0d23edd0 3

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com
C-more around your plant!
Practical, Powerful and Priced Right
6 TFT Touch Panel

starting at:
EA7-T6CL-R ( w/serial port )
540.00 u.s.
C-more operator touch panels offer:

Clear TFT 65K color displays with 6 to 15-inch screens (6-inch STN models also available) Analog touch screen for maximum exibility Easy-to-use software
Our C-more remote HMI application, for iPad, iPhone or iPod touch, is available on the App Store for $4.99. It provides remote access and control to a C-more panel for mobile users who have a wi- or cellular connection.
C-more touch panels in 6 to 15 screen sizes are a practical way to give plant personnel easy access to controls and data. Check out the powerful yet easy-to-use conguration software by downloading a demo version at: http://support.automationdirect.com/demos.html ALL C-MORE PANELS INCLUDE: Analog resistive touch screen with unlimited touch areas One USB A-type and one USB B-type port Serial communications interface FULL-FEATURED MODELS ADD: 10/100Base-T Ethernet communications CompactFlash slot for data logging REMOTE ACCESS AND CONTROL BUILT-IN No Additional Hardware required. The C-more Remote Access feature resides in all panels with Ethernet support, and requires no option modules. Access real-time data or initiate an action on a control system from anywhere, any time. (Requires software and rmware version 2.4 or later*, and an Ethernet C-more panel)
6-inch STN grayscale
CONNECT TO CONTROLLERS WITH DRIVERS FOR: All AutomationDirect programmable controllers Allen-Bradley - ControlLogix, CompactLogix, MicroLogix Ethernet, SLC Series, FlexLogix, SLC 5/05 Ethernet Modbus RTU and TCP/IP Ethernet GE SNPX Omron Host Link Adapter (C200/C500), FINS Serial and Ethernet Selected Mitsubishi FX Series, Q Series Siemens S7-200 PPI and S7-200/300 Ethernet (ISO over TCP/IP)
Research, price, buy at: www.automationdirect.com/c-more

C-more touch panel family:
6-inch TFT 65,538 colors 8-inch TFT 10-inch TFT 15-inch TFT
12-inch TFT
$432 (serial) $540 (serial) $540 (adds Ethernet) $757 (adds Ethernet)
Starting at:
Starting at:
$1,081
$1,727
$2,051
$2,484
8 to 15-inch units include both serial and Ethernet ports
Order Today, Ships Today!

* See our Web site for details and restrictions. Copyright 2013 AutomationDirect, Cumming, GA USA. All rights reserved.
1-800-633-0405
the #1 value in automation
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I NEED SOLUTIONS, NOT EXCUSES.
Your products must perform perfectly, right from the start. And be delivered on time, every time. If those terms dont work for you. You wont work with me. Period.
Scan this QR Code* to learn more about Numatics products.
* Requires QR Code reader
Fluid power solutions. Right. Now.

When you need the right products available at the right time, make the right choice. Ultra-reliable offerings from Numatics have you covered for all major pneumatic applications, from air preparation and motion control to valves and accessories. Many carry the longest life cycle ratings available. Recent innovations include our new G3 electronics platform the industrys most user-friendly platform for advanced fieldbus electronics. Plus Numatics Express guarantees shipment of many of our most popular pneumatic valves, regulators, mountings, and cylinders within 2 days! When other fluid power suppliers cant deliver what you want when you want it, youre looking at it: Numatics.
The Numatics trademark is registered in the U.S. and other countries. The Emerson logo is a trademark and service mark of Emerson Electric Co. 2011 Numatics, Inc.
1-888-NUMATICS (686-2842) | www.asconumatics.com/RightNow | e-mail: insidesales@numatics.com
DECEMBER 2013
Vol. 60 Number 12
C OV E R I N G C O N T R O L , I N S T R U M E N TAT I O N , A N D A U TO M AT I O N S YS T E M S W O R L D W I D E
38
Photo iStock.com/Huyangshu
EOI
PLC
Logic processing
30
Features
30 Smooth motion control strategies
Graphics processing
Enterprise Ethernet Historical data Alarms Security
Display/ touch in
Device network
41
Integrated systems, efficiency, motion profiles: Automated guided vehicles integrate power, without batteries; Variable frequency drive configuration, high-efficiency operation, and permanent magnet motors; and motion based profiles, libraries ease integration.
35 Understanding optimizers: Adding APC to your APC 38 Capturing far-flung data
Given the number of process variables interacting at most plants, finding the optimum mix to maximize profitability is beyond manual capabilities.
Advancements in RTU technologies help optimize data acquisition and control.
41 Lean automation architectures
Technical advances lead to more efficient automation solutions.
44 Artificial intelligence tools can aid sensor systems
At least seven artificial intelligence (AI) tools can be useful when applied to sensor systems: knowledge-based systems, fuzzy logic, automatic knowledge acquisition, neural networks, genetic algorithms, case-based reasoning, and ambient intelligence.
CONTROL ENGINEERING (ISSN 0010-8049, Vol. 60, No. 12, GST #123397457) is published 12x per year, Monthly by CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Jim Langhenry, Group Publisher /Co-Founder; Steve Rourke CEO/COO/Co-Founder. CONTROL ENGINEERING copyright 2013 by CFE Media, LLC. All rights reserved. CONTROL ENGINEERING is a registered trademark of CFE Media, LLC used under license. Periodicals postage paid at Oak Brook, IL 60523 and additional mailing offices. Circulation records are maintained at CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Telephone: 630/571-4070 x2220. E-mail: customerservice@cfemedia.com. Postmaster: send address changes to CONTROL ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Publications Mail Agreement No. 40685520. Return undeliverable Canadian addresses to: 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Email: customerservice@cfemedia.com. Rates for nonqualified subscriptions, including all issues: USA, $ 145/yr; Canada, $ 180/yr (includes 7% GST, GST#123397457); Mexico, $ 172/yr; International air delivery $318/yr. Except for special issues where price changes are indicated, single copies are available for $20.00 US and $25.00 foreign. Please address all subscription mail to CONTROL ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Printed in the USA. CFE Media, LLC does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the material contained herein, regardless of whether such errors result from negligence, accident or any other cause whatsoever.
DECEMBER 2013 CONTROL ENGINEERING www.controleng.com
secure plan(t)
Proactive Protection for your Process Control Systems.

Honeywell offers a systemic approach to help mitigate the risks of the evolving cyber threat landscape. Industrial IT Solutions is a complete portfolio of services and tools that employ best practices in process control and cyber security. Honeywell global experts help users develop a security scheme to preserve key assets and ensure data availability, integrity and condentiality. Honeywells Industrial IT solutions deliver a more predictable and secure environment regardless of control system vendor or location. Securing a reliable, productive operation.
For more information go to becybersecure.com Or visit our blog at insecurity.honeywellprocess.com Also, follow us @insecculture
2013 Honeywell International, Inc. All right reserved.
Remote I/O Has Never Been More Rugged and Reliable
Whatever W hatever Your Your E Extreme xtreme

The Moore Industries NET Concentrator System connects instruments and systems via Ethernet, MODBUS and wireless technologies, while protecting your data from the real world. The NCSs rugged industrial design protects against RFI/EMI, ground loops, vibration and the most severe temperature extremes: -40C to +85C (-40F to +185F). Whether youre managing a local process, or need to collect data from locations across the globe, our NET Concentrator System is ready for your real world.
Wireless Network Module for More Remote Locations
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Visit our website and download one of our Process Control and Distributed I/O Networks Problem Solvers. Learn more about our Remote I/O products at:
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DECEMBER 2013
C OV E R I N G C O N T R O L , I N S T R U M E N TAT I O N , A N D A U TO M AT I O N S YS T E M S W O R L D W I D E
Inside Machines
Starts after p. 46. If not, see www.controleng.com/archive for December.
M1
Building a better, more efficient plant

Variable frequency drives (VFDs) can significantly impact energy efficiency goals by optimizing performance and reducing energy consumption by up to 50%.
M5 M8
Motion control: To network or not to network

Understanding how motion control architectures fit a particular application also can help in deciding what motion control network should be used.
Avoid a control panel redesign

If youre dropping packets with field networking for motion control and getting errors or alarms, consider these four sometimes counter-intuitive alternatives to a control panel redesign.
PRODUCT EXCLUSIVE
departments
8 Think Again
Automate, integrate, optimize, and protect
23 International
Intelligent automatic systems and software platforms
10 Product Exclusive
A roundup of 2013 products PRODUCTS
24 International
Control Engineering China 10th anniversary ceremony
12 Apps for Engineers

Data display, friction calculator, switchgear
25 IT and Engineering Insight

Drowning in data, starved for information
14 Security
Plausible deniability is not a security strategy
26 Machine Safety
New international standard covers interlocking devices on guards
16 Application Update
Transitioning to digital overspeed protection
27 News
More industrial Ethernet spending, saving with software reuse
New options for material mixing
60 Products
Servo motors; robot controller; small-scale DCS; wireless Ethernet
Integrated vision system helps speed lumber mill production
64 Back to Basics
Controlling level in surge tanks
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CONTROL ENGINEERING DECEMBER 2013 5
DECEMBER
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Control Engineering digital edition extras

Now with each new issue, the digital edition of Control Engineering features extra content that isnt included in the print issues. See what youre missing at www.controleng.com/digitaledition
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Control Engineering conducts quarterly editorial research studies on various industry topics. Access the following full reports at: www.controleng.com/ce-research
System integration
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Exclusive blogs at www.controleng.com/blogs Real World Engineering: Penny wise, pound foolish Machine Safety: Has Moores Law helped us? Automation System Integration: Communicate effectively in engineering project management Join the discussions at www.linkedin.com/groups?gid=1967039 Pneumatic control methods may not be cool, but they can be very useful Using integrated PLC/HMI devices for temperature control What utility do I need on my PC to look at PLC programs?
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VIDEO: Cyber security videos free for a limited time
Through December 2013, you can access Matt Luallens 13-part cyber security videos, including the PDH exams, at no charge in exchange for some information. In place of the $89.99 payment, there is a survey with questions asking how you do training in your facilities. Go to www.controleng.com/ CyberSecurityTraining or scan the QR code to the right.
Find content from Control Engineering magazines from 1997 to the present.
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Keep current with the latest information and news with electronic newsletters.
System Integrator Guide
Consult our listing of more than 2,300 automation system integrators. You can find a specific company or run a seven-way multi-parameter search.
Precision, and Flexibility
Unbeatable Control,
Lowering cost, increasing productivity, and shortening design times are just some of the challenges industrial engineers face. The graphical system design approach combines productive software and recongurable I/O (RIO) hardware to help you meet these challenges. This off-the-shelf platform, customizable to solve any control and monitoring application, integrates motion, vision, and I/O with a single software development environment to build complex industrial systems faster.
NI LabVIEW system design software offers ultimate exibility through FPGA programming, simplies code reuse, and helps you program the way you thinkgraphically.
>> Accelerate your productivity at ni.com/industrial-control-platform
800 453 6202

2013 National Instruments. All rights reserved. LabVIEW, National Instruments, NI, and ni.com are trademarks of National Instruments. Other product and company names listed are trademarks or trade names of their respective companies. 12125
editorial
THINK AGAIN
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Automation needs to be interconnected, optimized, and protected. Heres why.

For oil production equipment, remote asset monitoring and predictive modeling avoids costly breakdowns by benchmarking multiple locations to identify operating parameters outside the norm. A cement company uses active energy management controlling pump, fan, and conveyor efficiencies to see what was supposed to happen as opposed to what did happen. Energy use is now a controlled variable.
Get secure, 416 days
utomate systems where it makes sense. Optimize systems and integrate information for those who need it, provide context to add value, and make smarter decisions. See 416 reasons to get over any insecurity about implementing multi-layer cyber security processes and technologies. Automated and connected enterprises are optimized for rapid value creation and supply chain integration; they are collaborative, demand driven, compliant with standards and regulations, sustainable, and secure, according to Keith Nosbusch, chairman and CEO, Rockwell Automation. Connected enterprises can accelerate faster than competitors, Nosbusch said. The Internet of everything will create $14 trillion in value, and the greatest value, by sector, is in manufacturing at 27%, Cisco said. Enablers include cloud mobility, big data analytics, smart things, and security. Manufacturing generates more data than any other sector, according to a McKinsey report. Even so, data historically has been trapped in assets without context. The key is to use automation to break down barriers and create actionable information, augmenting quality and energy efficiency, for a broader set of users. Transform data to knowledge and eventually to wisdom, Nosbusch said. He said that using a unified network infrastructure for the enterprise with an integrated control architecture will better connect people for collaboration and faster problem solving. Examples include Kings Hawaiian, which integrates more than 11 production machines for remote monitoring of processes. Toyota has plant-wide visibility and analytics, with access to EPA data, views into root causes of lost production, and real-time access to oven temperatures, for a reduction of rework by nearly a third during one year, saving more than $300,000.
8
Contributing Content Specialists
Ekaterina Kosareva, Control Engineering Marek Kelman, Poland Editor-in-Chief Ekaterina Kosareva, Control Engineering Russia Russia ekaterina.kosareva@fsmedia.ru marek.kelman@utrzymanieruchu.pl ekaterina.kosareva@fsmedia.ru Marek Kelman, Poland Editor-in-Chief Luk Smelk , Czech Editor-in-Chief Marek Kelman, Poland Editor-in-Chief marek.kelman@utrzymanieruchu.pl lukas.smelik@trademedia.us marek.kelman@utrzymanieruchu.pl Luk Smelk , Czech Czech Editor-in-Chief Andy Control Engineering China LukZhu, Smelk , Editor-in-Chief lukas.smelik@trademedia.us andyzhu@cechina.cn lukas.smelik@trademedia.us
Suzanne European Editor Ekaterina Kosareva, Control Engineering Russia Suzanne Gill, Gill, European Editor suzanne.gill@imlgroup.co.uk ekaterina.kosareva@fsmedia.ru suzanne.gill@imlgroup.co.uk
What damage could someone do inside your computer and control systems in 416 days? Thats the average time before a cyber security breach is discovered, according to Michael Assante, advisor and director at National Board of Information Security Examiners. Every one of these had updated security software and followed recommended procedures, he said. What else should companies do? A few basic steps include scanning USB sticks upon insertion, doing a network password reset for all devices, and training, especially for system integrators, including newly available certification. Think again: Not all threats can be thwarted, but companies need to act diligently, or they will fall prey, Assante said. These comments came from sources at Automation Fair and associated events by Rockwell Automation in Houston during November. ce
Andy Zhu, Engineering Publication Andy Zhu, Control ControlServices Engineering China China andyzhu@cechina.cn andyzhu@cechina.cn Jim Langhenry, Co-Founder/Publisher, CFE Media 630-571-4070, x2203; JLanghenry@CFEMedia.com Publication Services
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Go Online
www.controleng.com/archives December has more information, photos, and links, including more cyber security advice.
Mark T. Hoske, Content Manager

MHoske@CFEMedia.com
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Success Story
Automation Unleashed
When a leader in automated systems for the aerospace industry needed a feature-rich Industrial Ethernet standard to network their AGVs, they chose PROFINET.
Fori Automation: Detroit, Michigan
I needed to combine motion, safety, and wireless. PROFINET does that.

Greg Stegner, Controls Project Leader
To learn more, read the complete application story at www.us.pronet.com. Or, simply scan the QR code.
product
EXCLUSIVES
2013 Product Exclusive roundup

Products introduced during 2013 in the Control Engineering Product Exclusive pages are listed below.
ontrol Engineering Product Exclusive pages introduce automation, controls, and instrumentation products. Those introduced during 2013 follow. Product trends include higher performance, ease of implementation and use, along with simplified information
scalable modbus solutions

for your
compactlogix
LITE
Modbus TCP/IP
240 I/O words 160 commands 10 clients 2 servers
enhanced
Modbus TCP/IP
Up to 10,000 words of data for large scale applications 320 commands 20 clients 20 servers
Modbus serial
240 I/O words 30 commands 1 serial port
Modbus serial
10,000 words of data for large scale applications 500 commands 2 serial ports
CompactLogix L2x
COMM ADAPTER
COMM ADAPTER
CompactLogix
RUN FORCE I/O OK NS
L24ER QBFC1B
ETH P1
CFG BP OK
CompactLogix
RUN FORCE I/O OK
L36ERM
NS LINK 1 LINK 2 SD
ETH P1 P2
CFG BP OK
LINK 1 LINK 2 SD
CompactLogix L3x
ETH
ETH
P1 App
P2 App
Where Automation Connects
+661-716-5100 support@prosoft-technology.com www.prosoft-technology.com/modbus
integration, presentation, and flow. - User-friendly data acquisition, test, and measurement software: High-performance Dataforth IPEmotion software is available with the Dataforth MAQ20 data acquisition and control system. - Fanless industrial PC doubles performance: Siemens doubled performance capabilities of its embedded Microbox PC and panel PCs. They are fanless and withstand 24-hr operation and harsh environments. - Transport Ethernet, power over existing two-wire installations: Using patented PCN IP-485 technology, PCN IP-Excite provides a robust and reliable way to transport Ethernet and Power over existing twowire installations. - Rugged and powerful panel PCs: Maple Systems has three new rugged PC400C Series panel PCs with Intel 2.3 GHz dual core processor, 4 GB memory, 250 GB hard drive. - Software wizard provides easy embedded motion controller setup: PMD ProMotion software offers axis wizard and support for digital amplifiers and embedded motion development, easing setup of embedded motion controllers. - Multi-purpose digital panel meters: Precision Digital PD6080 and PD6081 Super Snooper Modbus Scanners can display 16 process variables, including Modbus registers, and two analog inputs. - Motion card integrates high-performance amplifiers, motion control package: PMD Prodigy/CME Machine Controller Card integrates up to four amplifiers and a positioning motion controller on one printed circuit card. - Touchscreen PLC has IO, Ethernet: Maple Systems HMC7000 line of Graphic HMCs (human machine controllers) combine a touchscreen machine interface, PLC and I/O. - Entry-level micro PLCs join controller platform: Mitsubishi Electric adds entry-level Micro PLC to the FX3 Series. - HMI includes Microsoft Windows 7 industrial panel PC: EZPanel PC HMI from EZAutomation incorporates a Microsoft Windows 7 industrial panel PC. - Centralized remote data management for SCADA, PLCs: eWon eFive is for integrated, open SCADA and PLCs, replacing legacy dial-up and radio modems. ce
www.controleng.com/archives December includes links to each product for more information, or browse all products at www.controleng.com/products.
10
A S I A PA C I F I C | A F R I C A | E U R O P E | M I D D L E E A S T | L AT I N A M E R I C A | N O R T H A M E R I C A
DECEMBER 2013 CONTROL ENGINEERING
Pumped Up
Whether youre an OEM pump manufacturer, a pump assembler or a maintenance and repair professional, theres a BaldorReliance motor designed and manufactured for your specific motor-driven pump system application. With BaldorReliance low and medium voltage horsepower ratings to 15,000 in single or three phase designs including explosion-proof, close-coupled, vertical P-base, submersible and immersible, no other motor manufacturer offers more choices, quality or pumped up reliability than Baldor.
baldor.com 479-646-4711
Unmatched Quality
Superior Reliability
Global Sales and Support
American Made Since 1920
2013 Baldor Electric Company
apps for
ENGINEERS
www.controleng.com/AppsForEngineers
Data display, friction, mechanics, switchgear

CFE Medias Apps for Engineers is an interactive directory of more than 170 engineering-related applications for Android and iOS operation systems, created by various companies. The app helps users do their jobs better and save time, providing a pre-sort of relevant mobile engineering applications loaded with various calculators, catalogs, file viewers, measurement tools, and more. www.controleng.com/AppsForEngineers iQagent iOS 5.0
Cost: Free Company: iQuest Inc. Company Website: http://iqagent.com

iQagent is a holistic data display and recorder for industrial and process environments. It will allow you to make your plant oor a data rich environment where you can access live process data, documentation, and resource links on specic machines, equipment, and processes on the plant oor. iQagent also works with Apple TV, so the display can be shown in real-time to management without having to disturb production.
Friction Calculator iOS 4.0+
Cost: Free Company: T2 Content Works Company Website: www.magnaplate.com/

Based on General Magnaplates friction calculation tool, this application provides dynamic as well as static coefcients of friction (COF) for many pairings of regularly used materials and engineered coatings.
Mechanics Basics Android 1.6, iOS 3.0
Cost: $1.99 Company: FPC Ltd. Company Website: www.fpcapps.com/products.html

Mechanics Basics contains a large selection of laws, equations, tables and reference material that engineers may nd useful during their day-to-day operations. The application covers beams, measurements, gears, conversion formulas, and more.
ProductWhiz Android 3.1
Cost: Free Company: Larsen & Toubro Ltd. Company Website: www.larsentoubro.com/
ProductWhiz is an app that helps the user select switchgears faster and more accurately than previously. The app let the user to select Type 2 coordinated switchgear for IE1 / IE2 motors, star-delta / direct-on-line starter, fuse / fuseless short circuit protection.
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SCARA Robots
Mitsubishi Electrics line of powerful, precise and compact robots are ideal for applications requiring payloads of up to 20 kg. They are supported by a comprehensive range of simulation and programming tools and well-integrated options that make set-up faster and operations easier. Mitsubishis unique 2-year limited warranty provides you with peace of mind. Fully leverage all the benets of automation, including higher product and process quality, lower production costs and improved worker safety. Consider Mitsubishi Electric robots. Visit us online to explore how we can help you automate.
Ceiling-mounted SCARA Robots
www.MitsubishiRobotics.com
cyber
SECURITY
Plausible deniability is not a security strategy

