Control Engineering 2018-02

www.controleng.
com
Be
fle
xi
bl
e
Ba th
sic a
C nk
on st
tro
l
o
le ne
rS
IM tw
AT or
IC ki
S7 ng
-1 p
20 o
0/ ss
F ib
21 for
details
ili
See page
tie
s
Your Success is Our Success
AutomationDirect is your trusted source for cost-effective control solutions
www.chemence.com
www.chemence.com
Chemence, the only industrial, consumer

and medical cyanoacrylate manufacturer
in the US, looks to AutomationDirect
for their manufacturing and packaging
James Catlett control needs.
Plant Manager
Chemence
“AutomationDirect’s low prices and free support keep us

coming back. Their automation products are exactly what
we need to get the job done and the new BRX PLC, with its
motion capabilities and built-in analog, is perfect for our
packaging lines.” - James Catlett
At AutomationDirect, customer satisfaction is priority
one and we are continually expanding our offering of
practical, cost-effective industrial control products to
meet a wide range of applications. The latest addition
to our Do-more! family of programmable controllers is
just another example. Starting at $199.00, the Do-more!
BRX PLC platform is packed with features and has the
tools you need to “get the job done” for less. www.BRXPLC.com
Order Today, Ships Today!

* See our Web site for details and restrictions. © Copyright 2016 AutomationDirect, Cumming, GA USA. All rights reserved. 1-800-633-0405 the #1 value in automation
input #1 at www.controleng.com/information
Connected Machines.
Efficient Communications.
Smarter Operations.
Kepware’s industry-leading industrial

connectivity solution provides:
A Scalable and Flexible Architecture

with connectivity to hundreds of protocols covering
DZLGHUDQJHRI3/&V578VȵRZFRPSXWHUV
VHQVRUVGDWDEDVHVFXVWRPDSSOLFDWLRQVDQG
other industrial data sources.
Streamlined and Reliable Data Access

for +0Ζ6&$'$0(6+LVWRULDQ(53FXVWRP
DSSOLFDWLRQVDQGLQGXVWULDOΖR7SODWIRUPVLQFOXGLQJ
ThingWorx®.
Increased Visibility
LQWRLQGXVWULDOGDWDȃVRHYHU\RQHIURPWKHVKRS
ȵRRUWRWKHWRSȵRRUFDQPDNHVPDUWHUGHFLVLRQV
Learn more at www.kepware.com/CE
© 2018, PTC Inc. (PTC). All rights reserved.
Slimmest. Smartest.
Easiest to Use.
Industry’s slimmest at 2 cm wide
Modbus, PROFINET, EtherNet/IP built in
LEDs visible from front and side
Flexible DIN rail mounting
Rugged steel housing
Designed for Today's Machine Builders and OEMs

If you're working with limited cabinet space, a tiny budget, and little to no formal network training, your
life just got a little easier. The affordable new SDS-3008 smart switch fits into the tightest spaces and
can be monitored over SCADA.
• Easier, more cost-effective alternative to full managed switches
• Rugged, ultra-slim form factor with multiple mounting options
• Simple one-page configuration requires zero network training
• Integrates with HMI/SCADA for network monitoring
Learn more at www.moxa.com/smartswitch.

Vol. 65
Number 2
FEBRUARY 2018
ANSWERS
8 | Updating a DCS for optimized operations
10 | Biopharmaceutical company optimizes
manufacturing processes with modern DCS
12 | Alarm management: Six hazards,
four strategies
14 | Avoid alarm overload with consolidation
and escalation
16 | Innovations in electric motor technology:
the first 100 years
18 | Measuring torque with angle sensors
8, 10 INSIDE MACHINES
M1 | Machine vision systems pushing auto-
COVER IMAGE, ABOVE: Emerson’s DeltaV Mobile gives users plant control data and
analysis tools whenever they need it from wherever they are. Courtesy: Emerson
INSETS: Banks Integration selected a virtualized distributed control system from Rock- motive industry towards full autonomy
well Automation for use at a pilot laboratory to support research and development (R&D)
for Gilead Sciences Inc. Courtesy: Rockwell Automation M3 | Robust vision inspection in five steps
M5 | Robotic machining used for aerospace
applications
INSIGHTS
5 | Research advice: Seven motor tips and
advice for users INNOVATIONS
6 | Think Again: New, innovative automation 28 | 2018 Engineers’ Choice Awards:
applications Spotlight on Innovation
46 | New Products for Engineers

Get credit for learning
CFE
TM
BACK TO BASICS
CFE Edu: https://cfeedu.cfemedia.com/catalog
(PLCs, IIoT, arc flash and more)
Webcasts: www.controleng.com/webcasts
Edu 48 | Automation product design
(Sensors, IIoT, and more)
advice from 2018 Engineers’
Choice winners
CONTROL ENGINEERING (ISSN 0010-8049, Vol. 65, No. 2, GST #123397457) is published 12x per year, Monthly by CFE Media, LLC, 3010 Highland Parkway, Suite #325 Downers Grove, IL 60515. Jim Langhenry, Group
Publisher/Co-Founder; Steve Rourke CEO/COO/Co-Founder. CONTROL ENGINEERING copyright 2018 by CFE Media, LLC. All rights reserved. CONTROL ENGINEERING is a registered trademark of CFE Media, LLC used under
license. Periodicals postage paid at Downers Grove, IL 60515 and additional mailing offices. Circulation records are maintained at 3010 Highland Parkway, Suite #325 Downers Grove, IL 60515. Telephone: 630/571-4070.
E-mail: customerservice@cfemedia.com. Postmaster: send address changes to CONTROL ENGINEERING, 3010 Highland Parkway, Suite #325 Downers Grove, IL 60515. Publications Mail Agreement No. 40685520.
Return undeliverable Canadian addresses to: 3010 Highland Parkway, Suite #325 Downers Grove, IL 60515. Email: customerservice@cfemedia.com. Rates for nonqualified subscriptions, including all issues: USA,
$ 150/yr; Canada/Mexico, $180/yr (includes 7% GST, GST#123397457); International air delivery $325/yr. Except for special issues where price changes are indicated, single copies are available for $30 US and $35 foreign.
Please address all subscription mail to CONTROL ENGINEERING, 3010 Highland Parkway, Suite #325 Downers Grove, IL 60515. Printed in the USA. CFE Media, LLC does not assume and hereby disclaims any liability to any
person for any loss or damage caused by errors or omissions in the material contained herein, regardless of whether such errors result from negligence, accident or any other cause whatsoever.
www.controleng.com CONTROL ENGINEERING February 2018 • 3

Keep Your Instrument Processes
Locked Down Tight.
Instrumentation that Keeps Danger at Bay

Put a fortress of protection around your process
with FS Functional Safety Series instrumentation
from Moore Industries. You can be conﬁdent that
SFY Functional Safety it will safeguard your processes when you need
Frequency-to-DC it the most. Our STA, SSX, SST, SRM, STZ and
Transmitter the NEW SFY Functional Safety Frequency-to-
DC Transmitter have been designed and built to
strict IEC 61508 standards, ensuring safe and
reliable function – particularly in environments
where hazardous or emergency situations are
likely to occur.
2018
HONORABLE
MENTION
Demand Moore Reliability

To learn more about our Functional Safety Series,

call (800) 999-2900, or go to: www.miinet.com/safetyseries
INSIGHTS
RESEARCH ADVICE
Mark T. Hoske, Control Engineering
Seven motor tips

and advice for users
Survey respondents on motors and drives survey from Control Engineering
provide tips related to motors. Online: see more advice about drives.
A
dvice for use of motor was included among related products) work to judge suitability for a
respondents to the Control Engineering purpose.
motor drive research study. Respondents
were asked what advice they would offer 5. Seek differentiation in motor products. Exam-
about motors. ine the power density, control precision, and phase
awareness advantages inherent in closed-loop brush-
1. Consider using advanced motor technologies. less torque (especially thin annular ring: large central
hole) motor innovations.
2. Engage your local vendor, and don’t overcom- Use passive cooling with sealed operations where
plicate the design. Servo and stepper motors are close
in price so the decision to use a servo should be func-
tion rather than cost.
possible. It is disruptive technology.
6. There is a significant lack of understanding

M More
INSIGHTS
KEYWORDS:
of motor theory, drive theory, and basic mechanics, Motors, motor tips
3. For large motors, provide at least two protec- which is needed for end users to better understand the Research from Control
tion devices, so if one should fail, an alarm is given equipment they purchase, as well as its capabilities and Engineering on motor drives
and the motor is not shut down, and the second pro- limitations. asked respondents for
tection device provides backup. advice.
The installation must be designed so the failed 7. Understand the load connected, what you Seven tips on motors
device can be removed and replaced without a shut- want to do with it, and how fast you want to do it. ce were offered, including
selection, motor design, and
down of the control circuit or the motor. application fit.
Edited by Mark T. Hoske, content manager, Control See two other motors
4. Gather knowledge about how motors (and Engineering, CFE Media, mhoske@cfemedia.com. articles in this issue, with
more online
CONSIDER THIS
New Products for Have you looked at Control
Engineering research reports
Engineers Database for additional motor and

drive and other advice?
Motor categories
www.controleng.com/
ce-research
Within the News Products for Engineers database at www.controleng.com/NP4E, ONLINE

Research delivers a dozen
find new product information in the “Actuators, motors, drives” group, under the drives tips: Respondents
following categories: of the motors and drives
survey from Control
• ac induction motor • electronically commutated motor Engineering give 12 tips
• ac motor • gear motor related to motor drives.
2017 Motor Drives Report:
• brush dc • internal permanent magnet (IPM) Five high-level findings: Key
• brushless dc motor motor trends in variable-speed,
servo and/or stepper, and
• brushless permanent magnet ac • linear motor
medium-voltage drives
(PMAC) motor • servo motor from buying and specifying
respondents to the Control
• brushless permanent magnet • stepper motor, step motor Engineering 2017 Motor
synchronous motor • variable or switched reluctance motor. Drives study. Amanda
• dc motor Pelliccione is the CFE Media
research director.

INSIGHTS
THINK AGAIN ®
3010 Highland Parkway, Suite 325, Downers Grove,

IL 60515. 630-571-4070, Fax 630-214-4504
New, innovative Content Specialists/Editorial

Mark T. Hoske, Content Manager
automation applications
847-830-3215, MHoske@CFEMedia.com
Jack Smith, Content Manager
630-907-1622, JSmith@CFEMedia.com
Kevin Parker, Senior Contributing Editor, IIoT, OGE
630-890-9682, KParker@CFEMedia.com
Startups, 3-D printing, drones, and automation in space Emily Guenther, Associate Content Manager
eguenther@CFEMedia.com
are among the expanding uses for automation. Amanda Pelliccione, Director of Research
978-302-3463, APelliccione@CFEMedia.com
S
Chris Vavra, Production Editor
CVavra@CFEMedia.com
tart-up automation-related com- Space Station (ISS), someone said, “I wish
panies, drones, 3-D printing, and I had a tool of this size.” Two weeks later, Contributing Content Specialists
space missions are among the NASA was uploading a digital file to the Suzanne Gill, Control Engineering Europe
suzanne.gill@imlgroup.co.uk
expanding uses for automation, as ISS. In space, it’s easier to have digital files Ekaterina Kosareva, Control Engineering Russia
explained at the 2018 A3 Business Forum than actual parts or tools for every possibil- ekaterina.kosareva@fsmedia.ru
in Orlando in January. Innovation also ity, especially for longer missions, she said. Seweryn Scibior, Control Engineering Poland
seweryn.scibior@trademedia.us
creates and extends interest in When used for health care, Lukáš Smelík, Control Engineering Czech Republic
engineering automation. low-cost 3-D printing may mean lukas.smelik@trademedia.us
Aileen Jin, Control Engineering China
Automation is being applied more patients get care more aileenjin@cechina.cn
for humanitarian benefits using quickly, especially in areas that
additive manufacturing and may not have specialized med- Editorial Advisory Board
drones, helping in remote geo- ical care. That would include www.controleng.com/EAB
Doug Bell, president, InterConnecting Automation,
graphical or economic situa- space. Astronauts cannot take www.interconnectingautomation.com
tions, including space travel, everything needed into space, David Bishop, president and a founder
Matrix Technologies, www.matrixti.com
explained Dr. Julielynn Wong, Mark T. Hoske, but they can bring or uplink 3-D Daniel E. Capano, president, Diversified Technical Services Inc.
MD, MPH, who is founder, Content Manager files for medical supplies. of Stamford, CT, www.linkedin.com/in/daniel-capano-7b886bb0
chairman, and CEO of 3D4MD. Drone technology also is Frank Lamb, founder and owner
Automation Consulting LLC, www.automationllc.com
Wong challenged assem- widely accessible and have Joe Martin, president and founder
bled automation leaders (about 650 were potential to help, especially those 1 billion Martin Control Systems, www.martincsi.com
Rick Pierro, president and co-founder
expected) to sponsor a 3-D printer make- people who live on less than $2 per day. Superior Controls, www.superiorcontrols.com
a-thon to address a humanitarian need. A Drones are used to speed drugs, lab sam- Mark Voigtmann, partner, automation practice lead
side benefit, she suggested, is attracting ples, medical supplies, and food in criti- Faegre Baker Daniels, www.FaegreBD.com
women and younger talent that automa- cal situations. Automation technologies
tion-minded companies try to attract and used in drones may include: motion con-
retain. Automation technologies used in trollers, motors, sensors, vision system, CFE Media Contributor
3-D printing include: sensors, actuators, actuators, GPS, HMIs (which may include Guidelines Overview
motion controllers, motors, a network, augment reality display and or smartphone Content For Engineers. That’s what CFE Media
stands for, and what CFE Media is all about –
a human-machine interface (HMI), and interface), wireless communications, and engineers sharing with their peers. We welcome
software. onboard networking. content submissions for all interested parties in
engineering. We will use those materials online, on
Sponsoring a medical make-a-thon our website, in print and in newsletters to keep
3-D printing, drones to address a humanitarian need can help engineers informed about the products, solutions
and industry trends.
Wong brought a carry-on-sized 3-D decrease the 9-month average wait for www.controleng.com/contribute explains how
printer to the presentation and set it to resources in the field. A Mars resupply mis- to submit press releases, products, images and
graphics, bylined feature articles, case studies, white
work on stage printing a part. Technology sion would be a similar time, she said. papers, and other media.
advances have made printers smaller. * Content should focus on helping engineers solve
problems. Articles that are commercial or are critical
In 2015, while listening in on astro- Startups in robotics of other products or organizations will be rejected.
naut communications on the International Startup companies offering various (Technology discussions and comparative tables may
be accepted if non-promotional and if contributor
new automation-related technologies
M More
corroborates information with sources cited.)
included a pick-and-place robotic arm * If the content meets criteria noted in guidelines,
INSIGHTS
expect to see it first on our Websites. Content for our
designed to mount on mobile robots, a e-newsletters comes from content already available on
vision-guided robot without position or our Websites. All content for print also will be online.
At www.controleng.com/magazine, see All content that appears in our print magazines will
more details and photos online, where this force sensors, robotic grippers, simple appear as space permits, and we will indicate in print
if more content from that article is available online.
article, in the digital edition links to: machine monitoring, and a talent assess-
* Deadlines for feature articles intended for the print
Additive manufacturing, drones, use ment and development dashboard soft- magazines are at least two months in advance of the
automation for humanitarian benefit ware. Think again about how to excite publication date. Again, it is best to discuss all feature
articles with the appropriate content manager prior to
Automation startups for robotics, vision, and involve the next generation in auto- submission.
machine monitoring, and talent. mation-related engineering. ce Learn more at: www.controleng.com/contribute
6 • February 2018 CONTROL ENGINEERING www.controleng.com

