Control Apl 15

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* See our Web site for details and restrictions. Copyright 2014 AutomationDirect, Cumming, GA USA. All rights reserved.
1-800-633-0405
input #1 at www.controleng.com/information
the #1 value in automation
APRIL 2015
Vol. 62
Number 4
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
42
30
Courtesy: GE Measurement & Control, a division of GE Oil & Gas
Features
30
34
38
41
42
34
Validation among insecurities

Cover story on network security: Implement a secure patch management approach for industrial controls. Todays
industrial control system (ICS) threats can target outdated systems or careless errors on the network.
Wireless security basics, standards

Cover story: Without effective data security, wireless technology could not grow and people would rely only on wired
systems along with the cost and inconvenience associated with them. Industries and businesses want to prevent
intellectual property and production from being compromised.
A dual split-range control strategy for pressure and flow processes

Maintaining setpoint for two-mode or wide-range operations can be much easier when there are two
control devices.
Read 3 more Digital Edition Exclusive articles

Need for better security: SCADA/HMI connecting with mobile Internet; Six ways a mobile service app helps businesses improve field equipment performance; CANopen provides distributed control functionality.
Feed forwards augment PID control

To help closed-loop motion control applications, feed forward augmentation can be used to reduce the error more
quickly, rather than relying on the proportional-integral-derivative (PID) control algorithm alone.
CONTROL ENGINEERING (ISSN 0010-8049, Vol. 62, No. 4, 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
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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.
APRIL 2015 CONTROL ENGINEERING www.controleng.com
Maximize Productivity of
Mission-Critical Assets
Prepare for a world where remote assets are intelligently sharing information with each
other and operations centers around the world to maximize productivity. This is the
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APRIL 2015
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 appears after p. 45; if not, see Digital Edition: www.controleng.com/DigitalEdition.
M1
Feedback for machine motion
M7
Six debugging techniques for

embedded system development
Learning and propagating various debugging techniques reduces bug count
and increases code quality. Here are six techniques that can go a long way in
assisting the debugging process. Reset software coding expectations and get
better results for embedded systems development.
M1
M9
M7
PRODUCT EXCLUSIVES
Closing servo-motor loops with feedback devices improves performance, but

care must be taken with design and installation. Closing the loop improves
monitoring, measuring, and controleven when outside forces cause deviations to the desired setpoint.
Open standards to help CNC machines,

digital manufacturing
The Organization of Machine Automation and Control (OMAC) is working on
the Standard for Exchange of Product model Data (STEP) for manufacturing, to
streamline use of machine tools and digital manufacturing. Savings of 15% to
50% are expected in various stages of the machining lifecycle.
departments
8 Think Again
news
24
Company building manufacturing

site and customer service center
in Tennessee
25
Aerospace research lab expands;

CSIA names Jos Rivera as CEO
26
U.S. to be Partner Country at Hannover Messe 2016; Human-robot

collaboration, future of technology
are focus of Automate 2015
28
MORE HEADLINES
Continuous control efficiency
10 Product Exclusives
Compact industrial computer
OPC server added to DAQ,
controls
12 Integrator Update
Using CFE Medias Global System
Integrator Database
PRODUCTS
16 Research
System integration:
5 hardware trends
17 IT Insight
How to get ready for big data
products
60
Solid-state interface relays; Miniature

magnetic encoders; Programmable
CAN to USB interface and datalogger;
Web-based visualization software; PCIe
board has sensor
61
Dual level power terminal blocks; Com

munications interface option for CNC
systems; Low harmonic distortion drive;
Router firmware for cyber security;
Mobile app updates email notification, build interface
62
Robot with elevated payload; Solenoid

and pneumatic valve series
18 International
Chinese environmental
protection law means more
monitoring, controls
20 Apps for Engineers

Easy calculations
22 Application Update
Acoustic emission sensing helps
position control
64 Back to Basics
Why team communications fail
www.controleng.com
CONTROL ENGINEERING APRIL 2015 5
More resources posted daily at:
APRIL
Trending
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Control Systems
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System Integration
Networking & Security
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Education & Training
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Need for better secu
rity: SCADA/HMI connecting with mobile
Internet
Monitor offshore oil, gas fields; Finding system

integrators for machinery, system projects;
SCADA remote access
Go online to read Control Engineerings exclusive web content at
www.controleng.com/news:
New way to monitor offshore oil, gas fields
Finding system integrators for machinery, system projects
FAA exemption permits drones for oil and gas inspections
Will advancements in virtual reality technology shift how we see field service?
The rise of mobile devices and SCADA remote access
Join the conversation online at www.linkedin.com/groups?gid=1967039
What would you like from your automation and control provider?
What is the difference between fixed and modular configuration of PLC?
What are some options for PLC and HMI beyond the standard products?
Manufacturing automation,
Integrating wireless with wastewater, 2015 Engineers Choice
Awards winners announced
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Information control: Automation helps original equipment manufacturers innovate
System integration: Integrating wireless with wastewater
CEs Top 5 reader favorites: 2015 Engineers Choice Awards winners announced
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Six ways a mobile

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CANopen provides distributed control
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Control Engineering
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March 10: Integrating wireless into an
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April 7: Integrated drive systems: A holistic approach to energy savings
May 7: Anatomy of an incident: Safety
best practices from lessons learned
Oil and Gas Engineering

Oil & Gas Engineering
provides industry-specific solutions designed
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and increase productivity through the use of
industry best practices
and new innovations,
increase efficiency from
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In the April issue:
Hacking oil and gas control systems:
Understanding the cyber risk
Uncapping the benefits of wireless
technology
Understanding business drivers in O&G:
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editorial
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Enabling efficiency
in continuous control
These 7 signs of a continuous process could indicate that the ISA 106 standard may offer effective
and efficient help for continuous control operations
beyond the scope of ISA 88, said Dow Chemical.
hat state are your control systems

in? The ISA 106 standard for
continuous processes may help if
these sound familiar:
1. Start-up, run, and shutdown are
repeatable and optimized.
2. Abnormal situation management uses
additional control strategies.
3. Intelligent alarming is used based on
mode of operation.
4. Equipment, devices, and controllers
are automatically enabled based on
mode of operation.
5. Redundant equipment (such as
pumps) are automatically swapped.
6. Operators run a process unit instead
of individual devices.
7. Start-up and shutdown (which may
be infrequent) includes automatic
sequencing of the plant (unit to unit).
Loop-based vs. state-based
Dr. Yahya Nazer, M&E consultant engineering solutions at Dow Chemical Co.,
said Dow is applying state-based control
(or unit-based control) to all major Dow
plants. Doing so makes it easier to have
safe, effective, and efficient operations, he
explained at ARC Forum 2015, in February. Dr. Nazer, the ISA 106 co-chair, said
state-based control (also called unit-based
control) is designed to enable the operator
to run (interact with) the process unit (distillation unit or reactor), versus focusing on
how each piece of equipment, such as pump
and valve, should operate (often described
as the focus of loop-based control).
He began with ISA 106 about four years
ago as a way to transition from Dow Mod5
control systems to more modern control
systems. About 75% of Dow assets now are
using this wider-view approach. Nazer said
he believes the related ISA Technical Report
(TR) was the most quickly produced TR in
the history of ISA standards work.
ISA-TR106.00.01-2013 Procedure Automation for Continuous Process Operations