Beware, you may have been instructed to avoid reading this article.
R
Matt Luallen Cybati
My early attempts to sell cyber security at a U.S. DOE National Laboratory failed horribly. I did not connect my efforts to the mission of the laboratory.
ecently I became aware of several legal departments advising managers to stay unaware of control system cyber vulnerabilities outside of specific information provided by their vendors. Why? If the vendor states that a system is secure, then the asset owner and operator may be able to claim ignorance and avoid legal liabilities associated with loss of life or the unavailability of a critical asset. Plausible deniability is not a security strategy for several reasons. First, many ICS (industrial control system) protocols (e.g., Modbus/TCP, DNP3, Profinet, EtherNet/IP, BACnet, etc.) can be vulnerable due to no authentication, poor authentication, the owners chosen implementation, and poor vendor implementation within the cyber asset. Consider recent vulnerabilities identified by Adam Crain and Chris Sistrunk with DNP3 (ICSA-13-291-01 and others), and expectations of more to come with Modbus/TCP. Second, a Google search of control system vulnerabilities yields 2.4 million hits. Third, new ICS cyber asset vulnerabilities are coming to light with ICS-CERT notices increasing rapidly.
So are you better off trying to build adequate levels of protection, or should you hope to hide behind plausible deniability? Your vendor might not help you with the latter. Many now issue disclaimers pushing responsibility back on you. They warn that their system must be placed within a secure zone of your facility and point at standards and organizations like NIST 800-82, ISA 99 / IEC 62443, IEEE, NEI, AGA, NNSA, ISO 27001, API, ChemITC, individual governments, and several more that I probably missed. Think about your role at your facility. Most companies want to ensure a Go Online level of profitability through a safe, reliable, and availControl Engineering has extended the time available able operation. Your perto access Matt Luallens 13-part cyber security trainsonal desire is food, shelter, ing course at no charge, including PDHs. Go to: and a safe environment for www.controleng.com/CyberSecurityTraining you and maybe a family. https://cybati.org The world has changed with Follow security vulnerability announcements at threat agents increasing in http://ics-cert.us-cert.gov/standards-and-references number and capabilities.
Hide, or defend yourself?
Some are sponsored by major military powers. You can be the change agent that brings about a cultural shift toward a serious defensive strategy. That responsibility fell on me many years ago, but my early attempts to sell cyber security at a U.S. DOE National Laboratory failed horribly. I did not connect my efforts to the mission of the laboratory or convince our Nobel Prizewinning scientists. The scientists wanted high availability of their research so that they could collaborate with the world, and my firewalls were interfering. Eventually, we put security in terms they understood. Instead of just focusing on cyber attacks, we explained, What if someone were to manipulate your data, release your data early, or under a different brand? That got their attention and they asked for security controls. The lesson: Every environment is different based upon corporate motives and ownership. You need to identify what will sell security in your organization. Dont wait for somebody elseyou do it, and do it now. Your company and your livelihood are at risk. Seek out an opportunity to start a change, if not at work, maybe where you live. Many control systems impact your environment: fresh water, natural gas, electricity, traffic control, your automobile, and the food supply. Attend a city council meeting and ask about protecting your local water supply. Ask your auto mechanic about the latest firmware update to your ECU or ABS. Cyber space is now a battlefield, and ICSs are vulnerable. Take steps to protect yours: inventory your assets, document their communication patterns and the logic operating them. Are there reasonable restrictions on people to operational, cyber, and physical activity? Establishing baselines of normal operation helps you determine when there is something unusual. Basic security principles apply whether youre dealing with physical or cyber security. Once you have the tools, you will begin to develop a sixth sense about whats happening in your networks. Overcoming budgetary restrictions and political resistance may take some doing, but you might be the thing that makes a difference. ce Matt Luallen is founder of Cybati, a security training and consulting organization.
14
break through the
NOISE
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3X
Higher
4.40
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1.57
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While transmit pulse amplitude (signal size) has helped to make guided wave radar technology the standard for accurate, reliable level measurement, the fact is signal-to-noise ratio (SNR) represents a far more critical indicator of level control performance. For superior SNR in all process conditions, no other GWR device beats the Eclipse Model 706 transmitter from Magnetrol.
To learn more about the breakthrough ECLIPSE Model 706 GWR transmitter visit eclipse.magnetrol.com or contact your MAGNETROL representative today.
magnetrol.com 1-800-624-8765 eclipse.magnetrol.com

2013 Magnetrol International, Incorporated
application
UPDATE
Pushing machines to the limit: Transitioning to digital overspeed protection

Understand rotating machinery designs and limits, conduct thorough analysis, and test for protection from overspeed catastrophes.
ngineers need to understand rotating machinery designs and limits, conduct thorough analysis, and test for protection from overspeed catastrophes.Operating machinery within designated limits leads to optimal performance and useful machinery lifecycle results. Running an engine too fast can lead to compromised employee safety, system failures, damaged systems, and unplanned downtime. Over the past five years, solutions are available to help eliminate potential risk factors and improve the overall safety and efficiency of plant operations.
Primary risk is overspeed
Go Online
www.controleng.com/archives December online version of this article also covers digital benefits, overspeed protection, lessons learned, and has related resources and links.
An overspeed event occurs when the system operates above the maximum allowable continuous designed rotating turbine speed. The consequences of running the turbine beyond its allowable continuous design speeds varies by turbine type and model and depends on several factors, including the duration of the overspeed event and the speed attained. Many turbine manufacturers typically design their rotors to be able to withstand up to 120% of the maximum allowable continuous operating speed. When a turbine operates beyond the designated operational speed limit, the stress on the machine may exceed the strength of the mechanical connection between the turbine blades and the rotor hub, resulting in operational failure and the potential release of blades from the rotor. With
Overspeed solutions help improve the reliability and protection for your most critical assets. Courtesy: GE Measurement and Control
16
some engines, even a momentary overspeed event can result in greatly reduced engine life or even catastrophic failure. The Electric Power Research Institute (EPRI) estimates that the destruction of a large steam turbine, combined with the value of the lost power generation, can cost a plant more than $100 million (R. Torok, 2006, EPRI). To prevent machinery from operating beyond the recommended limits, there are a few lines of defense. The first is the primary turbine control system, and the second is the failsafe, such as a mechanical emergency overspeed governor more commonly referred to as an overspeed trip bolt. Two primary control systems are responsible for the first line of overspeed protection on turbine applications, mechanical hydraulic control (MHC) and digital electrical hydraulic control (DEHC). The MHC turbine (the industry standard for decades) bleeds the emergency trip oil when an overspeed event occurs to reduce turbine speed. Most turbines with a MHC system have had one hydraulic oil system, where the same hydraulic oil was used for turbine bearing lubrication and the turbine control oil systems. These systems ultimately operated with poor quality oil, which in turn had negative consequences on primary and emergency overspeed control system elements. This has led to numerous instances where overspeed protection has failed to function properly over time in MHC applications. DEHCs use sensors, electronic hardware, and customized software that allow operators to identify potential problems before they occur. With DEHCs, plant operators can test their overspeed systems and controls, offline and online, without added system wear. Tests can be designed to occur at lower revolutions per minute (RPMs) speed and without the risk of shutting down the entire plant. The MHC to DEHC conversion eventually reduces scheduled maintenance and unplanned downtime, saving time and money. The transition period also provides an opportunity to upgrade the overspeed trip bolt and primary controls. ce - Darren Herschberger is a product line leader for GE Measurement and Control, a division of GE Oil & Gas. Jim Blanchard is product line manager for GE Oil & Gas. Edited by Mark T. Hoske, Control Engineering, mhoske@cfemedia.com.
simply. better.
Innovations to make your team more exible and efcient.

Experion PKS Orion employs a distinctive portfolio of scalable capabilities for innovative project execution and system management. Experion SCADAs superior HMI radically simplies engineering and operations over thousands of assets. Our SCADA solution provides equipment based conguration with minimal effort, automatically generated displays, pan and zoom interaction, dashboard style presentation and task based lters that focus the operators attention on whats important. Honeywell leads the way in utilizing process knowledge, making your team more exible and efcient.
www.honeywellprocess.com/pks
Come see the new Experion PKS Orion at the 2013 Honeywell Users Group EMEA in Nice. Register today.
2013 Honeywell International, Inc. All right reserved.
application
UPDATE
New options for material mixing

Shaken, not stirred: drives and controls enable novel, impeller-free acoustic mixing.
mechanical resonancebased mixing technology was developed by an industrial engineering and design firm, Resodyn Acoustic Mixers. ResonantAcoustic Mixing (RAM) relies on low-frequency, high-intensity acoustic energy at nominally 60 Hz to fluidize the mix and create a phenomenon called acoustic streaming and micromixing within the material. RAM blends various types of materials in precise ways often unattainable by traditional methods, while avoiding the Resodyns innovative ResonantAcoustic purity- and safety-related drawbacks of Mixing (RAM) technique blends various using impellers or blades. RAM techtypes of materials in faster, more precise nology also is much faster than tradiways than attainable by traditional methtional mixing and has mixed materials ods, while avoiding the purity- and safetywhere conventional mixers have failed. related drawbacks of using impellers or The RAM process requires excepblades. Images courtesy: Bosch Rexroth tional control of the machines powerful electric motors and drives, which produce resonant acoustics by spinning pairs of offsetting eccentric masses. By changing the phase angle of the offset between the pairs of eccentrics, the amplitude of the shaking of the mixing chamber is controlled. The vibration generated causes the mixture to interact in tune with the container producing the fluidization that permits even mixing throughout. Taking the motors in and out of phase with each other can create accelerations up to 100 g and results in an almost unlimited number of mixing actions. Rexroth IndraDrive M digital Resodyn recently upgraded its RAM 5 resointelligent servo drives offer nant mixing platform, which was limited to regenerative power capabilities volumes of approximately 5 gal., to a recently to divert kinetic energy from the launched 55-gal. version. machines servo motors to the We had a great concept, and we wanted to ac line. An embedded Rexroth take it to the next level where we could control the MLD PLC is designed for open machines production time, cost, and complexity automation and ideal for mulwhile saving our customers as much energy as postiple communications protocols. sible during mixing, said Resodyn senior engineer Brian Seaholm. The goal was to extend machine capabilities, not its size (35 sq ft) or intricacy. Go Online Resodyns first priority was to streamline the www.controleng.com/archives machine by limiting the number of machine comDecember has a longer version of ponents, reducing communications cabling, and this article, with more photos. improving the machines control capabilities. But www.resodynmixers.com that would mean updating and simplifying the www.boschrexroth-us.com programming and communications protocols. And Northwest Motion because operation depended on a unique Resodyn www.nwmotion.com black box computer, multiple communications
18
protocols would be required between the computer and the RAM 5 drives and motors. To meet the challenge, Resodyn called upon a machine control provider that had supplied electric drive technology to the first generation RAM 5. And, as Seaholm said, precise synchronization of RAM motors is needed, since speed and angle are constantly changing. Thats important because maintaining resonance, an enabling feature of the RAM technology, requires precise control of different specific vibration frequencies, and because uncontrolled resonance can do serious damage to the machine. Resodyn also teamed up with well-established fabricator Northwest Motion, which has the machine programming background needed to handle multiple communications protocols. That company had previously helped another client create a cement mixer using similar resonant technology.
New drive and controls
The first step in updating the RAM 5 was selection of digital intelligent servo drives, which integrate a modular power supply unit and drive system, and offer regenerative power capabilities to divert kinetic energy from the machines servo motors back to the ac line. That way, excess power could generate energy instead of excess heat as the unit shifts from consuming power to producing it. The drive platform provides a compact solution, and Resodyn knew it was ideal for motors in this multi-axis system. The drive supports the multiple communication protocols to communicate between the black box and interface PC. The servo drives were married with four liquid-cooled, high-speed rotary motors with maximum speed of 11,000 rpm. They synchronize the eccentric masses in two pairs, to impart force to the system. That combination gives Resodyn excellent power and a relatively small footprint, said Patrick OConnell, Northwest Motions regional motion control specialist. The next step was to ensure a smooth conversation between the communications languages and protocols controlling the mixing. A programmable logic controller (PLC) is embedded in the drive for added simplicity and reduced fabrication time and costs. This PLC is designed for open automation and flexibility of communication design, ideal for a machine that would require multiple protocols. Components are controlled and synchronized
in conjunction with our own computer controls, and their PLC supported this, said Seaholm. So the biggest factor in making everything work was the programming skill and experience of those involved in the project.
Harmonious partnership
The team chose SERCOS III for the main bus to keep the drives synchronized for exact positioning. Control between the Resodyn black box, the RAMs PC, and the master drive relies on OPC Server and RS232, sensing and responding to minute changes in the resonant condition. Encoder emulation allows the drives to report back to the black box. Machine control and I/O rely on analog signals as well as digital, with an analog link between the black box and the drives. Seaholm said this helped keep mixing within demanding specs and was important for recipe-based operation, with the operator inputting complete acceleration setpoint and timing instructions at the start of each job depending on the mixture. An Ethernet-based OPC Server connects the operator to the embedded PLC via the PC-based HMI. For controls, component engineering, programming code, and communications, engineers wrote
sample code for machine setup and testing. The cooperative effort created benefits customers wantand at a competitive price, said Seaholm, who estimates that the drive-based platform reduced each RAM units electronics costs by thousands of dollars. These savings extend to the newly launched Resodyn RAM 55 technology. Advantages include more precise, even mixing; mixing at various scales (macroscopic, microscopic, and even molecular levels); and cleaner, more reliable operation. RAM mixing makes it easier for manufacturers to meet strict pharmaceutical or cosmetics regulations, since theres no impeller to clean and no need to open chemical containers for mixing. Seaholm said the RAM 5 produces huge time savings over traditional mixingreducing one application from hours to minutesand that recipe-based input makes it easier for end-users to switch parameters between each mixing job. Drive regeneration and near power factor of unity, substantially reduces energy costs. We can help manufacturers get a competitive edge, Seaholm said, with the RAM 5 or 55. ce - Edited by Mark T. Hoske, content manager, Control Engineering, mhoske@cfemedia.com. See another photo, more details online.
control and I/O rely on analog signals as well as digital, with an analog link between the black box and the drives.
Machine
Mobility, Ethernet and Wireless Study

sponsored by
This study was conducted by Control Engineering to learn more about evolution and integration of mobility, Ethernet, and wireless technologies and how theyre helping users of automation, controls, and instrumentation be more productive. This study addresses:
Are mobile devices being used in the workplace, and what types? Do the mobile devices use Ethernet protocols? Which? Do the mobile devices use wireless protocols? Which? How are the mobile devices integrated with controls, automation and instrumentation? How is security implemented for these devices?
To view and download the study please visit:
www.controleng.com/2013MEWStudy
application
UPDATE
Integrated vision system helps speed production, maximize efficiency at Pleasant River Lumber
CASE STUDY: Integrating a new vision system can calculate the measurements of each tree-length log in about 7 seconds, 9 logs per minute, nearly 10 times faster than previously. Key concepts
Integrated vision system speeds production, maximizes efficiency at sawmill Tree-length log measurements are calculated in about 7 seconds, 9 logs per minute, nearly 10 times faster than previously.
leasant River Lumber produces more than 100 million board feet of spruce dimensional lumber and eastern white pine annually from its three mills in Dover-Foxcroft, Hancock, and Enfield, Maine. Mills like Pleasant River Lumber need to be highly efficient to stay competitiveand this efficiency needs to begin almost immediately after a tree is cut. The companys original approach to lumber processing, tree-length logsup to 64-ft long, the most economical for a mill to purchase were delivered to the mill yard where five manual slashers, large circular saws, cut them into 16-ft lengths, usually leaving a short piece as waste. Since the entire process was done manually on multiple logs at the same time, there was no optimization of the material or of the time and effort required to process it, said Christopher Brochu, one of the six partners who operate Pleasant River Lumber. A human being made a decision as to where to cut each log, and it was
impossible to determine accurately how to cut the log to get the greatest value from the material, Brochu said. In addition, operating the slashers themselves was expensive in fuel and labor, and the company lost money on the waste material, which often had to be trucked away.
Getting an optimum Look
To adapt to environmental conditions, the Teledyne Dalsa vision system offers automatic ambient light detection, changing the exposure time quickly to ensure needed contrast; overhead LED lighting provides greater consistency. All images courtesy: Teledyne Dalsa
20
When Pleasant River Lumber purchased its Dover-Foxcroft, Maine, mill in 2004, the partners committed to a $12 million investment to modernize the facility, including the part that processed tree-length logs for milling. Recognizing the benefit of leveraging technology for improved productivity and efficiency, the partners turned to Mainebased Progress Engineering, which specializes in designing and implementing process automation solutions, with forest products industry experience. Progress Engineering designed a hybrid system using solutions from a number of vendors, which would allow Pleasant River Lumber to increase efficiency by getting the greatest amount of fiber possible from each tree-length log. As Dana Hodgkin, the president of Progress Engineering, explained, the new process begins in the mill yard where each log is evaluated using a vision system that captures log images. Six ceiling-mounted color cameras work in tandem to take images of each log. Images are stitched together by a vision appliance and vision system software, which calculates the length and diameter of each log, with accuracy to within an inch, Hodgkin said. That data is then seamlessly communicated via Ethernet with a PLC optimization system developed by Progress Engineering. Progress Engineerings original design used a camera from another manufacturer, and Hodgkin cited problems with the prior design. The first camera we considered...didnt offer a way to capture a clear view of an entire log, which was critical to getting the accurate measurements that ensured the rest of the system operated as required. There were also challenges with the
Process Measurement
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OM-DAQ-USB-2401 $529
With tree-length logs up to 64 ft long, Teledyne Dalsas Geva Vision Appliance and Sherlock software calculate the precise length and diameter of each tree-length log in about 7 seconds, and communicate this data to a PLC which determines the optimum location for each cut. Six ceiling-mounted Genie 1600 color cameras take the images.
other cameras ability to operate in a rugged mill environment. When our first design failed, we researched alternatives. Since the competitive solution had challenges operating effectively in an environment where conditions, particularly lighting, changed frequently, ensuring the new vision system could work under these conditions was a key selection factor. One wall of the facility is open to the elements, which means that lighting, temperature, and even wind can vary from hour to hour. The vision system used offers automatic ambient light detection and can change the exposure time quickly to provide the right level of contrast between the log and the background for each image. Overhead LED lighting provides greater consistency. The vision system adapts to changing conditions, Hodgkin said, who praised the machine vision experts involved. Once the PLC system receives the data about the length and diameter of each log, it integrates with a new bucking systemequipment including log singulators and sawsthat forms the majority of the new production system. Manufactured by Endurance Equipment, this part of the system analyzes the data from the vision system, determines the optimum location for each cut, and then cuts each tree-length log in a process that is fully automated. Investing in this new system was critical for Pleasant River Lumber to become more efficient, and to be highly efficient, we need to get the most usable material possible from each log, Christopher Brochu said. Raw material accounts for 70% of our total cost, so the more lumber each log generates, the more competitive we can be. The new vision system begins the production process with precise measurements of each log.
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The changes have been so significant that Pleasant River Lumbers partners see few similarities between the new production process and the previous approach. In particular, they note that the vision system has helped them meet several of their key objectives, beginning with determining the accurate length and diameter of each tree. The critical starting measurement... enables the rest of the system to calculate exactly how a log should be cut, said Pleasant River partner Jason Brochu. Getting an accurate length and width measurement is vital because the saws on the new system are accurate to a quarter of an inch, but this is irrelevant if our initial measurements arent right.
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application
UPDATE
Another key objective was to speed processing time, and the new system increased production capacity. The vision system can calculate the measurements of each tree-length log in about 7 seconds, or evaluate about 9 logs per minute. This is nearly 10 times fasterand far more accuratethan our previous process, Jason Brochu added. In the highly automated process, an operator is involved for the brief second required to assure that the decision the system makes is accurate. There is an override capability if needed, if a log has a significant defect, for example, but since implementation, weve found that the system is accurate more than 95% of the time. The system also virtually eliminates waste. All lumber processing is now done at a central location, so we can capture everything from the small pieces that cant be used in production lumber to the sawdust and bark, Christopher Brochu noted. Then we can sell it all at a profit to get value for every by-product of the system. We now have a zero-waste operation, which aligns with our environmental goals, and gives us a new revenue stream. Lumber is a commodity, so the product itself has little to differentiate it from competitive solutions. Pleasant River Lumbers new automated system gives the company competitive differentiation in the marketplace, however, in that the dimensions of the lumber produced can be changed quickly to meet market conditions. For example, if certain lengths and dimensions are in greater demandand so are selling at a better pricePleasant River Lumber can cut its logs accordingly, meeting the demand sooner.
Dimensions match market
In a fully automated process, tree-length logs are cut based on measurement data communicated to a PLC optimization system. The Teledyne Dalsa vision system has automatic ambient light detection that changes exposure time.
Go Online
www.enduranceequipment.com www.pleasantriverlumber.com Progress Engineering www.progresseng.com www.teledynedalsa.com
Our new production system has made us more efficient, more productive, and more nimble, said Jason Brochu. Because we can work quickly and accurately, we have the flexibility needed to change the lengths as often as we need to, to adjust to the current market. With our old system, changing the length of the logs we cut was virtually impossible, Brochu said. The newly integrated vision system is a key element in a new lumber production system that has completely transformed business, Christopher Brochu said. ce - Maureen Clancy is marketing project manager at Teledyne Dalsa. Edited by Mark T. Hoske, content manager, Control Engineering, mhoske@cfemedia.com.
INTERNATIONAL
Intelligent automatic systems and software platforms
Control Engineering China interviewed Albert Huang, Advantech vice president for Industrial Automation Group, about how intelligent automatic systems and software platforms will help develop Internet of things and intelligent cities.
ntelligent automatic systems and software platforms will be applied toward development of Intelligent Cities and the Internet of Things (IoT) over the next five years, as outlined in the Advantech 2018 China Vision during the 2013 Advantech Automation Cooperation Partner Conference on July 12, 2013. The companys new Chinese slogan, Driving towards intelligent cities; become a leading example in the Internet of Things industry, replaces its prior one, Enabling an Intelligent Planet. The new slogan more clearly conveys Advantechs corporate mission for today and tomorrow in the Greater China region. During the conference, Paul Luo, president of Advantech China, announced that the company will integrate and merge its automation and industrial PC divisions and form a larger business division for the Greater China region. Advantechs industrial automation division will focus on vertical industries such as power and energy, traffic monitoring, production and equipment automation, environment and facilities monitoring systems, and intelligent agriculture solutions. The company also plans to actively push iAutomation as the framework for IoT development. The changes also are expected to help the company to further leverage its PC-based automation technology and provide a solution for industrial customers.
process and satisfying communication needs through one network and industrial Ethernet. OpenADM (Open Automation Device Management) is a cloud-based automation equipment management system, which includes automation products provided by Advantech and its partners. Advantechs automation equipment includes information extraction, controllers, I/O devices, human machine interfaces (HMIs), embedded industrial personal computers (IPCs), and more. OpenADM supports mobile devices and can be integrated with supervisory control and data acquisition (SCADA) and HMI. The IPC can be managed through the cloud, a new experience for the company and its customers.
Less configuration
Cloud technology, software
Among the steps Advantech took to initiate its intelligent automation plan for the next five years, the biggest steps seem to be in cloud technology and software. It is an obvious change for the hardware-oriented automation supplier. Albert Huang, Advantech vice president for Industrial Automation Group, noted that the companys latest three core automation products are: AdamNet, OpenADM, and WebAccess cloud service. AdamNet puts a programmable layer on its automation equipment (such as on-site information extraction equipment). It doesnt require an interface to transfer data and support the transmission of cloud data directly, streamlining the
WebAccess is an intelligent automation product in the IoT framework, a SCADA system that supports cloud technology, with a larger set of goals. Huang described Advantechs long-term vision: WebAccess aims to become a Totally Integrated Automation (TIA) Portal* to help Chinese people around the world. (*TIA is the Siemens unified software platform.) The Advantage open system automation software will integrate multiple management tools with SCADA under a common intelligence automation framework, eliminating long-term difficulties that users have with settings when parameters have not been automatically transmitted. Huang said: Automation products created under the Internet of Things framework must be based on Ethernet, support the cloud, and use an open system. In the future, WebAccess... will also be an open protocol-based management portal that could be connected to various equipment. For this goal, Advantech established a WebAccess+ IOT application alliance in November 2012 and partnered with computer industry companies to accelerate related business models and WebAccess development. ce - Andy Zhu is editor-in-chief, Control Engineering China. Edited by Mark T. Hoske, Control Engineering, mhoske@cfemedia.com.
Albert Huang, Advantech vice president for Industrial Automation Group, discusses how intelligent automatic systems and software platforms will help develop Internet of things and intelligent cities. Courtesy: Control Engineering China
Go Online
www.controleng.com/archives December has links to related information. www.controleng.com/international has more global coverage. www.cechina.cn
23
www.controleng.com www.controleng.com CONTROL CONTROL ENGINEERING ENGINEERING DECEMBER MONTH 2013
INTERNATIONAL
Control Engineering China 10th anniversary ceremony

