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NOVEMBER 2013
Vol. 60 Number 11
C OV E R I N G C O N T R O L , I N S T R U M E N TAT I O N , A N D A U TO M AT I O N S YS T E M S W O R L D W I D E
36
Control Engineering illustration by Tom Rybarczyk
Features
28 Building an integration strategy 36 Long-length linear encoders look lively
42
Few technical barriers stand in the way of plant-to-enterprise integration today. It promises real-time data for making better decisions and optimizing production. But without a comprehensive corporate plan that sets goals and outlines results, mere connectivity is doomed to disappoint.
Linear encoders provide direct position feedback to various machine tool and automation systems. Working in a linear format allows extreme length position measurement and controlcritical for machine tool accuracy and production of precise large-scale parts. Focus here is linear encoders with 3-meter or greater measurement length.
42 True cost of systems integration: Consider lifecycle costs, benefits 50 Vote now for Engineers Choice finalists
Systems integration may be considered as one of the last items in the project, treated as a commodity, like some equipment. True cost of systems integration can be more complicated. Understand and measure these costs to keep the budget balanced over time. See supporting Control Engineering system integration research.
The official ballot is open for voting for Control Engineering North American print and digital edition subscribers, for a limited time. Cast your vote at www.controleng.com/VOTE2014.
CONTROL ENGINEERING (ISSN 0010-8049, Vol. 60, No. 11, GST #123397457) is published 12x per year, Monthly by CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Jim Langhenry, Group Publisher /Co-Founder; Steve Rourke CEO/COO/Co-Founder. CONTROL ENGINEERING copyright 2013 by CFE Media, LLC. All rights reserved. CONTROL ENGINEERING is a registered trademark of CFE Media, LLC used under license. Periodicals postage paid at Oak Brook, IL 60523 and additional mailing offices. Circulation records are maintained at CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Telephone: 630/571-4070 x2220. E-mail: customerservice@cfemedia.com. Postmaster: send address changes to CONTROL ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Publications Mail Agreement No. 40685520. Return undeliverable Canadian addresses to: 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Email: customerservice@cfemedia.com. Rates for nonqualified subscriptions, including all issues: USA, $ 145/yr; Canada, $ 180/yr (includes 7% GST, GST#123397457); Mexico, $ 172/yr; International air delivery $318/yr. Except for special issues where price changes are indicated, single copies are available for $20.00 US and $25.00 foreign. Please address all subscription mail to CONTROL ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. 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.
NOVEMBER 2013 CONTROL ENGINEERING www.controleng.com
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Go Deep Safely With Your HART Data
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C OV E R I N G C O N T R O L , I N S T R U M E N TAT I O N , A N D A U TO M AT I O N S YS T E M S W O R L D W I D E
Inside Process
Starts after p. 54. If not, see www.controleng.com/archive for November.
P1
The long and short of connecting sensors to control rooms

Temperature sensors, more than most other types of instrumentation, can require specialized cabling and treatment to provide accurate data.
P7
Upgrading control systems for storm water management in a very cramped budget environment
Existing configuration tools and code libraries helped Detroits wastewater system reduce design and commissioning time.
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departments
8 Think Again
Enable floor to enterprise integration
22 International
Industrial Internet helps make use of saved data
10 Apps for Engineers

PRODUCTS Sound meter, friction calculator, filters, mechanical basics
24 News
Industrial Internet, predictive analytics, new machine-human collaboration
12 Product Exclusive
Centralized remote data management for SCADA, PLCs
67 Exclusive Digital Edition

New: The digital edition now includes additonal pages and articles that you cant see in print. www.controleng.com/digitaledition
14 IT and Engineering Insight

Socializing success with automation standards, models, systems
68 Products
Level sensors; washdown robot; HMIs; signal splitter; motor controller
16 Application Update
Printer breaks world record with advanced servo, motion controller
72 Back to Basics
4 steps to energy integration
18 Machine Safety
Thinking of bypassing an e-stop?
20 International
New level measurement
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editorial
THINK AGAIN
Enable floor to enterprise integration
Automation and controls increasingly are being integrated with enterprise-level applications through the manufacturing execution and manufacturing operations management systems.
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lant to enterprise integration and other issues related to manufacturng efficiency were among topics discussed when Dennis Brandl, chairman, MESA Americas board of directors, and Michael Yost, president, MESA International, spoke with CFE Media recently about system integration. Probably 70-80% of companies still could benefit from more effective use of enterprise-level applications through the manufacturing execution systems (MES) and manufacturing operation management (MOM) systems, Brandl said. Those not effectively using MES/MOM may be using spreadsheets or customized connections between the floor and enterprise systems. Using standards-based architectures and best practices is key to efficient and effective integration to get the best corporate value, he suggested. Brandl said that perhaps 70% of companies could be applying tools that use ISA 88 (batch control, also good for broader modular software applications) and ISA 95 (plant to enterprise) standards. Many know they have a problem, but dont know the solution. Many hear that they need lower cost solutions for analysis of big data analysis, though perhaps not necessarily enterprise resource planning (ERP) software. On that topic, I think well see some movement within the next 9 months, Brandl said. Yost expects to see a greater push toward understanding the return on investment (ROI) for MES and MOMs. At present, most connectivity from the plant floor to the enterprise and beyond is very narrow, addressing a particular problem or perhaps a broader issue by application. This can lead to increasing the scope of application. Another approach has been more of a strategic directive rather than tactical problem solving, Brandl said. Bigger companies have productivity issues related to spending $500 million or more on ERP systems when
8
the ERP data needed isnt there. Solutions providers are adding it all up and helping customers to get that value back, which can be substantial. Brandl said examples include Cargill, Merck and Johnson & Johnson. Often, the solution isnt installing 50 ERP terminals, but using MES effectively to put data where it needs to be. The ISA 95 effort focused on the integration of data from programmable logic controllers (PLCs) and distributed control systems (DCSs) with business level systems, Brandl said, with MES serving as the magic in between. Initially the problem was that we needed to integrate plant floor and business systems to fully understand the whole value we were getting. Value comes in automating workflow, reducing error rates by half, cutting rework, while increasing quality and customer satisfaction, Brandl said. MOMS and MES are ERPs interface to the real world, Brandl said. Consider it a 10%-15% tax on the cost of the ERP system to make it more effective. ERP systems arent designed for things like obsolete inventory, weighing, and dispensing. Others have very specific issues, such as trying to track equipment for regulatory reasons. Brandl said that in recent MESA meetings in Copenhagen, attendees discussed the changing role of information technology (IT), cloud, big data, and bring your own device (BYOD). Think again about what these will mean as manufacturing integrates more closely with the enterprise. ce
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Go Online
www.controleng.com/archive November, with this article, link to more on plant to floor integration, MES, MOM, cloud, big data, mobility, MESA, and related topics, including this issues cover story.
Mark T. Hoske, Content Manager

MHoske@CFEMedia.com
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Sound meter, friction calculator, filters, mechanical basics

CFE Medias Apps for Engineers is an interactive directory of more than 170 engineering-related applications for Android and iOS operation systems, created by various companies. The app helps users do their jobs better and save time, providing a pre-sort of relevant mobile engineering applications loaded with various calculators, catalogs, file viewers, measurement tools, and more. www.controleng.com/AppsForEngineers Decibel 10th iOS 4.0+
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Fit4Filter Android 2.3, iOS 4.0

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Web download link: http://bit.ly/16PcPj7 (Android), http://bit.ly/W3yoaR (iOS) This app can be used to quickly and easily nd and order a replacement your old lter elements. The lter database is periodically updated to ensure that the info you are viewing is always current and relevant.
TeslaSCADA Android 2.3-2.3.2

Cost: Free Company: Tesla LLC Company Website: www.teslascada.com Web download link: http://bit.ly/1cmCK8u (Android)
TeslaSCADA offers visualization between an Android device and indsitrual automation applications and equipment based on OPC UA, an efcienct and scruity standard allow encrypted transmission, authentication, and encrypted access. This application can be used as an OPC UA client.
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ith eFive, eWON is aiming at a new market: scalable centralized remote management via SCADA (supervisory control and data acquisition). These remote management systems are used to process a large number of measurements in real time and to control technical installations remotely. For decades, legacy radio and dial-up modems have been used to connect remote sites with the central station. Increasingly, utilities are challenged with limited bandwidth, difficult maintenance, and expansion difficulties when using legacy modem systems.. eFive allows infrastructure managers to have permanent secure connections (VPN) between the SCADA and the remote sites using public networks at reasonable costs. With eFive, we are addressing the water and renewable energies markets such as biogas, photovoltaic, and wind power, explained Serge Bassem, CEO and co-founder of eWon. The eFive product can serve up to 100 remote sites. eFive opens up new and interesting prospects for all PLC (programmable logic controllers) and SCADA integrators working on remote management projects. Previously, remote management and connectivity solutions for distant sites were complex, requiring major financial, resource, and information communications technology (ICT) investments. The eFive hardware changes the paradigm providing a cost competitive and scalable technology to add secure cenGo Online tralized remote m a n a g e m e n t For more products, see via SCADA. www.controleng.com/products Pierre Crokaert, CTO and co-founder of eWON, said, The connection is easy to set up, irrespective of the brand of SCADA or controller. This can also constitute a financial advantage for the customer. ce
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NOVEMBER 2013 CONTROL ENGINEERING
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INSIGHT
Socializing success with automation standards, models, systems

No matter how you like to share information, short text, explanatory text, audio, or video, there is a way to socialize the success you have had with new standards, models, or systems. Set up policies that encourage your people to share knowledge.
Dennis Brandl President of BR&L Consulting
People who need to know about the successes are often the last to hear about the benefits.
f you have ever been tasked with trying to move your company to new standards, new methods, or new systems, you probably realize that moving your company can be like steering a supertanker. Companies and supertankers make long, slow changes in direction. There are usually demonstrable success stories from installing a new system or standard; often the successes were used to justify rollout to the entire company. However, the people who need to know about the successes are often the last to hear about the benefits, because too few companies internally market their success stories. As engineers we often think that if we build a better mousetrap, the world will come to us, but that is not what really happens. Good ideas and new systems must be internally marketed to be successful, and social media provides a low-cost internal marketing method. Social media has changed the way that good ideas and new systems are now promoted and distributed. Ideas can go viral when your content resonates so enormously that readers share the information with others, and others then share it, and it ends up being the latest big thing. The sharing occurs when your ideas are blogged, tweeted, emailed, discussed at meetings, and become part of new project plans. The best way to make your good ideas on new systems go viral is by socializing your successes. If you have successful projects, then internal wikis, blogs, and podcasts are ways to socialize your successes.
Blog summaries
active projects, describing lessons learned and problems seen, and one posting a month for sustaining projects. Blogs are a good way for people who like to write short paragraphs to express themselves.
Wiki details
Wikis are also a way to share best practices and lessons learned. Wikis are more permanent than blogs and provide a way to quickly search through a large collection of semi-structured information. Wiki pages are usually one printed page long, about 400 words, but can often run to multiple pages for complex topics. Wikis are good for people who like to write explanatory text and who like lots of pictures and figures. A collection of wiki pages for your successful projects provides an un-intrusive way for others in your company to learn about successful projects. Those who dont like to write can use podcasts to socialize successes. Podcasts can be audio only or can include video. Podcasts are a good way to share both current and more permanent information. Podcasts that explain concepts and describe successes are usually short, only a few minutes long, and are usually added to blogs and wikis. No matter how you like to share information, short text, explanatory text, audio, or video, there is a way to socialize your successes. It is important to set up policies that encourage your people to share their knowledge. Consider making it a yearly goal that people regularly contribute to wikis, blogs, or other information sharing systems. Socializing your successes will help you move your organization in a new direction by using the power of social media to make your good ideas go viral. ce - Dennis Brandl is president of BR&L Consulting in Cary, N.C., focused on manufacturing IT. Send comments to controleng@cfemedia.com.
Audio, video alternatives
Go Online
www.controleng.com/archive in November has more advice under this headline. At www.controleng.com search related topics.
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Blogs are a great way to share current information. A blog allows multiple writers to write about current projects and to document newly discovered information, in a writer friendly format. Blog entries are usually short, one or two paragraphs, and often have links to places where more information is available. When sharing information, it is important to keep the blogs current; this means two to three postings a week for
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Our XP700 operator interface, combined with the XV102 HMI/PLC, provides powerful functionality and dependability for awless control over precisely coordinated production. While Eaton software provides real-time visualization and seamless project designing. M+C Schiffer consistently meets the exacting production standards of global leaders such as Johnson & Johnson Reach and Procter & Gamble Oral-B. Because Eaton anticipates tomorrows needs today.
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application
UPDATE
Printer breaks world record with advanced servo, motion controller

M&R Printing Equipment beats its own world record by 12% for speed printing using latest generation, advanced servo motor and stand-alone motion controller in its new machine design.
&R Printing Equipment challenged itself to beat the world record for the most T-shirts printed by one operator in one hour, a benchmark the company set in 2010 at 1,909 shirts per hour with the M&R Challenger III press. M&R also set the previous record in 2005 with 1,805 shirts per hour on the M&R Formula press. To see if the new concept M&R Challenger III D J4 automatic textile press could accurately index faster than prior M&R presses, the company chose a very public venue, FESPA (Federation of European Screen
Printing Associations), said to be the largest global event for the wide format print industry. The servo systems incorporated within the press would have to deliver improved performance with short settling time and be highly accurate despite the systems inertia. M&R, said to be the worlds largest manufacturer of screen printing equipment, has production facilities in Glen Ellyn, Ill., Niles, Ill., and Wojnicz, Poland. To beat the T-shirt printing speed record, M&R required that its new highspeed concept press provide fast index time, quick setting time, rapid closed-loop control, and extremely accurate positioning control. The complex application also required reliable motion control.
New demands, next generation
The development team raises its hands in victory after setting a new printing record for most T-shirts printed in 1 hour; Rich Omar, winning operator, is in front with the signed T-shirt. Mitsubishi Electric Automation MR-J4 Servo and Q170MCPU standalone motion controller helped M&R Printing Equipment break its prior world record by a doubledigit percentage. Courtesy: Mitsubishi Electric Automation
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A 20-year history of working with the same automation supplier that supplied a safety servo drive and motor used for the Challenger III press convinced M&R to upgrade the servo systems using the same manufacturer for the Challenger III D J4 press. To meet the new demands of the M&R concept press, the motion controller required built-in motion, logic control, and Ethernet network capabilities. Using a motion controller and PLC, motion control data is shared via the builtin EtherNet/IP (an ODVA Ethernet protocol) port. Designed to handle the most complicated highspeed applications, the controller includes built-in power supply, an external encoder interface, and high-speed registration inputs. Tight cooperation continues between M&R Printing Equipment and its automation supplier. Maintaining product legacy is important to our future development needs, said M&Rs chief electrical engineer, Bo Biel, emphasizing the importance of sharing the same vision for the development of our products. At FESPA 2013, M&R set a new world record of 2139 T-shirts screen printed in one hour by a single operator, in front of a crowd of printing
At the FESPA show, M&R Printing Equipment is on its way to breaking its own record for number of T-shirts printed in 1 hour, 2139, with help from advanced servo and controller technologies. Courtesy: Mitsubishi Electric Automation
New record achieved
Mitsubishi Electric Automation MR-J4 applies a high-speed servo control architecture to a dedicated execution engine. Speed frequency response is increased to 2.5 kHz, achieving the industry-leading level of speed, based on Mitsubishi Electric research as of January 2013. Compatible servo motors are equipped with a high-resolution absolute encoder of 4,194,304 pulses/rev (22-bit), improving the processing speed substantially, the company said, for better performance for high-end machines. Courtesy: Mitsubishi Electric Automation
industry professionals. For the increase, more than 12% higher than the prior record, the operator used M&Rs highperformance Challenger III D J4 automatic screen printing press, M&Rs Passport automatic T-shirt unloader, and M&Rs Fusion electric conveyor dryer to achieve the feat. When asked about the significance of beating its own world record, Biel explains that setting the new benchmark requires testing new technologies for future product development, to improve performance and increase production output. He expects the automation company to continue to support our development needs 5, 10, or 30 years from now, Biel said.
Adaptive control, closed loop
Think Inside the Box.

