Control Engineering - December 2020

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Vol. 67
Number 12

®

DECEMBER 2020

ANSWERS

16 | How modern simulation
software addresses
intralogistics challenges

20 | AMP upgrades to edge
controllers

22 | Cybersecurity and the rise
of IT-enabled OT systems

16 26 | Secure-by-design industrial
products are increasingly
COVER: Tall storage and shuttle racks—with advanced lift and trans- important
port technology—make the most of available space in distribution and p.20
fulfillment centers. Serving as a digital twin, advanced simulation soft-
ware can help fulfillment and distribution centers remain competitive, 30 | How IT/OT convergence
from design to operation. Courtesy: Siemens affects networking

INSIGHTS 41 | Developing a great p.30
sequence of operations:
6 | International: Flexible process control Additional answers
8 | Technology Update: Cloud efficiency
42 | What you need to know
platform developed for databases about cybersecurity
10 | Technology Update: Benefits of an alarm
Online learning: Plan to attend now
management philosophy
www.controleng.com/webcasts
NEWS
12 | Control system best practices; INSIDE MACHINES

wearable exoskeleton; Stretchable M1 | Direct-drive advantages, part 1
sensor gives robots, VR a human M3 | How RFID improves machine
touch; Headlines online include Top 5
performance
14 | Think Again: Data flow, alarms, M8 | The need for robotic offline
simulation, cybersecurity, robotics
programming in a COVID-19 world

CONTROL ENGINEERING (ISSN 0010-8049, Vol. 67, No. 12, GST #123397457) is published 12x per year, Monthly by CFE Media and Technology, LLC, 3010 Highland Parkway, Suite #325 Downers Grove, IL 60515. Jim
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www.controleng.com control engineering December 2020 • 3

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DECEMBER 2020

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45 | Resiliency, security needed for digital automation future of Things (IIoT)
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www.controleng.com control engineering December 2020 • 5

INSIGHTS

INTERNATIONAL: PROCESS CONTROL

Ralf Jeske, ABB Automation

Flexible process control systems
MAn alternative modular automation approach to large-scale automation systems is emerging.
odularization breaks down sys- assembly). The PEA includes the combined mechani-
tems, plants, processes, and unit cal equipment and controller, and uses an MTP inter-
operations into standard, modu- face, which contains a vendor-neutral and functional
lar components, much like those description of the process module automation and can
popular children’s building bricks be generated by the engineering tool of the module.
that can be mixed and matched freely to make any Through a simple import of the MTP into the pro-
number of different creations. The concept centers cess control engineering of the production plant, the
around the pre-fabrication of specific and complete module can be integrated. This is described in the
operational packages, which include the automation standard VDI-2658, developed in Germany and being
to control them. The ease of assembly this brings has adopted as IEC 63280 for automation engineering of
led to major reductions in on-site work time, com- modular systems in the process industry. Using PEAs
plexity and a reduction in the possibility of error. takes less time and on-site work to deploy production
As a concept, modular automation has been lines and equipment. With automation already inte-
around for some time, with construction and shipping grated into the mechanical production equipment, as
industries among early adoptors. Until recently, use MTPs within the PEA, deployment to get it running
was confined to a small number of examples in pro- onsite is not difficult. Flexibility to meet rapid changes
cess industries, with no large rollouts. With advances in market demand has been a major driver, especial-
in the automation technology that controls mechan- ly for the pharma and biopharma sectors where it is
ical industrial equipment, modular automation has becoming common to make very small batch quan-
become easier to integrate into existing systems, wid- tities of highly specialized products and medications.
ening adoption for use in industrial production lines. For highly-targeted individual treatments, for can-
This is a big change from the large-scale plant-wide cer patients for example, the batch size can even be as
automation systems that have been at the heart of pro- small as one specific medication or formula.
duction line control for decades and are designed to
supervise and control entire production plants. Pilot trials at Bayer AG
The aim is to modularize common unit operations Bayer AG, a life sciences company, successful-
M More into packages to allow customizing of both the prod- ly conducted a pilot study based on an MTP con-
INSIGHTS ucts made and the production quantities, giv- trol sub systems and a modular configuration tool,
ing major competitive advantages in terms of running with a modular-enabled system for the
flexibility and time to market. The concept orchestration. This is the world’s first commer-
KEYWORDS: process also allows rapid changes in deployment of cial modular-enabled process automation solution,
control, process equipment production assets, to make specific product and Bayer has publicly stated that it sees it as a first
assembly types and volumes when and where needed. step in moving from monolithic automation sys-

Modular automation has tems covering the complete production plant to a
become easier to integrate
into existing systems. NAMUR as a catalyst, MTP
more flexible and market-oriented plug and pro-
Module type packages Helping to move modular automation duce solution.
(MTP) for building modular forward is done by NAMUR, an internation- The modular automation sector now is using the
automation capability into al user association based in Germany that
a process module can be focuses on automation technology and digi- term “numbering up” capacity instead of “scaling
integrated. up,” reflecting the number of PEAs put into service
talization in process industries. NAMUR has to meet demand. The modular, flexible approach
Automation will be led the fundamental efforts to develop stan- allows both regional redeployment as well as prod-
distributed where needed dards which serve as a base for modular auto- uct-specific redeployment. This clearly offers much
in the future rather than at a mation to be built upon in industrial plants. greater flexibility than would ever be possible using
fixed location.

ONLINE It sees increasing flexibility of production the large, fixed-plant infrastructure that most

More about scalability plants, using modularization, as a key tool to industrial processes are built upon today. ce
in greenfield and retrofit meet fast-changing market demands, espe-
applications with this article cially for chemicals and pharmaceuticals. Ralf Jeske is global product manager for ABB Auto-
at www.controleng.com. mation, Germany. This article originally appeared
CONSIDER THIS A few years ago, NAMUR introduced the on Control Engineering Europe’s website. Edited by
module type packages (MTP) standard for Chris Vavra, associate editor, Control Engineering,
What do you see as the building modular automation capability into
future for process control and a process module (or PEA, process equipment CFE Media and Technology, [email protected].
process manufacturing?

6 • December 2020 control engineering www.controleng.com

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input #5 at www.controleng.com/information

INSIGHTS

TECHNOLOGY UPDATE: CLOUD PLATFORM

Chris Adam, Purdue University

Databases and cloud efficiency
ACloud efficiency system targets data-intensive uses, like COVID-19 pandemic.
Purdue University data science and cloud computing services with the NoSQL technol-
machine learning professor wants to ogies Apache Cassandra and Redis.
help organizations and users get the
most for their money when it comes “Let’s help you get the most bang for your buck
to cloud-based databases. The tech- by optimizing how you use databases, whether on-
premise or cloud-hosted,” Chaterji said. “It is no
nology, in addition to helping databases during the longer just about computational heavy lifting, but
data-intensive COVID-19 pandemic, also may help about efficient computation where you use what
self-driving vehicles operate more safely on the road you need and pay for what you use.”
when latency is the primary concern. Somali Chat- Chaterji said cloud technologies using automated
erji, a Purdue assistant professor of agricultural and decision making often only work for short and repeat
biological engineering, and her team created a tech- tasks and workloads. A more optimal configuration
nology called OPTIMUSCLOUD. handles long-running, dynamic workloads, such as
The system is designed to help achieve cost and sensor networks in connected farms or high-perfor-
performance efficiency for cloud-hosted databases, mance computing workloads from scientific applica-
rightsizing resources to benefit both the cloud vendors tions or the COVID-19 simulations.
who do not have to aggressively over-provision their “Our right-sizing approach is increasingly
cloud-hosted servers for fail-safe opera- important with the myriad applications running
M IMNoSrIeGHTS tions and to the clients because the data on the cloud with the diversity of the data and the
center savings can be passed on them. algorithms required to draw insights from the data
“It also may help researchers who are and the consequent need to have heterogeneous
KEYWORDS: cloud technology, crunching their research data on remote servers that drastically vary in costs to analyze
COVID-19 data centers, compounded by the remote the data flows,” Chaterji said. “The prices for on-

OPTIMUSCLOUD was
developed by Purdue University working conditions during the pandemic, demand instances on Amazon EC2 vary by more
researchers to help with cost and where throughput is the priority,” Chater- than a factor of five-thousand, depending on the
performance efficiency for cloud- ji said. “This technology originated from virtual memory instance type you use.”
hosted databases. a desire to increase the throughput of
Uses include the IIoT, COVID-19 data pipelines to crunch microbiome or Chaterji said the system has numerous applica-
pandemic and self-driving vehicle metagenomics data.” tions for databases used in self-driving vehicles (where
safety. The Purdue technology works with latency is a priority), health care repositories (where
three cloud databases: Amazon’s AWS, throughput is a priority), and Internet of Things (IoT)
ONLINE Google Cloud, and Microsoft Azure. infrastructures in farms or factories.
Under topics, see virtualization Chaterji said, with some engineering, it
and cloud stories at would work with more specialized cloud The software runs with the database server. It
www.controleng.com. providers, such as Digital Ocean and uses machine learning and data science principles
FloydHub. to develop algorithms that help jointly optimize the
CONSIDER THIS virtual machine selection and the database man-
What applications would agement system options. Chaterji said, “Even the
benefit from data-intensive cloud It is benchmarked on Amazon’s AWS best data centers run at lower than 50% utilization;
technology?
costs passed down to
end-users are huge-
ly inflated .... You
don’t want to buy the
whole car when you
only need a tire.” ce

A Purdue team created a technology called OPTIMUSCLOUD – which is designed to help achieve Chris Adam is with
cost and performance efficiency for cloud-hosted databases. Courtesy: Purdue University Purdue Universi-
ty. Edited by Chris
8 • December 2020 control engineering Vavra, associate edi-
tor, Control Engi-
neering, CFE Media
and Technology,
[email protected].

www.controleng.com

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INSIGHTS

TECHNOLOGY UPDATE: ALARM MANAGEMENT

Martyn Hilbers, PLC-Easy

Benefits of an alarm
management philosophy

Giving operators on the manufacturing floor a simple and clear-cut philosophy for

alarm management with a simple and clear-cut system can help reduce downtime

and improve overall automation and efficiency.

A larm acknowledgement is a widely reason of the hold of the phase (and possibly the
accepted industry practice, but the operation and procedure), but it is important the
reason why we apply alarm acknowl- operator is not overwhelmed with alarms.
edgement is a question not often Alarm rationalization, efficiencies
asked. During a recent meeting for
a project with the purpose of developing an alarm This requires identifying possible situations
management philosophy and implementing an involving multiple pieces of equipment and imple-
alarm rationalization, the question “why we need menting alarm masking schemes for these situation
alarm acknowledgement” arose. to give the operator one message conveying the rea-
The essence of an alarm is to notify operators son of the hold. For large processes, this is where an
about a process is going or is out of bounds and alarm management philosophy and the implementa-
requires intervention because the automation sys- tion of an alarm rationalization becomes important.
tem is incapable to change the situation. Alarm
acknowledgement is used to help the operator It will require an ongoing effort to keep the
manage the active alarms. It allows the operator to alarm rationalization and alarm-masking schemes
distinguish which alarms have been addressed and up to date in order to provide the operator with
which have not, providing the operator with effective alarms, however for many organiza-
M IMNoSrIeGHTS a to-do list. tions this often falls by the wayside. The effects of
neglecting alarm management are not immediately
From an alarm acknowledgement stand- noticeable nor impactful. However the effects com-
point, this leads to an assumption it has pound over time and lead to significant production
KEYWORDS: Alarm been accepted the control system can gen- inefficiencies.
management, alarm erate multiple concurrent alarms that affect
acknowledgement the process. It is also acceptable that the Circling back to why we need alarm acknowl-
automation is not capable to deal with many edgement, the answer to that question says some-
Alarm management is situations and/or the automation is generat- thing about the alarm efficiency and the level of
acknowledged as a need, ing too many alarms. automated operation vs. manual operation of the
but how it is managed is not automation.
often addressed. Raising the bar on alarm
Too many alarms on acknowledgement
the manufacturing floor
can cause confusion for Fewer alarms are more effective When sitting down to discuss and design a new
operators. Can we avoid too many alarms? Consider automation system, should the question “do we need
the following: a valve limit switch has mal- alarm acknowledgement” be in the top 10 of our
The need for alarm functioned and on opening the valve pro- requirement list when selecting and/or developing
management is tied into an automation system?
the level of automated and
manual processes on the vides a failed to open alarm. The valve is If this question is on top of the list and answered
manufacturing floor. part of an equipment module and this too “No,” the implication is the system is expected to
ONLINE needs to provide an alarm of this event. The perform at a higher automated level, is applying
equipment module is part of a phase and alarm rationalization and requires less operator
Go to www.controleng.com the phase might be part of an operation and interaction. ce
for additional stories about part of a procedure.
alarm management and Martyn Hilbers, principal engineer, PLC-Easy. Edited
safety. In order to put the phase on hold and by Chris Vavra, associate editor, Control Engineering,
possibly the operation and perhaps even CFE Media and Technology, [email protected].
CONSIDER THIS a procedure, an alarm condition must be
What challenges does your propagated from the valve up through the
company face when dealing hierarchy. It is important to provide the
with alarms and how can they operator with a notification that explains the
be overcome?

