Control Engineering Europe - All Articles

Invensys acquires SmartGlance Software

Tue, 18 Jun 2013 13:43:02 GMT

Invensys acquires SmartGlance Software

Invensys has announced the acquisition of the SmartGlance mobile reporting product of Sarla Analytics, LLC.

Founded in 2010, Sarla Analytics is part of The Sarla Group of software companies. Its mission is to leverage the power of enterprise mobility to increase productivity, reduce costs and streamline operations. SmartGlance, the industrial mobile reporting business app, delivers secure, on-demand access to rich, graphical reports from any operations data source via mobile devices, allowing industrial personnel to make smarter, faster decisions from anywhere, at any time and on any device. The SmartGlance product will become part of the Invensys Wonderware portfolio of software product offerings.

Commenting on the move, Rob McGreevy, vice president of platform and applications software Solutions at Invensys, said: “Acquiring this technology accelerates our delivery of solutions that leverage the power of mobile devices and managed systems via cloud and SaaS models. It strengthens our current leadership position in mobile industrial data reporting and reinforces our commitment to deliver access to information, analytics and KPI’s to a user’s device of choice.”

SmartGlance provides connectors for accessing data from different manufacturing sources, including both Invensys and non-Invensys systems. This offers customers real-time access to important business data alerts and notifications. It also allows them to view that information in a native mobile application optimised for any mobile device, such as smart phones and tablets.

SmartGlance also supports quick and more accurate decisions, giving the ability to take action, share data and collaborate with colleagues. Additionally, it gives the ability to push data from virtually any data source, including popular process historians and any SQL database.

“Many of our customers are already using SmartGlance to securely view or push their real-time and historical plant-wide data to mobile devices,”continued McGreevy. “With access to the right information at the right time, our ‘mobile’ or remote user base is able to assign resources and resolve issues quickly. Our customers span more than 750 registered devices used across several industries, including food and beverage, dairy, oil and gas, pharmaceutical, life sciences, mining, utilities and alternative energy markets, such as wind and solar power.”

Enthusiasm for energy harvesting returns

Tue, 18 Jun 2013 13:40:57 GMT

Enthusiasm for energy harvesting returns

Raghu Das, CEO at IDTechEx comments on the apparent increase in interest in energy harvesting technology.

2008 to 2010 saw huge enthusiasm and interest in the development of small energy harvesters. The substantial research of previous years was turned into commercialisation efforts for several new forms of energy harvesting.

Added to the commonly used electromagnetic and photovoltaic devices were piezoelectric, thermoelectric and others. In addition, much needed new forms of energy storage became available in the form of solid state lithium thin film batteries with growing work on supercapacitors.

Many in IC design were chasing the third need – ultra low power devices – driven, in part, by consumers desiring longer lasting consumer electronics in between charge times.
Target markets for these new devices were initially identified decades ago, with often disparate uses in consumer devices including solar powered calculators, movement powered watches and bicycles dynamos. Although interest in these areas continued, for many, wireless sensors became the primary target market for energy harvesting.

The interest dip
From 2010 through 2012 the sector began to loose steam. These were not new technologies being designed from scratch with years of fundamental research being needed – products existed but sales were not materialising in any significant way.
There are many reasons for this which IDTechEx has explored, but mainly it is cost, slow adoption of wireless sensors (which exist in islands of application but not yet the large volumes envisaged), supply chain fragmentation, and the lack of complete solution providers.

What’s next?
From many inputs across industry IDTechEx now sees positive signs. These include recent fund raising or acquisitions (LORD MicroStrain, Nextreme Thermal Solutions are some examples). Broader and exciting product portfolios are emerging from technology developers such as Microgen and system integrators including ABB and Logimesh. The big silicon companies are back with renewed focus. Some things are different compared to a few years ago though – less research on piezoelectrics, but more activity on thermoelectrics. And perhaps most importantly, there is a pragmatism around emerging applications, which, at least for wireless sensors, will start off in small closed systems providing rapid paybacks for adopters – such as fast adoption of energy harvesting powered sensors to monitor train wheel axles with many more applications emerging.

Vibration analyser promises faster data collection and analysis

Tue, 18 Jun 2013 13:38:43 GMT

Vibration analyser promises faster data collection and analysis

Emerson Process Management has introduced the CSI 2140 Machinery Health Analyser, the next generation of its portable tool for analysing machinery vibration to detect potential problems before they lead to unplanned downtime.