Complex logic, multi-axis motion, visualization & IT connectivity all in one multi-core enabled controller.
Those involved said high-performance servo motor and stand-alone motion controller provided: Motion control with built-in logic control Industry-leading speed frequency response Patented model adaptive control High resolution feedback Closed loop control with external encoder Benefits such as short settling time, robust disturbance compensation, fast response, as well as high positioning accuracy, speed, and precision. ce - Greg Hookings, marketing communication manager, Mitsubishi Electric Automation. Edited by Mark T. Hoske, content manager, CFE Media, Control Engineering, mhoske@cfemedia.com.
Go Online
www.controleng.com/archive, November links to video, more photos, product details www.meau.com www.fespa.com
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SAFETY
10/7/13 11:22 AM
Thinking of bypassing an e-stop?
Is it ever permissible to install a bypass switch or to disable an e-stop? For some reason, some Internet safety forums have had this continuing discussion. See the one requirement consistently missing from these international discussions, then ask these 4 questions.
s it ever permissible to install a bypass switch the risk assessment discussion? or to disable an e-stop? For some reason, a few 4 questions to ask yourself safety forums on the Internet have had this Questions follow on this topic: discussion going for months. These are inter1. Does the current risk assessment allow for a national discussions, yet one requirement in the given hazard to become unmitigated? analysis is missing consistently. 2. Does your company safety policy allow for a On this subject, can you actually imagine sevgiven hazard to become unmitigated? eral engineers corroborating and contributing argu3. Do machine safety application standards like mentation on how to install and why not to install a J.B. Titus, CFSE, IEC 60204-1, ISO 13849-1, or in the U.S., NFPA bypass switch on an e-stop circuit? The discussions Certified Functional 79, allow e-stops to be bypassed or disabled? veer off into SIL levels, PL (performance levels), 4. Is there any established and documented MTTFd (mean time to fail dangerous), B10 values, Safety Expert (CFSE) compliant basis whereby it is okay to bypass an and more. Sometimes theres even a brief discussion about the Machinery Directive or different standards like e-stop? Well, if the answers to these questions are generally NO, IEC 61508-1, IEC 62061, ISO 13849-1, and IEC 60204-1, and different ways to derive calculations based on different then why would anyone even consider designing and engineering an e-stop bypass? interpretations. Also, Id want to know if the person asking the question is Just when it looks like the discussion is about to arrive at a conclusion, someone asks something like, Well, just what is it talking about an application based on international standards youre trying to accomplish? And, why is this question on the or domestic U.S. standards. The answer to that question might table? Then a strategy discussion launches on why and how a then promote discussions involving risk assessment, that is: ISO 12100 versus ANSI B10.0. Im sure you get the point! ce safety function can be bypassed. - J.B. Titus, Certified Functional Safety Expert (CFSE), So, what is the one requirement not even hinted at so far? Thats right, the risk assessment! Why is it that these discus- writes the Control Engineering Machine Safety Blog. Read more: www.controleng.com/blogs sions can go on for months back and forth and no one interjects
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INTERNATIONAL
New level measurement

New level sensing technology is said to offer a cost-effective way to accurately measure liquid levels without the need for calibration across a large number of fluids. Suzanne Gill, Control Engineering Europe, spoke to the principal engineer involved.
r. Temoc Rodriguez, principal engineer at Cambridge Consultants, was surprised to discover there was still a need for innovation for a device that employed a relatively simple concept. We see a significant demand for adaptable technology, in everything from consumer appliances and medical instruments to agricultural and large-scale industrial containers, he said. The Fringe Effect Level Transducer (FELT) has been developed to offer a better way to moniThe Fringe Effect tor the level of a wide variety of fluids. FELT has Level Transducer no moving parts and is immune to temperature (FELT) has been develchange. It is robust and is not affected by exteroped by Cambridge nal interference such as metal objects, people, or Consultants to offer a electrical noise. better way to monitor Part of the criteria for the product design was the level of a wide varito affordably and accurately eliminate a range of ety of fluids. FELT has common problems encountered with existing level no moving parts and is sensing technologies, and provide a continuous immune to temperature measurement of the liquid level. FELT consists of change. It is robust and three parallel low-cost, simple, and customizable is not affected by exterelectrodesone measurement electrode, one refnal interference, such as erence electrode, and a common electrode. There metal objects, people, or is no direct contact between the electrodes and the electrical noise. Courtefluid being measured. An electric field is applied sy: Control Engineering to the electrodes to measure the ratio of the elecEurope tric charge between the measurement and reference electrodes and, as a result, a continuously accurate liquid level can be determined. We found that existing fluid measurement Consider this... technologies that can achieve similar accuracies tend to use radar or ultrasonics and are very Avoiding recalibration costly. Cheaper devices have accuracy issues and when liquids or processes use probes that require careful calibration, said change may be the key Dr. Rodriguez. The FELT probe and electronics advantage of a new level are calibrated at factory using average statistical sensor. data across a number of fluids with high dielectric constant. This is said to result in an accuracy of better than 5% across fluids Go Online and temperature. Calibration of the probe www.controleng.com/international for a known application fluid can improve has other global coverage. accuracy to 2%. www.controleng.com/archive Dr. Rodriguez explained: FELT is an November links to other CEE articles. immersion transducer that works on the - Exploring robotics for the factory principles of fringe electric fields between of the future electrodes which propagate through the - Working toward an intelligent liquid. A time varying electric field is energy management solution applied to the electrodes of the probe,
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resulting in a current flowing between the electrodes which can be measured. These currents are proportional to the intensity of the electric field. As the fluid level rises around the transducer, the current increases, and this can be measured. The FELT design is unique in that it incorporates a reference sensor and a measurement sensor in the same probe, which can compensate for variations in the fluid. Because the measurement is directly linked to the dielectric constant of fluid, that dielectric constant typically changes with temperature or the composition of the fluid, which could upset the measurements, continued Dr. Rodriguez. There are some off-the-shelf technologies that use the same principles, and these can give erroneous readings when the fluid changes. We overcame this problem by adding a reference sensor into the system. Taking a ratio between the measurement electrode and the reference electrode cancels out the dielectric constant of the fluid, which means that if this changes, as a result of temperature variations or fluid composition changes, it will not affect the level measurement. Although the standard polypropylene casings of the probe can be affected by the properties or composition of the fluid being measured, it is possible to customize the probe body for different application fluids, said Dr. Rodriguez. In some applications, fluid composition or temperature may change. However, this will not affect the level measurement. The target market for the probe is for use in vessels of up to 1 m in depth with a span of between 100 mm and 1 m. We hope to see the product coming to market within 6 months, said Dr. Rodriguez. We have a working prototype. Cambridge Consultants is in discussion with a level transducer company to accelerate route to market. An alternative route to market is through customization for integrated assemblies. Another potential route to market could be through licensing parts of the design to meet specific original equipment manufacturer (OEM) requirements to improve the sensitivity, or cost, of a system. ce - Suzanne Gill is editor of Control Engineering Europe. This article originally appeared at www.controlengeurope.com and was edited for Control Engineering.
MONTH 2013 NOVEMBER 2013 CONTROL CONTROL ENGINEERING ENGINEERING www.controleng.com www.controleng.com
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INTERNATIONAL
Industrial Internet helps make use of saved data

Control Engineering China interviewed Bernie Anger, general manager, Control and Communication Systems, GE Intelligent Platforms, about benefits of industry Internet.
G
Bernie Anger is general manager, Control and Communication Systems, GE Intelligent Platforms. Courtesy: Control Engineering China
E Intelligent Platforms (GE-IP) started its Connected World road show in Beijing, China, on Aug. 8, 2013. Control Engineering China talked with Bernie Anger, general manager, Control and Communication Systems, GE Intelligent Platforms, about industrial Internet and its future benefit to industries. Bernie described industrial Internet in details and benefits compared to Internet. He anticipates great inspiration for those involved in automation over the next 5-10 years.
Control Engineering China (CEC): Please explain the differences in industrial Internet, Internet, and industrial Ethernet. Anger: People who talk about industrial Ethernet usually discuss how to use different protocols to connect among I/O points, controllers, and other controlled devices in the control network. Internet is the biggest, most powerful international commercial infrastructure in the world now. People depend on it to share information, do business, and to use telecommunications and other public services also. However, GE defined a new concept called industrial Internet. Its different from industrial Ethernet, or Internet, because its purpose is unique. Our industries have been isolated in different vertical sections. If we consider the power that Internet brought to us in the commercial world, it encouraged us to bring this kind of power into industrial applications. Industrial Internet is going to build a robust, secure, real-time, high-performance Internet for industrial applications based on Internet foundations. GE connects smart machines to other machines and connects machines to people. We also do the intelligent analysis. Both parts help people make better decisions. Thats the key benefit for customers. Go Online Industrial Internet requires security See related article from Control Engias well as high-speed, real-time perneering China on the GE Intelligent formance. We also need technologies Platforms Connected World road to prevent from the impact of failure, show topic. because its more critical than any failure www.controleng.com/international on traditional Internet. ... has more on this, and on Control We can describe the key value of Engineering Chinas 10th anniversary. industrial Internet to users in three ways.
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The value comes from increased intelligence, flexibility, and speed. People receive smart asset operation information over the network. Original equipment manufacturer (OEM) users can use this information to make better, smarter machines. End users can gain efficiency, flexibility, and higher priority control during production. Speed comes in different ways. With big data, OEM users support speed and can redesign and innovate products more quickly, end users share data, use data, even sell data, or create new business models using data. Data will be quite valuable. CEC: How can an industrial enterprise optimize industrial Internet? Anger: It depends on what users have already done. Generally speaking, while GE-IPs customers looks at their control layer, at the very least they should think of three questions. The first is, have I already taken advantage of Ethernet in plant? The second is, have I put enough computing power in the controller, to connect controllers? The third is, do I have the security, structure, and connectivity to create a connection path to the cloud at the same time? If we called it stage 1, then stage 1.5 should be saving data, starting to create the history of the data. Data is more valuable at time goes by. After that, stage 2 should be to consider how to use data, with cloud computing, intelligent analysis, and a smart platform. The last stage should be thinking how to collaborate with data. The Internets major function is to share content, from open sources. A company over industrial Internet only needs to care about creating 10% unique value over a 90% common resource. In automation, we still have too many people creating everything themselves. In stage 4, people share common things and create unique things for earning value. People dont need to worry about which stages they must reach. The future is bright, and megatrends will push them forward. ce - Andy Zhu is editor-in-chief of Control Engineering China. www.cechina.cn. This was edited shorter for this page.
Advanced Cell Bypass
Modular Topology
Low-Voltage IGBT
Reliability built in.

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To create the industrys most reliable medium voltage variable frequency drive, we spent the last 17 years developing and refining the technology behind it. Today, the Siemens ROBICON Perfect Harmony drive incorporates 50+ patented innovations into its unique topology, including low-voltage IGBT and the worlds only Advanced Cell Bypass system. These features not only decrease downtime; they also improve energy efficiency and limit wear and tear. By eliminating power interruption and introducing topology modularity, the Siemens ROBICON Perfect Harmony drive provides up to 20 years of superior performance. Its unrivaled reliability has made it the No.1 drive sold worldwide with 10,000+ installations. When you want a drive with industry-leading reliability, rely on the industry leader. Rely on Siemens.
24 / 7 / 365 Support Technology is what brought us to the forefront of world-class reliability, but our technical support before, during and after installation is what keeps us there.
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industry
NEWS
and reduce emissions as well. Business and technology leaders can implement solutions to improve efficiency and ultimately create smarter, faster, and more predictive solutions to improve productivity, efficiency, and reliability, according to Jeff Immelt, GE chairman and CEO, at the GE Minds + Machines 2013 conference in Chicago. At last years conference GE (NYSE: GE) announced the launch of its portfolio of industrial Internet solutions. Launched in January, GEs Grid IQ Insighta predictivity solution for the electric utility industrywas among the first solutions rolled out as a part of GEs expanding portfolio of industrial Internet solutions. The advanced analytic solution helps utilities turn mounds of data into actionable information, Immelt said. Comments follow below from leaders presenting at the conference. Todays electrical distribution systems continue to evolve as new smart devices are added to the network. With each installation comes the capability to better monitor and report important data related to energy usage, outages, and changes in demand. This mass influx of raw data has led to a major void that must be addresseddata is currently being generated exponentially faster than it can be analyzed. To fill this void, utility companies often search for software that can help break down data from sensors and smart devices to find value hidden in a sea of raw data, GE said. Grid IQ Insight provides utilities with advanced analytic capabili-
Industrial Internet, predictive analytics, new machine-human collaboration

Industrial Internet, predictive analytics and new machine-human collaboration in the workplace can significantly boost productivity, create new jobs and skills, and minimize unplanned downtime in major industries, GE said, with the potential to save on more than 300 million hours in servicing complex machines. GE released 14 predictive software technologies to help with that
from sensors and smart devices into actionable information.
Turn mounds of data
Jeff Immelt, GE chairman and CEO, describes how GE is focused on outcomes for customers, at the Minds + Machines conference, Oct. 9, in Chicago. Courtesy: CFE Media, Steve Rourke
ties to meet business needs and create a stronger connection to the machines that power the grid, the company said. It applies proven analytics to make sense of big data collected from intelligent machines to better predict, manage, model, and forecast potential problems that a utilitys electrical grid may face, GE said. The software strategi-
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cally monitors influential datasuch as electrical usage, grid performance, and weather historycreating an interconnected ecosystem of people and machines to better equip utilities with the information and tools needed to optimize use of electrical distribution systems. Utilities can then apply the information and knowledge gained through Grid IQ Insights advanced analytics and visualization to ensure a more efficient and reliable energy supply to customers. Making sense of grid data can be both a challenge and an opportunity, said Michael Carlson, general managersoftware solutions, GEs Digital Energy business. Software can help with emergence of the industrial Internet. These innovations will enable the integration of people, machines, and big data with analytics, creating a living network of information capable of developing more reliable and efficient energy solutions in the future, Carlson said. One way GEs Grid IQ Insight connects minds and machines is through its capability to monitor social media for outage information. Grid IQ Insight software can analyze social content to identify postings that can help locate a trouble spot or outage in a utilitys electrical distribution system, GE said. In many cases, the outage location can be detected before the first customer calls the utility to report a problem.
Data advice
Generac to acquire Baldor Generators

Generac Holdings Inc. announced the signing of a purchase agreement with Baldor Electric Co. a whollyowned subsidiary of ABB Group, to acquire all of the assets of Baldors generator products division, Baldor Generators. Following the close of the transaction, the employees of Baldor Generators will become employees of Generac and the Oshkosh, Wis., facility will become part of Generacs manufacturing footprint. Generac will continue to support Baldor Generators existing customers and distribution network going forward. The acquisition is expected to close in the fourth quarter of 2013, pending closing conditions. The terms of the transaction were not announced. ce
Florian Zettelmeyer, MIT Graduate, professor, and director of the Center for Data Analytics, Kellogg School of Management at Northwestern, also emphasized that businesses need to adjust their processes and understand analytics. They need to empower people to better understand whats going on in real time by measuring the right things. Data scientists, experts in analysis, are in great demand and can help with what questions to ask, meaning of data, and how to link causes and effects. Zettelmeyer offer four ways to make the industrial Internet work more effectively: 1) share information; 2) use data in new ways; 3) start in byte sizes; and 4) scale to opportunities. See more photos, information, and graphics, online. ce
NEWS NOTES
Congratulations to Control Engineering China (CEC), celebrating 10 years this month. See selected CEC translations and other global coverage at www.controleng.com/international. www.controleng.com has more about each item below. n Greater manufacturing connectivity, communications Harting looks ahead. n Improve production, design, engineering, operations, maintenance SPS IPC Drives automation trade fair, Nov. 26-28, Nuremberg, Germany. n PID math demystified, part 3: More on derivative control. n PINA General Assembly looks ahead to growing industrial Ethernet deployments. n SATORP Jubail refinery project enters commissioning phase. n U.S. Manufacturing Day events were celebrated on Oct. 4.
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Were you on the OSHA top 10 list of violations?