10 • December 2020 control engineering www.controleng.com

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INSIGHTS

NEWS

Researchers designing wearable

The Occupational Safety and Health HTF project has three goals – to develop the market, but they mainly target the
Administration (OSHA) said one in 10 lightweight, flexible, high-performance, industrial/manufacturing setting. The
construction site workers is injured every personalized wearable exoskeletons for exoskeleton is still a new concept in con-
year, and 21% of worker fatalities are in construction workers; develop machine struction because the construction site is
construction. Aiming to improve work- learning-based human skill modeling and more dynamic and complicated.
er safety and efficiency, LSU and Rutgers training in construction; and initiate new
University researchers hope to develop an cross-disciplinary collaboration and foster “We’re seeing how we can explore
integrated, multidisciplinary approach to engagement with industry partners and personalized exoskeleton or robotics
bring emerging robotic technologies, such stakeholders. technology,” said Chao Wang, an assis-
as a wearable exoskeleton, to the construc- tant professor at LSU. “In a manufactur-
tion industry to save lives and time. “Construction workers get hurt for ing facility, a worker probably does the
three reasons,” said Fereydoun Aghaza- same thing 1,000 times a day. It’s repeti-
The researchers received a $150,000 deh, an LSU professor of engineering. tive, which is perfect for an exoskeleton
planning grant from the National Science “Number one, they are tired. Number two, because they design it just for that one
Foundation to develop an exoskeleton. the task is beyond their capacity. Num- task. A construction site is a lot differ-
The award gives LSU and Rutgers one ber three, they are not properly trained. ent. You must be able to climb stairs, walk,
year to create a team of researchers to If they don’t have the capacity to do the squat, and reach out to different levels
compete for a $3 million research grant physical work, how can we enhance their depending on what trade you are in.
in March. So far, their project is ahead of physical capability? We can give them
the game since there are few, if any, con- more power. This project is all about that.” “That makes it difficult to design an
struction companies that have actually exoskeleton because you need something
adopted exoskeleton technology. Wang, who serves as the project’s prin- that can help with all of these tasks. We
cipal investigator, says there are a few exo- are investigating how to make the exo-
Exoskeleton project goals: This FW- skeleton products currently available on skeleton smart enough to recognize what

Stretchable sensor gives robots, VR a human touch

RESEARCHERS at Cornell University have created a complicated, combinational way, and there are a lot of

fiber-optic sensor that combines low-cost LEDs and dyes, deformations happening at the same time,” Bai said. “We
resulting in a stretchable “skin” that detects deformations wanted a sensor that could decouple these.”
Bai’s solution was to make a stretchable lightguide for
such as pressure, bending and strain. This sensor could
give soft robotic systems – and anyone using augmented multimodal sensing (SLIMS). This long tube contains a pair
reality technology – the ability to feel the same rich, tactile of polyurethane elastomeric cores. One core is transpar-
ent; the other is filled with absorb-
sensations that mammals depend ‘The sensor can detect ing dyes at multiple locations and
on to navigate the natural world. connects to an LED. Each core
pressure, bending or elongation is coupled with a red-green-blue
The researchers are working sensor chip to register geometric
to commercialize the technology
for physical therapy and sports changes in the light’s path.
The dual-core design increases
medicine. A 2016 stretchable sen- by lighting up the dyes, which
sor sent light through an opti- the number of outputs by which
cal waveguide, and a photodiode ’act as spatial encoders. the sensor can detect defor-
detected changes in the beam’s mations (pressure, bending or
intensity to determine when the
material was deformed. The lab also made sensors using elongation) by lighting up the dyes, which act as spatial
encoders. Bai paired that technology with a mathematical
optical lace and foams.
Doctoral student Hedan Bai drew inspiration from silica- model that can decouple different deformations and pin-
based distributed fiber-optic sensors, which detect minor point locations and magnitudes. Sensors are wearable and
wavelength shifts as a way to identify multiple properties, may boost virtual and augmented reality experiences. ce

such as changes in humidity, temperature and strain. Silica
fibers aren’t compatible with soft and stretchable electron- David Nutt, Cornell University. Edited by Chris Vavra,
ics. Intelligent soft systems present structural challenges. associate editor, Control Engineering, CFE Media and
“We know that soft matters can be deformed in a very Technology, [email protected].

12 • December 2020 control engineering www.controleng.com

Digital edition? Click on headlines for more details.
See news daily at www.controleng.com

exoskeleton Headlines
online
task the construction worker is doing and perform for more years and do so safely
adjust its power level and control strategy and efficiently. The team said it would also Top 5 Control Engineering articles
to more effectively assist with the work.” open the door to more women being able Nov. 9-15
to do jobs that were once solely for men. The most read articles covered SCADA,
The researchers will study what tasks HMI and MES projects, the 2021 Engineers’
each construction crew member per- There are some issues the team is try- choice finalists [vote by end of December],
forms in order to develop and train ing to work out, such as the cost of the top 5 VFD parameter changes, advanced
an exoskeleton that fits different con- exoskeleton and how it could work safe- process control changes and matching
struction tasks. They will consider if ly in different weather conditions since it motors and drives.
the robotic exoskeleton should support would be powered by battery. The team
the upper or lower body and how much is collaborating with industry companies Lithium-metal batteries offer
power should be given. and trade schools who are not yet aware of alternative for users
this technology but will help them devel- Lithium metal solid-state batteries can pro-
The team says its motivation for this op a better product. vide a safer, more powerful alternative to the
project comes from the workforce short- current standard.
age in the United States. There are plenty “It takes industry and society working
of construction jobs along the Gulf Coast together to make this happen,” Aghaza- Squeeze-twist coupling material
but not enough workers. Wang said what deh said. ce strengthens actuators
caused the workforce shortage is con- University of Wisconsin-Madison engineers
struction workers aging or retiring due to Libby Haydel, communications special- have made an asymmetric material that
an injury and a decrease in young people ist, LSU College of Engineering. Edited twists, which could help advance actuator
doing construction work. by Chris Vavra, associate editor, Control technology.
Engineering, CFE Media and Technology,
With an exoskeleton to alleviate risk of [email protected].
injury, more construction workers could

Boeing updates 737 Max control system and its policies and
procedures designed to strengthen training, safety, quality

On Nov. 18, the FAA approved Boeing’s request Addressing changes to Boeing company policies, a
to resume Boeing 737 Max (737-8 and 737-9) Nov. 18, 2020, Boeing statement said:
operations. That news, summarized below, is “In addition to changes made to the airplane and pilot
posted at www.controleng.com as an update to a Nov. training, Boeing has taken three important steps to
13, 2019, “Think Again” Control Engineering commen- strengthen its focus on safety and quality.
tary that noted: “Best practices matter when designing
control systems.” 1. Organizational alignment: More than 50,000 engi-

Addressing design changes, Boeing said in an Oct. 25, neers have been brought together in a single orga-
2019, statement: “Boeing has redesigned the way Angle nization that includes a new Product & Services
of Attack (AoA) sensors work with a feature of the flight Safety unit, unifying safety responsibilities across
control software known as Maneuvering Characteristics the company.
Augmentation System (MCAS). Going forward, MCAS
will compare information from both AoA sensors before 2. Cultural focus: Engineers have been further
activating, adding a new layer of protection. In addi-
tion, MCAS will now only turn on if both AoA sensors empowered to improve safety and quality. The
agree, will only activate once in response to erroneous company is identifying, diagnosing and resolv-
AOA, and will always be subject to a maximum limit that ing issues with a higher level of transparency and
can be overridden with the control column. These soft- immediacy.
ware changes will prevent the flight control conditions
that occurred in this accident from ever happening again. 3. Process enhancements: By adopting next-gener-
In addition, Boeing is updating crew manuals and pilot
training, designed to ensure every pilot has all of the ation design processes, the company is enabling
information they need to fly the 737 MAX safely.” greater levels of first-time quality. For more informa-
tion, visit www.Boeing.com/737-max-updates.” ce

Mark T. Hoske is content manager, Control Engineering,
CFE Media and Technology, [email protected].

www.controleng.com control engineering December 2020 • 13

INSIGHTS ®

THINK AGAIN 3010 Highland Parkway, Suite 325, Downers Grove,
IL 60515. 630-571-4070, Fax 630-214-4504
Data flow, alarms, simulation,
cybersecurity, robotics Content Specialists/Editorial

Control Engineering highlights automation, controls and Mark T. Hoske, Content Manager
630-571-4070, x2227, [email protected]
Ainstrumentation successes at www.controleng.com and in print. Jack Smith, Content Manager
utomation, controls, and instru- itive with other companies and maintain 630-571-4070, x2230, [email protected]
mentations are critical, innova- the capacity to fill incoming orders, busi- Kevin Parker, Senior Contributing Editor, IIoT, OGE
tive, interesting and productive, nesses must increase fulfillment speeds. 630-571-4070, x2228, [email protected]
and Control Engineering offers Advanced simulation software addresses Emily Guenther, Director of Interactive Media
information on Boeing’s automation these and other issues by bringing togeth- 630-571-4070, x2229, [email protected]
adjustments to its 737 Max (News, prior er the software and live equipment worlds. Amanda Pelliccione, Director of Research
page) and developments on data flow, This enables optimization of a warehouse 978-302-3463, [email protected]
alarm design, digital twins and simulation environment first in software – where cre- Chris Vavra, Associate Editor
efficiency, cybersecurity and robotic pro- ating prototypes and modifying the process [email protected]
gramming, among others. is relatively inexpensive and simple – so the
Data flow optimization – Technology resulting real-world deployment operates Contributing Content Specialists
Update from Chris Adam, Pur- efficiently. Simulation demands
due University: Current cloud time, money, and attention, the Suzanne Gill, Control Engineering Europe
technologies using automat- benefits often outweigh costs. [email protected]
ed decision making often only IT helps OT – cybersecu- Ekaterina Kosareva, Control Engineering Russia
work for short and repeat tasks rity article from Larry O’Brien, [email protected]
and workloads. The team creat- ARC Advisory Group: Secure- Agata Abramczyk, Control Engineering Poland
ed an optimal configuration to by-design principles apply to [email protected]
handle long-running, dynam- software, devices and networks. Lukáš Smelík, Control Engineering Czech Republic
ic workloads, whether it be Many commercially-available [email protected]
workloads from the ubiquitous Mark T. Hoske, products and applications were Aileen Jin, Control Engineering China
sensor networks in connect- Content Manager not developed using these princi- [email protected]

ed farms or high-performance ples. Security by design does not Editorial Advisory Board
computing workloads from scientific appli- absolve the end user from following good
cations or the current COVID-19 simula- cybersecurity practice, project implemen- www.controleng.com/EAB
tions from different parts of the world in a tation or operations work processes. Other Doug Bell, president, InterConnecting Automation,
rush to find the cure against the virus. strategies include supply chain cybersecuri- www.interconnectingautomation.com
Alarm design and management – ty, provenance (determining where system
Technology Update from Martyn Hilbers, computing components like chipsets come David Bishop, president and a founder
PLC-Easy: When discussing and designing from and their inherent levels of security) Matrix Technologies, www.matrixti.com
a new automation system, should the ques- and other issues. Daniel E. Capano, senior project manager, Gannett Fleming
tion “do we need alarm acknowledgement” Robotic programming article from Engineers and Architects, www.gannettfleming.com
be in the top 10 of our requirement list Michael Castor, Yaskawa Motoman Robot- Frank Lamb, founder and owner
when selecting and/or developing an auto- ics Division: Flexibility provided by offline Automation Consulting LLC, www.automationllc.com
mation system? If this question is on top of programming software for robotics offers Joe Martin, president and founder
the list and answered “No,” the implications many perks and enables a higher mix of Martin Control Systems, www.martincsi.com
is that the system is expected to perform at jobs with a simple transition from one job Rick Pierro, president and co-founder
a higher automated level, is actively apply- to the next. Larger companies with multi- Superior Controls, www.superiorcontrols.com
ing alarm rationalization and ultimately ple locations and/or workcells may be able Mark Voigtmann, partner, automation practice lead
requires less operator interaction. to reduce programming time and inconsis- Faegre Baker Daniels, www.FaegreBD.com
Digital twins and simulation cost tencies by distributing the programmed job
savings – cover story from Colm Gavin, from a central, controlled source. Improve- CFE Media and Technology
Siemens Digital Industries Software: ments in sensor technology for tasks such Contributor Guidelines Overview
Successful fulfillment center operation as robotic welding have come a long way
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zation and efficient automation concepts, for end users spanning diverse industries. stands for, and what CFE Media is all about –
especially focused on removing costs and Think again about what automation, engineers sharing with their peers. We welcome
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al handling equipment. To remain compet- can do to advance your world. ce engineering. We will use those materials online, on
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and industry trends.
www.controleng.com/contribute explains how
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input #8 at www.controleng.com/information

ANSWERS

COVER STORY: DIGITAL TWIN SIMULATION SOFTWARE

Colm Gavin, Siemens Digital Industries Software

How modern
simulation software addresses
intralogistics challenges

Advanced simulation software provides optimization insight, enabling
distribution and fulfillment centers to address issues and optimize efficiency.

The end of the year is notorious for caus- These managers and their personnel are faced
ing sudden onsets of panic as the weight with difficult tasks, with internal production
of the holidays hits, and the realization expectations from the corporate level and exter-
of purchasing gifts sinks in. Every pres- nal delivery expectations from customers adding
sure experienced by the general public to the heat. Fortunately, digitalization is continu-
around this time of year, however, is multiplied by ously providing new methods for intelligent and
an order of magnitude for distribution and fulfill- efficient operation in warehouse settings. Thanks
ment center managers. to advanced simulation software, taking care of
intralogistics – the management and optimization
of internal production and distribution processes
– is constantly evolving and improving.

As anyone who has set foot in a modern ful-
fillment center knows, its managers must be resil-
ient, and be able to adapt and scale intralogistics
processes. It takes thoughtful warehouse design
and preparedness to address these issues, and
advanced simulation software can help fulfillment
and distribution centers remain competitive, from
design to operation.