Allied Delivers
Innovative, and
Industry-Proven
Control Solutions
Reliable, easy-to-install
products for both inside and
outside the cabinet.
© Allied Electronics & Automation, 2018 Find this and more at alliedelec.com 1.800.433.5700
ANSWERS
COVER STORY: DCS
Aaron Crews, Emerson Automation Solutions
Updating a DCS for

optimized operations
If a company’s distributed control system (DCS) is more than 10 years old,
it is likely a significant barrier to reaching production goals.
A
lthough vintage distributed control Take advantage of information across
systems (DCS) might continue to the Industrial Internet of Things (IIoT)
operate reliably, facilities that employ The IIoT and the technologies that surround it
them may be lulled into a false sense offer profound power to the modern facility. Infor-
of security thinking, “Everything is mation distribution, a smart infrastructure, the
fine.” In reality, maintaining the status quo of older integration of systems, and the sharing of exper-
DCSs leaves organizations falling behind. When tise improve reliability, bring sharper insights, and
facilities delay or avoid system updates, risks grow. deliver decision-making power to the right people.
Emerson’s DeltaV Competitors improve their operations. Person-
Mobile (cover photo nel leave and organizational expectations change. Find strong productivity through
above) gives users both Dynamic markets require agility and insights older operational improvements
plant control data and DCSs cannot provide. When updated, DCSs enable When people can view and use information
analysis tools whenever facilities to take advantage of recent and powerful wherever they are in the formats they need, they can
they need it from wher- technology advances. better respond to the process, make productive deci-
ever they are. Cour- Twenty or 30 years ago, many technologies sions faster, and drive operational improvements
tesy: Emerson Automa- such as wireless networks, intelligent devices, and leading to safety, reliability, and efficiency. Recent
tion Solutions of course, the internet, did not exist. These inno- advances in DCS foundations employ HTML5 to
vations allow modern systems to offer greater reli- create an environment where digital workers can
ability and are designed with greater consideration view and use data from many sources across the
M More
ANSWERS
for system interoperability, flexibility, analytics,
operator awareness, and alarm management. Per-
haps most importantly, features and methodologies
organization. This gives them more ways to visual-
ize information and augment their environment on-
the-fly for better real-time results.
KEYWORD: Distributed
control system supporting cybersecurity and safety have become
Although vintage stronger and more standardized over the years. Opportunities and success in updates
distributed control systems The cost of addressing security, connectiv-
(DCSs) might continue to Protect with enhanced ity, and operations is minor compared to the
operate reliably, facilities cybersecurity power returns obtained by the organization because auto-
that employ them may be
lulled into a false sense of Manufacturers designing systems built circa mation is a lever for business success. The end
security. 1990 and 2000 could not anticipate the security results of improving automation include distrib-
Facilities employing older issues industries face today. Facilities employing uting information securely and easily to and from
systems do not operate many older systems today do not operate within the the DCS and simplifying operations for stronger
within a security-conscious security-conscious environment that provide the productivity.
environment.
agility and lifecycle management structures neces- After updating, the DCS will no longer limit
Modern DCSs have
embedded security upgrade
sary to respond to new and frequent threats. Put- production and efficiency and will enable organiza-
options. ting strategies in place for those systems can be tions to move closer to operational certainty. Secu-
extremely difficult. rity and information reach will be flexible enough
CONSIDER THIS
In many cases, it is impossible to properly secure to take advantage of upcoming opportunities and
Does your plant have a
legacy DCS that prevents
these older systems. If the team tries to respond to meet demands from the marketplace for safety and
your company from a cyber attack without the right infrastructure and production. ce
optimizing operations? tools, mistakes are probable, expenses are high, and
GO ONLINE the probable downtime is much longer. Plus, the Aaron Crews is director global modernization
Read the full version
team would be forced into upgrading to address solutions at Emerson Automation Solutions. Edited by
of this article at the security breach in a reactive action rather than Jack Smith, content manager, Control Engineering,
www.controleng.com. through proactive planning. CFE Media, jsmith@cfemedia.com.

We kick acid.
Having washdown or corrosion issues?
It’s time to kick acid with our Food
Industry Package. It conquers corrosion
with its epoxy primer, USDA finish, fully
encapsulated stator, epoxy conduit box,
and stainless steel TorqLOC® keyless
hollowshaft. It’s no wonder that our
motor lasts 10 times longer than the
competition in extreme environments
such as the poultry industry!
seweurodrive.com / 864-439-7537
ANSWERS
COVER STORY: DCS
Stephen Rose, Rockwell Automation
Biopharmaceutical company optimizes

manufacturing processes with modern DCS
Gilead Sciences used a new, flexible distributed control system (DCS) for a pilot lab to
support research and development (R&D), clinical trials, and meet pipeline demands.
A
new distributed control system (DCS) The virtualized platform consisted of nine vir-
is helping a biopharmaceutical com- tual servers, but only required two physical host
pany in a pilot laboratory application machines onsite to run the human-machine inter-
support research and development face (HMI) and historian software. The virtualized
(R&D) and meet pipeline demands. solution helped reduce costs by minimizing the
For 30 years, Gilead Sciences Inc., head- amount of hardware and power needed.
M More
ANSWERS
quartered in Foster City, Calif., has devel-
oped treatments to address significant unmet
medical needs. Banks Integration Group was
The information-enabled functionality of the
new system included redundant historian capabil-
ities to provide production intelligence to opera-
KEYWORD: Distributed control tasked to design, program, and install a pro- tors and scientists. The system pulled the data into
system (DCS)
cess control information system within a trend reports that the scientists rely on for day-to-
How a DCS can help streamline
manufacturing processes constructed pilot lab to provide an easier day decision-making instead of manually collecting
Choosing a DCS for production way to collect data, reporting, and provide the data.
improves intelligence enough flexibility to grow with Gilead. Banks Integration implemented five thin-client
How to improve the data HMI stations throughout the pilot lab as part of the
collection and reporting process. Selecting a DCS for the system. At each station, scientists can easily access
GO ONLINE new pilot lab historian data to view trends and pull robust reports
More information is available Banks Integration wanted a system that in real-time. The HMIs include alarm notification
online, including a link for more could easily integrate with the new equipment software. The software is integrated with the alarms
about Banks Integration Group. and vendor-supplied control systems in the and DCS’ events component and automatically send
CONSIDER THIS new, 23,914-sq-ft pilot lab. alarm email notifications to the appropriate person-
How can other industries Banks Integration selected a virtualized nel to help make more informed decisions.
optimize their manufacturing DCS to meet project requirements and reduce Because the DCS was built on open software and
processes with more modern server hardware. Having one common sys- communication protocols, it could be integrated
control systems? tem across all of the facilities would allow Gil- with the PLC-based original equipment manufac-
See two more photos on p. 3. ead the flexibility to maintain the system and turer skid equipment deployed across the pilot lab.
make necessary changes, which has some-
thing it had struggled to do in the past with other Improved visibility, flexibility,
proprietary systems. and scalability
Banks Integration leveraged the DCS library of The new system is also flexible, which allowed Gil-
process objects for life sciences. This “out-of-the-box” ead to adapt each manufacturing process for each dif-
library of modules included preprogrammed code, ferent drug at the lab. The facility produces a wide
modules, and faceplates customized for life sciences range of products for research and experimentation,
applications and a full set of design and testing docu- rather than one drug consistently. So, they created
mentation that followed the good automated manu- a DCS based on a reusable, maintainable library of
facturing practice lifecycle model. Using the process code modules to help ensure system changeovers are
A greenfield pilot lab objects library allowed Banks Integration completed streamlined.
required Gilead Sci- the programming in days compared to weeks. System scalability also means the company can
ences to select a pro- expand and integrate additional systems as the future
cess and information Less programming, hardware pipeline grows. ce
system that could ease A big benefit of using the library of process
flexibility and compli- objects for validation testing meant Gilead had the Stephen Rose is an account manager at Rockwell
ance as the company necessary design and test documentation, knowing Automation. Edited by Emily Guenther, associate
grew. Courtesy: Rock- that the automation vendor had tested and verified content manager, Control Engineering, CFE Media,
well Automation the modules. eguenther@cfemedia.com.

Technology Elevated to the Cloud.
Grounded by Honeywell’s Dependability.
Experion® PKS and SCADA control are now available
Time to Elevate in secure hosted solutions - for lower upfront cost

and continual support. Experion Elevate is process
Your Thinking. SCADA delivered as a scalable service. Open VEP

(Virtual Engineering Platform) – Engineer’s
Choice Honorable Mention - offers
off-process development, testing,
and training.
2018
Connected Industrial
HONORABLE
MENTION
For more information, please visit

www.honeywellprocess.com/Elevate
Connected Plant www.honeywellprocess.com/OVEP
© 2018 Honeywell International Inc.
Connected Worker
ANSWERS
HOW TO MANAGE ALARMS
Shashidhara Dongre and Manoviram Rath, L&T Technology Services
Alarm management:
6 hazards, 4 strategies
Alarm management in an IIoT world: Correlation and classification of industrial
process control alarms are vital for safety, speed, and efficiency. Software helps.
A
n alarm management system loses more than 5% of its total capac- which could prove to be a hindrance to the
communicates any hindrance in ity each year due to slowdowns and an process operators responding to a critical
the smooth functioning of plant approximately equal amount due to off- situation. Six hazards are highlighted.
operations. Plant manufactur- spec product, quality giveaway, and other
ing remains a key element of the overall lost opportunities, not considering any 1. With more low-cost sensors and
business ecosystem and business continuity unscheduled unit outages that might occur. digital controls, the ease and low cost of
is a direct function of the uptime of such Correlation and classification of alarms adding alarms could lead to unchecked
plants. Large displays that show a number before they are shown to the operator is growth in the number of alarms installed
of alarms and information associated with vital. Companies also are exploring aug- at the plant. This leads to the problem of
it could be baffling to the operator. This mented reality (AR) and virtual reality alarm floods, which is where the same fault
could strain human alertness levels and (VR) to complement alarm management. triggers multiple alarms in a short time.
hamper the operator’s capacity to deal with Alarm management systems are one of
a potential situation. the undervalued aspects of process auto- 2. Multiple alarms show extensive
General results indicate a typical plant mation and face a number of challenges, amount of data to the operator. During an
Your enclosure alternative.

