique designs for higher performance
in its automation applications. Now, it has a new solution option to
offer customers that can deliver durable, lightweight parts in metal at
affordable prices.
“We are always working within the design constraints of

traditional manufacturing,” said Shannon. “Now we can focus on
design intent and process optimization to meet or exceed our
customers’ expectations. We will definitely continue to offer our
customers end-of-arm tooling produced with binder jet 3D printing.
An important feature for us to offer our customers is how this
technology reduced the payload on the robot.”
For Aiello and the FreeFORM team, this project showed the new
design possibilities they can now offer in standard and durable metal
materials at affordable prices. The FreeFORM team has deep experience
in powder metallurgy and MIM, and they say the parts they are now
producing with binder jet 3D printing are equivalent to the type of
product they were producing with those traditional processes. However,
now they can make those parts without tooling and with more
geometric freedom than before.

“This project shows exactly why we started the company—to help

customers solve challenging problems,” Aiello said. “Binder jetting was
really the only way to go for this project. It was one-fourth the cost of
DMLS, and we did it in a strong material that reduced the payload on
the robot. As Allegheny Electric Service rolls this technology out, it’s
going to be a bigger savings for their customers.”
ABOUT THE AUTHOR

Andrew Klein is ExOne’s Global Director of Technology. He
is responsible for the development of ExOne’s metal binder
jet printers.

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Bringing
Your Factory
to the Edge
in 2021
By Mark Russell, Allied Electronics
Use existing field

devices, network
connections, and
controllers to build
an edge-connected
system that harnesses
the full power of
factory data.
Is your factory living in the dark

ages? Are you constantly checking
manual reports to see your
production scores? Do you wish
that you could check your factory
health on your smart device from
anywhere in the world? If so, you
could benefit from taking your
factory to the edge.

In this article, we will discuss what you need to know to convert

your legacy equipment into an edge-connected system and all the
advantages this transition can offer. By the end, you will understand
how an edge-connected factory can enable you to view and harness
your production data and make it work for you.
Layers of an edge-connected factory

You do not have to start from nothing to harness the power of the edge.
You can convert your legacy equipment to edge control, whether you
have a system based on PLC-5, S3, or a cutting-edge ET 200SP or NX102.
You can make a move toward the edge without redesigning

your control strategy. Most of us have our preferred fieldbuses,
and fortunately there are plenty of options out there to make us all
feel comfortable. Many of us are also starting to develop our own
favorite cloud options, SQL flavors, and non–IEC 61131-3 programming
environments.
To begin our discussion, we will spend some time looking at the

major parts of an edge-connected factory, how these parts connect,
and what functions they provide. We will move up the layers of data
flow, starting with field components and working our way toward the
cloud and true data empowerment.
Field components
The Omron NX102
Field components consist of sensors, motors, conveyors, actuators, and
machine automation
all the other things that either look at or interact with the real world. controller. (Image
Field components can be old or new, as long as they function in your courtesy of Omron.)
facility.
For field components, the IO-Link communication protocol can

come in handy for install and control strategies, but is not necessary for
data harvesting or easy edge conversion of a factory. This means that no
matter what field components you have, as long as they work, you don’t
need to fix what isn’t broken.

Connectivity
Next, we will take a look at the connectivity of field components. There
are two approaches, and we will start with the simple one: straight
copper connection. This applies to anything connected directly to
control hardware through basic (usually direct) wiring, whether that
is digital I/O connected to the controller or analog sensors, high-
speed counters, or pulse outputs. This is the easy approach, because
the number, placement, and technology type of straight copper
connections pose no challenge to implementing edge technology.
The second approach to connectivity is networked field

components. This could apply to human machine interfaces (HMIs),
variable-frequency drives (VFDs), remote I/O over a fieldbus, or any
field device that interacts with or serves the controller in the system.
These types of devices will lead you to your first real decision about the
architecture of your edge solution. There are two ways to go:
▶ Option 1: Read data directly from these devices.
▶ Option 2: Ignore the data at this level and read the relevant
information from your controller.
There are cases to be made for both options. We will look at them
each in turn.
Option 1: Read data directly from field devices

Reading information directly from our fieldbus-connected devices
works great for a retrofit if you are an end user and not a programmable
logic controller (PLC) programmer, or if you do not have access to the
controller in the system because the integrator did not provide source
codes. You can use a number of protocol converters and commercially
available edge connection devices to take your machine-level data to
an edge platform with some basic education online.
For a large number of users, this option will get their factory “talking”
to them for minimal human or equipment capital. It will require only
protocol conversion and an edge connector (which we will discuss in a
moment) and the cloud setup of choice, which can be outsourced.

Option 2: Read data from controller, ignoring field devices

This option is great for PLC programmers or other users who may want
to condition their data or limit the number of end points that need
to be managed to bring data to the edge. Reading data directly from
the PLC allows you to add scaling, build data types for managed data
or even build-related data points. All of this could also be done in your
cloud or other edge supervisory control and data acquisition (SCADA)
environments (again, more on that later).
Reading data directly from the PLC allows you

to add scaling, build data types for managed
data or even build-related data points.
Controllers
Next up the electron flow is controllers. This level involves the
simplest and perhaps the most crucial decisions you will make when
considering an edge solution for your plant floor. There are several
factors to consider in this layer of your automation system.
The first question to ask is: Do you like what you have? If the
answer is yes, look into what fieldbuses your controller has available. Are
you using an octal-based controller with tried-and-true RS-232 serial
communication or Data Highway Plus? Do you have the ability to install
more options? These are not barriers to getting to the cloud, just new
challenges that can be leveraged into useful data.
The next question to ask is: What communication buses do you

have? EtherNet/IP, Profibus, Profinet, EtherCAT, EthernetTCP, or ASCII?
None of these are necessarily easier than the others, but EthernetTCP
tends to make things a bit more streamlined.
Ultimately, what you are deciding in this layer is two-fold. First, do you
keep your current controller, or do you modernize? Second, what fieldbus
would you like to use? Keep in mind that while certain fieldbuses might
make getting to the edge easier, any of them can be harnessed.

Protocol conversion
The next layer up is protocol conversion. This layer may not be necessary
if you are using a controller with built-in edge connectivity. There are
several such controllers from most of the major players, but they are
relatively new, and as we have mentioned in this article a few times
now, we do not want superfluous upgrades to our systems.
If you are not using an industrial Ethernet–based system, then you

will definitely need protocol conversion. Even some of the Ethernet–
based systems will still benefit from being converted. To make working
with your data as easy as possible, getting to either EtherNet/IP or
Modbus TCP/IP could streamline your process.
Cloud and edge connectors

The first truly new piece of technology we will consider is the
cloud connector and edge connector. These terms are somewhat
interchangeable, but there is a difference.
A cloud connector is nothing more than a piece of software (which

could be on a separate piece of hardware) that allows you to publish
data to a cloud provider through a connection string. This could be
either predefined for providers like AWS or Microsoft Azure, or through
a generic address and server setting string. When using a cloud
A Red Lion Controls protocol

converter. (Image courtesy of
Allied Electronics.)

connector, you will have to do all of your data refinement, monitor

programming, or any other data harvesting and management tasking
through your cloud platform, often using something like node.js or
HTML and Java Script.
An edge connector, on the other hand, is a bit more sophisticated.

These can be integrated into a controller or can be standalone pieces
of equipment. Edge connectors offer several functions that help you
condition your data for use in visualization and data utilization systems.
Often, edge connectors will also work as protocol converters for fieldbus
systems. The choice of how to harness your data is completely up to
the end users. The best advantage of this flexibility is that it allows end
users to leverage their own strengths in either industrial or computer
programming.
The last layer

The last layer in the architecture could be any number of things,
depending on how you plan to use your data. It could be a cloud
server that you have programmed for anything from data logging to
messaging to visualization. You could also host an instance of several
versions of cloud servers on your factory premises, and this would
be called a “fog” application—helpful in industries that are highly
regulated and have stringent data security needs, as you can control
the entirety of the application. You could have moved into several
web-based SCADA services such as Inductive Automation’s Ignition. The Opto 22 groov
Or you may simply want a data historian that can hold values for RIO edge connector.
quality and accounting later. (Image courtesy of
Allied Electronics.)
In this last layer, the key is to decide how you want to leverage your
data and then compare the advantages of providers in the chosen space.
Advantages of an edge-connected factory

Now that we have gone through the layers of an edge-connected
factory, let’s look at the advantages of an edge-connected system.

Remote access to data

The most obvious benefit of edge-connected factories is the ability to
access your data when not on the factory floor. This remote access to data
comes with several side benefits. For instance, it gives you the ability to
track efficiencies or weak points inside your factory in a more business-
friendly platform. It also gives you the ability to bring data from multiple
sites into one place. This allows you to compare how your facilities differ
and effectively manage resource distribution, such as deciding to replace
a certain piece of equipment in one factory before another.
Dashboards at every level

Having an edge-connected factory also allows for multiple data streams
that can be tailored for particular users or levels of the business.
You can harness the low-level data stream for the maintenance and
continuous improvement staff to keep your operation up and look
for cycle improvements. You can create a higher-level dashboard that
shows live data in a simple format for operation managers to be able
to monitor the output of the facility and keep the process moving
smoothly. Lastly, you can create a feature-rich visualization system that
you can access from anywhere with an Internet connection to keep all
stakeholders in the loop. Perhaps the most useful aspect of a multilevel
dashboard system with remote access is the amount of support that
can be offered from off-site personnel to workers trying to remedy
breakdown situations.
Brand agnosticism
The essence of a cloud system is based on data, not hardware. As such,
part of the beauty of this approach is complete brand agnosticism.
Because you do not need to have your whole plant on one type of
fieldbus, you are free to add pieces in the quickest and cheapest
manner. This frees up capital in both a human and machine sense to
truly make your factory an on-demand data pipeline.
Take the edge connector component of your architecture. Several

edge connectors, such as the PLCnext from Phoenix Contact or the

groov EPIC or RIO systems from Opto 22, give programs access to
software packages with RESTful interfaces and APIs to connect to them.
This means one can query data from a field device into an automated
report that can be run on-demand through a dashboard or be waiting
for you in your inbox each morning.
One of the best software tools in the market for creating reporting,
messaging, and general on-demand information is Node-RED, an
open-source graphical flow-based programming tool. The beauty of
this interface is the simplicity in which data can be processed from your
machine into a simple dashboard or pushed into an email, text, tweet,
or Slack feed. Node-RED allows any novice JavaScript users to truly
understand their data.
Information on demand
Now for a fun twist. Have you ever been standing in your kitchen and
asked “Hey Siri,” or “OK Google,” or “Alexa, what’s the temperature
outside?” and within a handful of seconds and no additional effort on
your part, you know if you need to grab that jacket? We all have—it is
the new way of the world.
Node-RED provides
graphical flow-
based programming
in a web browser.
(Image courtesy of
Node-RED.)

Now imagine you are in your office, it’s 7:30 at night, and you
are finishing up that last report for the boss. You need to know total
productivity that day. Sure, we just built a dashboard that has that
information, and perhaps you have a report in your email that has the
numbers you need. But with a little bit of ingenuity, you can instead
ask your Alexa-enabled device about your factory, since Node-RED is
an Alexa skill. It is not as easy as setting up your Echo to play your kid’s
favorite tunes, but with just a little bit of perseverance (or some help from
a programmer) you can make a flow in your edge controller’s Node-RED
instance, register it with your Amazon account, and voilà. Now you can
say “Alexa, ask Node-RED what my total output was today.”
Now that’s information on demand.
Building an edge-connected factory

As we have seen in this article, building an edge-connected factory
does not require ripping and replacing your legacy equipment. You can
use your existing field devices, network connections, and controllers to
build an edge-connected system that lets you harness the full power
of your factory data. Not only will this give you remote insight into your
operation and let you create custom dashboards for every level of user,
it will also unlock true information on demand.
This article was sponsored by Allied Electronics. For more information

about building your own edge-connected system, visit AlliedElec.com.
ABOUT THE AUTHOR

Mark Russell is an experienced control system expert
and technical application support manager with Allied
Electronics & Automation, headquartered in Fort Worth,
Texas. Allied is an omni-channel authorized distributor of
industrial automation and control products, electronic
components, and electromechanical products. With more
than 3.5 million parts from 500+ brand-name suppliers
available on www.alliedelec.com, Allied is your one-stop
shop for all your automation and control solution needs.