The new analyser is said to build on the capabilities of the CSI 2130, to provide new four-channel simultaneous data collection functionality, wireless and Bluetooth communication, and a full-colour touchscreen. The CSI 2140 is also said to deliver the fastest route collection capability on the market.

Data collection is over 50% faster than with other analysers, minimising the time spent in uncomfortable or dangerous environments and allowing technicians to complete the collection more quickly. The screen can be read in both direct sunlight and dark areas, and auto-adjusts based on ambient lighting.

With over 50% of mechanical issues being caused by bearing wear, effective monitoring of bearing health is a key component of a reliability programme. With four-channel data collection, users can collect vertical, horizontal, and axial readings on a bearing at the same time. Using this data and Emerson’s PeakVue technology, reliability technicians can detect compromised bearing performance earlier than with any other measurement technique. In addition, advanced diagnostics embedded in the CSI 2140 help users drive to the root cause of mechanical issues.

Most vibration programs require a cabled connection to the plant asset database in order to upload data for analysis. The CSI 2140, however, can send collected data wirelessly from the field to the office.

Additional CSI 2140 capabilities enable users to perform single, dual, or four-channel vibration analysis, cross-channel analysis, transient analysis, structural analysis, AC electric motor monitoring, and four-plane dynamic balancing – providing a complete, easy-to-use tool for fast, accurate assessment of rotating machinery health.

Integrated API-rated valves deliver system-level gains for wellhead OEMs

Tue, 18 Jun 2013 13:36:16 GMT

Integrated API-rated valves deliver system-level gains for wellhead OEMs

A new range of API-rated integrated valve assemblies from the Instrumentation Products Division of Parker Hannifin are said to offer wellhead equipment suppliers and operators the ability to make major enhancements to their 'Christmas tree' and related equipment designs.

The integration offered by the new valve assemblies reduces weight by up to 40% compared with double-block-and-bleed configurations using discrete valves, and can reduce space envelopes even further - by as much as 75%. Users can choose from a range of connection styles including flanged, welded, Grayloc hubs and Autoclave cone-and-thread connectors -– to suit the particular installation.

The new range offers integrated process-to-instrument interfacing solutions that reduce weight and size, and is said to eliminate many potential leak paths and risk, when compared with configurations based on discrete valves and connectors.

Parker's Pro-Bloc range of integrated manifolds for interfacing instrumentation to process piping, the Pro-Bloc API range integrates a complete double-block-and-bleed assembly of fire safe isolation and venting valves that is suitable for interfacing process pressure and temperature instruments. The assembly is available in three main forms – with ball valves, needle valves, or high-performance needle valves that can also meet the Class A or Class B ultra-low-emissions levels of the ISO 15848 standard. The new valve assemblies are initially available in three choices of pressure ratings: 5K, 10K and 15K PSI, and have been independently tested for conformance with the API 6A specification for wellhead and Christmas tree equipment.

Traditionally, OEMs and operators producing Christmas tree configurations and wellhead control systems have typically constructed any instrumentation interfacing subsystems required using larger process-sized valves that are rated to the API specifications preferred in this application sector. These systems have not benefited from the substantial size and weight savings – and designed-for-purpose flow paths –typical of the double-block-and-bleed manifolds that are readily available for instrument interfacing in other parts of the process world.

The integrated design also eliminates numerous interconnection joints, each of which is a potential leak path and source of unreliability, and system building cost; this can amount to a reduction of as many as four potential leak points compared to a system built from discrete valves.

The close-coupled flow paths inside Parker's Pro-Bloc API process-to-instrument valve assemblies are ‘purpose-designed’ to support accuracy of measurement. In the case of the ball valve variant of the design, the flow path is completely straight, with a uniform bore. It is not possible to create such a short flow path with a system based on discrete valves, and it can also be very difficult to avoid bends – and sometimes changes of bore sizes – that impact measurement accuracy by generating turbulence.

Parker developed these new integrated process-to-instrument interfacing solutions rated to API 6A after application-specific project experience on wellhead applications, and is now making the technology available to the wider market.

www.parker.com/ipd

ABB names Ulrich Spiesshofer as CEO

Tue, 18 Jun 2013 13:33:47 GMT

ABB names Ulrich Spiesshofer as CEO

The Board of ABB has unanimously appointed Ulrich Spiesshofer, the head of its Discrete Automation and Motion (DM) division, as chief executive officer.