ontrol Engineering China (CEC) staff and supporters gathered in the Shanghai Radisson Hotel to celebrate the publications 10th anniversary on Nov. 6, 2013. Business leaders from leading automation industry vendors and representatives of international organizations came to congratulate those involved. Jim Langhenry, Control Engineering publisher, CFE Media Group co-founder, and president group publisher, thanked the honored guests and addressed international automation trends in a keynote speech. Control Engineering China began China in 2003, expanding on prior exposure with Control Engineerings website and a prior publication, Control Engineering International. CEC has covered innovation in automation and controls, including product awards in all categories of industrial automation. It was the first to do a technical blog, online video seminars, and an industrial sector microblog platform. Control Engineering China and its mother brand, Control Engineering, influence Go Online Chinese engineer readers together. Today Control Engineering China, under the See additional coverage at framework of the Control Engineering www.controleng.com/international global network, integrates resources, colwww.cechina.cn laborates on coverage, and introduces Chi-
Automation and control industry leaders gather to congratulate, review manufacturing trends in Shanghai.
nese developments and practices to the world. To celebrate Control Engineering Chinas 10th anniversary, Control Engineering China and Plant Engineering China released a manufacturing blue paper for Chinese manufacturers, covering domestic manufacturing industry transformation, upgrades, trends, and technologies. Langhenry reviewed the following trends: - Machine to Machine (M2M) communications: Islands of disconnected automation are being connected as machines increasingly exchange information with each other, making decisions in closed-loop control. This is done with traditional industrial networks, and increasingly with industrial wireless and industrial Ethernet communications. Standards are important. - Industrial Internet: Companies are using the Internet and cloud (Internet-based servers and services) to exchange information from manufacturing to the enterprise and across the supply chain to analyze big data, optimize processes, and provide greater visibility to ensure information is getting to the right place, at the right time, to make the best decisions. - Internet of Things (IoT): Beyond M2M, each function of the control loop (sense, decide, and actuate) and other devices are connecting to the Internet, exchanging information, and making decisions, with and without human intervention. - Mobility: Building on trends mentioned, optimized information is being delivered in context-appropriate ways via industrial and commercial methods, such as smartphones and tablet computersmany enclosed in industrial enclosures and enhanced with mobile industrial applications, as provided in CFE Medias Apps for Engineers; see page 12 in this issue. - Cyber security: All of these require additional attention to cyber security. - Energy efficiency: Better information flow helps measure and optimize energy use. ce - Andy Zhu is editor-in-chief, Control Engineering China. Edited by Mark T. Hoske, content manager, CFE Media, Control Engineering, mhoske@cfemedia.com.
Automation and control trends
Jim Langhenry, Control Engineering publisher, CFE Media Group co-founder, and president group publisher, is shown with a display representing 10 years of Control Engineering China. Courtesy: Control Engineering China
24
INSIGHT
Drowning in data, starved for information
Ensure projects use 4 key practices to bring the value of big data analysis to your production floor.
IT & engineering
ig data is a big thing in information technology. Companies are collecting big data and analyzing it using sophisticated analytical tools to find hidden patterns and correlations. The shopping giant, Target, uses big data and analytics to determine when its customers have life changes, such as weddings, babies, and grandchildren, and then sends them individually targeted advertisements. Wouldnt it be great to be able to determine when your manufacturing systems have significant changes, such as failing equipment, changed raw material properties, or energy and labor costs, and to automatically determine the best operating conditions? That is the appeal of big data in manufacturing, and why manufacturing companies are starting big data projects for their production facilities. If you are starting a big data project, there are four important facts to remember.
1. Data needs context
of the historian data to an off-line system that is used for analysis or to consolidate the data into a data warehouse optimized for big data analysis.
3. Consider sample size
The first is that data without context has limited value. In the manufacturing world, context is provided by either the job or recipe step being executed. Each piece of data must also be associated with the job being executed or product being produced and with all associated quality measures for the job. This context allows job-to-job comparisons to detect significant changes. The first step in using manufacturing big data is to collect context or event information and link it to your plant historian. Fortunately, all major suppliers of plant historians provide event or context add-ons that can link MES workflows or recipe execution systems to the historian data. The second fact is that online historians are great tools for saving data, but not necessarily analyzing data. A good practice is to use offline copies or a data warehouse for analysis. Most plant data historians are optimized for writing data, and extracting the large amounts of data needed for big data analysis can take an extremely long time on a running system. A better strategy is to perform periodic backups
The third fact to remember is that you can prove anything with the right statistics. To prove the right thing, make sure that your sample size is large enough to determine correlations and causations. A small sample size may indicate invalid correlations and send you down the wrong path for corrections. It is also important to not confuse correlation with causation. Just because a correlation was discovered does not mean that the events are causally related. Data analysis can discover correlations, but there is still an engineering task required to determine if one is the cause of the other. It is important to have engineers or scientists involved in a big data analysis project so that real causations can be determined based on an engineering analysis and that data was not cherry-picked to find a correlation. The last fact to remember is that detecting patterns is something that people do naturally but is difficult to automate. You can use this to your advantage by empowering your people to search and discover in the data warehouse. Operational staff members often have deep knowledge of the production systems and relationships, and they can help discover hidden or non-obvious correlations. Adding context to saved data, working in a data warehouse optimized for analysis, objective storytelling, adequate sample sizes, appropriate conclusions about correlation and causation, and empowered personnel are key elements of a manufacturing big data project. Ensure your projects use these practices to bring the value of big data analysis to the production floor. ce - Dennis Brandl is president of BR&L Consulting in Cary, N.C. His firm focuses on manufacturing IT.
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Dennis Brandl President of BR&L Consulting
Operational
staff members
often have deep knowledge of the production systems and relationships, and they can help discover hidden or non-obvious correlations.
4. Empower people
2. Optimize for analysis
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www.controleng.com/archives has more under this headline. At www.controleng.com search related topics.
machine
SAFETY
New international standard covers interlocking devices on guards

Have you considered bypassing guard interlocks? Just-updated ISO 14119 Safety of machineryInterlocking devices associated with guardsPrinciples for design and selection may help. Six steps discourage defeat of safety interlocks.
H
J.B. Titus, CFSE, Certified Functional Safety Expert (CFSE)
ave you experienced any unintended ologies to mitigate hazards to acceptable levels. consequences of a temporary defeat In my opinion, we should always strive to reduce or bypassing guard interlocks? ISO the possibility to defeat or manipulate all guards 14119 Safety of machineryInter- maximizing safeguarding levels. locking devices associated with guardsPrinISO 14119: 2013 for interlocking devices is a ciples for design and selection has just been positive step in this direction. updated and could help mitigate these issues. A Type B standard, ISO 14119: 2013 Discourage defeat Recently, a blog post discouraged the defeatupdates the previous 1998 edition and harmonizes EN 1088 into one international stan- ing of safety interlocks. From that post, here are six pro-active steps to considdard. This update expands er for discouraging defeating original considerations to include additional technoloThis update expands of safety interlocks: 1. Update and/or conduct gies like RFID and electrooriginal considerations a risk assessment of your magnetic guard locking. It machine(s). also expands classifications to include additional 2. Review your safety culfor interlocking devices technologies like RFID ture to ensure that it doesnt and provides additional allow dangerous behaviors. requirements/specifications and electromagnetic 3. Evaluate the design of for installation. Extra care guard locking and access doors to make sure is provided for protection expands classifications that all conditions are met. against manipulation of 4. Train personnel and devices and guards in a reaand requirements. conduct audits on proper sonably foreseeable manner. procedures. Trapped key systems may 5. Document and keep not be fully addressed in your evaluation. In that case, you might find required records current. 6. Consider a certified safety controller to other application standards more helpful, like monitor your safe interlocks. ce ISO 13849-1, IEC 62061, or ANSI B11.19.
Risk assessment, slow speed
Generally speaking, risk assessments will identify hazards such that when a safety gate is opened, hazardous machine movements must be stopped or reduced to a safe slow speed. The same safety function could also apply to various removable guards, access doors, and other points of entry into hazardous situations where interlocking devices are applied. Safety experts are always paying special attention to all precautions, training, signage, and engineering method-
- J.B. Titus, Certified Functional Safety Expert (CFSE), writes the Control Engineering Machine Safety Blog. Edited by Mark T. Hoske, content manager, Control Engineering, mhoske@ cfemedia.com.
Go Online
www.controleng.com/blogs For engineering interaction, go to this blog for more on machine guarding and safety standards and leave your comments or questions.
26
industry
NEWS
Ethernet products and services spending and productivity
Almost half or respondents expect their Ethernet products and services spending to increase next year, while 43% dont foresee any change. Forty-nine percent of respondents believe that productivity as it directly relates to Ethernet will increase at their location in the next 12 months.
More industrial Ethernet spending, more productivity

The outlook for Ethernet spending is increasing, along with anticipated productivity gains, according to recent Control Engineering research on mobility, Ethernet, and wireless. Control Engineering, part of CFE Media, performed the research, in part, to better understand how users of automation, controls, and instrumentation are integrating Ethernet communications (which can support mobility and wireless technologies). These technologies are key components in plant to enterprise integration, industrial Internet, Internet of things (IOT), big data analytics, and manufacturing optimization. In the next 12 months, nearly half of survey respondents expect to spend more on Ethernet and increase productivity by about the same amount. An additional 40% expect to spend about the same on Ethernet products. The most common products used, specified, and purchased include switches, wire or cable, networks, connectors, and routers. When asked how integrated Ethernet is with controls, automation, and instrumentation, highly integrated was the most common answer. Control Engineering surveyed readers in October. Survey results from 200 respondents, analysis, and graphics comprise the November report on mobility, Ethernet, and wireless technologies. The summary results below focus on Ethernet. The survey results specific to mobility and wireless will be addressed in a later article. In this Control Engineering research on Ethernet: - 46% of respondents see Ethernet as highly integrated with controls, automation, and instrumentation, and 40% see Ethernet as somewhat integrated. - Around 60% of whats spent on Ethernet goes to products. Services get somewhat less. - Among those working on Ethernetrelated projects, operations/engineering and business IT were the most common, with manufacturing IT, system integrators, and consultants working on Ethernet somewhat less.
Products and services spending outlook
6% 43% 40% 9% 3%
Productivity outlook
4%
Decrease
41%
Remain the same Increase
40%
Significantly increase
9%
8%
Not sure
Nearly half of respondents expect to spend more on Ethernet in the next 12 months and increase productivity as a result, according to Control Engineering 2013 research on Ethernet. Courtesy: Control Engineering Mobility, Ethernet, and Wireless Study: Ethernet results
- Ethernet, industrial mobility, and wireless technologies are used 77% on the plant floor or operations areas, and half of respondents use these technologies to interconnect the plant floor with the enterprise. - Most used Ethernet protocols among respondents were EtherNet/IP, TCP/IP and UDP, Modbus TCP, ProDont do this with your Ethernet installation: Learn finet, and EtherCAT. - Around 40% of respon- about Ethernet technologies, applications, and dents said Ethernet was easy market trends in a two-part Ethernet webcast series to install; about the same offering a professional development hour for each. described it as more chal- Speakers include Mike Robbins, Network Engineering Manager, TriCore Inc., and Steve Schneebeli, lenging to implement. - Data access is the great- director of engineering/IT, Malisko Engineering. This est technology benefit of image is in Schneebelis presentation. Ethernet, cited by 63% of respondents. Two Control Engineering webcasts, - Security along with lack of train- offering one professional development ing, education, and support are among hour (PDH) credit each, cover the topmajor adoption challenges. ics of Ethernet technologies and case More graphics, more about respon- studies. www.controleng.com/webcasts dents, and more details and analysis - Mark T. Hoske, Control Engiabout this Control Engineering Ethernet neering, mhoske@cfemedia.com. CFE research is available. Search on 2013 Medias Amanda McLeman helped with Mobility, Ethernet, and Wireless Study survey preparation, compilation, and at www.controleng.com. analysis.
www.controleng.com
industry
NEWS
Standards-based software is easier to move from site to site, to upgrade, and to improve incrementally, suggested Peters. One customer, in the process of a multi-year software-upgrade project, ultimately was able to take software developed for a North American facility, put it on a USB stick, and then adapt and install the software in the customers Asian facility for 20% of the cost of the original, Barker said. Project costs for project commissioning were 10% less than expected. Standard project templates and an organized framework within the software helped decrease the time to adapt already configured applications to the new site, he explained.
Software structures
Create value through software reuse

Value of software standards was among automation system integration topics discussed by Mike Peters, director of sales, and Andrew Barker, PEng, director advanced control systems, Callisto Integration, at the Invensys 2013 Software Conference and Tech Support Symposium in October. Online see comments in a 3-minute video.
Motion control company to be acquired, integrated

Rockwell Automation announced it will purchase Jacobs Automation, a motion control company, and integrate it into Rockwells Automation Motion Business. Rockwell Automation (NYSE: ROK) announced that it has agreed to purchase Jacobs Automation, which specializes in track motion control technology. Jacobs Automation provides a motion control solution called the iTrak System. This technology is designed to performance across a wide range of packaging, material handling and other applications for the global machine builder market. iTraks technology enables independent control of multiple magnetically propelled movers on straight and curved paths. The system enables machine and equipment builders to reduce cost and complexity, while allowing end users to standardize on one platform for better optimization, improved reliability and faster system deployment. Jacobs Automation, based in Erlanger, Ky., will be integrated into Rockwell Automations Motion Business, within its Architecture & Software segment. The acquisition is expected to close January 2014.
Structuring software with reuse in mind takes more effort up front than single use, especially if those doing the configuration havent done it that way before, Barker noted. When a new product is developed in North America, it can be e-mailed to the Asian plant, where it can be in production there within a 48-hour period, Barker said. Food and beverage and SCADA solutions are more easily built in scalable fashion over time, using off-theshelf offerings, achieving a great return on investment (ROI), Peters noted. And software configuration help is available.
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New redundant feedback switching
Danfoss finishes acquisition of Sauer-Danfoss, expanding North American investment

After more than 10 years as part-owner, Danfoss has brought the Sauer-Danfoss business wholly into its business structure through an acquisition announced earlier this yearexpanding the companys business to include mobile hydraulic and electrohydraulic solutions. With North American headquarters in Ames, Iowa, the acquisition of SauerDanfoss signifies Danfoss continued dedication to the North American market, the companies said. As part of the acquisition process, Sauer-Danfoss changed its name to Danfoss Power North America Solutions, a new business segment is the largest within the Danfoss Group. market for Danfoss, Danfoss purchased the remainexpansion ing shares of Sauer. As part of the continues; Danfoss acquisition process, Sauer-Danfoss changed its name to Danfoss Power Power Solutions Solutions, a new business segment operates as a within the Danfoss Group. business segment In March 2013, Danfoss and Sauerin the Danfoss Danfoss announced that the companies signed a merger agreement, Group. wherein Danfoss acquired the 24.4% of Sauer-Danfoss shares that it did not already own. Globally, in 2012, Sauer-Danfoss had revenues of approximately $1.9 billion; Danfoss global net sales were approximately $6 billion. North America is the largest market for Danfoss, explained John Galyen, president, Danfoss North America. Were continuing to invest and expand our footprint here, and the addition of Sauer-Danfoss is another hallmark of our dedication to growth in the marketplace. Full acquisition also is a milestone for Danfoss globally, the company said. This is an extremely important step for the entire Danfoss Group, noted Danfoss president and CEO, Niels B.
Down with Downtime!

Its easy to up your uptime with redundant sensors and Delta.
Deltas motion controllers provide a multitude of feedback options, including input from redundant sensors. Now when a sensor fails, your system can keep running. See a demo and get a free Design Guide. Just call 1-360-254-8688 or visit deltamotion.com
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Christiansen. Sauer-Danfoss is a well-run global company, so, for us, it marks the convergence of two equal units that will become stronger as a result. Alstrm added, The merger also ensures our customers a high degree of continuity. Danfoss has had a long-standing relationship with Sauer-Danfoss through its board-level involvement, and has helped shape our existing strategy that we will continue to pursue.
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cover story
Smooth motion control strategies

Integrated systems, efficiency, motion profiles: Automated guided vehicles integrate power, without batteries; Variable frequency drive configuration, high-efficiency operation, and permanent magnet motors; and motion based profiles, libraries ease integration.
Automated guided vehicles integrate power, without batteries

Key concepts
Battery-free automated guided vehicles (AGVs) use inductive power transfer. AGVs integrated with automation and tracking software. Assembly line doubled throughput without an increase in staffing or floor space.
uperiorControls doubled assembly line throughput without more floor space or staffing by integrating battery-free automated guided vehicles (AGVs) with controls and manufacturing execution system (MES). A manufacturer of large, off-road vehicles had three objectives for an existing assembly line: 1. Significantly improve throughput without increasing floor space or staff 2. Create a type of assembly line which would be highly scalable for future change and growth 3. Implement appropriate use of new automation where it made financial sense and retain manual processes where they made sense.
The new assembly line using battery-free automated guided vehicles (AGVs) instead of traditional chain-based assembly line conveyance. A return on investment (ROI) approach was used to design the new line, with consideration for using automation where it was cost-justified while retaining manual processes where the expense of automation was not justified. The line has doubled throughput without an increase in staffing or floor space. The customer chose inductive-power based, intelligent conveyance, which requires installing data and communication cables in shallow channels with a flat floor finish. By choosing this type of conveyance integrated with software, controls, and manufacturing execution system (MES), changes to the lines path and processes can be implemented with minimal production disruption. Multiple battery-free AGV lines were installed for this customer in the United States; additional locations worldwide are under evaluation.
Station to station
Automated guided vehicles can advance asynchronously with careful integration of multiple systems. Courtesy: SuperiorControls
30
Customer benefits include: 1. Fast flexibility and scalability: 90% of the investment is above ground and line changes are minimally disruptive to production. Instead of hiring hundreds of millwrights to take down and install thousands of pounds of steel, the line can be re-routed or expanded with software and controls updates along with minor floor alterations. 2. Asynchronous indexing: Battery-free AGVs move from station to station when work is complete, untethered to any other station. This improved efficiency. 3. Chain-free paths: Unequal task times can
be managed by multiple assembly paths without coupling or decoupling or elaborate transfer methods. This saved time and increased throughput in areas such as test, where the vehicles do not wait in line to enter the test cell or decouple. 4. Full worker access: By eliminating chains, skillets, and tracks, workers have 360-degree access to the vehicle under production. This is important where manual processes are involved and improves safety, efficiency, and ergonomics. 5. Safer worker environment: A flat floor, free of pits, chains, and obstructions, eliminates the associated trip hazards. Battery-free AGVs sense an impediment and stop when the path is crossed. 6. Intelligent manufacturing: MES modules include error proofing, traceability, vision inspection, kitting, sequencing, and factory information systems, depending on customer requirements. 7. Customized AGVs: Each AGV is custom designed and can carry tools and cables. For the application shown, testing cables travel with the AGV, so that quick-connects for each type of vehicle are immediately available for the testing process. The AGVs were designed to accommodate multiple vehicle types and future vehicles. 8. Battery-free AGVs as opposed to batterypowered: No extra AGVs are needed to compensate for battery failure. There are no charging
Assembly lines can run more quickly when using battery-free AGVs, compared to more traditional methods of moving lines, according to SuperiorControls. Inductive power transfer (IPT) is used to convey heavy loads. Courtesy: SuperiorControls
stations and no battery safety or disposal concerns. 9. Conveyance prove-out: A battery-free AGV test track can test AGVs prior to shipment and reduce installation time at the customer location. - Rod Emery is vice president of Superior Controls. www.superiorcontrols.net
Variable frequency drive configuration, high-efficiency operation, and permanent magnet motors
ermanent magnet alternating current (PMAC) motors are seeing increasing demand in variable-speed, high duty-cycle motion control applications due to their higher efficiencies and energy saving potential across different speed and torque ranges. Figure 1 shows an example of motor efficiency in a 3 hp fan application, with a high-efficiency PMAC motor demonstrating a 5%-12% efficiency improvement over an induction motor. A variable frequency drive (VFD) is needed to control both PMAC motors and induction motors in variable speed applications. VFD configuration for PMAC motors and other considerations can lead to optimal system performance, which can mean the difference between success and failure in achieving the desired energy savings in motor applications. The term PMAC is used to designate permanent magnet motors that have sinusoidal back-EMF (back electromotive force) and can be efficiently driven by three-phase sine wave output VFDs. Brushless dc or permanent magnet dc motors are those with trapezoidal back-EMF driven by simple trapezoidal output drives. PMAC motors sometimes also are referred to as brushless PM or ECPM (electronically commutated permanent magnet).
Sensorless control, configuration
Key concepts
Properly configure variable frequency drives for permanent magnet alternating current (PMAC) motors for optimal system performance and desired energy savings Heed safety concerns if PMAC motors rotate in an unpowered state.
In the last few years, many of the major VFD manufacturers have introduced sensorless PMAC motor control capability to their lowcost drive models. Previously, use of permanent magnet motors was restricted to servo systems or specialized applications employing closed-loop feedback control. PM motors were effectively excluded from fan, pump, and other workhorse applications because of the cost and installation complexity of the associated closed-loop control systems. Now, with the addition of sensorless PMAC control algorithms to VFDs, the opportunity exists to reap the energy-saving benefits of permanent magnet motors in a wide range of variable-speed, high duty-cycle applications. Configuring VFDs for sensorless PMAC motor control is more complex than induction motors. 1. Induction motor control algorithms have been developed and refined over two decades;
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cover story
VFD control strategies differ significantly for IPM and SPM motors.
sensorless PMAC control is relatively new. 2. More variability exists among different vendors PMAC motors than for induction motors. VFD configuration for induction motors has reached the maturity of a routine operation: Nameplate motor characteristics are entered into the VFD, an auto-tune procedure is typically run, and the induction motor is then ready for use. With PMAC motors, more motor data may be required, including information not provided on the motor nameplate. PMAC motor performance may vary considerably with different VFDs, and is dependent on the suitability of the specific sensorless PMAC control as well as proper entry of the appropriate parameter configuration into the VFD. When selecting a VFD for PMAC motor operation, consult the VFD and motor manufacturer for technical advice. The PMAC motor manufacturer will likely list or recommend qualified drives verified to deliver the efficiency and robust performance for the PMAC motor design. They may also have developed, optimized, and tested VFD configurations, in a packaged solution with a PMAC motor and pre-programmed VFD.
PMAC motor characteristics
provided as a packaged solution, it is necessary to know the characteristics of the PMAC motor, and understand the specific control algorithms offered by the VFD. This information is required to determine if the motor-drive combination can meet the motion application performance goals.
Motor winding inductance
In addition to standard motor nameplate characteristics shared with induction motors (rated power, rated speed, rated frequency, full load amps, and nominal voltage), the PMAC motor characteristics of winding inductance, winding resistance, and motor back-EMF must be properly configured in the VFD. VFD auto-configuration for PMAC motors is improving. Several manufacturers include autotuning procedures that remove some requirements for manual VFD parameter configuration. In situations where the PMAC motor and VFD are not
PMAC motor designs fall into two primary categories: surface mount magnet (SPM) designs and interior permanent magnet (IPM) designs. IPM motors exhibit winding inductance that varies with rotor angle. Maximum motor winding inductance occurs at the quadrature-axis of rotor position and is termed q-axis inductance (Lq); minimum winding inductance occurs at the direct-axis and is termed d-axis inductance (Ld). SPM motors have winding inductance that is nearly invariant with rotor position (Ld Lq). Variance of winding inductance with rotor angle is termed magnetic saliency and may be represented as a percentage change ((Lq Ld) / Ld) * 100.0). SPM motors have negligible saliency; IPM motors have saliency from a few percent to 100% or more depending on the motor design. Figure 2 shows the winding inductance of an IPM motor with 20% saliency. VFD control strategies differ for IPM and SPM motors, particularly in the choice of suitable motor start algorithms, and in optimization of motor speed capability in the constant power region. Figure 3 shows the regions of motor operation. For accurate configuration of VFD inductance parameters is essential to achieve optimum torque output and motor efficiency for IPM and SPM motors. Magnetic pole position must be determined in a PMAC motor before rotation can begin. The PMAC-capable VFD may provide the ability to choose among motor start algorithms, each having a required level of magnetic saliency. An IPM motor, with a sufficient level of saliency, may allow the VFD to employ a high-frequency injection method where a high-frequency voltage signal is applied to the motor for a short period. The resulting current amplitude, which depends on rotor position, can be measured and used to determine rotor position without shaft rotation. SPM motors do not have magnetic saliency and require alternate methods of initial rotor position estimation; dc magnetization or similar methods may be employed to force the rotor into a known position. The acceptability of initial pole-locating rotation needs to be assessed for the intended motion control application. For most fan and pump applications, a small initial reverse rotation is likely acceptable; for other applicaMotor start, constant power
Motor efficiency in 3 hp fan application