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OPERATING
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How to Make your

Battery Smaller
and Less Expensive
Understanding your application By Sol Jacobs, Tadiran Batteries
can help to miniaturize your

battery-powered solution.
Choosing a battery for a consumer-grade device is relatively easy
compared to powering an industrial-grade device, where application-
specific requirements present far greater challenges. This is especially
true for low-power devices that need to be intelligently designed to
conserve energy so as to operate maintenance-free for decades in
remote locations and extreme environments.
Selecting a battery that is ill-suited for the application can cause

the power source to be unnecessarily large and expensive, especially
if it requires more frequent battery replacements, since the added
time and labor costs will far exceed the price of the batteries. For this
reason, specifying an industrial-grade battery is a critical decision that
requires a firm understanding of the various primary (nonrechargeable)
chemistries that are commercially available (table 1).

Primary Cell LiSOCL2 LiSOCL2 Li Metal Li Metal Alkaline LiFeS2 LiMnO2

(AA-size) Oxide Oxide
Bobbin- Bobbin- Lithium Lithium
type with type Modified Modified Iron Manganese
Hybrid Layer for high for high Disulfate Oxide
Capacitor capacity power
Energy density 700 730 370 185 90 335 330
(Wh/Kg)
Power Very high Low Very high Very high Low High Moderate
Voltage 3.6 to 3.9 V 3.6 V 4.1 V 4.1 V 1.5 V 1.5 V 3.0 V
Pulse amplitude Excellent Small High Very high Low Moderate Moderate
Passivation None High Very low None N/A Fair Moderate
Performance at Excellent Fair Excellent Excellent Low Moderate Fair
elevated temp.
Performance at Excellent Fair Moderate Excellent Low Moderate Poor
low temp.
Operating life Excellent Excellent Excellent Excellent Moderate Moderate Fair
Self-discharge Very low Very low Very low Very low Very high Moderate High
rate
Operating –55°C to –80°C to –45°C to –45°C to 0°C to –20°C to 0°C to 60°C
temp. 85°C, can be 125°C 85°C 85°C 60°C 60°C
extended to
105°C for a
short time
Table 1. Comparison of primary lithium cells
Here are some key considerations common to most low-power

applications:
Operating voltage – Simple math dictates that it takes two 1.5

V cells to deliver the same voltage as a single 3.6 V cell. Choosing a
battery with higher voltage can reduce the size and weight of the
device and potentially lead to even greater savings if fewer cells are
required.
Cold and hot temperatures – Extreme temperatures reduce battery

voltage and capacity under pulse. If a cell with a limited temperature
range is deployed in an extreme environment, oversized batteries may
be required to compensate for an expected drop in voltage under pulsed

load. This can be avoided by using a bobbin-type lithium thionyl chloride

(LiSOCl2) battery that features extremely high energy density along
with the ability to handle high pulses at extreme temperatures, thus
eliminating the need for extra capacity and/or voltage.
Lower self-discharge – Consumer-grade battery technologies

suffer from extremely high self-discharge of up to 8 percent per
month, thus requiring a larger battery to compensate for expected
capacity losses. Extreme temperatures also cause an accelerated self-
discharge rate with most battery chemistries. If the device needs to
operate maintenance-free for decades, then it is essential to specify
a battery with an exceptionally low self-discharge rate to eliminate
future battery replacements and to possibly enable the use of a
smaller battery.
For example, a superior-quality bobbin-type LiSOCl2 battery

features a self-discharge rate of 0.7 percent per year, retaining over
70 percent of its original capacity after 40 years. By contrast, a lesser-
grade battery using the exact same chemistry can experience a much
higher self-discharge rate of 3 percent per year, exhausting 30 percent
of its original capacity every 10 years, making 40-year battery life
unachievable.
Power is often confused with energy – Demands for battery

power (a measure of short-term energy consumed) are often confused
with the total amount of energy required (total battery capacity).
Certain wireless devices require relatively high amounts of power (high
pulses) for short bursts without exhausting a large amount of total
energy. Common examples include surgical power tools that may
operate for a few minutes, industrial actuation devices that perform
sporadically, and certain mil/aero applications.
Most commercially available battery technologies are not

designed to deliver a high power-per-energy ratio to satisfy this type of
requirement. They need to use more cells to compensate for their low
pulse design, which often leads to compromise solutions that add bulk
and unnecessary cell capacity.

Handling high pulse requirements – Throughout the

Industrial Internet of Things (IIoT) we are seeing growing demand
for applications requiring high pulses of energy to power two-
way communications and other advanced functionality. Alkaline
batteries can deliver high pulses due to their high-rate design,
but have major drawbacks, including low voltage (1.5 V), a limited
temperature range (0°C to 60°C), a high self-
discharge rate that reduces life expectancy,
and crimped seals that may leak. Alkaline
batteries often need to be replaced every
few months due to their very high self-
discharge rate, causing additional long-term
maintenance expenses as well as reliability concerns, which are often Bobbin-type
critical considerations for remote wireless applications. LiSOCl2 batteries can
be combined with a
patented Hybrid Layer
Standard bobbin-type LiSOCl2 batteries are overwhelmingly
Capacitor (HLC) to
preferred for long-term deployments in remote locations and harsh deliver up to 40-year
environments. These cells are not designed to deliver high pulses, service life along with
periodic high pulses to
experiencing a temporary drop in voltage when first subjected to a
power two-way wireless
pulsed load: a phenomenon known as transient minimum voltage (TMV). communications.
Consumer electronic devices often use supercapacitors to

minimize TMV. However, supercapacitors are ill-suited for most
industrial applications due to their inherent drawbacks, including
bulkiness, a high annual self-discharge rate, and a limited temperature
range. Solutions involving multiple supercapacitors also require the use
of expensive balancing circuits that draw additional current to further
increase self-discharge.
A simpler solution is to combine a standard bobbin-type LiSOCl2

cell with a patented Hybrid Layer Capacitor (HLC). The two technologies
work in parallel: the battery supplies low-level background current in
the 3.6 to 3.9 V nominal range; while the HLC acts like a rechargeable
battery to deliver periodic high pulses. This hybrid solution offers an
added bonus in the form of a unique end-of-life voltage curve plateau
that can be interpreted to deliver low-battery status alerts.

Long-life rechargeable Li-ion cells – If your

application demands enough energy to prematurely
exhaust a primary battery, it may require the use of a
rechargeable Lithium-ion (Li-ion) battery.
However, consumer-grade Li-ion cells have
serious performance limitations, including a
maximum battery life of approximately three
years and 300 full recharge cycles, a relatively
narrow temperature range with no ability to More rugged than consumer-grade rechargeable
discharge or recharge at extremely cold Li-ion batteries, TLI Series cells offer extended
temperatures, and the inability to generate service life (20 years and 5,000 full recharge
cycles), a wider operating temperature range
high pulses required to power two-way (–40°C to 85°C), and high pulse capabilities that
wireless communications (table 2). are ideal for energy harvesting applications.
TLI-1550 (AA) Li-Ion

Industrial Grade 18650
Diameter (max) [cm] 1.51 1.86
Length (max) [cm] 5.30 6.52
Volume [cc] 9.49 17.71
Nominal voltage [V] 3.7 3.7
Max discharge rate [C] 15C 1.6C
Max continuous discharge current [A] 5 5
Capacity [mAh] Up to 1000 3000
Energy density [Wh/l] 129 627
Power [RT] [W/liter] 1950 1045
Power [–20C] [W/liter] > 630 < 170
Operating temp. deg. C –40 to +90 –20 to +60
Charging temp. deg. C –40 to +85 0 to +45
Self-discharge rate [%/Year] <5 <20
Cycle life [100% DOD] ~5000 ~300
Cycle life [75% DOD] ~6250 ~400
Cycle life [50% DOD] ~10000 ~650
Operating life [Years] >20 <5
Table 2. Comparison of consumer versus industrial Li-ion rechargeable batteries

If the rechargeable device needs to operate for more than 300 full
recharge cycles, then additional consumer-grade Li-ion cells may be
required to reduce the average depth of discharge per cell. Choosing
a rechargeable battery with a higher cycle life can often reduce the
number of cells required. Industrial-grade rechargeable Li-ion batteries
are available that can last for up to 20 years and 5,000 recharge cycles
while also delivering the high pulses (15 A pulses and 5 A continuous
current) required to power two-way wireless communications. These
ruggedized cells also feature an extended temperature range (–40°C to
85°C), allowing them to be charged and discharged at extremely cold
temperatures.
Reducing battery size with solar-powered energy

harvesting
In some cases, PV panels and their companion rechargeable
batteries need to be over-designed to ensure reliable operation
under worst-case scenarios, such as five straight days of cloudiness.
One solution is to use primary (nonrechargeable) bobbin-type
LiSOCl2 cells as a backup solution to recharge the batteries on
sunless days, thus enabling the use of smaller PV panels as well as
smaller batteries. This type of backup energy supply is especially
valuable during months of extended darkness (polar winters) or if the
battery requires extended storage.
Cheaper can get more expensive – There are certain situations

where a short-term solution is preferred to achieve the lowest possible
initial purchase price. By contrast, many industrial applications require
long-term solutions to achieve a lower cost of ownership over the
lifetime of the device.
If your wireless device is intended for long-term deployment in

a highly remote and inaccessible location, then you will most likely
need a battery-powered solution that minimizes future battery
replacement. The additional cost of labor, loss of data integrity, and
downtime will far exceed any initial savings realized by specifying a
lower-quality battery.

In addition, you need to

be wary of the hidden costs
associated with excessive
battery size and weight. For
example, a compact and
lightweight power supply
could be especially valuable to
research scientists conducting
experiments in frigid Artic
conditions, as they have
limited dexterity and need to Oceantronic's GPS/ice buoy being
conserve energy. Solutions retrieved by helicopter to the Arctic
for use in experiments measuring
that reduce battery size and
wind, temperature, sunlight and
weight also serve to minimize ice thickness near the North Pole.
transportation costs, as the Courtesy Sigrid Salo NOAA/PMEL.
shipment of lithium batteries
has become more expensive
due to increasingly restrictive
UN and IATA shipping Oceantronics’ hybrid
regulations. lithium pack was
redesigned to reduce
As a general rule, if the wireless device is easily accessible size and weight.
The original battery
and operates at ambient room temperatures, then consider
pack (left) used 380
using a consumer-grade battery. However, if your application alkaline D-cells (54
involves a long-term deployment in a remote location or extreme kg). The improved
battery pack (right)
environment, then pay a little extra for an industrial-grade lithium
uses 32 bobbin-type
battery that can operate for the life of your device in order to LiSOCl2 D-cells and
reduce your total cost of ownership. four HLCs (3.2 kg).
ABOUT THE AUTHOR

Sol Jacobs is VP and general manager of Tadiran
Batteries. He has more than 30 years of experience in powering
remote devices. His educational background includes a BS in
engineering and an MBA.

| TC11-02USA |
System-integrated IIoT with

standard PC-based control
www.beckhoff.us/Industrie40
Beckhoff provides the ideal foundational technologies for Industrie 4.0 and Internet of Things (IoT)
applications via standard PC-based control. With the TwinCAT engineering and control software, machine
control systems can be extended to support big data applications, cloud communication, predictive
maintenance, as well as comprehensive analytical functions to increase production efficiency. As a
system-integrated solution, TwinCAT IoT supports standardized protocols for cloud communication and
enables the easy integration of cloud services right from the machine engineering stage. In addition to
fault analysis and predictive maintenance, TwinCAT Analytics offers numerous opportunities to optimize
machines and systems in terms of energy consumption and process sequences.
Single-pair Ethernet:
The Infrastructure for IIoT
SPE enables IT and automation
to walk hand in hand.
The Internet of Things (IoT) describes the networking of virtual and By Matthias Fritsche,
real physical objects to make them work together using information Jonas Diekmann,
and communication technologies. Objects in our daily lives acquire and Rainer Schmidt,
HARTING
digital skills. Thus, these physical objects can also participate in digital
networks. This process also takes place in industrial applications,
where it is called the Industrial Internet of Things (IIoT).
More and more industrial components are also becoming smart,

intelligent participants. These connections are no longer limited to
internal company networks, but devices are also becoming part of
the Internet. The increased collection, evaluation, and use of data
creates the need for more powerful infrastructure. At the same time,
this infrastructure is expected to take up less space and use fewer
resources. Efficiency is the key word here, as more sensors with their
increasing bandwidth requirements become network participants.
New technologies are required.