There were 42,502 violations in the OSHA Top 10 in 2013, a 56.3% increase from the 27,186 in the OSHA Top 10 in 2012. Fall protection is once again the top OSHA-cited workplace safety violation with more than 8,000 citations. Fall protection is the annual leader in the OSHA Top 10 Violations list, which was announced Oct. 1 at the annual National Safety Congress in Chicago. The 2013 Congress marks the 100th anniversary of the National Safety Councils charter. This years Top 10 list differs only in the order of finish and in the number of violations. The first four remain
Standard
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 1926.501- Fall protection 1910.1200 - Hazard communication 1926.451 - Scaffolding 1910.134 - Respiratory protection 1910.305 - Electrical, wiring methods 1910.178 - Powered industrial trucks 1926.1053 - Ladders 1910.147 - Lockout/tagout 1910.303 - Electrical, general requirements 1910.212 - Machine guarding
NEWS
Total violations
8,241 6,156 5,423 3,879 3,452 3,340 3,311 3,254 2,745 2,701
OSHA violations related to controls and machine safety include electrical and wiring methods (5), Lockout/tagout (8), electrical (9), and machine guarding (10). Courtesy: OSHA
unchanged from 2012, but there were almost 1,000 more citations in 2013 for fall protection than in 2012. Wiring methods moved from eighth to fifth on this years list, which machine guarding dropped from sixth to tenth. Todays presentation reminds us that its very important to learn from the past and address these top violations to help make our workplaces safer, said National Safety Council president and CEO Janet Froetscher. ce
5 reasons high school students should choose engineering

A major milestone in every young persons life is choosing how to spend the rest of his or her professional life. Based on personal experience, here are five reasons I think high school students should apply to engineering programs. 1. Large selection of engineering paths gives career flexibility. 2. Engineering occupations are high-paying. 3. Engineers job outlook is positive. 4. Engineers work is fun.
- Sonny K. Siu is a senior electrical engineer at Jacobs-KlingStubbins.

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NOVEMBER 2013 CONTROL ENGINEERING
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cover story
Building an integration strategy

Few technical barriers stand in the way of plant-to-enterprise integration today. It promises real-time data for making better decisions and optimizing production. But without a comprehensive corporate plan that sets goals and outlines results, mere connectivity is doomed to disappoint.
t one point in the classic film Jurassic Park, Dr. Ian Malcolm says, Your scientists were so preoccupied with whether or not they could, they didnt stop to think if they should. Malcolm may or may not have been right about the dinosaurs, but he most certainly would have been right had he been referring to plant-to-enterprise integration. A technology whose time has come, integration systems undoubtedly are finding their way into manufacturing facilities at an ever increasing rate. The question that remains, however, is just what are they doing for todays industrial operations? Jim Christian, product manager at Honeywell, puts it more directly: The question that applies across integration systems is not can I integrate? It is should I integrate? The tools to integrate are there. The key is in making sense of all that information and drawing value from it.
How hard can it be?
Control Engineering illustration by Tom Rybarczyk
It is not an easy job. And it requires a lot more effort than many companies may once have thought. Manufacturers are at all different places with plant-to-enterprise integration, observed Peter Martin, vice president and fellow at Invensys. In many cases, the primary approach has been to place a plant historian between automation systems and the ERP system, collect as much data as possible, and make it available, he said. And thats it! My facility is integrated. Martin smiled as he spoke, adding that too often manufacturers think merely connecting systems will make something good happen. Few stop to ask why they are integrating. As a result, many companies are exceedingly disappointed with the results of their integration efforts. Plant-
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to-enterprise integration is complicated. From the start, it requires cooperation and communication between disparate organizations. Often it demands a cultural shift in the way a company operates. Beyond applying the technology, facilities must develop a corporate strategy, outline anticipated results, and establish realistic goals and expectations. And first and foremost, they must understand their own systems and the systems that have come to be known as plant-toenterprise integration.
Embracing the integration challenge
Plant-to-enterprise integration today helps manufacturers remain competitive by processing and analyzing real-time data for better decision making. It requires cooperation and communication between disparate organizations and a corporate strategy that outlines anticipated results and establishes realistic goals. Courtesy: Honeywell
So what then is plant-to-enterprise integration? Sloan Zupan, senior product manager at Mitsubishi Electric, calls it highly integrated manufacturing where control architecture converses with business applications. Input from many areas, such as inventory availability, production scheduling, quality assurance, and maintenance operations, ensures that all disciplines know what the others are doing, he said. It helps pinpoint areas in need of improvement and optimizes operations. Integrating energy use from the plant floor to the enterprise, for instanceactually a relatively new concept lets management tie production to energy costs to gain a competitive edge. Once burdened by middleware, integration technology has evolved markedly. The need for software between the controls architecture and the enterprise applications is being eliminated, streamlining the capabilities for exchanging information between the IT systems and the plant floor. The resulting environment is more secure, more reliable, and more transparent. [Look for more on integrating energy use from the plant floor to the enterprise elsewhere in this article and online.] Two major, interrelated factors drive plant-toenterprise integration today: rapid technological advancements and a changing global economy. Advancements in integration technology in the last several decades have been nothing short of incredible, said Ming Ng, industrial networking product manager, Siemens Industry, calling them a perfect storm of factors driving companies to obtain data through connectivity. Weve reached critical mass. Companies integrate today because they must react faster to remain competitive. Integration gives them the capacity to bring functions together from multiple applications in real-time data for better decision making. And Ethernet gives them a common universal platform to enable it, allowing machines from different vendors using different technologies to operate on a common network.
Honeywells Christian voiced a similar view. Manufacturers need real-time information for decision making. Were involved in a multi-site project at a chemical and refining operation in India where the company wants to bring KPIs [key performance indicators] together on dashboards so that everyone, from corporate executives to site managers to operators, can see what is happening in their areas of control. A lot of those KPIs come up from the plant, but some come down from the business system. We are likely to see more of that, more bringing business information down to the plant level for decision making about safety, reliability levels, energy costs, and more. The thinking here is that if you bring everything together in one dashboard, those responsible for a unit can see everything and operate it better. Overall, U.S. manufacturing facilities face aging infrastructure. Too many still use outdated technology, and the time is coming when modernization can no longer be avoided if plantto-enterprise integration is to become a reality. Optimum enterprise connectivity involves horizontal as well as vertical integration that older technology cannot provide, pointed out Siemens Ng. Users faced with modernizing an aging infrastructure want to create an infrastructure that will take them through the next 10 or 20 years. That investment not only will enable integration, it will drive industrial manufacturing.
Making a cultural change
Manufacturers need realtime information for decision making. Integration systems help consolidate KPIs such as these from the plant floor and the business systems onto one dashboard so that everyone who needs to can see what is happening, maximizing performance and optimizing operations. Courtesy: Honeywell
Experts agree, however, the biggest barrier to drawing value from integration isnt technology or even its cost, but how it is applied. When done for a purpose, integration becomes incredwww.controleng.com
cover story
ibly beneficial. Plant-to-enterprise integration demands a facility do things differently. For example, management needs to trust front-line operators enough to give them the information they need to make better business decisions, said Invensys Martin. That is a cultural change. Connecting silos of information together is not what is needed. Management needs to figure out why and how getting information from point A to point B will add value. Perhaps the most difficult challenge of inte-
grating is that of simply getting started. Most companies struggle with building an integration strategy. Facilities must develop a plantto-enterprise connectivity strategy, insisted Mitsubishis Zupan. That will uncover the need for systems that provide the solutions and the capabilities that ensure data reliability. Among these are Gigabit Industrial Ethernet to enable efficient network use, security measures that keep personnel from indiscriminately accessing confidential or proprietary information, and stan-
Moving forward with plant-to-enterprise integration
acilities just getting started with plant-to-enterprise integration and those striving to advance their integration effortswill find it helpful to take time to review the current state of their companys integration culture and technology before moving forward. Focusing on the cultural aspects of integration is imperative to a solid foundation. Reviewing optimum applications of existing technology and planning future efforts can enabe more concrete results.
integration, not the integration itself, he said. Integration is an enabler. Only after you know what youre going to do with integration can the technologies be effectively applied.
Advancing technology
Looking at the technology side of getting started, Ming Ng, industrial networking product manager at Siemens Industry, emphasized that companies seeking to integrate operations do not need to rip and replace. A lot of existing infrastructure can be reused, he agreed, noting that in his experience, plant-to-enterprise integration efforts today typically focus on three areas: n Making the transition from an older fieldbus technology to Ethernet. Such facilities have installed bases and are seeking to put machines on Ethernet and/or connect islands of automation into a network, Ng explained. Ethernet offers many benefits unavailable with fieldbus technology. It will give the plant better data, and enable it to react faster and make better decisions, he said. With Ethernet products, the toolsets are better; most Ethernet-based products today have a built-in web server. With a standard laptop and an Ethernet cable, engineers can connect to the network for diagnostics and to see the messages in these devices. In the past, they would have needed special software, a dongle, and a lot of network knowledge. n Applying wireless; specifically, determining where it can be used and what benefits it can achieve. In most cases, facilities concerned about mobile and wireless technologies are those with a unique application or who have not used wireless before, said Ng. Planning is the most important part of any wireless effort, he said. Companies need to understand how to lay out a network. n Designing a network and working with IT effectively. Many production, plant, and controls engineers remain concerned about interacting with IT, admitted Ng. They may feel they have insufficient background or knowledge about networking, he added, but most controls engineers can install, configure, and use industrial networking devices. Toolsets are designed with a common lookand-feel so that engineers can own the network on the plant floor while IT maintains the office side. Delineating who has responsibility for what is crucial. Each side must take responsibility for the areas in which it has domain expertise. Most importantly, they must work together to find the integration points. Every situation is different. Facilities need to strive to build trust.
Cultivating strategy
Peter A. Martin, vice president and fellow with Invensys, recommends companies take action in five areas to strengthen an integration effort. They are: n Define your strategy. Have you clearly outlined a manufacturing and production strategy? Is it cost-based? Is it volumebased? How often does it change? Everyone needs to understand how the integration strategy impacts every aspect of an operation. n Perform an accounting review. Make sure plant personnel know how results are reported. Determine who contributes what throughout the physical plant. When we consult with companies about their integration programs, said Martin, we try to help them develop contribution algorithms so that they can learn what the strategic performance measures are. These include accounting measures that go down to the plant floor. Then we try to model those measures right in the control system. n Evaluate your human resources. What are the educational and experience levels of the plants employee base? Such an evaluation can help plants put information in a format best suited for each person or group. n Review the technology already in place, in IT and on the plant floor. Often such an analysis reveals new ways of using existing systems to implement and extend the infrastructure. n Develop a plan for improvement. Consider what other actions will further improve the operation. Are advanced controls needed? Would a new maintenance program reap benefits? Perform a constraint analysis to determine what might be getting in the way of improvements. These steps are helpful in determining an integration strategy, said Martin, stressing that such an analysis does not focus on products. Rather it considers how to measure, how to empower, how to use existing assets for improvement, and then how to integrate. You need to start by focusing on what you want to do with
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a checkbox. Security cannot be achieved using a single device or software package. A comprehensive security approach has to be established. Security is only as good as its weakest link. Security measures are ineffective if personnel arent trained correctly or if they bypass the measures. Security strategies require continuous attention and must evolve along with other integration strategies. The technology of plant-to-enterprise integration is only an enabler, added Martin, providing business and operational insights in real time to those who need them so that they can optimize what they do relative to the business. Without a comprehensive understanding of why, integration is worthless, he said. If a facility has taken the time to understand what integration is for and why it is doing it, then it becomes one of the most powerful and profitable tools a company can use. Plant-to-enterprise integration demands a culture of cooperation. Although different priorities characterize the engineering and IT organizations and the production and business functions, the territorial conflicts that once marked efforts to work together appear to have eased. More and more, the process control worlds and the business system worlds are merging, observed Honeywells Christian. A generation ago, control systems were strikingly different from IT systems. Today, the skill sets of each are not all that different. As these systems merge, any sources of strife likely will disappear after a while.
Moving the integration process forward
A variety of new products and systems help enable the real-time visualization plant personnel need to operate in an integrated environment. Among them is Invensys Foxboro Evo, a next-generation process information system designed to improve operational insight and integrity. The system uses advanced tools and applications across a high-speed, fault-tolerant and cybersecure hardware platform. Foxboro Evo features powerful processing capacity and advanced applications using a component object-based platform. The new applications improve the ability of plant personnel to contribute to the success of the business by streamlining and contextualizing information. It also gives operators a more complete, real-time view of plant activity via an updated highperformance, mobile accessible HMI. The system includes a new high-speed controller, field device management tools, a maintenance response center, an enterprise historian, 1-n redundancy and cyber security hardening. Integrated with a broad portfolio of roles-based engineering tools and productivity applications, the system provides visibility into historical, real-time, and predictive operating information to help drive production efficiency. The coupling of control and safety enables sharing of operational information while keeping the safety system functionally isolated and maintaining state-of-the-art cyber security. Courtesy: Invensys
dardized methods for moving information among multiple IT applications and a large variety of manufacturing assets. [For more on establishing and growing plant-to-enterprise integration programs and on understanding and applying Gigabit Ethernet, see separate sections of this article in print and online.]
Security vs. accessibility
A major goal of any plant-to-enterprise integration strategy is balancing accessible, free-flowing data with maintaining data security and integrity, stressed Ng. Manufacturers must develop a security plan and apply the security measures inherent in integration products, he noted. Everything can be used for good or for bad. The key with security is staying ahead of the bad. Security is a lifestyle, not
The benefits of integration are within the reach of most companies, but developing a strategy is critical. Manufacturers must determine the value they expect to get from their plant-toenterprise integration systems. Sometimes thats difficult, admitted Christian. Some companies expect a great many things. We work with them to map out what is possible. The first temptation for most facilities is to say they need everything; to be effective they have to trim things out and highlight whats really important. If production rates are down but quality, reliability, and safety are good, then the plant needs to focus on production so it can find out why it is down. Companies need to determine where the business optimization opportunities lie. Where are plant-to-enterprise systems likely to go in the future? The proliferation of wireless technologies within integration systems is a given, an expectation today. A technician with a smartphone in hand at a tank farm can get just as much information as one working at a central control panel, said Invensys Martin. Mobility puts intelligence in the field. Mobile devices are key to effective plant-to-
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enterprise integration, agreed Ng, noting that many companies look to cellular modem devices to give them the connectivity they need. We worked with a company that needed to bring production data from some 30 plants in different countries into a central location. Many of these plants were in areas with no strong Internet backbone, but that did have a cellular infrastructure. Dropping in cell modems gave the company access to the plant data it needed.
Keeping up with technology
Technology changes so fast today that forecasting the state of integration is uncertain at best, observed Mitsubishis Zupan. The future might find integration technology embedded in the controller instead of functioning next to it, he suggested. Wireless will certainly be more popular, and security enhancements much stronger. We foresee a proliferation of Gigabit Industrial Ethernet. Many networks are unable to handle the flow of information between production and business systems; Gigabit Industrial Ethernet eliminates that barrier. As it becomes more popular on the plant floor, information sharing between manufacturing assets in the IT environment will explode. Remember that integration doesnt create any additional information, said Christian. Integration systems only help sort through data that already exists, find what is relevant, and put it in useful context. The role of powerful domain-specific applicationsfrom maintenance and production systems to planning and schedulingwill remain strong. The next level of improvement will come once those individual areas are working well.
Then, widespread integration can take place as companies are able to see how planning affects reliability affects energy, and so on. An information system with the right level of integration and collaboration can raise each plant in the corporation to the level of the best, or maybe even better than the best. A few companies have reached that level. Many more would like to. ce Jeanine Katzel is a contributing editor to Control Engineering. Reach her at jkatzel@ sbcglobal.net.
Among popular plant-to-enterprise integration offerings is Mitsubishi Electrics MES Interface IT. This enterprise connectivity interface bridges the gap between factory and office by enabling bi-directional data communication from the production floor to enterprise IT systems. It offers controller-level direct database access to help standardize the way information is shared across the plant floor, from a variety of automation suppliers to many different IT applications. It can aggregate data and share information to a variety of applications where the data is needed. In addition, because the appliance is installed in the machine itself, in the same rack as the PLC, latency time is removed; the PLC controls the machine and runs as efficiently as it did before the high level of data integration was established. Courtesy: Mitsubishi
Go Online
A recent Control Engineering/CFE Media survey queried subscribers about the integration measures at their facilities, the benefits integration has brought them, the technologies applied, and plans for the future. Results are being compiled. Watch for a report summarizing what they said, soon to be available online. For additional information about plant-to-enterprise integration and integration products and systems, visit the websites of the companies mentioned in this article: www.honeywell.com www.iom.invensys.com www.mitsubishielectric.com www.usa.siemens.com
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motion control
Long-length linear encoders look lively