95 5
Motor efficiency (%)
90 0
PMAC motor
85 5 80 0 75 5 70 900
NEMA premium induction motor
1200
1500
1800
Speed (RPM)
Figure 1 shows motor efficiency in 3 hp fan application, with the NovaTorque PremiumPlus+R PMAC motor demonstrating a 5%-12% efficiency improvement over an induction motor. Figures courtesy: NovaTorque
32
Example inductance for IPM motor

28
14
Operating regions of motor

Example motor rated at 3 hp, 1800 rpm
12
Winding inductance (mH)
26
Torque (Nm)
24 22 20 18 16 Inductance Lq Ld
10 8 6 4 2 0 0 300
Contant torque Contant power
Motor start
600
900
1200
1500
1800
2100
2400
2700
Rotor electrical angle
Speed (RPM)
Figure 2 shows the winding inductance of an example IPM motor with 20% saliency. Magnetic saliency is the variance of winding inductance with rotor angle.
Figure 3 shows the regions of motor operation. For either IPM or SPM motors, an accurate configuration of VFD inductance parameters is essential for achieving optimum torque output and motor efficiency.
tions, such as conveyance, an initial motion in the reverse direction might not be acceptable. Most PMAC-capable VFDs employ motor current phase-advance in the constant-power operating region where motor speed exceeds the nominal speed of the motor. This operating region is typically voltage-limited; however, by employing phase advance techniques, the motor can operate at higher speeds without requiring additional voltage. Normally the phase of motor current and motor back-EMF are aligned resulting in maximum torque output. Advancing the current phase reduces motor torque; however, this is acceptable in the constant power region where the motor is thermally limited and higher speeds are desired. In the case of IPM motors with sufficient magnetic saliency, VFDs that have modern phaseadvance algorithms can operate the motor at higher speeds than typically possible with the conventional phase advance method used with SPM motors. Consult the PMAC and VFD manufacturers to determine the motor-drive phase advance capability and any hardware limitations that could impact motor or VFD reliability when the motor operates above nominal speed.
Motor back-EMF, frequency, current
PMAC motors generate sinusoidal backEMF voltage; the amplitude of the motor back-EMF is proportional to motor rotational speed. Slope of back-EMF amplitude vs. rotational speed is termed motor Ke. Unless the VFD is pre-programmed for the PMAC motor or has auto-tuning capability, the motor Ke will need to be entered as a parameter. Some VFDs require entry of backEMF at the nominal speed of the motor, rather than a Ke entry in typical units such as mV/rpm. PMAC motors produce back-EMF voltage when rotated in an unpowered state. Safety issues can occur with unpowered motor rotation; provide warnings and/or circuit protection as appropriate. VFDs employ pulse-width modulated (PWM)
switching of dc bus voltage to generate threephase sinusoidal current to the motor. The PWM switching frequency (sometimes referred to as carrier frequency) is normally a configurable setting of the VFD, with a typical selection range of 2-16 kHz. A low PWM switching frequency allows a high rated current output of the VFD but results in more audible noise from the motor; a high PWM switching frequency reduces the rated output capability of the VFD; however, the audible noise level of the motor is decreased. PWM switching frequency also affects VFD efficiency. VFD electrical losses increase approximately 2-3 watts per 1 kHz PWM switching frequency in typical 3-10 hp VFDs with conventional IGBT (insulated gate bipolar transistors) power electronics. Motor efficiency is essentially unchanged with varying the VFDs PWM switching frequency. In a 3 hp system the VFD efficiency is reduced approximately 1.0% for an 8 kHz increase in switching frequency. Balance the efficiency of using a low PWM switching frequency with audible motor noise. PMAC motors provide high operating efficiency over a broad range of speed and torque. To achieve the best possible part-load efficiencies it is important to ensure that the VFD minimum current parameter, if provided, is not set to an unnecessarily high level. The efficiency of a high-efficiency 3 hp PMAC motor varies in torque when operated with different VFDs. Changing a setting to match the application can improve motor efficiency 5%-10% at partial load.
Savings, with caution
For most fan and pump applications, a small initial reverse rotation is likely acceptable; for certain other applications, no.
PMAC motors offer an opportunity for significant energy savings over induction motor counterparts. However, care must be taken in the selection and configuration of an appropriate PMAC-compatible VFD to realize efficiency benefits and to ensure robust motor control. - Kim Baker is vice president, application engineering, NovaTorque Inc. www.novatorque.com
www.controleng.com
cover story
Motion profiles, libraries ease integration

Key concepts
Use motion profiles and libraries to match the motion application. Unified software architectures can handle motion, other control, IO, and communications. Open systems can ease integration.
hen determining the best standards, protocols, and solutions for a motion application, its always best when done from the point of reference of motion profiles. Electrical engineers and programmers must ask what must be accomplished with the motion system and work toward solutions that push the user to the correct methodology. When implementing a CNC system, for example, engineers wouldnt want to use CAM tables; they would opt for the longtime standard of G-code. For a packaging machine, system designers would likely use CAM tables and point-to-point motion as G-code, also typical in metalworking and woodworking, but unusual for a vertical form/fill/seal machine. Packaging is also home to numerous communication and programming standards, such as PLCopen (IEC 61131-3) and PackML from OMAC. Robotic applications are another unique area. Control programming software offers electronic gearing, camming, G-code, and robotics kinematics that can serve product tracking, product orientation, pick-andplace, and other motion control applications. Tools and libraries can fit a wide range of motion application types, so engineers can learn and work with one programming environment for point-to-point motion, NC, CNC, and/or robotics, across many industries and machine types for
packaging, plastics, alternative energy, and entertainment engineering. With all the possible motion control devices that might be required and application types involved, automation software can ease the integration of numerous motion-specific technologies (drives, actuators, motors, etc.) and auxiliary components. Numerous software driver tools facilitate connection to these kinds of industrial components and others, while managing multiple fieldbus networks for seamless integration. Whether dealing with a simple motion application with a couple axes or a complex system with dozens of axes of motion or more, it is possible to run the bulk (or all) logic on one hardware device if a multi-core-enabled PC-based controller is used. This can be in a cabinet-mounted industrial PC (IPC) or a DIN rail-mounted embedded PC. The latter comes with a form factor like a PLC or PAC with direct connections to I/O terminals. A do it all motion network helps. Among industrial Ethernet protocols, EtherCAT, for example, can serve as an I/O fieldbus and as a motion bus. The EtherCAT Technology Group (ETG) is supported by many drives vendors, resulting in dozens of available EtherCAT servo drives. Apply standards-based selection criteria with system openness in mind for all aspects of a motion control system. For all elements (controller hardware, software, and networking) its best to consider solutions that provide an easy way in and an easy way out, permitting the integration of other best-in-class, standards-based solutions. ce - Matt Lecheler is motion specialist with Beckhoff Automation. www.beckhoffautomation.com
Articles edited by Mark T. Hoske, content manager, Control Engineering, mhoske@cfemedia.com.
Go Online
Each of these three articles has additional information online. Do a keyword search at www.controleng.com or in the digital edition, click on each headline. www.controleng.com/archives December has more related to motion control, also in this issue: 16-Pushing machines to the limit: Transitioning to digital overspeed protection 18-New options for material mixing 20-Sawmill In the digital edition exclusives section: -Crane controls help make energy from waste -Magnets, sensors create paths for automated guide vehicles And in the Inside Machines section: M1-Building a better, more efficient plant M5-Motion control: To network or not to network? M8-Avoid a control panel redesign
Motion technologies in Beckhoff TwinCAT software include electronic gearing, camming, G-code, robotic kinematics, and others for product tracking, product orientation, pick-and-place, and other functions. Tools, libraries, and drives fit a wide range of motion applications and machine types for packaging, plastics, alternative energy, or even entertainment engineering. Courtesy: Beckhoff Automation
34
advanced process control
Understanding optimizers: Adding APC to your APC
Given the number of process variables interacting at most plants, finding the optimum mix to maximize profitability is beyond manual capabilities. Key concepts
ptimization can mean different ties for that component will affect the properties things to different people, so for of the final product. purposes of this discussion we For any given gasoline grade there are at least will concentrate on applying lin- as many product specifications as there are propear programming (LP) techniques, erties, both minimum and maximum. Moreover, either online or offline, to determine the mini- for each component used in the blend, there are mum cost solution, and therefore highest profit- also constraints related to availability, feedstock ability for a set of targets or setpoints to drive a tank inventory, product tank inventory, runprocess. In order for LP to evaluate process con- down from the unit, and pumping constraints, to ditions, it needs a process model to help it eval- name only a few. Finding the one value of each uate process conditions for a potential solution. component that delivers the final specification Consequently, it is usually applied in situations while honoring the constraints at the lowest cost where an advanced process requires evaluation of thoucontrol (APC) strategy, typically sands of possible combinamodel predictive control (MPC) tions. Optimizers can deliver Finding the one is already in use. this operating point faster and value of each In all cases the LP and model at significant savings over one component that must respect all the constraints that a traditional best pracwhich exist in the process, tice might suggest. This can delivers the final including safety-related limits save a refinery several milspecification such as pressure, product qualilion dollars per year, while ty specifications, and equipment reducing product quality givewhile honoring constraints such as fluid hanaway, eliminating rework, and the constraints at dling or metallurgical limits. improving overall production.
In most process manufacturing applications, the number of process variables requires sophisticated analysis to determine optimum operating conditions. Optimizers operate hand-in-hand with advanced process techniques to drive profitability. Accurate process models are necessary to ensure that all relevant operating constraints and safety measures are included in the calculations.
Why use optimization?
In todays operating environments with extensive heat integration, numerous process quality targets, and hundreds of constraints, the decision to drive a process in one direction or another or to push a constraint is anything but straightforward. Gasoline, for example, is a blend of as many as 12 or even more separate streams coming from refinery process units. These streams combine in a ratio control system to create a given gasoline grade. Each component has a cost, and the individual proper-
the lowest cost requires evaluation of thousands of possible combinations.
Closed-loop optimizers can be found in offsite product blending operations, process units, MPC (model predictive control) advanced controllers, planning and scheduling platforms, and raw material purchasing tools. These typically run on a minute-to-minute basis, but rigorous optimizers can run less frequently, from every few hours to once per day, with planning tools running on a weekly or monthly basis. In all these applications, optimizers are an integral part of the real-
Open vs. closed loop
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advanced process control
This diagram gives a highly simplified view of the elements related to producing gasoline. Keeping every one of them optimized requires more analysis than is practical with manual approaches. Courtesy: Invensys
time system and therefore must have dynamic behavior and must incorporate best automation practices to make any online closed-loop control system robust and reliable. On the other end of the spectrum, the planning department looks at the horizon measured in weeks and even months. In this case the optimizer is run in an offline mode to try out hundreds or even thousands of potential scenarios to get the best set of operating plans developed for the plant for the available raw materials to be purchased. LP is the main workhorse here, and hundreds of product qualities are considered along with a multitude of operating constraints. Optimizers are adapted to run in different scenarios with one of the most fundamental demarcation points being the online closed-loop service or the open-loop planning case. In the closed-loop case, such as in MPC, the LP is almost always used with a multivariate dynamic controller to decouple the interactions in the process and help drive the LP targets toward the optimum solution in a short amount of time and a stable manner. In these cases, the dynamic controller with the LP uses an empirical model of the process dynamics. This is just a fancy word for regressed models from process data that contain information on process dynamic behavior.
Process models
sort of regression using techniques such as least squares or partial least squares. They are relatively quick to develop, are based on process conditions, and contain dynamic features of the process. However, they are limited in that they generally dont predict very well outside of the range of data on which they are based. Rigorous models result from first principle relations that do not depend on process data, although almost all rigorous models are validated with data from an actual process. They can predict process values over a much wider range and are better at predicting such things as nonlinear behavior in the steady state. Although we have been discussing optimization tools in the LP context, many commercial offerings are capable of nonlinear programming (NLP) solutions. These are useful for certain types of applications like energy management, where major pieces of process equipment, such as a turbine, might not always be present when the solution is determined. These difficult situations call for another solver variant, the mixed-integer nonlinear program (MINLP). The common denominator for all these cases is that the tool will determine the best point or mode of operation as already discussed.
Data validation and reconciliation
The old computer programming axiom of garbage in, garbage out certainly applies to optimization, especially in the case of online optimization. As mentioned earlier, in those cases where online closed-loop optimization is applied, these solutions dont generally address process dynamics in any comprehensive manner. Consequently they are executed only when the process has reached steady state, requiring that the tools have sufficient facilities to detect that the process has reached steady state from the last set of moves requested by the optimizer. These steady state detection tools are used in conjunction with data reconciliation tools to spot, correct, and remove or even replace process values prior to the optimizer initiating its calculation sequence to arrive at the next solution. Constraints or limits are present in every context of optimization, whether it is MPC optimization or online/offline optimization. The process presents many constraints which must be respected and are therefore integrated programmatically into the software. Constraints might be with respect to product qualities or safety or equipment limits. In any case they must be respected and not violated. Sometimes, the optimizer cannot find a feasible solution with the existing con-
Earlier we mentioned that a model of the process was necessary for the optimizer to evaluate process conditions at the new operating point. For example, lets ask, If we increase the feed to the unit by 5%, what will the exit temperature from the reactor be, and does this violate any known constraints? There are two broad classes of models, empirical and rigorous. Empirical models are derived from data which is usually processed through a tool that performs some
Constraints
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straints and a constraint must be relaxed in order to find a feasible solution. In these cases the constraints selected to be relaxed or given up are determined ahead of time and ranked as to which constraint is least important.
Benefits, costs, and maintenance
Six to nine months is typical ROI for optimization applications, but there is wide variation across industries. Some of the greatest benefits have been achieved when they are implemented as part of an MPC program and when regulatory and advanced regulatory control layers are well Also, the technical capabilities to conceive, maintained and operating at peak performance develop, commission, and maintain an optimiprior to commissioning. zation system are always in short supply. GetAlthough optimization projects may compete ting staff with the right skills is a prerequisite to for resources, it is worth noting that the optimi- a successful project in addition to identifying and zation itself does not change the process or the enlisting a site champion. The right skills might existing automation hardware, except for the be within your company or within the supplier addition of another server class machine connect- organization, but not in your geographic locaed to the process or business network. tion, so we are seeing an increasing trend where Maintenance must multiple locations also be factored into and time zones are any discussion of ROI by Some of the greatest benefits accommodated on optimizers. Some the optimization tool assume that once comset, allowing mulhave been achieved when missioned, optimiztiple persons in difers require no ongoing implemented as part of an MPC fering locations to maintenance. Howprogram and when regulatory work collaboratively ever, operational conin real time. Two or and advanced regulatory straints, models, and more users should be objectives change over control layers are operating at able to view the same time and the optimizworkspace at the peak performance. er must be changed same time with both accordingly. Ongoing making changes with software and applithe underlying datacation support can average 10% of the original base managed in near real time. The successful project cost. tools of the future will support the transition of design models developed for steady state design Future requirements to be seamlessly translated into the online optiDespite their benefits, developing rigorous mization for both steady state and dynamic applifirst principle models can be time-consuming. cations, giving much greater leverage and reuse Combining empirical and first principle models than has been possible with previous generations is an emerging trend, which promises to reduce of tools. ce Tom Kinney is vice president, optimization, development time and ease future model maintenance. Integration of historians, feed property for Invensys. databases, and various planning tools is another trend, which can reduce staff time needed to Go Online update information manually while at the same time reducing errors. Lastly, the new generation For more information, visit: http://iom.invensys.com of users coming into the workplace demands a Go to www.controleng.com/archive to read more about level of ease of use not found in the previous advanced process control: generation of tools. Drag and drop, copy and Do-it-yourself model-based control, March 2013 paste, and touchscreen enabled are all trends Driving plant optimization with advanced process control, that will simplify the use and adoption of soft- November 2009 ware tools. The inclusion of features that are Subscribe to Process & Advanced Control eNewsletter at consistent with the mainstream desktop- and www.controleng.com/newsletters iPad-enabled generation will be ongoing.
VIDEO: Read this article online or in the Control Engineering Digital Edition to see a video where Dr. Tobias Scheele, vice president, design, simulation, and optimization, Invensys, provides additional information on the role and function of optimizers in complex chemical processes.
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data integration
Figure 1. Remote data monitoring is required in a host of industrial settings, including oil and gas, power, wastewater, and environmental monitoring. Courtesy Honeywell Process Solutions
Photo iStock.com/Huyangshu
Capturing
far-flung data
Advancements in RTU technologies help optimize data acquisition and control. Key concepts
The desire to gather more information from operating assets is driving greater sophistication of communication hardware. While there are various ways to aggregate data, RTUs are designed specifically for this purpose. Signal transmission options have also expanded, providing more ways to send information back to a centralized control system.
he use of remote terminal units (RTUs) began in the U.S. oil and gas industry in the 1980s, and has expanded to utilities, environmental protection, heating networks, water conservancy, and long-distance pipelines. Microprocessor-controller RTUs have evolved to help industrial organizations effectively deal with large distributed operations. Tightly integrated with supervisory control and data acquisition (SCADA) systems, they provide new insights into the production potential of distributed assets through efficient remote monitoring, diagnostic, and asset management capabilities. This discussion will take a look at recent advancements in RTU technology, which optimize data acquisition and control capabilities in a wide range of industry applications. Remote data monitoring is required in a host of industrial settings, including oil and gas, power, wastewater, and environmental monitor-
Background
ing. The common element is monitoring a variety of items that are spread over a large geographical area. A large number of RTUs installed in remote and/or hazardous locations may be used to log data and alarms from sensing or metering devices and send this information to a SCADA system in a central control room. The RTU may also receive data from the central station for process execution. The term SCADA usually refers to centralized systems which monitor and control entire sites, or complexes of systems spread out over large areas. One useful definition is that SCADA handles things outside the plant fence, while a DCS (distributed control system) controls more densely packed items in a plant or process unit. An RTU operates by scanning its inputs usually at a fairly fast rate. It may also do some processing such as change-of-state processing, time stamping of changes, and storage of data awaiting polling from the SCADA master. Some RTUs have the ability to initiate reporting to the SCADA master while others rely on the SCADA master to poll the RTU and request changes. The
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RTU may even handle alarm processing, particularly on degraded or low-bandwidth networks with slow update rates where SCADA-only alarming could miss a significant event. The data acquisition functions of an RTU in a SCADA system can be quite diverse. The device is designed to read both analog measurements and digital status data. It contains setup software to connect data input streams to data output streams, define communication protocols, and troubleshoot installation problems. In many industrial applications, data acquisition begins at the RTU level and includes meter readings and equipment status reports that are communicated to the SCADA system as required. Data is then compiled and formatted in such a way that a control room operator or pipeline controller using the HMI (humanmachine interface) can make supervisory decisions to adjust or override normal controls. With large quantities of RTUs performing a similar monitoring and control function, tabular summaries are the norm. This differs from a DCS where process-orientated displays are common. In addition, data may be supplied to a historian to allow trending and other analytical auditing. There are two basic types of RTUs on the market. One is a single board RTU, which is compact and contains all I/O on a single board. The other is a modular RTU, which has a separate CPU module and can have other modules addednormally by plugging into a common backplane.
Growing technologies
sive exercise. Central management requires remote data collection even in the most dispersed enterprises. Enterprises that may have discontinued remote data collection because of high investment requirements are finding it advantageous to implement todays less expensive smart RTU systems. Emerging 3G and 4G networks, along with new types of wireless instrumentation, have resulted in RTU signal transmission methods which are both reliable and cost-effective. Affordable photovoltaic technology and improved batteries, combined with new lowpower RTUs, makes it possible to place RTUs in locations not previously considered economical.
Evolving capabilities
Figure 2. Modern RTUs combine advanced capabilities for automation, monitoring, and telemetry in a single unit. Courtesy: Honeywell Process Solutions
Todays RTUs feature more versatile programmability and broader communication and protocol support. They also add greater flexibility to remote control applications. For this reason, RTUs are now widely used in mission-critical industrial automation environments. For example, rapidly developing green industries, such as solar power plants, wind power plants, and smart buildings, are new applications for RTUs. RTUs are gaining popularity for a variety of reasons: In a competitive business environment, enterprises have an ever-greater need for information. Some measurements were previously given up because they were scattered and the cost to collect data was too high. In the era of big data, data collection is increasingly viewed as an operational priority. As business and production operations expand in size, they can span wide geographical areas, making localized support an expen-
There have been significant developments in recent years in RTU hardware and software technologies. These developments have enabled more choices in the instrumentation that can be put into the field and the data that can be brought back to the control room. While conventional RTUs are based on proprietary operating systems and architectures, the newest instruments have adapted embedded system technology, resulting in products that are more cost-effective and extremely flexible. RTU designs have advanced to offer enhanced communications, database, and signal transmission capabilities. The devices feature low power consumption and serve as bridge points to sensor networks, as well as access points to mobile users in the field. They also respond to users queries and collect data from specific sensors. Modern RTUs go a step further by combining advanced features for automation, monitoring, and telemetry in a single unit. They are often equipped with Internet protocol (IP) and Web
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data integration
Integration of RTUs with SCADA systems allows users to realize the production potential of distributed assets through efficient remote monitoring, diagnostic, and asset management capabilities.
capabilities allowing users to access site information by mobile phone, tablet, or laptop, with Web pages served via the Internet or intranet, e-mail, and text messaging (See Fig. 2). The new breed of RTUs is designed to help industrial companies oversee and maintain large distributed operations encompassing hundreds or even thousands of remote production assets. These operations involve complex remote automation and control applications. Integration of RTUs with SCADA systems allows users to realize the production potential of distributed assets through efficient remote monitoring, diagnostic, and asset management capabilities. Some products are designed to optimize these applications through built-in, onboard smart I/O such as HART, with integration of field device management for interrogating instrument data and diagnostics as well as running methods like valve signaturesall via the RTU. Suppliers have also made significant strides in improving the overall user experience with RTUs. For example, incorporating removable, plug-in terminal blockswhich simplify wiring and shorten the time required for cabinet assemblyeases installation and configuration requirements. Additional improvements include modular designs for future expansions and bulk replication capabilities. Robust batch configuration tools allow a user to copy the configuration from one template to multiple RTUs, as well as create multiple RTUs in one task. Unique RTU parameters can then be updated from a single page across all copies. The days of putting personnel in cars and trucks at a drop of a hat to travel to remote sites is coming to an end. It is not only an expensive exercise, but also an unsafe oneand that is just the trip to the site. The traditional RTU strengths of data logging and good sub-system communications with local devices alongside the newer smart device integration with HART is enabling better fault modeling, both direct on the RTUs and at central locations. This means better decisions can be made about the actual health of the remote asset, possibly delaying a site visit for maintenance to a future, previously scheduled trip.
Integration with SCADA Systems
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For more information, visit: www.honeywellprocess.com Read more about RTUs at www.controleng.com/archives: Evolving RTU capabilities facilitate expanding oil and gas production, Oct. 2013 Optimizing your HMI, May 2011
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SCADA systems have progressed over recent years, taking advantage of more intelligent sensors and controllers, more powerful computing architectures, and sophisticated applications. They can better analyze data and provide operations personnel with improved monitoring and management capabilities. Modern SCADA systems can simplify engineering and provide a superior HMI with oper-
ational efficiency over thousands of distributed assets. Template-driven tabular summaries of large quantities of similar assets now come with task-based dashboards leading the operator and pipeline controller exactly to the assets that need their attention. What once was a time-consuming monitoring activity is now performed in seconds, and every operator is the best operator by using consistent tools that can evolve as best practice updates. And if a pipeline connects to a process plant, todays SCADA system can serve as an integrated, common HMI of the DCS. There is no longer a need for different operator platforms. However, with the wide range of RTUs and programmable logic controllers (PLCs) currently on the market, SCADA system engineers and decision-makers face several challenges. Which class of units provides the optimal functionality, expandability, and cost-effectiveness for a given SCADA application? Generally speaking, PLCs are designed to address plant floor, programmable automation applications with large quantities of local I/O. Wide area SCADA applications at remote sites are the core competencies for RTUs. They meet user requirements in terms of communication network interfaces, both for local sub-systems and remote uplinks, communication protocols, intelligent operation of wide area networks, inherent data logging, and low power consumption. RTUs also have to operate in hazardous and harsh environments associated with oil and gas, power, and utility applications. With their functionalities in communication peripherals, storage, and processing, RTU controllers are capable of delivering complex communication handling (e.g., encryption), or intensive front-end data processing involved with time stamp protocols or time stamps for historical data logging and retrieval. SCADA system designers are also employing distributed RTUs to reduce overall architecture deployment costs. Ongoing developments in RTU technologyintegrated as part of SCADA systems are driving a progressive trend in functionality. This is creating a shift from basic data collection and local control, to smart and intelligent data management that can significantly increase operational efficiency, improve reliability, lower maintenance costs, and reduce operator trips to the field. These solutions, employing advanced capabilities such as built-in HART I/O with field device integration, provide new insights into the production potential of distributed assets through efficient remote monitoring, diagnostic, and asset management capabilities. ce Paul Vellacott is a product marketing manager for Honeywell Process Solutions.
Integrating lean
Lean automation architectures
Key concepts
As a first step toward lean, look for wasted movements, time and effort, wasted space, and disorganized work areas. Ask operators how to eliminate waste Think visually about how and where things should go.
Technical advances lead to more efficient automation solutions
or decades, machine automation architecture has hardly changed. The basic makeup of control systems involved a programmable logic controller (PLC) with discrete and analog I/O running to the end devices, while an electronic operator interface (OI) provided an interface to set up, operate, and maintain the machine. Technical advances in processing and communications are yielding new capabilities for machine automation. These communications advances are at both the device and enterprise level and are enabling a streamlined automation architecture (see Figure 2). 1) Device level networking enables direct connections to intelligent end devices on a machine and can remove I/O and wiring from the control cabinet. In addition to simpler construction, direct connection to smart devices improves diagnostics and helps to increase machine up time. 2) Enterprise level networking, with the emergence of industrial Ethernet technologies, enables machines to connect into the manufacturing enterprise. This can provide significant value in monitoring operational efficiency, notification and resolution of machine alarms, and remotely troubleshooting and upgrading the automation programs. Technology advances also provide an opportunity to streamline the automation architecture into a simpler form shown in Figure 2 where the logic control, operator interface, device level communications, and enterprise level communications have been integrated into one automation component. For machine original equipment manufacturers (OEMs), advances in device and enterprise-level communications enable the combination of visualization and control, and a new level of connectivity. These changes make it possible to design and build smarter machinery faster at a lower cost with: An integrated development environment that allows faster machine design Fewer components and wiring means reduced machine construction costs Centralized remote access and administration, improving operation and reducing machine support costs.
Figure 1: Traditional machine automation architecture has communications limitations. Figures courtesy: Eaton
Figure 2: Streamlined machine automation: Communications advances are at the device and enterprise level and are enabling a streamlined automation architecture. Logic control, operator interface, device level communications, and enterprise level communications have been integrated into one automation component.
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Integrating lean
EOI
Graphics processing
PLC
Logic processing
While somewhat overshadowed by advances Serial coms Serial coms in enterprise networking, device-level networks have continued to progress, enabling more cost-effecDisplay/ Device I/0 touch in tive connection of even simple devices through a network to the Figure 3: The historical logic control within the system. These advanccomplementary electronic es have taken place both within the control caboperator interface (EOI) and inet and outside of it, to expand to the sensors programmable logic conand actuators mounted on the machine. Devicetroller (PLC) relationship is level networks yield multiple advantages: reducshown. EOI PLC ing time to wire and commission the control panel, removing the I/O cards from the Graphics Logic system, and improving operational processing processing diagnostic information for more reliEnterprise Ethernet able systems. Historical data The move away from I/O to netAlarms working for connecting sensors, Security actuators, and human interface in machine control is a key enabler of a Display/ Device network combined automation platform. Once touch in the role of the I/O cards in a system is Figure 4: This diagram removed or significantly reduced, the value shows the emerging overof having a separate PLC from the electronic lap of electronic operator operator interface (EOI) also is diminished. The interface (EOI) and programprocessing power available in todays micropromable logic controller (PLC) cessors makes handling the operator interface features, as vendors of each task and the programmable logic control task vied to address new requiremanageable from one device. Further, as remote ments for historical informaaccess is increasingly important, the case for a tion, alarming, and security. combined HMI-PLC is strengthened, changing the basic control system and enabling a leaner HMI/PLC automation approach that combines logic, visualization, and connectivity.
Enterprise Ethernet Logic processing Graphics processing Display/ touch in Historical data Alarms Security Device network
Networks streamline automation
HMI-PLC convergence
torical perspective of the PLC and OI technology and development is useful. Traditionally, the PLC was developed to provide control, sequencing, and safety functionality for manufacturing processes, replacing systems that involved numerous devicesmultiple control relays, timers and drum sequencers, and closed loop controllers. Largely, the I/O cards used to interface to the sensors, actuators, and simple operator interface devices (push buttons and pilot lights) made the controller. The electronic operator interface (EOI) was introduced to complement this simple PLC. By connecting to the PLC through a simple serial network connection, the EOI added the ability to present much richer information to the machine operator, replacing some of the simple push button and pilot lights in the process. This historical relationship between the EOI and PLC is shown in Figure 3. With industrial Ethernet, the advent of remote access in the automation space means increased automation functionality including: historical data capture and exchange, alarm notification and management, and security administration. These features have been introduced into both the PLC and EOI and tend to overlap today, as vendors of PLC and EOI equipment have vied to address new requirements for historical information, alarming, and security (see Figure 4). More is not always better and redundancy in EOI and PLC feature sets has several downsides: the needless duplication of hardware (Ethernet is required on both devices), unnecessary complexity of programming (redundant alarm systems), and increased risks of security holes. Instead of two devices with overlapping functionality, one device with a feature set that covers requirements without duplication means less equipment to buy, program, and configure (see Figure 5).
Streamline architecture
Figure 5: Convergence of human machine interface (HMI), programmable logic controller (PLC), and connectivity. Instead of two devices with overlapping functionality, one device with a feature set that covers requirements without duplication means less equipment to buy, program, and configure. Courtesy: Eaton
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The manufacturing community stands to make significant productivity gains with the emergence of industrial Ethernet applied to the factory floor. The expanding capabilities of networks and the smart devices that can interface over it are driving improved diagnostics, faster troubleshooting, and overall improvements in machine reliability. With the information that Ethernet connectivity is enabling, there are more opportunities to reduce the time and costs involved in diagnosing and fixing issues before they cause downtime or delay commissioning. These changes also impact on-machine automation systems, demanding a fresh look at the automation architecture and the role of the PLC and HMI in that system. To better understand the convergence of HMIPLC functionality and equipment options, a his-
Networking at the device and enterprise level is advancing and supporting new, streamlined automation architecture. Ultimately, this convergence can eliminate entire device levels and enable remote intelligence to reduce training costs, while empowering OEMs to take advantage of the best equipment from a range of suppliers. Integrated architecture is enabling lean automationboosting efficiencies and reducing wastein terms of equipment and time. In a highly competitive business environment, providing best-in-class solutions that are intelligent, intuitive, and elegant delivers a real business advantage and yields control systems that are faster to design, commission, and maintain. - Rich Harwell is advanced solutions manager at Eaton. www.eaton.com
Lean manufacturing processes