Thousands of products IN STOCK! Quality you can trust.
Industrial enclosures for all applications.
Visit hammondmfg.com
to find a Hammond enclosure distributor. Quality Products. Service Excellence.
(716)630-7030 | sales@hammfg.com
event when these alarms are triggered in a 3. Cloud-based alarm management: operator response guidance and abnormal
flood, it could lead to the operator missing A cloud-based alarm management appli- situation response guidance into an alarm
critical signals in the chaos. cation can help an organization enhance management strategy can help. ce
alarm management. It provides a plant
3. Without a disciplined alarm man- manager quick access to real-time mean- Shashidhara Dongre is head of delivery,
agement program, the systems and ingful alarms when mobile or away. plant engineering, and Manoviram Rath
momentum will be disrupted due to false is senior DGM, plant engineering, both at
triggers, which will prevent operators from 4. Integrated operator response L&T Technology Services, a CFE Media
correctly identifying critical alarms. guidance: An abnormal situation might content partner. Edited by Mark T. Hoske,
make the operator is incapable of dealing content manager, Control Engineering,
4. Alarm systems that have not with the situation efficiently. Integrating mhoske@cfemedia.com.
received the attention and resources that
are warranted often encounter the issue of
nuisance alarms, which are triggered when
no abnormal condition exists or when no
operator action is required. Rugged Precision
5. Alarms assigned with the wrong The MAQ®20 Industrial
priority can become unimportant to the
operator and potentially meaningless. Mul- Data Acquisition & Control System
tiple alarms can lead to wrong choices.
6. Some plants still use the alarm

management philosophy from when the
plant was built. This adversely affects the
speed and accuracy with which the oper-
ator can identify the alarms that require
immediate action.
Integrated alarms: 4 steps

Strategies are changing for deploying
an efficient integrated alarm management
system because of the Industrial Internet
of Things (IIoT). Integrated alarms should
follow four steps.
1. Alarm integration and correla-

tion: Alarms in a plant typically come from
disparate multivendor systems. Alarms
should be integrated using IoT as it will
enable the operator to quickly identify the
underlying cause. Signal Integrity, Compact Design
2 Software Packages for DAQ or T&M
2. AR and VR technologies can save
the operator a significant time in resolving • $17 per Channel Possible –
an issue. Lowest Cost in Industry
M ANSWERSMore • Up to 384 Channels in 19”

Instrumentation Rack
• Application Software from $250
KEYWORDS: Alarm management, alarm
strategies, alarm hazards • ±0.035% Accuracy
CONSIDER THIS • 1500Vrms Channel-to-Bus
How can smarter alarm strategies and Isolation
technologies improve overall effectiveness?
ONLINE • PID Software Control
- Up to 32 Loops with ReDAQ® Shape
More advice is in this article online. From
the digital edition, click on the headline.
- Unlimited Loops with IPEmotion
Get the process and advanced control • –40°C to +85°C Operating
newsletter at Temperature Instrument Class® Signal Solutions
www.controleng.com/enewsletter dataforth.com • 800-444-7644
February 2018 • 13
ANSWERS
ALARM MANAGEMENT
Travis Cox, Inductive Automation
How to avoid alarm overload

A
n operator’s dream shift doesn’t
include being overloaded by
alarms. In reality, it happens
Improve supervisory control and data acquisition (SCADA) more often than operators
and supervisors prefer. With a flood of
alarm management and avoid alarm overloading by con- supervisory control and data acquisition
solidating alarm systems and setting up protocols. (SCADA) alarm notifications, there’s a
danger of missing a critical alarm among
a sea of ordinary ones. Consider three
tips for improved alarm management.
1. Consolidation: Consolidating
ELECTRIC!
alarms allows the user to reduce clutter
and to process information more quickly
by receiving one notification with a list of
95 alarms instead of 95 separate notifica-
tions, which is exhausting and impossible
to manage. The principles of “delay” and
“frequency” are what make consolida-
tion work. When a delay is set, the user is
telling the system to hold onto an alarm
! for a while before sending out a notifica-
NEW tion. This gives the system time to take
in more alarms so it can collect a batch
and send them all. The user defines the
delay, which will vary by system. The
clock on the delay resets with each new
Series EGRR alarm. If alarms keep coming, the clock
Electric High
Series ECVA/ECVR Capacity Grippers will continue to reset, and the system
Rail Screw Electric wouldn’t send a notification. That’s where
Cylinders
frequency comes in.
2. Alarm frequency overrides

delay, sends the notification:
Series ESK/ESL Series ESFX Let’s say you set frequency to 60 seconds.
Electric Thruster Slides Modular Electric Slides
That means the system will send all the
collected notifications from the last 60
USDA Certified for CIP seconds, even if the delay clock is still
Series ECP being continually reset as new alarms
Series ESG Electric
Gantry Slides
IP69K Cylinders continue to come in. The delay setting
gets the system to collect a bunch of
alarms, and the frequency setting ensures
nothing is delayed for too long. Adjusting
• Electrically-powered units built on Your Motor, delay and frequency together while fine-
the foundation of PHD’s proven Your Way! tuning the system will allow companies to
pneumatic product technology find settings that work best.
With PHD Plus, you can use
the motor of your choice.
• Electromechanical actuators
offer ﬂexibility to use the motor
3. Escalate: Escalation involves telling
the system to notify others if the primary
of your choice
operator isn’t responding in a certain
• High thrust and speed capacities time. Type of notification also can be
escalated. (Read more online.) ce
Travis Cox is co-director of sales engineer-

ing at Inductive Automation. Edited by Jack
Call 800-624-8511 or visit Smith, content manager, Control Engineer-
phdplus.phdinc.com/plusad ing, CFE Media, jsmith@cfemedia.com.
P.O. Box 9070 • Fort Wayne, IN 46899 USA
input #9 at www.controleng.com/information 14 • February 2018

Protect against current and emerging USB-borne
threats with Secure Media Exchange.
Secure Media Exchange (SMX) reduces cyber security
Securely use removable risk and limits operational disruptions by monitoring,

protecting, and logging use of removable media
media across industrial throughout industrial facilities.
control networks.
An award winning technology
Connected Industrial
Connected Plant
Connected Worker
For more information, visit www.hwll.co/SMX
Cyber Security
Industrial Solutions
Cyber Security ©2018 Honeywell International Inc.

ANSWERS
MOTORS AND DRIVES
Dan Messina, Rensenhouse Electrical Supply
Innovations in electric motor

T
he concept of mechanical
motion from an electrical cur-
rent source is not new, but the
technology: the first 100 years discoveries of the past pro-
vide the foundation for today’s advanced
Motor advancements originated from 19th century experiments motors. In 1820, Hans Christian Oer-
sted observed that current from a battery
with electric coils and the three-phase induction motor. deflected a compass needle, and Andre-
Marie Ampere invented the solenoid coil.
Michael Faraday’s 1821 experiments
demonstrated rotation of a wire in a cir-
cular orbit around an electromagnet.
Have a Problem a Over the next 70 years, numerous elec-

trical giants progressed toward a true
Cabled Switch Can’t Solve?

induction motor and pushed inventors to
fund and create systems capable of power-
ing these new devices. (See more online.)
… a Steute Wireless Switch could be a solution. Now with an ac variable frequency
drive (VFD) the number of poles is no
longer a driving factor nor is applied fre-
quency a constant. Previously, motor
starting methods for ac induction motors
were either across the line or soft starting
(reduced voltage starting or split winding
delta/wye). Instead of a pure sine wave, a
VFD uses pulses of voltage in a method
called pulse width modulation (PWM).
The ac voltage is converted to dc then
inverted back to ac and the voltage is pulsed
though a solid-state switch, called an insu-
lated-gate bipolar transistor (IGBT). An
IGBT allows the user to modulate motor
speed by adjusting the Volts/Hertz ratio;
460/60 is full speed, and 230/30 equals
half speed, etc. This control method causes
electrical stresses, which led to the invert-
Problem: Manufacturer wanted a means of automatically signaling
er duty rated motor. In an across-the-line
the stock room when parts at remote assembly stations
motor starter, frequency is constant, and
needed replenishment.
voltage has an upper limit—no more than
the utility supply. With a VFD, frequency is
Solution: STEUTE provided rugged, battery-less, wireless position
no longer constant, and voltage is switched
sensing switches beneath the feed track for each assembly
(pulsed) thousands of times per second
item. When the last bin of each assembly part moves into
from zero to peak to mimic a sinusoidal
position for consumption, the switch senses the absence
wave form familiar to the motor. Peaks may
of an additional bin of parts sending a signal to the stock
reach 1,500 V or higher, which can damage
room. Additional stock is immediately dispatched to the
windings in an unsuitable motor.
assembly location, reducing downtime and increasing
Inverter duty rated motors combat this
productivity.
problem by using winding insulation that
eliminates corona inception voltage (when
What’s your problem? insulation becomes conductive). ce
Call to discuss a possible solution.
Dan Messina, CEP, is power technical con-
sultant, Rensenhouse Electric Supply in
Kansas City, Mo., part of CED’s Industrial
Creating Industrial-Grade Switch Solutions without Cables Solution Network. Edited by Chris Vavra,
production editor, Control Engineering,
CFE Media, cvavra@cfemedia.com.
(800) 927-6298 www.switches-sensors.zf.com/us E-Mail: switches-sensors@zf.com
input #11 at www.controleng.com/information 16 • February 2018
Simplify
pressure
calibration
for faster, more
accurate results
Let the new Fluke 729 Automatic Pressure Calibrator
change the way you calibrate.
• Fast, easy setup with automatic pressure regulation
• Automatic, no-hassle calibration and documentation
• Built-in HART communication
• No hand pumps or manual adjustments required
2018 Check out this

revolutionary tool at
fluke.com/729
©2018 Fluke Corporation.

6010485a-en
WINNER

ANSWERS
ENERGY EFFICIENCY
Brian Bannister, Lafert Electric Motors
Design motors to achieve

energy efficiency requirements
Original equipment manufacturers and end users can comply with (and exceed)
current electric motor energy-efficiency requirements (for extra benefits).
T
he European Commission’s statutory effi- motors outside the EU where equal efficiency levels
ciency regulations for electric motors, are not demanded.
which came into force in January 2017,
require all ac industrial electric motors IE4 and IE5 motors
with a rated output of 0.75 to 375 kW to High-performance permanent magnet IE4 and IE5
operate within the Regulations’ specified motors might be considered by some as excessive, but
M More
ANSWERS
parameters.
The most common solutions offered to
achieve these efficiency levels are based on
they do offer immediate and future benefits for origi-
nal equipment manufacturers (OEMs) and end users.
One immediate benefit is compliance for the fore-
KEYWORD: either an IE2 motor with a variable speed seeable future. Design engineers can develop equip-
Motor efficiency standards drive (VSD) package or a stand-alone, ment with confidence, knowing which motors they
European Commission direct on-line IE3 motor. Compliance can incorporate in their designs to achieve specif-
statutory efficiency regulations
for electric motors cover ac should be a company’s first goal; achiev- ic performance characteristics, while not having to
industrial electric motors from ing it can be dictated by numerous factors. change machines from a weight and size point of view.
0.75 up to 375 kW. For applications where equipment is driven Some IE4 and IE5 motors can offer up 50% savings in
High-performance permanent by motors with power ratings lower than weight and can reductions of up to two frame sizes.
magnet IE4 and IE5 motors offer 0.75 or above 375 kW, there are no specific When making decisions about how to meet the
benefits.
guidelines or requirements. required efficiency standard, return on investment
GO ONLINE Equipment and machine manufacturers (ROI) should be considered. An IE3 motor carries an
Read this article online at can continue to use IE1 efficiency motors estimated 20% premium over an IE2 alternative, but
www.controleng.com for more. in the European Union (EU) if they have energy savings from higher efficiency make it possi-
CONSIDER THIS them in stock, but cannot continue making ble for users to achieve payback in less than two years.
What benefits accrue by buying IE1 motors for customers in the EU. IE4 and IE5 motors will become standard in the
motor ahead of standards? They can continue to supply IE1 next few years. It is worth adopting the higher efficien-
cy motors today to gaining the energy savings now.
This might be the case with VSDs because both IE4
and IE5 permanent magnet motors require them.
While compliance is obligatory, it is up to the
OEMs and end users to adhere to the standards.
According to the United Kingdom’s Department
for Environment, Food and Rural Affairs’ (DEFRA’s)
June 2013 environmental reporting guidelines. (See
details with this article online.)
It’s better for manufacturers to build in compliance
with the future in mind so they can avoid product
redesigns and associated price increases later on. ce
Brian Bannister is a motor specialist at Lafert Elec-

tric Motors. This article appeared Oct. 30, 2017 on
the Control Engineering Europe website. Edited by
High performance permanent magnet motors aren’t required yet by the Chris Vavra, production editor, Control Engineer-
European Commission’s statutory efficiency regulations but offer benefits ing, CFE Media, cvavra@cfemedia.com. See more at
for OEMs and end users. Courtesy: Lafert Electric Motors www.controleng.com/international.

ADVERTISEMENT
L &T Technology Services
Limited is a leading global
pure-play engineering services company
in the areas of mechanical and
manufacturing engineering, embedded
systems, software engineering and Dr. Keshab
Panda
with a multi-vertical expertise across process engineering.
Chief Executive
five industry segments and serves more Officer and
than 200 customers globally, 48 of Chief Executive Officer and Managing Managing
which are included in the top 100 Global Director, Dr. Keshab Panda says, Director
Engineering R&D spenders. With a “In an evolving technology landscape,
annualized run rate of USD 500 million harnessing organizational efficiency and
in revenues, the company offers reducing business complexities is vital
consultancy, design, development and for having the edge over the competition. real-time responses with sensors and
testing services across the product LTTS as a leading global engineering visualization technologies including
and process development life cycle. services company has expertise that ability to handle change using predictive
spans across Smart Products and and preventive data analytics. LTTS is
Having valuable experience in multiple Manufacturing Services to Mechanical at the global forefront of enabling smart
technologies, industry knowledge, Engineering and Embedded System manufacturing having already carved
multi-site project management expertise, and Applications. We integrate Next- out success stories for its clients such as
and cutting-edge engineering tools, Gen technology to deliver innovative integrating a new automobile model into
L&T Technology Services enables its cus- solutions helping organizations existing manufacturing lines using virtual
tomers to reduce time-to-market of their re-imagine their operating models and simulation of robotic welding, PLC
end products and services, innovate revitalize the business strategy.” programming and HMI design.
On Digital Engineering, LTTS’

indigenously built i-BEMS platform
is deployed to develop the world’s
smartest office campus in Israel in
collaboration with Microsoft. The smart
campus will be the centerpiece for a new
era of modern Smart City technologies
The company’s delivery centers in Peoria, Illinois, USA and Bangalore, India
that use energy efficiency systems, light-
to create new products and solutions, The company is placing its bet on four ing controls, thermostats and sensors.
reduce cost of development and meet pillars of new-age engineering —
increasing regulatory requirements. namely Digital Engineering, Smart The company has a customer base spread
With a strong focus on innovation Manufacturing, Pervasive Engineering across the globe including 52 Fortune
driven technology, the company has and Perceptual Engineering. Pertaining 500 companies. Its global workforce
created several unique engineering to Smart Manufacturing particularly, it is numbering over 11,000, are spread across
solutions and has extensive presence in known that the manufacturing sector has 15 global delivery centers, 28 global
multiple sectors having filed 287 patents lagged behind the services growth, mak- sales offices and 38 innovation labs.
including co-owned with clients. ing it imminent for businesses to consider L&T Technology Services has been
The ER&D portfolio of the company the ‘smart’ proposition. This is mainly conferred with multiple awards and
caters to all major industries like with aim of boosting efficiencies and re- accolades by a number of recognized
Transportation, Industrial Products, ducing costs. With Smart Manufacturing international institutions and has a part-
Telecom and Hi-Tech, Medical Devices at the helm, factories are now serving as nership with multiple technology leaders
and Process Industry offering solutions Intelligent Integrated Plants enabling like Microsoft, PTC and WindRiver.
Tel: +91 80 6767 5173 www.lnttechservices.com