Linear encoders provide direct position feedback to various machine tool and automation systems. Working in a linear format allows extreme length position measurement and controlcritical for machine tool accuracy and production of precise large-scale parts. Focus here is linear encoders with 3-meter (about 10-ft) or greater measurement length.
Frank J. Bartos, PE
Key concepts
Use linear encoders, optical or magnetic, for direct position feedback. Extreme length position measurement and control aid machine tool accuracy and production of precise large-scale parts. Linear encoders >3 m are covered here.
igh dynamic operation characterizes CNC systems and precision assembly equipment where linear encoders work. Position measurements must be provided in tough environments and often under high traverse speeds and accelerations. Growing use of linear encoders with directdrive linear motors underlines those requirements. For example, some encoder models offer traverse speeds of 20 meters/sec (65.6 ft/s) or greater. Dirt, oil, chips, and contaminants are especially detrimental to optical encodersrequiring physical protection of the device or enhancement of the measurement process. This is one area where operation of linear encoders differs from that of their rotary-encoder cousins, which work in a sealed environment. Linear encoders can be cat-
egorized in different ways. Encoders fall into two main technologiesoptical and magneticwhich also apply to rotary encoders. Inductive encoders are not covered here.
Optical or magnetic sensing
The photoelectric sensing method shown applies to an optical linear encoder using a glass scale. With a steel scale, a slightly modified, reflective scanning method is usedwhere light shines on the scale tape and reflects back onto the scanning reticle. Courtesy: Heidenhain Corp.
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Linear encoders consist basically of a measuring scale containing extremely fine graduations (or magnetized information) that convey position and a scan head to read the scale. In simplest terms, the measurement process of optical linear encoders entails photoelectric sensing of the scale and a scanning reticle that move relative to each other (see diagram). Projected light is modulated as it either passes through gaps in the gratings when the scale and reticle are aligned, or is blocked when lines of one grating coincide with gaps of the other. An array of photovoltaic cells converts these light-intensity variations into electrical signals. The specially structured grating of the scanning reticle filters the light to generate nearly sinusoidal output signals. Further signal processing at the scan head or the system controller yields position output. Optical linear encoders use a glass or steel scale. Glass is generally limited to measurement lengths to about 4 m, with steel scales applicable for much longer lengths. Glass scale length is limited by the accuracy of machines that manufacture them, noted Nathan Mathiot, product specialist machine tool marketing at Heidenhain Corp. Main components of magnetic linear encoders are a magnetic tape and a scan head. Position information magnetized on the tape in a sequential code serves as the measurement scale. Tapes come in various lengths and can be extremely long. Theyre typically laminated on a steel strip and have adhesive backing for ease of mounting on a machine. Position information is sensed as the scan head travels over the measuring tape.
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motion control
This Electroimpact Inc. wing-panel assembly machine at the Broughton, U.K., Airbus A380 production line uses Renishaw RGH41 optical linear incremental encoders. RGS40 tape scales are fitted in three working areas along the machines 160-m traverse distance. Courtesy: Renishaw plc.
Long-length linear (LLL) encoder applications dont always require the precision of optical technology, explained Corrie Fearon, marketing manager for Encoder Products Div. of Renishaw plc. Magnetic encoders provide an alternative, with 20 micron/meter (m/m; 1 m = 0.00004 in.) accuracy typical for high-end versions. Magnetic encoders offer wider installation/running tolerances, immunity to dirt and contamination, and generally a cost saving compared to optical encoders, Fearon said. (See more on accuracy and applications below; also at Refs. 1 and 2, online.)
Other encoder categories
value and eventually it repeats, he added. Renishaw likewise noted a maximum length limit for incremental encoders in terms of yield on making the scale that long, but has supplied tape scales up to 100-m long. For absolute encoders, maximum length of Renishaw Resolute optical encoder scales is currently 10 meters, limited by the code words selected for optimum dirt immunity and performance characteristics, Fearon stated. Maximum length of the LMA-10 magnetic encoder scale is 16.2 m. Optical linear encoders are further designated as sealed or exposed devices. In sealed units, a metallic housing and elastic sealing lips protect the scale, scan head, and guideway from ingress of contaminants found in industrial environments. Exposed (noncontact) linear encoders are physically simpler and often used in cleaner environments.
Harsh working environments
Linear encoders are also designated as incremental or absolute type devicesterms that carry over from rotary encoders. Absolute encoders provide position essentially upon power up. Incremental encoders require axis movement to first establish a reference position. However, distancecoded reference marks (DCRMs) spaced along the scale minimize the need for machine movement. Encoder electronics establish the absolute reference after traversing two DCRMs, which typically means a movement of a few millimeters, according to Heidenhain. Reference marks are calculated by a formula, which leads eventually to a repeated unique position value and thereby becomes a length limit for incremental tape scales with DCRMs, Mathiot said. The longest distance-coded linear encoder made by Heidenhain has been 72 meters. Absolute tape scales are also limited in measurement length by the pseudo-random code (PRC) placed on the track. As an example, Mathiot cited the LC281 linear encoder with 32 bit memory. Each 10-nanometer step uses 1 of 4,294,967,296 possible position values stored in the memory. The PRC is unique for every position
Noncontact optical linear encoders in particular face harsh conditions and need corrective enhancement of the optical scanning. Fearon noted two basic ways to mitigate effects of contamination: use optical filtering or average the scanning over a relatively larger area. Filtering, the more powerful method, amplifies good signals at the fundamental frequency to which the optics are tuned, while rejecting other harmonics caused by contamination. This method is suitable to incremental encoders. Adding auto gain control (AGC) to the system helps boost dirt immunity still further, but adding AGC to a weak optical scheme simply amplifies poor signals and will not overcome phase-shift, or other issues, Fearon said. Renishaws Resolute line of absolute, noncontact linear encoders applies different, advanced techniques to obtain dirt immunity. After capturing an image of the measurement scale, the encoder performs cross-checking and error-rejection via an on-board digital signal processorcounteracting chaotic light back-scatter onto the scan head from grease, oil, or particulate contaminants on the scale. High system redundancy allows the correct position to be determined even with large parts of the image obscured, according to Fearon. To provide further safety and diagnostic coverage, Resolute encoders include a position-checking algorithm that tracks position, ensuring that only correct data are sent to the system drive/controller, Fearon added. Actually, two independent calculation methods are used and checked in the scan head. Then, one correct result is sent, relieving the drive/controller from that task (see more at Ref. 3). Sealed optical linear encoders minimize or
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motion control
m and 0.2 m, respectively.

Accuracy of signals
Actual encoder scale accuracy can often be significantly better than the specified value. An example shown is Renishaws RTLC optical scalewith 4 micron total accuracy over the entire 11.9-m length. Courtesy: Renishaw plc.
Go Online
Ref. 1 - LLL encoder addendum Ref. 2 - Encoder application Ref. 3 - Position determination/ checking algorithms www.heidenhain.com www.renishaw.com www.sickusa.com Further reading: Electromagnetic linear encoders to the rescue
40
eliminate the need for extensive dirt immunity measures. Heidenhain offers both exposed and sealed encoders but applies the latter exclusively in the environment of numerically controlled machine tools. A sealed linear encoder is the correct encoder for harsh environments, where coolant, oil, and chips are present, Mathiot said. Examples of Heidenhain sealed LLL encoders include LC211 (absolute) for measurements up to 28 m and LB382 (incremental) available for up to 30 m and 72 m on special order. Both models use a steel scale tape. These encoders offer 5 micron (m) accuracy gradedefined as position error tolerance over any 1-m measurement length. Some other models offer 3 m accuracy. Sealed encoders intended for non-CNC machine applications have up to 3 m measuring range and typically 10 m accuracy grade. Heidenhain likewise noted methods that lower sensitivity to contamination for its exposed LLL encoders, which find application in high-accuracy production/assembly machines, measuring devices, and direct drives. One method mentioned is single-field (rather than four-field) scanning to generate position signals. While output signals with single-field sensing experience amplitude change due to contamination, offset and phase position are said to remain unchanged. Signals remain highly interpolable and position error within one signal period remains small, according to Heidenhain. Representative exposed encoders include LIC series (absolute) and LIDA series (incremental) with position error per signal period of up to 0.08
Use of a large scanning field relative to the scale grating period also reduces contamination sensitivity. Reportedly, high-quality signals are output in the presence of contaminants up to 3-mm diameter and position error stays well under scale accuracy grade specs. Some of the scale accuracies cited above refer to certified values. In practice, encoder scales achieve substantially better results (see diagram). Sick Inc.a subsidiary of German company Sick AGoffers several LLL magnetic encoders. TTK70 noncontact absolute encoder has 10 m accuracy grade, applicable up to the units full 4-m length. LinCoder L320, another noncontact absolute device, comes in lengths up to 40 m and with a 0.3 mm/meter accuracy spec (at 20 C). Another encoder product from Sick is particularly noteworthy for its extreme-length measurement capability. Pomux KH53 provides absolute position measurement for up to 1.7 km (thats 1,700 m). With its IP 66 rating and an aluminum housing, Pomux KH53 is a very rugged solution for those extreme length and harsh environment applications, said Mandee Liberty, absolute and linear encoders product manager at Sick. Long-length linear encoders range over wide applications. Sick cited applications for KH53 in overhead cranes and storage/conveyor systems, among others. Liberty noted success for KH53 in those applications with measuring lengths in the 15 to 800 meter range. In Renishaws experience, long-length encoder applications include large bearing grinding machines, LCD screen manufacturing stages, wide format printing, and machines for laser/water-jet cutting and aircraft wing production (see photo). Heidenhain noted application examples in the manufacture of wind turbine components and automotive parts on a transfer line. In a related market trend, the company sees its customers moving toward use of encoders with linear motors to obtain faster machining of parts. ce - Frank J. Bartos, PE, is a Control Engineering contributing content specialist. Reach him at braunbart@sbcglobal.net.
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Linear encoders can provide high accuracy measurement over long distances; what application could you improve with better feedback?
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project management
Consider lifecycle costs, benefits

Systems integration may be considered as one of the last items in the project, treated as a commodity, like some equipment. True cost of systems integration can be more complicated. Understand and measure these costs to keep the budget balanced over time. See supporting Control Engineering system integration research. Key concepts
System integration shouldnt be considered a commodity. Effective system integration lowers costs and increases value over the project lifecycle. It is better to involve a system integration expert earlier in project design, rather than later.
True cost of systems integration:
hen installing a new line or process, many people consider systems integration as one of the last items in the project. The cost is often viewed simply as the purchase price of the system, and is often treated as a commodity just like any runof-the-mill piece of equipment. Buyers should beware, as the true cost of systems integration can be a lot more complicated than that. Learn more about how to understand and measure these costs, and the budget will stay in balance over the long haul.
Good beginning, good ending
The up-front costs of a system integration project include the cost of materials, software licenses, travel, installation, and various sorts of technical labor. There are a wide variety of factors that can significantly influence these costs for any given production line or process. Some systems provide very tight control of the processing equipment or production line, while others have more variability. Certain ones are rigid in their actions and only allow a pre-defined set of operations, whereas others allow much more flexibility. Some have massive redundancies and others have multiple points of failure. Systems can be very intuitive to operate or require substantial training. Some are extremely safe to run; with little risk to people, high degrees of product integrity, and layers of protection for processing equipment. Others carry significant risks if not operated as intended. Certain features, such as safety, product integrity, and equipment protection, tend to be universally desired. Others, like flexibility or ease of
operations, can be a matter of budget, preference, process, or business requirements. All of these have an influence on both the initial upfront costs and the total true cost of the system over time. It is important to sort out these factors up front. For example, in general the tighter you wish to control a process, the more you need to measure it. The more you measure it, the higher your costs in the form of instrumentation, sensors, I/O modules, electrical engineering, programming, installation, and maintenance. There is always a balance point between the cost of waste due to variance in a process and the total cost required to control the process within a certain limit. Higher value raw materials and finished products require tighter control. Paying attention to this balance point up front can yield great dividends in the long run. There is a fiscal context to both under-controlling and over-monitoring a process or production line. Various factors influence up-front costs, as well as the carrying costs over time.
Lifecycle costs: Prosperity over time
Most systems are in operation for years. It is important to consider what the operational requirements will be over time. One item to consider is the flexibility of operations. It is relatively straightforward to design and install a system with a limited number of pre-programmed operations. It is usually more complicated and expensive to design, test, and install a system with a large number of flexible operations. Many manufacturers have an increasing number of products SKUs (stock-keeping units) and need a lot of agility built into control systems.
42
The age of enlightenment has arrived.
Introducing the Foxboro Evo system.
Protect Engineer Maintain
Evo
Foxboro
Operate Manage
Youve been waiting for a control system that shines light into every corner of the plant. So every member of your team can be enlightened with the context-rich information they need to manage risk and turn opportunities into prots. A system with the power and exibility to know the past, collaborate in the ever-evolving present, and even predict the future. This is the next generation of advanced automation. This is Foxboro Evo. See what the Foxboro Evo process automation system can do for you at
This changes everyone
Foxboro.com/FoxboroEvo
Tel: 1-888-FOXBORO E-mail: foxboro.marketing@invensys.com Copyright 2013. All rights reserved. Invensys, the Invensys logo, Foxboro, and Foxboro Evo are trademarks of Invensys plc,its subsidiaries or afliates. All other brands and product names may be trademarks of their respective owners.
project management
The true cost of systems integration can be a lot more complicated than buying system components. Learn more about how to understand and measure these costs to balance your budget over the long haul.
For such manufacturing operations, it will likely make sense to invest up front in a system that will accommodate this requirement over time. Putting such flexibility into the hands of operations staff usually will be a lot less expensive than repeated redesigns by technical staff over the lifecycle of the system. For many facilities downtime spells disaster. In some instances the loss associated with one hour of downtime can outweigh the entire up-front cost of the system. It is important to get a clear handle on the true costs of downtime for the line, facility, or connected supply chain. Redundancy can be designed into all systems on many levels including servers, controllers, workstations, and more. This will add to up-front costs, but it can be a smart trade-off if the downtime tolerance is low.
Staffing: Turnover, ergonomics
Courtesy: TriCore
System workstations need to be relatively close to where the work is performed and in sufficient quantity so that multiple operators are not tripping over each other trying to access the system. A little more infrastructure of this sort can save a lot of labor costs over the life of your system.
Staffing: Be safe, not sorry
Another item to consider is the staff turnover rate for those individuals in operations and maintenance. Just like so many smart devices on the market today, easy intuitive control system operations generally require a bunch of smarts under the hood. There is a wide array of operator interface and visualization products on the market, and an almost infinite way to configure them. If your staff turnover rate is high and your process is complex, it might make economic sense to spend a bit more up front with higher end visualization products and configurations to make staff training easier. Dont forget the ergonomics of how people interact with your system as they perform their work. The number and location of your operator workstations should take all of this into account.
The safe operation of your system should be the top design consideration. A system needs to protect people above all else, but also be concerned with product integrity and protection of processing equipment. The risk of loss in any of these areas can far exceed the total up-front cost of the system. The chief risk to people comes in areas that are semi-automated, mixing automated equipment operations with manual human operations. Sensors and programming are needed in the right mix to prevent unsafe operations from starting, and to stop operations when an unsafe condition is sensed. Protecting product and equipment should be approached in a similar manner. Adequate permissives must be programmed to insure safe setups; operations at cross purpose must be interlocked; and critical faults must be programmed to immediately stop all unsafe operations. As part of the design process, a functional description detailing all of these items is invaluable. Distribute the functional description document to all relevant stakeholders for input. This is a great way to ensure that all bases are covered. Prior to installing any system, you may need regression testing to ensure all permutations of operations are performing properly. This all takes time and money, but it can be a small
44
project management
When system integrators join the projects