Intralogistics issues
for simulation software

Though increased consumer demand creates lucra-
tive business opportunities, the challenges to over-
come in the world of distribution and fulfillment
centers are great. In addition, the COVID-19 pandem-
ic has created new workplace safety needs, increasing
the need for low-touch and no-touch processes.

The finite size of fulfillment centers requires
intelligent use of technology to make more effi-

16 • December 2020 control engineering COVER: Figure 1: Tall storage and shuttle racks—
with advanced lift and transport technology—
make the most of available space in distribution
and fulfillment centers. Serving as a digital twin,
advanced simulation software can help fulfillment
and distribution centers remain competitive, from
design to operation. All images courtesy: Siemens

www.controleng.com

‘Systems need to generate
insights in digestible formats,

reducing complexity for inter-

action among humans, auto- Figure 2: The Siemens Plant Simulation Tool can be used to create a
digital twin for optimizing design of a new facility, or for experiment-
’mation and information. ing with methods for improving operations in an existing warehouse.

cient use of limited space (Figure 1). It also requires Figure 3: Ergonomics analysis helps identify optimal positioning of
effectively planning the layout, strategically placing pick-and-place machines, platforms, and other mechanisms.
products and improving material flow availability, improve operational effectiveness.
along with maintainability and performance.
A facility simulation tool provides a virtual view
Growing global ecological awareness and ris- into warehouse operations. At design time, software
ing energy prices are motivating many compa- engineers can create a multi-dimensional ware-
nies to work towards carbon neutrality, impacting house environment in conjunction with the facility
how work is done in a warehouse. To support these designers, enabling a three-dimensional simulation
efforts, methods must be put in place to monitor of how the warehouse will perform.
energy consumption and provide insights on ways
to further increase energy efficiency. Transparency Users are provided with the ability to simu-
initiatives also often require this data to be made late the distribution center layout, visualize mate-
publicly available. rial flow, monitor programmable logic controllers
(PLCs), configure intelligent industrial devices and
Adding to these technology-related difficulties, apply advanced statistical tools to analyze process-
there are often not enough IT staff available to keep es. Engineers can run these processes and monitor
up with advancements in automated technology – each in real time, model production data and opti-
too much data, not enough information processors. mize the facility configuration to determine a more
To overcome this obstacle, warehouse staff need efficient design (Figure 2). Monitoring includes
systems that generate insights and present them in the ability to visualize real-time PLC input/output
digestible formats, reducing complexity for interac- updates in accordance with the program logic.
tion among humans, automation and information. Analyzing logistics applications
with software
Overcoming these hurdles to successful fulfill-
ment center operation requires increasing appli- For material handling applications, the soft-
cation of digitalization and efficient automation ware provides the capability to access working
concepts, especially focused on removing costs and conditions. It also includes built-in ergonomics
reducing risks when installing new material han- analysis for optimal positioning of pick-and-place
dling equipment. Furthermore, to remain com-
petitive with other companies and maintain the
capacity to fill incoming orders, businesses must
increase fulfillment speeds. Though the challenges
abound, there is a way to optimize efficiency and
meet the many needs of modern fulfillment centers.

Digital twin for design optimization
Advanced simulation software addresses these

and other issues by bringing together the software
and live equipment worlds. This enables optimiza-
tion of a warehouse environment first in software
– where creating prototypes and modifying the
process is relatively inexpensive and simple – so the
resulting real-world deployment operates efficient-
ly. Though simulation demands time, money and
attention, the benefits often outweigh the costs.

An advanced simulation software suite helps
warehouse managers digitalize the value chain at
the time of conceptual design and during com-
missioning on the warehouse floor, and also after
deployment for review and analysis of methods to

www.controleng.com control engineering December 2020 • 17

ANSWERS

COVER STORY: DIGITAL TWIN SIMULATION SOFTWARE

Figure 4: An
ultramodern
sorting and con-
veyance system
implemented by
a global shipping
company at one
of its international
airport locations.

machines, platforms, and other mechanisms to automated lifts and scanners, stack lights, AGVs,
provide mechanical advantages for manual human and material flows – all operating in sync.
motions (Figure 3). Nine ways simulation software can help

By using advanced software through iterations Many other equipment types can be staged in
of simulations, robots can learn optimal paths the simulation workspace:
and movements, and trackless automated guided
vehicles (AGVs) can determine best routing. The 1. High-density storage and retrieval systems
software runs thousands of possible movement for food, hard items, and consumer-packaged
schemes, taking into consideration all proposed goods
equipment and its location on the warehouse floor,
and provides the most efficient robot movements 2. Functional safety devices
and AGV routes.

Motors, drives, other automation 3. Advanced optical identification devices for
Physics calculations – including gravity, friction, product movement tracing

and torque – are built into the software, increasing 4. Scalable and flexible shuttle systems
the simulation’s realism and building confidence 5. Control components for advanced shuttle
in the mechatronic models. A mechanical engi-
neer can be tasked with confirming the kinemat- vehicles, onboard and non-onboard
ic components are optimally configured, and once 6. Real-time, fail-safe communication with
mechanical components and statistics are known,
designers can properly size motors, drives, and industrial wireless local area networks for
other equipment. reliable, high-speed, and cyber-secure con-
nection among devices in the warehouse
From this software suite of tools, users can auto- 7. Industrial radio frequency identification
mate multi-domain engineering, enabling collab- (RFID) systems for product index tracking
oration with consistent data among the various 8. Edge computing devices
engineering disciplines. The software can automat- 9. Compact and mobile controllers embedded
ically generate electrical drawings and PLC proj- in other equipment.
ects, which provides a head start on the engineering While a simulated view of plant floor pro-
effort and reduces overall design time. cesses plays out, users can simultaneously mon-

Once this basic code is generated, programmers
can make adjustments impacting later simulations,
and they can drill down as deep with code updates
as required.

This enables users to view a full model of the
future warehouse floor – complete with conveyors,

18 • December 2020 control engineering www.controleng.com

itor human-machine interface (HMI) displays Figure 5: Siemens ProDiag feature, embedded in its Simatic WinCC
and PLC ladder logic operation within the simu- HMIs, enables operators to jump from an alarm directly to the PLC
lation software to help virtually commission the code from where it was triggered, enhancing troubleshooting capa-
machines. These virtualized simulations are digi- bilities and facilitating quicker recovery.
talized plans for warehouses and distribution cen-
ters, helping ensure the physical deployments will
operate as intended.

Modeling underwent a transformation from 2D
sheets to 3D virtual renderings a short while ago,
and now, real-time feedback and motion also is
attainable. Software simulation allows designers to
model and visualize how a facility will operate in
advance of real commissioning. As a result, multi-
disciplinary design teams can adjust early in the
game, yielding positive productivity.

Simulation software results HMI screen, with no need to pull out a laptop and
A large-scale manufacturer of home care prod- plug in to the PLC (Figure 5).

ucts was able to consolidate four distribution cen- Furthermore, these same configurations gath-
ters into one facility to simplify operations and er and store real-time data and provide operators
reduce overhead cost. Using an advanced simula- with the ability to play back previous data on the
tion software suite, this manufacturer effectively HMI, helping them to determine what triggered
modeled and implemented a facility only half the the alarm condition. These tools, accessible on
size of its previous facilities’ combined areas while the warehouse floor, help reduce downtime and
increasing processing capacity. increase throughput.

It increased its product storage density by 50%, Simulation software helps moving,
and now utilizes around 90% of its volumetric sorting, picking, packing
storage capacity. Furthermore, it requires 20% less As society becomes increasingly connected,
transport within the facility than it did prior to warehouse technology is advancing. Customer and
the consolidation. Greater efficiency, made possi- corporate expectations also are increasing, as well.
ble through advanced simulation and cutting-edge Left to outdated tools and methods, distribution
intralogistics technology, provided the manufac- and fulfillment centers cannot keep up.
turer with higher profit margins and a reduced But by using advanced simulation software and
carbon footprint. modern technology for moving, sort-
ing, picking and packing – warehouses
In another example, a global shipping company can overcome these challenges. While M MANorSeWERS
recently implemented an ultramodern sorting and simulation requires additional initial
conveyance system at one of its international air- costs and efforts, future time and effi- KEYWORDS: Simulation software,
port locations (Figure 4). ciency savings typically far outweigh warehouse manufacturing
the costs. Simulation software helps improve
Using components, which included PLCs and the management and optimization
drives, it was able to achieve a sorter transport Through simulation in projects’
speed of eight feet per second and peak perfor- early stages, system designers can sim- of internal production and
mance of 9,000 parcels of various size per hour. plify scope, reduce total time and effort distribution processes.
Simulation software system required to implement, and help ensure Digitalization provides new
diagnostics for runtime more efficient fulfillment center opera- methods for intelligent and efficient
tion. When the rubber meets the road, operation in warehouse settings.
Once a facility is up and running, simulation this can make the difference between a Advanced simulation software
maintains its value as a tool for experimenting happy delivery recipient and a livid cus- brings the software and live
with process or program adjustments, while sys- equipment worlds together.
tem diagnostic software capabilities add value to
optimization efforts. tomer whose order got lost in the ware- ONLINE
house. ce See additional stories about
Diagnostic tools enable predictive maintenance
by alerting personnel of issues detected in the simulation software at
facility in advance of equipment failure. In some Colm Gavin is the portfolio development www.controleng.com.
system diagnostic configurations, certain events,
like broken wire or low voltage, are embedded in manager for Siemens Digital Industries CONSIDER THIS
the PLC for communication with an accompany- Software. Edited by Chris Vavra, associate What immediate benefits could
ing HMI. In such a case, maintenance technicians editor, Control Engineering, CFE Media your facility gain from advanced
can troubleshoot common issues right from the simulation software?
and Technology, [email protected].

www.controleng.com control engineering December 2020 • 19

ANSWERS

EMBEDDED CONTROLLERS

Josh Eastburn, Opto 22

AMP upgrades
to edge controllers

Largest U.S. rotary heat-treating facility modernizes controls and

automation with tight database integration.

A utomation upgrades were needed to query language (SQL) database, which served as
ensure reliable operations at Ameri- the repository for material tracking and process
can Metal Processing (AMP), which recipes.
specializes in rotary heat treatment Controls upgrade: Sensors,
for deep case carburizing, carboni- controls, drives
triding, and neutral hardening processes.
Given the scope of its controls upgrade —
However, with control system components including computerized weighing, burner con-
dating back to the late 1990s, some experiencing trol, and drive control — along with these other
regular failures, others approaching end-of-life, opportunistic improvements, AMP knew it would
and no automation staff on-site to support them, require a custom solution. After researching the
“We knew we were on borrowed time,” said Grant state of the art, they decided an edge program-
Pinkos, president of AMP. mable industrial controller would offer the most
value and versatility.
Realizing the need to modernize, Pinkos also
saw an opportunity to make the system better than Even without controls expertise in-house,
before. “We wanted it to be more than a control Pinkos was confident taking on the task. “I could
system,” he said. “We wanted it to be intelligent.” see the pieces coming together... When I realized
I could do data logging with [an edge controller],
For AMP, this meant addressing the need for that checked another box for me. Once we found a
automated interlocking and alarm notification
as well as integrating their backend structured

Figure 1: One of AMP’s seven upgraded furnace lines takes advantage of modern, flexible
controller architecture with Opto 22’s groov EPIC (edge programmable industrial controller).
Images courtesy: Opto 22

20 • December 2020 control engineering www.controleng.com

Figure 3: Opto 22’s groov EPIC provides an ecosystem of embedded
applications for visualization, device integration, connectivity and
data processing.

Figure 2: The new operator interface, built operators to the specific piece of equipment need-
using the Opto 22’s groov EPIC embedded HMI ing attention.
server, incorporates data from many sources,
including an IP camera feed and work order Controls enable integrated recipe
database. management
With the furnace line’s controller connected to
way for our lot tracking database to use REST calls the company database, Pinkos was able to put the
to extract data from the [controller], then we had a final piece of the puzzle in place by integrating rec-
complete solution.” ipe management and work order tracking into the
control program and HMI. Instead of requiring
In just a few months, and at a fraction of the cost operators to manually copy recipe parameters from
of traditional solutions, AMP had a design that was a separate computer, the controller queries the data-
ready to deploy when one of its existing program- base for the appropriate process values (feed rate,
mable logic controllers (PLCs) finally died. retort speed, temperature, oscillation period, and
more) and feeds them to the control program. Work
Five-stage design with order information entered by the operators is then
controls for each recorded back into the database along
with process data captured from the run. M AMNorSeWERS
Each of AMP’s seven furnace lines consisted of KEYWORDS: Industrial controllers,
five stages (feeding, washing, heating, quenching, Many of AMP’s customers are Tier edge controllers
and conveying), each run by separate control devic- 1 and 2 suppliers to original equipment See how an upgrade includes
es. Pinkos’s design incorporated many of these con- manufacturers (OEMs) in the automo- sensors, controls and drives.
trol elements into one program. Then, using the tive industry, so AMP knew investing in Recognize a five-stage design
controller’s embedded human-machine interface tight integration would be important in with controllers for each.
(HMI) server, he created a unified operator inter- the long run. These changes also helped Learn how controls enable
face incorporating additional data sources: IP cam- reduce operator error, streamline 24/7 integrated recipe management as
era feeds, process trends, and alarm notifications. process monitoring and improve cus- part of the design.
tomer confidence. “The new system is
Then, in addition to signaling process alarms easy to understand and even easier to
with light and sound beacons around the furnace visualize,” Pinkos said, “which builds
perimeter, AMP connected the edge controller to confidence with existing customers and CONSIDER THIS
the company PA system. They used the control- helps attract new ones.” ce Beyond reliability, what capabilities
ler’s embedded IoT engine to query the company’s are your applications missing
operations database for alarm occurrences, gen- without an automation upgrade?
erate a string representation of each (for example,
“Temper furnace 204 overtemp alarm”), and send Josh Eastburn is director of technical ONLINE
the string through a text-to-speech (TTS) function, marketing, Opto 22. Edited by Mark T. If reading from the digital edition,
creating unique audio announcements that directed Hoske, content manager, Control Engi- click on the headline for more
neering, CFE Media and Technology, resources.
[email protected]. www.controleng.com/magazine

www.controleng.com control engineering December 2020 • 21

ANSWERS

IT FOR OT AUTOMATION

Steven Seiden, Leighton Johnson, Dr. Tony Barber, Acquired Data Solutions; Djenana Campara, KDM Analytics.