ANSWERS
INSIDE MACHINES
Winn Hardin, AIA
Machine vision systems

push automotive autonomy
Car manufacturers turn to machine vision companies for deep learning
algorithms to help autonomous cars navigate and process large amounts of data.
T
he race is on to make self-driving vehicles said Bier. “This key advance has enabled the deploy-
ready for the road. More than 2.7 million ment of vision into vehicles.”
passenger cars and commercial vehicles AImotive is a software company bringing deep
equipped with partial automation already learning algorithms to fully autonomous vehicles. Its
are in operation, enabled by a global auto- hardware-agnostic platform uses neural networks
motive sensors market estimated to reach $25.56 bil- to make decisions in any type of weather or driving
lion by 2021. condition. Four parts follow. 1) Recognition engine
Carmakers are building on automated driver-assis- uses camera images as the primary input. 2) Location
tance systems, which include functions such as self- engine supplements conventional map data with 3-D
parking and blind spot monitoring, as the foundation landmark information; 3) Motion engine takes the
for developing self-driving cars. The core sensors that positioning and navigation output from the location
facilitate automated driving—camera, radar, lidar, and engine to predict movement patterns of surroundings;
ultrasound—are well developed but keep undergoing 4) Control engine guides the vehicle through low-lev-
improvements in size, cost, and operating distance. el actuator commands, such as steering and braking.
Other technological challenges include mastery of For an automated vehicle to make critical decisions
deep learning algorithms to help cars navigate public based on massive volumes of real-time data coming
roadways and handle heavy data processing. To help from multiple sensors, processors would have had to
find a path toward total autonomy in driving, auto- become more powerful computationally while con-
makers are turning to machine vision software com- suming less operational power. Software suppliers in
panies to help. this space are developing specialized processor archi-
tectures “that easily yield factors of 10 to 100 times
Algorithms get smarter better efficiency to enable these complex algorithms
The machine vision industry is no stranger to the to fit within the cost and power envelope of the appli-
outdoor environment, with years of experience devel- cation,” said Bier. “Just a few years ago, this degree of
oping hardware and software for intelligent transpor- computational performance would have been consid-
tation systems, automatic license plate readers, and ered supercomputer level.”
border security applications. While such To make safe, accurate decisions, sensors need to
M More
ANSWERS
applications require sophisticated software
that accounts for uncontrollable factors
process approximately 1 GB of data per second, Intel
said. Waymo, Google’s self-driving car project, uses
KEYWORDS: Machine vision, like fog and sun glare, self-driving vehicles the chipmaker’s technology in its driverless, camera-
autonomous vehicles encounter and process many more vari- equipped Chrysler Pacifica minivans, which are shut-
Automotive companies rely ables that differ in complexity. tling passengers in Phoenix as part of a pilot project.
on machine vision companies “Autonomous driving applications have The industry needs to determine where the deci-
to help develop smarter
autonomous vehicles.
little tolerance for error, so the algorithms sions should occur. “In our discussions with manufac-
Automated vehicles need to
must be robust,” said Jeff Bier, founder of turers, there are two trains of thought,” said Ed Goffin,
make decisions with massive Embedded Vision Alliance, an industry marketing manager for Pleora Technologies. 1) Ana-
amounts of sensor data. partnership to help companies integrate lyze data and decide at the smart camera or sensor
GO ONLINE vision into systems. “To write an algorithm level, and 2) feed data back over a high-speed, low-
Read this story online at
that tells the difference between a person latency network to a centralized processing system. ce
www.controleng.com for more and tree, despite the range of variation in
AIA machine vision stories. shapes, sizes, and lighting, with extremely Winn Hardin is contributing editor for AIA. This arti-
CONSIDER THIS high accuracy can be very difficult.” cle originally appeared in Vision Online. AIA is a part of
Should autonomous vehicle
Algorithms have reached a point where, the Association for Advancing Automation (A3), a CFE
knowledge be applied elsewhere on average, “They’re at least as good as Media content partner. Edited by Chris Vavra, produc-
in the supply chain? humans at detecting important things,” tion editor, CFE Media, cvavra@cfemedia.com.
M1 • February 2018 CONTROL ENGINEERING www.controleng.com

NO NODES...
LIKE OUR NODES.
The WAGO-I/O-SYSTEM
The System that Started the Modular I/O Revolution
r Fieldbus independent – supports 16+ protocols
r 500+ digital, analog and special function I/O modules
r Compact – up to 16 DI or DO in just one 12 mm wide module
r XTR Series for eXTReme temperature, shock and vibration
r Add-on instruction library for RSLogix 5000® software
www.wago.us/IOsystem
56/RJL[LVDUHJLVWHUHGWUDGHPDUNRI5RFNZHOO$XWRPDWLRQsQRHQGRUVHPHQWRUDƱOLDWLRQLPSOLHG
ANSWERS
MACHINE VISION
Jon Breen, Breen Machine Automation Services LLC
Robust vision inspection

in 5 steps
When performing a machine vision inspection, users should
assess the application, optics, lighting, setup, and runtime.
M
achine vision inspection is a pow- Table: Recommended machine vision
erful, versatile tool in automa- pixels for an application
tion. Despite constant technology Recommended
advances, machine vision imple- number of pixels
mentation tends to follow the same Measurement tolerance =
Linear measurement
process with most of the same best practices and pit- 10 pixels
falls. Follow these five steps in the process to align Area measurement 5 x 5 mm
with best practices and avoid potential pitfalls. 25 – 35 mm
Text recognition (OCR)
(character height)
1. Assess the application
More
M ANSWERS Some things aren’t a good fit for
machine vision. Experience is usually a
Camera manufacturers usually have an online cal-
culator to assist with this.
good indicator, but if there are any ques-
KEYWORDS: Machine vision, tions about feasibility, test it first. Unfore- 3. Consider lighting
inspection seen challenges can cause costly hardware The purpose of lighting is to make key features
A robust machine vision changes and schedule delays. highly visible, while reducing the visibility of features
inspection should factor the
application, optics, lighting,
that might confuse the inspection tools. Finding the
setup, and runtime. 2. Select the camera and optics right solution can require experimentation, creativity,
There are many tools designed Select a camera based on these features: and experience. This is the part of the inspection most
to make machine vision • Color vs. monochrome likely to change during installation, so do the due dili-
inspection a simple process. • Resolution gence for the implementation and test this beforehand
GO ONLINE • Firmware features to ensure things go smoothly.
Read this article online at • Inspection speed
www.controleng.com for more. • Lens focal length. 4. Set things up
Once all the parts are assembled, it’s time to make
things work. Get aperture and exposure in the ball-
park so focusing is possible. Set focus. Revisit aperture
and exposure. Setup location and inspection tools.
There’s no one right answer, but the rule of thumb is to
use the simplest inspection tools that do the job well.
5. Consider runtime
Initial programming is usually done on a small
sample of parts, but they don’t represent the entire
population. Train the system on a small sample, then
validate and tweak using a larger sample.
Do the work up front and validate thoroughly,
which will result in a system to be proud of. ce
Jon Breen is owner/controls engineer, Breen Machine

Setup is crucial for a machine vision application and a major factor Automation Services LLC. Edited by Chris Vavra, pro-
is providing a good field of view for the inspection. Courtesy: Breen duction editor, Control Engineering, CFE Media,
Machine Automation Services cvavra@cfemedia.com.

Seamless Integration
Free Custom Yamaha Add-On Instructions For Allen-Bradley PLCs
• Seamless integration using

custom Yamaha AOIs
• Simple drag and drop ladder
programming with
Allen Bradley RS Logix 5000
• Teach and replay points
in a Yamaha robot using
your own HMI
• Plus get FREE one-on-one
technical support with YRG!
For free technical support and

seamless integration visit:
www.yrginc.com/aoi
YRG
™
ROBOTICS
Compact Logix
or Control Logix
9101 Clubridge Drive

Fort Wayne, IN 46809
Phone: 260.747.3482
ANSWERS
INSIDE MACHINES
Tanya M. Anandan, RIA
Robotic machining used

for aerospace applications
Robotic waterjet systems use a mix of water and garnet that exits the waterjet
to make precise cuts for an industry that demands perfection.
R
obotic machining has come a long way and smooth motion to the waterjet process. With six
and has proven to be robust and accu- degrees of freedom, its articulated arm can approach
rate enough to achieve the demanding a workpiece from virtually any angle and follow a
tolerances required by the aerospace smooth, accurate, and highly repeatable toolpath to
industry. In one example, a robotic create precision cuts and contours. In metal cutting
waterjet system cut an integrated bladed rotor (IBR) applications, the waterjet rough-cuts the components,
for a commercial jet engine. which subsequently undergo final milling operations.
Using tap water mixed with an abrasive media Howes said a waterjet “can cut metal, composites,
that shoots out of a small orifice at ultra-high veloc- glass, stone, paper, food, just about anything. With
ity, a robotic waterjet system can cut through solid waterjet, you could be cutting metal one day and cut-
metal up to a foot thick. A six-axis robot can maneu- ting foam the next day on the same machine.”
ver a waterjet nozzle across a part, shaping the grace- Aquarese systems are used to cut titanium alloys,
ful contours of jet engine airfoils with ease. Inconel, Ni-based alloys, other superalloys, stainless
“This is 3-D cutting with waterjet,” said Dylan steel, and composites. Abrasive waterjet is required for
Howes, vice president of business development for cutting metals. Garnet is the abrasive media in 99% of
Shape Technologies Group. “The Aquarese system is such applications. Water and garnet exit the waterjet
the only 3-D robotic abrasive waterjet machine able cutting head at nearly four times the speed of sound to
to achieve 94,000 psi (6,500 bar).” increase cutting power by 1,000 times. It is a cold-cut-
The waterjet machine integrates technology with ting process without thermal fatigue.
advanced robotics to provide turnkey solutions for
Shape Technologies Group’s aerospace, energy, and Robotic accuracy, repeatability, rigidity
automotive customers. The robot brings flexibility Robotic waterjet has been used more commonly
for softer materials until the aerospace industry real-
ized its value for cutting metals and composites.
“It has become a more common application
because we can achieve better performance,” said
Sebastien Schmitt, North American robotics divi-
sion manager for Stäubli Corp. “We’ve made so much
progress with the rigidity of the arm and precision. It
makes it possible to work in that domain. Accuracy,
repeatability, rigidity, all this comes from our patented
gear box that we manufacture and design in-house.”
A high-payload 100 kg robot is for rigidity and to
withstand the ultrahigh-pressure waterjet. Schmitt
said performance competes with traditional milling
methods. “The cost of a 5-axis computer numerical
control (CNC) machine is three or four times the cost
of a system like you see here.”
Aquarese uses a humid environment robot devel-
Robotic waterjet system produces a stream of water traveling at oped specifically for wet environments. The enclosed
supersonic speed to cut a variety of materials, including superalloy arm structure is IP65-rated and reinforced by arm
components used in the aerospace industry. Courtesy: Shape Tech- suppression for added waterproofing. The IP67-rated
nologies Group/RIA wrist is corrosion-resistant and protected against low-

Robotic waterjet Your Single Source
for Automation
stripping system for
removing coatings from
turbine components.
Courtesy: Shape Tech-
nologies Group/RIA
Solutions
pressure immersion. The tool flange and critical parts are made
of stainless steel to hold up in corrosive environments. Longev-
ity is important, especially when the robot is working in harsh
environments.
The proprietary robot programming language is optimized for
compatibility with computer-aided design (CAD)-to-path soft- Automation 3200
ware. Howes said it’s a simple process to import a CAD model
and generate an optimized toolpath. The waterjet systems are pro-
grammed using a software suite bundled with the system. For 3-D
robotic waterjet cutting, a module with functions for specific appli-
cations is supplied. Applications include roughing blisks and fan
blade trimming. “We can also integrate the core removal systems
with cutting solutions for de-gating, as well as systems for remov-
ing the flashing from forged materials” using robotics, said Howes.
Ensemble®
Research enables more robotic machining