Most respondents said that system integrators typically join the team during the project design (31%), but 29% of respondents prefer they join at project inception.
31% 27%
Costs and considerations
for control system design and implementation should be an integral part of all project
29%
When system integrators usually join When system integrators should join
20% 16% 10% 5% 2% 6% 7% 4% 21%
planning.
9%
9%
Project inception
Project design
Project Project specification simulation, emulation, or testing
Project Project For the startup implementation entire project lifecycle
Those involved with system integration know that system integrators should be involved earlier in the project lifecycle, according to recent research from Control Engineering. (308 answered ths question.) Courtesy: Control Engineering System Integration research report, 2013
cost compared to potential losses in any of these areas. A final word on safety: On workstations, it is all too easy to configure all sorts of measurement values as alarms. This can be self-defeating, as it creates noise that makes it difficult to separate real problems from simple process status. Human response to alarm conditions is a necessary element for safe operations. Only configure alarms that are actionable to better manage safe operations and mitigate your risk of loss in this regard.
Preventive, predictive analytics
it fails, or waste time and money on premature maintenance. Recording and analyzing actual run and cycle times can allow preventive maintenance to be performed in the most efficient, effective manner. Finally, the ability to monitor operations over time can yield data that can turn into actionable information to help improve the operating efficiency of the processing equipment or production line. These analytics include operational equipment effectiveness (OEE) analysis, downtime analysis, statistical process control (SPC), linear regression performance analysis, and more. Such analytics can unleash hidden capacity in the processing system, without the need to capitalize new equipment.
Integrated planning
The final consideration on the true cost of system integration is the potential savings it can generate. A smartly designed system can provide both operational and maintenance savings over the life of the system. Use of historian products and manufacturing analytics afford deep insight into the behavior of a processing system or production line. These powerful tools can deliver significant return on investment over the life of a system. Should something unexpected happen in a process, systems with complete historian capabilities can be invaluable in diagnosing what happened. This could include recording all device actuations, operator actions, and sensor measurements from moment to moment. The plummeting cost of information storage makes such solutions much more financially viable than they were just a few years ago. When compared to the costs of a product recall, the cost of this extra visibility can be insignificant. Measuring and trending device actuation cycle times or run times can be a great aid in preventive maintenance for related devices. It is almost always cheaper to properly maintain a device based on its usage than operate it until
Costs and considerations for control system design and implementation should be an integral part of all project planning, not an afterthought at the end. The long-term costs and benefits are often much more complicated than they appear on the surface. Proper design practices should include considerations not just for the immediate project, but for the anticipated behavior and value the system can provide over time. Follow the guidelines outlined here to enable your system to provide the most value to manufacturing operations and to keep long-term costs in check. ce - David McCarthy is president and CEO of TriCore Inc. Edited by Mark T. Hoske, content manager, CFE Media, Control Engineering, mhoske@cfemedia.com.
Go Online
www.tricore.com www.controleng.com/archive November: Link to Control Engineering System Integration research and additional project management advice.
Consider this...
At what point are you involving experts with eyes on project lifecycle costs and benefits?
46
break through the
NOISE
Better Signal-to-Noise Ratio Means Better Level Control Performance
3X
Higher
4.40
Model 706 SNR
1.57
Competitor SNR The ECLIPSE Model 706 transmitter has a signal-to-noise ratio nearly 3 times higher than competitors.
While transmit pulse amplitude (signal size) has helped to make guided wave radar technology the standard for accurate, reliable level measurement, the fact is signal-to-noise ratio (SNR) represents a far more critical indicator of level control performance. For superior SNR in all process conditions, no other GWR device beats the Eclipse Model 706 transmitter from Magnetrol.
To learn more about the breakthrough ECLIPSE Model 706 GWR transmitter visit eclipse.magnetrol.com or contact your MAGNETROL representative today.
magnetrol.com 1-800-624-8765 eclipse.magnetrol.com
2013 Magnetrol International, Incorporated
systems
SAFETY
mation vendors, organizational diversity between the two product teams is only the first level of separation.
3: Systematic safeguards
5 things to consider when selecting a safety system

Pure modularity
Performance requirements now drive the selection process.

afety is among the top priorities in any manufacturing facility, and given the changes in the industry, technology and even standard, there are a lot of concerns starting with the selection of a safety system. The performance based safety standards (IEC61508 and IEC61511/ISA84) have changed the way safety system selection should happen. Todays system selection is driven by performance requirements.
1: Hazard understanding
Valve Terminal MPA-L

Easy to assemble Individual valve modularity Serial communication for electrical and pneumatic components Capacity for 32 valves per terminal
This has nothing to do with the safety system hardware. It is critical in the process to understand the scope of the process hazards and to determine the necessary risk reduction required. This should be done to create the Safety Requirements Specification (SRS) necessary to start a system selection. Even when replacing an existing system, this is critical as the risk profile of the plant may have changed since installation. Technology diversity: There has been a long standing requirement that a safety system must be different (or diverse) technology from its process automation counterpart to avoid common cause failures. Most safety systems rely on component redundancy (hardware fault tolerance, or HFT) to meet reliability and availability requirements, introducing a degree of common cause failure directly into the safety system. Rather than redundancy, leading systems now provide diversity of technologies designed into logic solvers and I/O modules, along with a high degree of diagnostics, to allow a simplex hardware configuration to meet SIL3 requirements. Product implementation diversity: The standards are imposing diversity on the way manufacturers deliver the product you buy. Even though most safety systems are manufactured by process auto
This addresses how much protection against mistakes is built into the safety system. You should be asking for certified software libraries that offer functions according to the SIL requirements of the application compiler restrictions to enforce implementations according to the SIL requirements; user security management to separate approved from non-approved users for overrides, bypass and other key functions; and, audit trail capability to record and document changes to aid in compliance with functional safety standards. Previous generations of safety systems met reliability requirements through HFT. This feature helped to provide availability and kept plants running in the event of a component failure with the safety system. Whether you needed it or not, you paid for it. Understand if you need high availability or not as some processes can easily tolerate shutdowns from spurious trips when using simplex configurations that still deliver appropriate SIL coverage.
4: Availability
2: The more diverse the better
5: Separate, interfaced, or integrated?
For more information: Call: 1-800-Go-Festo 1-800-463-3786 www.festo.com/us/mpa-l
Global manufacturer of process control and factory automation solutions

Using the SRS and your business requirements, make a clear determination of one of these three requirements. Integrated offers many key benefits, drawing on common capabilities of the process automation system not related to the safety functions directly. But only being interfaced or even kept completely separate are options, and need to be thoroughly considered. Achieving the desired risk reduction involves more than just choosing a system. ce - Luis Duran is product marketing manager, ABB Safety Automation System business.
48
2014
FINALISTS
Were throwing away money repairing and calibrating old flow and density meters. I need a reliable technology that eliminates routine maintenance and helps me improve my plant performance.
YOU CAN DO THAT
Easy to install, minimal cost to maintain and superior measurement delivers the results you need. Volumetric meters have moving parts that can wear down. Plus, they require additional pressure and temperature devices to convert measurements to mass or standard volume. A single Micro Motion Coriolis meter and density meter measures liquids, slurries and gases for direct mass flow, volume flow, liquid density and temperature. With meters installed in nearly every conceivable application, you can count on expertise and performance that will help you save and make money. Learn more at: www.EmersonProcess.com/MicroMotion

2013. Micro Motion, Inc. All rights reserved. The Emerson and Micro Motion logos are respective trademarks and service marks of Emerson Electric Co. and Micro Motion, Inc.
engineers choice
VOTING
Vote now for
Engineers Choice Finalists

The official ballot is open for voting for Control Engineering North American print and digital edition subscribers, for a limited time. Cast your vote at www.controleng.com/VOTE2014.
2014 V
FINALISTS
ote now! For a limited time, the official Engineers Choice ballot is open for voting for Control Engineering North American print and digital edition subscribers. At www.controleng.com/VOTE2014, vote for the best Engineers Choice finalists of 106 entries across 23 categories after logging into the website. Based on your experience, please vote in as many categories for which you feel qualified based on technological advancement, service to the
industry, and market impact. Details and photos are available for each product. Winners and honorable mentions will be featured in the February 2014 issue of Control Engineering. Note: Only qualified subscribers are eligible to vote. One ballot per subscriber will be accepted. Multiple ballots from the same subscriber will be invalid. Manufacturers of products listed as finalists are not eligible to voteballots submitted by these manufacturers will be invalid.
Hardware - Handheld test, measurement, calibration MC2-IS Intrinsically Safe Multifunction Calibrator (Gen II), Beamex, www.beamex.com Fluke 1730 Three-Phase Electrical Energy Logger, Fluke Corp., www.uke.com Fluke 709H Precision Current Loop Calibrator with HART Communications, Fluke Corp., www.uke.com Fluke Ti400 Infrared Camera, Fluke Corp., www.uke.com MFC5150 Hand-held HART Communicator, Meriam Process Technologies, www.meriam.com Personal Electronic Dosimeter, Tracerco, www.tracerco.com CA700 Portable Pressure Calibrator, Yokogawa Corp. of America, www.yokogawa.com/us Hardware - HMI, operator interface, thin-client TPC-2140WP HD TFT LCD Touch Panel Computer, Advantech, www.advantech.com ViewMarq Industrial LED Message Display, AutomationDirect, www.automationdirect.com EZPanel PC HMI, EZAutomation, www.ezautomation.net Monitouch Technoshot Series Programmable displays, Fuji Electric Corp. of America, www.americas.fujielectric.com Experion Collaboration Station Large-format, Multi-touch Display, Honeywell Process Solutions, www.honeywellprocess.com OmniClient HMI, Kontron, www.kontron.com/hmi
50
HMI5000HD, Maple Systems Inc., www.maplesystems.com SIMATIC IFP1900 MT Multi-touch Flat Panel Monitor, Siemens Industry, www.usa.siemens.com/industry Hardware - Industrial PCs CX9020 Embedded PC, Beckhoff Automation, www.beckhoffautomation.com EXPC-1319 UL Class 1, Div 2 Panel Computer, Moxa Inc., www.moxa.com Designline Industrial PC, Phoenix Contact, www.phoenixcontact.com Hardware - Integrated HMI controllers EZTouchPLC Micro, EZAutomation, www.ezautomation.net FT1A SmartAXIS HMI Touch PLC with IO, IDEC Corp., www.idec.com/usa UniStream HMI Touch Panel, Unitronics, www.unitronics.com Machine & Embedded Control - Discrete sensors, vision DS1000 Series 3D Displacement Sensors, Cognex Corp., www.cognex.com Inductive Angle Sensors, Turck, www.turck.us Machine & Embedded Control - PLCs NI cRIO-9068 Software-designed Controller, National Instruments, www.ni.com SIMATIC S7-1500 Controller, Siemens Industry, www.usa.siemens.com/industry SLIO PLC, VIPA Automation, www.vipausa.com
Motion Control - Drives XT Motor Control Center, Eaton, www.eaton.com Allen-Bradley Kinetix 5500 Servo Drive, Rockwell Automation, www.rockwellautomation.com Allen-Bradley PowerFlex 525 AC Drive, Rockwell Automation, http://ab.rockwellautomation.com SINAMICS v20 Variable Frequency Drive, Siemens Industry, http://usa.siemens.com/drives MV1000 Medium Voltage AC Drive, Yaskawa America Inc., www.yaskawa.com Motion Control - Motors Ensemble LAB Motion Control Platform, Aerotech Inc., www.aerotech.com AM8500 Series Servo Motors, Beckhoff Automation, www.beckhoffautomation.com EXCM Mini H-Gantry XY Planar Surface Gantry, Festo Corp., www.festo.com SIMOGEAR Gear Motor, Siemens Industry, www.usa.siemens.com/drives Network Integration - Ethernet hardware EKI-3725 5-Port Gigabit Unmanaged Industrial Ethernet Switch, Advantech, www.advantech.com iMcV-Giga FiberLinX-III Gigabit Intelligent Ethernet Media Converter, B&B Electronics, www.bb-elec.com EDR-810 10-port Industrial-grade Secure Router, Moxa Inc., www.moxa.com Allen-Bradley Stratix 5700 Managed Industrial Ethernet Switch with Network Address Translation, Rockwell Automation, www.rockwellautomation.com
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BIMBA BRANDS I ACRO I MEAD I MFD I PNEUMADYNE I TRD