ow do you get started making a manufacturing process lean, so you can then apply automation, where it makes sense? Just take a look around. Look for wasted movements, time and effort, wasted space, and disorganized work areas. The next step is to ask operators how to eliminate waste and think visually about how and where things should go. Often, a simple instructional or operational sign can help an operator remember and prioritize steps in a process. Color-coded shadow boards can help users and tool crib managers track tool usage, minimizing theft, and track whos hogging the hammer. Manufacturers typically deal with seven forms of waste: inventory, overproduction, transport, defects, overprocessing, motion, and waiting, said Melissa Topp, the director of global marketing for enterprise software provider, Iconics. Lean manufacturing is an iterative approach that encourages manufacturers to eliminate those sources of waste. Technology solutions accompanying each phase concentrate on manufacturing intelligence reporting, alarm management, and downtime reduction. The huge manufacturing automation industry encompasses technologies such as computer controlled machines for processing and handling products, process automation systems, general motion control systems, automation related software, and condition-monitoring equipment and systems. Benefits of automation include global competition, meeting orders more quickly, faster deliveries, increasing shift productivity, lowering operating costs, increasing yields, reducing load/ unload times, reducing damage or breakage during handling, less material waste, and labor savings. In Australia, theres no such thing as cheap labor, explained James Abbot, Challenge Engineering. Abbot relies on computer numeric control (CNC) machining, which offers multiple manufacturing processes in one machine. Setup is streamlined, with most tools already in a carousel that can hold up to 72 tools, but all turning, milling, and drilling operations can be carried out in one setup. This type of automation machinery maximizes staffing and helps the company maintain a competitive edge over imported rivals, particularly with a strong Australian dollar.
Return on investment (ROI)
When faced with production requirements that exceeded current operational capabilities, PGT Industries applied Iconics software to the 12 most critical production assets to analyze the overall equipment effectiveness (OEE) of the current plant. The software was used to zero in on sources of loss of OEE, focusing on availability, quality, and performance. PGT Industries realized enough
savings and cut enough waste that it postponed its plans to build a third production facility, resulting in major savings for the company, and discovered that it could run at 1.5 times its previous production capacity with the same capital assets. With these findings, PGT Industries decreased labor and energy costs by 20%. Automation played an important role in the recipe for Barbers Farmhouse Cheesemakers success. The challenge there is to ensure accurate size and weights for cheeses (required by U.K. law), while minimizing oversized portions. Barbers engineers implemented an automated weighing and cutting system and reduced give away from between 4% and 5% to less than 1%. Some experts believe automated processes should be phased in systematically. Automation typically isnt a solution that can be tried, fixed, and changed easily, and should occur in the latter stages of a lean implementation to eliminate worker ergonomic overburden as well as mitigate potential safety concerns, said Paola Castaldo, Oregon Manufacturing Extension Partnership. She added, But designing automated systems before going through the rigors of lean could potentially fix the wrong problem because you could be automating a broken system. However, when human constraints get in the way of continuous flow and quality, automation could be the only way to deliver the next incremental improvement and be an appropriate solution. ce - Jack Rubinger, public relations, Graphic Products. Articles edited by Mark T. Hoske, Control Engineering, mhoske@cfemedia.com.
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Labeling personal protective equipment and tools can eliminate wasted time and augment a manufacturers safety culture. Courtesy: DuraLabel, www.DuraLabel.com
Go Online
www.controleng.com/archives December, see these articles for more information, images, and links additional resources on lean manufacturing and automation.
Consider this...
Are the people closest to your processes rewarded for leaner processes that eliminate waste?
sensors
Artificial intelligence tools can aid sensor systems