He will succeed Joe Hogan in this role on September 15, after which, Hogan will continue with ABB for some months as senior advisor to the Board.

Spiesshofer joined ABB’s executive committee in 2005 and was named responsible for DM in 2009. He has led a doubling of the division’s revenues by organic and inorganic means, and the integration of Baldor. He has increased profit margins through a turnaround in robotics, as well as the profitable growth and relentless execution of the motors and drives activities.

“ABB has developed a strong bench of talent: I am extremely pleased that the new CEO comes from within the company, and brings a solid track record and deep knowledge of the portfolio,” said ABB Chairman Hubertus von Grünberg. “Ulrich has been a key force in shaping and implementing ABB’s strategy, and the integration of Baldor stands out as a benchmark for successful large acquisitions.”

Spiesshofer initiated other business expansion activities in DM based on organic growth and acquisitions. These helped the division to grow faster than the market and expand into new business areas such as e-mobility and UP), as well as to better balance the business geographically.

Current CEO Joe Hogan said: “Ulrich has done a tremendous job in DM based on the solid knowledge and experience acquired in many successful years within ABB and outside. With his strong contribution and team-oriented collaboration, our mid-term strategy has been making great progress.”

“I am excited about the opportunity to lead ABB and serve our customers, building on Joe’s success,” said Spiesshofer. “I am looking forward to keep working with all my colleagues in the executive committee and the entire ABB team. Together, we will continue to drive profitable growth and relentless execution for the company.”

Enhanced version of integrated production control system

Tue, 18 Jun 2013 13:30:57 GMT

Enhanced version of integrated production control system

Yokogawa Electric Corporation has introduced the CENTUM VP R5.03, an enhanced version of its integrated production control system.

Yokogawa has been continuously developing and enhancing CENTUM VP as a cornerstone of its Industrial Automation business’s VigilantPlant vision for operational excellence. In accordance with the strategies set out in its Evolution 2015 mid-term business plan, CENTUM VP has been enhanced with a variety of new functions.

New features in CENTUM VP R5.03 include a wide area communication (WAC) router for control via public communications networks, enhanced batch functions, easy integration with intelligent electric devices (IEDs), and an eight-loop operation keyboard.

Yokogawa has developed a WAC router that enables a CENTUM VP system to remotely monitor and control equipment over a wide area network (WAN) established using public communication lines, satellite links.

The WAC router provides the same reliability and security as the Vnet/IP control network that is used with Yokogawa production control systems. It compensates for limited bandwidth and transmission delays by prioritising communications based on data type and target. The router also has dual redundant communication modules. Each of these modules can be linked with the WAN by up to two communications lines. The router enables reliable and inexpensive monitoring and control of widely distributed facilities such as the offshore platforms used in oil and gas exploration and production.

The CENTUM VP R5.03 batch package is based on ISA-88 and has enhanced functions that allow greater flexibility when accommodating changes in production procedures. The number of operating procedures has been increased, and the recipe procedure has been given additional levels of granularity which is said to simplify the process of making recipe changes.

CENTUM VP R5.03 supports the IEC 61850 communication protocol, which has been widely adopted in the electric power industry and other industries that operate extensive electrical facilities. This latest version can integrate data from intelligent electric devices and can be used to monitor the operations at power plants whose electrical facilities have been designed based on the IEC 61850 standard, allowing better integration with power plant operations, and enabling the monitoring of electrical facilities at many other types of plants.

A new keyboard has been released with sets of dedicated function keys that can be used to simultaneously adjust eight control loops. For graphic, alarm, and trending operations, there are also dedicated control keys, operation confirmation keys, window call-up keys, a total of 64 special function keys, and keys for alarm acknowledgment and key locking. This keyboard has been designed to make it easier for plant operators to perform their tasks.

Reap the rewards of an integrated maintenance solution

Tue, 18 Jun 2013 13:21:32 GMT

Reap the rewards of an integrated maintenance solution

Managers of maintenance systems continually strive for leaner, more optimised work flows for asset repair and maintenance services. Gaining access to, and harnessing information, is key to achieving this goal. Suzanne Gill reports on one solution.

Many maintenance management systems still operate in isolation from other systems that contain valuable information. Having the ability to integrate a variety of systems to channel this information can provide a more efficient and effective way of servicing assets.