Cybersecurity, IT and OT

Information technology strategies can help combat new cybersecurity vulnerabilities

and deploy a solid cybersecurity program for operational technology use for industrial

Econtrol systems, RTUs and SCADA, as IIoT deployments increase.
xploitation of resources has been a con- has been given to cybersecurity.
cern to mission operations since the During the past decade, there has been a major
dawn of the industrial age. Cybersecuri-
ty concerns have increased, as well. With increase in the demand for connected OT utiliza-
advancement of information technology tion with multiple deployments of advanced tech-
nologies requiring connectivity for operations and
(IT), opportunities to compromise, corrupt, and dis- equipment maintenance. Using IT-enabled OT sys-
able networks and systems has exponentially grown, tems and components increases vulnerabilities, due
creating new development of malicious mechanisms. to the convergence of IT and OT, have exposed new
Although the first cybersecurity patent was regis- opportunities for cyber-attacks.
tered in the early 1980s, the enablement of business
needs and protecting mission operations are increas- Summer 2020 cybersecurity advisory
ing priorities for national security and intelligence In July 2020, the National Security Agen-
agencies. Cybersecurity within IT has seen exponen- cy (NSA) and the Cybersecurity and Infrastruc-
tial growth over the last three decades, but security ture Security Agency (CISA) of the Department of
of traditionally standalone, non-connected systems in Homeland Security (DHS) alerted U.S. corporations
M More the operational technology (OT) space contin- to take immediate actions to reduce vulnerabilities
ANSWERS ue to lag behind due to the independent nature and exposure across all OT and ICSs.
of their functionality. OT systems include
KEYWORDS: Industrial The advisory, “NSA and CISA Recommend
industrial control systems (ICSs) such as super- Immediate Actions to Reduce Exposure Across all
cybersecurity, IT/OT visory control and data acquisition (SCADA) Operational Technologies and Control Systems,”
convergence systems, distributed control systems (DCSs), (U/OO/154383-20 | PP-20-0622 | July 2020 Rev
Understand the summer remote terminal units (RTUs), and program- 1.0), stated: “Over recent months, cyber actors have
2020 cybersecurity advisory, mable logic controllers (PLCs). With the onset demonstrated their continued willingness to con-
risks, infrastructure of the Internet of Things (IoT) as applied to duct malicious cyber activity against Critical Infra-
See cybersecurity risks
and rewards of integrated IT OT, the Industrial IoT (IIoT), more attention structure (CI) by exploiting Internet- accessible OT
and OT.

Review risk
management
modeling, automation,
tools

CONSIDER THIS
Has your IT/
OT cybersecurity
risk management
advanced to meet the
needs of advanced
automation and IIoT?

ONLINE Figure 1: The standard approach to modeling risk within operational technology (OT), according
If reading from the to NIST, which defines risk as “risk is a function of the likelihood of a threat event’s occurrence
digital edition, click on and potential adverse impact should the event occur.” Courtesy: NIST via Acquired Data Solutions
the headline for more and KDM Analytics
resources.
www.controleng.com/
magazine
www.controleng.
com/networking-
and-security/
cybersecurity

22 • December 2020 control engineering www.controleng.com

assets. Due to the increase in adversary capabilities tions extend their customer bases and the CI grows. Figure 2: This
and activity, the criticality to U.S. national security The energy production sector is among many CI is the scientific
and way of life, and the vulnerability of OT systems, areas experiencing this cross-over of IT and OT lens that all risks,
civilian infrastructure makes attractive targets for inter-mixtures of technologies, hardware and soft- explicitly cyber-
foreign powers attempting to do harm to US inter- ware combinations to benefit organizations, com- security risk,
ests or retaliate for perceived U.S. aggression.” panies, agencies, and corporations that use these should be viewed,
connected components and systems. according to NIST
This critical warning establishes a call to action Converging safety, security and dependability Special Publica-
for U.S.-based utility companies that do not adhere requirements shows the immense need for a holistic tion 800-30, rev.1
to federally-regulated security guidance leaving approach for CI and the various control systems con- (2018), page 12.
much of their CI potentially compromised. The tained across the domains for risk understanding. This Courtesy: NIST
implementation of cybersecurity approaches and multi-faceted view is needed in all CI sectors. As IT is via Acquired Data
the prevention of vulnerability exploitation is one being used to support OT operations, the merging of Solutions and
of the largest concerns for most CI manufacturers, these two technologies brings new risk factors into the KDM Analytics
policy developers, and federal leadership. operations and maintenance of each area.
Connectivity, critical infrastructure, risk The IT employee now has machine-level commu-
nications and connections with OT-based data. Its IT
Imagine a CI manufacturer or a utility supplier security components are not designed to sense and
without a clear understanding of the security implica- ‘As IT supports OT areas, the merging of
tion on critical services, such as energy, water, and/or technologies brings new risk factors into the
food. Imagine unintentionally, or intentionally, prop-
agating a virus on a large-scale complex system that ’operations and maintenance of each area.
supports U.S. transportation communications, and/or
emergency services infrastructures and not knowing monitor, using networking protocols not familiar to
or understanding the multiple vulnerabilities opportu- the monitoring activities, with the attendant risks
nistic hackers can exploit on U.S. operational network being transmitted and received on a daily basis. This
through the U.S. defense industrial base (DIB). can, and often does, lead to unidentified vulnerabili-
ties in the IT devices and applications which result
This is why applying the maturity and auto- in breaches, failures and unexpected negative results.
mation of cybersecurity to CI could provide com-
prehensive identification and assessments of IT data structure impact on OT
vulnerabilities while employing a security and risk OT systems are being installed, implemented and
culture among federal, state and local decision mak-
ers. This includes protection from inappropriate deployed with connections and monitoring from the
accesses to CI systems and reduction of data disclo- IT side. IT inputs to OT systems are not designed or
sure, compromise, and/or loss through the optimi- configured to handle these new and different data
zation of these assessment via automation. types and structures. IT and OT differences cause OT
DHS: Three infrastructure areas to react in unknown and unexpected ways, causing
the OT to operate less than optimally. This can nega-
The Department of Homeland Security divides tively impact services that affect our way of life, such
infrastructure into three areas. as energy delivery, water delivery and other areas.

1. Physical infrastructure: Cable fiber, dams/ To produce and support the converged OT with
the IT, we need to understand and work with the
reservoirs/treatment plants, corporate institutions, areas of concern these systems perform. There
delivery sites, farms/food processing plants, gov- are risks to our operations, products, services and
ernment facilities, hospitals, nuclear power plants, activities. Risk is developed when a threat, taking
power plants/production sites, railroad/highway advantage of a weakness or discrepancy within the
bridges/pipelines/ports.

2. Critical infrastructure/key resource: Agricul-

ture and food, banking/finance, chemical, commercial
facilities, communications, dams, defense industrial
base, emergency services, energy, government, infor-
mation technology, monuments/icons, nuclear, postal
and shipping, public health, transportation, water.

3. Cyber infrastructure: Control systems, hard-

ware, information services, software.
Integrated cybersecurity risks, rewards

Because everything is connected, unpatched vul-
nerabilities, misconfiguration or application weakness
can subvert connected systems and put all at risk.

The linking between IT and OT systems expands
daily as new technologies are introduced; organiza-

www.controleng.com control engineering December 2020 • 23

ANSWERS

IT FOR OT AUTOMATION

system, produces an adverse impact on the system, 1. Performing risk modeling
activity, or organizational process. These issues 2. Isolating and containerization of
can cause loss of revenue, loss of data (resulting
in loss of profits due to regulatory fines), loss of components
customers, loss of reputation, even possible loss
of market share; all of which affect the organiza- 3. Defining OT attack patterns
tion as a whole, not “just” IT or the cybersecurity 4. Establishing and implementing a secure
teams.
Risk management applicability to OT/CI supply chain.
These techniques help the organization determine
To address cybersecurity concerns in OT/CI, the the high areas of risk, as well as what needs to be pro-
following question should be addressed: tected and monitored to prioritize the security efforts
for the OT under consideration. Figure 2 provides
• What are components relevant in OT and CI? the scientific lens that all risks, explicitly cybersecu-
• How are they connected? rity risk, should be viewed, according to NIST Spe-
• What data is stored and/or in transit between cial Publication 800-30, rev.1 (2018), page 12.
This process produces quantifiable risk calcula-
each component and any external entities? tions for each area and allows the organization to
• What are the risks, threats, and vulnerabilities produce areas of prioritized risk for mitigation and
to drive decision-making actions.
within the system? OT risk management, automation
• Where do you find them? This type of tool can take the model-based systems
• How are they uncovered? engineering (MBSE) approach and extends the analy-
The system analysis and curiosity begin the pro- sis capabilities to assess cybersecurity postures based
cess of “risk modeling.” Figure 1 outlines the stan- on components, elements, information exchang-
dard approach to modeling risk within OT, according es, and data flows. Automated risk accelerators were
to National Institute of Standards and Technology developed based on the unified architecture frame-
(NIST), which defines risk as “risk is a function of the work (UAF) to widen breadth and depth of analysis to
likelihood of a threat event’s occurrence and potential address evidence-based cybersecurity and risk assess-
adverse impact should the event occur.” ment. Such a tool provides a comprehensive view of
Unique to OT cybersecurity, there are multiple current, relevant cybersecurity guidance from inter-
approaches that can aid cybersecurity professionals national and national standards organizations, such as
with analyzing risk to comprehensively develop the NIST. The second approach, isolation and container-
appropriate response(s). These include: ization of components, allows for OT components iso-
lation that blocks exposure to the outside risks present
in the OT operating environment.
In the third approach, the automated risk modeling
tool graphically displays a schematic diagram of the
attack patterns/paths that are assessed by the tool. In
the fourth approach, secure supply chain produces
an operating activity that is secure throughout the
environment, which provides a reduced risk arena
for the OT and connected IT to work. This provides
the organization to reduce and manage risks which
provide secure OT based actions and activities.
Such techniques offer critical insight and cyberse-
curity analysis results in the proactive protection of
OT components for the system of interest to cost-
effectively and efficiently manage cybersecurity. ce

Figure 3: KDM Analytics’ (KDMA) Blade RiskManager (BRM) takes Steven Seiden is the president of Acquired Data Solu-
the model-based systems engineering (MBSE) approach and extends tions. Leighton Johnson, CISSP, CISM, CMMC-AB
the analysis capabilities to assess cybersecurity postures based on Provisional Assessor L-3, is a senior cybersecurity
components, elements, information exchanges, and data flows. Cour- engineer at Acquired Data Solutions. Dr. Tony Bar-
tesy: Acquired Data Solutions and KDM Analytics ber, CSEP, RMP, is a system engineering executive at
Acquired Data Solutions. Djenana Campara is pres-
ident of KDM Analytics. Edited by Mark T. Hoske,
content manager, Control Engineering, CFE Media
and Technology, [email protected].

24 • December 2020 control engineering www.controleng.com

The digital challenge

Dr.-Ing. Hans Egermeier | Lenze

With the digital transformation already in full swing,
is your company prepared for the fundamental
changes facing our entire industry?
Industry 4.0, the Industrial Internet of Things (IIoT),
big data – common everyday terms for actions
and innovations that are already transforming the
machine-building business. Due to the acceleration
effects of digital technologies, the change will be
exponential – so there’s no time to lose.
Learn the steps you should take to master
digitalization – you’ll get basic technical
information, clarification on how various issues
are connected, tips on overcoming obstacles,
and suggestions for further reading.
Download the paper at: https://bit.ly/2Bzr7Lv

+1 800 217-9100 • info.us@ Lenze.com
www.lenze.com

input #9 at www.controleng.com/information

ANSWERS

IT ADVICE FOR OT AUTOMATION

Larry O’Brien, ARC Advisory Group

Secure-by-design
industrial products are
increasingly important

Cybersecurity often is the catalyst for control system modernization,

and industrial and critical infrastructure sector projects increasingly specify

automation products and systems that are designed as cybersecure.