Research is underway at the Boeing Manufacturing Devel-
opment Center (BMDC) on the campus of the Georgia Institute
of Technology in Atlanta. The BMDC is focused on implement-
ing industrial automation in non-traditional ways, such as shim- Soloist®
less machining. The center is located in the 19,000-sq-ft Delta
Advanced Manufacturing Pilot Facility (AMPF).
Technologies developed at Georgia Tech have been transi-
tioned into production at Boeing, including new design methods
for advanced commercial aircraft, flow control for commercial
and military aircraft, vision systems for hole countersinking, and
autonomous robotics for assembly.
Other research includes teaching robots tasks through human
demonstration and exploring the use of robots as flexible fixtur-
ing devices. Robotic-assisted manufacturing will continue to be a CADFusion Motors Amplifiers
focus for researchers as advanced manufacturing grows. ce
Tanya M. Anandan is contributing editor for the Robotic Indus- Aerotech Automation Delivers...
tries Association (RIA) and Robotics Online. RIA is a not-for-prof- • High performance
it trade association dedicated to improving the regional, national, • Advanced controls for superior contouring,
and global competitiveness of the North American manufacturing in-position stability, move and settle, and
velocity control
and service sectors through robotics and related automation. This
article originally appeared on the RIA website. The RIA is a part • Reduced setup time
of the Association for Advancing Automation (A3), a CFE Media • Integrated calculators and extensive diagnostics
content partner. Edited by Chris Vavra, production editor, Control • Ease of use
Engineering, CFE Media, cvavra@cfemedia.com. • One software environment: .NET, C, G code,
LabVIEW®, MATLAB®, or AeroBasic™
M More
ANSWERS Industries
• Laser processing • Target tracking
KEYWORDS
Robotics, aerospace • Stencil cutting • Beam steering
Robotic waterjet machining is a cold-cutting process with no • Wire bonding • Dispensing
mechanical stress and part integrity is not compromised. • Stent manufacturing • Packaging
Researchers are looking at enabling technologies designed to allow • Sensor testing
• Grinding
robots to produce more complex features and surfaces.
• Web applications • Case erectors
GO ONLINE
Read this story online at www.controleng.com for more information.
CONSIDER THIS
What other applications would benefit from robotic waterjets?
www.aerotech.com • 412-963-7470
CONTROL ENGINEERING February 2018 • M6 input #18 at www.controleng.com/information
AH1217A-CSG
2018
ENGINEERS’ CHOICE AWARDS
Spotlight on innovation
Best automation, control, and instrumentation
products in 26 categories.
T
he 31st annual Control Engineering Engi- Engineering’s subscriber lists—all of whom are respon-
neers’ Choice Awards shines a light on 26 sible for or influence technology purchases, or have
categories of control, instrumentation, and hands-on day-to-day interaction with the technologies
automation products, revealing the best of in each category—then voted to identify the products
those introduced in 2017 as chosen by the Control they felt were the most exceptional based on tech-
Engineering print and digital audience. Review the nological advancement, service to the industry, and
winners and honorable mentions here to see if their market impact. The result is a short list of Engineers’
innovative solutions can help resolve one of your Choice Awards winners and honorable mentions in 26
most pressing problems. categories. A total of 1 grand winner, 26 winners, and
Also, join us in congratulating these technological 28 honorable mentions were named for 2018.
innovators. Let them know you learned about their Control Engineering staff thanks those who nomi-
solutions in Control Engineering, and tell them what nated products and voted. Find more product innova-
problems you need solutions for next. Their con- tions in the New Products for Engineers Database at
tinuous improvement ensures that manufacturers, www.controleng.com/NP4E. The 2018 Engineers’
machine builders, and automation system integrators Choice Awards will be presented to the winners on
can achieve the levels of agility, efficiency, and effec- April 16, 2018, in Chicago.
tiveness necessary to compete—and win—in today’s global
economy. Amanda Pelliccione is project manager of events and
A total of 88 finalists from 44 companies were listed on bal- awards programs, Control Engineering, CFE Media,
lots for evaluation. Automation professionals from Control apelliccione@cfemedia.com.
Engineers’ Choice Awards Index: 1 Grand, 26 Winners, 28 Honorable Mentions

29 UniStream Multi-Touch PLC, Unitronics 34 Simocode pro current/voltage measuring module, Siemens
29 ELM EtherCAT I/O, Beckhoff Automation 36 Sitrans FS230 digital clamp-on ultrasonic flow system,
29 729 Automatic Pressure Calibrator, Fluke Corp. Siemens
30 Allen-Bradley VersaView 5200 thin client, 36 Simatic PCS 7 V9 process control system, Siemens
Rockwell Automation 36 VeriSafe absence of voltage tester, Panduit
30 UNO-2484G modular, customizable, fanless PC, Advantech 36 Secure Media Exchange (SMX) for USB ports,
30 EZTouch I/O, EZAutomation Honeywell Process Solutions
30 EZRackPLCO, EZAutomation 38 FactoryTalk Batch V13, Rockwell Automation
32 Allen-Bradley Kinetix VPC servo motor, 38 Dream Report automated reporting and data analysis
Rockwell Automation software, Ocean Data Systems
32 Simatic S7-1500 T-CPU motion controller, Siemens 38 Studio 5000 integrated development environment,
Rockwell Automation
32 ASCII to EtherNet/IP gateway, Phoenix Contact
38 FactoryTalk Analytics for Devices, Rockwell Automation
32 Allen-Bradley Stratix 2500 lightly managed switch,
Rockwell Automation 39 Plantweb Insight, Emerson Automation Solutions
34 u-remote IO-Link Master, Weidmuller 39 InduSoft Web Studio V8.1, Schneider Electric Software
34 WI-I/O-2-E-N-GBL industrial wireless modem and I/O, 39 IoT Gateway, Bosch Rexroth
Weidmuller 39 MobileHMI V10.95, Iconics
34 Sinamics V20 Smart Access web server module, Siemens 40-44 Honorable Mentions
READ MORE ONLINE, including how to enter, at www.controleng.com/EngineersChoice.

®
2018 Engineers’ Choice
GRAND AWARD
Hardware – Hardware – Handheld Test,

Data Acquisition Measurement, Calibration
ELM EtherCAT I/O 729 Automatic Pressure

Beckhoff Automation Calibrator
Fluke Corp.
T he ELM EtherCAT I/O

module features metal
housing that optimizes
T he 729 automatic pres-
sure calibrator simpli-
fies the calibration process by
shielding and cooling in automatically generating pre-
UniStream Multi-Touch PLC measurement technology cise test pressures, improv-
Unitronics applications. At the same ing calibration integrity by
T
time, the durable housing compensating for leaks, and
he Grand Award—first introduced with provides enhanced flexibil- automatically documenting
the 2017 program—is bestowed upon ity at the interface level, such the pressure calibration pro-
the product that received the most over- as for LEMO or BNC plug cess to help meet compliance
all votes in the 2018 program. This year’s connectors or for the well- and regulatory requirements.
Grand Award recipient is the UniStream Multi- established cage clamps as With the rugged, portable
Touch PLC from Unitronics. a quickly customizable and 729, technicians input a tar-
The UniStream Multi-Touch programmable standard solution. Mea- get pressure and the calibrator
logic controller (PLC) with a 10.4-in. multi-touch surement accuracy of 100 automatically pumps to the
human-machine interface (HMI) panel enables the ppm at 23°C, precise sub-1 desired set-point while the
use of gestures using two or more points of contact μs synchronization, 24-bit internal fine adjustment con-
via mobile device. Multi-touch and two-hand ges- resolution, and a high sam- trol stabilizes the pressure at
tures—including Pinch and Zoom, Press and Hold, pling rate of up to 50,000 the requested value, deliver-
Double-Tap, and Swipe–offer increased operating samples per second deliver ing more accurate results and
safety and an improved user experience. Features high-quality data acquisi- speeding the calibration pro-
of this all-in-one PLC include media viewers, Real tion. With the ELM mod- cess. The 729 features auto-
Time Streaming Protocol, a built-in webserver, a ule, high-end measuring matic pressure generation and
variety of I/O options, auto-tune proportional-inte- devices and comprehensive control for multiple tests, easy
gral-derivative (PID), and recipe programs and data automation technology are calibration documentation,
logging via data tables and sampling. UniStream combined into one universal HART communication, and
provides completely modular and scalable hardware system. measurement of milliamp sig-
for customizable control, backed by efficient pro- www.beckhoffautomation.com nals on transmitter outputs
gramming software. Input 201 at www.controleng.com/information and sourcing and simulation
www.unitronics.com of milliamp signals.
Input 200 at www.controleng.com/information
www.fluke.com
www.controleng.com CONTROL ENGINEEERING February 2018 • 29

2018
ENGINEERS’ CHOICE AWARDS ®
Hardware – HMI, Operator Hardware – Hardware – Integrated Machine & Embedded

Interface, Thin-client Industrial PCs HMI Controllers Control – PLCs
Allen-Bradley UNO-2484G EZTouch I/O EZRackPLC

VersaView 5200 Advantech EZAutomation EZAutomation
Rockwell Automation
T he Allen-Bradley VersaV-
iew 5200 ThinManager
thin client is ideal for Thin-
T he UNO-2484G modu-
lar, customizable, fanless
PC with up to four iDoor or
T he EZTouch I/O flexible,
compact touch screen
controller is a modular all-
T he EZRackPLC is an
advanced programmable
logic controller (PLC) that is
Manager distributed applica- five HDMI ports is equipped in-one HMI and PLC unit Industrial Internet of Things
tions. The thin client is used with an Intel Core i7/i5/i3 that can act as a standalone (IIoT) and Wi-Fi Ready and
for displaying content deliv- processor, 8 GB of DDR4 machine controller or smart has USB data logging up to
ered from a remote Thin- memory, and rich I/O— HMI with local I/O for exist- 64 GB and programming
Manager server. Users can including 4 GbE, four USB ing PLCs. The EZTouch software and simulator pack-
have multiple thin clients set 3.0, four RS-232/422/485, I/O saves space, time, and age. This rugged, modular
up across a plant or facility one HDMI, and one display money for various control rack din-rail or panel-mount
and various roles with the port (4K). With an optional applications. Flexible I/O PLC features an integrated
convenience of having them second stack expansion kit modules include ac and dc message queuing telemetry
all maintained by the Thin- that adds the four iDoor or inputs/outputs, relay out- transport (MQTT) protocol,
Manager server. All con- five HDMI ports for added puts, voltage and current direct connectivity to exter-
tent remains on the server flexibly functionality, the analog I/O, thermocouple nal devices, and easy-to-set-
so downtime is reduced in UNO-2484G is designed to and resistance temperature up secure communication
the event of a failure. Inte- deliver high-performance detector (RTD) inputs, high- with other networks. The
grated widescreen display computing and maximum speed counter inputs, and EZRackPLC is designed to
size options range from 12- flexibility. With the iDoor pulse width modulation for be a “bridge” between exist-
to 22-in., provides one exter- modules, users can extend motion control. Display sizes ing operational technology
nal display output ports that or customize the platform range from 6 to 10 in. With within a plant, such as fac-
support up to 2560 x 1600 features to provide purpose- built-in communication pro- tory machines and plant
displays, and can operate in built, future-proof solutions tocols that require no addi- database networks, so valu-
0 to 50°C conditions. for diverse machine automa- tional modules, the EZTouch able data can be shared reli-
www.rockwellautomation.com tion, industrial IoT SCADA I/O can be integrated with ably and securely to improve
Input 203 at www.controleng.com/information server, and performance nearly all existing PLC plant productivity and
control applications. installations. efficiency.
www.advantech.com www.ezautomation.net www.ezautomation.net
Input 204 at www.controleng.com/information Input 205 at www.controleng.com/information Input 206 at www.controleng.com/information

2018
Motion Control Motion Control – Drives Network Integration – Network Integration –

Ethernet Hardware Ethernet Switches
Allen-Bradley Kinetix VPC Simatic S7-1500 T-CPU ASCII to EtherNet/IP Allen-Bradley Stratix 2500
Rockwell Automation Siemens gateway Rockwell Automation
Phoenix Contact
T he Allen-Bradley Kinetix
VPC servo motor pro-
vides smooth, integrated
T he Simatic S7-1500 tech-
nology CPU (T-CPU)
combines an expanded range
T he ASCII to EtherNet/
IP gateway easily net-
works legacy ASCII devices
T he Allen-Bradley Stratix
2500 lightly man-
aged switch provides the
motion control over Eth- of motion control functions to the EtherNet/IP network. security, resiliency, seg-
erNet/IP networks. The into one controller, signifi- It also integrates those leg- mentation, and bandwidth-
Kinetix VPC continuous cantly increasing perfor- acy devices into an indus- optimization benefits of a
duty servo motor is opti- mance with a fast backplane trial control system. The managed switch without
mized to run on Kinetix bus, Profinet interface, and gateway comes in a compact the need for extensive con-
5700 servo drives. A cool- short reaction times. Differ- DIN rail form factor that is figuration. The Stratix 2500
ing fan and cooling fins on ent CPU types are available easy to install and does not can prioritize critical indus-
the motor provide increased for multiple performance occupy much space in the trial network traffic. It also
torque and power output. In classes. A wide range of sig- control cabinet. It features can be configured for appli-
addition, encoder options nal modules for input and 256-bit AES encryption cation-specific needs. The
with improved resolution output as well as technology and authentication mecha- lightly managed switch
and accuracy provide more modules for special techno- nisms to prevent unauthor- exceeds the capabilities of an
precise and responsive con- logical functions, such as ized access. The advanced unmanaged switch by moni-
trol. The Kinetix VPC also counting, and centralized diagnostic functions of the toring and optimizing traffic
helps reduce machine down- and decentralized commu- serial port enable the user flow and providing diagnos-
time and uses larger, more nication modules are avail- to perform quick and easy tic information to help mini-
robust bearings to improve able to serve as interfaces to troubleshooting. The seam- mize downtime. It also can
L10 bearings life by up to the machine or plant. The less integration of virtual support up to 64 VLANs
60%. An optional single Simatic S7-1500 is approved COM ports through native for logical segmentation,
cable for power and feed- for protection class IP20 and Microsoft Windows drivers which helps reduce total cost
back helps reduce installa- designed for installation in a guarantees consistently high of ownership. Port security
tion, setup, and maintenance control cabinet. performance, especially for allows users to disable ports
time compared to dual-cable www.usa.siemens.com multiport applications. or control end-device con-
motors. Input 208 at www.controleng.com/information www.phoenixcontact.com/us nectivity based on the media
www.rockwellautomation.com Input 209 at www.controleng.com/information access control address.
Input 207 at www.controleng.com/information www.rockwellautomation.com