At least seven artificial intelligence (AI) tools can be useful when applied to sensor systems: knowledge-based systems, fuzzy logic, automatic knowledge acquisition, neural networks, genetic algorithms, case-based reasoning, and ambient intelligence.
even artificial intelligence (AI) tools are reviewed that have proved to be useful with sensor systems. They are: knowledge-based systems, fuzzy Seven artificial intelligence logic, automatic knowledge acquisi(AI) toolsknowledgetion, neural networks, genetic algorithms, casebased systems, fuzzy based reasoning, and ambient intelligence. Each logic, automatic knowlAI tool is outlined, together with some examples of edge acquisition, neural networks, genetic its use with sensor systems. Applications of these algorithms, case-based tools within sensor systems have become more reasoning, and ambientwidespread due to the power and affordability of intelligencecan be present-day computers. Many new sensor applicaused to improve sensor tions may emerge, and greater use may be made of systems. hybrid tools that combine the strengths of two or more of the tools reviewed. The tools and methods reviewed here have minimal computation complexity and can be implemented with small sensor systems, sinCase gle sensors, or system Database arrays with low-capability microcontrollers. The appropriate deployInput Output ment of the new AI tools Interface Engine will contribute to the creation of more competitive sensor systems and applications. Other techFigure 1 shows a casenological developments in AI that will impact based reasoning (CBR) sensor systems include data mining techniques, system. As with rulemulti-agent systems, and distributed self-organizbased systems, CBR ing systems. Ambient sensing involves integratsystems are good at ing many microelectronic processors and sensors representing knowledge into everyday objects to make them smart. in a way that is clear to They can explore their environment, communihumans; however, CBR cate with other smart things, and interact with systems also have the humans. Advice provided aims to help users cope ability to learn from past with their tasks in intuitive ways, but the reperexamples by generating cussion of such integration into our lives is diffiadditional new cases. cult to predict. Using ambient intelligence and a Figures courtesy: Unimix of AI tools uses the best of each technology. versity of Portsmouth The concepts are generically applicable across
Key concepts
industrial processes. Research below intends to show these concepts can work in practice.
Creating smarter sensor systems
Sensor systems can be improved using artificial intelligence (AI). AI emerged as a computer science discipline in the mid 1950s, and it has produced a number of powerful tools that are useful in sensor systems for automatically solving problems that would normally require human intelligence. Seven such tools are here: knowledge-based systems, fuzzy logic, inductive learning, neural networks, genetic algorithms, case-based reasoning, and ambient-intelligence. AI systems have been improving, and new advances in machine intelligence are creating seamless interactions between people and digital sensor systems. Although the introduction of AI into industry has been slow, it promises to bring improvements in flexibility, reconfigurability, and reliability. New machine systems are exceeding human performance in increasing numbers of tasks. As they merge with us more intimately, and we combine our brain power with computer capacity to deliberate, analyze, deduce, communicate, and invent, then we may be on the threshold of a new age of machine intelligence. AI (or machine intelligence) combines a wide variety of advanced technologies to give machines an ability to learn, adapt, make decisions, and display new behaviors. This is achieved using technologies such as neural networks, expert systems, self-organizing maps, fuzzy logic, and genetic algorithms, and that machine intelligence technology has been developed through its application to many areas where sensor information has needed to be interpreted and processed, for example assembly, biosensors, building modeling, computer vision, cutting tool diagnosis, environmental engineering, force sensing, health monitoring, human-computer interaction, Internet use, laser milling, maintenance and inspection, powered assistance,
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Input
Fuzzify Inputs
Apply Rules
Management Design Production
E E Advice E E Improvement Monitoring Data Analysis Problem Solving
Energy Efficiency Knowledge Management
Energy Efficiency Services
Aggregate Outputs
Defuzzify
Output Repository
Figure 2 shows an architecture for a fuzzy logicbased controller.
Manufacturing Unit: Aml Data Energy Measurements Process Data User Knowledge
robotics, sensor networks, and teleoperation. These developments in machine intelligence are being introduced into ever more complex sensor systems. The click of a mouse, the flick of a switch, or the thought of a brain might convert almost any sensor data to information and transport it to you. Recent examples of this research work are provided, which include work at the University of Portsmouth. Seven areas follow where AI can help sensor systems.
Energy Efficiency Observer
Aml Processing System
Figure 3 shows an experimental system to test the use of ambient intelligence to improve energy efficiency.
Object List
CAD Model Generation
Object Identifier
Weld Identifier
1. Knowledge-based systems
Knowledge-based (or expert) systems are computer programs embodying knowledge about a domain for solving problems related to that domain. An expert system usually has two main elements, a knowledge base and an inference mechanism. The knowledge base contains domain knowledge which may be expressed as a combination of IFTHEN rules, factual statements, frames, objects, procedures, and cases. An inference mechanism manipulates stored knowledge to produce solutions to problems. Knowledge manipulation methods include using inheritance and constraints (in a frame-based or object-oriented expert system), retrieval and adaptation of case examples (in case-based systems), and the application of inference rules (in rule-based systems), according to some control procedure (forward or backward chaining) and search strategy (depth or breadth first). A rule-based system describes knowledge of a system in terms of IF THEN... ELSE. Specific knowledge can be used to make decisions. These systems are good at representing knowledge and decisions in a way that is understandable to humans. Due to the rigid rule-base structure they are less good at handling uncertainty and are poor at handling imprecision. A typical rulebased system has four basic components: a list of rules or rule base (a specific type of knowledge base); an inference engine or semantic reasoner (infers information or takes action based on the interaction of input and the rule base); temporary working memory; and a user interface or other connection to the outside world through which input and output signals are received and sent. The concept in case-based reasoning is to adapt solutions from previous problems to current problems. These solutions are stored in a
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New Robot Program MOTOMAN ROBOT SYSTEM
database and can represent the experience of human specialists. When a problem occurs that a system has not experienced, it compares with previous cases and selects one that is closest to the current problem. It then acts upon the solution given and updates the database depending upon the success or failure of the action. Casebased reasoning systems are often considered to be an extension of rule-based systems. They are good at representing knowledge in a way that is clear to humans, and have the ability to learn from past examples by generating new cases.
2. Case-based reasoning
Case-based reasoning has been formalized for purposes of computer reasoning as a four-step process: 1) Retrieve: Given a target problem, retrieve cases from memory that are relevant to solving it. A case consists of a problem, its solution, and, typically, annotations about how the solution was derived. 2) Reuse: Map the solution from the previous case to the target problem. This may involve adapting as needed to fit the new situation. 3) Revise: Having mapped the previous solution to the target situation, test the new solution in the real world (or a simulation) and, if necessary, revise. 4) Retain: After the solution has been sucwww.controleng.com
In Figure 4, a proposed system flow diagram shows how a system could gather data from an image sensor. Visual data and CAD model data will be used in conjunction to determine an object list; that object list will be passed to a weld identifier module that will use AI techniques to determine weld requirements.
sensors
cessfully adapted to the target problem, store the resulting experience as a new case in memory. Critics argue that it is an approach that accepts Case Base Rule Base Fuzzy Logic anecdotal evidence as its Reasoning main operating principle. Without statistically relevant data for backing and implicit generalization, Decision System there is no guarantee that the generalization is correct. All inductive reasoning where data is too scarce for statistical releIn Figure 5, the senvance is based on anecdotal evidence. sor systems make weld The concept in case-based reasoning (CBR) requirement suggesis to adapt solutions from previous problems to tions to a weld identifier current problems. These solutions are stored in a module shown here. database and represent the experience of human This module evaluates specialists. When a problem occurs that a syssuggestions and detertem has not experienced, it compares with premines the optimum weld vious cases and selects one closest to the current path. Suggestions will problem. It then acts upon the solution given and then be passed to the updates the database depending upon the success existing robot program or failure of the action. generator. CBR systems are often considered to be an extension of rule-based systems. As with rulebased systems, CBR systems are good at representing knowledge in a way clear to humans; however, CBR systems also have the ability to learn from past examples by generating additional new cases. Figure 1 shows a CBR system. Many expert systems are developed using programs known as shells, which are readymade expert systems complete with inferencing and knowledge storage facilities but without the domain knowledge. Some sophisticated expert systems are constructed with help of development environments. The latter are more flexible than shells, providing means for users to implement their own inferencing and knowledge representation methods. Expert systems are probably the most mature among tools here, with many commercial shells and development tools available to facilitate their construction. Once the domain knowledge to be incorporated in an expert system has been extracted, the process of building the system is relatively simple. The ease with which expert systems can be developed has led to a large number of applications of the tool. In sensor systems, applications can be found for a variety of tasks, including selection of sensor inputs, interpreting signals, condition monitoring, fault diagnosis, machine and process control, machine design, process planning, production scheduling,
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and system configuring. Specific tasks undertaken by expert systems are assembly, automatic programming, controlling intelligent complex vehicles, planning inspection, predicting risk of disease, selecting tools and machining strategies, sequence planning, and controlling plant growth.
3. Fuzzy logic
A disadvantage of ordinary rule-based expert systems is that they cannot handle new situations not covered explicitly in their knowledge bases (that is, situations not fitting exactly those described in the IF parts of the rules). These rule-based systems are unable to produce conclusions when such situations are encountered. They are shallow systems which fail in a brittle manner, rather than exhibit a gradual reduction in performance when faced with increasingly unfamiliar problems, as human experts would. The use of fuzzy logic, which reflects the qualitative and inexact nature of human reasoning, can enable expert systems to be more resilient. With fuzzy logic, the precise value of a variable is replaced by a linguistic description, the meaning of which is represented by a fuzzy set, and inferencing is carried out based on this representation. For example, an input from a sensor system of 20 can be replaced by normal as the linguistic description of the variable sensor input. A fuzzy set defining the term normal sensor input might be: normal sensor input = 0.0/below 10 widgets per minute +0.5/1015 widgets per minute +1.0/1525 widgets per minute +0.5/2530 widgets per minute +0.0/above 30 widgets per minute. The values 0.0, 0.5, and 1.0 are the degrees or grades of membership of the sensor ranges below 10 (above 30), 1015 (2530), and 1525 to the given fuzzy set. A grade of membership equal to 1 indicates full membership, and a null grade of membership corresponds to total non-membership. Expert system knowledge employing fuzzy logic can be expressed as qualitative statements (or fuzzy rules), such as, If the input from the room temperature sensor is normal, then set the heat input to normal. A reasoning procedure known as the compositional rule of inference (the equivalent of the modus-ponens rule in rulebased expert systems) enables conclusions to be drawn by generalization (extrapolation or interpolation) from the qualitative information stored in the knowledge base. When a sensor input is detected to be slightly below normal, a controlling fuzzy expert system might deduce that the sensor inputs should be set to slightly above normal. (This conclusion might not have been contained in any fuzzy rule stored in the system.)
Fuzzy expert systems (FES) use fuzzy logic to handle the uncertainties generated by incomplete or partially corrupt data. The technique uses the mathematical theory of fuzzy sets to simulate human reasoning. Humans can easily deal with ambiguity (areas of gray) when decision making, yet machines find it difficult. Figure 2 shows an architecture for a fuzzy logic-based controller. Fuzzy logic has many applications in sensor systems where the domain knowledge can be imprecise. Fuzzy logic is well suited where imprecision is inherent due to imprecise limits between structures or objects, limited resolution, numerical reconstruction methods, and image filtering. Applications in structural object recognition and scene interpretation have been developed using fuzzy sets within expert systems. Fuzzy expert systems are suitable for applications that require an ability to handle uncertain and imprecise situations. They do not have the ability to learn as the values within the system are preset and cannot be changed. Fuzzy logic successes have been achieved in the areas of cooperative robots, mobile robots, prediction of sensory properties, supply chain management, and welding.
4. Automatic knowledge acquisition
Getting domain knowledge to build into a knowledge base can be complicated and time consuming. It can be a bottleneck in constructing an expert system. Automatic knowledge acquisition techniques were developed to address this, for example, in the form of IFTHEN rules (or an equivalent decision tree). This sort of learning program usually requires a set of examples as a learning input. Each example is characterized by the values of a number of attributes and the class to which they belong. One approach is through a process of dividing-and-conquering, where attributes are selected according to some strategy (for example, to maximize the information gain) to divide the original example set into subsets, and the inductive learning program builds a decision tree that correctly classifies the given example set. The tree represents the knowledge generalized from the specific examples in the set. This can subsequently be used to handle situations not explicitly covered by the example set. In another approach, called the covering approach, the inductive learning program attempts to find groups of attributes uniquely shared by examples in given classes and forms rules with the IF part as conjunctions of those attributes and the THEN part as the classes. The program removes correctly classified examples from consideration and stops when rules have been formed to classify examples in the set.
Another approach is to use logic programming instead of propositional logic to describe examples and represent new concepts. That approach employs the more powerful predicate logic to represent training examples and background knowledge and to express new concepts. Predicate logic permits the use of different forms of training examples and background knowledge. It enables the results of the induction process (the induced concepts) to be described as general first-order clauses with variables and not just as zero-order propositional clauses made up of attribute-value pairs. There are two main types of these systems, the first based on the top-down generalization/specialization method, and the second on the principle of inverse resolution. A number of learning programs have been developed, for example ID3, which is a divideand-conquer program; the AQ program, which follows the covering approach; the FOIL program, which is an ILP system adopting the generalization/specialization method; and the GOLEM program, which is an ILP system based on inverse resolution. Although most programs only generate crisp decision rules, algorithms also have been developed to produce fuzzy rules. The requirement for a set of examples in a rigid format (with known attributes and of known classes) has been easily satisfied by requirements in sensor systems and networks so that automatic learning has been widely used in sensor systems. This sort of learning is most suitable for problems where attributes have discrete or symbolic values rather than those with continuous-valued attributes as in many sensor systems problems. Examples of inductive learning applications are laser cutting, mine detection, and robotics.
Fuzzy logic has many applications in sensor systems where the domain knowledge can be imprecise.
5. Neural networks
Neural networks can also capture domain knowledge from examples. They do not archive the acquired knowledge in an explicit form such as rules or decision trees, and they can readily handle continuous and discrete data. They also have a good generalization capability as with fuzzy expert systems. A neural network is a computational model of the brain. Neural network models usually assume that computation is distributed over several simple units called neurons, which are interconnected and operate in parallel. (Neural networks also are called parallel-distributed-processing systems or connectionist systems.) The most popular neural network is the multilayer perceptron, which is a feedforward network: all signals flow in one direction from the input to the output of the network. Feedforward networks can perform static mapping between an input space and an output space: the output at a
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sensors
Many new sensor systems applications may emerge, and greater use may be made of hybrid tools that combine the strengths of two or more of these tools.
Author
David Sanders is research coordinator, School of Engineering, Reader in Systems & Knowledge Engineering, University of Portsmouth, U.K. Edited by Mark T. Hoske, content manager, Control Engineering, mhoske@cfemedia.com.
given instant is a function only of the input at that instant. Recurrent networks, where the outputs of some neurons are fed back to the same neurons or to neurons in layers before them, are said to have a dynamic memory: the output of such networks at a given instant reflects the current input as well as previous inputs and outputs. Implicit knowledge is built into a neural network by training it. Some neural networks can be trained by being presented with typical input patterns and the corresponding expected output patterns. Error between the actual and expected outputs is used to modify the strengths, or weights, of the connections between the neurons. This method is known as supervised training. In a multi-layer perceptron, the back-propagation algorithm for supervised training is often adopted to propagate the error from the output neurons and compute the weight modifications for the neurons in the hidden layers. Some neural networks are trained in an unsupervised mode, where only input patterns are provided in training and the networks learn automatically to make groups with similar features. Artificial neural networks (ANNs) typically have inputs and outputs, with processing within hidden layers in between. Inputs are independent variables and outputs are dependent. ANNs are flexible mathematical functions with configurable internal parameters. To accurately represent complicated relationships, these parameters are adjusted through a learning algorithm. In supervised learning, examples of inputs and corresponding desired outputs are simultaneously presented to networks, which iteratively selfadjust to accurately represent as many examples as possible. Once trained, ANNs can accept new inputs and attempt to predict accurate outputs. To produce an output, the network simply performs function evaluation. The only assumption is that there exists some continuous functional relationship between input and output data. Neural networks can be employed as mapping devices, pattern classifiers, or pattern completers (autoassociative content addressable memories and pattern associators). Recent applications are feature recognition, heat exchangers, inspection of soldering joints, optimizing spot welding parameters, power, tactile displays, and vehicle sensor systems.
found applications in sensor systems involving complex combinatorial or multi-parameter optimization, including assembly, assembly line balancing, fault diagnosis, health monitoring, and power steering.
7.
Ambient intelligence has been promoted for the last decade as a vision of people working easily in digitally controlled environments in which the electronics can anticipate their behavior and respond to their presence. The concept of ambient intelligence is for seamless interaction between people and sensor systems to meet actual and anticipated needs. Use in industry has been limited, but new, more intelligent and more interactive systems are at the research stage. AI can increase effective communication, reduce mistakes, minimize errors, and extend sensor life. Over the past 40 years, artificial intelligence has produced a number of powerful tools, including those here. Use of these tools in sensor systems applications have become more widespread due to the power and affordability of present-day computers. Many new sensor systems applications may emerge, and greater use may be made of hybrid tools that combine the strengths of two or more of these tools. Other developments in AI that will impact sensor systems include data mining, multi-agent systems, and distributed self-organizing systems. Appropriate deployment of new AI tools will contribute to more competitive sensor systems. It may take another decade for engineers to recognize the benefits given the current lack of familiarity and the technical barriers associated with using these tools. The field of study is expanding. Tools and methods have minimal computation complexity and can be implemented on small assembly lines, single robots, or systems with low-capability microcontrollers. These approaches proposed use ambient intelligence and the mixing of different AI tools in an effort to use the best of each across many processes. ce
Ambient intelligence
Expanding systems, intelligence
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How can you apply artificial intelligence tools to help other areas of control, automation, and instrumentation?
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6. Genetic algorithms
A genetic algorithm is a stochastic optimization procedure inspired by natural evolution. A genetic algorithm can yield the global optimum solution in a complex multi-modal search space without requiring specific knowledge about the problem to be solved. Genetic algorithms have
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Building a better, more efficient plant

Variable frequency drives (VFDs), which can significantly impact energy efficiency goals by optimizing performance and reducing energy consumption by up to 50%, are among options in the U.S. Department of Energy Better Buildings, Better Plants Program.
ccording to the U.S. Department of Energy (DOE), the Better Buildings, Better Plants Program is a national partnership initiative to drive a 25% reduction in industrial energy intensity in 10 years, while decreasing carbon emissions and enhancing U.S. competitiveness. Led by the Advanced Manufacturing Office (AMO) within DOEs Office of Energy Efficiency and Renewable Energy (EERE), the initiative is designed to encourage and recognize U.S. companies that are raising the bar for all manufacturing facilities by establishing and achieving ambitious energy efficiency goals. Among enabling technologies are variable frequency drives (VFDs), which can significantly impact the goal by optimizing performance and reducing energy consumption by up to 50%. To date, 123 Better Buildings, Better Plants Program Partners are demonstrating their commitment to energy savings by signing a voluntary pledge to reduce energy intensity by 25% over the next 10 years. Collectively, these companies are showing that good energy management practices are good for business, good for the economy, and good for the environment. The Energy Policy Act of 2005 defines energy intensity as the primary energy consumed by each unit of physical output in an industrial process. These units of physical output (also called units of production) can be the number, mass, volume, size, functionality or economic value of a product. In pledging to reduce their energy intensity by 25%, companies agree to establish an energy intensity baseline and track the change in energy intensity throughout their participation in the program. They also develop an energy management plan within one year of being a Program Partner with a blueprint for achieving targeted energy reductions. In addition, Program Partners must designate a corporate energy manager who will be DOEs
point of contact for the partnership and annually report energy intensity and energy use data and achievements to DOE. In exchange for their pledge, Program Partners have access to a technical account manager (TAM) assigned by DOE to organize and coordinate services. TAMs will help establish and analyze key energy use data and metrics for the development of baselines and plans. They will also identify emerging, energy-efficient technologies applicable to plant operations. In addition, AMO and its partners will offer Program Partners combined assessment and training programs in plant settings. This includes guidance on how to identify and prioritize energy-saving opportunities, effectively implement and replicate energy-saving projects, and integrate assessments into an energy management strategy. Workshops are available on financing options, advanced technology, energy analysis software, energy management, and other topics. The program also offers Program Partners access to proven energy analysis software tools and other technical resources from DOE, states, utilities, and other partner organizations. The Better Buildings, Better Plants Program gives national recognition to participating companies when they sign the pledge and achieve progress toward energy intensity targets. This includes a welcome letter from DOE, a feature on the DOE website, a congratulatory letter after achieving an annual improvement rate equal to or better than 2.5%, and a letter and plaque from DOE upon achieving the 10-year target.
Improving efficiency today
By varying the frequency of the electrical current supplied to a motor, VFDslike the compact Danfoss VLT AutomationDrivecan reduce a motors rotational speed to match the workload more precisely, multiplying energy savings. Images courtesy: Danfoss
Companies that make the pledge to be a Program Partner have at their disposal a variety of actions to help achieve the energy intensity reduction goal. Insulation can be improved, leaks in compressed air systems repaired, motion sensors and energy-efficient lighting installed, and
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GET IT ALL FROM PMD
Motor upgrades are one way plant managers can reduce a facilitys energy use. A system with a Danfoss VLT OneGearDrive can reach an efficiency level as high as 89%, yielding savings as much as 25% compared to conventional systems. It also reduces spare parts inventory. Courtesy: Danfoss
PMD offers a complete range of motion control products and solutions. Recognized as a top innovator and leader in the motion control industry, we have over 5 million axes installed worldwide. If you have an application in need of a solution, weve probably already solved it.
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other enabling technologies introduced. Among these enabling technologies are variable frequency drives (VFDs), which can significantly impact the goal by optimizing performance and reducing energy consumption by up to 50%. VFDs provide easy and efficient control of any device powered by an ac motor, including fans, pumps, compressors, hoists, etc. The resulting energy savings are tied to the technology and the fact that applications need less energy when idle or operating with partial loads. By varying the frequency of electrical current supplied to a motor, VFDs can reduce a motors rotational speed to match the workload more precisely, which multiplies energy savings and, through smoother control, reduces noise and maintenance and improves reliability. Controlling pressure also reduces losses in irrigation and distribution systems, conserving water. Customized proVariable frequency drives (VFDs) from Danfoss helped Holcim (U.S.) slash its Ste. Genevieve facilitys utility bill by enough to pay for the installation in less than 2 years.
gramming enables a plant manager to determine what parameters are essential to their specific need. To optimize VFD performance, plant managers can take advantage of a manufacturers commissioning service and maintenance programs. A professional start-up service includes a review of the drive installation, ensuring appropriate cooling clearances and connection integrity. Drives are then programmed for the specific application, enabling an organization to realize the full benefits of VFD technology. Customer orientation training may also be provided to help familiarize plant staff with the drives programming and operation. Preventive maintenance ensures that equipment runs efficiently and safely over the course of its lifetime, saving energy, improving functionalities, and avoiding downtime and costly equipment failures. VFD parameters can be periodically adjusted for changing application requirements. Drive service professionals provide VFD services to enable organizations to focus their technical personnel on other core business operation activities. Motor upgrades also can help a plant achieve its energy intensity reduction goal. Integrated motors and gear boxes can combine highly efficient permanentmagnet three-phase synchronous motor and an optimized bevel gear box. The drive helps to optimize plant productivity and increase energy efficiency. The system efficiency level can be as high as 89%, with energy savings as much as 25% compared to conventional systems. A compact integrated motor and gear-
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The Holcim (U.S.) Ste. Genevieve facility used Danfoss VLT AutomationDrives, designed to handle industrial applications, for industrial fan motors, cutting the plants utility bill by enough to pay for the project in less than 2 years, and reducing utility demand charges by reducing inrush current at start-up. Holcims Michael Ifurung checks a setting on the drive.
box can be used in transport and conveying systems, as well as machines and equipment. The drive has been designed for use in the food and beverage industry, although it offers significant benefits in all conveyor drive applications. Compared to traditional systems, an integrated unit can cover many applications with one drive size and only a low number of variants, reducing spare part inventory. Uniform mechanical dimensions ease engineering, and depending on the application, plant managers can choose between two versions, one for use in dry and wet production areas and another for use in wet areas, areas with high cleaning intensity, and aseptic and clean room production areas.
By installing the drive, plant managers can realize longer service intervals. The drive system runs 35,000 operating hours in partial operation between oil changes (by using food grade oil). This means long service intervals, low maintenance cost and effort, and low operating costs. VFDs, high-efficiency motor upgrades, and other high-efficiency technologies can help plants successfully reduce energy use and operating costs. And, by participating in the Better Buildings, Better Plants Program, facilities can help shape tomorrows industryspurring job creation and a stronger economy and contributing to a more sustainable environment.
VFDs reduce energy consumption
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Real-world examples of the energy savings associated with the installation of VFDs include two very different operations: the Ste. Genevieve cement manufacturing facility near Bloomsdale, Mo., and the Gunns Hill Cheese plant in Woodstock, Ontario, Canada. Operated by Holcim (U.S.), one of the largest suppliers of portland and blended cements and related mineral components in the United States, the Ste. Genevieve plant is the largest one kiln line cement plant in North America. It can produce more than 4 million metric tons of cement per year and 12,000 metric tons of clinker per day. Clinker is the critical mineral compound used in making cement. The operation in Ste. Genevieve uses several fan motors, ranging up to 350 hp, to create the proper airflow in the cooler, where hot clinker is cooled from as high as 1450 C to 100 C. When initially installed, the motors used across-the-line starters, with dampers that applied full-voltage to the motor terminals at start-up, resulting in high start-up inrush currents. Additionally, the dampers were operating at less than 100% open for a majority of the year. To increase overall efficiency, the company installed variable frequency drives designed to handle industrial applications on the fan motors. The variable frequency drives slashed the plants utility bill by enough to pay for the project in less than 2 years and reduced utility demand charges by reducing inrush current at start-up. In addition, for the second year in a row, the company received the U.S. Environmental Protection Agencys Energy Star for Super Energy Efficiency. At Gunns Hill Artisan Cheese variable frequency drives were installed in three areas (fluid pumps, the ventilation system, and the cooling compressor) to improve energy efficiency and control. Three VFDs were applied to drive the pumps used to off-load milk from the truck into the raw tank, transfer milk into vats and for washing, in three speeds without motor damage. Another drive was applied to the reverse pressurized air handler that supplies the entire facility with 100% fresh air. The air handler only needs to supply make-up air to maintain the required positive air pressure in the plant. Another was used in a NEMA 12 enclosure to modulate the compressor in the outdoor chiller, reducing costs and providing adaptability. ce
- Patrick Appleby is vice president, industry and food and beverage, Danfoss. Edited by Mark T. Hoske, content manager, Control Engineering, mhoske@cfemedia.com.
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Motion control:
To network or not to network?