T hose in the industrial and critical infra- industrial control system cybersecurity standards
structure sectors increasingly seek prod- (formerly ISA-99), also can be a challenge since
ucts and solutions that are inherently many users are unfamiliar with the various certifi-
cybersecure. In many cases, cyberse- cation and standards bodies. While even products
curity provides the catalyst for control not certified to a published standard can sometimes
system modernization projects. This is especial- provide acceptable cybersecurity, this requires clos-
ly true in cases where users discover they can no er scrutiny of vendor offerings and their associated
longer support an installed base that requires an development and sourcing practices. Using certifica-
increasing amount of time and resources to make it tions to help pre-qualify potential products can save
cyber-secure. asset owners considerable time and effort.
Industrial products require
Much of the cybersecurity focus for industry and security by design
infrastructure to date has focused on providing lay-
ers of cybersecurity on top of existing infrastructure, Most operational technology (OT)-level prod-
rather than procuring products and applications that ucts and applications in industry and critical infra-
provide a level of inherent cybersecurity. Inherent structure worlds aren’t designed from the ground
cybersecurity is often achieved through some com- up to incorporate cybersecurity. Until recently,
bination of product design features and a secure features, functions and open network connectivi-
development lifecycle process. From the supply ty have received more attention. The drive toward
chain perspective, many end users also are looking “openness” in the 1990s and early 2000s resulted
to source inherently secure components, micropro- in a cybersecurity mindset focused on adding lay-
ers of cybersecurity in OT-level systems to address
‘ cessors and embedded systems. potential vulnerabilities. While this mindset is still
Using cybersecurity certifications to help required for effective cybersecurity, many end users
pre-qualify potential products can save asset are finding it is much easier and less expensive
owners considerable time and effort. investing in products designed from the ground up
’In addition to closer supplier scrutiny during to incorporate security rather than increase invest-
the selection process, the built-in, secure-by-design ments to lock down products that are not secure.
approach also requires secure implementation,
installation and maintenance approaches through- Security by design should go beyond the prod-
out the system or product’s lifecycle. Two separate ucts themselves and how they are designed to
but related lifecycles are at play here: One for prod- incorporate secure development lifecycle prac-
uct development and one for implementation and tices for applications. The same principles apply
support. Looking for products certified to a cyber- to the processes used in control system engineer-
security standard, like the ISA/IEC 62443 series of ing, installation and startup. End users also are
taking a closer look at the security of the supply
chain, specifically in how systems are developed
and manufactured, and if the systems utilize secure
components and embedded systems.

26 • December 2020 control engineering www.controleng.com

‘Many ICS end users have not Figure 1: Average lifecycle of process automation system compo-
developed good selection nents shows that automation isn’t supported indefinitely and older
criteria for systems and appli- systems may require replacement due to increased cyber risk. Work-
cations; industry and infrastruc- stations and consoles may require attention in less than 5 years and
ture systems may not consider controllers in less than 15 years. Courtesy: ARC Advisory Group
cybersecurity at all.
’Industrial IoT increases • Security management
need for cybersecurity
The new wave of products for Industrial Internet • Specification of security requirements
of Things (IIoT), such as edge computing devices;
cloud computing platforms; and smart, connected • Secure by design
sensors provides an additional level of complexity
for end users from a cybersecurity perspective.
While many of these “industrial edge” offerings
incorporate good cybersecurity, such as “zero trust”
architectures, others do not. Since many of these
offerings are making their way from the informa-
tion technology (IT) world into the OT world, they
must be more closely scrutinized to evaluate cyber-
security risk.

Cybersecurity as a catalyst • Secure implementation
for system modernization • Security validation and verification testing
• Management of security-related issues
Control systems in industrial and critical infra- • Security update management
structure environments typically have extremely • Security guidelines.
long lifecycles. Many distributed control systems Driving cybersecurity into the
(DCSs) and programmable logic controllers (PLCs) ICS procurement process
have been in service for 20 years or more. Many end Selecting secure-by-design products and appli-
users are finding the older installed base is too com- cations can be challenging for many ICS end users.
plex, costly, and risk-prone to continue to support Many have not developed good selection criteria
from a cybersecurity perspective. This often pro- for systems and applications. Many systems used
vides the impetus for a control system migration or in industry and infrastructure are obscure and may
modernization project. not consider cybersecurity at all. At the same time,
Security by design, many of these offerings are becoming more IoT-
cybersecurity standards enabled, which compounds the risk.
While most major DCS suppliers offer control-
The ISA/IEC 62443 series of standards are the lers and other system components that are ISASe-
key cybersecurity standards for manufacturing cure-certified, many suppliers that offer lesser
and critical infrastructure. The series is recognized known types of systems, such as terminal automa-
internationally and the product of decades of work tion systems, RTU-based SCADA systems, boiler
by end users and suppliers. While the initial focus controls and compressor controls may not incorpo-
of the standards was on describing reference archi- rate secure-by-design principles.
tectures and fundamental concepts like defense-in- Having a good selection and procurement process
depth, the IEC 62443 standards today encompass also means different stakeholders within the end user
all aspects of industrial cybersecurity, from prod- organization must also be involved. The normative
uct and application development through the com- requirements described in the IEC 62443 standards
plete lifecycle. provide a solid foundation for such a process.

The IEC 62443-4-1 standard specifies process
requirements for the secure development of prod-
ucts used in industrial control systems (ICS). It
defines a secure development lifecycle (SDL) for
developing and maintaining secure products. This
lifecycle includes the following practices:

www.controleng.com control engineering December 2020 • 27

ANSWERS

IT ADVICE FOR OT AUTOMATION

Security by design means a better design that incorporate the highest degree of inher-
return on investment ent security. This is often the result of partnerships
between specialist networking suppliers and auto-
Many end users have achieved better return on mation suppliers.
investment (ROI) and lower lifecycle costs by invest-
ing in secure-by-design technologies. Many end Other automation suppliers offer design features
users have dwindling resources for managing cyber- in process safety systems to prevent unauthorized
security issues. In addition to adding cost to prevent user access devices. All system suppliers are incor-
threats during day-to day operations, the cybersecu- porating these or similar features. New features are
rity dimension of systems design and engineering being rolled out continuously, which means users
can add to the cost and time required to complete a should evaluate what existing and potential suppli-
project. Incorporating security by design can reduce ers have to offer.
engineering costs and overall project costs as well as
operational and maintenance costs. Cybersecurity product testing
and certification
Examples of security by design
in products and systems Other products provide security by design by
Many products for industrial and critical infra- undergoing a certification or registration process
structure applications provide some security by where they are tested against a cybersecurity stan-
design that can help end users reduce lifecycle dard. One example is the ISASecure family of certi-
costs and improve cybersecurity. Some products fied products, which are tested against the ISA/IEC
offer security by design in their inherent design 62443 cybersecurity standard. ISASecure offers certi-
or physical properties. These include things like fi-cations for both physical products such as control-
data diodes or unidirectional gateways, which pro- lers, PLCs, gateways and routers. This also goes for
vide secure unidirectional or even bidirectional systems, which includes process automation systems
communications. and process safety systems. It also offers secure soft-
Data diodes can incorporate enhanced security ware development lifecycle certifications for systems
into the inherent design of the product or through and applications developed by certified suppliers.
M MANorSeWERSlayers of secure software and network design. One
data diode provider, for example, offers Beyond cybersecurity
a data diode that incorporates physical layers of protection
send-only and receive-only circuits with
KEYWORDS: Cybersecurity fiber optic communications. Layers of protection are necessary. But it is per-
lifecycle, process automation haps even more important to incorporate secure-
upgrades Other data diode suppliers use COTS by-design principles into products and applications
Design cybersecurity into components to build their data diodes, to ensure a certain level of security right “out of the
automation and systems, but incorporate specialized content box.” Ensuring devices are secure by design is the
including Industrial Internet of inspection engines and other software- goal of many cybersecurity efforts, such as ANSI/
Things upgrades. CAN/UL 2900 Standard for Software Cybersecuri-
based methodologies to ensure secure ty for Network-Connectable Products and ISASe-
Consider cybersecurity as a unidirectional communication. cure. Secure-by-design principles apply to software,
catalyst for system modernization Many other products incorpo- devices and networks. Many of today’s commer-
and use of cybersecurity cially-available products and applications were not
standards. rate secure-by-design principles into developed using these principles.
Drive cybersecurity into automation and control systems or
the industrial control system instrumentation. While important, security by design is not a pana-
procurement process. These could include unique back- cea. It does not absolve the end user from following
good cybersecurity practice, project implementation
CONSIDER THIS plane designs, port locking features, or or operations work processes. Incorporating security
Like automation safety, other features. A smaller, but innovative by design is one aspect of a well-rounded and compe-
cybersecurity requires more than automation supplier, for example, may tent cybersecurity organization and strategy.
attention to product design. offers inherent secure-by-design prin-
Other aspects of security in the system design
ONLINE ciples into several of its systems com- process are also becoming more crucial. These
If reading from the digital ponents, including backplane, power include supply chain cybersecurity, provenance
edition, click on the headline for supply, and others. Ask an automation (determining where system computing components
more resources. supplier or industrial cybersecurity sup- like chipsets come from and their inherent levels of
security) and other issues. ce
www.controleng.com/magazine plier about secure-by-design features are
www.controleng.com/ integrated into products. Larry O’Brien is vice president, ARC Advisory
networking-and-security/ The other dimension to look for with Group. Edited by Mark T. Hoske, content manager,
cybersecurity Control Engineering, CFE Media and Technology,
See related New Products security by design is system and net- [email protected].
for Engineers under the work implementation. Some suppliers
cybersecurity product category can offer tested and verified reference
at www.controleng.com/NPE architectures for system and network

28 • December 2020 control engineering www.controleng.com

input #10 at www.controleng.com/information

ANSWERS

AUTOMATION ADVICE FROM IT

Mark Mullins, Fluke Networks

How IT/OT convergence
affects networking
Information technology and operational technology can integrate, but needs

differ. Industrial visibility, interconnections, scalability, wireless mobility, remote

data collection and data analytics are among 7 benefits of IT/OT data flow.
IoT/IIoT and IT/OT convergence continues to
draw attention for the potential benefits they sors that can collect and transmit vital manufacturing
bring. IoT (Internet of Things) and IT (infor- information for real-time analysis from anywhere, the
mation technology) are associated with data- IT and OT worlds are merging into one.
centric networks; the IIoT (Industrial Internet 7 benefits of IT/OT data flow
of Things) and OT (operational technology) are While OT networks are still going to carry out
associated with industrial networks like supervisory functions like monitoring and controlling industri-
control and data acquisition (SCADA) systems used al machines and field devices at the I/O level such as
for monitoring and control industrial devices. relays, electronic flow meters, remote telemetry units
IT and OT networks were once distinctly different (RTUs) and programmable logic controllers (PLCs),
departments with their own architectures, protocols, the implementation of Ethernet and smart sensors
standards, cabling and connectivity. Many on the OT shifts these systems away from proprietary environ-
side tended to be proprietary and vendor controlled. ments to one of open standards and protocols. This
With the proliferation of industrial Ethernet applica- allows data to move more freely, all the way from the
tions, such as Modbus TCP/IP, EtherCAT, EtherNet/ field sensor to the factory backbone and on to the IT
IP and Profinet and network-based smart IIoT sen- network and eventually the internet service provider
(ISP) network and the cloud. This exchange of data
is the foundation of IT/OT convergence that enables:

1. Real-time visibility of industrial information
from any location

2. Interconnecting of multiple sites and facilities
3. Scalability to reach to more environments
4. Wireless communications for mobility on the

factory floor
5. Data collection from remote sites via 4G/5G

cellular technology
6. Data analysis via more devices and back-end

system applications
7. Standardization and rapid deployment for

faster time to market

Figure 1: MICE environmental classifications help with design of These capabilities pave the way for enhanced plan-
industrial cable and network components. MICE stands for mechani- ning and decision making, improved efficiency, less
cal, ingress, climatic/chemical and electromagnetic. Images courtesy: downtime, reduced maintenance and better produc-
Fluke Networks tivity, which lowers costs and maximizes profitability.
To leverage IT/OT convergence, IT and OT depart-
ments within a manufacturing company need to
come together to ensure both networks are designed
and deployed in a way that makes data accessible,
meaningful and secure. A key factor is understand-
ing that because the data is now in a common format
that can traverse IT and OT networks and the inter-

30 • December 2020 control engineering www.controleng.com

Figure 2: Fluke Networks’ DSX CableAnalyzer
M12 channel adapters for M12D (4 position)
and M12X (8 position) allow for testing and
certifying installed channel links to ensure reli-
able Ethernet transmission in the demanding
MICE environment of industrial network appli-
cations.

net, the cabling and connectivity that comprises these
networks, as well as the environments in which they
reside and testing considerations, are not the same.