In the automation world, the phrase “automation island” was coined

to refer to the entire range of independent and proprietary (yet analog)
networks that dominate the field level. This classic system schism
between Ethernet/Internet and analog fieldbus systems should now be
broken up and eliminated. The goal is to extend Ethernet from the cloud
to every sensor. Each sensor will be smart and capable of being evaluated
individually—and therefore an essential step on the road to IIoT.
The appropriate infrastructure is still missing, however. Current

networks are based on two-pair or four-pair cables and connectors. This
conventional infrastructure is too large and too expensive when you
think about the sheer number of sensors and actuators that have to be
connected in the field. Bus cables are designed to be space saving and
ough economical for a reason.
MPE VS. SPE

he
The solution for a high-performance Ethernet infrastructure is
based on a single pair of twisted copper wires: single-pair Ethernet (SPE).
art
oud
assic
an now
r. Thus,
velop-
sor
alization
system
evel
ew TCP/
as the
ing,
gabit
lready
s. IEEE
2.3ch),
MPE stands for multipair Ethernet, which uses two- or four-wire pairs.
4
MPE stands for Multi Pair Ethernet, which uses two or four wire pairs

One pair is enough – SPE makes the field level smart

From the cloud to the sensor: this is a claim that has recently been
heard more often in the automation environment. This claim is normally
made in connection with megatrends such as IIoT and Industry 4.0
(I4.0). It refers to continuous TCP/IP–based communications based on
Ethernet, which currently mostly ranges from cloud applications down
to the distribution level in manufacturing. Where previously there was
a classic break in communication systems between Ethernet and
bus systems, modern components can now bring fast Ethernet (up
to 1 GBit/s) to the smallest application using just one twisted wire pair.
Thus, SPE enables consistent usage of TCP/IP for the first time. And that
drives the development of new devices and application fields, especially
for sensor/actuator networks. The sensor becomes “intelligent”
and a part of the overall network. This speeds up parameterization,
initialization, and programming. When using SPE—whether with a
simple state sensor or a modern vision system consisting of a high-
resolution camera—the Internet of Things becomes reality, and the field
level becomes smart.
The roots
After the automobile industry, which needed a replacement for the
CAN bus, identified this new TCP/IP–based transmission method,
the IEEE 802.3 working group released the first SPE standard as the
standard 100BASE-T1 in IEEE 802.3bw-2015 clause 96. Self-driving or
semi-autonomous driving, however, requires even higher data rates.
So, after the first SPE standard for 100Mbit/s, a gigabit version followed
quite quickly. Ethernet technology based on IEEE 802.3bp 1000BASE-T1
is already available today and delivers 1 Gbit/s transmission speeds using
only one pair of copper wires.
IEEE published a standard in 2021 for up to 10 Gbit/s (IEEE 802.3ch),

which is required for high-resolution sensors and video transmissions.
A standard for only 10 Mbit/s (IEEE 802.3cg) was published in February
2020. This standard is very relevant for many industry sectors, as it
allows transmission distances of up to 1,000 meters and can therefore

replace almost all fieldbuses. Another working group was set up in

March 2019 to deal with transmission rates above 10 Gbit/s. Their targets
are 25 Gbit/s and 50 Gbit/s. These high-data rates are the technology
required for autonomous driving and new zonal computer architectures
within vehicles. SPE is the ideal technology for this.
Industrial automation recognizes this potential

The production and automation industry has a similar problem as the
automotive industry in that it demands integrated industry, meaning
the integration of the field level (sensor/actuator networks) down to the
tool and workpiece within automated production. It requires a network
strategy that can be used universally while also being sustainable well into
the future. In other words, IT solutions are needed that are not proprietary
and provide the availability and security standards that are common in the
industry. SPE is the right technology for this. It offers many advantages:
▶ end-to-end TCP/IP communications as an alternative to proprietary

bus or power interfaces
▶ high security and 100 percent availability
▶ enormous range from a few meters up to more than 1000 meters
Single-pair Ethernet transmision length and speed

Legend:
MultiGig IEEE 802.3ch - MultiGigBASE-T1 Standard final released
2.5/5/ Standard in progress
10 GBit/s HARTING internal
tested transmission
length
1 GBit/s IEEE 802.3bp - 1000BASE-T1

Data speed
100 Mbit/s IEEE 802.3bw - 100BASE-T1
10 Mbit/s IEEE 802.3cg - 10BASE-T1
0 5 15 40 100 250 500 1000

Transmission length [m]
Graphic display of range and transmission speeds for the current IEEE 802.3 SPE standards.

▶ minimal space required for cables and distributors
▶ easy to install
▶ simultaneous power supply for end devices and sensors using

power over data line
▶ rechargeable and nonrechargeable batteries are not needed,

which is an important environmental consideration.
▶ reduces costs with better operational reliability.
Thus, SPE is a technology that removes most of the restrictions of

wired communications. It also compensates for the disadvantages of
cable compared to other technologies (such as wireless)—based on the
types of applications considered here. In summary, SPE highlights the
advantages of copper fiber optics as a transmission medium. Wireless
communication is also facing new competition.
Applications
Ethernet is represented through all types of industrial applications, from

the company headquarters to the control level. This is where converters and
gateways are currently used to establish a connection to fieldbus systems.
However, as more sophisticated and powerful sensors and actuators are also
finding their place at the field level, there is a clear need for Ethernet at the
field level. A large number of field devices can be supplied with Ethernet
in a space-saving and cost-effective manner when SPE is used. This makes
converters and gateways obsolete, because every sensor IP can be addressed
in a deterministic manner (with TSN). Simply speaking, MPE can be used all
the way to the field level and then continuously with Ethernet directly at the
field level. Using SPE, the claim “from sensor to cloud” becomes reality, and
HARTING components provide the infrastructure for I4.0 and IIoT.

Power over data line

Like multipair cabling, there is a new standard for remote power supply
for SPE that is analogous to Power over Ethernet (PoE); it is called power
over data line (PoDL) (IEEE 802.3bu). This combination of data and
power using very small plug-in connectors and single-pair cables helps
to support the trends toward miniaturization, higher data rates, and
modularization for more complex systems. These are all prerequisites
for the rapid development of nonvehicle SPE applications in industry,
smart cities, buildings, etc.
Ethernet over copper for over 1000 meters?

SPE technology has already achieved the same performance as today’s
predominant “multipair Ethernet” (MPE) within a very short period of
time. Currently, the only limitation is the limited range for 100 Mbit/s
and gigabit SPE (15 m and 40 m respectively), which results from the
requirements of the main target group in the automotive industry.
Single-pair Ethernet transmision length and speed
100 Gbit/s
25 / 50 Multi
Gig
Data speed
2019/2020
MultiGig 50 m?
2.5/5/
10 GBit/s 23 h-M
IEEE 802.3ch ltiGi
MultiGigBASE-T1
06/2016 100 – 250 m?
1 GBit/s
0BASE T1
IEEE 802.3bp - 1000BASE-T1
11/2015 200 – 500 m?
100 Mbit/s
0BASE T1
IEEE 802.3bw - 100BASE-T1
2019
10 Mbit/s IEEE 802.3cg - 10BASE-T1
0 5 15 40 100 250 500 1000
HARTING internal tested transmission length

Experts agree that greater transmission lengths can also be

achieved. The chart shows the extended transmission lengths that are
technically possible. However, for these extensions of the SPE standards
to be covered by IEEE 802.3 and, in particular, for the semiconductor
industry to invest in the development of these new chip sets, it is
necessary to define the new target applications and suitable market
potential. This requires the open cooperation of all interested parties
for the extended SPE ranges. The first presentations at IEEE 802.3 have
already been published and were well received. Further supporters for
these target standards are very welcome.
There is still a long way to go before the

single-pair Ethernet infrastructure and its
associated potential are firmly established.
Currently several solutions and standards are
being discussed.
T1 industrial style: All standards united in support

There is still a long way to go before the SPE infrastructure and its
associated potential are firmly established. Currently, several solutions
and different standards are being discussed on the market, with a
particular focus on the interfaces for SPE. Users are now rightly asking
whether manufacturers will develop a consistent and compatible
solution based on a uniform standard, or whether there will be multiple
solutions and incompatible mating faces. Thus, it is necessary to take
a closer look at the cooperation of various standards committees and
their work relating to Ethernet communication.

IEC SC46C IEC SC48B IEC TC/

Components Wires and Electrical connector SC86A/B/C
committees symmetric cables Fiber optics
CLC TC 215
Electrotechnical aspects of
telecommunication equipment
Cabling systems
ISO/IEC SC25 WG3
Customer-premises cabling CISPR-I
EMC for IT equipment
User groups IEEE 802.3 IEC SC65C ISO/IEC JTC 1 IEC TC 100
Ethernet Industrial networks ITU-T
ISO/IEC SC25 WG3: ISO/IEC JTC 1/SC 25/WG 3 plays a central role in
the standardization. This is where the cabling standards in compliance
with ISO/IEC 11801 are created and maintained.
IEC SC46C: Committee for cabling components: copper data cables
IEC SC48B: Committee for cabling components: connectors
IEEE 802.3: Cable-based Ethernet protocol standards
IEC 61156-x – Standardization of single-pair Ethernet

cables
Within the IEC SC46C working group for the standardization of data
cables as bulk goods, the following standards are currently in progress:
▶ IEC 61156-11: SPE data cable up to 600 MHz bandwidth for fixed
installations (final published)
▶ IEC 61156-12: SPE data cable up to 600 MHz bandwidth for flexible
installations (CD available)
▶ IEC 61156-13: SPE data cable up to 20 MHz bandwidth for fixed

installations (CD available)

▶ IEC 61156-14: SPE data cable up to 20 MHz bandwidth for flexible

installations (planned).
Further standards projects, for example for higher bandwidths to

support data rates above 1 Gbit/s, will be processed in the future.
T1 Industrial specifications
IEC 63171-6 – Standardization of single-pair
Ethernet connection technology
HARTING submitted the first
Mechanical draft standard for the SPE
performance
• Typicall
connector to SC48B Ethernet
as early Interface
as 2016, andDesign
it was published as
• Plug as pin version
IEC 61076-3-125
• up to the
Jack CD document.
as socket version In 2017, the company
• AWG 28-22
CommScope submitted another SPE mating face for standardization
• 1000 Mating cycles for IP20 and 500 for M12/M8
and decided to
• create thesteel
Stainless IECshielding
63171 series
platesof standards for all SPE
• Stainless steel looking latch
connectors. Accordingly, the project team PT63171 was set up at
• Temperature range: -40°C up to +85°C
SC48B and commissioned
• with the
Shock and vibration task ofacc.
resistance preparing this new
to IEC 61373
Category 1B (Railway Standards)
series of standards. The standards already in process up to this
point will be completed as self-contained documents and later
Electrical Performance
integrated into• this new
Rated series
Voltage: of standards as revisions.
60V
• Rated Current: 1,5A@60°C
• Voltage
The following proof projects are currently in progress:
standards
• pin-to-pin 1000V DC
• pin-to-gound 2250V DC acc. to IEEE 802.3cr
▶ IEC 63171:• Base
360°standard
Shielding with all necessary specifications and test
sequences• (CDV
EMC resistance
available)acc. to E3
▶ IEC 63171-1: SPE connectors from CommScope based on LC

interlock, for M1I1C1E1 applications
HARTING published
Technology Group | First Name Last Name | 2019-00-00 | Title of Presentation
▶ IEC 63171-2: SPE connectors from Reichle & De-Massari for M1I1C1E1
applications published
▶ IEC 63171-3: SPE connectors from Siemon based on a pair of the

well-known Tera connectors for M1I1C1E1 applications (withdrawn)
▶ IEC 63171-4: SPE connectors from BKS for M1I1C1E1 applications (CD
available)
▶ IEC 63171-5: SPE connectors from Phoenix Contact based on the

IEC 63171-2 mating face for M2I2C2E2 and M3I3C3E3 applications
(second CDV in preparation)

▶ IEC 63171-6 (previously IEC 61076-3-125): SPE connectors from

HARTING and TE Connectivity for M2I2C2E2 and M3I3C3E3
applications published since 23 January 2020, second edition in work.
Note: IEC 63171-1 (LC Style) and IEC 63171-6 (Industrial Style) are
complete standard documents with all necessary specifications
and test sequences. All standards started after this refer to the base
standard IEC 63171 and describe only the different mechanical versions.
The cabling standards for SPE

SPE and its standardized connectors are incorporated into the current
cabling standards. Internationally, this applies primarily to the series
of standards for structured cabling according to ISO/IEC 11801:2017
and, in a similar way, to the European series of standards in CENELEC
according to EN 50173. Here, SPE is included in part 3 of industrial
cabling in the annex (amendments). The central document for these
annexes is the ISO/IEC TR 11801-9906, Balanced single-pair cabling
channels up to 600 MHz for SPE.
The implementation of SPE in the ISO/IEC 11801 documents is very

important. It is the only standard to describe the cabling channels with
all the necessary parameters (length, number of connections, bandwidth,
and the complete set of technical transmission-related parameters
including NEXT, FEXT, and shielding properties) in relation to the MICE-
specified environment, so that this can be tested with measurements
after the installation parallel to this. The industrial installation standards
will be adapted as a basis for the cabling of automation solutions
according to IEC 61918 (IEC SC65C). It remains to be seen to what extent
this will affect the automation profiles themselves. What is certain is that
PI (with PROFINET according to IEC 61784-5-3) and ODVA (with EtherNet/
IP according to IEC 61784-5-2) are actively involved in the further
development and implementation of standards for SPE.
In conjunction with the component standards for connectors and

cables, all users of SPE can receive clear guidelines for the construction
and testing of appropriate transmission paths. For 1 Gbit/s SPE, this
cabling is initially limited to a range of 40 m. For the 10 Mbit/s variant,
ranges of 1000 m and beyond can be implemented.