Models and Terminology, approved in August
2013, looks at what is state-based control
and at loop-based control versus state-based
control, and related topics. Nazer described
the difference in operator attention required
similar to an automobile drivers difference in
using standard versus automatic transmission.
With most loop-based systems, the operator
identifies the state, executes commands, and
waits for next state. In contrast, a state-based
control (SBC) system identifies the state of the
process and executes commands. The operator is permitted predefined transitions, and the
SBC defines next state.
State-based control benefits
Benefits include a more holistic view

and efficient use of existing control assets.
A typical loop-control framework requires
two or three times the attention from the
operator compared to a state-based architecture, Nazer suggested. SBC allows a
procedural automation, fewer open loops,
and more automated operations, showing a
step-by-step view of automatic operations.
Dow, for instance, is using fewer vessels
since implementing SBCs. SBCs also have
comparable design development and implementation costs compared to the standard
automation approach, approximately 1.5%
to 2.5% of the total cost of project.
If you think standards impede progress,
think again by examining the workflow benefits of ISA 106. ce
Go Online
Atop www.controleng.com search this article
headline to see 7 more benefits, go to the technical
report, link to related standards articles.
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EXCLUSIVES
product
Compact industrial computer

with 10-year warranty
The SEL-3360S from Schweitzer Engineering Laboratories (SEL) features Intel Core i7 processors, -40 to +75 C operation, no vents, and no moving
parts and can withstand up to 15 kV of electrostatic discharge and shock up to 15 g.
he new SEL-3360S from Schweitzer Engineering

Laboratories (SEL) features Intel Core i7 processors, -40 to +75 C operation, no vents, and no moving
parts. Designed for small spaces in extreme environments, the SEL-3360S uses powerful and efficient Intel Core i7
dual- and quad-core processors. To ensure the highest reliability, the SEL-3360S supports two solid-state 2.5-in. SATA drives
and RAID configurations using single-level cell NAND flash.
Up to 16 GB of error-correcting code RAM provides ample
memory for demanding applications. The SEL-3360S also
comes with a 10-year, no-questions-asked worldwide warranty.
Built to utility substation standards, the SEL-3360S will withstand up to 15 kV of electrostatic discharge, high electromagnetic
interference, and shock up to 15 g. With an observed mean time

between failures (MTBF) of greater than 100 years, SEL computers have 10 times the reliability of typical industrial computers.
Out-of-band remote management features, such as Intel Active
Management Technology (AMT), provide high serviceability to
the SEL-3360S. Users can perform diagnostics, install software or
operating systems, and even command a reboot remotely. SELs
unique system monitor (SysMon), Backup and Recovery Tool
(BaRT), and watchdog timer maximize system availability by
alerting users about potential issues and minimizing operational
outages should a system failure occur. ce
Schweitzer Engineering Laboratories Inc. (SEL)
www.selinc.com/3360-ce4
OPC server added to data

acquisition and control system
Dataforths introduction of an OPC Server for the Dataforth
MAQ20 Industrial Data Acquisition & Control System ensures
data collection and analysis using the MAQ20 is now significantly broader-based and easier to use.
ntroduction of an OPC Server for the Dataforth MAQ20

Industrial Data Acquisition & Control System ensures data
collection and analysis using the MAQ20 is now significantly broader-based and easier to use.
Our MAQ20 OPC Server provides a common interface to
the MAQ20 system that is usable by any SCADA, HMI, or
other custom software that is an OPC client, said John Lehman, Dataforth engineering manager. This eliminates the need
for a custom interface or driver when using the MAQ20 with
industry standard software, and it enables real-time information exchange on local hosts or over distributed networks.
The MAQ20 OPC server uses Kepware Technologies KEPServerEX OPC Server and Modbus TCP driver, which have
been configured for the MAQ20 system.
OPC servers consist of three basic parts: channels, devices,
and tags. A channel represents the communication medium
from the host computer to one or more devices. For example,
the MAQ20-COM4 communications module has an RS-485
port and an Ethernet port; a serial or Ethernet connection
between the host computer and the MAQ20 would be a channel in an OPC server.
10
A device is the hardware with which the server communicates. The device driver provides the interface to the data
acquisition hardware. For the MAQ20 OPC server, the MAQ20
Data Acquisition System is the device.
A tag represents addresses within the hardware with which
the server communicates. The KEPServerEX OPC Server
allows both dynamic tags and user-defined static tags. Dynamic tags are entered in the OPC client and specify device data.
User-defined static tags are created in the server and support
tag scaling. When the MAQ20 system is used as the device,
tags are assigned to the addresses within the MAQ20 I/O modules and communications modules from which data is read and
to which data is written. ce
Dataforth
www.dataforth.com
Go Online
www.controleng.com/products has additional products. Also see the product section in this issue. Interested in introducing a product to the world
here? Contact Mark T. Hoske, mhoske@cfemedia.com
Au
tho
Your 1 Choice for

Automation & Control
ST
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1.800.433.5700
Allied Electronics, Inc 2015 Allied Electronics and the Allied Electronics logo are trademarks of Allied Electronics, Inc.
An Electrocomponents Company.
tor
integrator update
Using the CFE Media

Global System Integrator Database
When a manufacturing company or other customer buys sophisticated automation
technologies, the success of the implementation and the ultimate value depends
on the technical talent and delivery skills of the system integrators who implement
the solution. Use CFE Medias Global System Integrator Database to
find the best system integrator for the solution.
Key
concepts
System integrators help
with efficient implementation of complex automation systems.
Multiple criteria can be
used to narrow the pool of
available system integrators.
An online database can
help with the SI selection
process.
hen a manufacturing company

or other end user buys sophisticated automation technologies, products, and software,
the technology sale is only
the beginning of the process. The success of the
implementation and the ultimate value delivered
to the customer depends on the technical talent
and delivery skills of the system integrators who
implement the solution.
Choosing the right system integrator (SI) for
a complex automation solution increases the
opportunity for a successful technology implementation. Finding the right SI firm with the
appropriate experiences is an essential step in
obtaining the desired results. After identifying
specific requirements criteria, the system integrator selection process can begin.
industry certifications, such as Microsoft,