Diverse industrial cables, connectors Figure 3: Fluke Networks’ DSX CableAnalyzer tests for different
The cabling plant that comprises the OT net- end-to-end cable configurations including E1, E2, and E3 limits per
industry standards.
work is subject to harsher conditions. Out on the
factory floor or within a processing facility, cables jacket materials have a far greater tem- M MANorSeWERS
and connectors used to connect the industrial field perature range, flexibility, and chemical
devices and equipment must be robust enough to and abrasion resistance than polyvi- KEYWORDS: IT/OT convergence,
withstand a variety of elements including vibra- nyl chloride (PVC) used for commer- industrial networks
tion, extreme temperature, liquids, dust, chemi- cial-grade cables. Applications where Examine how IT/OT data flow
cals and interference. ANSI/TIA-1005 and ISO/IEC cables are exposed to frequent bend- provides at least seven benefits.
11801 industry standards use mechanical, ingress, ing, flexing and twisting (think robotics Fit environmental specifications to
climatic/chemical, electromagnetic (MICE) spec- and other repeated motion applications) the industrial network application.
ifications to classify components based on factors may require high-flex cables that contain
such as vibration, force and impact (mechanical); higher strand counts per conductor. CONSIDER THIS
protection against dust and liquids (ingress); tem- Is your industrial network enabling
perature, radiation and pollutants (climatic/chemi- IT and OT managers need to be on the or constricting data flow and
cals) and noise interference (electromagnetic). The same page when it comes to testing. This information development?
parameters determine various degree of environ- includes proper training and outfitting
mental conditions and an associated MICE level, technicians with quality testers capable of ONLINE
with MICE 1 defining a typical office environment, connecting to both RJ45 and M12 con- If reading from the digital edition,
MICE 2 defining a slightly harsher environment nectors and testing for continuity, length, click on the headline for “Industrial
and MICE 3 defining heavy industrial. crosstalk and shield integrity. ce cabling problems.”
www.controleng.com/magazine
MICE 2 and MICE 3 environments that com- Mark Mullins is product manager at Fluke www.controleng.com/
prise the OT network require different Ethernet Networks. Edited by Mark T. Hoske, content networking-and-security
connectors compared to those used in MICE 1 IT manager, Control Engineering, CFE Media
networks. Unlike common commercial-grade RJ45 and Technology, [email protected].
connectors used for connecting computers and
devices in the office, industrial-grade RJ45 connec-
tors often include features such as chemical-resis-
tant thermoplastic housing and IP67-rated seals
for ingress protection. OT networks also use M12
locking connectors for I/O connections on indus-
trial equipment because they are far more durable
and better designed to handle the ongoing vibration
since they are locked into place.
Industrial Ethernet cable benefits

Industrial Ethernet cables are no different than
commercial-grade Ethernet cables in terms of data
transmission capabilities, but shielded cabling con-
struction is more common for copper cables in OT
networks due to electromagnetic interference from
switching relays, AC drives and other noise sources.

Industrial Ethernet cables may also have dif-
ferent temperature ratings and jacket material
depending on the environment where deployed.
Fluorinated ethylene polypropylene (FEP), thermo-
plastic elastomer (TPE) and polyurethane (PUR)

www.controleng.com control engineering December 2020 • 31

ANSWERS

INSIDE MACHINES: MOTORS & DRIVES

Dakota Miller and Bryan Knight, Yaskawa America

Direct drive vs. geared rotary
servomotor: A quantification
of design advantage: Part 1

A geared servomotor can be useful for rotary motion technology,

but there are challenges and limitations users need to know.

F or decades, geared servomotors have applying torque to the load to decelerate it (Figure
been one of the most common tools 1C). This loss of motion is called backlash, and is
in the industrial automation toolbox. typically measured in arc-minutes, equal to 1/60th
Geared sevromotors offer positioning, of a degree. Gearboxes designed for use with ser-
velocity matching, electronic camming, vos in industrial applications often have backlash
winding, tensioning, tightening applications and specifications ranging from 3 to 9 arc-minutes.
efficiently match the power of a servomotor to the
load. This raises the question: is a geared servomo- Torsional stiffness is the resistance to twist-
tor the best option for rotary motion technology, ing of the motor shaft, transmission elements, and
or is there a better solution? the load in response to the application of torque.
In a perfect world, a rotary servo system would An infinitely stiff system would transmit torque
have torque and speed ratings that match the to the load with no angular deflection about the
application so the motor is neither over-sized nor axis of rotation; however, even a solid steel shaft
under-sized. The combination of motor, transmis- will twist slightly under heavy load. The magni-
sion elements, and load should have infinite tor- tude of deflection varies with the torque applied,
sional stiffness and zero backlash. Unfortunately, the material of the transmission elements, and
real world rotary servo systems fall their shape; intuitively, long, thin parts will twist
M MANorSeWERS short of this ideal to varying degrees. more than short, fat ones. This resistance to twist-
ing is what makes coil springs work, as compress-
In a typical servo system, backlash is ing the spring twists each turn of the wire slightly;
defined as the loss of motion between fatter wire makes a stiffer spring. Anything less
KEYWORDS: servomotors, the motor and the load caused by the than infinite torsional stiffness causes the system
direct-drive motors mechanical tolerances of the transmis- to act as a spring, meaning potential energy will
Real-world rotary servo sion elements; this includes any motion be stored in the system as the load resists rotation.
systems fall short of the ideal
performance due to technical loss throughout gearboxes, belts, When combined together, finite torsional stiff-
limitations. chains, and couplings. When a machine ness and backlash can significantly degrade the
Several types of rotary is initially powered on, the load will performance of a servo system. Backlash can
servomotors can provide benefits float somewhere in the middle of the introduce uncertainty, as the motor encoder indi-
for users, but each has a specific mechanical tolerances (Figure 1A). cates the position of the motor’s shaft, not where
challenge or limitation. Before the load itself may be moved the backlash has allowed the load to settle. Back-
lash also introduces tuning issues as the load cou-
Direct drive rotary servomotors by the motor, the motor must rotate to ples and uncouples from the motor briefly when
offer the best performance, but the load and motor reverse relative direction. In
they’re more expensive than addition to backlash, finite torsional stiffness
gearmotors. take up all slack existing in the trans- stores energy by converting some of the kinetic
mission elements (Figure 1B). When the energy of the motor and load into potential ener-
ONLINE motor begins to decelerate at the end of gy, releasing it later. This delayed energy release
causes load oscillation, induces resonance, reduc-
See more motors and drives a move, the load position may actually es maximum usable tuning gains and negatively
articles at impacts the responsiveness and settling time of the
www.controleng.com/motors-drives. overtake the motor position as momen-
tum carries the load beyond the motor
position.
CONSIDER THIS The motor must again take up the

What do you look for when slack in the opposite direction before
selecting a servomotor?

M1 • December 2020 control engineering www.controleng.com

load to the motor. Whereas the gearmotor config-
uration uses a coupling to a relatively small diam-
eter shaft, the direct drive system bolts the load
directly to a much larger rotor flange. This config-
uration eliminates backlash and greatly increas-
es torsional stiffness. The higher pole count and
high torque windings of direct drive motors
match the torque and speed characteristics of a
gearmotor with a ratio of 10:1 or higher.

‘A direct drive rotary servomotor offers
the best performance and lowest system

complexity, but at higher cost than a

’gearmotor.
The least common and most complicated con-
Figure 1: In a typical servo system, backlash, figuration is a fully closed-loop system, where- Figure 2: The perfor-
rotation and slack are all elements that are part by a regular rotary servomotor and gearbox or mance of a gearmotor
of the drive process. Images courtesy: Yaskawa other transmission elements is combined with a and direct drive ser-
America second encoder used to measure the position of vomotor are tested
the load, masking, but not eliminating the effects by mounting each to
servo system. In all cases, reducing backlash and of backlash. This adds significant cost and com- a common load that
increasing the stiffness of a system will increase plexity of a second encoder, additional machining simulates a high iner-
servo performance and simplify tuning. and mounting hardware, additional cabling, and tia rotary indexing
added maintenance. table.
Rotary axis servomotor configurations
The most common rotary axis configuration Of these three system designs, the direct drive
rotary servomotor offers the best performance
is a rotary servomotor with a built-in encod- and lowest system complexity, but at a high-
er for position feedback and a gearbox to match er cost than the gearmotor solution. Attempting
the available torque and speed of the motor to the to quantify the performance advantage through
required torque and speed of the load. The gear- manufacturer manuals and catalogs is
box is a constant power device that is the mechan- impossible though, as the motors
ical analog of a transformer for load matching. seem remarkably similar in terms
of specification.
An improved hardware configuration uses a
direct drive rotary servomotor, which eliminates In part 2 of this article, the per-
the transmission elements by directly coupling the formance of a gearmotor and direct
drive servomotor (Figure 2) are
tested by mounting each to a com-
mon load that simulates a high
inertia rotary indexing table. Using
a 30-bit ring encoder on the load,
the motion of the load is recorded,
and compared to each motor. Per-
formance metrics including positioning
accuracy, backlash, settling time and total motion
cycle time are evaluated and weighed against the
cost and complexity of each system. ce

Dakota Miller is automation product specialist, Yas-
kawa America; Bryan Knight is product marketing
manager, Yaskawa America. Edited by Chris Vavra,
associate editor, Control Engineering, CFE Media
and Technology, [email protected].

www.controleng.com control engineeering December 2020 • M2

ANSWERS

INSIDE MACHINES: RADIO FREQUENCY IDENTIFICATION

Linda Htay, Idec Corp.

How RFID improves machine
performance, safety

RFID authentication devices on original equipment manufacturer (OEM)

machinery ensure the proper users are taking permitted actions, providing

performance benefits and improved safety. See five methods for security

for industrial machinery.

A utomated equipment and machinery
can incorporate many ways for users
to monitor and control operation,
such as with buttons, switches, and
touchscreens. When original equip-
ment manufacturers (OEMs) design and build
machinery, they want to deliver easy-to-use func-
tionality. However, they must balance this desire
with the need to verify authorized users are at the
controls and making acceptable selections.

Several authentication methods are possible,
ranging in the security levels, user convenience,
and features they provide. The simplest schemes
may not offer enough protection, while the most
complex are usually expensive and limiting.

Balanced solutions provide strong security and
audit logs – and they are simple to implement,
cost-effective to maintain, and easy for end users
to work with, which is where radio-frequency iden-
tification (RFID) can play a role.

Figure 1: Unlike common commercial-grade RFID readers, Authentication drivers
industrial-rated readers are available to fit common 22 mm for industrial machinery
panel-mount knockout holes while resisting harsh environ-
ments. Images courtesy: IDEC Corp. It is possible to design machinery void of
authentication methods, just as a car could be
built with an on/off switch instead of an ignition
key, or a house with no locks on its doors. Just as
there are logical reasons to implement authentica-
tion solutions on cars and houses, there are moti-
vations for doing so on industrial machinery, such
as achieving operation restriction, traceability or
both. Sometimes these motivations are driven by
technical initiatives, but often they are mandated
by regulatory requirements.

Operation restriction can sound negative, so
operation permission may be a better term. OEMs
and end user manufacturing companies incorpo-
rate authentication methods to ensure proper per-

M3 • December 2020 control engineering www.controleng.com

‘Traceability drivers involve gathering data,
and manufacturers can use authentication to

log which users operated a machine and the

’actions performed. Common use of automation
authentication
sonnel are accessing machinery controls, but they Modern digital devices used
don’t want to limit authorization to a binary yes for industrial machine automation
or no. Authentication extends into defining groups – including PCs, human-machine
of personnel and even individuals, with granular interfaces (HMIs), and mobile devices
selection of what machinery information they can – have made passwords a common authen- Figure 2: RFID tags
view and adjust. tication method. Passwords can provide a limitless can be traditional
Industrial machine traceability: number of authentication levels per user, and are cards, but the key
Who did what, when, why inexpensive to manage. Unfortunately, they can be fob style shown
forgotten or leaked, and can be difficult to use in here is especially
Some companies may add permissions to bet- many industrial settings where gloves are used or suitable for industri-
ter ensure safe and proper equipment operation. where a full keyboard or touchscreen may not be al-rated smart RFID
In other cases, compliance with industry safety available. readers like the
standards such as ISO16090 (for machine tools) Biometrics such as fingerprint and face scan- Idec KW2D series,
or ISO10218-1 (for industrial robots) can lead to ners are common in consumer electronics and which can include a
adopting authentication methods. some commercial applications. Because they use bracket to hold the
personal and non-transmittable information, they tag in place.
Traceability drivers involve gathering data, and are relatively secure, do not require operators to
manufacturers can use authentication to log which carry or remember anything and often cannot
users operated a machine and the actions per- be duplicated or lent out. Unfortunately, biomet-
formed. This history may be used for information- ric techniques are expensive to implement and
al purposes, which a company can analyze with manage. They don’t work well around machinery
the goal of improving performance. Or, the data where gloves, helmets, masks and safety glasses
trail may be stored to satisfy an industry require- may impede their function, either.
ment, such as FSSC22000 for food safety, which This brings up RFID, which occu-
calls for traceability in the manufacturing process. pies a sweet spot within industrial M AMNorSeWERS
Five methods for security machinery authentication. RFID tags KEYWORDS: Radio frequency
for industrial machinery are familiar to most anyone who has identification, RFID, original
used a parking lot or building access equipment manufacturer
Several levels of security are possible, each with system. They are simple and relative- (OEM)
a range of benefits, disadvantages, and costs. The ly inexpensive to manage, and they are Review methods for controlling
following methods are suitable for adapting into not easily duplicated. Although they are and monitoring how machines
industrial machinery use, and are familiar to most easy to lend, authentication is easy to
consumers: modify because they are digitally man- operate and who controls them.
aged. As a physical token, RFID tags See how radio frequency
• Physical/mechanical keys and sensors are readily implemented for identification (RFID) is a passive
• Magnetic strip cards / swipe cards industrial applications. tag system, but it can be used in
• Passwords many industries and applications.
• Biometrics
• RFID. Industrial-specific RFID devices Learn how many RFID scanners
Physical keys are the oldest and most familiar RFID is a preferred technology for are designed to work in harsh
of the authentication methods. They are simple environmental conditions.
and low cost, but easy to copy or lend. OEMs can many applications because the user’s
implement a basic key switch into their machine, tag is lightweight and does not require ONLINE
but it provides a binary or limited selection by any batteries. Reader devices, typically Read additional stories about
user who gains access to the key. Magnetic strip installed in a fixed location, generate RFID systems at
cards are an improved version of physical keys, a radio signal, causing a passive tag in www.controleng.com.
which add some digital capability. However, they range responds with a unique signal.
may not be convenient to carry and protect at CONSIDER THIS
industrial sites. Consumer-grade RFID readers What do you use RFID systems
commonly found in commercial appli- for and what benefits have they
provided?