Greater system interoperability can also benefit other systems and their associated workflow. By having additional information on the maintenance and condition status of assets, for example, system managers can operate their departments more efficiently because they are able to make better informed decisions.

A recent whitepaper produced by Edward Garibian of eRPortal Software Group discusses the benefits of interoperating maintenance with ERP, GIS and HMI/ SCADA systems and presents the different approaches that organisations are taking to address this interoperability challenge.

Commenting on his own solution, the eRPortal, Garibian said: “Our core product is a maintenance management suite which automates the processes and tasks of overall operation of maintenance – both of the facility and machines – physical infrastructure and assets.

“eRPortal is completely independent so it doesn’t matter which MES or ERP systems are sitting at the top end or what HMI/SCADA system is lower down, the system will interoperate. It is an OPC client and also has .NET and ACTIVE X control which can reside inside the customers package of choice to give two way integration.”

The solution is retrofittable, sitting on top of systems already in place and communicating with these systems. It can be a hosted system. Garibian explains: “We offer a choice of the system being either hosted in a secure environment or the software can be licenced in a more traditional way for those preferring to self-host. However, if the system is taken out of this traditional model eRPortal takes over responsibility for maintenance of the system and ensures its uptime, taking away the need for dedicated internal resources.

“We have seen a steady move towards hosted systems over the past five years – going from 10 – 20 % using a hosted model to around 50%.

eRPortal can also offer a mobile asset management solution. Garibian said: “Interoperability can extend to information at the operators fingertips while they are out in the field. If a SCADA tag triggers an alarm or work order ERPortal’s mobile functionality it makes it possible for operatives to react to the incident much more quickly.”

Integration benefits
Integrating maintenance management and ERP, for example can help address the maintenance, operational, and financial challenges of industrial or other physical plant operations. With comprehensive and visible asset management, including reporting of usage, maintenance schedules, and costs, lean operations are achieved, organisational resources are better utilised, and cross-departmental functions are more closely aligned, with data being exchanged between critical functions, such as work requests, purchasing, inventory and preventive-maintenance scheduling.

By incorporating and allocating maintenance costs into the factory operating model, more accurate costs-of-goods-sold values are achieved. In addition, visibility and reporting of costs and incident details related to asset-downtime events and history allow improved communication and information sharing between maintenance personnel and operations.

HMI/SCADA integration
Maintenance management, integrated with HMI/SCADA systems, can provide a streamlined solution for efficient handling of assets. This includes the ability to synchronise with the plant-floor operating model by creating assets and their associated hierarchies each time a new piece of equipment is created in the factory automation system.

Once assets are identified and visible, the next step is to involve the utilisation optimisation of these assets. Maintenance management software that seamlessly integrates with HMI/ SCADA systems enables usage-based preventive maintenance processes.

Interfacing with the SCADA/control system allows the ‘tags’ that monitor the assets in real-time during production to be used to trigger condition or predictive maintenance work orders anytime a value falls out of operating specification. These rules can be setup to capture critical conditions before a major fault occurs. The work order triggered can be pre-configured to align with the conditions that occur and knowledge of the asset being monitored.

Large manufacturing firms will most likely already have a high degree of integration between asset management and other applications and functionality throughout the enterprise. Smaller organisations, however, more often implement point solutions – software that addresses each area or department individually. Due to the lack of integration among the systems, this can result in the need for a spreadsheet and paper approach to be taken in an attempt to fill in the information gaps caused by disconnected applications. The difficulty of this task leads many to simply operate as efficiently as they can with just the information from the maintenance management solution.

Even for organisations with limited deployment, consulting and process re-engineering resources, each department will define and implement a best of breed solution that can help to reduce costs. However, the ability for each solution to integrate with other systems is still critical and software applications that fit within set IT policies and platforms, and that are built upon an architecture of interoperability, can be deployed. A key attribute of the underlying software platform is the inclusion of protocols such as Web Services and XML, which facilitate integration with other systems.

Solutions that deploy a well-supported backend database, such as Microsoft SQL Server are also useful. In addition to facilitating integration with other systems, mainstream back-end databases enable support for additional third-party applications.

Another key attribute is to look for a browser-based front-end. This allows users to access the solution from any Internet connection and provides additional flexibility in adapting the solution to different situations.