Harmonization mating face/connector dimension

cable diameter
Further documentation on SPE cabling relevant to the
U.S., Canada, and Mexico are being prepared at ANSI/TIA-568.5
and TIA In order
TR-42.7. to meetinthe
This is updated the TIA-42 documents as an
addendum: various requirements
TIA-1005-A-3. ofthese additions is
The content of all
the industry,
largely identical. it is AWG
important to cover the 18/16
These cabling standards provide the user with information
widest possible range of
about the structure of the cabling, the cabling components that
cables. Therefore we
should be used to achieve the performance specifications, and
have matched the
the limit values for testing the cabling. Thus, they are the most
AWG
28/22
dimensions of the T1
important instrument for setting up and commissioning SPE
Industrial with the cross
cabling systems. They also ensure compatibility between devices
2,8
and cablingsections
by providing AWG 28-16.
references So
to component standards
that on the one hand
(e.g., connectors according to IEC 63171-6). This compatibility is
applications
a basic prerequisite that functionality
for the proper require of networks and
3,1
connectionsvery
basedthin and
on SPE flexible
and, thus, the foundation of IoT/IIoT.
cables as well as
The use of cabling components other than those specified in Ø 0,5
applications
ISO/IEC 11801-3 Amendment 1in harsh
would be theoretically possible.
6,1
environments
However, these would no longer can be to the standard and
conform
served.
would risk incompatibilities and loss of functionality.
For this reason, at the start of 2018, ISO/IEC JTC 1/SC 25/WG 3 and
HARTING
TIA-42 started international selection Technology
processes Groupuniform
to define | First Name Last Name | 2019-00-00 | Title of Presentation
interfaces. These two selection processes were co-initiated by IEEE 802.3,

which requested a recommendation for a SPE MDI (SPE device interface)
from ISO/IEC and TIA.
More than 20 national expert panels participated in this selection

process. Two connector-mating profiles emerged from this selection
process as the preferred choices:
▶ For building wiring, the mating face according to IEC 63171-1. This
mating face is based on the proposal by CommScope.
▶ For industrial and applications adjacent to industry (M2I2C2E2 and

M3I3C3E3), the mating face according to IEC 63171-6 (formerly IEC
61076-3-125). This mating face is based on the proposal made by
HARTING T1 Industrial.

The selection process at TIA-42 has confirmed the results of ISO/

IEC, and as such there is significant global consensus on the SPE
interfaces. These selected mating faces are now being incorporated into
the corresponding international cabling standards. IEEE 802.3 has also
specified these SPE interfaces in the IEEE 802.3cg as the recommended
media dependent interface (MDI).
This is required for large-scale usage. Thus, it is also required

to successfully market SPE technology along with the consistent
compatibility of devices, cables, and connectors throughout different
types of applications. This provides planning security for all market
participants.
Note that MICE describes environmental conditions for

installations. It also provides planners and users with valuable
information for specifying technical equipment and cabling. The
requirements for mechanical robustness (M), IPxx degree (I), chemical
and climatic resistance (C) and electromagnetic safety (E) are described.
In the broadest sense, M1I1C1E1 describes an environment similar to
that inside an office building. M3I3C3E3 describes a fairly extreme
environment such as that found in industry or outdoors.
Deep-dive into technology

Even if twisted pairs of wires are required for existing four-pair
data cabling as well as for SPE, the requirements for cabling and
connection technology are quite different. This is especially the case
for transmission lengths with the currently available SPE transmission
standards, as well as the radio frequency (RF) requirements, which are
particularly evident for these required bandwidths.
Four-pair Ethernet cabling (MPE) Single-pair Ethernet (SPE)

Data rate Bandwidth (Cat.) Transmission length Bandwidth (Cat.) Transmission length
10 Mbit/s 16 MHz (Cat. 3) 100 m 20 MHz 1000 m
10 Gbit/s 500 MHz (Cat. 6A) 100 m 4-5 GHz tbd. 15 m

Migration from multipair cabling (MPE) using SPE

(cable sharing)
High data rates are possible over one pair of wires—so why not
combine four SPE paths in your existing infrastructure? This idea of
using four-pair cabling for SPE by means of “cable sharing” is quite
straightforward. This is possible for special cases, but it does not really
make sense technically and economically. On the one hand, SPE
cabling requires higher bandwidths compared to MPE, especially
for cross talk. Also, compared to MPE with 100 meter transmission
length, so far SPE has only shorter transmission lengths of 40 meters
at 1000BASE-T1 for shielded cables. For this migration scenario, the
user must check each path of the installed cabling for SPE. Thus, the
actual economic viability of such usage strategies is questionable. For
example, for an installed Cat. 6A cabling to qualify for 1000BASE-T1,
the transmission length must not exceed 40 meters, and the
corresponding RF parameters must be qualified for up to 600 MHz. If
all this matches perfectly, you could then transmit four times 1 Gbit/s
over SPE, even though this Cat. 6A cabling path could also support
10 Gbit/s MPE.
The connection technology for SPE

Individual connector types are inseparably linked to a specific
application and have been, of course, internationally standardized.
Well-known examples of this are the RJ45 connectors for Ethernet
and the concise HDMI or DVI connectors for video transmission.
Thus, standardized interface connectors are required in order to have
a successful market launch for new network technologies such as
SPE. This is because only with standardized interfaces is it possible
to network a wide variety of devices in a uniform data network. The
design of the SPE connectors (according to IEC 36171-6) was based
on the specifications of the associated IEE 802.3 standards and other
market requirements.

Overview of the electrical characteristics

Nominal voltage
A differential voltage signal of ±1 V is usually used for pure Ethernet
transmissions. When determining the nominal voltage of an SPE
connector, however, the parallel use of the two wires must also be
considered for the remote power supply. The method used for this in
SPE is power over data line; it is standardized according to IEEE 802.3bu.
Similar to PoE, the maximum rated voltage is 48 VDC, resulting in a
maximum supply voltage of 60 VDC to the power sourcing equipment
(PSE). In contrast to PoE, PoDL defines additional typical onboard
voltages of 12 V and 24 VDC, which are used in vehicles.
Insulation voltage
Even though the IEEE 80.3 SPE standards do not define explicit
specifications for insulation requirements pertaining to the largest
group of users in the automotive industry, the same requirements are
applied for normal applications in building and industrial cabling as
exist for four-pair Ethernet with 1.5 kV (rms) contact–to-shield and 1.0 kV
(rms) contact-to-contact (refer to Section 126.5.1 IEEE 802.3cr).
Rated current
The PoDL requirements are also decisive when determining the rated
current. In the current standard, Table 104-1 IEEE 802.3bu specifies
the maximum feed-in power as 63.3 W, which corresponds to a
maximum supply power at the powered device of 50 W. This results in
1.36 A at 48 V at the minimum permissible supply voltage. However, a
rated current of 4 A DC has been selected to maintain a sustainable
interference level into the future.
Background: According to the National Electric Code (NEC) for the

North American market, the maximum power for NEC Class 2 devices is
limited to 100 W; this is also the maximum remote power supply power for
the PoE standard IEEE 802.3bt. This means that future PoDL expansions
will remain below 100 W and the 24 V supply voltage used in industrial
automation will result in a rounded maximum-rated current of 4 A.

ments per-
or normal RF transmission parameters
t–to-shield For transmitting data, SPE uses a full-duplex connection on a
differential wire pair with an impedance of 100 ohm. To achieve lower
interference sensitivity (especially for use in electric vehicles), a lower
d, Table coding with PAM3 up to 1000BASE-T1 and PAM4 for 2.5/5/10GBASE-T1
mum supply was chosen for SPE. This increases the bandwidth requirement
e supply enormously compared to the multipair Ethernet standards. For
eforlevel
insulinto
ation requiremexample,
ents per- IEEE 802.3ch for multi-gigabit SPE up to 4 GHz at 10GBASE-T1
RF transmission
for norm
quirements are applied (compare al parameters
with 10GBASE-T of only 500 MHz) is currently being discussed.
with
mum 1.5 kV (rms) contaForct–totransmitting
-shie ld data, SPE uses a full-duplex connection on a differential wire pair with an impedance of 100
Therefore, the RF requirements for cable and connection technology
ower for Ohm. In order to achieve
are increasing, and a lower interference sensitivity
very symmetrical connector (especially
designfor is the use in electric vehicles), a lower
necessary
ndt. Inthe
the 24
coding
curreVnt standard,
to Table with PAM3
reliably meetup to 1000BASE-T1
these stricter RFand PAM4 for 2.5/5/10GBASE-T1
requirements. For this reason,was thechosen for SPE. This increases
corresponds to a maxithe mumbandwidth
contacts
supply requirement
of the T1 Industrial enormously compared
connector to the multi-pair
are arranged Ethernet (MPE)
symmetrically in astandards. For example,
the minim um perm issib le supp ly
IEEE802.3ch
completelyfor multi-Gigabit
closed shield SPE up to 4 GHz at 10GBASE-T1 (compare with 10GBASE-T of only 500 Mhz) is
housing.
a sustainable inter ference level into ion para
transmiss Therefore, mete rs
currently beingRFdiscussed. the RFuplexrequirements for cable and connection
connection on a differential wire pair with
an impetechnology
dance of 100 are increasing
For trans mitti ng data, SPE uses a full-d
lower
merican market, the maxi andmum The symmetrical
a very coupling capacitances
connector design andisinductances
Ohm. In order to achieve lower inter feren
necessary
ce sensitivityto
ofcially
both
reliably
(espe conductors
formeet
the these
use ric vehic
in electstricter RF arequirements.
les),
For this
was chos en for SPE. This incre ases
m remote power supplyreason, to
powe r forshielding or the printed circuit
the board
PAM 4 are
for 2.5/ 5/10GBASE-T1
identical. There is no
the contacts of PAM
coding with the 3T1 Industrial connector are arranged symmetrically
up to 1000 BASE -T1 and in a completely closed shield
and the 24 V
ll remain below 100 W interference ly comp ared to the multi-pair Ethernet (MPE) standards. For example,
with
band the
width requ irement enormous
differential data transmission. This means that the
housing. The coupling capacitances and inductances
the of both conductors pare withto10GBtheASE-shielding or Mhz)
T of only 500 the isprinted circuit
ated current of 4 A. IEEE8 02.3 ch for mult i-Gigabit SPE up to 4 GHz at 10GBASE-T1 (com
signal path is identical in both conductor paths, and differences ectioin theology are
n techn incre asing
board are identical and there is no interferenceRFwith
currently being discussed. Therefore, the
theents
requirem differential
for cable anddata
conntransmission. This means that the
For this
signal propagation time are avoided. n is necessary to reliably meet these stricter RF requirements.
signal path is identical
and a very in
symmbothetricconductor paths and differences in the signal
al connector desig propagation
ally in a completely closed
time are
shiel d avoided.
connector are arranged symmetric
reason, the contacts of the T1 Industrial shielding or the printed circuit
inductances of both conductors to the
housing. The coupling capacitances and mission. This means that the
ference with the differential data trans
board are identical and there is no inter l prop agation time are avoided.
paths and differences in the signa
signal path is identical in both conductor
Symmetrical design of
the mating face according
to IEC 63171-6
according to IEC 63171-6

Symmetrical design of the mating face
Symmetrical design of the matingactface according to IEC 63171-6