www.controleng.com control engineeering December 2020 • M4

ANSWERS

INSIDE MACHINES: RFID

‘RFID tag at a machine access
or safety cage location may

be used in conjunction with
unlock solenoids to allow the

Figure 3: Smart RFID readers can communicate tag information over door to open for permitted
an industrial communication protocol like Modbus TCP/IP, and each
tag carries a unique ID which is associated with a user or group and ’personnel.
can be assigned specific functionalities.
carrying and using in production environments
cations are often robust, but they usually are not (Figure 2). Each tag carries a unique ID, which can
built to withstand the temperature, vibration, and be registered and associated with a user or a work-
washdown/chemical environments associated er category.
with many machines. Most readers are designed
to use rectangular cutouts, which are not conve- Users may present tags at a reader for an inter-
nient for many control panel designs. mittent acknowledgement, but sometimes an
application requires the user to place the tag in
However, some industrial-grade RFID read- constant contact with the reader during certain
ers are explicitly designed to fit industrial-friendly operations. In such a scenario, some industrial
common control panel form factors, such as the RFID readers include a mechanism to hold the tag.
22-mm knockout hole (Figure 1). These devices
also are available with IP67 ratings, meaning they RFID readers are intelligent devices. On the
are protected from dust, low-pressure water jets front end, they must interpret IDs from physical
and even immersion situations sometimes found tags; on the back end, they must communicate
with industrial installations. with supervisory systems. This is usually per-
formed with an industrial communication proto-
Industrial-rated RFID readers can take func- col such as Modbus TCP/IP (Figure 3), through
tionality a step further with LED multi-state and which the reader can send complex tag IDs or sim-
color indicator lights on the face, which can be ple authorization levels to the supervisory system,
activated to identify conditions such as standby, as well as receive commands to operate its light
success or error. Some also can generate an audible indicators and buzzer.
signal to give users operational feedback.
RFID applications and
RFID standards for cards, tags, fobs advanced RFID benefits
Not all RFID tags are created equal, though.
Industrial RFID readers are often integrated with
There are global RFID standards such as the programmable logic controllers (PLCs) which
ISO14443A, ISO15693, and ISO18092 that apply control machinery such as machine tools and injec-
to credit-card style configurations. While cards tion molding equipment. Consider one of these
can be useful for industrial applications, there are machines, which may have a few types of users:
also key fob styles which may be more suitable for
• New or temporary staff
• Trained operators
• Technical leads
• Maintenance personnel.

When the new staff applies their RFID tags,
machine operation can be limited to their skill
level and operating authority. Trained operators
may be able to access normal operation moni-
toring and control functions; technical leads are
authorized to adjust advanced settings and make
special production runs. Maintenance personnel
may be restricted from running the system nor-

M5 • December 2020 control engineering www.controleng.com

PLC
+

HMI

OPERATE. CONTROL.
VISUALIZE.

TOUCH PANEL 600: PLC + HMI ALL-IN-ONE

• High resolution graphics and glass panels
• Support of all six IEC PLC programming languages
• Multiple fieldbuses: Ethernet/IP, MODBUS TCP/UDP, CANopen, EtherCAT
• IIoT-Ready: Sparkplug, native MQTT with built-in Firewall and VPN
• Linux OS with Docker Container capabilities

input #11 at www.controleng.com/information

Learn more about our HMI family: www.wago.us/touchpanel

RS 232
485

ANSWERS

INSIDE MACHINES: RFID

‘Machines and equipment of all types can solenoids to allow the door to open for permitted
benefit from applying industrial-rated RFID personnel. Workers who inspect parts could con-
readers and tags. The ability to manage and firm their review by scanning a tag. RFID tags can
track user authority can be used to ensure be incorporated into maintenance procedures to
basic access control and improve overall confirm personnel are working in the right areas,
safety. Advanced features include paperless enhancing safety.
’traceability and database connectivity.
mally, but they may be allowed to jog motors and Engineering teams also can review logged user
manually actuate devices. activity to analyze machine operation and deter-
RFID for access, machine procedures mine more efficient ways to run. All actions can be
For traceability, preceding users and their stored and retrieved in a database environment to
actions can be logged by the PLC and HMI. If the facilitate analytics and avoid inefficient paper logs.
RFID tag is at a machine access or safety cage loca-
tion, it may be used in conjunction with unlock Machines and equipment of all types can ben-
efit from applying industrial-rated RFID read-
ers and tags. The ability to manage and track user
authority can be used to ensure basic access con-
trol and improve overall safety. More advanced
functions, such as paperless traceability and
database connectivity, can help OEMs and man-
ufacturers cost-effectively meet regulatory require-
ments and optimize machine performance. ce

Linda Htay, product marketing specialist, IDEC Cor-
poration. Edited by Chris Vavra, associate editor,
Control Engineering, CFE Media and Technology,
[email protected].

KNOW THIS FEELING?

Then stop using complicated controllers for
precision motion. You shouldn’t need a Ph.D. in
control systems to program your controller.

With Automation1, you can now reduce your
set up time — in many cases, from days down
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interface and machine setup wizard. Automation1
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platform available.

Make your motion easier. input #12 at www.controleng.com/information AT0520A-CSG
Visit aerotech.com/automation1.

ANSWERS

INSIDE MACHINES: ROBOTIC PROGRAMMING

Michael Castor, Yaskawa Motoman Robotics Division

Robotic offline programming
in a COVID-19 world
Offline robot programming platforms are increasingly being used during

Rthe COVID-19 pandemic. See four scenarios and programming features.
obotic automation and other advanced has workers striving to complete high-mix, low-
technologies have proven vital for busi- volume runs at a record pace. To deal with the
nesses in recent months for sustain- changeover required, a greater focus has been given
ing and improving productivity in a to smart technologies, such as OLP software, to
demanding, yet uncertain, markets reduce programming downtime and optimize over-
affected by the pandemic. From welding to coating, all equipment efficiency (OEE).
robots with feature-rich technologies can help busi-
nesses achieve greater accuracy and higher quality SCENARIO 3: Adding automation quickly
with increased efficiency. Similar to scenario two, the increase in demand for
While robotic automation can accelerate produc- products, especially those important to battling the
tion output, it also can cause significant downtime if pandemic, companies need to integrate new robots or
a solid robot programming plan is not in place. To redeploy old ones. Either way, to facilitate a smooth-
facilitate robot uptime – especially for manufacturing er transition to the manufacturing of these essential
companies that cannot afford to interrupt production products, using OLP software has been suggested.
while a robot program is being written point by point
from a teach pendant – offline robot programming SCENARIO 4: Testing a new approach
platforms increasingly are being used to accommo- Loosening government restrictions have busi-
date complex system layouts. nesses reopening, which results in a new sense of
urgency for revitalizing production. As a result, com-
Four scenarios for robotic pany leaders have decided to tackle tough challeng-
offline programming es through creative and collaborative approaches to
Using a 3D representation of a robotic workcell robotic automation. Either current robots are being
that visually demonstrates how a robot moves along redeployed or new robots are being purchased. Quite
a programmed path, offline programming (OLP) possibly, robotic automation is being introduced
can be accomplished through original equipment to the factory for the first time. Regardless of the
manufacturer (OEM) -specific software platforms or
third-party options. OLP also gives experienced and
novice robot programmers the ability to create, test
and adjust a robot program or job from the conve-
nience of a PC-based virtual programming environ-
ment before it is implemented on the factory floor.
Due to events surrounding the COVID-19 pandem-
ic, many manufacturers are finding themselves in
one, or more, of the four following situations:

SCENARIO 1: Restricted access on the floor Figure 1: Offline programming (OLP) can be accomplished through
The whirlwind of new health concerns and reg- original equipment manufacturer (OEM)-specific software platforms
or third-party options. Images courtesy: Yaskawa Motoman
ulations has prompted businesses to implement
social distancing, along with work from home
(WFH) policies. This has caused restricted access
to robots on the factory floor, making it difficult to
program/re-program jobs.
SCENARIO 2: Adapting to changing demand

An uptick in demand for general use products

www.controleng.com control engineeering December 2020 • M8

ANSWERS

INSIDE MACHINES: ROBOTIC PROGRAMMING

ticular fashion to weld a specific part?”and other
considerations.
Four robotic offline programming
benefits for manufacturers

Aside from addressing the previously mentioned
scenarios, the proper and effective use of OLP soft-
ware can help manufacturers achieve various pro-
duction goals including:

Figure 2: OLP can approach, a viable method for setting up new, more 1. Execute fast integration with robots
help manufactur- complex, robot jobs with offline programming. Offline programming provides a way of creating
ers execute faster Four key features of robotic offline
integration, quick programming a robot job while a workcell is still in the construc-
changeovers and tion phase. This process speeds up integration time,
more. While OLP software is not limited to the follow- as data files can be transferred once the workcell
ing, most users seek offline programming platforms is complete and installed on the shop floor. While
that have an extensive model library and offer these minimal touch-up may be required, having a robot
four key features: job prepared beforehand is a huge timesaver.
2. Perform quick changeover of robots
1. Robot collision detection
If several robots are working in close proximity, If a robot is being used to process multiple parts,
offline programming enables the ability to program
it is vital they are programmed to work as a team. the robot for “part B” while “part A” is being run.
During the offline programming process, the colli- Once “part A” is complete, the programmed files can
sion detection feature signals potential interference be downloaded to the robot controller to run “part B.”
hazards, allowing the programmer to make cost- 3. Set up functional safety for robots
saving adjustments before the program is intro-
duced to the factory floor. OLP allows for items like arm interference,
speed limits and safety zones to be established. This
M More 2. Robot path planning includes the ability to graphically overlay the safety
While a robot is programmed to move zones (robot range limits) during simulation, allow-
from point to point, it is imperative to ing visual confirmation and testing with motion in
ANSWERS plan around specific items like fixtures for the simulation.
4. Achieve quick cycle times for robots
KEYWORDS: offline robotic holding parts. With path planning, pro-
programming, COVID-19 When extremely fast cycle times are required, OLP
gramming a robot to maneuver around platforms can help users monitor the duty cycle of a
Offline robot programming fixed points is made easier, as it acti- robot so the life of the motor can be monitored.
platforms are increasingly being vates collision detection to help avoid
used to accommodate complex interference. The flexibility provided by OLP software offers
system layouts. many perks and enables a higher mix of jobs with a
3. Robot conveyor tracking simple transition from one job to the next. Similar-
The COVID-19 pandemic is When parts are in different positions, ly, larger companies with multiple locations and/or
forcing many manufacturers to workcells may be able to reduce programming time
use offline robot programming conveyor tracking can help the robot and inconsistencies by distributing the programmed
because of workplace align those parts, as needed. job from a central, controlled source. Furthermore,
restrictions. 4. Robot cam path improvements in sensor technology for tasks such as
Offline robot programming, robotic welding have come a long way in the recent
when used properly, helps If performing a welding application, past, providing considerable advantages for end users
manufacturers address current dispensing application or other complex spanning diverse industries.
market challenges. task, the cam path feature can help auto-
mate the process. Instead of manually Once implemented and properly used, the col-
ONLINE teaching points to the robot, cam path lective use of software – along with feature-rich
See additional stories about provide these points automatically. sensors –can help manufacturers address current
robotics and COVID-19 at market challenges and the growing needs of a high-
www.controleng.com. These features and more work mix low-volume production environment.
together to help conceptualize possi-
CONSIDER THIS ble robot scenarios such as, “How fast Michael Castor is product manager, material han-
What benefits would your robots can a robot go with a particular appli- dling at Yaskawa America Inc. – Motoman Robot-
and manufacturing facility gain cation?” or “Can a robot move in a par- ics Division. Edited by Chris Vavra, associate editor,
from offline robot programming? Control Engineering, CFE Media and Technology,
[email protected].

M9 • December 2020 control engineering www.controleng.com

ANSWERS

TECHNOLOGY UPDATE

Zach Goldsworthy, LEED AP BD&C, Siemens Industry Inc.