A fully-automated maintenance solution should include comprehensive asset tracking and condition assessment, cost reporting, maintenance scheduling and work order management, and tracking of maintenance-related materials. From the all-important integration perspective, the solution should address this full spectrum of maintenance challenges with a web-enabled, open architecture.

www.erportalsoftware.com
www.adprosys.com (UK & Ireland distributor)

Quick wins blind manufacturers to long term energy savings

Wed, 12 Jun 2013 09:50:33 GMT

Quick wins blind manufacturers to long term energy savings

Manufacturers are still looking in the wrong places for energy savings, according to a new energy report sponsored by ABB.

The Works Management Energy Report 2013 reveals that when it comes to saving electricity costs, some 70% of manufacturers intend to make energy savings by switching off unnecessary lights, with 67% intending to invest in more energy efficient lighting.

Although easy to achieve, this focus on lighting costs is blinding manufacturers to the much more substantial savings that can be achieved with energy efficient motors and variable-speed drives.

Making compressed air use more efficient was also favoured by manufacturers. John Guthrie, energy manager for ABB’s drives and controls business in the UK said: “Reducing lighting costs is always worthwhile, but the real savings are achieved by reducing energy use within manufacturing processes.”

The survey reveals that many manufacturers are still not aware that motor driven applications account for some 65% of all electricity use in industry. Yet, only 10% of these applications have an efficient method of speed control to match motor speed with process demand. Targeting these energy intensive applications, like pumps, fans and compressors is the way to make substantial long term cuts in energy bills.

“Most companies can save thousands of pounds worth of electricity and some can even save hundreds of thousands of pounds by upgrading existing industrial processes, often at comparatively low cost,” said Guthrie.

Some 72% of respondents to the survey have seen their energy costs rise this year, a figure that is 12% up on last year. Fifteen percent have seen a rise of 10% or more and a third have seen a rise of between five and nine percent.

“The potential energy savings in industry are staggering. Realising these savings could help to substantially reduce CO2 emissions. However, once again, our survey suggests people are looking for savings in the wrong places and need to look beyond the obvious if they are to make a lasting difference to their costs,” Guthrie concludes.

Variable speed drive range launced

Wed, 12 Jun 2013 09:36:42 GMT

Variable speed drive range launced

Bosch Rexroth has unveiled its new series of variable frequency drives for general automation, materials handling, pumps, fans and conveyors.

Better known for providing tailored solutions, the EFC 3600 series, which will be available from The Inverter Drive Supermarket, sees Rexroth venturing into an ‘off-the-shelf’ product range.

The new variable speed drive range features both a Proportional Integral Derivative (PID) and a sequence control system, and allows energy-efficient operation of equipment and machinery at their optimal operating point. The in-built control systems also enable load dependant adjustment of the voltage and frequency curve, extending motor service life.

A high intermittent overload capacity of up to 200%, as well as high initial torque of up to 150%, means that the drives can be adapted for a range of uses including heavy duty and energy-saving applications.

Initially designed for applications in the 370W to 4kW range, the EFC 3600 also features integrated brake choppers and mains filters, reducing the need for additional components.

Speaking about the launch, Bosch Rexroth Automation specialist, Paul Streatfield said: “The new EFC 3600 series marks the first time that we have entered the low-cost, high-volume drives and controls market. This has been made possible by advances in technology, which mean that we can now provide intelligent drives that can be adapted for a wide range of applications."

Ethernet adoption in process automation to double by 2016

Wed, 12 Jun 2013 09:29:48 GMT

Ethernet adoption in process automation to double by 2016

According to a new study from IMS Research – now part of IHS Inc – Ethernet nodes in process industries are set to almost double from 2011 to 2016, as the technology increasingly challenges fieldbus for leadership in the industrial networking market.

Industrial Ethernet nodes in process industries are projected to rise to 8.7 million units in 2016, up 96% from 4.4 million in 2011. This means that industrial Ethernet will account for 45% of networked nodes connected in process industries in 2016, up from 39% in 2011. Such growth will come at the expense of fieldbus, anticipated to expand at a rate of 51% during the same five-year period.

“The process industry is renowned for being slow to adopt new technology,” said Tom Moore, analyst for industrial Ethernet and fieldbus technologies at IHS. “However, in some key areas, industrial Ethernet adoption is beginning to overtake fieldbus as the mainstream networking technology.”

A good example is within the process sector is safety. Although not always driven by compulsory legislation, process safety systems are updated fairly regularly by companies that want to ensure operator safety and maximise line up-time. This shorter life cycle means that new technologies can break into the market more quickly and are easier to implement, as there is greater opportunity for refreshing the network upon refitting.