Cont
12
12
Contact
54
Technical design of the SPE connection technology in

compliance with IEC 63171-6
The aim of the design for the SPE interface was to consider all the
electrical parameters already explained above with sufficient reserve for
future higher bandwidths, the requirements regarding a remote power
supply (PoDL), and the variety of housing designs already accepted and
widely used on the market. Multiple factors were important: a balanced
relationship between the market demands for miniaturized interfaces
and high robustness, as well as good handling and a well-designed
termination area to match the wire and cable diameters to be used.
Following these design objectives, 0.5 mm contacts with a contact

gap of 2.8 mm were chosen for the contact system. The contact spacing
is matched to fit with the cable cross-sections to be connected. For the
short transmission distances with 100BASE-T1 and 1000BASE-T1, AWG
26 or AWG 22 conductors with wire core diameters of approximately
1 mm or 1.6 mm diameter can be used. For the 10BASE-T1L 1000 m with
longer range, however, AWG 16/18 conductors with a typical wire core
diameter of approximately 2 mm are required; thus, a 2.8 mm contact
distance is optimal.
M12 for Transportation

According to the IEEE 802.3 standards, longer ranges can only
be achieved with shielded transmission paths. For this reason, and to
ensure secure transmission even in harsh industrial environments,
a shielded design has been
consistently implemented. At the
same time, these shielding plates
also provide the robust mechanical
interlocking for the IP 20 version.
The metallic latch lever eliminates
the problem of the broken latching
mechanism—a common criticism
with RJ45. M8 and M12 circular
connectors have established
themselves for usage in industrial
applications.
HARTING Technology Group | First Name Last Name | 2019-00-00 | Title of Presentation 13/19
Accordingly, screw-type, snap-in, and push-pull interlocks have

been added for the M8 construction types of the new SPE mating
face to make them a uniform “data container.” The M12 designs with
screw and push-pull interlocks are also standardized, to accommodate
the large cable cross-sections for the 1000-m 10BASE-T1L channel.
This means that the same mating face is used in all designs, and
IP20 connectors can also be connected to the IP65/67 interfaces for
parameter configuration or testing.
Usage of the widely accepted M8/M12 types ensures good market

acceptance while also reducing the necessary investment costs, since
many suppliers have the corresponding housing designs already
available. The use of identical socket and plug-in connector inserts (“data
containers”) throughout all construction types guarantees that there are
uniform technical characteristics in all the product series. This makes it
easier to implement cost-efficient production through economies of scale.
Thus, the SPE interfaces according to IEC 63171-6 provide an internationally
standardized mating face that optimally supports the future usage of SPE
in industrial applications. By using this standardized SPE data container,
it is also easy to integrate this IEC 63171-6 mating face into other designs,
such as the connector system with internal M12 push-pull interlock that is
currently being developed as a new standards project.
An ecosystem of strong partners

Industrial Ethernet is becoming widespread in automation and I4.0
applications. More and more devices and solutions from a wide range
of sectors are becoming “smart”—for this, they need the right Ethernet
infrastructure. The SPE ecosystem shows us how technology, standards,
infrastructure components, devices, and test equipment logically build
on and support each other. They ultimately provide a solid foundation
for the digitization of multiple different markets.
That is why HARTING has worked actively in the field of

standardization and developed an infrastructure suitable for industrial
usage. HARTING now actively supports device manufacturers as they
implement SPE.

All partners together wish to provide the building blocks for the
SPE ecosystem. They see themselves as partners for the industrial
Ethernet user groups, since SPE can provide a new infrastructure for
these protocols (such as PROFINET), which would enable IP-based
communications all the way down to the field level. Just as the slogan
promises: “SPE – the infrastructure for IIoT.”
This means that SPE will not only support many applications in
a more efficient and environmentally friendly manner, SPE will also
enable many new applications. In addition to the currently predominant
discussion of the technical side of digitization, the social challenges
and effects of digitization on our democratic societies, which were only
formed at the beginning of the first industrial revolution, must also
be discussed throughout society. In his book The Web of Digitization:
Humanity in Upheaval – on the Way to a New Worldview, published
in 2018, Ulrich Sendler gives a detailed overview of the development
of industry, technologies, and society. This is a book that is worth
reading, with many suggestions about the steps required to ensure that
digitization succeeds socially and serves the well-being of humankind.

Where are we headed?

New applications fields—such as autonomous driving, IoT, and IIoT—
require new and more powerful network technologies. SPE is one
such technology. The ability to simultaneously supply power and
data to devices with only one connection is a huge advantage over
wireless solutions. The remote power supply via PoDL makes batteries
and accumulators superfluous—a big advantage for environmental
compatibility and sustainability. Cable-based transmission methods
have the additional advantage of no regulatory restrictions regarding
the usable frequency ranges, so no license fees are incurred for
the necessary frequency bands. Because frequency bands are not
allocated uniformly (even internationally), equipment with radio
interfaces must always be adapted to different market requirements.
1 Switch
This is not necessary for cable-based transmission methods. Thus,
uniform devices can be developed that can be used globally.
Together with the time

sensitive network (TSN)
standards developed in IEEE
802.1, Ethernet technology is
being expanded along with all
necessary mechanisms in order
to implement determinism for
data communications—this is
a prerequisite for all real-time
applications.
SPE, therefore, qualifies as a

perfect infrastructure solution and
“enabler” for IoT and IIoT, making
it an important building block for
integrated industry.
For SPE to fully develop this

potential within an ecosystem,
HARTING Technology Group | First Name Last Name | 2019-00-00 | Title of Presentation 10/19

the partners from different industrial sectors must work together

intensively and make this vision possible. This starts with the joint
international standardization in IEEE 802, ISO/IEC, and TIA. It continues
with the development and production of the necessary components
starting with semiconductors, magnetic components, connectors/
cabling components, and measurement technology. Only when the
standards and components are available (at least in initial sample
quantities) will users be able to equip their multitude of possible
devices with SPE transmission technology and open up a wide range of
new applications.
ABOUT THE AUTHOR

Matthias Fritsche is product manager and Ethernet connectiv-
ity expert at HARTING. He keeps an eye on the latest trends and
developments in industrial Ethernet communication for HARTING.
He also sits on various standards committees and actively pro-
motes standards and norms for users. Fritsche has both accompa-
nied and driven the topic of single-pair Ethernet for several years
and sees it as the future infrastructure for industrial networks.
Matthias Fritsche is product mana- Jonas Diekmann JonasisDiekmann

a technical is a technical
editor at the HARTING Rainer Schmidt is the business
Technology
ger and Ethernet connectivity expert editor at the HARTING Technology development manager for industri-
at HARTING. He keeps an eye on Group, the where Group,he is responsible for PR,for
where he is responsible press, marketing, and
al cabling con-
at the HARTING Techno-
latest trends and developments in PR, press, marketing and content logy Group in Germany.
industrial Ethernet communication tent management for the
management forelectronics
the Electronicsdivision.
di- The co-author hasin international
Schmidt is active
for HARTING. He also sits on various also been working vision. on
The the
co-author
topic has
ofalso
SPEbeen standardization,
for several years and bring- for example in IEC
standards committees and actively working on the topic of SPE for se- SC65C (IEC61918, IEC61784-5
promotes standards and norms for ing customersveral andyears
readers nearer
and bringing to the subject with
customers technical
series), Cenelec TC215 (EN50173
users. The author has both accom- and readers nearer to the
articles highlighting the future of Gbit Ethernet. subject and 50174 series) and TIA TR-42.
panied and driven the topic of Single – with technical articles highlight- Schmidt is chairman of ISO/IEC
ct mana-
Pair Ethernet for several years and
Jonas Diekmann is a technical
ing the future of Gbit Ethernet.
Rainer Schmidt is the business
JTC 1/SC25 and a member of SC
y expert sees it as
editor theHARTING
at the future infrastructure
Technology development manager for industri- 25/WG 3 (ISO/IEC11801 series).
e on the forGroup,
industrial he is responsible for Rainer Schmidt
wherenetworks. al cabling at theis the business
HARTING Techno- development manager for in-
nts in PR, press, marketing and content logy Group in Germany.
cation management for the Electronics di- dustrialSchmidt
cabling atinthe
is active HARTING Technology Group in Germany.
international
n various vision. The co-author has also been standardization, for example in IEC
ctively working on the topic of SPE for se- Schmidt is active
SC65C (IEC61918, inIEC61784-5
international standardization, for example in
ms for veral years and bringing customers series), Cenelec TC215 (EN50173
accom- and readers nearer to the subject IEC SC65C (IEC61918,
and 50174 series) and TIAIEC61784-5
TR-42. series), Cenelec TC215 (EN50173
of Single – with technical
More information articles highlight-
at www.HARTING.com Schmidt is chairman of ISO/IEC
rs and ing the
© Copyright future
2020 of Gbit Ethernet.
HARTING and -50174
Electronics GmbH ViSdP series),
JTCHARTING
1/SC25 and aand
member
Electronics TIA
of SCTR-42. Schmidt is chairman of ISO/IEC
GmbH
ucture 25/WG 3 (ISO/IEC11801 series).
JTC 1/SC25 and a member of SC 25/WG 3 (ISO/IEC11801 series).
18
Rainer Schmidt is the business

.com
ogy development
nics GmbH - ViSdP HARTING manager for industri-
Electronics GmbH
for al cabling at the HARTING Techno-
nt logy Group in Germany. 18
s di- Schmidt is active in international
been standardization, for exampleA in IEC of the International
subsidiary 59
se- SC65C (IEC61918, IEC61784-5 Society of Automation
mers series), Cenelec TC215 (EN50173

ect and 50174 series) and TIA TR-42.
ht- Schmidt is chairman of ISO/IEC
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Understanding
and Minimizing HMI/SCADA
Know where vulnerabilities lie and the steps needed
to secure interfaces and monitoring systems.
By Gimmi Filice, GE Digital
Being at the heart of an operation’s data visualization, control, and

reporting for operational improvements, human-machine interface (HMI)
and supervisory control and data acquisition (SCADA) systems have
received a great deal of attention, especially due to various cyberthreats
and other media-fueled vulnerabilities.
The focus on HMI/SCADA security has grown exponentially, and as

a result, users of HMI/SCADA systems across the globe are increasingly
taking steps to protect this key element of their operations.
The HMI/SCADA market has been evolving with functionality,

scalability, and interoperability at the forefront. For example, HMI/
SCADA software has evolved from being a programming package that
enables quick development of an application to visualize data within
a programmable logic controller (PLC) to being a development suite
of products that delivers powerful 3D visualizations, intelligent control
capabilities, data recording functions, and networkability.

With HMI/SCADA systems advancing technologically and

implementations becoming increasingly complex, some industry
standards have emerged with the goal of improving security.
However, part of the challenge is knowing where to start in securing
the entire system.
The purpose of this article is to explain where vulnerabilities within

an HMI/SCADA system may lie, describe how the inherent security of
system designs minimize some risks, outline some proactive steps
businesses can take, and highlight several software capabilities that
companies can leverage to further enhance their security.
SCADA security in context

The International Society of Automation (ISA) production model
demonstrates the layered structure of a typical operation, and shows
that HMI/SCADA security is only one part of an effective cybersecurity
strategy. These layers of automated solution suites share data, and
wherever data is shared between devices, there is a possibility for
unauthorized access and manipulation of that data.
This article concentrates on the HMI/SCADA layer, but
unless other potential weaknesses at other levels
are covered, the operation as a whole remains
vulnerable.
Component vulnerabilities within

an HMI/SCADA system
To minimize existing security gaps,
companies need to first understand
where vulnerabilities typically lie
within the system. Powerful
software features, along with
advancements in automation
hardware and industrial
communications, have

made control systems multilayered, complex, and

susceptible to threats. An HMI/SCADA system’s
level of security is best understood if broken down
into two major elements: communication and
software technology.
Communication
Communication advancements have made
large-scale HMI/SCADA system implementations
successful for many industry applications. There
are two levels of communication that exist
within the system—information technology (IT)
and the field, which have notable security level
differences.
IT: Components of an HMI/SCADA

system are modular, not only to allow for easy
troubleshooting, but also to distribute the
computing load and eliminate a single point
of failure. It is not uncommon to have multiple
thick, thin, web, and mobile run-time clients
connected to the main HMI/SCADA server hub
over an internal Ethernet-based network; however
in some cases, systems may use external leased
lines, modems, wireless, cellular, or satellite
technologies as well. The main HMI/SCADA server
hub also consists of multiple networked servers to
distribute the load, ensure uptime, and store the
mass amount of data. With these components all
networked in some way, they use standardized
common protocols to transfer data—all of which
are largely unencrypted, requiring weak or no
authentication.
Field: HMI/SCADA implementations

frequently consist of a number of widely dispersed

remote sites with a control or data gathering function, all connected to a

central control and monitoring point. Data has to be passed between the
control room and the remote terminal units (RTUs) over a network (which
may be fiber optic, telephone, or wireless), and the protocols for passing
this data have frequently been developed with an emphasis on reliability
and ease of implementation rather than security.
Modern computing facilities have made secure practical

encryption almost impossible to defend against a determined hacker,
so communications between devices need to employ several layers of
defense with the primary aim of making access to the data difficult and
detecting if the data has been compromised.
Software technology
Software over the years has largely become feature-bloated as
companies keep adding new capabilities while maintaining all of the
existing ones, increasing the complexity of software security. There are
two separate but dependent software technologies in the system, the
HMI/SCADA software and the platform operating system, which have
distinct differences when it comes to security.
“Some would say that even if companies could keep their

platforms current, with the fast pace of consumer-based
operating systems and large number of system exploits,
platform operating systems are the single largest security
risk in the system.”
HMI/SCADA software: Most HMI/SCADA software installations

have either external network connections or direct Internet-based
connectivity to perform remote maintenance functions or connect
to enterprise systems. Although these types of connections help
companies reduce labor costs and increase the efficiency of their field
technicians, it is a key entry point for anyone attempting to access with
a malicious intent.