ISO, Control System Integrators Association (CSIA)?
Will the SI provide post-project support?
Can the SI meet the time schedule and performance criteria?
What are the proposed commercial terms
for the SI?
Optimal system integrator profile
Go Online
Use the Global System Integrator Database at
www.controleng.com/globalsi-database
Search for this article online at
www.controleng.com to link
to other useful resources.
12
Based on discussions with multiple end users

and SIs, below are several critical questions that
a potential client should ask during the selection
process:
What is the SIs profile (location, size, years
in business)?
Is the company skilled in the application of
target technologies?
Are staff members experienced, trained, or
certified in using the desired technologies?
Does the SI or its employees have project management or other core technology
certifications?
How many solutions has the system
integrator delivered using the targeted
technologies?
What is the system integrators vertical
market experience?
Will the system integrator provide dedicated
resources for the project?
Is the SI firm certified by any of your technology vendors, and does it have other
As systems become more complex and

require integration with other systems, the impact
of finding the right system integrator is greater.
In general, depending on the application, the
complexity of integrating programmable logic
controllers and human-machine interface systems (PLC/HMI) can be less complex than implementing supervisory control and data acquisition
(SCADA) systems. Because of integration with
enterprise, controls, and other systems, manufacturing execution system (MES) integration can
be the most complex of the three. Courtesy: JS
Kiser Consulting
Vendor program membership
Many clients prefer to work with certified system integrators because they want to reduce project
risk. More importantly, they want to avoid situations where a SI is learning on the job at the customers expense. Clients also want to ensure that
automation solutions work once theyre deployed
and get finished on time. SIs involved in a ven-
Putting the I/O in IoT
Complete Ethernet Remote I/O Solutions
Enhance Automation Systems with Flexible

Distributed Control I/O Modules
Distributed Control with Peer-to-Peer and Graphic Condition Logic
Popular Protocols; Modbus / TCP and ASCII / UDP
DHCP, configuration export, group configuration
Webpage hosting; HTML5, REST, Java Script
Supports smart phone and tablets
Free universal configuration utility software and .NET drivers
Support Daisy-chain Ethernet (ADAM-6200 series)
ADAM-6200 Family
www.advantech.com
ADAM-6000 Family
integrator update
The top level of a listing in the Global System Integrator Database readily
shows contact, location, awards and certifications, key statistics, and other
information. Courtesy: JS Kiser Consulting, CFE Media
dors product and technology certification program

makes this much more likely.
Leading automation vendors recognize
that their market success and brand reputation depends on the availability of a capable
body of system integrators that have invested
in staff training and have proven their abilities
to deliver successful projects with the vendors
technologies.
Anyone searching for the right SI should
understand the selected technology vendors system integrator program to determine if a potential system integrator partner has achieved
recognition within the program. Several automation vendors have multi-tiered SI programs that
recognize SI capabilities with their tools. Examples are Rockwell Automation Recognized System Integrator, Siemens Product Specialists, and
Schneider Electrics Endorsed System Integrators
Certified Alliance Partners, to name a few.
How to locate an SI partner and
determine if it fits the needed profile
Industries served: This selection allows system integrators to identify the

primary industries they serve. Also, they may list any reference projects they
have delivered in North America or worldwide outside of North America. This
screenshot and those below, courtesy: CFE Media
To find an integrator with the optimal profile,

online directories are available. CFE Medias
Global System Integrator Database can be
searched by system integrator name, industries
served, engineering specialties, vendor experience or affiliations, professional affiliations,
annual revenue, and/or location.
To get the most out of the Global
System
Integrator
Database,
visit
www.controleng.com/global-si-database and
select an SI. When evaluating SI listings, note
the key areas in the sample listing shown.
Selecting a system integrator

Engineering specialties: SIs deliver solutions using a wide range of technologies that require a variety of engineering skill sets. The directory allows
the system integrator to highlight key engineering specialties.
After narrowing the selection to a small

group of potential system integrator candidates
and reviewing experience and capabilities, it is
important to interview the candidates. The results
of the interview and the responses of the systems
integrators will aid in providing the necessary
background to finalize a selection. ce
- James Kiser, principal, JS Kiser Consulting; edited by Mark T. Hoske, content manager, CFE Media, Control Engineering, mhoske@
cfemedia.com.
Project profiles: This area allows system integrators to upload information

about projects and solutions they have delivered.
14
Partnership programs (shown online): This

area lists the vendor programs in which the SI
actively participates.
Vendor experience (shown online): SIs work with
a variety of vendor products and can affiliate with
many technology vendors. Here the SIs may list
the vendors and products they have worked with.
Freelance. Maximum automation with minimal

engineering at Wake Stone.
Using the Freelance control system, ABBs partner, Carolina Automation Systems
(CAS), was able to engineer, commission, test and declare their project at Wake
Stone Corporation online in just eight weeks. With Freelance, Wake Stone now has
a powerful automation system that is not only cost effective in terms of hardware
and software, but is also easy to use.
Download the complete case study at:
www.abb.com/freelance
ABB Process Automation Division

Control Technologies | Essential Automation
LinkedIn Group: ABB System Freelance
Additive manufacturing's
impact over past 3 years
Has made a positive change
16%
44%
research
40%
2014 SYSTEM INTEGRATION STUDY:
5 hardware
integration trends
eventy-five percent of respondents

to the Control Engineering 2014
System Integration Study perform system integration services, either
for their own projects or for third-party
affiliates. Of these integrators, 84% have
recently integrated human machine interface (HMI) hardware or equipment, operator interface (OI), control panels, alarms,
annunciators, data acquisition equipment,
or data recorders or plotters. Below are
five high-level findings impacting system
integration services today as they relate to
integrating these technologies:
1. Projects per year: The average system integrator works on eight projects per
year that involve integrating HMIs, OIs,
and related equipmentwith 47% working on 10 similar projects or less annually.
2. Project size: The average HMI,
OI, etc. integration project is valued at
$65,000, with 38% of system integrators
working on similar projects rated over
$100,000.
3. Valuable skills: Respondents integrating HMI, OI, and related equipment
agree that having engineering skills (99%)
and project management skills (93%) are
highly important when performing quality
Will make a
positive change
Great potential for