“There is also a move to greater connectivity,” continued Moore. “Networking is becoming more of a commodity, which means that remote monitoring and control is more accessible. This is also true of discrete automation.

Process components and systems, such as remote terminal units and distributed control systems, are already widely networked. Approximately 95% of new-unit shipments are projected to be network enabled in 2016, up from 90% in 2011. “The increase is projected to be relatively slow, but is likely to reach 100%. Network-enabling products are now almost seen as a commodity and are expected by the process industry. As networking ability increases, the number of average nodes is also increasing. This enables the use of more elaborate networks and topologies,” Moore said.

The use of industrial Ethernet is expected to grow across industrial automation. IHS projects a compound annual growth rate of just north of 14% to 2016 for new process-automation networked nodes. The growth rate is well above that for new fieldbus nodes, envisioned to be less than 9% to 2016.

Fieldbus, does still have some advantages. HART, for example, a big part of process industries, is able to overlay signals on 4-20mA wiring, a major advantage for those with existing infrastructure. There is also the sizable legacy of some fieldbus solutions, which means that a large amount of machinery still uses older protocols.

Local energy distribution concept for IP 67 systems

Wed, 12 Jun 2013 09:23:25 GMT

Local energy distribution concept for IP 67 systems

The new EP9214 power distributor box from Beckhoff enables the local distribution and switching off of the power supply, providing the ability to exceed the power limitation specified by typical M8 plug connectors.

The IP 67-rated EtherCAT Box I/O modules typically use M8 plug connectors for supplying power, which according to the plug connector standard are only suitable for a maximum amperage of 4 A. Therefore, it may not be possible to simply loop the supply through when modules have a large number of outputs.

A further limitation concerns the cables: the M8 plug connectors can only be used up to a maximum cable cross-section of 0.34 mm2. If the cables from the control cabinet to the machine are long, an excessive voltage drop can occur at higher currents. As a result, the 24 V DC voltage (±15/20 %) can no longer be maintained and the modules or connected sensors/actuators may no longer work properly.

The EP9214 power box is said to solve these challenges. Equipped with 7/8in plug connectors, it maintains a total current of 16 A for each control and peripheral voltage with cable cross-sections of 1.5 and 2.5 mm2. Even higher starting currents are briefly permissible at the outputs, so that a trouble-free start-up of the connected devices is guaranteed. Wiring in the field using the power distributor box is significantly simpler and less expensive than equipping the system with additional terminal boxes with fuses.

The diagnostic and control functions of the EP9214 provide additional benefits. Apart from monitoring the input current, the currents in the control channel and the peripheral voltage channel are also monitored separately. In addition, the monitoring, limitation and, if necessary, the switching off of the power supply is possible for both channels. The EP9214 power box can be fully controlled via the EtherCAT network and the current diagnostics can be carried out conveniently via the controller. The eight 24 V DC voltage circuits can also be separately switched on or off directly via EtherCAT in order to increase the energy efficiency of the plant.

Anybus NP40 network processor rated best in class by Frost & Sullivan

Wed, 12 Jun 2013 09:10:09 GMT

Anybus NP40 network processor rated best in class by Frost & Sullivan

Frost & Sullivan has presented HMS Industrial Networks with the 2013 European Industrial Communication Processors New Product Innovation Award in recognition of its new network processor, the Anybus NP40.

High functionality, flexibility and easy integration were some of the features acknowledged by the research team at Frost & Sullivan.

The Anybus NP40 is the new network processor from HMS Industrial Networks and is the core component in the upcoming Anybus CompactCom 40-series.

Anybus CompactCom is a line of communication interfaces in chip, brick or module formats, which are embedded into industrial devices to enable communication with an industrial network.

The Anybus CompactCom 40-series, based on the Anybus NP40 network processor, supports all major industrial networks but is said to be especially suitable for high-end industrial Ethernet and fieldbus applications. The processor promises practically ‘zero delay’ between the device and the network and is suitable for high-performance applications with fast network cycles and synchronisation demands such as servo drive systems.

The Anybus NP40 processor allows the same CompactCom hardware to be used, to support several networks. For example, it is possible to install the CompactCom 40-series Ethernet hardware into an industrial device and simply download ready-made firmware to connect to the desired network.