A great sequence of operations

Applications, repairs and risk reduction, failure modes, retrofits, documentation

and project scope are ways to develop a critical power sequence of operation.
E mergency parallel switchgear is vital to
a building’s resiliency or for processes Sequence of operations modes Seven modes of sequence
inside, and the sequence of operation of operation for emergency
(SoO) for starting and stopping emer- 1 Normal operation parallel switchgear are
gency parallel switchgear rarely receives 2 Loss of normal source normal operation, loss of
3 Retransfer sequence

the same level of attention. Sequence of operation 4 Failure modes normal source, retransfer
parts, including considerations and what makes a 5 Load shed sequence, failure modes,
good SoO, were covered in an Oct. 8, hour-long 6 Load bank load shed, load bank and
training course on the topic. Also covered was how 7 Monthly generator test monthly generator test.
transfer switches could be prioritized based on code Courtesy: Siemens Industry
and operation of the sequence of operation system.
A live question and answer session followed the
training, “Developing a great sequence of operations” allows the system to be more responsive and resilient.
produced by CFE Media and Technology, owner of
Control Engineering, Plant Engineering, Consulting- 5. Are retrofit considerations different than
Specifying Engineer, and CFE Edu online training.
working with new equipment? In what ways?
Answering questions below was one of the Yes, retrofit projects need to take into account
course instructors (archived through December),
existing conditions and the overall ability of the
Zach Goldsworthy, LEED AP BD&C, national emergency parallel switchgear and related equip-
healthcare market leader, Siemens Industry Inc. ment; this would include generators to parallel or in M AMNorSeWERS
older transfer switches the ability to be shed.
Answers for SoO applications KEYWORDS: Sequence of
1. How many other applications might benefit 6. What are SoO documentation best practices? operations, emergency
parallel switchgear
from electrical sequence of operations and why? At the beginning of the project a comprehen- Review risk
Any electrical distribution that has automat- sive one-line diagram along with a thorough under- considerations related
standing of the facility is critical for understanding to sequence of operation
ed operation should have a sequence of operation the full scope. At the end of the project, thorough for emergency parallel
developed, which should include different opera- as-builts and narrative are required. switchgear and related
tions/sources along with failure scenarios. equipment used in critical
I also recommend reviewing the as-builts and power applications.
2. Even though the sequence of operation is sequence of operation at the end of the project with Consider sequence of
the complete team. The facility type or industry operation failure modes,
automated, can we still have manual operation? does not change the best practice recommendations retrofit and repairs.
The manual operation option is best practice and but it is more important in critical power facilities, Learn about documentation
such as data centers, healthcare, and other areas, best practices for sequence
allows additional flexibility. It is also recommended including critical industrial applications where of operations.
that additional or follow up training is included. power loss would be costly or dangerous.
CONSIDER THIS
3. If equipment failure changes SoO are there 7. What else needs explaining? Need a refresher course
on sequence of operations
requirements for repair times? Thorough site investigation and review of the for emergency parallel
There are no published or required times for project scope are critical for a successful sequence switchgear?
of operation. Engagement with the manufacturer
equipment to be repaired but best and recommend- is also recommended to understand the impacts of ONLINE
ed practice is as soon as possible to minimize the risk the layout or configuration on emergency parallel If reading from the digital
to the facility, occupants and community. This is also switchgear and related equipment. ce edition, click on the headline
why many facilities require levels of redundancy. for more resources.
Edited by Mark T. Hoske, content manager, Con- www.controleng.com/
4. Are there often overlooked details? trol Engineering, CFE Media and Technology, magazine
[email protected]. https://cfeedu.cfemedia.
Failure modes are not always thoroughly consid- com/
ered. Most systems have one sequence that does not
consider other variations. If the system is expected to
be responsive to other failures, the detailed sequence

www.controleng.com control engineering December 2020 • 41

ANSWERS

WEBCAST ON CYBERSECURITY

Mark T. Hoske, Control Engineering

What you need to know
about cybersecurity

A webcast on cybersecurity offers information about cybersecurity architectures,

training, best practices, risk assessment and trends based on research.

W hat do you need to know about Gosine noted that cyber threats to the industrial
cybersecurity related to con- control system (ICS) potentially can create health
trols, automation, and instru- and safety catastrophes through the interruption of
mentation, especially with more critical operations. Those involved with ICS cyber-
remote connections resulting security should:
from the COVID-19 pandemic? Capabilities inher-
ent in existing cybersecurity design methodologies • Make the security strategy your own
and technologies will be explored along with what • Build a security program will result in reduced
should be covered in cybersecurity training. When
was your last cybersecurity risk assessment? The perimeter operating costs and costs of com-
webcast is designed to help attendees: pliance with NERC-CIP, NRC, CFATS, NIST,
ISA-SP99 and other standards, guidance, and
• Identify architectures for cybersecuri- regulations.
ty designs for controls, automation, and • Visibility of your operations, partners and
instrumentation. vendors – know who is on your network, what
• Learn what should be covered in cybersecu- they are running and how they are configured
rity training. • Adopt security intelligence/situational aware-
• Receive tips about cybersecurity best ness – it is about integration, visibility and
practices. system feedback
• Review elements of a cybersecurity risk • Have a governance structure that includes
assessment. all stakeholders.
M MANorSeWERS • Review related Control Engineering Mind your cybersecurity zones:
cybersecurity research results consequence, vulnerabilities, threats
and advice. Bonnette said what distinguishes or defines a
cybersecurity zone is often misunderstood. Unique
KEYWORDS: Industrial Presenters are: zones may be driven by either a higher or lower
cybersecurity, cybersecurity • Brad Bonnette, technical direc- consequence of the subsystem being compromised,
risk assessment or an increased likelihood (threat exposure) due
Industrial cybersecurity tor, Wood Automation and Control, to physical or logical access, such as “exposed” or
webcast looks at what you Wood “untrusted” edges. Bonnette said third-party inter-
need to know. • Anil Gosine, global projects, MG faces are often lumped into one large zone, but they
Considerations include Strategy+. require additional zoning following a risk assess-
industrial control system Mark Hoske, content manager, Control ment as not all third-party systems have the same
cybersecurity Engineering, CFE Media and Technology consequence, vulnerability or threat exposure.
Cybersecurity zones often will serve as moderator and present cyber- For more on these points, view the webcast; a
are misunderstood. security research. question and answer session with the speakers will
ICS cybersecurity: Advice, be archived with the webcast for one year from the
CONSIDER THIS integration, visibility, feedback Dec. 3 event. Access the Control Engineering web-
Are you reducing In discussions prior to the Dec. 3 web- cast archive at www.controleng.com/webcasts/past.
cybersecurity risk to an cast “Cybersecurity: What you need to
acceptable level? know,” the presenters offered the following ce
information.
ONLINE Edited by Mark T. Hoske, content manager, Control
www.controleng.com/ Engineering, CFE Media, [email protected].
webcasts
www.controleng.com/
webcasts/past

42 • December 2020 control engineering www.controleng.com

INNOVATIONS See more New Products for Engineers. PE
www.controleng.com/NPE
NEW PRODUCTS FOR ENGINEERS

Integrated servo drives can be placed on machine

The AMI812x series of integrated servo drives expands the Beckhoff com-
pact drive technology portfolio (up to 48 Vdc) with devices for distrib-
uted installation in the field. The integration of servomotor, output stage
and fieldbus connection in a space-saving design makes the drives ideal for
automation outside of control cabinets in the motion power range up to
400 W. The AMI812x integrated servo drive can be placed directly on the
machine without a control cabinet and without upstream I/O, enabling the
implementation of highly compact machines without control cabinets. At market introduction, the AMI812x series includes
three overall lengths in the F2 flange code with standstill torques from 0.5 to 1.1 Nm. The AMI812x is optionally available
with a multi-turn absolute encoder without battery backup and with a backlash-free holding brake.

Beckhoff Automation, www.beckhoff.com Input #200 at www.controleng.com/information

Non-fusible disconnect switches Bluetooth dual-mode
wireless modules
AutomationDirect has added enclosed versions and
non-enclosed DIN rail and panel/door mount ver- The FWM7BTZ61 series of Blue-
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The terminal screws are all accessible from one side. acy Bluetooth
ML1 compact switches are available for applications from 16 to 40A. For more demand- Classic BR/
ing applications loads, the ML2 to ML3 series accommodates loads from 63 to 125A. EDR, giving
Merz UL 508 disconnect switch with enclosure is a non-fusible, UL 508/UL 60947 man- designers the
ual motor controller 600 Vac disconnect switch rated at 25-125A (3-pole) and 40-63A flexibility to choose
(3-pole + neutral). The gray polycarbonate plastic enclosure with red handle is NEMA/ between the two modes with one
UL Type 1, 3R, 4, 4X rated. module. The symbol rate and
data rate accommodates 1Mbps
AutomationDirect, www.automationdirect.com Input #201 at www.controleng.com/information and improved 2Mbps to facilitate
communication speed with other
Advanced I/O for mechancal engineering Bluetooth Low Energy devices.
Wago Corp.’s I/O System Advanced is designed for mechanical In addition, Classic mode sup-
engineering applications. Connectivity and speed are the foun- ports 1Mbps (BR: basic rate) and
dations of modern production facilities. The system provides 2 and 3Mbps (EDR: Enhanced
an IP20 solution that integrates time-sensitive networking Data Rate) communication. The
(TSN) and OPC UA. As a gateway to the universal WAGO 750 series also supports a wide range
Series I/O System, the new I/O System Advanced combines the prov- of operating voltages from 1.71 to
en benefits and functionality of the 750 Series with a fresh and ergonom- 3.63V, which enables the mating
ic design, mechanical features that help prevent errors and outstanding performance. with various system design and
The results: short reaction times, high signal transmission synchronicity and the ability to power supply conditions.
use fast Ethernet fieldbuses (such as Profinet, EtherCAT, EtherNet/IP).
Fujitsu Components America Inc.
Wago Corp., www.wago.com Input #202 at www.controleng.com/information www.fujitsu.com

Input #203 at www.controleng.com/information

www.controleng.com Thermal mass flowmeter measures pure and mixed gases

The Proline t-mass F300 thermal mass flowmeter are designed to measure pure gases and gas
mixtures, and each has numerous alarm functions, as well as bidirectional measurement capabil-
ity and reverse flow detection. Whether compressed air, natural gas, protective gas or oxygen, end
users wanting to record gas flows with proven and robust state-of-the-art measuring technology
no longer need to make compromises. The all-metal sensor design and monitoring functionality
helps ensure optimum process measurement. Even when process conditions fluctuate significantly,
gas flows can be measured with high accuracy. Even when process and ambient conditions signifi-
cantly fluctuate, t-mass ensures high measurement accuracy (±1.0%) with excellent repeatability
(±0.25%). Gas flows with low pressure and a low flow velocity can also be measured easily.

Endress+Hauser, www.us.endress.com Input #204 at www.controleng.com/information

control engineering December 2020 • 43

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INNOVATIONS

BACK TO BASICS: DIGITAL AUTOMATION

Gregory Hale, ISSSource

Resiliency, security, automation

Manufacturing’s resilience has been strong during the COVID-19 pandemic, and cybersecurity

Ineeds to be stronger than ever as the nature of work changes.
t is becoming more important to talk about the “It is not the same electricity; it is about solar
booming levels of digitalization in the manu- energy, decentralized microgrids, net-zero buildings,
facturing automation sector, and rightly so, the and electric vehicles,” he said. “By combining those
increased connectivity and the hike in efficien- two disruptions, the future will be smart and green.”
cies continue to grow at a huge rate.
To reach that level of sustainability, the indus-
When talking about those increased levels of con- try has to grasp four elements to achieve a stronger
nectivity, however, what often is understood and never environment.
talked about out loud is how cybersecurity needs to be
the backbone of the entire endeavor. Part of that sense Leveraging digital efficiency
of assurance comes from the construction of the resil- “We get there by massively leveraging digital effi-
ient nature of the manufacturing enterprise, which has ciency; digital technology to reach a much better
truly come to light in the COVID-19 era. efficiency in every building and every city and every
“Think about the critical networks of our cities, the manufacturing facility,” Tricoire said. “As digital
water networks, the electrical networks, think about brings levels of efficiency to a much lower cost point,
the core chains of food, of pharmaceuticals, we were then we can increase the rate of retrofit in existing
there to support the reliability and the continuity of installations. The problem is with the existing stock
service of those processes,” said Jean-Pascal Tricoire, of buildings and manufacturing facilities, we need to
chairman and chief executive of Schneider Electric digitize the existing installations to make sure every-
during the Schneider Electric virtual Innovation Sum- thing we do is much more efficient.”
mit North America 2020. “And the one thing we have The second element of the equation is circu-
learned is that resilience comes from the automa- larity, he said. We have to develop a more circular
tion of processes that can keep going locally without economy, so we save on resources. The third point is
human intervention and that comes from digital mon- everything will be massively more electrical, Tricoire
itoring of installations. If your installation is plugged said. In the next 20 years there will be a much larger
in and if it’s under monitoring of analytics, of AI, then investment in electricity. The final point, he added, is
you are in a much better position to understand what that it will be green electricity.
is going on and prevent any breakdown. What we have “We are facing many crises at the moment,” Tri-
learned also is that one is as resilient as the weakest coire said. “Everybody is talking about COVID-19
point in their processes. Resilience is the sum of resil- and a recession and we are losing site that we are
iency and actually is a multiplication of the resilience facing climate change. Climate change M MINoNrOe VATIONS
of the grid, of the power system, of the building sys- remains one of the big problems of our
tem, of the IT system and of the process.” generation. We are the first generation
to know about climate change, but we
Remote collaboration, cybersecurity may be the last generation to be able KEYWORDS: digitalization,
cybersecurity, COVID-19
As we are adapting to this work from home envi- to change the course of climate change Manufacturing has been resilient
ronment, digitalization is growing by leaps and because this phenomenon is accelerating and strong during the COVID-19
bounds and it is making it possible to collaborate and needs us to change the trajectory.” pandemic.
remotely to increase agility and ensure operations Cybersecurity is an important, but
continue to move forward. If it isn’t already, digitalization will soon not always talked about, aspect of
be the way of the world. It has to be secure, manufacturing’s resiliency.
Digital really started 30 years ago when the inter- and the companies that take advantage of Digitalization is a transformative
net started to take off and it dramatically changed the efficiencies and advantages will be able – and disruptive – part of how
the way we live and work together, Tricoire said. We to achieve great dividends. ce manufacturing is changing for the
better.
are now in the second phase of the digital revolution
which is the Internet of Things (IoT) connecting us Gregory Hale is the editor and founder ONLINE
to machines and connecting machines to machines. of Industrial Safety and Security Source See additional stories from
On top of that, Big Data and artificial intelligence are (ISSSource.com), a CFE Media content Gregory Hale and ISSSource at
also major innovations helping move the industry for- partner. This article is from ISSSource’s web- www.controleng.com.
ward. Another disruption, Tricoire said, is the world site. Edited by Chris Vavra, associate edi- CONSIDER THIS
will become massively more electric. But it will be a tor, Control Engineering, CFE Media and What steps are you taking to
different kind of electric. prepare for manufacturing’s future?
Technology, [email protected].

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