increasing productivity
system integration work, as well as a vast

knowledge of industry standards (98%),
national standards (90%), and capital cost
consciousness (89%).
4. Project delivery: Seven in 10 of
respondents HMI, OI, etc. integration
projects were completed on time within
the past 12 months, with 53% of respondents claiming that their last project was
finished on time. Of the recent projects
that did not meet deadline, the primary
causes of delay involved communications between the system integrator and
the clientsuch as scope creep, delays in
approvals, etc.
5. Project budget: Thirty-five percent of respondents most recent HMI,
OI, etc. integration projects were unable
to fit within the original budget. Of these
respondents, 64% were able to agree upon
a new budget with their client that was
then met, and only 18% said the budget
deviance wasnt large enough to affect the
project too much. ce
View additional findings at
www.controleng.com/2014SystemIntegration.
< 80%
of mobility,
Ethernet, or wireless technologies

used by engineers are provided
to them by their company. Source:
Control Engineering 2014 Mobility,
Ethernet, and Wireless Study
2 in 24 months:
The average control system net-
work experiences two malicious

cyber incidents over the course of
24 months. Source: Control Engineering 2014 Cyber Security Study
56%
of system integra-
tors consider a project successful and effective if it increased

productivity and was delivered
on time and on budget. Source:
Control Engineering 2014 System
Integration Study
Top 5 system integrator key challenges

Hiring engineering talent
for system integration
61%
Hiring engineering talent

for industry expertise
46%
35%
Continuing education
Communication skills
Competition
www.controleng.com/ce-research
16
33%
28%
FOR MORE RESEARCH INFORMATION
More research
Control Engineering surveys its
audience on five topics each
year: cyber security; career and
salary survey; system integration; information integration; and
mobility, Ethernet, and wireless.
All of the reports are available
online at:
www.controleng.com/ce-research.
Advantech IoT Structure

Application Cloud
Advantech IoT Cloud

Open SSL
IoT Gateways/
Controllers and
Nodes
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INSIGHT
IT & engineering
Get ready for big data by

getting the architecture right
Managing big data can be an issue for many manufacturers with a strong online presence
that needs to be integrated into production facilities. This is easier when multi-threaded
applications are introduced. Use these architectures and open-source technologies used
by Amazon and others to improve big data gathering and analysis.
o prepare manufacturing sites for new

big data requirements apply the same
architectures and open source technologies used by Amazon and others, creating a big data system for gigabytes of
unstructured production data. Big data is not just
something that web-based companies need to
deal with. Additional product tracking, tracing,
and investigations requirements are adding big
data requirements to production facilities. Fortunately, manufacturing has already learned how
to handle big data by using data historians. Data
historians can keep years of tagged data and are
a vital part of any production facility. However,
the data in data historians are simple, usually
just a tag ID, a value, and a status. The big data
architecture required for tracking, tracing, and
investigations is often more complex, comprised
of pictures, unformatted text, formatted text, and
other types of unstructured data.
One recent example of a production big data
project was discussed at a recent ISA FPID Symposium. It consisted of a new automated production line for a regulated device. There are 12
image files being collected at various stages of
assembly per assembled device per second. The
image files must maintain batch and lot context,
be maintained for multiple years, and be searchable with access to any image file in less than 1
second to allow for investigations, recalls, and
audits. There would be more than 1 billion image
files that must be managed for one production
line, and more lines are planned for the future.
This situation is outside the scope of the built-in
capabilities of the file system, databases, and commercial tools, so an innovative solution was used.
Internet innovation has the answer
The Internet is known for innovation and,

fortunately, innovation can be applied to manufacturing big data problems. The same free and
open source systems and data handling architectures used by web applications to search through
hundreds of thousands of products or millions of
blog posts in less than a second can be used for

manufacturing big data. Using a multi-threaded
application a working prototype was developed
in a week, and a full system was deployed within
two months. General purpose IT solutions can be
effectively used in manufacturing, but one vital
element cannot be missed. The system must have
a robust and well-defined architecture. Specifically on any big data project, the architecture is
critical to its success. Too many industrial applications are hacked together, resulting in systems
that dont meet the performance needs, are not
scalable, and are not supportable.
Multi-threaded applications also are a good
architecture model to use when different parts of
the system have varied performance characteristics. Multi-threaded systems take advantage of the
fact that most CPUs spend a lot of time waiting for
memory fetches. During the waiting time the CPU
can be operating on other threads pre-fetched data,
increasing the overall system performance. This big
data projects architecture used one thread to identify new images, another to copy image files to a
file server, and another set of threads to create the
indexes of the files and associate them to the correct batch and lot. Each action could be running at
different cycles, and a multi-threaded system with
queues ensures that no data is lost.
Multithreading concepts should only be introduced where brute force computing cannot keep
up with data throughput requirements. However, with careful planning and by using a robust
thread-safe architecture, a big data collection and
indexing system can be built to handle gigabytes
of unstructured records with sub-second retrieval
times. By applying the same architectures and
open source technologies used by Amazon and
others, a big data system can handle gigabytes of
unstructured production data. ce
- Dennis Brandl is president of BR&L Consulting in Cary, N.C., www.brlconsulting.com.
His firm focuses on manufacturing IT. Edited by
Eric R. Eissler, editor-in-chief, Oil & Gas Engineering, eeissler@cfemedia.com.
Dennis Brandl
President of BR&L
Consulting
www.controleng.com
By careful
planning and
using a robust
thread-safe
architecture, a big
data collection
and indexing
system can be
built to handle
gigabytes of
unstructured
records with subsecond retrieval
times.
Go Online
www.controleng.com/archives
has more under this headline,
with discussion of opensource software to help big
data implementations.
INTERNATIONAL
Profit vs. environment:
Whats the impact of the