Platform operating system: Operating systems that employ

elements of consumer or “open” source operating systems such as
Windows Server, Linux, and Unix variants are increasingly popular
because they help reduce costs. This trend toward open technologies
has made proprietary custom, closed, highly secure systems a direction
of the past, but it increases the risks.
Also, due to the fact that HMI/SCADA systems are complex and
contain multiple layers of technology, even a simple system patch is
a major undertaking that requires planning, funding, and time. The
risk elements are also substantial because many systems now rely
solely on their HMI/SCADA system for visualization, data recording, and
some control elements. And to this point, some companies hold back
on patches, service packs, and upgrades, while others choose not to
apply any new patches, employing a “it works, don’t touch it” policy.
Furthermore, software patches have generally been developed to cover
for a security breach that has already occurred.
The inherent security of system

designs minimizes some risks
The good news is that some vulnerability is
minimized by the nature of system design
and HMI/SCADA software design; whereby
the fundamental principles and canons of
engineering mandate safe and reliable systems.
This ensures a basic level of security to protect
against an intruder.
Engineers design systems with intentionally

broken automated chains—meaning in some
cases functions require physical confirmation
before the software performs commands, and
in other cases, the SCADA software only does a
portion of the command, requiring one or many
additional manual steps to execute the function.
Inherent system security is best surmised at the
software and hardware levels.

Software: Although many view HMI/SCADA software as a tool that

provides a means for dynamic operator input and visualization as a
flexible information terminal, the reality is that HMI/SCADA software
capabilities are much more exhaustive. When elements such as control
and logic capabilities are added, system engineers must examine the
risk from a potential failure standpoint and the extent of control that is
allowed without being in line of sight of the area being controlled.
Software is also developed from the operator’s perspective and

uses company guidelines throughout the application to ensure the
operator is controlling with intent. While this does not necessarily bring
additional security from external intruders, it does provide enhanced
protection against mistakes. For example, the “select before operate”
design philosophy is typically used in HMI/SCADA applications, which
requires the operator to select an item on the screen, pull up the
controlling elements, operate the item, and finally confirm to send
the command. This may seem like a simple ideology or a drawn out
process, but this intentional design ensures that an operator’s actions
are deliberate as opposed to a hasty reaction to an urgent situation.
Hardware: At this level, design engineers employ many techniques

to ensure safe control, either physically or by the HMI/SCADA software.
Thousands of individual devices and RTUs can exist in a system and are

typically implemented with an area-based manual or automatic control

selection; field technicians use manual control to perform maintenance
or to address a software failure—locking out the software control and
establishing local control.
Additionally, when engineers design this level of the system,

many hardware-based fail safes are built in the design, such as fusing
or hardwire interlock logic to examine the local situation, so when
components are commanded by the HMI/SCADA software, there is a
hardware level of checks to ensure it can be executed. This protects the
system from unsafe or even incorrect software control. Furthermore,
many critical applications use triple and quad-redundant logic
controllers to ensure continuous operations.
The general design rule that system engineers apply for all levels
of a system can be surmised by the statement “if a single point of
failure exists, protect it or provide secondary means.” Therefore, design
philosophies typically drive a holistically safe and secure-by-design
environment, which can severely impede an intruder’s ability at the HMI/
SCADA level to impact the entire system.
Inherent security examples

Manufacturing and part movement
1. An HMI/SCADA system is programmed to command an automated
gantry to move manually.
2. To move the automated gantry, the HMI/SCADA “soft” button, as

well as separate manual push buttons, must be engaged.
3. The automated gantry system is also interlocked with photoelectric

sensors, and will not move if it detects any object within its
operating area.
4. Additionally, there are two physical mats on the plant floor outside
the operating area within line of sight of the gantry on the plant
floor—one in front of the HMI/SCADA terminal and one in front of
the manual push-button station. These mats have built-in sensors to
ensure that someone is physically present before operating.

5. All conditions must be true for the automated gantry systems’

manual functions to be powered up and engaged. This type of
system design is largely for the safety of the workforce, but also
ensures that hackers cannot independently operate this function if
they have control of the HMI/SCADA system.
Water treatment and chemical control

1. An HMI/SCADA system in a water treatment plant is the main
control point for chemicals being added to the water.
2. One of the key chemicals controlled by the HMI/SCADA system

is chlorine. Excessive amounts of chlorine could be hazardous
to public health, and conversely too little can also put people
in danger, so engineers have designed a level of safety into the
automation system.
3. While the HMI/SCADA system controls the main chlorine

values, downstream chlorine meters continuously measure the
concentration level and have the ability to cut off the chlorine
addition in the event of abnormal levels.
4. The metering control elements are isolated from the HMI/SCADA

control with the only interaction between the systems being a one-
way alarming connection to annunciate in the event of abnormal
levels of chlorine.

5. Additionally, water treatment facilities

are mandated to frequently test the
chemical makeup of the outgoing
water. The system’s operators analyze
the test results daily and have the
ability to cut off and bypass the
chemical systems based on the test
results.
6. With this multi-tiered automation

and manual ability designed into the
system, the system as a whole has
an inherent level of security against
rogue remote control and malicious
attacks.
Considerations to critically
examine your system
1. Examine your field assets, particularly
older, remote components
▶ How does the SCADA

communicate with them? Can
this be secured?
▶ Is the control network adequately

separated from other networks?
▶ Where are the points of entry/

failure? Are there redundant
options?
2. Examine your IT assets
▶ Are the services/software running

on an asset the minimum needed
to maintain functionality?

▶ How secure is that software and does the software employ

passwords, biometrics, or retina protection?
▶ Do you have easy access to the operating

system and SCADA system patches? Is this
performed regularly?
3. Examine your change management software

policy
▶ What is the policy for implementing an

operating system and SCADA patches—does it
cover all assets?
▶ Are all assets protected (covered by firewalls and antivirus

software)?
▶ How easy is it to manage user accounts across all layers of

software—is there an integrated system that includes the
operating system and software products, or does each product
have separate user accounts and passwords?
4. Examine your access control
▶ Does your SCADA software allow anonymous client

connections?
▶ Is there a robust login policy with regular renewal of passwords?
▶ Does each user have an appropriate limit to their actions?
Be proactive: Enhance your security with software

capabilities
Even the safest system design and industry standards cannot secure a
system 100 percent, and therefore, companies should not rely on them
wholly to protect their systems. Instead, they should take a proactive
approach to enhancing security, and a good starting point is knowing
what technologies are available to help them best meet their needs.
Selecting a trusted solution provider with deep expertise, experience,

and advanced technologies is also critical. Off-the-shelf solutions

such as GE Digital’s iFIX and CIMPLICITY HMI/SCADA software have
successfully helped companies minimize their security gaps with a
broad range of security-based software technologies, including:
▶ Biometrics – When biosecurity elements are integrated to the

system, customers can program their system to require finger
scans to perform specific functions, such as switching on and off
the grid’s main switch gears, which ensures that the appropriate
person be physically present to execute the order. This type of
integration eliminates the possibility of a hacker performing the
same operation virtually—reducing the overall potential impact
and enhancing the overall system security.
▶ Electronic signature – Many view this option as a simple reporting

tool, however the features are much more comprehensive.
For example, it can introduce authentication potential at the
command level to verify the user performing
the operation with a username and password
as well as a separate authentication, typically
a manager, for verification. The information
is then stored in a system audit trail that can
be recalled in the future; some customers
also choose to integrate this feature with
biometrics to eliminate the use of a single,
widely known username and password.
▶ Authorized connections and client/server

data encryption – Many off-the-shelf HMI/
SCADA software products now have built-
in features that limit the allowable client
connections to known computers and
use integrated data encryption for client
communications. This protective capability
eliminates the possibility of a hacker
simply loading the HMI/SCADA client and
connecting over the network.

▶ Domain Authentication – To leverage complex alphanumeric

passwords at the HMI/SCADA level, some software packages
offer an add-on capability that introduces Windows® Domain
Authentication security integration. For example, GE Digital
features an application add-on that maps group memberships
to its HMI/SCADA software roles and when integrated, the users
and subsequent passwords are managed at the IT level. This
allows the HMI/SCADA application to use existing group IT-level
policies, which are typically very stringent and can exceed industry
requirements.
Investing in system security in today’s business

climate
Improving an overall system’s security can be a costly endeavor, and
companies must find the right balance between cost, design, and
process to make their systems safe. This is especially true as companies
face increasing cost reductions mandated in today’s challenging
economic environment. In response, off-the-shelf HMI/SCADA vendors
have developed industry solution packs that include specifically tailored
tools to help reduce development and overall system costs.
For example, GE Digital offers several

solutions with complete, predeveloped,
“Always refer to your software
HMI/SCADA drag-and-drop elements,
provider’s secure deployment
graphics, toolsets, and configuration tools
guide.”
that significantly reduce both the initial
and ongoing costs associated with HMI/
SCADA software. Companies can then
reroute the resulting cost savings into additional security software and
hardware to augment the inherent safety of their systems—reducing
overall vulnerability.
The cost of implementing an HMI/SCADA security policy should

also be evaluated against the risk of a security breach—in terms of
reputation, liability, and intellectual property. Companies may discover a

proactive approach actually reduces overall costs by ensuring business

continuity when compared to the potential operational and financial
loss that can occur due to the exposure of an unprotected system.
Proactive approach
The vulnerabilities of HMI/SCADA systems can pose a serious threat,
and the complexity of multilayered technologies can make it difficult
to completely secure one’s operation. As discussed in this article,
the inherent safe design of most HMI/SCADA systems offers some
protection, but they are by no means enough to fully protect systems.
That’s why it is important for companies to better understand

where vulnerabilities exist within their systems and to take a proactive
approach to address those susceptible areas. Off-the-shelf HMI/SCADA
vendors offer software solutions with security-based capabilities,
which can help companies enhance the protection of their critical
infrastructure assets and reduce costs for a sustainable competitive
advantage.
ABOUT THE AUTHOR

Gimmi Filice, senior product manager, GE Digital, has 25 years
of automation software experience and is a well-known expert
in HMI/SCADA and data management. He has developed and
managed software that is the foundation for plant automation at
thousands of sites—ranging from water/wastewater, power, and
automotive to stadiums and airports—including GE’s own facto-
ries. Filice knows the answer to almost any automation software
and data management question, and he is dedicated to his cus-
tomers’ long-term success.

Connecting the Factories

of Tomorrow—Today
Current technologies are enhancing our

connectivity today and bringing us closer
to seamless connectivity tomorrow.
By Sandro Quintero and Tom Worsnopp, Festo
With the rise of the Industrial Internet of Things (IIoT), production

systems are driving toward a “seamlessly connected” future, in which all
mechanical, electrical, and intelligent interfaces work together as one
complete package—including the motors, drives, controllers, and cloud.
Although we are not there yet, this future holds exceptional promise for
the factories of tomorrow in terms of higher productivity rates, better
product quality, and lower costs.
If seamless connectivity is the future, then “enhanced connectivity”

is the here and now. Technological developments are already underway
at the field level of industrial automation, distributing intelligence
among devices that formerly were unintelligent. At the same time,
open interfaces like the Open Platform Communications United
Architecture (OPC UA) are bringing us one step closer to true device

interoperability. Together, these developments have vast implications

for how we design, deploy, and maintain our production systems in an
increasingly digital world.
This article will explore several current technologies, including

smart pneumatic components, Internet of Things gateways, and
open communication standards, that demonstrate our current era of
enhanced connectivity on the shop floor. With the right changes, these
technologies can be the stepping stones to a truly connected future.
Emerging intelligence at the field level

In a typical factory, the production floor consists of various
electromechanical components like linear devices, rotary drives, servo
drives, and grippers, as well as more complex mechanical systems
like multi-axis Cartesian handling systems. To realize the
full vision of Industry 4.0, all relevant data from
production processes, including the status
of these “unintelligent” devices,
must be made available
in real time.