2018
WINNER
2018
Network Integration – Network Integration – Network Integration – Power – Energy, Power

I/O Systems Wireless I/O Wireless Products Protection, UPS
u-remote IO-Link Master WI-I/O-2-E-N-GBL Sinamics V20 Smart Access Simocode pro
Weidmuller Weidmuller Siemens Siemens
T he u-remote IO-
Link Master increases
machine availability by using
T he WI-I/O-2-E-N-
GBL industrial wireless
modem and I/O is designed
S inamics V20 Smart
Access web server mod-
ule is a small rugged device
T he Simocode pro cur-
rent/voltage measur-
ing module enables users
IO-Link right down to the with IIoT and Industrie 4.0 that connects any type of to achieve a high degree of
sensor/actuator level. This in mind. Easily configure smartphone or tablet with- measuring accuracy and a
level of transparency per- the wireless device as a hot out having to install special wide measuring range simul-
mits easy wiring, automatic spot modem or as an I/O software or download data. taneously, allowing Simo-
parameter setting, efficient radio for use around the This allows machine build- code pro also to be a sensor
communication, and exten- world through a webpage. ers and end users to transfer for motor data. With this
sive diagnostic options. The The user-friendly web-based settings, enabling fast com- measuring module, users get
4-channel IO-Link Master programming interface missioning with wizards and improved measuring accu-
meets current requirements allows for users to be able easy testing of the motor racy for all measured val-
by means of simplified to setup and deploy large or settings. The Sinamics V20 ues, allowing measurement
installation and commis- small networks within a few can be applied to operate of motor current, voltages
sioning, extended power clicks and automatically fixes pumps, fans, compressors, up to 690 V, and monitoring
supply, automatic parameter errors. The WI-I/O-2-E-N- and conveyor systems, as of power-related measured
setting, and expanded diag- GBL provides robust/secure well as for simple drive tasks quantities. Also, ground-
nostic functions. The extra two-way wireless commu- in the processing and han- fault detection is available
features offered ensure eas- nications in extremely chal- dling industry. Smart Access with adjustable warning
ier commissioning, more lenging indoor and outdoor works with both Apple iOS and tripping thresholds
transparent processes, and industrial environments. It is and Google Android operat- and decoupling modules
a greater level of efficiency. ideally suited for water and ing systems, along with com- are no longer required.
These enhancements gener- wastewater in-plant appli- monly used HTML5 capable The Simocode pro features
ate a higher return on invest- cations, oil and gas remote web browsers. standard mounting rail rep-
ment. The product permits sensor monitoring, discrete www.usa.siemens.com etition on the front of the
a web-based configuration factory automation, inven- Input 213 at www.controleng.com/information device for compact system
of the IO-Link Master and tory management, and ware- configuration.
IO-Link devices. Additional housing applications. www.usa.siemens.com
standalone software tools are www.weidmuller.com
not required. Input 212 at www.controleng.com/information
www.weidmuller.com

2018
Process Control – Process Control Safety – Safety – Process Safety,

Process Sensors Systems Machine Safety Intrinsic Safety
Sitrans FS230 Simatic PCS 7 V9 VeriSafe Secure Media Exchange

Siemens Siemens Panduit (SMX)
Honeywell Process Solutions
T he Sitrans FS230 digi-

tal clamp-on ultrasonic
flow system is suitable for
T he Simatic PCS 7 V9
process control system
is focused on supporting
V eriSafe simplifies a work-
er’s process to comply
with safety regulations that
T he Secure Media
Exchange (SMX) pro-
vides multiple layers of pro-
a broad array of industries future-oriented digitaliza- require conducting a voltage tection against USB-borne
requiring high-quality liquid tion down to the field level. verification test to validate threats at industrial sites.
flow measurement, includ- It includes powerful, com- the absence of voltage when It features threat intelli-
ing water and wastewater, oil pact hardware that supports servicing electrical equip- gence and threat-detection
and gas, food and beverage, Profinet to allow greater ment. The VeriSafe absence cloud to keep systems up to
pharmaceutical, and chemi- freedom in plant design and of voltage tester automates date against these threats.
cal. The flow system consists operation. Profinet provides the voltage verification pro- Even though USBs repre-
of a Sitrans FST030 transmit- the prerequisites for power- cess, which traditionally sent one of the top threats in
ter paired with Sitrans FSS200 ful, plant-wide communi- includes a number of com- the industrial space, they’re
clamp-on ultrasonic sensors. cation in real time, which is plex and time-consuming still the principal vehicles
The transmitter includes a indispensable in the era of stages when using hand-held for updating and maintain-
digital sensor link that digi- Big Data. The Simatic PCS portable test instruments. ing PCN configurations.
tizes the signal at the earli- 7 saves time when integrat- Once installed, a simple SMX addresses this by mon-
est stage of measurement, ing field devices: the Simat- push of a button on the Veri- itoring, protecting, and log-
resulting in an optimal sig- ic compact field unit (CFU) Safe enables qualified elec- ging the use of USBs and
nal-to-noise ratio. With its initializes connected field trical workers to verify the removable media through-
integrated PerformanceP- devices automatically and absence of voltage and see an out industrial facilities. SMX
lus algorithm, the transmit- integrates them into the proactive indication when the secures open USB ports
ter detects even the smallest cess control system. What absence of voltage is con- from non-checked devices
changes in flow for consis- used to take 30 minutes now firmed. This provides a way like smartphones and other
tently high accuracy of 0.5% takes less than one. to safely, reliably, and effi- removable media. SMX
to 1% of flow rate and a very www.usa.siemens.com ciently verify the absence bridges the divide between
stable zero point. Input 216 at www.controleng.com/information of voltage before accessing IT and OT requirements for
www.usa.siemens.com potentially dangerous elec- safer process manufacturing.
Input 215 at www.controleng.com/information trical equipment. www.honeywellprocess.com
www.panduit.com Input 218 at www.controleng.com/information

A New Dimension in HMI/SCADA
ICONICS is honored to be named a Control Engineering 2018 Engineers’
Choice Award winner. Our MobileHMI™ automation software features the
latest technology, including an innovative holographic machine interface (HMI)
that integrates with devices like Microsoft HoloLens and RealWear HMT-1.
Experience this and more groundbreaking technology firsthand at one of
our upcoming World Tour events.
2018
Register for our Connected Intelligence World Tour!
Coming to a city near you: www.iconics.com/CIWorldTour WINNER
© 2018 ICONICS, Inc. All rights reserved.

2018
Software – Software – Asset Software – Software –

Applications Management, Reporting Control Design Data Analytics
FactoryTalk Batch V13 Dream Report Studio 5000 FactoryTalk Analytics for
Rockwell Automation Ocean Data Systems Rockwell Automation Devices
Rockwell Automation
F actoryTalk Batch V13

software enhances scal-
ability and responsive
D ream Report V4.8 is
user-friendly, automated
reporting, and data analysis
T he Studio 5000 integrated
development environment
includes expanded integra-
F actoryTalk Analytics for
Devices provides health
and diagnostic analytics
control of distributed, software designed for indus- tion with engineering tools, from industrial devices. It
skid-level phases with the trial automation applica- predeveloped application crawls industrial networks,
integrity of plant-level coor- tions. These environments content to replace custom discovers assets, and pro-
dination, while delivering an require one or more Dream code, and additional features vides analytics by transform-
improved, reliable user expe- Report servers with the abil- to help enhance security. The ing the data generated into
rience with built-in mobil- ity to support remote and Studio 5000 Architect appli- preconfigured health and
ity. Integration with the concurrent development. cation collaboratively can diagnostic dashboards. The
SequenceManager solution By default, a Dream Report exchange data with popular system also delivers “action
enables batch sequencing server will support a local or engineering tools, such as cards” to the user’s smart-
to occur at either the con- remote developer. Addition- EPLAN (Rittal) and Auto- phone or tablet if a device
troller or server level. This al development CALs are CAD (AutoDesk). This bidi- requires attention. As the
allows machine builders to available to facilitate mul- rectional data transfer helps application uncovers infor-
develop and deliver fully tiple concurrent developers improve startup time by mation about how the devices
tested skids that end users complete with check-out and reducing the need for engi- are related to each other, such
can integrate into batch pro- check-in functionality, ver- neers to manually re-enter as their network topology
cess with minimal validation sion management, and audit control data from engineer- or fault causality, it starts to
and commissioning effort. It trails. Additional enhance- ing tools into the Studio understand the system on
also minimizes the rework ments include support for 5000 software. Predeveloped which it is deployed to make
required when manufactur- Wonderware Online InSight application content was prescriptive recommenda-
ers with small, controller- (from Schneider Electric) added to the Studio 5000 tions. For example, with the
based batch systems expand and enhanced GE SmartSig- Application Code Manager appliance in place, it can
to larger, server-based batch nal and GE Historian Driv- application. Engineers can send users an action card a
systems. ers; enhanced Alarm Filters use the content instead of drive needs to be reconfig-
www.rockwellautomation.com improve ISA 18.2 report- creating custom code to save ured to maintain optimal
Input 219 at www.controleng.com/information ing, and numerous other time and more easily stan- performance.
enhancements improve flex- dardize systems. www.rockwellautomation.com
ibility and usability. www.rockwellautomation.com Input 222 at www.controleng.com/information
http://dreamreport.net Input 221 at www.controleng.com/information

®
Software – Software – Software – Industrial Internet Software – Mobile Apps

Diagnostics HMI Software of Things Connectivity for Controls, Automation,
Instrumentation
Plantweb Insight InduSoft Web Studio V8.1 IoT Gateway MobileHMI V10.95
Emerson Automation Solutions Schneider Electric Software Bosch Rexroth Iconics
T he Plantweb Insight
application monitors
the health of steam traps,
I nduSoft Web StudioV8.1 is a
platform agnostic SCADA/
HMI development and run-
T he IoT Gateway makes
it easy to connect to
Industrie 4.0 environments
M obileHMI V10.95
brings the power of
HMI/SCADA technolo-
pumps, heat exchangers, and time software that incorpo- without intervening with gy to any smartphone, tab-
other plant assets. Leverag- rates all the tools users need automation logic. The pre- let, browser, or web-enabled
ing Pervasive Sensing strat- to create SCADA and HMI cisely coordinated combina- device. Users can interact
egies, Plantweb Insight applications, business intel- tion of control hardware and with their SCADA informa-
strategically interprets plant ligence dashboards, and software designed for imple- tion using a Microsoft Holo-
data to provide personnel OEE solutions. With run- menting IT applications col- Lens mixed reality device.
with actionable information. times available for Microsoft lects sensor and process The Holographic machine
The intuitive, browser-based Windows, Linux, and Wind data, transmits it to the man- interface delivers 2D and 3D
user interface enables quick- Rivers Systems VxWorks, ufacturing execution system holograms to users, allow-
er and more informed deci- InduSoft Web Studio can cre- (MES), cloud applications, ing them to digitally inter-
sions to ensure reliability, ate powerful IIoT applica- or local machine state moni- act with their equipment in
improve safety, and reduce tions that can be deployed toring systems and enables a mixed reality environment.
energy use. The pre-built on small-footprint embed- process data analysis. The Easy-to-use configura-
analytics and domain exper- ded devices and accessed IoT Gateway is a path to tion wizards and respon-
tise embedded in the appli- remotely from mobile bringing legacy machinery sive technology enable users
cations minimize required devices, such as tablets, into the digital age. By over- to import pre-existing 3-D
configuration, allowing the smartphones, and wearable laying IoT enabled hardware, models and smart symbols
flexible software to be eas- gadgets. Over 250 commu- the IoT Gateway collects to quickly get up and run-
ily integrated with existing nication drivers, in addition valuable data from non- ning in no time. This wave
infrastructure. Abnormal to support to standards such data-enabled machines and of mixed reality technolo-
situations and predictive as OPC UA/DA/XML/.NET/ processes. gy addresses a variety of use
diagnostics are presented to HDA, MQTT, and patented www.boschrexroth-us.com cases across manufacturing,
personnel in real-time, elim- solution for database connec- Input 225 at www.controleng.com/information energy management, indus-
inating the need for manual tivity, make it easy to integrate trial, and building automa-
calculations or periodic data sensors, controllers, ERP sys- tion applications.
collection. tems, and cloud analytics that www.iconics.com
www2.emersonprocess.com can be accessed anywhere.
Input 223 at www.controleng.com/information www.indusoft.com
www.controleng.com CONTROL ENGINEEERING February 2018 • 39

2018
Honorable Mentions
Hardware – Data Acquisition Hardware – Integrated HMI Controllers
MAQ20 TPC-5000
Dataforth Corp. Advantech
The MAQ20 high density voltage discrete The TPC-5000 two-
output module has 20 isolated discrete piece modular touch
output channels that can switch up to 60 V panel computer fea-
dc signals and sink up to 3 A of current. tures an Intel Core 6th
www.dataforth.com generation i-3 processor with 8 GB of DDR4 SODIMM and an
industrial-grade LED LCD with a 50,000-hour lifespan.
www.advantech.com
H
Hardware – Handheld Test, Measurement, Calibration
AMS Trex Device Machine & Embedded Control – PLCs

Communicator BRX PLC
Emerson Electric Co. AutomationDirect
The AMS Trex device communica- Features of the compact BRX
tor allows users to move data to and PLC include built-in data log-
from the communicator using the ging, motion control, serial and
connectivity option that is most con- Ethernet communication, an
venient to them. interchangeable (hot-swappable)
www.emerson.com
Input 228 at www.controleng.com/information communications port, and integrated high-speed I/O.
www.automationdirect.com
Hardware – HMI, Operator Interface, Thin-client
GT2107 Motion Control

Mitsubishi Electric PurePower
Automation Bosch Rexroth
The GT2107 wide HMI is a com-
The PurePower filter media reli-
pact and cost-effective 7-in.
ably retains harmful contami-
wide-screen graphical opera-
nants found in hydraulic fluid,
tor terminal with WVGA resolu-
including those not visible to the
tion and is available with either a
naked eye, reducing the risk of electrical discharges.
black or silver bezel. www.boschrexroth-us.com
https://us.mitsubishielectric.com Input 233 at www.controleng.com/information
Hardware – Industrial PCs