new Chinese environmental
protection law?
Environmental Protection Law of China has been officially implemented since Jan. 1.
It might have a negative impact on the old manufacturing and process control sectors
and open new doors for green engineering investments in existing plants and in
automation, controls, and instrumentation, technology retrofits, according to Control
Engineering China. It is projected that the investment in Chinas atmosphere, water
and soil protection will be close to $1 trillion.
I
Aileen Jin, editor-inchief, Control Engineering China, explains that
the new environmental
protection law in China
may translate into large
investments in controls,
automation, and instrumentation.
s environmental protection a
luxury or a necessity to Chinese manufacturing industry, now vigorously pursuing
Industry 4.0? Two incidents have
drawn intensive attention from
people at the beginning of the
New Year: Lanzhou Municipal
Government sued CNPC Lanzhou
Petrochemical Co. and publicly
accused it of being lack of sense
of social responsibility as a central
enterprise. Also, the government
claimed that CNPC Lanzhou Petrochemical Co. discharged pollution illegally for
multiple times in recent years to result in serious air
pollution. Local media has highlighted the difficult
situation faced by government concerning environmental pollution control. To solve the problem,
implementing the new Environmental Protection
Law of China seems to be a solution.
More rigorous punishment
Go Online
This was translated and
edited for Control Engineering from Control Engineering
China.
www.cechina.cn
See other international
coverage at...
www.controleng.com/international
18
The most rigorous Environmental Protection Law of China was officially implemented
since Jan. 1. The new act has granted bigger
power to the environmental protection department. For example, the fine for violating the law
is calculated and added on a daily basis without upper limit. This enables the environmental protection department to seal up and detain
pollution discharge equipment and even impose
administrative punishment on the persons in
charge of enterprises illegally reject or evade
responsibility.
MONTH
APRIL
2015
2015
2013
CONTROL
CONTROL
ENGINEERING
ENGINEERING www.controleng.com
www.controleng.com
These measures seem to end

the long-existing cat and mouse
game between government and
pollution discharging enterprises (especially workshop-style
small-sized enterprises). However, when it comes to large
enterprises related to national
economy and the peoples daily
life, governments and enterprises have to face the challenges as
how enterprises can manage to
survive despite the severe punishment and who should pay
expensive environmental protection cost for
enterprises.
Profit vs. environment
Take iron and steel industry, a major pollution industry, as an example. Excess production
capacity plus high reliance on imported iron
ore has resulted in high cost and low profit of
iron and steel enterprises in recent years. The
implementation of the new Environmental Protection Law and more rigorous discharge standards undoubtedly makes things worse for these
enterprises. Some iron and steel enterprises
indicated that they had to lose more than $32
for production of each ton of steel after they
made huge investment in purchasing environmental friendly equipment.
This phenomenon also exists in the cement
industry. According to the investigation conducted
by Chinese Research Academy of Environmental
Sciences, the input of cement denitration equip-
ment will increase the cost of each ton of

cement from $3.21 to $6.42 after implementation of the new discharge standards.
If calculated according to annual cement
production capacity of 2 billion tons, the
operating cost of environmental protection facilities of Chinas cement industry
will perhaps exceed $6.4 billion.
An environmental protection project
often features big investment in the early
stage, long payback period and low return
on investment. Besides, with financing difficulties, many enterprises would
flinch. For this matter, Wu Xiaoqing, vice
minister of the Ministry of Environmental
Protection, insisted on reforming the policy mechanism and establishing environmental protection financing mechanism.
The environmental protection investment
in key industries and key areas were currently insufficient. It is projected that the
investment in Chinas atmosphere, water
and soil protection will be close to $1
trillion.
(HMIs), will draw increasing attention.

The abundant experience of traditional
automation manufacturers in system
integration and overall solutions offer
them more first mover advantages in
this Blue Ocean market. The cooperation
between Schneider Electric and Beijing
Origin Water Technology Co. last year
exactly aimed at the market prospect of

water treatment industry. It could yet be
regarded as a wise strategic layout. ce
- Aileen Jin, editor-in-chief, Control Engineering China. Edited by Joy
Chang, digital project manager, Control
Engineering, jchang@cfemedia.com
Rugged Precision
The MAQ20 Industrial
Data Acquisition & Control System
Opportunities for green

engineering
With the countrys increasing attention to environmental protection, the

growth model at the expense of environmental damage will become a past
tense. The sharp increase of enterprises
demands for environmental monitoring instrumentation, atmospheric pollution control system, waste management
equipment, and sewage treatment system
will open a new market for the Chinese
environmental protection industry.
When strengthening pollution source
monitoring, enterprises shall also center
on overall factory operation and control level. Cure the disease rather than
the symptoms. Enterprises shall apply
advanced automation control technology
to gradually eliminate the backward hardware and software so as to not only reach
the national environmental protection
standards but also improve enterprises
production capacity and efficiency and
improve market competitiveness. In some
sense, the manufacturing upgrade is killing two birds with one stone.
In the future, it is expected that industrial-grade products used environmental
protection fields, like programmable
logic controllers (PLCs), remote data
acquisition, variable frequency drives
(VFDs), and human-machine interfaces
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apps for
ENGINEERS
www.controleng.com/appsforengineers
Easy calculations
Mechatronics
Motion Solutions
A unique platform for
handling solutions
CFE Medias Apps for Engineers is an interactive directory of engineering-related applications for Apple iOS and Android operating
systems form various companies. Weve
categorized apps by category, company, and
type. This month, see these applications for
making calculations easy.
Box/Conduit Fill Pro
Android 4.0+
Cost: $1
Company: Comoving Magnetics
Website: http://comovingmagnetics.com/wp
Calculate the maximum wires in a conduit, minimum box size, and minimum
conduit/nipple size. The calculations use the NEC 2008/2011, designed to give
electrical engineers the correct information in the field.
Toothed belt axis ELGA-RF
Calculator ++
Android 2.3+
Cost: Free
Developer: Sergey Solovyev
Website: http://se.solovyev.org
This app is an advanced scientific calculator enabling users to perform basic
and complex mathematical calculations on a mobile device.
Integrated servo motor MTR-ECI
Electrical Calculator
Android 2.0.1+
Cost: Free
Company: Navaile
Website: www.navaile.com
Electrical Calculator is designed for electricians. It is based on NEC 2008/2011.