After a benchmark of the available industrial communication processors on the market, Frost & Sullivan has deemed the Anybus NP40 to be the best available industrial communication processor. Frost & Sullivan research snalyst, Emil Lazarski, said: “Features such as an innovative design and high functionality, combined with the ability to support various industrial networks in a user-friendly and cost-effective manner, make these chips very attractive to diverse end users, such as equipment manufacturers who will have the possibility to offer universal communication interfaces to their customers. In addition, compared to competing alternatives, all solutions based on the NP40 can gain from having a highly integrated design and being more compact. This is beneficial for customers because they can easily integrate HMS Industrial Networks´ solution into their final product with a minimal physical footprint.”

Pilot valve terminal features flexible connections

Wed, 12 Jun 2013 09:06:08 GMT

Pilot valve terminal features flexible connections

The valve terminal VTOC from Festo is said to be particularly suitable for pilot control of process valves in the semiconductor, photovoltaic, flat-panel, biotech, pharmaceutical and process industries – and can now be specified with a customised pin allocation.

The valve terminal – for up to 48 3/2-way valves – can be used wherever safety considerations require pilot valves with spring return. It is said to be suitable for reliable pilot control in gas box applications owing to its separate conductive tracks and push-in connectors. It also features double-pin actuation of each coil, which means that the valves do not automatically switch through on the circuit board in the event of a short circuit. External isolation can be incorporated for additional interlocks.

The VTOC also offers multi-pin plug connection with Sub-D plug or flat cable with different outlet directions. In addition, the valve terminal can be connected on IO Link via an M18 connector, or to numerous Fieldbus and Industrial Ethernet networks using Festo’s modular node. The highlight, however, is said to be the customised pin allocation, which provides simple and safe configuration into critical control systems, whether a multipin or a communications network is used.

Industry prepares for the next ‘industrial revolution’

Wed, 12 Jun 2013 08:48:12 GMT

Industry prepares for the next ‘industrial revolution’

Industry 4.0 was high on the agenda of lots of exhibitors at the Hannover Messe this year. Referred to by many as the ‘fourth industrial revolution’ the concept of Industry 4.0 is to merge the virtual world with the real world, bringing IT and production closer together. Horizontal integration, from product to production, is one of its major ambitions. Industry 4.0 now also forms the cornerstone of the German government’s high-tech strategy to secure the competitiveness of German industry.

Siemens used Hannover this year to showcase how it, and its customers, will meet today’s challenges and shape the new production age. Speaking at the event, Siegfried Russwurm, CEO of Siemens Industry Sector, said: “Never before has the world of manufacturing and production technology been changing as rapidly and fundamentally as today.

Although Russwurm believes that there is some way to go before Industry 4.0 becomes reality, Siemens is already laying the essential foundations for its implementation. A decisive role will be played by industrial software which allows the integration of product development and production, and consequently paves the way for the holistic optimisation of product development and production processes. “The increasing penetration of IT and the growing integration of all industrial technologies are taking place in evolutionary steps from today’s perspective. However, looking back, the completely IT-based interaction between human, product and machine could prove to be a real industrial revolution,” said Russwurm.”
Before the Hannover event CEE spoke with Eckard Eberle, CEO of Industrial Automation Systems, Siemens Industry Sector, to find out more about Siemens views on the fast changing industry needs.

“Industry is getting more and more complex,” he said. “Products need to get to market in ever shorter time frames, which requires the whole development and production phases to be shorter too. This means that the product and production design processes will need to more closely collaborate in the future.”

Explaining further, he said: “The information created in the design phase needs to be used to a greater degree throughout the production process.” One example which shows how this can work to good effect is at a Rolls Royce facility in the UK. Originally it took more than one week, from conclusion of a product design change, to create a work plan for the shop floor. “Siemens helped the company to more closely integrate its system with the company’s MES. This allows the company to create the data and change the design. The new data then goes straight to the shop floor via the MES system. Today they are able to make changes within two to three hours, allowing the company to speed up the production process.

“We have many examples where such integration is taking place. However, we expect that, within the next 10 to 20 years, the entire data flow will be seamless.”

Safety challenges
As the automation landscape continues to develop with Industry 4.0, companies also face new safety challenges. The increasing trend for machine networking requires automation to merge with the IT world. The challenge lies in standardising the needs of both worlds to form appropriate, practical solutions. New safety objectives include, for example, the protection of production data, product and plagiarism protection, know-how protection, access protection integrity protection, and remote maintenance.