Understanding how motion control architectures fit a particular application also can help in deciding what motion control network should be used.
otion control is the art and science of controlling motors to affect a precise movement profile, and understanding motion control architectures can help in determining if or when a motion control network should be used. Whether used to move test tubes or to cut metal, motion controllers plan the trajectory, drive and monitor the motors, and provide regular status updates to the higher level controller. Two primary control architectures are used for the design of motion control systems; centralized and distributed. With the introduction of high-speed, low-cost digital control networks, new choices are available for building distributed control systems. And with the advent of ever-higher power and more compact switching amplifiers, centralized designs are increasing how much of the controller can reside on one printed circuit card. Understanding these technology trends can help explain how and when these two different control architectures should be applied.
What shape is the motion application?
dling system that has a central robot (4 axes), a wafer aligner (3 axes), and a valve controller (1 or 2 axes). In this architecture the network typically connects the local robot or valve controllers to a central network, but the actual motion control is local to the robot, aligner, or valve. The overall machine controller doesnt give commands such as move robot axis #2 to position 12345, it gives commands, such as extend robot arm, which the local robot controller interprets and executes. An example of a stand-alone application is a tape archival system that allows an operator to walk up to the control panel and request a specific tape for retrieval. Here the stand-alone machine controller may execute a whole sequence of arm moves based on a local user-provided command such as retrieve tape # 1234. In this approach a network, if one is connected, is used for reporting and monitoring rather than active control.
NETW ORK
Key concepts
Understanding motion architectures can help with machine design and network selection and design. Two motion control devices include distributed drives and machine controller cards.
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Axis 2
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Axis 6
The nature of the applications control problem has a major impact on which control approach, centralized or distributed, is more appropriate. In some flat motion control applications motors will be controlled more or less equally by a central PC or controller; there are hierarchical applications where the axes are clustered into 2, 3, or more functional axes; and there are stand-alone applications where the machine controller operates largely or entirely without network connection and oversight. Figures 1-3 show this. An example of a flat motion control problem is a printing press with multiple servo-controlled spools. Timing is critical, and the central controller, usually a PC or PLC, must drive all axes in synchrony. Typical commands are move axis #1 to position X, move axis #2 to position Y, etc. An example of a hierarchical motion control application is a semiconductor wafer han-
Intelligent drive or PLC
Figure 1: Flat control architectures connect each element of the machine directly onto the network. Figures courtesy: Performance Motion Devices
NETW ORK
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Figure 2: Hierarchical architectures use networks to synchronize among one or more local controllers.
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can be used for motion as well as other functions. These Axis general purpose networks 1 Application Sensor Code include RS-485, CANBus, Microprocessor Axis EtherCAT, Ethernet Power2 link, Profibus, Interbus-S, Axis 3 and Ethernet. Display Motion What protocol for these Processor Axis networks? The most popu4 lar is CANopen (hosted on the CANBus network and Figure 3: Stand-alone architectures have little or no on EtherCAT). This protocol network connectivity and execute the entire machine makes it possible to buy offbehavior locally on the controller card. the-shelf CANopen-connected sensors and motion drives. Plug in distributed motion drives A fully plug-and-play It is also important to understand the standard is not quite a reality yet. This is options for the physical devices that can because many vendors build CANopen be used in a motion control system. Two motion extensions into products, making are: distributed drives and machine con- them incompatible with other vendors troller cards. There are many variations of products. these devices, but they boil down to just The options can be confusing, but for one of these two physical device types. most users designing a machine, it realDistributed motion control drives, ly comes down to three choices: RS-485 sometimes also called intelligent ampli- (yes, the old standby), CANBus/CANofiers, communicate to a central host via pen, and Ethernet or one of the determina network and provide a suite of motion istic Ethernet variations (EtherCAT or controller features, such as profile genera- Ethernet Powerlink). tion, loop closure, and amplification. Two kinds of distributed drives are Machine controller cards The major alternative to distributed used, depending on the application. The first can be referred to as a tightly coupled drives is a machine controller card, also drive, and uses high-speed, deterministic called a motion control card. The distincnetworks such as SERCOS, EtherCAT, or tion is that a motion control card connects Ethernet Powerlink. The second can be via a backplane bus to a separate mothreferred to as a loosely coupled drive and erboard or processer card, but here we uses slower speed networks such as an will refer to stand-alone single-card controllers and backplane motion cards as Ethernet protocol, CANBus, and RS485. Tightly coupled drives require a machine controller cards. In the machine controller approach, a motion card, or a PC running special software, to synchronize and coordinate microprocessor holds the machines applimotion of each axis. Each drive receives cation code, and a motion controller IC rapid, synchronized, position, and/or (a motion processor) generates profiles, velocity updates, up to several thousand times per second. Loosely coupled drives also are controlled from the host, but assume more profiling capability in the drive and greater latency. Commands are sent to each drive such as move the axis to position x using a point-to-point s-curve. Interactions in those drives tend to be more autonomous and use local sensor inputs to stop and start motion.
Motion network selection
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Networks that can connect to these devices can be dedicated motion-only networks, such as SERCOS, or networks that
Figure 4: Distributed drives connect via a network and provide traditional motion functions such as profiling, servo loop closure, and real-time monitoring.
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does servo loop closure, and manages the time-critical elements of axis control. It is possible, especially for simple control applications, for the machine application microprocessor and motion processor to be the same. Machine controller card advantages include easier serviceability since repair of the entire controller card is a simple swap-out. Wiring is reduced since amplifiers are located on the card. Also the cards physical form factor of the card (and connector interfaces) can be tailored for the application. There are two major variations of machine controller cards: off-the-shelf and custom built. Off-the-shelf cards, particularly bus-connected motion cards, have been around for a long time and are available from several vendors. Custom built cards, while more work on the design side, are also a strong choice. The most important trend here is integration of the amplifier (IC or module-based) onto the card. Another trend is use of off-the-shelf IC-based motion controllers, which provide profile generation, servo loop closure, commutation, and time-critical functions, such as automatic safety responses, programmable breakpoints, and other types of automatic motion axis management.
How to choose a network
Champ
Figure 5: Machine controller cards combine a general purpose microprocessor with a dedicated motion controller. Increasingly, the motion amplifiers are located right on the card.
Heres how to select a motion control network. When considering a distributed motion network, try to anticipate the kinds of signaling required in an application. Does the behavior of the motion depend on the status of signals located on another part of the machine? Will sensors, and other non-motion controlled actuators, such as relays, be on the network bus? How quickly does the motion have to shut down if an error occurs? Another important consideration regarding how, and how much, a networkbased approach influences the mechanical organization of the connected machine, that is: How will the machine be serviced if electronics are physically distributed throughout the machine? Although the traditional card rack that the technician services may be a mess of wires, there is something to be said for keeping everything under one roof. Serviceability and lifetime ownership cost strongly affect control system design choices. Distributing the control by placing amplifiers near the motors may not always be feasible for weight, heat, or other environmental reasons. The traditional control rack cabinet can be air conditioned and insulated from the machine
www.controleng.com
operating environment. This is often not possible if the controls are distributed. When is one control approach used over another? There is no easy answer; sometimes two architectures can be used equally well for a given application. The more cost sensitive the application, the more likely the motion application designer will design a card and, depending on power level, integrate onboard amplifiers. When designing a card, it is possible to choose the connectors needed and set the form factor of the card for that particular motion application. Highly synchronized applications such as machine tools will gravitate toward multi-axis motion cards or a tightly coupled distributed drive approach. These drives allow a lot of flexibility in motor type and power range. Dont forget that a motion control card will be needed for overall path generation, or a PC with dedicated G-code software will be needed. A large middle ground of applications, such as medical automation, semiconductor automation, scientific instrumentation, and low-power general automation, can be served by several approaches including off-the-shelf machine controller cards, custom-built machine controller cards, or loosely coupled distributed drives. ce - Chuck Lewin is founder and vice president of engineering, Performance Motion Devices. Edited by Mark T. Hoske, content manager, Control Engineering, mhoske@cfemedia.com.
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inside machines
Avoid a control panel redesign

If youre dropping packets with field networking for motion control and getting errors or alarms, consider these four sometimes counter-intuitive alternatives to a control panel redesign. Key concepts
When motion network communications contain errors or create alarms, consider: n Whats working and whats not n Checking wiring and settings n Trying latency quick fixes and noise-related quick fixes.
hen motion network communications contain errors or create alarms, consider four quick-fix alternatives before redesigning a control panel. These include looking at the problem and solutions, checking wiring and settings, trying latency quick fixes, and trying noise-related quick fixes. Field networking, such as EtherCAT, Powerlink, CANopen, and Mechatrolink, are growing in popularity, replacing traditional motion control communications (+/-10 V, or pulse trains). When noise affects a field network line, or if sources of latency affect the network line, the consequences are usually a dropped packet. When a packet drops, motion field devices for positioning will often linearly extrapolate the next data point based on the previous two data points, to determine where the position of the motor should be. Enough dropped packets in a short amount of time (such as three consecutive missed packets) can result in the field device throwing an alarm. This results in stopped motion; otherwise, the machine could produce undesired parts. An exam-
ple would be cutting a circular shape: missed packets would result in linear extrapolation, so the circle is no longer circular. When users see these kinds of alarms, the machine panel that contains the devices is usually already built, and the devices were not installed or used exactly as specified by the devices users manual. Users might find that no major redesigns can be performed within the project timeframe, and thus a quick fix is sought instead of redesigning the panel to install the devices according to the devices users manual. The quick fixes below may help, though some are counterintuitive, like using nonshielded cables instead of shielded cables. This is because a system that has devices already installed (but not according to the device manufacturers recommendations) has an unknown noise immunity profile.
1. What fixes can help?
The first troubleshooting step is to find a way to determine which quick fixes might help and which might not. One way is to find a dropped packet counter implemented by either the master device or the slave device. In an EtherCAT drive, a Sync Error Counter records every time a packet is dropped. By checking this monitor, a user can determine how much faster or slower this counter is increasing, and thus can determine if the quick fix is helping or hindering the dropped packet rate. Without a counter, consider modifying the master application code to perform its own monitoring if response data arrived from the field device. If modifying the master application code is not a feasible option, then find how often alarms appear on the drives, and check if the alarms occur sooner or later as the quick fixes are implemented. The second step in this troubleshooting is to check for wiring mistakes and communication setting incompatibilities. There is a distinction between the specifications of the network itself
2. Check wiring, settings

Using a network such as Mechatrolink for I/O and motion control networking can simplify network configuration, reduce wiring, and lower cost. www.mechatrolink.org Figures courtesy: Yaskawa
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versus the implementation of the network in the field device, which can result in communication incompatibilities. Here is a list to check: a. Check the users manuals of all networked devices to determine if they support the network communication cycle time that the master is using. For example: Ethernet-based networks can operate at 31.25 microseconds, but not all devices on the network can operate at that rate. The fastest communication cycle time for servo drives in todays industry is 125 microseconds. b. Check the users manuals of all the devices on the network to determine if there are any communication cable length restrictions. Ethernet-based network vendors publish 100 meters for the communication cables, but not all devices are capable of being connected with 100 meters yet still maintain a usable signal. c. Check the communication cable wiring, such as plugging the communication cables into the correct ports (from one devices OUT port, to the next devices IN port). d. Check if termination resistors are needed, and install them. Networks like CANopen require a termination resistor at the start and end of the network. e. Check the networks installation specifications to determine if a repeater is necessary, and check if the number of devices on the network exceeds the maximum. In some networks, a repeater is needed to achieve the published maximum number of devices allowed for the network.
With motion control communications in a computer numerical control (CNC) machine, dropped data in communications can translate into a linear extrapolation, causing rework or creating scrap. Network topology can create latency, especially with a commercial off-the-shelf hub. In some applications, a line topology may run better.
3. Try latency quick fixes
The third step is to implement quick fixes related to noise. Those helpful in the past include: a. If the master is PC-based, closing some PC programs may allow the processor to use more time for the network communications. Increas-
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ing the priority of the communication task may also help. b. Remove network hubs from the network by changing the topology to line topology. COTS network hubs are not always designed for industrial network communications and add network latency. Even industrial network hubs may cause packets to drop if not installed properly because of noise. Taking hubs out of the system may help communications. c. Increase the communication cycle time in the master. Setting a longer communication cycle will give a larger window for a packet to arrive on time and not be considered dropped. d. Check the communication cycle time in the master. In some cases, the base time of the master is 0.333 microseconds, and there is a multiplier of the base time that the master will use for the communication cycle. If the multiplier is x3, then the communication cycle is 0.999 microseconds, which is not the same as 1.000 microseconds. In this case, the base time can be changed to 0.250, with a 4x multiplier for the communication cycle. e. Change the network clock method. In some networks, like EtherCAT, there are different methods for clock synchronization, including using the master as the networks reference clock, or using the first slave on the network as the networks reference clock. Using the master as a reference clock can cause network latency, especially if the master is performing multiple tasks such as being used as a general PC. Switching the network clock method to use the first slave on the network as the reference clock may improve the synchronization of the network, reducing network latency.
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4. Try noise-related quick fixes
Ethernet-based like EtherCAT, Powerlink, and Mechatrolink. Shielded Ethernet cables are readily available commercially off-the-shelf (COTS, at local electronic stores). If shielded communication cables are used but were made in-house, check that the shield is connected to the metal part of the connector; otherwise, the shield is not grounded. Changing from shielded to nonshielded cables may improve communications. b. Use of ferrite cores on the communication cables. Two passes (one loop) through a ferrite core compared to one pass through a ferrite core can make a difference. Putting one core on the cable versus putting one core on each end of the communication cable also can help. c. Length of communication cables. Since noise is not always easy to characterize, using shorter cables may help, but using longer cables may also help. Ether can be tested in a situation for a quick fix. d. Route the network cables away from cables that carry power. Power carrying cables or conductors like main power or motor power cables can cause interference to network cables. Separate network cables from power cables or conductors by at least 30 cm. e. Enable communication data retries in the master. If the network supports resending dropped data within the communication cycle time, or data retries, then enabling this in the master gives dropped data an additional chance to be transferred. Networks like Mechatrolink support this feature built in, so all Mechatrolink masters can use this feature. ce - Derek Lee is motion product engineer, Yaskawa America Inc. Edited by Mark T. Hoske, content manager, Control Engineering, mhoske@cfemedia.com.
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Noise-related quick fixes that have worked in previous situations include: a. Switch to shielded communication cables or nonshielded communication cables. Many field networks are
M10
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Control Engineering Digital Edition Exclusives provide additional information not included in the paper edition. As with all Digital Edition content, click on any highlighted headline to read a longer version online.
TECHNOLOGY UPDATE
DE-1 Isolating high-speed data interfaces
Choosing the right isolator requires knowing system requirements and which high-speed interface meets the requirements for isolating their signal paths using digital isolators.
APPLICATION UPDATE
DE-5
Crane controls help make energy from waste
Olmsted County increased the energy processed at its waste-to-energy facility by doubling the amount of refuse it burns every day with integration of updated drives, motors, and controls.
DE-7 Magnets, sensors create paths for automated guide vehicles
APPLICATION UPDATE
An automated guided vehicle (AGV) can be built with as little as two components: a magnetic guide sensor and a dual-channel motor controller.
Go to www.controleng.com/digitaledition today!
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technology
UPDATE
Isolating
high-speed data interfaces

igh-speed interfaces are used for fast data transfers in data communications hubs, wireless base stations, flat-panel displays, servers, and peripherals like printers and digital copy machines. Typical distances reach from a few inches (between ICs or from board to board) up to several meters (between systems). Due to the short data link distance, ground potential differences between driver and receiver are assumed to be small, and the required common-mode input voltage range of a receiver is commonly limited to a few volts. Increasingly high-speed interfaces are installed in industrial applications. This harsher environment presents external noise sources, such as motors and generators, which couple noise currents into the local grounds. These currents can raise the ground potential differences between bus nodes beyond the common-mode voltage range of bus receivers, causing data errors and even device damage. Implementing galvanic isolators into the
signal and supply lines of the interface components removes the ground potential difference between bus nodes and limits the commonmode voltage to the drivers output offset and assures robust data traffic. Choosing the right isolator requires knowing the system requirements. To ease the design task, understand the most popular high-speed interfaces, low-voltage differential signaling and multi-point low-voltage differential signaling (LVDS and M-LVDS), and the requirements for isolating their signal paths using digital isolators.
LVDS
Figure 1. LVDS point-to-point data link: H-bridge output stage of an LVDS driver switches a constant current source of 4 mA alternately between its two differential output terminals. Figures courtesy: Texas Instruments
DE-1
LVDS is a low-voltage, differential signaling scheme used for high-speed data transmission in point-to-point and multi-drop data links. Defined in the TIA/EIA-644 standard, it is the most commonly used differential interface. LVDS uses current drive technology, where the H-bridge output stage of an LVDS driver switches a constant current source of 4 mA alternately between its two differential output terminals (Figure 1). A single 100 Ohm resistor placed at the receiver input terminates the differential pair to eliminate reflections and also converts the line current into a differential receiver input voltage of 400 mV nominal. The differential voltage swings around a 1.2 V common-mode potential, which is the typical driver output offset voltage (Figure 2). Typical LVDS applications include highspeed backplane communication, data transmission, and clock distribution across cables and between systems, so from board-to-board, as well as intra-circuit communication links within one printed circuit board (PCB). The two bus topologies supported by LVDS are point-topoint and multi-drop. A point-to-point data link (Figure 3) connects a single driver to a single receiver via a pair of wires or traces. The receiving end of the link has a termination resistor. Often multiple
point-to-point links are designed in parallel to increase the total bandwidth between two communication points. In a multi-drop topology a single driver drives multiple receivers as shown in Figure 4. Because LVDS is designed for point-topoint applications, its finite drive capability limits the number of receivers that can be connected and the signaling distance that can be accomplished.
M-LVDS
To extend LVDS technology to multi-point applications, a new standard (TIA/EIA-899) for multi-point LVDS or M-LVDS was created. M-LVDS allows higher speed communication links than RS485 or controller area network (CAN) with less power. To support the higher bus load of multi-point applications, M-LVDS drivers have higher current drive capability than LVDS drivers. They can drive up to 32 nodes over longer signaling distances with slew-rate controlled transitions to minimize electromagnetic interference (EMI) in long cable runs. M-LVDS receivers have a wider common-mode input voltage range than LVDS receivers and provide an option of failsafe receivers for bus idle conditions. In a multi-point topology each bus node can either send or receive. Two types of multipoint buses exist: a half-duplex and a full-duplex version shown in Figures 5 and 6. A half-duplex bus uses two wires across which one node may transmit while another node receives data. In a full-duplex bus, two signal pairs (four wires) are used. One pair connects the driver of a master node to the receivers of multiple slave nodes. The other pair connects the drivers of the slave nodes to the receiver of the master node. This topology allows the master to either broadcast data to all slaves or address a specific slave node, while simultaneously receiving data from the slave nodes, one slave at a time. An important condition of a multi-point bus is bus idling, that is, when no driver is driving the bus and the differential bus voltage is zero. The output of a standard or Type-1 M-LVDS receiver, with symmetrical input thresholds of 50 mV, will be undefined. To assure a defined low receiver output state during bus idling, a Type-2 M-LVDS receiver has offset input thresholds of +50 mV to +150 mV. For comparison, Table 1 (online) lists the main driver and receiver characteristics of LVDS and M-LVDS components.
Figure 2. LVDS bus voltage levels: Differential voltage swings around a 1.2 V common-mode potential, which is the typical driver output offset voltage.
Figure 3. LVDS point-to-point link connects a single driver to a single receiver via a pair of wires or traces. The receiving end of the link has a termination resistor.
Figure 4. LVDS multi-drop bus: In a multi-drop topology a single driver drives multiple receivers.
Isolating the data link
Table 1 shows that the input voltage range of LVDS and M-LVDS receivers is limited to just a few volts, thus allowing for ground potential differences (GPDs) in non-isolated data links of not more than 1 V. In real-world applications, however, even short bus lengths can have GPDs of up to 30 V and more, thus exceeding the receiver maximum input voltage range by far. Figure 7 shows a non-isolated data link. Because the receiver inputs are internally biased with reference to the receiver ground, the maximum receiver input voltage is the sum of the sigwww.controleng.com
CONTROL ENGINEERING DECEMBER 2013 DE-2
technology
UPDATE
Due to a tight time budget and low power consumption, digital capacitive isolators are well suited for isolated high-speed interfaces.
for in an isolator data sheet are: tPLH, tPHL, the propagation delays for lowto-high and high-to-low transitions PWD, the pulse-width distortion or the magnitude of the difference between propagation delays, |tPHL tPLH| tSK(o), the channel-to-channel skew, the difference between transitions of multiple channels tSK(PP), the part-to-part skew, the difference between transitions of multiple devices. For easy comparison Table 2 (online) lists these timing parameters for a capacitive and an inductive 150 Mbps, 4-channel, digital isolator. The parametric values of both isolator technologies are almost identical except for the large partto-part skew of the inductive isolator. This means that as long as the potential data link is limited to 4-channels, only requiring a single isolator IC, synchronicity is warranted due to low channel-tochannel skew. For higher channel counts requiring more than one isolator device, the 16 ns skew of the inductive isolator must be compensated for using field-programmable gate arrays (FPGAs) with dynamic phase adjustment (DPA). If, however, DPA is not available, the only way to assure synchronous data transfer is by adhering to a strict timing budget, which is easily accomplished using a capacitive isolator. Bearing in mind that the inductive isolation technology is in its third generation, there is doubt that part-to-part skew is going to improve for inductive isolators.
Power consumption
Figure 5. M-LVDS half-duplex bus: In a multi-point topology each bus node can either send or receive. Two types of multipoint buses exist: a half-duplex and a full duplex version.
Figure 6. M-LVDS full-duplex bus: In a multi-point topology each bus node can either send or receive. Two types of multipoint buses exist: a half-duplex and a full-duplex version.
nal voltage (VD), the driver output offset voltage (VOS), and the voltage difference between driver and receiver grounds (GPD). Hence, whether a data link works flawlessly or suffers damage from overvoltage potentials greatly depends on GPD. Isolating the bus components from the local node circuits (Figure 8) removes the large GPD between driver and receiver. The driver and receiver grounds are now floating. With the only common-mode component being VOS, the receiver ground assumes VOS potential. The resulting voltage difference between driver and receiver grounds is also VOS. Thus, galvanic isolation assures robust data traffic by making the data link independent from large ground potential differences. Careful selection of digital isolators is advised as these isolators introduce additional propagation delays, jitter, and skew, which all affect the signal timing on the bus lines. If these parameters exceed certain values, synchronicity between signals of a single signal pair and between the parallel signal pairs of a multi-channel link might not be provided. The most important timing parameters to look
DE-3
Another important decision factor when
Figure 7. Non-isolated LVDS data link: Because the receiver inputs are internally biased with reference to the receiver ground, the maximum receiver input voltage is the sum of the signal voltage (VD), the driver output offset voltage (VOS), and the voltage difference between driver and receiver grounds (GPD).
selecting isolator technology is the power or current consumption at high data rates. After all, LVDS was created on the premise of providing gigabits at milliwatts. Hence, a high-speed isolator must provide sufficiently low-current consumption to honor this premise. A comparison of supply current per channel in Figure 9 shows that inductive isolators possess low-power consumption only at low data rates of up to 10 Mbps, where they typically replace optoisolators. At around 15 Mbps, however, capacitive isolators already begin consuming less current. And at data rates of 50 Mbps to 150 Mbps, the capacitive technology shows its superiority by consuming only half to one-third the current that inductive isolators require.
Budget, low power
Figure 8. Isolated LVDS data link: Isolating bus components from the local node circuits removes the large GPD between driver and receiver.
Due to a tight time budget and low power consumption, digital capacitive isolators are well suited for isolated high-speed interfaces such as LVDS and M-LVDS. Texas Instruments provides a huge portfolio of LVDS single and multi-channel drivers and receivers, M-LVDS transceivers, and high-speed, digital isolators. ce - Thomas Kugelstadt is a senior systems engineer with Texas Instruments. Edited by Mark T. Hoske, content manager, CFE Media, Control Engineering, mhoske@cfemedia.com.
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Figure 9. Supply current per channel for capacitive and inductive isolators: Inductive isolators possess low-power consumption only at low data rates of up to 10 Mbps, where they typically replace optoisolators.
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application
UPDATE