Among the calculations the app can do include grounding tables, motor FLC
tables, voltage drop, Ohms law, and wire size and capacity. Apps currently
under development include conduit fill and electrical utility jurisdiction based on
GPS location.
Mini H-Gantry EXCM
Statics
iOS 5.0+, Android 2.2+
Cost: $1.99 (iOS), $2.25 (Android)

Company: Campolese S.R.L.
Website: www.campolese.com
For more information:

Call: 1-800-Go-Festo
1-800-463-3786
This app is a fast standard beam solver (currently supported, cantilever, inclined,
arches, fixed-fixed and fixed supported beams loaded with forces, moments
and distributed loads) that calculates moments, shears, axial forces, rotations
and lowerings by simply inserting input parameters. Its also possible calculate
the area moment of inertia for rectangular sections.
www.festo.us/mms
Global manufacturer of process control

and factory automation solutions
20
Integrate systems.
Visualize processes.
Control your future.
Leidos Engineering is helping the nations leading
manufacturers optimize their enterprise processes from
standalone product investments. We drive meaningful
results for years to come with deep data analytics,
insightful dashboard reporting, and specialized
software solutions.
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leidos.com/activate
application
UPDATE
Acoustic emission sensing

helps position control
Machine tool maker Max-Tek prolongs grinding wheel life by using acoustic emission
sensing and controls for precise wheel shape, improving quality while saving time and cost.
One grinding wheel dressing pass is said to be enough 80% of the time, avoiding unneeded
second dressings. An automotive component manufacturer provides an example.
Key
concepts
Grinding machine may
more dressing cycles than
necessary because of
inaccurate measurements.
Acoustic sensors and
control software compare
grinding wheel size to an
ideal to minimize overdressing, saving time and
extending wheel life.
n fabricating precision metal parts such

as automotive components, it is important to maintain precise grinding tolerances
throughout a production run, so grinding
wheel dressing is a necessary operation. Ideally,
a wheel should be dressed only when its shape
falls out of specification, and no more material
should be removed from the wheel than is necessary to restore it to its desired shape.
Monitoring the profile of a grinding wheel
during the dressing operation can be difficult
because the operation typically takes place
beneath a high-volume stream of cooling oil.
That makes visual techniques for observing
wheel profile ineffective. Therefore, to ensure
quality, machine builders typically run an extra
dressing cycle to ensure that the desired shape
is attained.
This used to be the strategy of Max-Tek
LLC, a manufacturer of superabrasive grinding
machines based in Newington, Conn. Max-Tek

Machines (Figure 1) produces metal components
for the automotive and aerospace industries.
Quality control
For our customers, ensuring that production

parts meet very precise tolerances is a make-orbreak issue, said Ed Elie, Max-Tek president.
Because we knew that one dressing pass over the
grinding wheel might not be enough to bring it to
the correct shape, we ensured that, even though it
might result in some unnecessary wheel wear, our
machines always did a second dressing pass.
To minimize waste, the company sought
advice from its manufacturer of acoustic sensing technologies, which solves the problem of
how to view the profile of the grinding wheel
through the stream of cooling oil. The acoustic
sensor monitors the high-frequency vibration
of the dressing wheel as it contacts the grinding wheel and listens for the sound of the
two coming together. The sensitive instrument
requires only a small number of grains of the
wheels to make contact to indicate a touch.
Wheel shape confirmation
Figure 1: Max-Teks peel grinding machine reduced the number of dressing

cycles using ExactDress software from Schmitt Industries. Courtesy: Schmitt
Industries
22
Software controls the dressing process by

measuring the live acoustic emission signature of
the dressing operation and comparing it with the
profile of a known successful wheel dress. When
there is a match, the system knows that the wheel
is dressed correctly.
Now, we know that a single dressing pass
is sufficient more than 80% of the time, said
Elie. This saves our customers both time and
cost. They dont need to replace grinding wheels
nearly as often.
To set up the software controls, a learn cycle
is first initiated whereby the system gain and
overall measurement scale, measurement window, and crash and gap sensitivity parameters are
set for the particular wheel to be dressed. Then
a successful dressing cycle is performed and the
Figure 2: The SBS

Balance System
software, ExactDress, uses acoustic
emission sensing
to monitor grinding
wheel shape during
dressing, matching
it with a profile of a
completed dressing
operation. Shown
are the operator
panel with a sample
grinding profile, a
control board, and three sensor types. Courtesy: Schmitt Industries
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acoustic signature is recorded. Once the reference data set is

finished and stored as a known good dress, the data can be
used to evaluate subsequent dresses of the same process.
CNPt Series
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Automotive peel grinding
A manufacturer of precision automotive components uses

Max-Teks peel grinding machines. Peel grinding uses a narrow grinding wheel to grind a part in a process that is much
like cutting with a conventional lathe. The tool is plunged into
the part (a casting in this case) and is moved along the surface,
taking off between 35 and 38 1000ths of an inch with each
pass, to create the desired finished shape, accurate to within
8 microns. The high-precision process enables the machine to
make complex, small features. Because it concentrates grinding force over a relatively small area, peel grinding works well
on hard materials that conventional machining cannot handle.
Prior to installing the control software that uses acoustic
sensing on the machine, the customer would need to dress the
grinding wheel every few parts, said Elie.
We never knew if the wheel was being dressed adequately the first pass, so we typically over-dressed to make sure
that the correct profile was being maintained, Elie said.
Because a relatively small grinding tool is used, over-dressing can result in frequent replacement of the tool, increasing
production costs and downtime unnecessarily.
Acoustic emission technology helps both grinding
machine designers and operators save money and improve
productivity. ce
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- Mark Astor is application engineer at Schmitt Industries;

edited by Mark T. Hoske, content manager, Control Engineering, mhoske@cfemedia.com.
Go Online
www.controleng.com/archives in March see this article for more information, including sensor and software product details.
Consider this...
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industry
NEWS
Company building manufacturing

site and customer service center
in Tennessee
ABB is investing $30 million in
building a new manufacturing site in
Memphis, Tenn., to focus on smart products and the Internet of Things (IoT) for
industries such as oil and gas, power
generation, mining, and health care. CFE
Media spoke with Brian Herington, U.S.
local division manager of low-voltage
products at the ABB Automation and
Power World show in Houston, Texas.
He talked about the $30 million investment in building a new manufacturing
site and expanding its customer experience center for its Low-Voltage Products
division in Memphis, Tenn., as well as
the industrys gradual movement toward
the Internet of Things (IoT), and smart
products. The investment is expected to
create more than 200 jobs, with another 100 jobs expected to be added over
the next five years. The facility will be
located in the Memphis area and will
cover more than 120,000 sq ft.
Applications for low-voltage products are targeted for the oil and gas,
food and beverage, power generation,
mining, and healthcare industries. ABB
is spending more
than $1.5 billion per
year to innovate and
bring new technologies to the market.
One of the new ABB plans on investing $30 million to create a manufacturproducts to be man- ing site and a customer experience center in Memphis, Tenufactured at the new nessee as well as upgrade its training suite. Courtesy: ABB
facility in Memphis
is the E-Max II breaker, launched in fall is progressing toward new dimensions
2014, which is expected to be the cor- of connectivity and smart integration.
nerstone of that plants product line. This
The products have been assembled
breaker is a smart breaker and power and portfolios built around vertical a marmanager with seven communication ket, which has provided better solutions
protocols and the ability to have a plug- for end users. Reduction in materials has
and-play option, which allows it to com- made these devices smaller and lighter, in
municate with other parts of the facility turn making them easier to use and inteand manage energy. The E-Max II was grate into legacy systems. The future is
designed with retrofits in mind, and this now and the new technologies should be
makes it easier to upgrade facilities.
taken advantage of, he suggested.
Herington emphasized that much of
ABB also will invest in a customer
this technology is going to be part of experience center at its existing Memthe IoT and engineers should be learn- phis location, which is now the Americas
ing and placing emphasis on these new headquarters for the division. ABB plans
smart technologies, which offer better to upgrade its training suite, as well.
solutions to end users. Herington said
- Eric R. Eissler, editor-in-chief, Oil &
this is one example of how the industry Gas Engineering, eeissler@cfemedia.com
First we raised the bar.
Then we lowered the price.
For a full list of available enclosures