“Pilz is playing its part in ensuring that safety is recognised as a critical success factor in Industry 4.0,” said Susanne Kunschert, director at Pilz GmbH & Co. “We are advocating a holistic approach to protection in both its forms – safety and security. We want to use our experience from the machinery safety and automation sectors to drive this important work forward.”

On the product side, Industry 4.0 presents challenges for the modularisation and distribution of control functions. Pilz is pursuing a modular, distributable approach to enable the benefits of a decentralised control structure to be enjoyed without the increased complexity that would normally result when programs are distributed on different control systems.

Pilz predicts that, in the future, intelligent sensors and actuators in distributed systems will increasingly assume the functions of control systems. Improved interaction between machine modules, as well as between man and machine is the aim. Safe motion controllers, which are interconnected synchronously and safely via real-time Ethernet, already support local control and evaluation functions. Pilz is moving forward in this direction with its intelligent camera systems for safe, three-dimensional zone monitoring and camera-based protection and measuring systems.

PC-based technology
As a pioneer of PC-based control technology, Beckhoff has pursued the convergence of IT and automation technoloiges from early on and has introducted corresponding solutions to the market, such as Scientific Automation and TwinCAT 3. PC-based control from Beckhoff now enables universal vertical, horizontal and cross-company integration and therefore, says the company, provides an ideal basis for future Industry 4.0 solutions.

WLAN solution for safety-critical applications
Commenting on the OpenBAR-R WLAN solution from Hirschmann Automation & Control, a Belden brand, Prof. Dr Peter Frohlich, director of business development at Belden EMEA said: “OpenBAT-R will open up a wealth of new possibilities for wireless communication in automation, power generation and other critical applications.” Traditionally users demanding such high availability would not have relied on WLAN according to IEEE 802.11. However, the transmission reliability offered by OpenBAT-R, which depends on the company’s Clear Space technology, which can improve the latency and jitter caused by retransmissions by a factor of more than 10, which means that even real-time and safety applications are now possible via WLAN. “For example, it can make the control and visualisation of large and topologically complex wind farms more reliable and more efficient,” said Frohlich.

The new ‘Open’ platform makes it possible to realise wireless solutions in areas where this was not possible until now and allows users to choose the right product variant for the best solution, so they need only pay for what is really needed. The Open-BAR devices have enhanced shock and vibration stability, making them extremely suitable for use in harsh and demanding industrial environments such as power transmission and distribution, where thanks to remote service access application: operators can access internal networks from outside and as a result reduce the risk of entering areas with high tensions and in mining applications where the system’s vibration resistance allows the use of wireless links for equipment on vehicles, so intelligent devices can be used for the optimisation of processes and reduced risk of accidents.

Open networking capabilities
Control Techniques, an Emerson Industrial Automation company demonstrated the open Ethernet capabilities its new Unidrive M family of drives and how this can deliver maximum synchronisation accuracy.

A demonstration on the stand showed an open system, in which a Unidrive M drive controlled the synchronisation between two Unimotor HD servomotors monitored by a standard IP network camera – all linked by an open IEEE 1588 Ethernet network.

The new drive family benefits from an open creation environment offering machine designers the widest choice of components and meaning that they are not restricted by closed systems. The system uses the the CODESYS programming platform with standard IEC 61131-3 programming languages and standard Ethernet for communication across drives, I/O, HMIs, PLCs and other industrial devices. Connectitivity with PROFINET RT, EtherNet/IP, Modbus TCP/IP and EtherCAT devices, is also supported.

A lean strategy
A highlight on the Eaton stand was a demonstration of the implementation of its Lean Solution strategy, showing how connection and communication technology, automation and power management can be intelligently combined. Visitors to the stand were able to experience how they might implement savings and optimisation potential with their machines and plants. Lean power innovations incorporated in the model included PowerXL variable speed drives, and PKE motor starters which use the SmartWire-DT interface for improved monitoring and analysis.

SmartWire-DT is the company’s intelligent control panel wiring solution, designed to reduce panel complexity by consolidating complex circuit wiring into a single 8-pole cable. Connecting to Smartwire requires just crimping and connection to anywhere along the length of the wire.

For power distribution and power management, the company also showed new communication-enabled drawer units for motor control centres, which incorporate SmartWire-DT connection. This communication capability opens up the possibility of diagnostic functions that could simplify troubleshooting and reduce plant downtimes.