Motion Control – Drives
C6015 Sytronix DRn 5020
Beckhoff Automation Bosch Rexroth
The C6015 industrial PC
The Sytronix DRn 5020 hydrau-
opens up application
lic motor pump optimizes par-
areas for PC-based con-
tial load and idle (dead-head)
trol technology, is fully
operation in a hydraulic con-
suited to industrial appli-
stant pressure system for per-
cations, and measures 82
formance levels from 4.0 kW (5 hp) and up.
x 82 x 40 mm. www.boschrexroth-us.com
www.beckhoffautomation.com Input 234 at www.controleng.com/information

®
Your Global Automation Partner
Network Integration – Ethernet Hardware We’ve got a

IMP-C1000-SFP
Antaira Technologies cable for that.
The IMP-C1000-SFP is a compact, IP30 rated gigabit Ethernet-to-Fiber
media converter featuring a 10/100/1000TX Ethernet port that sup-
ports IEEE 802.3 at high power PoE supplying up to 30 Watts.
www.antaira.com
Network Integration – Ethernet Switches
SDS-3008 Smart Switch

Moxa Americas
The slim, 8-port, industrial-grade SDS-3008 Smart Switch features an
easy-to-navigate dashboard that allows activation of pre-configured
automation protocols in one click and remotely manage the unit on
HMI/SCADA systems.
www.moxa.com
Network Integration – I/O Systems
ELX EtherCAT I/O

Beckhoff Automation Our Reelfast™ bulk cable
The ELX EtherCAT I/O with intrinsically safe inputs/out-
program inventories more
puts and compact design, enables direct connection
of field devices located in hazardous areas—classified than 5.5 million meters of
Zones 0, 1, and 2.
www.beckhoffautomation.com
cable for countless industrial
and process automation
Network Integration – Wireless I/O
applications. You’ll get
NPort IAW5000A-6I/O
precisely the cable you want
Moxa Americas
in exactly the length you need.
The NPort IAW5000A-6I/O 3-in-1 wireless serial server conve-
niently integrates a RS-232/422/485 serial device server, a Wi-Fi Custom design available.
client/bridge, and multiple digital I/Os into one compact device.
www.moxa.com
Network Integration – Wireless Products
FL WLAN 1101
Phoenix Contact
The FL WLAN 1101 wireless module combines access point
and antenna technologies in one housing; it is mounted like
an antenna directly to the machine, mobile vehicle, or con-
trol cabinet.
www.phoenixcontact.com/us
Call 1-800-544-7769 or
CONTROL ENGINEERING February 2018 • 41 visit turck.us/bulkcable
2018
Honorable Mentions
Power – Energy, Power Protection, UPS Process Control – Process Sensors
5P, Eaton Sitrans TO500

The 5P rackmount uninterruptible power Siemens
supply (UPS) delivers reliable back-
The Sitrans TO500 multipoint
up power for a variety of applications,
measuring system is used for
enhancing business continuity and lower-
evaluating a large number of
ing environmental footprint, allowing for
temperature measuring sensors arranged on a very narrow fiber-
deployment in tight spaces.
optic temperature measuring lance.
www.eaton.com
Input 240 at www.controleng.com/information www.usa.siemens.com
Process Control – Process Sensors
Process Control Systems
Micropilot FMR6x
Open Secure Automation (OSA)
Endress+Hauser
Bedrock Automation
The 80 GHz Micropilot FMR6x free space
The Open Secure Automation (OSA)
radar level instrument is suitable for use
system with Cybershield 2.0 enables
in tanks or silos with complex geometries,
authentication and encryption of I/O
obstacles, baffles and/or nozzles.
networks and field devices, and it protects compliant networks
http://us.endress.com
Input 241 at www.controleng.com/information and user applications such as controller configuration.
https://bedrockautomation.com
Safety – Machine Safety
Highest efficiency power supplies in low profile Allen-Bradley GuardShield 450L

casing are fully compliant to ErP directive. Rockwell Automation
Suitable for household appliance and industrial The Allen-Bradley Guard-
applications. Shield 450L safety light
curtain system is a flexi-
ble, cost-effective solution
that enhances safety while
improving productivity
through innovative trans-
ceiver technology.
www.rockwellautomation.com
Safety – Process Safety, Intrinsic Safety

TBLC Series 6–90 Watt SFY
• Lowest no load power consumption Moore Industries
• Built in EMI-Filter meets EN 55032 class B
The SFY functional
• Output power limit to NEC class 2
safety SIL-3-capa-
• Best output-overload characteristics (constant current)
ble frequency-to-dc
• Highest power density
transmitter monitors
• –25 °C to 55 °C full load operation frequency, period, high or low pulse width,
and contact closure signals and converts
the input signal to a proportional, input-to-
output isolated 4- to 20-mA output.
www.miinet.com
Reliable. Available. Now. www.tracopower.com
42 • February 2018
®
Your Global Automation Partner
Software – Applications
Virtual Central Lock (VCL)

Tosibox Oy
Virtual Central Lock (VCL) is a premium soft-
ware-based solution that provides flexible and
secure remote connections for organizations
who use cloud services or have an existing server
WARNING
infrastructure.
www.tosibox.com
Software – Asset Management, Reporting

Not suitable for repairing
AMS Device View
flimsy connectors
Emerson Electric Co. (or your reputation).
AMS Device View features intuitive dash-
boards and focused alerts for quick access
of the data needed to respond to issues Rugged, reliable industrial automation
effectively; it delivers health and calibration
products from Turck are built to perform
status information through a browser-based
in the toughest conditions, and our
interface.
www.emerson.com engineered solutions are customized to
meet your application challenges. Cheap
Software – Asset Management, Reporting knock-offs can’t compare. Turck works!
ABB Ability Electrical
Distribution
Control System
Thomas & Betts Corp.
The ABB Ability Electrical Distribution
Control System is a cloud-based energy
management, remote supervision, and
diagnostics system that connects a facil-
ity’s electrical equipment with the Inter-
net of Things.
www.tnb.com
Software – Control Design
Open Virtual Engineering

Platform (Open VEP)
Custom Connectivity
Honeywell Process Solutions Whether it’s a harness with custom wiring
The Open Virtual Engineering Platform topology or a custom cable color for a
(Open VEP) is a cloud-based service standard connector, Turck’s expertise
that allows instant access to a fully func- creates your best solution.
tional, off-process distributed control
system (DCS).
www.honeywellprocess.com
Call 1-800-544-7769 or
CONTROL ENGINEERING February 2018 • 43 visit info.turck.us/connectivity
2018
Honorable Mentions
Software – Data Analytics Software – Industrial Internet of Things Connectivity
EcoStruxure Profit KEPServerEX V6

Advisor Kepware
Schneider Electric The KEPServerEX V6 industrial
EcoStruxure Profit Advi- connectivity platform leverages
sor uses Big Data ana- OPC and IT-centric communica-
lytics to measure the tion protocols to provide a single
financial performance of source of industrial data to appli-
an industrial operation in cations through one user interface.
real time, enabling industrial users to control the profitability of www.kepware.com
an operation.
www.schneider-electric.com
Software – Mobile Apps for Controls,
Automation, Instrumentation
Software – Diagnostics
FactoryTalk
Guardian Support TeamONE
Emerson Rockwell
Electric Co. Automation
Guardian Support is FactoryTalk TeamONE
a prognostic service help industrial teams
designed to optimize improve productivity and is designed for hybrid connected
the reliability and per- industrial environments and can be downloaded, installed, and
formance of automa- used on Apple iOS and Google Android smartphones.
tion systems, enabling www.rockwellautomation.com
real-time visualization
and management of these systems.
Left out?
www.emerson.com
Software – HMI Software

How to enter
G
VTScada V11.3 et a head start on the 2019 Engineers’
Trihedral Choice Awards program by listing prod-
Engineering Ltd. ucts in the New Products for Engineers data-
VTScada V11.3 is available base (www.controleng.com/NP4E) and complet-
for download from an FTP ing the entry form on the Awards Programs
site; features include Twilio, a tab of your company’s vendor/manufacturer
web-based communications profile. All product nominations, including
platform for voice telephony supporting materials and payment, are sub-
alarm notification functional- mitted through the database. Submit new or
ity as an alternative to voice significantly modified hardware, software, or
modems. combination introduced and available in North America
www.trihedral.com
Input 252 at www.controleng.com/information from November 2017 through October 2018 for the 2019
awards. The product details provided should be factually
convincing and clearly differentiate benefits in the voting
criteria: technological advancement, service to the indus-
try, and market impact. (Hint: We observe that engineers
appreciate quantified benefits more than adjectives.)

MEDIA SHOWCASE FOR ENGINEERS
Your place for new products, literature, Apps, Videos, Case Studies and White Papers.
MULTI-CONTACT
connectors
With Silver-Nickel Butt-Style Contacts
for Maximum Performance & Durability
The Unlimited Platform for
SCADA and So Much More
• Unlimited licensing
• SCADA, IIoT & MES together
• Instant web deployment
• Totally cross-platform
• Built on open IT standards
• Installs in minutes
FEATURES AVAILABLE
7 to 37 contacts
4mA to 150A per contact
Easy-to-wire contact terminals
Discover more at:
inductiveautomation.com/ignition meltric.com
800.433.7642
Input #100 at controlengineering.hotims.com Input #101 at controlengineering.hotims.com Input #102 at controlengineering.hotims.com
Want to receive your

Control Engineering
O&GEng-CE 2017-06_TRGuide_MediaShowcase2x4_MII.indd5/17/2017
1 2:23:54 PM
stay magazine as a
informed digital publication?
Stay current
with technology and
trends in electrical,
mechanical,
instrumentation Update your subscription,
and automation. and get our digital edition,
on a more interactive and
user-friendly platform,
in your email in-box.
To subscribe, visit Update now at:

www.controleng.com/subscribe www.controleng.com
Input #103 at controlengineering.hotims.com Input #104 at controlengineering.hotims.com Input #105 at controlengineering.hotims.com
ce2014_digitlEditn_6th.indd 1 2/24/2014 11:44:33 AM

ce_stayInformed_6th.indd 1
www.controlengineering.com
2/24/2014 10:15:42 AM
CONTROL ENGINEERING February 2018 • 45
INNOVATIONS See more New Products for Engineers.
www.controleng.com/NP4E PE
NEW PRODUCTS FOR ENGINEERS
Push-in conductor connection clamps

Rittal Corp.’s maintenance-free conductor connection clamps feature push-in technology for quick
connection to many different types of conductors. The push-in conductor connection clamps reduce
potential defects, like incorrect compression/torques or clamp loosening. Now panel builders and
switchgear manufacturers can connect cables, wires, and protective and neutral conductors directly
to busbars. In addition, short-circuit resistant voltage taps can be added onto the main busbar sys-
tem, or installers can string distributors or blocks with a large number of connector clamps to pair
with outgoing cables. The push-in conductor connection clamps are available in two clamping ranges, 0.5 to 4 mm2 and 1.5 to 16
mm2, and for copper busbars, 5 and 10 mm thick in each clamping range.
Rittal Corp., www.rittalenclosures.com Input #255 at www.controleng.com/information
Isolated dc-dc Graphic terminal

converter series series for smaller
TDK Corp.’s 100 W-rated TDK-Lamb- applications
da i3A series of non-isolated dc-dc Rockwell Automation’s Allen-
converters are capable of operating Bradley PanelView 5310 family
from an input voltage of 9 to 53 V. The of graphic terminals are available in 7-, 9-, and
step-down converter delivers an out- 12-in. display sizes and are designed to scale an integrated
put voltage that is adjustable from 3.3 system down to smaller application to make design, main-
to 16.5 V or 5 to 30 V with output currents of up to 8A. The tenance, and operation tasks more efficient. Users also can
series is designed for medical, communications, industrial, and use enhanced integration to create high-speed jog buttons
test and measurement equipment applications. The converters instead of hardwired buttons. These auto-diagnosing but-
also can be used in conjunction with a single output 12 V, 24 V, tons can interact with the controller at input/output (I/O)
36 V, or 48 V ac-dc power supply to generate multiple added speeds to help reduce downtime and improve productivity.
regulated outputs, with or without battery backup. Rockwell Automation www.rockwellautomation.com
TDK Corp. www.tdk.com Input #256 at www.controleng.com/information Input #257 at www.controleng.com/information
PRODUCT & LITERATURE SHOWCASE

Signal Conditioners
5B / 7B / 8B Signal Conditioning Solutions www.Acromag.com/CE & Ethernet I/O
More Models, More Protection, Less Noise, Lower Cost 877-295-7057
580+ different 5B, 7B, and 8B signal conditioners provide accurate, isolated Instrument
Class® performance to ensure the integrity of your industrial automation, data acquisition,
process control, and quality assurance systems. Custom modules available.
• ± 0.03 to ± 0.05% Accuracy • ANSI/IEEE C37.90.1 Transient Protection We have the experience to help you solve
• 1500Vrms Isolation • 3- to 6-Pole Low-Pass Filtering your monitoring and control challenges.
• Up to 240Vrms Input Protection • -40°C to +85°C Operating Temperature Get your new product guide today
4-20mA Isolators & Splitters
• CSA C/US Certified & ATEX Compliant Ethernet, Modbus, Profibus I/O
(5B, 7B)
• C-UL-US Listed (8B) Input #110 at controlengineering.hotims.com
Call 800-444-7644 or visit www.dataforth.com

Input #109 at controlengineering.hotims.com
eNewsletters Go online to view the weekly

Subscribe today by visiting: www.controleng.com/newsletters Top 5 Reader Favorites!