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See more news daily at www.controleng.com/news
Aerospace research lab expands, renovates

Purdue University is expanding the
Maurice J. Zucrow Laboratories, which
are focused on aerospace research for
NASA, the U.S. Air Force, and other
agencies and companies. Expansions
include test cells to support laser-based
measurements, renovations to the highpressure lab, and more office space for
faculty and students. Zucrow is jointly
operated by the universitys School of
Mechanical Engineering and the School
of Aeronautics and Astronautics.
Zucrow, founded in 1946 on a 24-acre
site, comprises six facilities. It has produced more than 1,000 graduates in 70
years, including NASA astronauts. Notable graduates include Neil Armstrong,
Eugene Cernan, Roger Chaffee, and
Virgil Gus Grissom. Existing highpressure lab includes two test cells
with two test beds each. The lab houses
were developed in 1964 as a part of
NASAs Apollo program. The new building will house five test cells and allow
companies to have dedicated research
space in addition to space for students
and faculty.
The new building will have a 2,000sq-ft laser lab to study jet engine combustion to better simulate performance
and improve designs. A new air heater
will produce higher temperatures and
pressures.
Construction is expected to begin in
2016 on the 9,600-sq-ft facility and last

a year. Cost is $8.2 million; $5 million is
coming from Lilly Endowment Inc. as
part of a $40 million grant to the university, the largest cash donation Purdue
University has received. The university
aims to increase the number of students
and faculty in the College of Engineering, responding to the need for skilled
workers to replace an aging workforce
in engineering and manufacturing
industries. Read more online.
- Edited from press releases from
Purdue News by Julie Rosa and Emil
Venere. Chris Vavra is production editor, Control Engineering, CFE Media,
cvavra@cfemedia.com.
Purdue president, Mitch Daniels,

speaks during the announcement of the
Lilly Endowment Inc. grant to the university on February 18. Courtesy: Charles
Jischke, Purdue University
CSIA names Jos Rivera as organizations CEO

Jos M. Rivera began as the new CEO for the Control System Integrators
Association (CSIA) on March 23. He was selected after a wide search was conducted by a task force composed of five system integrators. Rivera has had a
successful global career in the automation industry working in six countries
most often with a regional or global role.
During his tenure as senior vice president strategy and communications,
industry business at Schneider Electric, Rivera realigned the automation business and the overall company energy efficiency direction. He crafted and
executed the strategy to enter the process automation market, first through an
alliance with a leading process automation supplier, later through the acquisition
of Invensys plc in 2014. He had an 11-year career at Emerson Electric in roles for
the process automation market. He began as a sales engineer with Siemens.
He holds an MBA, MS and BS degrees in Electrical Engineering. Prior CEO Bob
Lowe, retired. The CSIA Executive Conference begins April 29 in Washington, D.C.
- Edited from a CSIA release by CFE Media, Control Engineering
Rittal durability and pricing beat our competition once again

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NEWS
See more news daily at www.controleng.com/news
U.S. to be Partner Country

at Hannover Messe 2016
The United States has accepted an invitation to be the
Partner Country for the Hannover Messe 2016 trade fair in
Germany. The formal announcement came March 24 in a letter from U.S. Commerce Secretary Penny Pritzker to Germanys U.S. Ambassador Peter Wittig. Control Engineering last
reported the United States as a partner country in 1996.
Hannover Messe 2016 is of exceptional importance to
the development of our transatlantic trade relations, Wittig
said. Having the U.S. as the featured Partner Country will
give us a golden opportunity to convey our dynamic business
relations to the fullest while at the same time widening and
deepening them.
President Barack Obama is expected to appear at Hannover
Messe 2016, which will be April 25-29 in Hannover, Germany,
and address the opening ceremonies in an event that also will
showcase American culture. As the guest of German Chancellor Angela Merkel, President Obama is expected to be accompanied by the largest U.S. manufacturing delegation ever to
appear at the worlds largest industrial trade show.
Hannover Messe has been fostering deeper ties with
U.S. industry, staging business summits and inviting American delegations to Hannover to promote transatlantic trade
The Netherlands was the 2014 Partner Country at Hannover

Messe. The United States will be the 2016 Partner Country.
Courtesy: Hannover Messe
relations, Hannover Messe officials said in a press release.

Hannover Messe officials have been negotiating with U.S.
officials for the past five years to bring the worlds largest
manufacturing economy to Partner Country status.
- Bob Vavra is content manager, Plant Engineering, CFE
Media, bvavra@cfemedia.com. Read more online.
Human-robot collaboration, future

of technology at Automate 2015
Hannover Messe Industrie Hall 12, Stand D 73
The ISA-TS soft starter (200 kW to 3 MW, up to 11 kV) is suitable for

drives with a low starting current and/or a high starting torque. As
compared to a frequency converter of similar rating the ISA-TS needs
just 50 % of the space. Reduce costs, energy consumption and space
requirement with the new ISA-TS from IGEL.
IGEL Electric GmbH Industrieweg 13 15 48324 Sendenhorst Germany
Fon +49 (0)2526 9389-0 Fax +49 (0)2526 9389-22 info@igelelectric.de igelelectric.de
Automate 2015 at McCormick Places North Hall featured a number of exhibits with robots working on pickand-place applications as well as grabbing and moving
items that were not in pre-determined locations. As automation becomes more cost effective, small to mediumsized businesses are adopting robotics, machine vision,
and motion control technologies to improve efficiency.
Several discussions and presentations focused on
human-robot collaboration and what this means for manufacturings future. Topics included safety, making robots
more human in capabilities, and what a smarter robot will
mean for the future of humans on the plant floor.
The general tone about collaborative robots was optimistic, though there was agreement that a lot of work
must be done on safety and related technologies. Those
challenges, however, pale in comparison to what such
robots would mean for manufacturing. The manufacturing industry needs this technology, said Ebsen Ostergaard, CTO, Universal Robots. There is so much potential
and we need to have a pragmatic approach about it.
Apple co-founder Steve Wozniak appeared as the final
keynote speaker on Wednesday, focusing on the future of
engineering. For future entrepreneurs, he advised: Find
some engineers that really think out of the box. Engineering involves such careful thinking and problem solving.
- Chris Vavra is production editor, Control Engineering,
CFE Media, cvavra@cfemedia.com.
26
CFE Medias
Global System
Integrator Database
CFE Medias Global System Integrator Database is an interactive