Copyright 2013 Bimba Manufacturing Company. All Rights Reserved.
engineers choice
VOTING
Vote now at www.controleng.com/VOTE2014
Industrial Ethernet Multiprotocol Three Protocol IO Device, Turck, www.turck.us Secure Gigabit Routers, Weidmuller, www.weidmuller.com Network Integration - I/O systems EP9214 EtherCAT Box I/O Module, Beckhoff Automation, www.beckhoffautomation.com U-Remote Distributed I/O, Weidmuller, www.weidmueller.com Wireless Mesh I/O and Gateway (WI-I/O 9-U2), Weidmuller, www.weidmuller.com Network Integration - Network hardware VPort 56-2MP-T Wide-temperature HD IP Camera, Moxa Inc., www.moxa.com Overmolded Mil-Spec Cordset, Turck, www.turck.us Network Integration - Wireless products APN-310N Single Radio Industrial 802.11a/b/ g/n Wireless LAN Access Point, Antaira Technologies, www.antaira.com Spectre 3G-W Cellular Router with Wi-Fi, B&B Electronics, www.bb-elec.com FL WLAN 5101 IEEE 802.11n Wireless Networking, Phoenix Contact, www.phoenixcontact.com 802.11abgn Fast Industrial Hotspot, ProSoft Technology, www.prosoft-technology.com Power - Energy, power protection Heavy Duty Safety Switches, ABB Low Voltage Products, www.abb.us/lowvoltage OTDC200US11 Solar Switch, ABB Low Voltage Products, www.abb.us/lowvoltage UNO-4683 Substation Computer with Domain I/O Modules, Advantech, www.advantech.com 93PM Uninterruptible Power System, Eaton, http://powerquality.eaton.com Fuses Made Simple, Eatons Bussmann Business, www.cooperbussmann.com SurgePOD Heavy Duty Power Supplies, Eatons Bussmann Business, www.cooperbussmann.com PS6R Series Power Supplies, IDEC Corp., www.idec.com/usa UNO POWER Power Supplies, Phoenix Contact, www.phoenixcontact.com TermSeries Multi-Voltage Relay, Weidmuller, www.weidmuller.com Process Control - Flowmeters Daniel 3818 LNG Ultrasonic Flow Meter, Emerson - Daniel Measurement & Control, www.daniel.com Compact Density Meter, Emerson Micro Motion, www.micromotion.com Rosemount 3051SFC Compact Annubar Flowmeter, Emerson Process Management, www.rosemount.com MTI10/MTL10 Thermal Mass Flowmeter/ Temperature Transmitter, Spirax Sarco Inc., www.spiraxsarco.com/us
Process Control - Process sensors A-Series Miniature Explosion Proof Pressure Switch, Ashcroft Inc., www.ashcroft.com Rosemount 3051 Wireless Pressure Transmitter, Emerson Process Management, www.rosemount.com Rosemount 3308 Wireless Guided Wave Radar Transmitter, Emerson Process Management, www.rosemount.com SmartLine Pressure Transmitter, Honeywell Process Solutions, www.honeywellprocess.com LevelFinderPlus Nucleonic Instrument, Tracerco, www.tracerco.com Process Control Systems Furnace Tracker System, Datapaq Inc., www.datapaq.com Foxboro Evo Process Automation System, Invensys, http://iom.invensys.com DCS Migration PlantPAx Test and Debug, ProSoft Technology, www.prosoft-technology.com PlantPAx v3 Process Automation, Rockwell Automation, www.rockwellautomation.com Safety - Machine safety AC500-S Safety PLC, ABB Automation Products GmbH, www.abb.com/plc Focus II Safety Light Curtains, ABB Jokab Safety, www.abb.com/lowvoltage AZM300 Solenoid Locking Keyed Interlock Switch with RFID, Schmersal, www.schmersalusa.com Safety - Process safety, intrinsic safety GDU-Incus Gas Leak Detection, Emerson Process Management, www.emersonprocess.com/safety Liquiphant FailSafe FTL8x Point Level Measuring System, Endress+Hauser, www.us.endress.com SSX/SST Safety Isolator and Splitter, Moore Industries, www.miinet.com Software - Applications QuickDAQ 2013 Ready-to-Measure Application Software, Data Translation Inc., www.datatranslation.com Premium Platform for Experion Virtualization, Honeywell Process Solutions, www.honeywellprocess.com Energy AnalytiX v10.8, Iconics, www.iconics.com KEPServerEX v5.12 Communications Platform, Kepware Technologies, www.kepware.com OPC UA Embedded Server SDK, MatrikonOPC, www.matrikonopc.com MXcong Ethernet Switch Conguration Software, Moxa Inc., www.moxa.com Dream Report v4.52 Integrated Reporting Software for Industrial Automation, Ocean Data Systems, www.dreamreport.net Software - Control design Autodesk AutoCAD Electrical 2014, Autodesk Inc., www.autodesk.com
TwinCAT v3.1 Programming and Runtime Software, Beckhoff Automation, www.beckhoffautomation.com/twincat3 Open Core Engineering IEC and IT Programming Software, Bosch Rexroth Corp., www.boschrexroth-us.com Solidworks 2014 3D Design Software, Dassault Systmes, www.solidworks.com S88 Builder Conguration Software, ECS Solutions Inc., www.ecssolutions.com FAST Modular Machine Programming Software, Lenze Americas, www.lenze.com Totally Integrated Automation Portal (TIA Portal) v12 Engineering Framework Software, Siemens Industry, www.usa.siemens.com/industry Software - Diagnostics Hierarchy Reporting INTUNE+ v5.8 Process Variability Software, ControlSoft Inc., www.controlsoftinc.com Power Xpert Insight Monitoring Software, Eaton, www.eaton.com PlantTriage v12 Control Loop Monitoring System, ExperTune Inc., www.expertune.com FactoryTalk VantagePoint Energy, Rockwell Automation, www.rockwellautomation.com InsightSuiteAE Plant-wide KPI Software, Yokogawa Electric Corp., www.yokogawa.com Software - HMI software Galileo v8 HMI Optimization Software, Eaton, www.eaton.com EZ SoftHMI, EZAutomation, www.ezautomation.net InduSoft Web Studio v7.1 + SP2 Scalable Automation Software, InduSoft Inc., www.indusoft.com FactoryTalk View v7 HMI Software, Rockwell Automation, www.rockwellautomation.com Software - Mobile apps for controls, automation, instrumentation Fault Current Calculator (FC2), Eatons Bussmann Business, www.cooperbussmann.com Endress+Hauser Operations Portable Device Information, Endress+Hauser, www.us.endress.com MobileHMI v10.8, Iconics, www.iconics.com InduSoft Web Studio Mobile Access, InduSoft Inc., www.indusoft.com groov Web Browser Portable Device Development Software, Opto 22, www.opto22.com
Go Online
Read about the 2014 finalists and cast your vote at www.controleng.com/VOTE2014.
52
2014
FINALISTS
Power Revolution
Flexible, Expandable, Powerful
Now a single power supply can provide 24, 15, 12, and even 5V DC. This breakthrough design eliminates the need for multiple power supplies, saving both cost and panel space. Just snap on a module with the voltage you need, when you need it. With a new slim design that consumes less panel space than many lower output power supplies, full function at higher temperatures, and efciency ratings among the best available today, the new PS6R delivers all the power and exiblity you need! Check out the new PS6R at www.IDEC.com/PS6R
2014
FINALISTS
More performance. Simplified. u-remote.

Weidmullers new u-remote is an innovative remote I/O system. It features hot swappable universal analog, universal digital, a wide operating temperature range and power-feed slices for tool free, completely modular solutions.
11.5mm
At only 11.5 mm wide per module, u-remote helps you save valuable cabinet space.
u-remote provides reduced wiring times with Weidmullers Push-In technology in a neat clearly visible, single-row strip.
The u-remote integrated web server speeds up installation and provides real time network access. Field bus couplers include ProfiNet, EtherCat, Ethernet IP and Modbus.
Individual I/O status indication with tri-color LEDs and individual marking tags allow for easy identification.
Lets connect.
www.weidmuller.com/uremote
inside process: PART 3
The long and short of to control rooms
connecting sensors
Will this be strictly analog, or is a digital device-level network (fieldbus) used in the plant? If so, which one?
Connection options
Temperature sensors, more than most other types of instrumentation, can require specialized cabling and treatment to provide accurate data.
he choices made to get temperature measurements to the control room can have a profound impact on plant operation and costs. Temperature measurement can be found in control, monitoring, or logging situations, and quite often temperature is the most commonly measured variable in a plant. Every application has its own unique requirements for accuracy, reliability, and compatible system architecture. Matching these requirements with the right connectivity choice will ensure that the temperature measurement will provide the right performance for the right cost. The ultimate objective is to get the temperature measurement to the control room with the accuracy, repeatability, and stability required for the application. In addition, the solution should offer ease of maintenance and the lowest practical cost of ownership. The design engineer must consider a number of technology, performance, and cost of ownership issues to make a proper decision. As you begin evaluating an application, consider these questions: Are the measurements made with an RTD (resistance temperature detector) or TC (thermocouple)? How far are the measurement points (sensor locations) from the system connection? How are the connections made at each end? Are there junction boxes, conduits, or wire-ways? How and where is the raw sensor signal converted to a useable measurement value? Will using a transmitter help? If so, what kind of transmitter? Where could a transmitter be mounted? Is a wireless transmitter an option?
Key concepts
Temperature sensors have more options for connecting them to a control system than most other types of instruments. Various connection strategies have different trade-offs for durability and accuracy. Using a transmitter at the sensor can eliminate many of the headaches that can go with other sensor wiring methods.
There are several options to consider in choosing a reliable method to get the signal from the field sensor to the control system in a way that delivers the performance levels required by the application. Figure 1 illustrates the most common choices. Direct wiring Connect field sensors directly to input card racks within control room systems. The signal is conditioned or converted into an analog signal or digital value representing the temperature measurement for use in that system. Remote I/O I/O cards, racks, and power supplies are positioned into field marshaling cabinets that are connected to the control system via a digital link. The same attributes as direct wiring apply, but the sensor wiring runs are shorter. Multiplexors Typically using either serial RS232C or RS485 communications or Ethernet, multiplexers communicate with the control system. The communications can be any of a number of host protocols such as Modbus, OPC, Profibus, or other proprietary protocol. While generally reliable, this is a dated approach that has seen a decline in use. Locally mounted transmitters A transmitter is usually located in a connection head or enclosure mounted integrally with the sensor or in very close proximity. The most basic is a simple 4-20 mA output version with limited options and features. HART-enabled transmitters, which are the most common, provide a high-performance and cost-effective option for most applications. Fieldbus architectures use either Foundation fieldbus or Profibus, allowing multiple transmitters to share a common two-wire signal cable to the control room. Adoption of either of these
www.controleng.com
CONTROL ENGINEERING NOVEMBER 2013 P1
inside process
There are many options for bringing sensor data to the host system. The difficulty is evaluating the differences and choosing the best for a given application. Courtesy: Emerson Process Mangement.
fieldbus architectures is usually a management decision that applies to the entire plant facility or to a unit operation. Wireless is a rapidly growing technology with WirelessHART (IEC62591) and ISA100.11a (IEC62734) growing in numbers of deployments. Wireless transmitters can provide the same process variable information and diagnostic capabilities as wired versions.
Critical factors
There are pros and cons to every technology, as shown in Figure 2. You should look for the solution that best matches your needs with the best cost-to-performance ratio. Direct wiring using long sensor cables has to transmit low-level sensor signals that are very susceptible to interference. This electrical interference can come from sources such as pumps, motors, variable frequency drives (VFDs), and radios as well as sources of electrostatic discharge (welders and lightning) and other electrical transients. There is the potential for very large errors to be induced on the low-level sensor signals, and the longer the sensor lead wires, the greater the risk. Direct wiring may provide an adequate installation if the wire run distances are short and there is good separation and protection from interference sources.
Remote I/O cabinets may be cost effective for high-density measurement locations and where adequate protection from interference can be provided. Remote I/O requires an operating power source, which typically needs redundancy or an uninterruptible power supply for critical applications. An installation may also require environmental protection. Situations where a large number of measurement points are centrally located may allow for relatively short wire runs, but the sensor wire length may still be an issue for noise susceptibility and potentially significant errors. The best and most common alternative is to use a transmitter, either analog or fieldbus, that is designed to reject common mode and normal mode interference, as well as provide a high degree of immunity to electromagnetic interference (EMI), electrostatic discharge (ESD), and radio frequency interference (RFI). Where possible and practical, transmitters should be mounted close to the measurement point to minimize any potential noise pickup by the sensor leads. This is especially important for low-level TC signals, which are especially susceptible to noise. Such transmitters may be simple 4-20 mA analog or HART enabled. Fieldbus transmitters have the same characteristics with all-digital architecture.
P2
Fluke puts HART communication in a precision loop calibrator.