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

Aaron Maassen, ®
Classified, Product Mart,
Media Showcase
630-571-4070 x2216
ad index
AMaassen@CFEMedia.com Company Page# RSN Web
AR, IL, IN, IA, KS, KY, LA, MN, MO, Allied Electronics . . . . . . . . . . . . . .7 . . . . . . . . . . 4. . . . . . . .www.alliedelec.com
MS, NE, ND, OK, OH, SD, TX, WI,
Central Canada AutomationDirect . . . . . . . . . . . . . .C2 . . . . . . . . . 1. . . . . . . .www.automationdirect.com
Bailey Rice Dataforth Corp . . . . . . . . . . . . . . . .13 . . . . . . . . . 8. . . . . . . .www.dataforth.com
(630) 571-4070 x2206
BRice@CFEMedia.com Fluke Corp . . . . . . . . . . . . . . . . . . . .17 . . . . . . . . 12 . . . . . . .www.fluke.com
AK, AZ, CA, CO, HI, ID, MT, HAMMOND MANUFACTURING . .12 . . . . . . . . . 7. . . . . . . .www.hammondmfg.com
NV, NM, OR, UT, WA, WY,
Western Canada Honeywell Inc . . . . . . . . . . . . . . . . .11 . . . . . . . . . 6. . . . . . . .www.honeywellprocess.com/elevate
Iris Seibert
Inductive Automation. . . . . . . . . . .Bellyband . . . . . . . . . . .www.inductiveautomation.com/iiot
(858) 270-3753
ISeibert@CFEMedia.com Kepware Technologies . . . . . . . . . .1 . . . . . . . . . . 2. . . . . . . .www.kepware.com/CE
CT, DE, MD, ME, MA, NC,
Moxa Technologies . . . . . . . . . . . . .2 . . . . . . . . . . . . . . . . . . .www.moxa.com
NH, NY, NJ, PA, RI, SC, VA,
VT, WV, DC, Eastern Canada PHD, Inc. . . . . . . . . . . . . . . . . . . . . .14 . . . . . . . . . 9. . . . . . . .https://www.phdplus.phdinc.com/plusad
Julie Timbol
(978) 929-9495 SEW-EURODRIVE, Inc. . . . . . . . . . .9, C4 . . . . . 5, 27 . . . . . .www.seweurodrive.com
JTimbol@CFEMedia.com
Siemens. . . . . . . . . . . . . . . . . . . . . .C1, 21 . . . . . 15 . . . . . . .www.usa.siemens.com/basic-controllers-ce
Internation (outside U.S., Candada)
Steute Industrial Controls, Inc. . . .16 . . . . . . . . .11 . . . . . . .www.switches-sensors.zf.com/us
Stuart Smith
+44 208 464 5577 TRACO POWER . . . . . . . . . . . . . . . .42 . . . . . . . . 24 . . . . . . .www.tracopower.com
stuart.smith@ssm.co.uk
Turck Inc. . . . . . . . . . . . . . . . . . . . . .41, 43 . . . . 23, 25. . . . . .www.turck.com
Publication Services Yaskawa America, Inc. . . . . . . . . . .C3 . . . . . . . . 26 . . . . . . .www.yaskawa.com
Jim Langhenry, Co-Founder/Publisher, CFE Media
JLanghenry@CFEMedia.com
Steve Rourke, Co-Founder, CFE Media
SRourke@CFEMedia.com Engineers’ Choice Awards
Trudy Kelly, Executive Assistant,
630-571-4070, x2205, TKelly@CFEMedia.com Beckhoff Automation LLC. . . . . . . .31 . . . . . . . . 19 . . . . . . .www.beckhoff.com
Elena Moeller-Younger, Marketing Manager
773-815-3795, EMYounger@CFEMedia.com EZAutomation . . . . . . . . . . . . . . . . .33 . . . . . . . . 20 . . . . . . .www.EZAutomation.net
Kristen Nimmo, Marketing Manager
KNimmo@CFEMedia.com Honeywell Inc . . . . . . . . . . . . . . . . .15 . . . . . . . . 10 . . . . . . .www.hwll.co/SMX
Brian Gross, Marketing Consultant, Global SI Database
630-571-4070, x2217, BGross@CFEMedia.com iCONICS. . . . . . . . . . . . . . . . . . . . . .37 . . . . . . . . 22 . . . . . . .www.iconics.com/CIWorldTour
Michael Smith, Creative Director
630-779-8910, MSmith@CFEMedia.com Moore Industries - Intl. Inc . . . . . . .4 . . . . . . . . . . 3. . . . . . . .www.miinet.com
Paul Brouch, Director of Operations
PBrouch@CFEMedia.com Ocean Data Systems . . . . . . . . . . .35 . . . . . . . . 21 . . . . . . .www.DreamReport.com
Michael Rotz, Print Production Manager
717-766-0211 x4207, Fax: 717-506-7238 Unitronics . . . . . . . . . . . . . . . . . . . .19 . . . . . . . . 13 . . . . . . .www.unitronics.com
mike.rotz@frycomm.com
Maria Bartell, Account Director, Infogroup Targeting Solutions
847-378-2275, maria.bartell@infogroup.com
Rick Ellis, Audience Management Director Inside Machines
303-246-1250, REllis@CFEMedia.com
Letters to the editor: Please e-mail us your opinions to Aerotech Inc . . . . . . . . . . . . . . . . . .M6 . . . . . . . 18 . . . . . . .www.aerotech.com
MHoske@CFEMedia.com or fax 630-214-4504. Letters should
include name, company, and address, and may be edited. WAGO Corp. . . . . . . . . . . . . . . . . . .M2 . . . . . . . 16 . . . . . . .www.wago.us
Information: For a Media Kit or Editorial Calendar,
email Trudy Kelly at TKelly@CFEMedia.com. YRG ROBOTICS. . . . . . . . . . . . . . . .M4 . . . . . . . 17 . . . . . . .www.yrginc.com/aoi
Marketing consultants: See ad index.
Custom reprints, electronic: Brett Petillo
Wright’s Media, 281-419-5725, bpetillo@wrightsmedia.com REQUEST MORE INFORMATION about products and advertisers in this issue by using
the http://controleng.com/information link and reader service number located near each.
If you’re reading the digital edition, the link will be live. When you contact a company
directly, please let them know you read about them in Control Engineering.

INNOVATIONS
BACK TO BASICS ON PRODUCT DESIGN
Chris Vavra, Control Engineering
Automation product design advice

from 2018 Engineers’ Choice winners
Several 2018 Control Engineering Engineers’ Choice winners offer advice on what makes a
successful automation product design in controllers, actuators, wireless, and other automation.
E
ffective product design advice systems that interface to analog signals and organizations can help, such as the close
follows from several 2018 Con- to generate output signals, which control working relationship with Microsoft and
trol Engineering Engineers’ pumps, motors, and other machinery. the OPC Foundation. Programs offer
Choice Winners. Regardless of opportunities and insights for participants.
the application or purpose, each Dean Mallon, Endress+Hauser Working with the OPC Foundation pro-
has the same goal in mind: To improve Emphasis on standardized device vides an opportunity to share source code,
automation and create better products for platforms increases safety, reliability, host interoperability studies, and exchange
customers. Representatives from several and reduces costs for planning, procure- information with other members for the
Engineers’ Choice winners shared advice ment, and operation. Standardized device interoperability of best-of-breed real-time,
on what they are striving for and what concepts across all measuring param- alarm management, and historian systems.
they believe makes a successful product. (If eters create invaluable benefits in terms
you’re reading the digital edition, click on of reducing complexity. When creating Justin Shade, Phoenix Contact
the authors’ names to read the online ver- product design standards across platforms Getting re-occurring feedback from the
sion, to expand on the highlights here.) and complying with industry standards, field and marketing teams to understand
consider device operation and documen- how the industry and use cases are chang-
Jeff Payne, AutomationDirect tation, status and error diagnosis, compo- ing to adapt products is critical. To learn
Mobile technology is a driving fac- nents, and spare parts. more about the available technologies, the
tor greatly impacting industrial control best place to start would be to discuss appli-
system designs. Manufacturers continue Vikram Kumar, EZAutomation cations with a manufacturer’s salesperson,
to make smartphones, tablets, and other The most important advice about auto- wireless system integrator, or wireless value-
devices ever thinner, smaller, and more mation product design is to ensure the added reseller. These contacts can walk
powerful. Using COTS products (Ethernet research and development (R&D) team through available products, how they func-
connectors, cable, switches, and periph- is directly exposed to and in communication, and help identify the best option for an
eral devices) saves money and simplifies tion with customers. Industrial Internet of application. Discussions also might include
setup and wiring. Every time a new gen- Things (IIoT) boils down to incorporating system design and pre-installation services
eration of Ethernet is introduced in the machine learning and big data technology, the company provides to ensure an installa-
commercial arena, it soon migrates into harnessing the sensor data, and machine to tion goes smoothly. Training can help.
the industrial world, improving the price/ machine (M2M) communications where
performance ratio. the data is accurately and consistently cap- Chris Vavra is production editor,
tured and communicated. After visiting Control Engineering, CFE Media,
John Lehman and numerous facilities wanting to capture the cvavra@cfemedia.com.
Georg Haubner, Dataforth data in real time, a PLC with advanced
Plant instrumentation has become the
nerves and brain of the modern manu-
facturing plant. It regulates and supervis-
communications capabilities was devel-
oped. It is important to develop a project
scope in the beginning and stick to it as
M More
INNOVATIONS
es the operation of the equipment within much as possible throughout the design. KEYWORDS:
the plant. It also provides the means to Automation, product design
make plants economically viable. Obtain- Melissa Topp, Iconics GO ONLINE
ing, maintaining, and improving analog Automation software improves by More product design advice
measurement quality is the goal of proper keeping an eye on the future of infor-
If reading from the digital edition, click on
signal conditioning and is a fundamental mation technology (IT), maintaining each headline below for more details from
concern in automation product design that involvement in industry partnerships, each of the sources cited here.
is often overlooked. To achieve optimal and adhering to the customers’ needs. www.controleng.com/magazine
system performance and save resources, Beyond finding inspiration through con- CONSIDER THIS
design teams need to rely on proven prod- tinuous technological innovations, work- What do you think makes a successful
ucts from industry experts and front-end ing relationships with companies and automation product?

Always the Right Move
YASKAWA
AMERICA
One Choice for All

Controlling a robot arm, a servo axis, a VFD drive
or a custom robotic mechanism is all the same
task for an MP3300iec machine controller. It uses
familiar IEC61131-3 and PLCopen programming
to operate them all, and will even allow you to
substitute one motion device for another without
reprogramming.
Looking for motion control that can change and

grow as readily as your machines do? Move to
the MP3300iec by contacting your Yaskawa
representative.
Yaskawa America, Inc. Drives & Motion Division 1-800-YASKAWA yaskawa.com For more info: http://go.yaskawa-america.com/yai1136

Control Freak?
If you like being in control, then
SEW-EURODRIVE is your perfect
partner! We put you in charge of
every move with our gearmotors
and electronics. No headaches, no
whining, and virtually no maintenance.
You build it and we move it…simple!
Don’t you wish all partners were this

easy…?
seweurodrive.com | 864-439-7537

Control Engineering 2018-02

Hochgeladen von

Dokumentinformationen

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Control Engineering 2018-02

Hochgeladen von

Copyright:

Verfügbare Formate

www.controleng.

Chemence, the only industrial, consumer

“AutomationDirect’s low prices and free support keep us

Order Today, Ships Today!

Kepware’s industry-leading industrial

A Scalable and Flexible Architecture

Streamlined and Reliable Data Access

Learn more at www.kepware.com/CE

Modbus, PROFINET, EtherNet/IP built in

LEDs visible from front and side

Flexible DIN rail mounting

Rugged steel housing

Designed for Today's Machine Builders and OEMs

Learn more at www.moxa.com/smartswitch.

46 | New Products for Engineers

www.controleng.com CONTROL ENGINEERING February 2018 • 3

Instrumentation that Keeps Danger at Bay

Demand Moore Reliability

To learn more about our Functional Safety Series,

Seven motor tips

6. There is a significant lack of understanding

Engineers Database for additional motor and

Within the News Products for Engineers database at www.controleng.com/NP4E, ONLINE

www.controleng.com CONTROL ENGINEERING February 2018 • 5

3010 Highland Parkway, Suite 325, Downers Grove,

New, innovative Content Specialists/Editorial

6 • February 2018 CONTROL ENGINEERING www.controleng.com

Updating a DCS for

8 • February 2018 CONTROL ENGINEERING www.controleng.com

Biopharmaceutical company optimizes

10 • February 2018 CONTROL ENGINEERING www.controleng.com

Time to Elevate in secure hosted solutions - for lower upfront cost

Your Thinking. SCADA delivered as a scalable service. Open VEP

For more information, please visit

Your enclosure alternative.

6. Some plants still use the alarm

Integrated alarms: 4 steps

1. Alarm integration and correla-

M ANSWERSMore • Up to 384 Channels in 19”

How to avoid alarm overload

2. Alarm frequency overrides

Travis Cox is co-director of sales engineer-

input #9 at www.controleng.com/information 14 • February 2018

Securely use removable risk and limits operational disruptions by monitoring,

media across industrial throughout industrial facilities.

input #10 at www.controleng.com/information

Innovations in electric motor

Have a Problem a Over the next 70 years, numerous elec-

Cabled Switch Can’t Solve?

2018 Check out this

©2018 Fluke Corporation.

input #12 at www.controleng.com/information

Design motors to achieve

Brian Bannister is a motor specialist at Lafert Elec-

18 • February 2018 CONTROL ENGINEERING www.controleng.com

On Digital Engineering, LTTS’

Tel: +91 80 6767 5173 www.lnttechservices.com

Machine vision systems

M1 • February 2018 CONTROL ENGINEERING www.controleng.com

Robust vision inspection

Jon Breen is owner/controls engineer, Breen Machine

M3 • February 2018 CONTROL ENGINEERING www.controleng.com

• Seamless integration using

For free technical support and