Smart components are the prerequisite for real-time data availability

and play a critical role in the consistent and uniform exchange of
information within production processes.
A testament to enhanced connectivity, many formerly unintelligent

components now incorporate IIoT functionality, data processing,
and diagnostic capabilities, rendering them smart. These new local
functionalities bring multiple performance benefits to the overall
operation, especially where efficiency and maintenance are concerned
(see sidebars for examples).
One example of newly distributed intelligence at the field level

is the Motion Terminal VTEM—the first valve that makes pneumatic
functions available through motion apps. Designed with enhanced
connectivity in mind, it enables users to adapt quickly and easily to
changing process parameters in a way that improves production
flexibility compared to “hardwired” technologies. It also integrates
intelligent sensors for control, diagnostics, and self-learning tasks,
eliminating the need for additional components.
The Motion Terminal VTEM provides the functionality of traditional

2/2-, 3/2-, 4/2- or 4/3-way valves, as well as proportional technology
and servo-pneumatic functions. At the same time, users can perform
How IIoT functionality improves maintenance processes

Implementing components and machines with smart functionality goes a long way toward avoiding
unwanted downtime. Picture a machine working on a Friday evening after everyone has already
clocked out. This machine detects an anomaly—an increase in friction, for example—on a pneumatic
actuator, and then calculates that the part will fail in the next three-to-four days. Without any human
intervention, the machine talks to the tool crib about inventory and places an order for a spare part
after learning it is not currently in stock. At this point, the purchasing manager receives a simple
email alert on his smartphone, asking him to approve the order. Once Monday morning rolls around,
the machine calculates that the actuator is now at 80 percent failure and automatically moves the
maintenance appointment to earlier in the week after the part arrives.
This example demonstrates the power of machine visibility, especially during periods of
unattended operation, and also shows how the addition of simple IIoT functions can transform
unplanned, costly downtime to just a few clicks on a device.

motion tasks with a single valve type, integrating complex movements,

variable positioning, and preset travel time all in one device. Other
smart functions of the Motion Terminal VTEM include:
▶ Energy-efficient apps. The Motion Terminal VTEM includes an

“ECO drive” motion app that automatically reduces pneumatic
energy to the level required for movement. As a result, it keeps
energy consumption to a minimum for simple motion tasks that
do not need additional end-position force.
▶ Leakage diagnostics. By detecting leaks at an early stage,

the Motion Terminal VTEM increases process reliability and
productivity. It also reduces unnecessary energy losses.
▶ Condition monitoring. Thanks to this capability, the Motion

Terminal VTEM reduces the life-cycle costs of systems. It also
facilitates a faster return on investment and makes you more
competitive in the market.
With its combination of traditional valve technology and digital

motion apps, the Motion Terminal VTEM replaces over 50 individual
components—all while improving manufacturing flexibility, reducing
system complexity, and enabling new data analysis and condition
monitoring capabilities at the field level.
Facilitating component integration with IoT gateways

One of the biggest challenges to implementing the seamless
connectivity vision is the integration of networked components and
systems. Traditionally, integrating servo drives and controllers from
different manufacturers is a complex and laborious task, driving up
both engineering time and costs. In addition to changes in software
and hardware platforms, software engineers face different fieldbus
systems, software modules, and data protocols that require them to
master several programming languages. They must also understand
how individual components behave in relation to one another. In these
situations, electromechanical drive systems can take a long time to
debug, and any technical difficulties that arise during commissioning
can cause unscheduled production delays.

A step in this direction, IoT gateways like the CPX-IOT enable

users to connect drives and other components for visibility into
various operating parameters, including temperature, speed, and
voltage. The gateway not only consolidates machine and production
data, but it also makes this information easier to manage. Depending
on the complexity, users can connect up to 31 components and
modules at the shop floor level. They can then receive real-time,
cloud-ready data via secure open interfaces. This capability opens up
many data analysis options—f rom smarter maintenance practices to
digital twins.

Open protocols for device interoperability

Whether for mechanical or control systems, an overwhelming
number of products, components, and solutions are available from
different manufacturers—each one with its own interface, hardware,
programming language, and communication protocol. As mentioned
earlier, machine builders and engineers often spend a lot of time
integrating these various components into their machines. Fortunately,
new open communication protocols are paving the way for true device
interoperability in connected environments.
One example, IO-Link, provides a new standardized I/O technology

interface that expands fieldbus and industrial Ethernet systems. In
addition to transmitting process data, it lets users download parameter
data from the control system to the sensor or actuator, and then send
diagnostic data back to the control system. Whereas integrating a
fieldbus interface down to the lowest field level was once a costly
endeavor, IO-Link transmits digital or analog values with only a simple
three- or five-wire cable.
A second example,
OPC UA, is a vendor-
neutral software interface
that transports machine
data, including process
values and measurements,
and then describes
that data semantically
in a machine-readable
way. Because OPC UA
works independently of
the operating system,
it provides an open
communication solution
from front-end devices,
sensors, actuators, and
controllers right up to the

cloud. In addition to bringing the industry closer to true “plug and

play” functionality, this interface enables the seamless integration of
components—allowing them to talk to each other, as well as gather
and exchange data easily.
To reap these benefits, suppliers of factory automation solutions

are increasingly adding open interface compatibility to their
components as a way to provide seamless communication between
front-end devices, controllers, and the cloud. For example, Festo has
already embedded OPC UA into its valve terminals, enabling plant
managers, engineers, and operators to realize the benefits of smart
manufacturing. When paired with IoT gateways like the CPX platform,
operators can quickly and easily collect device information and statuses
via an Ethernet connection and OPC UA protocol. From there, the
system can then send that information to the cloud via a second
Ethernet connection and IoT protocols, such as Advanced Message
Queuing Protocol (AMQP) or MQ Telemetry Transport (MQTT).
A glimpse into the future: Using IIoT data to inform production

This scenario explores how IIoT data on consumer trends can inform production
schedules—and is one of the many ways the larger digital world can be reflected
on the shop floor. Imagine an electronics company that uses popular social media
platforms to analyze data related to smartphone usage. The company can monitor
how many people are watching videos on the phones, and then aggregate and
analyze this data to create a production forecast based on trending models or
colors. This kind of information is especially helpful if there is no historical data to
guide the production of new goods or services.

The road ahead

As connected technologies continue to take off, factories are moving
toward a future in which all components, controllers, and the industrial
cloud are seamlessly integrated, yielding countless production benefits.
Although progress is well underway, we are not quite there yet. The
last mile will require a continued drive to tie together formerly siloed
systems, to embrace open communication standards, and to fully
implement digital strategies, from the shop floor to the enterprise level.
To learn more about putting IIoT into practice, please visit

https://www.festo.com.
ABOUT THE AUTHOR

Sandro Quintero is a product market manager at Festo
with more than 10 years of experience in industrial auto-
mation. He has worked with customers across different
industries, such as medical, food processing, mining, auto-
motive, and most recently, electronics and assembly. This
has allowed him to acquire skills in different areas, such as
sales, product support, and project management. Quintero
earned a bachelor’s degree in mechatronics engineering
from the Universidad Autónoma de Ciudad Juárez. He then
obtained an MBA from the University of Texas at El Paso.
Most recently, he has continued his education by attending
the Harvard Negotiation Institute at Harvard Law School
and by obtaining a Marketing Strategy Certificate from
Cornell University.
Tom Worsnopp is product market manager for electric

automation at Festo North America. His expertise is in
electromechanical actuators, servo drives and motors, PLCs,
and HMIs. Worsnopp has a master’s degree in mechani-
cal engineering with a focus in mechatronics, including
mechanical and electrical design and programming. He has
worked at Festo for nine years, and is based in the NY office.

Improving Operations with

Localization Solutions
Increasing efficiency using real-time, By Jeff Graupmann,
SICK USA
tag-based localization solutions.
Logistic processes within distribution and fulfillment centers must
be efficient. The goal is to lower costs and increase the quality of
sequential processes to ensure maximum throughput and productivity.
Entirely in keeping with the smart manufacturing approach, the data
collected in this area forms the basis for commercial decisions and
indicates possible opportunities for optimization. Being able to localize
goods during transport, in particular, constantly poses new challenges

for companies. Only if you know where each object is at any given time
is it possible to analyze the material flow chains, optimize transport
processes, and increase the quality of supply.
This article from SICK shows why reliability and transparency

in the material flow are decisive factors in production logistics
and intralogistics, and how you can achieve them with the help of
localization solutions. It explains the concept of tag-based localization,
and describes possible applications of such a real-time locating system,
as well as the benefits that full object traceability brings to production
and logistics companies.
What are real-time localization solutions?

Real-time localization systems (RTLS) provide information about the
exact location of an object being traced at any given time. These systems
offer valuable information about where exactly a certain item currently
is in a production facility. To do so, the item must be equipped with a
sender or tag that the appropriate system infrastructure can detect.
Different localization scenarios generally require different

localization technologies. In fully automated applications, it is possible
to perform the object identification and localization using scanning
systems. Other technologies that may also be suitable include radio
frequency identification (RFID), Global Positioning System (GPS), LiDAR,
and Bluetooth Low Energy (BLE).
Ultra-wideband technology
Ultra-wideband (UWB) technology is a common solution for real-
time localization. Similar to BLE, UWB is a short-range wireless
communication protocol that operates through radio waves. However,
it operates at very high frequencies and can be used to capture very
precise spatial and directional data useful for localization of assets.
When compared to other solutions intended for identification

and object tracking in automated applications, a real-time UWB tag-
based localization system has enhanced accuracy, positioning, and

radio frequency security. It can also be used in conjunction with other

technologies, such as code readers, 2D and 3D cameras, 2D and 3D
LiDAR sensors, and RFID read/write devices.
Real-time UWB tag-based localization solution for

partially or nonautomated applications
A real-time UWB tag-based localization solution comprises UWB tags
and receiver antennas. The tags send very brief UWB signals (“blinks”) at
regular intervals, received by the surrounding antennas. The antennas in

turn send the time stamp of the received UWB signals to the localization
platform via the Ethernet infrastructure. The localization platform then
calculates the position of the tags by precisely measuring the difference
between the times at which this signal arrived at different antennas.
Since only the differences in the arrival times are used to calculate
the tag locations, the principle of operation is referred to as the time
difference of arrival (TDoA). A real-time UWB tag-based localization
solution ensures that the location information about tracked goods or
assets is also available in partially and nonautomated applications. A
connected localization software, for example Asset Analytics from SICK,
calculates the corresponding location of the tag based on the data
obtained. Besides visualization functions, the localization software also
offers intelligent standard functions or user-specific services for further
utilizing the obtained information.
Transparency and data acquisition in process chains

and value chains
Intelligent networking of machines and processes using various
information and communication technologies plays an important role
in modern production and logistics companies. It serves a key purpose:
to collect data along the process and value chain for evaluation and
implementation.
Absolute reliability of the processes and data is essential for

this because the knowledge gained is the basis for various kinds of
commercial decisions. The objective, therefore, must be to avoid system
discontinuities, as these can result in delayed and noncongruent
information both in the field and at the IT level and, thereby,
have a negative impact on transparency. In intralogistics, system
discontinuities occur, for example, when objects (assets) or materials at
sources leave a rigid production, assembly line, or stationary conveying
technology to be transported by mobile transport equipment like
forklifts, industrial trucks, tugger trains, or mobile robots.
In contrast to fixed transport systems, no identification or

localization of the assets or materials occurs during transport through
the facility. This is like a blind spot for the control level. The assets or

materials are not tracked and, in the worst-case scenario, may even be
lost without anyone knowing. Process efficiency suffers significantly
due to this lack of transparency, which can lead to shrinkage, delays,
deliveries to the wrong location, and numerous other errors.
Real-time UWB-based localization solutions can prevent this

because they ensure full transparency throughout the material flow. A
system that automatically tracks assets with the help of UWB tags and
provides insights into the status of the company makes it possible to
focus on business decisions and optimization. Companies that spend less
time on data collection can devote more time to reducing investment
expenses, increasing revenue, and improving work processes.