Olmsted County increased the energy processed at its waste-to-energy facility by doubling the amount of refuse burned daily, with integration of updated drives, motors, and controls.
lmsted County, Minn., has a wasteto-energy facility that burns nonrecyclable refuse to produce energy. To increase the amount of waste turned into usable energy, the facility underwent an expansion to increase its capacity from 200 tons to 400 tons of waste processed per day, with integration of updated drives, motors, and controls. The nearly $100 million project began in October 2007 and was completed in June 2011. Since opening in 1987, the Olmsted Waste-to-Energy Facility (OWEF) has processed more than 1.5 million tons of garbage into high-pressure steam and electrical energy used by nearby government buildings and sold to the power grid. The existing plant had two 100-ton-per-day boilers. A 200-ton-per-day boiler was added during this expansion to increase capacity. Each boiler has a hopper that is fed waste by two 7.5-ton bridge cranes. With two boilers, the manual oper-
ation was an efficient method of moving refuse from the garbage pit to the loading hoppers. Now, with three boilers, the operation needed to vastly improve its efficiency to meet the project goal of doubled throughput. Olmsted County hired Superior Crane to provide new trolleys, including new trolley and hoist motors, for each of the two waste handling grapple cranes. New semi-automated crane controls aimed to increase the cranes speed, reliability, and productivity. Superior Crane installed new variable frequency drives (VFDs) throughout the system, as well as a programmable logic control-
Semi-automated control
allows positioning over a
specific, predefined area of the pit as requested by the crane operator.
At Olmsted Waste-to-Energy Facility, Magnetek, which provides material handling power control and automation, was brought into the project to provide new semi-automated crane controls aimed at increasing the cranes speed, reliability, and productivity. This is the chute and grapple. Images courtesy: Magnetek
DE5
ler (PLC) interface for each crane that allows the operator to pick a load of waste out of the storage pit and place it into one of the fuel loading hoppers. New arm chair control consoles were also incorporated for safe and convenient operator control of the cranes. Two overhead bridge cranes are located 100 ft above the pit that is 21 ft deep, 50 ft wide, and 100 ft long, and holds up to 2,000 tons of refuse. Either crane can travel from one end of the pit to the other as the grapple descends to take bites of the stored waste to transfer combustible material from the storage pit to the loading hopper. The new semi-automated control allows the hoist, bridge, and trolley to effectively position the grapple over a specific, predefined area of the pit as requested by the crane operator. Once the load has been picked, the automated control system moves the hoist, bridge, and trolley as necessary to provide the most efficient path to the hopper. The waste, after being loaded into the hopper, slowly travels 16 ft down onto the feed rams. The
At Olmsted Waste-to-Energy Facility, Superior Crane installed new Magnetek Impulse G+ Series and Impulse VG+ Series variable frequency drives throughout the system, along with Magneteks new arm chair control consoles, incorporated for safe and convenient operator control of the cranes. Here the storage pit is shown.
feed rams force the waste into the boilers. Ultrasonic monitors track the level in the hoppers and inform the operator when another load is needed. Each of the three fuel loading hoppers is fed alternately with the crane and grapple.
Semi-automated
performed on-site start-up services and training. As a result, Olmsted County increased the energy processed at its waste-to-energy facility by doubling the amount of refuse burned daily.
Project summary
From the pulpit control station, 35 ft above the pit, an operator commands the semi-automated movement of the cranes and grapples from an operators chair communicating with a PLC in a central control room equipped to monitor and operate the facility. Two operators chairs exist, one for each crane. However, the system is designed to allow an operator at either chair to operate either crane on a first-come-first-served basis. Alternatively, two service stations are positioned on either end of the runway to allow manual control of the cranes for repair and maintenance. The waste-to-energy facilitys efficiency and throughput were improved with two semi-automated bridge crane control systems using variable frequency drives, new hoist motors, and updated cab chair controls. The system also incorporates PLCs programmed to meet the projects specific requirements. To ensure that the cranes operated per Olmsteds specifications, VFD vendor system engineers
For the Olmsted County Waste-toEnergy Facility bridge crane project, the following automation products and services were used: variable speed drives (two models), PLC, hoist motors, cab chair console controls, engineering services, and application expertise. New retrofit control systems for two overhead bridge cranes were used to feed an additional furnace, doubling waste processing. New trolley-hoists increased crane performance. Updated drives, controllers, and motors ensured continuous operation. Semi-automated crane controls increased efficiency and reliability. ce - Lynn Bostrom is director, communications, Magnetek. Edited by Mark T. Hoske, content manager, CFE Media, Control Engineering, mhoske@cfemedia.com.
At Olmsted Waste-to-Energy Facility, Superior Crane and Magnetek improved the waste-to-energy facilitys efficiency and throughput by providing two semi-automated bridge crane control systems using Magnetek Impulse variable frequency drives, new hoist motors, and updated cab chair controls. Pit and cranes are shown.
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At Olmsted Waste-to-Energy Facility, to ensure that the cranes operated per specifications, Magnetek system engineers performed on-site start-up services and training, working with Superior Crane, a full-service design, engineering, and crane manufacturing firm specializing in overhead material handling equipment.
CONTROL ENGINEERING DECEMBER 2013 DE6
application
UPDATE
Magnets, sensors create paths for automated guide vehicles

n automated guided vehicle (AGV) can be built with as little as two components: a magnetic guide sensor and a dual-channel motor controller. The AGV will follow a track made of an adhesive magnetic tape affixed on the floor. The magnetic sensor will measure how far from the center of the tape it is and provide the information to the motor controller, which will then adjust the steering so the vehicle remains at the center of the track. Magnetic markers positioned on the left and right side of the track give the AGV location information that will be used to make stop and fork left/right decisions.
Magnetic track guiding
following techniques. The other two main techniques are induction wire guide and optical. A table compares each of these techniques.
Chassis design
When designing the vehicle, there are four basic ways of providing drive and steering, shown in the diagrams. Some types are easier to build; others have better steering characteristics. Two of these designs are fully symmetrical and may be operated in both directions. The chassis design table lists the characteristics of each design. The sensor should be placed as shown in the above diagrams for each chassis design. For the first two chassis types, the sensor must be placed near the front edge of the chassis. On long AGVs, this means that a little steering will cause a wide swing at the front and will make the steering control more difficult. On the steerable drive wheel design, the sensor can be placed on the chassis. Or it may be made part of the wheel assembly and turn with it. For best results, place the sensor at 30 mm above the floor and ensure that the height fluctuates within +/-10 mm at most as the AGV moves along the track. The MGS1600C has several output types. Features and typical uses are shown in the sensor attributes table. In the MultiPWM mode, the sensor data is output on one wire in a series of variable width pulses, containing the track detect signal, track position, and left and right marker detect signals. This pulse can be connected to any of the Roboteq motor controllers pulse inputs. Once the pulse input is configured as Magsensor, the sensor information is transferred transparently and continuously to the motor controller, from where it can be processed using the MicroBasic scripting language, or accessed by an external computer or PLC via the controllers serial or USB port.
Sensor mount
An AGV uses a magnetic guide sensor from Roboteq. Courtesy: Artisteril SA of Barcella, Spain.
Magnetic tapes are one of several line-
Automated guided vehicles table: Tracking comparison

Technique
Magnetic Guide Induction wire Optical
Easy to lay
Yes No Yes
Easy to change
Yes No Yes
Passive
Yes No Yes
Dirt immune
Yes Yes No
Invisible
Yes Yes No
Sensor-motor controller interface
When comparing AGV tracking techniques, magnetic tape is the easiest to lay and modify while providing excellent durability and reliability, compared to induction wire and optical. Courtesy: Roboteq
Automated guided vehicles table: Chassis design

Design
4 wheel drive Center drive and casters Steerable drive motor Rear drive and rack steering
Simplicity
Simplest Simple medium Complex
Steering
Coarse Precise Very precise Precise
Reversible
Yes Yes No Difficult in reverse
Various AGV designs differ in characteristics, as shown. Courtesy: Roboteq

DE-7
Electrical wiring
The wiring diagram shows the magnetic guide sensor and motor controller in a typical four-wheel-drive chassis. This diagram is applicable to all Roboteq dual-channel brushed motor controllers. A figure shows the controllers connector details. This wiring is compatible with all Roboteq controllers equipped with a 15-pin DSub connector. The sensor and button can be connected to any other pulse and digital inputs. Refer to the product datasheet for the list of available signals and pin outs. The pulse output is on the blue wire of the sensor cable. The sensor and controller must be configured so that they will each function as desired, and communicate with each other. The sensor is configured by default to output MultiPWM pulse and therefore can be used without further configuration if the track is made of Roboteq-supplied 25 mm magnetic tape. Once powered, the Tape Detect LED will flash at a low rate if no tape is present. When tape is in range, the LED will be on steady, and its color will change when the tape is at the right or left. For configuration, monitoring, and troubleshooting, connect the sensor to the PC via the USB connector located under the screw plug. Run the Magsensor PC utility to change the tape width if using a 50 mm tape, or use the waveform display view to monitor the shape of the magnetic field. With no tape present, the PC utility must
Automated guided vehicles: Sensor attributes table

Output
RS232 Multi PWM Analog PWM CAN USB
Sensor data sent

All Position, Tape detect, markers Position only Position only All All
Noise immune
Yes Yes No Yes Yes Yes
Use
PLC, computers Roboteq motor controllers PLC PLC PLC, computers PC motherboards
Sensors used for AGVs vary in attributes. Courtesy: Roboteq
Configuration, testing
show a nearly flat line. For best results, always perform a zero calibration when operating the sensor in a new environment. Moving a tape under the sensor will cause a bell curve to appear on the chart. The curve must be on the positive (up) direction. If the curve is going down, change the Tape Polarity set- Magnetic guide sensor will detect the center positing in the configuration of an adhesive magnetic tape up to 60 mm away. tion menu. Makers Courtesy: Roboteq will also cause a bell curve, but the curve should be going down. A screenshot shows the resulting curve when plac-
Four typical AGV chassis designs are shown. Courtesy: Roboteq

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An additional set of queries is available for reading this information from the motor controller. The queries can be sent either from the motor controllers serial port, or from within a MicroBasic script running in the motor controller. (See the query set table.)
Implementing the AGV controls
Once the sensor and motor controllers are verified to work, we can proceed to the automatic mode. In this article, all the computation is done in the motor controller using the MicroBasic scripting language The sensor outputs a value that is the tapes distance from the center of the track. This information is then used to correct the steering. If the tape is centered, the value is 0, and no steering correction is needed. The farther the track is from the center, in one or the other direction, the stronger the steering change. In this example, a proportional control is implemented. For best precision and response time, the control algorithm may be improved to a full PID (proportional-integral-derivative). How the throttle power is controlled (when to start, stop, accelerate, slow down) is application dependent. In this example, the AGV will be made to move when a tape is detected, take left or right forks, and stop at precise locations. The AGV will then resume moving after a set time, or when a user button is pressed. The AGV will stop when the track is no longer present. In a practical implementation, the AGV throttle will be controlled by an external device, such as a PLC. The PLC must then be connected to one of the motor controllers inputs. The throttle information can be an analog voltage or a variable duty cycle PWM signal. The sensor has an algorithm for detecting and managing up to two-way forks and merges along the track. Internally, the controller always assumes that two tracks are present: a left track and a right track. When following one track, the sensor considers that the two tracks are superimposed. When entering forks, the track widens, and so does the distance between the left and right tracks. When approaching merges, the sensor will report a sudden spread of the left and right tracks but will otherwise operate the same way as at forks.
Steering control
An example AGV wiring diagram is shown. Courtesy: Roboteq
ing a left marker and a centered track.

Motor controller configuration
A sensor and button connect to the AGV motor controller. Courtesy: Roboteq
Magnetic sensor connectors and LED indicators are shown. Courtesy: Roboteq
To receive and recognize data from the sensor, the controller must first be connected to a PC running the Roborun+ PC utility. In the configuration menu, the pulse input that is connected to the sensor must be enabled and configured as Magsensor. Next, the controller must be configured to operate in mixed mode so that the steering command will apply a different amount of power to the left and right motor for making turns.
Magsensor to controller
Throttle control
Fork, merge management
This is the captured magnetic field waveform when no tape is present. Courtesy: Roboteq
DE-9
When the sensor and the motor controller are connected to each other using the single wire and MultiPWM mode, the sensor data are transferred periodically, and in the background, into the motor controller from which they can be accessed and used.
Localization using markers
Magnetic markers are a piece of magnetic tape of opposite polarity located left and/or right of the center track. Markers provide a very simple and cost-effective method to identify specific locations along the track. This application uses markers on the left or right side to indicate which track to follow at a fork. Markers located at the left and right side will indicate a stop location. More elaborate marker arrangements can be made to carry more information about a location on the track. An example of multi-level markers is provided in a diagram. It is common to require that the AGV be driven manually, to place it in position, or to move it along an untracked path. Buttons, a joystick, a PLC, or an RC radio can be connected directly to the motor controllers free inputs. The program running inside the motor controller can easily be made to switch from automatic to manual command. Manual override is not described here. The test track figure shows a simple AGV track with several loading stations and one stop station. For simplicity, the AGV here will stop 30 seconds at every station, or until the operator presses the push button. The flow chart shows the structure of the MicroBasic program that will run inside the motor controller to move and steer the AGV along the track. The full source code is provided at the bottom of the article. Before the sensor can be used for automatic steering, it is a good idea to test drive the chassis manually, either by attaching a joystick to the PC that is connected to the motor controller, or by using an RC radio. If the vehicle is difficult to drive manually, in automatic mode it will be equally challenging. Modify the design so that it drives and steers as smoothly and accurately as possible. When running the program for the first time, it is recommended to lift the AGVs wheels off the ground. Then place a piece of magnetic tape below the sensor. Verify that the left and right wheels start rotating when the tape is detected. Verify that the left and right rotation speed changes as the tape is moved away from the sensors center, in a manner that would cause the AGV to rotate so that the sensor would become
Manual steering override
centered with the tape. If the AGV rotates away, then invert the polarity of the Gain value in the script. With the AGV wheels on the floor, verify that the steering correction is such that the sensor never moves far from the track. Increasing the Gain value will cause a stronger correction when the sensor moves away from the tape, but it can make the AGV oscillate if the gain is too high. Find the optimal Gain value for stable and accurate tracking.
Testing fork, stop markers
This is the captured magnetic field when the left marker and center track are present. Courtesy: Roboteq
Test track description
Manual AGV test drive
Testing the automatic steering program
Markers are best tested with the AGV on the track. Verify that the AGV follows the expected track at a fork. When entering a merge, ensure that the AGV is following the correct track and that it will not jump to the opposite track Diagram shows the left and right AGV track when it enters the sensors captures at the forks and merges. Courtesy: Roboteq range. Verify that the AGV stops when a left and right marker are detected at the same time. Check that the AGV resumes motion after 30 seconds, or when the button is pressed. Beware that as the AGV moves away from the marker pair, one of the two markers will disappear from the sensors range before the other. The other marker will remain Markers are used for indicating fork, merge, active for a short duration and stop locations. Courtesy: Roboteq and will therefore be considered as a left or right fork marker. Ensure that one marker is present before the next fork or next merge following a stop location. Using a more complex steering algorithm: The sample script uses a simple proportional control, where the amount of steering correction is the distance from the center track, multiplied by a gain factor. For better results, the script may need to be enhanced so that a proportional-intewww.controleng.com
Improving the AGV
application
UPDATE
gral or full proportionalintegral-derivative control is used instead. The amount of correction can also be capped to avoid oversteering. In a variable speed system, it may also be desirable to have a different correction gain at slow and high speeds.
Diagram shows an example of a multi-level marker. Courtesy: Roboteq
An example AGV track shows one possible layout. Courtesy: Roboteq
In this application example, we used a simple left and right marker pair to identify a stop location. In typical applications, more information is needed about location so that the AGV will change its behavior. For example, identifying segments of tracks where the AGV must move at a high speed and others at low speed, identifying load stations requiring longer pause time than others, or identifying charging stations where the AGV will stop only when its battery level is low and resume when the battery is charged. One simple and free technique is to count markers in a track segment delimited by a marker Here is the program flow chart for the example segment on the opposite provided. Courtesy: Roboteq side. A figure shows such a marker configuration. When a left marker first appears, the counter is reset. The counter is then incremented at every appearance of a right marker while the left marker is still present. When the left marker disappears, the counter is evaluated and the AGV can alter its operation accordingly.
Improving stop position accuracy
Using multi-level markers
Using secondary marker adds precision for longitudinal stop positioning. Courtesy: Roboteq
GV localization, safety
For safety reasons, it is typically necessary to fit the AGV with an infrared or a laser range finder so that it will stop if a person or obstacle is detected along the track. Range finders typically provide a digital signal which can easily be connected to an input on the motor controller or to a PLC if one is present. If more information is needed by the AGV about its location along the track, RFID tags positioned in key locations are a good solution. However, RFID tags typically imply the presence of a microcomputer or a PLC on the AGV to process the data and make navigation decisions. The source code (see online version of this article click on headline at top) is written in Roboteqs MicroBasic language and runs inside the motor controller to perform the AGV functionality described in this article. ce - Cosma Pabouctsidis is senior technologist, Roboteq Inc. Edited by Mark T. Hoske, content manager, CFE Media, Control Engineering, mhoske@cfemedia.com.
Script source
In applications requiring the AGV to stop at a very precise location, a secondary sensor, oriented at 90 degrees from the main sensor, can be added. This sensor can then be used to locate another magnetic guide with 1 mm position accuracy. Sensors and guides arrangements are shown in the figure.
Go Online
Click the headline for more photos and programming information. Search AGV at www.controleng.com for other AGV advice. www.roboteq.com
DE-11
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Motion control feedback improves precision, increases uptime

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Using licensed radio frequency bands for long-range wireless Ethernet

Eaton has released its new Elpro 450U-E licensed wireless Ethernet modem family, designed to extend the range of networks in difficult applications. Units in the group can support 60 to 450 MHz licensed frequencies, allowing users to choose the best for a given application. Operating at 360 to 512 MHz, and up to 5.0 W, the 450U-E is optimized for throughputs of up to 19.2 kbps which provides robust and secure two-way wireless communications in extremely challenging outdoor environments over obstructed paths typical of remote monitoring and control applications. The family offers node-to-node deterministic mesh network repeatability for further range and multiple channel spacing options to increase network scalability. Integrated Modbus server capability allows seamless integration with smart sensors, RTUs, or I/O expansion using Elpro 115S expansion modules.
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Distributed control system for smaller plants integrates with third-party devices and drives
Honeywells Experion LX is a purpose-built distributed control system (DCS) for small to mid-size operations with continuous and batch process control applications. Experion LX is designed specifically for plants or units with fewer than 5,000 I/O points, one engineering server, and up to 15 operator stations. It encompasses technology from Honeywells Experion Process Knowledge System. For end users with batch processes, the batch execution software operates in a redundant controller instead of a computer, eliminating the need for extra hardware and reducing the communication load and time for execution of each batch phase. Experion LX is designed to be delivered through system integrators and integrate with third-party devices and drives.
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RFID transponder for large-scale deployments reads up to five meters

Hartings VT92 RFID transponder for North America has a read range up to five meters by adjusting the antenna structure to pitch to 920 MHz. Passive UHF RFID operates globally from 866 to 930 MHz, but within this range there are target frequencies based on the location of the user. By pitching to the North American frequency, the VT92 nearly doubles the usual read range for tags on metal read by a stationary reader. Durable IP69K housing ensures consistently reliable operations in -65 to 210 C storage temperatures. That high heat resistance makes it autoclavable ideal for medical sterilization applications necessary in hospitals and research facilities.
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BASICS
Tuning surge tank level control loops

This type of PID loop has a different objective than most, which calls for a different strategy.
hile almost all PID loop tuning rules aim for fast response, For more information, visit: even the IMC and Lambda rules fall short for a surge tank control www.dataforth.com loop, so we need a different strategy for this Subscribe to Process & application. Advanced Control eNewsletA surge tank, shown in Figure 1, helps ter at www.controleng.com/ newsletters absorb flow rate fluctuations from the upstream process, so the flow to the downstream process changes less rapidly. To do this, the controller must allow the level to go up and down and not try to hold the level close to its setpoint. The controller should simply keep the surge tanks level between its upper and lower limits with the least change to its output. The level-averaging method minimizes control valve movement during disturbances, keeps the level between its limits, and brings the level back to setpoint over the long term. The tuning Figure 1: A typical surge tank configuration rule describes how to tune with its level control loop. Courtesy: Dataforth surge tank level controls
Go Online
using this method and is designed for use on a non-interactive controller algorithm with its integral time set in minutes, such as the algorithm in the Dataforth MAQ20 system. To tune the controller for level-averaging control, three key factors must be quantified: Residence time (tres): Residence time is the time it will take the tank to drain from 100% to 0% level if there is no incoming flow and the outlet valve is 100% open. It can be calculated by dividing the volume of the vessel between 0% and 100% of its level measurement span (V) by the maximum flow rate with the outlet valve wide open (Qmax): tres = V / Qmax The same unit of measure must be used for volume in V and Qmax, and Qmax must be expressed in volume per minute. Change in flow rate (fmax): The greatest expected change in flow rate should be expressed as a percentage of maximum valve capacity. Historical trends of the valves position can be used to find the largest change the controller output has made over a relatively short period of time. Maximum deviation from setpoint (Lmax): The maximum allowable deviation of level from its setpoint should be specified as a percentage of the full span of the level measurement. Once the three quantities are available, tuning settings can be calculated for the controller: KC = 0.74 fmax / Lmax TI = 4 tres / KC TD = 0 Where KC is controller gain; TI is integral time in minutes; and TD is derivative time. The typical response of a surge tank tuned with this level-averaging tuning rule is shown in Figure 2. Although Ziegler-Nichols and most other tuning methods for level controllers are not suitable for use on surge tanks, the level-averaging tuning rule will keep the tanks level between its upper and lower limits with the least possible amount of change to the controllers output. ce Lee Payne is CEO of Dataforth.
Tuning procedure
Figure 2: A surge tank control loop responding to disturbance using the level-averaging method on a non-interactive controller algorithm with its integral time set in minutes, such as a Dataforth MAQ20 system. Courtesy: Dataforth
64
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Enterprise Ethernet Historical data Alarms Security

35 Understanding optimizers: Adding APC to your APC 38 Capturing far-flung data

Advancements in RTU technologies help optimize data acquisition and control.

41 Lean automation architectures

Technical advances lead to more efficient automation solutions.

44 Artificial intelligence tools can aid sensor systems

DECEMBER 2013 CONTROL ENGINEERING www.controleng.com

Proactive Protection for your Process Control Systems.

Remote I/O Has Never Been More Rugged and Reliable

Whatever W hatever Your Your E Extreme xtreme

Wireless Network Module for More Remote Locations

Demand Moore Reliability

Building a better, more efficient plant

Motion control: To network or not to network

Avoid a control panel redesign

12 Apps for Engineers

25 IT and Engineering Insight

CONTROL ENGINEERING DECEMBER 2013 5

Process Manufacturing Discrete Manufacturing

Networking & Security

Education & Training

Control Engineering digital edition extras

More learning, less surfing

Information integration Mobility, Ethernet, and wireless

Education and training

Useful eGuides on many topics Control Engineering research reports

Channels and new product areas

Site search engine

Point, click, watch

System Integrator Guide

DECEMBER 2013 CONTROL ENGINEERING www.controleng.com

Precision, and Flexibility

>> Accelerate your productivity at ni.com/industrial-control-platform

800 453 6202

Content Content Specialists/Editorial Specialists/Editorial

Automation needs to be interconnected, optimized, and protected. Heres why.

Contributing Content Specialists

Mark T. Hoske, Content Manager

DECEMBER 2013 CONTROL ENGINEERING www.controleng.com

Fori Automation: Detroit, Michigan

I needed to combine motion, safety, and wireless. PROFINET does that.

2013 Product Exclusive roundup

scalable modbus solutions

Where Automation Connects

+661-716-5100 support@prosoft-technology.com www.prosoft-technology.com/modbus

DECEMBER 2013 CONTROL ENGINEERING

Global Sales and Support