Introducing the Fluke 709H: The power of HART in the reach of every technician.
The new Fluke 709H: two-in-one loop calibrator and HART communication tool Read device parameters, perform mA trim, and more Easy to use alternative to complicated HART communicators Loop calibrator with best in class accuracy Saves time, makes testing simple Fast. Easy. Within your reach.
C O M M U N I C AT I O N F O U N D AT I O N
Learn more: www.uke.com/709H
inside process
The use of transmitters is sometimes thought to be expensive, but when the cabling and maintenance costs are considered, the balance shifts.
Each approach has its tradeoffs, and the best combination will depend on the needs of the process at that measurement point. Courtesy: Emerson Process Management
The use of transmitters is sometimes thought to be expensive, but when the cabling and lifecycle maintenance costs are taken into consideration, this balance shifts. The wireless transmitter option may prove to be cost effective for many applications, particularly where it is difficult or expensive to install traditional instrument infrastructure. A highly robust wireless system, as is available today, is achieved by proper network design. This approach is suitable for just a few measurements, or a system can be designed for an entire process unit operation. Consideration of the high-cost of installation of direct wired systems and their high cost of ownership including maintenance and performance issues strongly suggests that using a transmitter approach has a clear advantage for most applications. n Specifying a single temperature transmitter, sensor, and thermowell assembly to meet a specific performance goal simplifies purchasing and places responsibility on a single vendor. n Transmitters can provide higher accuracy performance, often reducing the accuracy percentage by half. n An individual sensor type can be changed from TC to RTD or to a different type of TC or RTD and the same transmitter can normally be
Transmitters vs. direct wiring
reconfigured easily to the new sensor type. The output cable and the DCS input card stay the same. For direct-wired systems, the extension cable would likely need to be changed as well as the DCS input card. n The standard two-wire copper wiring used with transmitters is far less expensive than the TC extension wire or four-wire RTD extension cable used with direct wiring. n Higher performance is assured since a transmitter and sensor assembly may be calibrated as a system for optimal accuracy. This cannot be done with a direct-wired system and sensor. Extraordinary performance can be achieved by using the sensor-transmitter matching procedure inherent in high-end transmitters. While I/O subsystems (DCS or PLC input cards) have reasonable specifications, they are no match for the performance of todays quality temperature transmitters. n A transmitter facilitates using all copper wiring in the field, eliminating the potential for wiring installation errors that come from using different types of TC extension wire. n A transmitters ability to work with multiple sensor types means that a user can often buy all its transmitters from the same manufacturer and likely even the same model, which minimizes spares. n A 4-20 mA signal or digital fieldbus data from a transmitter is far less susceptible to EMI, ESD, and RFI than the low-level signals from a sensor. Some transmitters also offer intelligent filtering options to protect data integrity. Such software may not even be available in the control system host. n Safety-related applications are by far best done in a transmitter-equipped system. In an SIS (safety instrumented system), an error in excess of 2% is considered an undiagnosed failure. n Some transmitters offer an option that supports local display in the field, either as a builtin readout or mounted externally. This can be a major advantage when troubleshooting or in situations where operators are routinely in the area.
n Troubleshooting and maintenance time can be reduced by using the extensive transmitter
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inside process
diagnostics that are either not available or very limited in DCS input cards. A single type of high-level input card is required for the control system instead of a mixture of highlevel and more expensive low-level cards, reducing inventory. Copper wire typically lasts for the life of the plant, eliminating the need to periodically replace degraded TC extension wire.
Good design yields costeffective performance
tion and networking design, always consider overall cost of ownership and not just purchase cost. Production interruptions due to instrument failures, poor sensor performance, higher maintenance costs, or more frequent replacement associated with low-cost products or deficient designs most often tilt the cost of ownership scale strongly in favor of a design using high-quality components. ce
When creating your instrumenta-
uct manager for Emerson Process Management.
Jim Cobb is a senior prod-
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This is the third part of this temperature series. Also read the earlier installments at www.controleng.com/archive: Make the right choice: RTD vs. TC, July 2013 Taking the mystery out of thermowell selection, September 2013 To learn more about measuring temperature, go to www.rosemount.com/TempGuide and order the Engineers Guide to Industrial Temperature Measurement.
You can order a free copy of this temperature measurement guide from Emerson Process Management.
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inside process
Upgrading control systems for storm water management in a very cramped budget environment
Existing configuration tools and code libraries helped Detroits wastewater system reduce design and commissioning time.
etroits wastewater treatment plant is one of the largest in the U.S., serving more than one-third of Michigans population. The plants size and complexity are rooted in a convergence of three major forces: industry, water, and weather. The citys population exploded in the 1920s with the advent of automobile production. The newly minted Motor City continued to grow, ranking among Americas top 10 major metro areas for the rest of the 20th century. The city is also synonymous with water: Its name comes from the river that runs through it, which French explorers called Rivire du Dtroit and translates to River of the Strait. That strait todays Detroit Riverleads to Lake Erie and the rest of the Great Lakes. Like many of Americas urban waterways, the Detroit River and its tributaries were once badly polluted by raw sewage and storm water runoff. Construction of the citys treatment plant in 1939 and a major series of expansions and upgrades over the next 50 years significantly improved effluent water quality. But a major problem remained: Heavy rains and snow melts sometimes overloaded the treatment plant, allowing polluted storm water to run into the Detroit River and the connecting Rouge River. The Rouge, which lies at the center of a large watershed in the metro Detroit area, was so polluted by chemically laden runoff that the river caught fire in 1969. To improve protection from runoff, the city began building a network of combined sewer overflow basins 25 years ago. Today, the department operates eight such basins, strategically located in places where storm runoff would otherwise reach the rivers. By capturing and substantially treating the storm water, the basins play a major role in protecting the surrounding watersheds along with the people and wildlife living there.
Operators can see what is happening anywhere in the system. This keeps travel between sites to a minimum. Photos courtesy: Rockwell Automation
In just the first three months of 2011, for example, the basins collected more than 5 billion gal of runoff that would have otherwise escaped into waterways. While a third was pumped to the main plant for treatment, the rest of that water was treated in the basins.
Similar process, different systems
Each combined sewer overflow facility differs somewhat in size and design, but all basically apply the same treatment process: retaining the overflow, mechanically screening out solids, and disinfecting the water with sodium hypochlorite (bleach). Basins also have equipment that operators use to monitor flow rate and volume, collect samples, remove residual water from the basins, and clean them after a wet-weather event. Despite their similar functions, the basins process control instruments vary widely. Thats
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Key concepts
Municipalities, like many companies, may have to undertake major control system upgrades even when budgets are very limited. Use of existing graphics and software can save money over creating new and unique solutions.
inside process
partly because the basins were constructed over the course of the last three decades at a time when automated control technology was quickly evolving. The comparatively slow pace of public works projects tended to keep them as originally installed with few upgrades. From concept to commissioning, each basin required several years to complete because of strict municipal codes requiring public planning, open bidding, and official oversight. Meanwhile, federal and state water quality standards were becoming more stringent, adding another layer of complexity. Through the years, weve had to update the process control systems at various basins to comply with changing
The lack of a standardized platform hampers troubleshooting and maintenance, and inventory is another problem, because we need to keep so many different spare parts on hand.
regulations, explained Anil Gosine, process control system administrator for the Detroit Water and Sewerage Department (DWSD). He describes the result as a myriad of different process control systems at different locations. At one basin, we have process control equipment from four different vendors. The lack of a standardized platform hampers troubleshooting and maintenance, and inventory is another problem, because we need to keep so many different spare parts on hand.
Selecting a solution
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In 2004, DWSD hired a consultant to design new, more effective and efficient control systems for two existing Combined Sewer Overflow Facilities. DWSD engineers specified Rockwell Automation as the vendor for the process control systems after performing a lifecycle cost analysis. We carefully compared the options that DWSD is standardizing on, looking at capital and lifecycle costs, Gosine explained. We already use hundreds of their products, so were familiar with the quality of their technology, maintenance tasks, and troubleshooting techniques. The new system is built on Rockwells PlantPAx process automation system, which is an integrated control and information solution that combines capabilities of DCS with access to process information to help achieve plantwide optimization. System integrator Process Control & Instrumentation (PCI), LLC, was awarded the contract for replacement of nonfunctional control system instrumentation at two DWSD CSO Basins. PCI worked with
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inside process
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ments in a way that reduces the time required to design, install, operate, and maintain a wastewater project. The toolkit contains configured files, selection Using the library tools, and examples of how to connect But PCI faced a dilemma when the ControlLogix controller to the facilit received the contract to retool the itys HMI hardware and other devices basins. The company had strategically over EtherNet/IP and DeviceNet netoffered the lowest bid to win the proj- works. The toolkit also provides sysect with DWSD, as well as partner with tem architecture drawings, basic status, Rockwell Automacontrol and diagnostion for the first time. tic logic, as well as We have access However, once into faceplates for Facthe project, PCI engitoryTalk View Site to a lot more data neers were concerned Edition HMI softin an integrated that the total cost of ware used in the new replacing the obsoDetroit basins. format at these two lete control systems PCIs controls basins. That has would exceed the engineer on the agreed-upon contract DWSD basins projreally improved the amount. ect said, In the past, diagnostics allowing wed have to proRockwell Automation engineers gram the HMI sepmore preventive recommended a soluarately from the maintenance. tion that they thought controller and then could help keep the link them togethproject within budgetits PlantPAx er. The toolkit comes with 80% of the Process Library and Water Wastewater necessary code, predefined and factoAccelerator toolkit. The process library ry-tested. So youre free to focus on is a software application for the Logix customizing the machine control for the Control Platform that includes an array customer. of pre-engineered code that can be used The Rockwell Automation team on in various applications. It also incorpo- the project worked closely with PCIs rates custom faceplates based on specif- engineers on how to use the process ic plant roles, icons, and documentation. library and the accelerator toolkit to The toolkit customizes those ele- custom configure the system for the
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Detroit basins. We needed to modify the toolkit to make the process data presentation familiar to DWSD operating folks, the PCI engineer explained. Some graphic faceplate elements didnt align with DWSDs color and naming conventions. For instance, they were used to seeing a red light when a piece of equipment was turned on, instead of the green light built into the process library. So we made that change and others that created a special standard toolkit just for Detroit.
Saving on commissioning
The PCI engineer estimated that the process library and toolkit cut his work in half for both basins, saving around $120,000 in programming and systemsintegration time. Another $90,000 was saved in factory-acceptance testing and start-up/commissioning. Programming the first motor took two hours, but after that I just had to copy and paste the code, said the PCI engineer, who now is working on his fourth project using the process library and toolkit. The cooperation Ive gotten from Rockwell Automation has been amazing. I had the opportunity to interface with the original programmer of the toolkit to make the changes as needed. DWSD officials estimate the new tools from Rockwell Automation provided a 50% reduction in design time,
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contract oversight, and post-contract documentation and support. Theres a much shorter learning curve for the operators with the PlantPAx system, said Gosine, who helped oversee the project for DWSD. We also have access to a lot more data in an integrated format at these two basins. That has really improved the diagnostics, allowing more preventive and predictable maintenance. Gosine added that DWSD is in the process of standardizing two more basins with the same approach. He expects that in the future, DWSD can make upgrades to the retrofitted basin controls using the process library, meaning engineers wont have to completely recreate process standards and codes, saving time and money. ce Steve Liebrecht is a solution architect for Rockwell Automation.
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Read more about water utility applications at www.controleng.com/archive: Water utility systematizes maintenance and operational procedures, March 2012 System upgrade saves operating costs, October 2011 For more information, visit: www.dwsd.org www.rockwellautomation.com
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Seven tips follow on how to build value into engineering training, based on the Nov. 5 Real World Engineering blog post by Ric Gibson, a technology leader at Maverick Technologies. 1) Training delivery should be split roughly into thirds, with presentation, demonstration, and exercise / discussion. 2) Course material should be written at about a junior-high school reading level. By the way, reading level is not indicative of aptitude. 3) Dont rush training development. For instructor-led training, allow 2-3 weeks of development per course delivery day. 4) Choose your instructors carefully. An otherwise brilliant engineer may not have the delivery skills and patience necessary for knowledge transfer where there is a broad diversity of student experience and learning styles in the same classroom. An instructor with exceptional public speaking and delivery skills may not have the real-world project experience to offer relevance. 5) If youre going the train-the-trainer route, dont go more than two generations. The person who receives the original training should be the person doing the secondary delivery. 6) Who are your learners? Consider factors such as: education, experience, language, culture, work shift, and position within the company. 7) What are the attitudes? Students usually fall into one of the three categories: explorers, hostages, or vacationers. ce Read more at www.controleng.com/blogs.
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work switches and industrial radio frequency identification (RFID) components and systems Mitronics: Harting 3D Molded Interconnect Device (MID) prints layers of circuits onto molded plastics, minimizing the need for wiring and boards inside components. company continues to expand from passive to active systems. My grandfather developed the original Han connector, Harting said, noting appreciation he receives when family members visit customers, asking about their needs. He expects continued growth for Harting and expansion into intelligent systems
Harting 3D Molded Interconnect Device (MID) plates layers of circuits onto molded plastics, eliminating wires to each LED in this lighting assembly used around a machine vision lens. Images courtesy: CFE Media, Mark T. Hoske
Greater manufacturing connectivity, communications

Connectors and cables, circuit board connections, Ethernet switches, RFID systems, and circuits printed on 3D molded plastic were shown at the Harting annual press conference and customer event. The Oct. 9 event, highlighting current and future capabilities of the third-generation family business, was held in St. Charles, Ill., a few miles from Hartings Elgin, Ill.,
Harting connectors and cables are available for many applications and networks.
facility. Customer meetings preceded the media event. Members of the Harting family (see photo) discussed current and future company capabilities, as a pioneer of connectivity technologies and solutions. Among first company developments was a power connector; now connectors regularly carry power, signal, and data, and can be customized for other needs, such as pneumatics and hydraulics, as well. Technical experts covered four main areas of Harting products and solutions (see photos): Industrial connectivity: modular, rugged space-saving, easy-to-use products from Harting Han and Harting PushPull product lines Electronic connectivity: robust board connectivity and new board-toboard and board-to-cable solutions as well as complex, high-speed backplane design, and production services Smart network infrastructure capabilities: with rugged Ethernet net-
Harting offers a suitcase full of configurable options for its connector systems, as shown at the recent Pack Expo show in Las Vegas, helping the company to reach beyond traditional power, signal, and data in any combination via one connection.
Family and other Harting representatives emphasized the need to understand customer needs to meet long-term (2020) company goals for growth. With final tally of 2013 results still in process, Jon DeSouza, president and CEO of Harting Inc. of North America and Harting Canada Inc., noted some challenges in the North American market in the first half, but said the second half bounced back, with a strong fourth quarter. Philip Harting, Harting vice president, also in charge of networks and connectivity, said current estimates put turnover near 500 million Euro, as the
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over the next 10 years. One new initiative underway is an effort at adding intelligence to Harting modular connector systems, so process and machine data can be pulled into higher-level systems at the point of connection. Dietmar Harting, Harting president and personally liable partner (second generation), discussed Hartings tremendous opportunities in the wind industry. The company manufactures connectors, cabling, assemblies, and other components for wind power generators connection to the power grid. With Germany set to retire its fleet of nuclear power plants by 2022, Dietmar Harting expects renewable energy opportunities to grow. At the German headquarters, Harting changed the gas supply from natural gas to 100% CO2 neutral biomethane in January 2012. A part of this gas was used to produce CO2 neutral electricity in Hartings block heat and power plants. Since January 2013 the company has been receiving all electricity from hydropower. ce - Mark T. Hoske, content manager, CFE Media, Control Engineering and Plant Engineering, mhoske@cfemedia.com.
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CONTROL ENGINEERING NOVEMBER 2013 DE-1
INTERNATIONAL
Fractional order PID controller improves motor velocity control

Compare the integer order proportional-integral-derivative (PID) controller (IOC) with the fractional order PID controller (FOC) for improving the velocity control loop of the permanent magnet switched motor (PMSM), according to research highlighted in Control Engineering Poland.
Artur Kobykiewicz, Krzysztof Pietrusewicz
or the velocity control loop of a permanent magnet switched motor (PMSM), compare the integer order PID controller (IOC) with the fractional order proportional-integral-derivative (PID) controller (FOC).
Fractional order calculus
Fractional order PID controller
There are many ways to describe fractional order calculus. To solve the problem of describing the elements of the fractional order PID controller, the GrnwaldLetnikov definition was used.
Todays increased computing power displaces tools that have been used for hundreds of years in research and modeling of physical phenomena. Such modeling can use fractional order calculus with integrals and derivatives of real order instead of integer order. The result is a significantly more comprehensive description of a given phenomenon, and this, in turn, leads to better results. Such an approach may have some implications in automation and control theory. Because objects controlled by engineers are of fractional order, it seems logical to apply fractional order controllers (with adequate properties) to control them.
where Formula (1) for <0 shows the fractional integration process, whereas for >0 shows the fractional differentiation process. It is possible to clearly present the elements of the fractional order PID controller. Equation (2) shows the discrete fractional integration term and equation (3) the discrete fractional differentiation term.
Figure 1 shows a rapid prototyping test stand. Ethernet Powerlink real-time deterministic Ethernet is used for cyclic communication between the B&R RT APC620 and Acopos drive with only current controller implemented (as shown in Figure 2). Images and graphics courtesy: West Pomeranian University of Technology, Control Engineering Poland
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The main difference between the IOC and FOC is the sum in equations (2) and (3), which determines the memory of the fractional order elements. In a classical PID controller the current value of the state x(t+1) is dependent only on the previous value of the state x(t) and the current input value u(t), whereas in the fractional order PID controller the current value of the state x(t+1) depends on all the previous states. The coefficients and are directly dependent on the order of the element and bind together all the memory states. The general definition of the PID controller is assumed and described by equation (4).
where e(t) is a control error at a given moment t, and Ts is a sampling time, whereas I
and symbolize a fractional order integral and a derivative, respectively. By choosing =1 and =1 the classical PID controller of integer order is achieved.
Test stand
Figure 1 presents the test stand where the experiment was performed. It is the rapid prototyping platform, which integrates the designing stage, complex simulation analyses, and prototyping of newly designed algorithms in the target control system. The general scheme used on the control system is shown in Figure 2. A cascade control system with velocity control loop and torque (current) was applied. The parameters of the current controllers selected for the simulation are predefined as the default set by the servodrive producer for a given motor. In this case the following parameters are set: Kv=54.587318, Ti=0.00088248722.
Figure 2 shows the PMSM control system.
IOC and FOC, compared
During the research, the optimal settings of the controllers were selected. Equations (5) and (6) present the FO and IO controllers, respectively.
Figure 3 shows the response to reference velocity signal for these settings. The experiment confirms the assumption. The best FO PI controller obtains significantly better results than the classical IO PI controller. The response of the motor controlled by the FOC is noticeably closer to the reference signal and has faster reaction to its changes. To objectively assess control quality the obtained results were supported by the values of integral criteria ITAE (Integral of Time multiplied by Absolute value of Error): ITAE_ IO=1005.04 and ITAE_FO=806.19, which shows that the improvement of control quality exceeds 19%.
Differences shown
selected. Also, settings of the optimal controllers (IO and FO) differ only in parameter responsible for the order of integral term. This offers the possibility to implement a new algorithm to the target control system, take the settings from the controller already working in the system, and then finetune the order of the implemented controller to achieve the Figure 3 displays the best IO controller (red line) optimal performance compared with the best FO controller (green line), including a reference value (blue line). of the system. The research is part of the project, Development of the construction and experimental tests of a mechatronic machine tool feed unit with a drive controlled by an intelligent modular actuator (MNiSW Project No. N 502 336936, code-name M.A.R.I.N.E. (multivariable hybrid ModulAR motIon coNtrollEr)). ce - Artur Kobykiewicz and Krzysztof Pietrusewicz are with West Pomeranian University of Technology, Szczecin. They contribute to Control Engineering Poland. Edited by Mark T. Hoske, content manager, CFE Media, Control Engineering, mhoske@cfemedia.com.
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www.controlengineering.pl www.controleng.com/international
FOC provides significant improvement when compared to IOC. The research also proves that for an FO object, the FO controller should be
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CONTROL ENGINEERING NOVEMBER 2013 DE-3
INTERNATIONAL
Industrial Internet brings huge changes, benefits to industry

Benefits of industrial Internet are many, according to Rich Carpenter, chief technology officer, GE Intelligent Platforms, in comments to Control Engineering China.
he benefits of industrial Internet are many. What is industrial Internet? What can those in automation get from industrial Internet and how? Rich Carpenter, chief technology officer of GE Intelligent Platforms, explained these concepts to Control Engineering China, during a recent visit to Beijing.
Third revolution of Internet
available benefits of industrial Internet development, he said.