Advantages of a real-time UWB tag-based localization

system
Localization data enables agile planning of production and logistical
processes, thereby ensuring better delivery quality and greater
reliability. Knowledge of the precise location of assets or materials in
real time brings crucial transparency to the material flow. The real-time
UWB tag-based localization system therefore contributes to savings in
time and money, as it allows for the analysis of asset movements and
the identification and elimination of workflow bottlenecks. This type of
localization system can be used both indoors and outdoors, taking into
consideration country-specific regulations.
The advantages of a real-time UWB tag-based localization system

at a glance are:
▶ Continuously tracking all physical movements with no “blind spots”

improves real-time transparency.
▶ Improved planning and control of material flows and reduced

search times lead to a minimization of idle times and a higher
capacity utilization.
▶ By monitoring the movement of goods through automated

transfers of transported materials and information triggers as they
enter or exit certain configurable zones, it is possible to achieve a
higher level of process automation.
▶ Transparency and a better overview in large plants or on

large premises increase productivity, as does the automated
management of storage spaces with no manual posting processes.
▶ Minimal downtimes, flexibly prepared or scheduled setup times,

and dynamic, optimizable, and adjustable routes lead to higher
overall equipment effectiveness.
▶ The availability of specific production equipment or goods can be

checked in real time.
▶ The system allows flexible navigation within logistics and

production processes.

Implementing a real-time UWB tag-based localization

system
The following components play a decisive role when implementing a
real-time UWB tag-based localization system:
▶ Physical devices: SICK offers a complete UWB technology-based

localization system comprising tags, antennas, and the Asset
Analytics platform.
▶ Localization area: The physical space in which localization services

are required. It must be covered by a set of antennas.

▶ Localization cell: The localization area is divided into localization

cells. Each of these is covered by at least four antennas that are
located within line of sight of a master antenna. The localization
area is also divided into virtual zones based on the signal quality.
The signal strength depends primarily on the distance and any
physical obstacles in and around the signal path.
▶ Master antenna: Each localization cell must have a master

antenna in order to synchronize the antennas within that cell.
When using the localization system from SICK, each antenna
can be adjusted to the master antenna mode. No radio
connection between the master antennas and neighboring cells
is required.
▶ Absolute position: This is calculated based on the TDoA, which is

calculated to an accuracy in the submeter range (± 30 cm) using at
least three antennas.
▶ Presence information: The antennas are used to trace the entry

and exit of assets in the respective localization cells. Localization is
performed based on the nearest antenna.
The experts at SICK advise customers on how best to design the

antenna infrastructure in their localization area from an optimization
perspective. They ensure that the client’s performance requirements on
the localization are met using the minimum number of devices, which
maximizes the return on investment.
The prerequisite for successfully applying the TDoA principle of

operation is that the antennas used to calculate the tag location are
very precisely synchronized. On the other hand, the tags require less
precise synchronization, which makes it easier to operate them using
less power. The antennas are synchronized with a selected master
antenna at regular intervals. Because one master antenna generally
does not provide sufficient radio coverage to synchronize the entire
localization area, the area is divided into localization cells, each of
which is synchronized by its own master antenna.

The Asset Analytics visualization and analysis platform

from SICK
Asset Analytics is a technology-independent and highly flexible
platform for visualizing and evaluating location and sensor data.
A large number of modules for extending Asset Analytics are

available. They make it possible to display, combine, and even merge
data from different types of sensors, for example UWB, LiDAR, RFID, or
bar code sensors. Asset Analytics does not require any installation or
special configuration on the end user devices. The data for all objects
being traced can be viewed in real time in a web browser running on
any computer, tablet, or cell phone after logging in with a username
and password.
A flexible role-based user management feature allows different

access rights to be assigned. This enables numerous different users,
depending on the type and size of the company, to obtain a transparent
view of their own data and minimize the time they spend searching.
Core functions of Asset Analytics

▶ Data visualization: Clear presentation, e.g., of current objection
locations, location, and status information, as well as additional
sensor information in real time
▶ Data analysis: Processing the collected data, e.g., to analyze

routings, transport times, and downtimes, as well as identify
opportunities for optimization
▶ Event management: Automatic triggering of user-defined actions

such as SMS or email notifications, e.g., when entering or exiting
predefined geozones
▶ Integration and API: Asset Analytics can be integrated into

your application via the API using the REST, WebSocket, or
MQTT interfaces. SICK can also create custom connectors for
the customer’s enterprise resource planning (ERP) system,
manufacturing execution system (MES), or other systems

▶ Protection against manipulation: All actions in Asset Analytics are

logged with time, user ID, and action details, so that unintentional or
deliberate manipulation of the system can be recognized and undone.
Application examples for tag-based localization solutions

When implementing tag-based localization solutions, first it is necessary
to clearly define the application goals. The requirements on the data to be
collected play a decisive role here. In addition, the value and characteristics
of the assets being tracked and the application conditions are important.
Application example 1: Tracking industrial vehicles and

high-value assets
The ability to determine absolute locations is particularly useful for
tracing large and high-value assets in open areas (i.e., conveyors
and other material handling machinery, industrial mobile robots, or
stationary robots).
Localization is performed using a UWB tag applied to the asset. The

antennas installed on the walls or the ceiling of the localization area and
operated using Power over Ethernet (PoE) receive the signals from the
tags and transmit the time stamp to a localization platform. This stores the
information together with the metadata in a database. All of this data can
be accessed via the API of localization software, for example Asset Analytics
from SICK. This can then be used to export raw data or processed data.
Application example 2: Tracking pallets and containers

It is also helpful to track assets deemed low value and high volume.
These include, for example, consumables such as boxes of screws in the
manufacturing industry, toolboxes in the automotive industry, or pallets/
containers of goods.
This form of tag-based localization solution employs the principles of

summarizing assets and linking different technologies. Small objects are
identified, for example, based on their bar code and stacked on a pallet
that has been equipped with a low-cost RFID tag. The identified objects
are associated with the pallet details.

The pallets are then transported using manned forklift trucks. The
manned forklift trucks are equipped with an RFID read/write device, a
UWB tag, and further sensors. When a manned forklift truck picks up a
pallet, the RFID read/write device automatically identifies the pallet. The
identification data stored in the RFID tag of the pallet is forwarded to
the localization software via TDC-E gateway systems from SICK.
The localization software then links this data to the manned forklift
truck, and thereby indirectly to its location, because this can be determined
in real time by means of the UWB tag. When the sensors detect that the
manned forklift truck has put the pallet down again, the current location of
the forklift is stored as the last known location of the pallet.
Since this application does not require each of the small objects
and assets to be equipped with the higher-priced UWB tags,
companies can achieve considerable cost savings.
Using localization data to create geozones

On its own, the data from UWB localization systems, such as LOCU1xx
and LOCU2xx, and IIoT gateway systems, such as TDC-E from SICK, as
well as any supporting sensor technologies, does not create a greater
benefit for logistics processes. The data can, however, be further
processed using software and thereby generate added value.
To do so, the localization and time data from all localization

systems used must be merged with suitable software algorithms and
powerful middleware and interpreted as information. For example, the
localization data obtained could be used to automate posting processes
(i.e., item postings in an ERP system via middleware) without the need
for manual intervention.
This is done using geozones, which allow users to track high-value

components and know exactly when the items have been dropped off
in a particular zone. Once that action is completed, it can be tied into
the ERP system, showing exactly how many parts are used and how
many more may be needed.

It is also possible to perform a completeness check in a picking

process using the localization data obtained. In addition to its own
visualization and analysis functions, Asset Analytics also offers open
interfaces that enable raw data and pre-processed data to be used in
companywide supply chain and asset management systems as well as
in cloud applications.
This connectivity enables the localization data to also be used

at the level of the ERP system or MES in order to obtain a better
understanding of the material flows. It is thereby possible, for example,
to evaluate the running and transport times between sources and sinks
and intervene in the supply chain to optimize it.
Savings potential through the use of tag-based

localization solutions
The savings achieved through the use of UWB tag-based localization
solutions are apparent at several locations in the material flow.
Thanks to the higher data transparency and real-time localization

of assets, the time spent each day on searching and the associated
legwork are significantly reduced. The number of truck trips between
the warehouse and production facilities can also be reduced as a
result of the optimized material flow. Furthermore, the automated
posting of items based on the localization data obtained (e.g., for
goods receipts in production areas) eliminates the need for manual
posting processes. With these potential savings, the total cost of
ownership of a real-time UWB tag-based localization is amortized
within just a few years.
The SICK localization system: Complete solution from

a single source
The localization of assets and the gained transparency in the material
flow offer clear added value for production and logistics companies.
The localization data obtained with a real-time localization system
enables the agile planning and optimization of production and logistical
processes, thereby ensuring better delivery quality and greater reliability.

SICK offers complete localization solutions that include all

the necessary components tailored to the specific requirements
of the customer. The solutions include not only high-performance
hardware and software, but also comprehensive service offerings
that are available to customers both online and on site and provide
comprehensive support.
The complete solutions from SICK ensure that all requirements

on reliability and performance for the precise traceability of objects
in indoor areas are met when implementing a real-time localization
system. Every system meets the highest quality standards and offers
industry-specific functionality.
This is possible thanks to SICK’s longstanding experience in the

area of identification and localization technologies, top down expertise
from the network technology right to the associated protocols and
certification, as well as comprehensive experience gained from
digitalization projects in real-life companies. Competent advice, best
possible support, training offerings, and comprehensive but easy to
understand documentation round off these technological solutions.
SICK also pays particular attention to the time to value of every
digitalization project as well as the acceptance of all involved parties
and users, because these often neglected but important aspects can
frequently make or break a project.
ABOUT THE AUTHOR

Jeff Graupmann, Market Product Manager - Profiling &
Anti-Collision Systems at SICK USA. With over 20 years of
experience in the industrial automation industry, Graupmann
has extensive expertise in mobile platform solutions. He has
been with SICK for over six years and applies his expertise
as a market product manager for profiling and anti-
collision systems. He has a bachelor’s degree in mechanical
engineering and his MBA from the University of Minnesota.


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VOLUME 3

IIoT & Industry 4.0

A subsidiary of the International

IIoT & Industry 4.0: Fueling Post-Pandemic Prosperity

All that and more is what you’ll find in this edition of

About AUTOMATION 2021

International Society of Automation Renee Bassett, Chief Editor

Page 6 IIoT and Sensing on the Edge

Modern instrumentation provides plenty of information—

Case study: Robotics Integrator Discovers

Metal 3D printing provided weight and cost savings over

Bringing Your Factory to the Edge in 2021

Use existing field devices, network connections, and

How to Make your Battery Smaller and

Understanding your application can help miniaturize your

Single-pair Ethernet: The Infrastructure for

SPE enables IT and automation to walk hand in hand.

A subsidiary of the International 3

Understanding and Minimizing HMI/SCADA

Know where vulnerabilities lie and the steps needed to

Page 75 Connecting the Factories of Tomorrow—

Current technologies are enhancing our connectivity today,

Improving Operations with Localization

Increasing efficiency using real-time, tag-based localization

A subsidiary of the International 4

Ready for Liquid Analysis 4.0 – with Memosens 2.0

Do you want to learn more?

By Ryan Williams, Endress+Hauser

Smart instruments have been available Modern instrumentation

Endress+Hauser estimates that of its 40 million process instruments

A subsidiary of the International 6

If a single smart instrument, such as a Coriolis meter, can provide a

Because of the immense amount of data, and the problems

Figure 1. A process plant may have

A subsidiary of the International 7

Major instrument manufacturers are well aware of the problem,

Handling massive amounts of data

While the automation system is mostly interested in flow values

Many smart instruments have diagnostics to indicate problems

Error code Error Actions Alarm type

962 Partially filled pipe Check for gas in process Warning

910 Tubes not oscillating Check input configuration Alarm

912 Medium inhomogeneous Check process condition Warning

913 Medium unsuitable Check process conditions Alarm

948 Oscillation damping too high Check process conditions Warning

Figure 2. Typical errors that can be generated by an Endress+Hauser Proline flowmeter.

A subsidiary of the International 8

temperature, signal asymmetry, exciter current, carrier pipe

Every instrument manufacturer’s diagnostics differ, but each

In many cases, this is accomplished by the automation system,

This type of solution presents problems. Networks can be unduly

Rather than use a historian, all edge data

Data is collected only periodically because the automation system

A better solution—now being offered by several major instrument

A subsidiary of the International 9

Connecting at the edge

The edge device is programmed to extract instrument data from

A subsidiary of the International 10

Once the instruments are connected to an Ethernet-based

For example, Endress+Hauser has multiple approaches to selecting

Inside the cloud

Instrument diagnostics – Software built into modern instruments

During verification, the current conditions of various parameters