Keys to industrial Internet
Carpenter predicted great changes for this age of industrial Internet. Recently, he explained to Control Engineering China: From the first Internet revolution, consumers interacted with the Internet to get information. With the second iteration Internet, Rich Carpenter is chief technology officer of e-commerce and busiGE Intelligent Platforms. Courtesy: Control ness were established. Engineering China Now the third Internet revolution is underway, the so-called industrial Internet. As industrial equipment is connected to Internet, he explained, people and equipment are better connected via Internet technologies, resulting in higher productivity and higher reliability. That is the core benefit to customers. Industrial Internet also can resolve challenges related to industrial automation by using knowledge resources across entire industries. We think it can bring a new ecosystem to the Internet. People share information over the Internet, and today, video also can be shared, Carpenter noted. Industrial Internet, using the Internet as a basic infrastructure, can do things that couldnt be done previously. Machine to machine (M2M) communications, connecting people with machines, and intelligent decisionmaking using big data analysis all are among
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Use of the word revolution clearly shows the huge anticipated changes that will result from industrial Internet. Carpenter addressed important related network technologies at two levels. From a low level, information security is the most important issue. People need secure connectivity of equipment, and very simple transportation of data, from the customer side (where the machines are located) to the cloud [web-based applications]. Secure transportation and communications are very important, since security preserve reliability, protecting against unpredictable threats. Appropriate levels of security should be required for online equipment access. At a high level, industrial Internet requires better data organization. How can industrial customers search and find trends in data? In Carpenters opinion, data must be organized very carefully. Organizing data in the right way is the only way to seize all necessary information from many interconnected industrial platforms. Customers should give greater attention to big data opportunities, he suggested, by recording all data from equipment, plants, and even enterprise level systems. This includes data from sensors, and from the design, manufacturing, and related service. All data can be collected with cloud computing technology. Considering the industrial demands of reliability and safety, Carpenter doesnt suggest migrating all functionality into cloud-based applications. He said, Controls still need to be close to equipment. We dont want the cloud to affect the controls. However, for decision-making, industrial Internet will definitely use the cloud. Having many customers data in the cloud improves decision making for each customer and can help determine if actions are required for other customers as well, he noted. For any industrial customers unsure about cloud-based security, Carpenter explained that cloud-computing is less about technology and more about enabling people to achieve new goals.
To decide where to deploy the cloud is another issue. Different customers or different countries may have their own concerns. GE can provide technical services to meet customers data privacy concerns and regulations in different countries, he said. Customers can choose where to deploy the data center as needed. At present, 25% of GE customer data is based in the cloud, and 75% is within customer-based systems, he said, although changes continue. Carpenter confidently predicted that the ratio will reverse over the next 5 years, because cloud-based offerings cost less and are more secure.
Changing now to industrial Internet
Peoples behaviors in automation are already changing, influenced by the effect of industrial Internet growth, he said. For example, more mobile devices are being used in industries. Traditionally, many workstation screens have been deployed in a central control room for operators. Today, crossplatform mobile customers can share the same information seen in the operation center. It is a different method of interaction with the control system, Carpenter said. Also, as users collect more data, it is difficult to distinguish which
parts are useful to meet specific demands. Therefore, analytics and data sciences have became extremely important to understand the meaning of data. Data scientists will be a new role, separate from traditional control engineers or IT workers. They will have the professional knowledge and information about machine learning. And they can analyze big data to determine the right decisions for decision makers, he said. ce - Andy Zhu is editor-in-chief of Control Engineering China. This appeared in Control Engineering China www.cechina.cn and was translated for the Control Engineering North American print and digital edition. Edited by Mark T. Hoske, content manager, CFE Media, Control Engineering, mhoske@cfemedia.com.
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software &
PRODUCTS
Solar tracking motors interface with central controller
The Gen 4 solar tracking motors from Dunkermotoren feature integrated electronics and inclinometer options and can interface directly with the main power plant tracking controller. The design includes all-in-one brushless dc motors with optional onboard inclinometer and optional direct inclinometer input. Units include integrated power and control electronics, eldbus communication, and gearing with planetary, worm, or wormetary options. Motors in this family can be networked in groups of up to 65,535 tracking axis and interface directly with the main power plant tracking controller, eliminating the need for many components currently found on traditional tracking systems.
Dunkermotoren
Vibrating fork level switches certified for safety tanks

The Rosemount 2120, 2130, and 2160 vibrating fork liquid level switches have been certied for safety tanks and are also designed for pump control and hygienic applications. The group has been tested for overll protection and certied by the German DiBt WHG approval authority, which allows them to be used under safety devices for tanks and piping related to water pollution control. Sensors in this series are suitable for a wide range of liquid applications. They are virtually unaffected by turbulence, foam, vibration, solids content, coating, or liquid properties. Users can select from a range of process connections, with a wide choice of housing and wetted part materials. Conventional wired and wireless versions are available.
Emerson Process Management
www.dunkermotor.com
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Widescreen slim profile multitouch displays are IP65 rated

American Industrial Systems industrial multi-touch interactive monitors are IP65 rated, with slim prole and glass front surface for HMI software developers and designers. The projected capacitive sensor provides a gesture-based interface that allows interactions such as pan, zoom, and rotate. The panel offers a true widescreen experience, with a 16:9 ratio at full 1920 x 1080 resolution, providing 40% more screen area than conventional 4:3 displays. The NEMA 4-4x IP65 rating makes them suitable for applications requiring a rugged and durable HMI design. Using MS Windows 7, they can be directly connected to industrial processing machinery, control, and automation systems. Standard 15.6, 18.5, and 21.5 in. screen sizes.
American Industrial Systems (AIS)
www.aispro.com
www.emersonprocess.com
Digital pH/ORP sensor and PC software platform

Yokogawas SENCOM platform product series for the digital measurement of pH and ORP consists of a module, sensor, cable, and software that are designed for digital measurements in process industries like oil, petrochemicals, iron and steel, electric power, and water utilities. The FLXA21 transmitter gives the package powerful digital signal processing capabilities that enables the system to work together. The general-purpose FU20F sensor is suitable for a wide range of applications. It can store digital data and be calibrated using the software included, either in place or in a lab. The software platform also includes an integrated database capable of storing data for up to 100 SENCOM sensors. Yokogawa, www.yokogawa.com
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Advanced controller for data acquisition and control

Advantechs APAX-6572 integrates computing, control, and communication into an open system architecture that is designed for factorywide data acquisition and control, as well as unit operations. The unit contains an Intel Atom D510 1.66GHz CPU, 2GB RAM controller with 3x GbE LAN, 2x COM ports, 1x VGA, and 4x USB 2.0 ports. It comes with four slots for expansion, allowing customers to install four communication modules to support up to 18 COM ports or four APAX-5095P CAN port cards for a maximum of eight CAN ports, or a combination of the two. It supports the IEC-61161-3 standard for LD, FBD, IL, SFC, C, C++ and C# as well as .NET class libraries, thereby providing an open and flexible programming environment. Advantech, www.advantech.com
Real-time interface connects, integrates with mobile software

Tatsofts FactoryStudio Enterprise now provides a comprehensive .NET real-time framework designed specifically to integrate with the OSIsoft PI historian system through a deep-level native communication layer interface. Leveraging the PI AF SDK, FactoryStudio uses high-speed native protocol drivers, no OPC, COM, or any other layer is necessary. The PI tags and assets are visible automatically and immediately for use in your custom .NET, C#, VB.NET scripts, graphical displays, SQL integrations, data entry, and more. With advanced MS Windows Presentation Foundation display editor, users are able to provide a unified view of KPI, PI Batch, PI Asset Framework, PI Event Frames, and MES data all on the same display accessed via Windows PC, Web Browser, Cloud, and native iOS clients. Tatsoft, LLC, www.tatsoft.com
Waterproof hygienic robots for wash down applications

Codian Robotics D4 HD hygienic robots are IP69K rated, making them ideal for pick-and-place operations in wash down environments. Three models accommodate work envelope sizes of 800, 1,100, and 1,300 mm. The family features 316L stainless steel and type 1 titanium construction, sealed cable gland, sealed motor and gearbox compartments, and watertight construction of main body and rotation axis. Sealed compartments allow the use of standard motors and gearboxes, lowering the cost of replacement parts, and allowing standardization of spares with our other robots in the D4 family. Applications include handling meat, fish, and wet food products, along with pharmaceutical and medical devices.
Codian Robotics
Pneumatic valve terminal simplifies fieldbus connections

The VTUG pneumatic valve terminal from Festo offers flexibility in the choice of control options, including simplified fieldbus connectivity and other performance benefits. It is designed for food, beverage, packaging, electronics, semiconductor, and light assembly industries where low cost, high flow rate, small footprint, and long cycle life are essential. These manifold and valve housings can be mounted in cabinets, on machines, and on robotic end effectors. Connectivity options support control through a multipin connector, one-cable IO-link interface to a master controller, or through Festos CTEU fieldbus module to DeviceNet, EtherCAT, CANopen, Profibus, and several other protocols. Festo, www.festo.com
www.codian-robotics.com
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software &
PRODUCTS
Medium voltage ac drive is compact, saves energy
Yaskawas MV1000 medium voltage ac drive family use a modular, compact design for energy savings and compatibility with the 1000 series low voltage ac drive product family. This drive family is uses Yaskawas Smart Harmonics technology to reduce input THD to less than 2.5% without lters, exceeding the requirements of IEEE519-1992 by almost 50%. It also provides galvanic isolation between power input and output. Units in the family use two ve-voltage step bridges per phase to generate a 17-level line-to-line voltage output delivered to the motor. The near sinusoidal waveform results in low THD voltage, low torque ripple, and excellent low speed torque, all without the need for output lters. The MV1000 also features a compact modular design that facilitates transportation, installation, and maintenance.
Yaskawa America Inc.
Signal conditioner series can interface with multiple devices

Omegas DRSP-I dc current signal splitter series feature one 4-20 mA input to two 4-20 mA outputs with full isolation. Each input has zero and span adjustments. The DRSP-I series also features an output test button for each channel, built-in loop power supplies for sink/source I/O. It can split, convert, boost, and rescale process signals and has the ability to interface a process signal with multiple panel meters, PLCs, recorders, DCSs, and SCADA systems. Typical applications include isolation, output splitting, output device separation and redundancy or a combination of these. They are designed for chemical, petrochemical, water, and environmental industries.
Omega Engineering
www.omega.com
www.yaskawa.com
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P11 . . . . . . . 39 . . . . www.aispro.com P9 . . . . . . . . P3 . . . . . . . . P5 . . . . . . . . P6 . . . . . . . . P8 . . . . . . . . P12 . . . . . . . P10 . . . . . . . P12 . . . . . . . 37 33 34 35 36 40 38 41 .... .... .... .... .... .... .... .... www.ModemSafetySystem.com www.fluke.com www.iom.invensys.com/EN/Pages/AllPartnersList.aspx WWW.LOADCONTROLS.COM www.predig.com www.solutionsdirectonline.com www.ueonline.com www.winsted.com
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BASICS
4 steps to energy intelligence in plant-to-enterprise integration

With the economy picking up again, manufacturers are scaling up their operations. Factories can gain a competitive edge using energy intelligence.
With a comprehensive energy management solution, including all the necessary hardware and software, manufacturers can measure energy consumption and acquire energy visibility to production lines, processes, machines, and energy hogs such as compressors, chillers, and boilers.
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nergy intelligence requires the ability to identify maintenance needs early, prevent sudden failures, and avoid unexpected downtime. It requires scheduling energy hogs to minimize their impact and being conscious of energy costs. It also means getting energy KPIs under control to reduce a plants carbon footprint and meet corporate sustainability goals. Energy intelligence goes beyond using the power meter to correlate energy with labor, time, productivity, and moregiving manufacturers the control they need from the plant floor to the enterprise layer. Energy intelligence can drastically improve efficiency of such equipment as compressors, chillers, and boilers. It is vital in the measurement and verification of power factor correction and VFDs (variable frequency drives) for fan and pump applications, energy efficient lighting, and other energy conservation-related activities. With the marriage of energy visualization dashboards and production information, energy intelligence is becoming a mind-shift agent on the plant floor, as well as at the enterprise layer. It becomes a means of keeping track of environmental and sustainability goals and certification of LEED, Energy Star, and ISO 500001. To achieve energy intelligence, consider this four-step process: 1. Measure all energy assets. 2. Visualize energy usage from process, machine, and building automation systems, as it correlates to production and energy dashboards accessible with standard web browsers and mobile devices. 3. Reduce energy use by operating motors with VFDs, choosing high efficiency motors, shifting and staging loads at appropriate times, using the energy standby mode for energy hog loads during break times, automating processes, and making behavioral changes. 4. Manage energy as a task of continual improvement following the ISO 50001 energy management standard: plan, do, check, action. To achieve energy intelligence, manufacturers require energy solutions that provide vari-
ous types of energy monitoring capabilities. These include a diverse energy product portfolio ranging from PLC-based energy modules to stand-alone energy meters with open networks. With a comprehensive energy management solution, including all the necessary hardware and software, manufacturers can measure energy consumption and acquire energy visibility to production lines, processes, machines, and energy hogs such as compressors, chillers, and boilers. A comprehensive portfolio of energy management solutions should include an energy monitoring solution that provides easy-to-read visual data identifying how much and where energy is being used by various building loads and processes. A monitoring solution must also collect usage data from all energy typeselectricity, water, gas, compressed air, and steam. After determining problem areas within a facility, factories can implement a viable energy savings plan to reduce consumption and demand through a dynamic demand control/response solution. Demand management applications control electric demand charges by turning off noncritical loads for short windows of time, cycling building automation loads while taking the space comfort and production criteria into consideration. With electrical distribution networks across North America aging, utility companies anticipate getting help from the commercial and industrial customer base. Participating customers are rewarded with incentives. An energy intelligence infrastructure can be implemented through multiple phases starting with measuring the top layer energy loads. Afterward, they can move to specific machines and processes. Once a comprehensive energy infrastructure is deployed, the manufacturer can practice agile preventive maintenance, satisfy EPA requirements, keep track of energy KPIs, drive continual energy efficiency and conservation improvements, and meet supply chain energyrelated goalsall while maintaining a competitive edge. ce Ghulam Kahn is a senior automation solutions engineer for Mitsubishi Electric.
EXPERIENCE
TODAY
1990
We recently came across a two decades old photo of some young up and coming engineers that were part of our drive engineering team at the time. Guess what? All those people are still with us. In fact, they are among our company leaders today. Imagine. Twenty years of experience from each of them going to work for you every day. Incredible knowledge. Penetrating insights. Real results. Yaskawa puts all of that to work for you every day. Think of what you can do with a partner like that.
MV1000 Medium Voltage AC Drive
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