community of global end-users and system integrators hosted by
Control Engineering, Plant Engineering, and our global partners in Asia and
Europe. Through this database you will be able to connect with System Integrators by
searching their corporate profiles which highlight: industries served,
engineering specialties, product experience, geography, and other pertinent data.
Find and connect with the most suitable service provider
for your unique application.
Start searching the Global System Integrator Database now!
www.controleng.com/global-si-database
HEADLINES
ONLINE
FAST
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The new USB 3 uEye CP Incredibly fast, incredibly reliable,
incredible sensors
See www.controleng.com/news for daily

coverage including the items below.
Industry Events
At www.controleng.com, on the right side,
click into the events box, for more on:
Interphex, New York City, April 21-23
www.interphex.com
2015 Global Automation Conference,
Dallas, April 27-May 1
www.real-time-answers.com/
global-automation/schedule
CSIA Executive Conference, Washington,
D.C., April 29-May 2
www.csiaexecutiveconference.org
IPACK-IMA 2015, Fieramilano,
Milan, Italy, May 19-23
www.ipackima.it/en/default.asp
Automation in Manufacturing, Detroit, June 4
www.amtonline.org
Engineers Choice winners announced
Control Engineering and CFE Media presented
the 2015 Engineers Choice Awards to the 26
winners and 27 honorable mentions on March
23 in Chicago. The winners were selected by
Control Engineerings print and digital audience
from 94 finalists from 56 companies.
Marketing to Engineers
CFE Media hosted the 2015 Marketing to
Engineers event at the Park Hyatt Chicago
on March 23. Industry experts presented tips
for marketing communications, new product
introductions, marketing campaigns, industrial
branding, and other tools for effectively marketing to engineers.
Top 5 Control Engineering articles
Mar. 2-8 most visited articles on the Control
Engineering website (among those posted in
the last two months) were: high-performance
HMIs, the 2015 Engineers Choice winners,
alarm management philosophy, PID for motion
control and robotics, and artificial intelligence
for control engineering.
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Dock slowdown has impact on sliding PMI

The dock slowdown on the West Coast got
most of the blame as the PMI fell from 53.5%
in January to 52.9% in February. It remains
solidly above the growth line of 50%, where it
has been for the past 26 months.
Electric vehicle batteries could benefit
from paper-like material
Bourns College of Engineering researchers
created silicon nanofibers 100 times thinner
than human hair for potential battery use.
How to hike safety, reduce failures
High-hazard process industries require
increasingly stronger safety systems.
www.ids-imaging.com
Radio chip for the Internet of Things

MIT researchers have a transmitter design
that to improve use of Bluetooth and wireless
communication protocols.
28
APRIL 2015 CONTROL ENGINEERING
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Industries with remote facilities using telemetry technologies need tools for
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cover story
Validation
among insecurities
Network security: Implement a secure patch management approach for industrial

controls. Todays industrial control system (ICS) threats can target outdated systems
or careless errors on the network. Securing connected machines in the industrial
sector has complexities that differ from protecting a business datacenter.
[In this issue, the next article explains wireless cyber security.]
Key
concepts
Industrial control systems (ICS) need a different
approach to patch management than IT systems.
Cyber security risk
assessment should include
cost of operational downtime and to reputation.
A validated patch
management system
while managing outdated
hardware and software
can be part of a proactive
lifecycle management
plan to avoid costly forced
downtime.
ndustrial controls systems (ICS) need a secure

patch management approach, as threats can
target outdated systems or careless networking errors. Industrial sector cyber security has
a unique set of complexities that differ from
business datacenter cyber security.
As media headlines have demonstrated, cyber
security breaches across industries inflict heavy
costs, loss of trust from customers, and damage
to an organizations credibility. In 2014, hackers stole 76 million records from financial services firm JP Morgan Chase and more than 80
million customer records from healthcare provider Anthem. The Target data breach cost $162
million in cyber-security-related expenses across
2013 and 2014. While the financial costs related to a breach can be staggering for any industry, in the energy sector, where just an hour of
downtime can correlate to millions of dollars in
lost production, the potential implications can be
extremely detrimental to business success.
Cyber security risk: Operations,

reputation
Energy companies are accelerating implementation of full-scale cyber security programs and policies. In particular, oil and gas
organizations, which are regulated differently
than the power generation industry, face huge
risks associated with industrial control system
vulnerabilities.
For example, an oil and gas company calculated that the failure of one of its control systems
human-machine interfaces (HMIs) and the resulting downtime of two days would cost the organization an estimated $12 million in lost production.
30
This calculation weighed the risks of waiting

another year to install cyber security protection
rather than immediate installation. Given the operational and reputational costs of not implementing
security programs, there should be no delay.
In general, the energy industry relies on more
outdated equipment than the commercial sector.
In the business environment systems have updated software and hardware components needed to
effectively combat todays threats, which often
target outdated systems or careless errors on the
network. While the Sony breach raised greater awareness and concern about nation states as
perpetrators of cyber threats, there are numerous
vulnerabilities closer to home.
Patching ICS vulnerabilities
The root cause of many large-scale breaches is often an unpatched device lingering on
the network and creating vulnerabilities for the
entire organization. With an ICS, patching the
network involves much more than just updating
an app on an iPhone or updating software on a
personal computer.
Patch management can be a time-intensive
exercise, and to be truly effective it requires thorough operational testing. Validated patch management in an environment that mimics the plant
environment helps energy organizations manage
patches in an efficient and effective way to keep
systems online and protected against the latest
known vulnerabilities.
Do-it-yourself patch management
Approaches for executing patch management

differ in the energy sector today.
Software: When it comes to the most critical assets, operators rely on advanced software to maintain secure operations through
full visibility of equipment events and performance. Courtesy: GE Measurement & Control, a division of GE Oil & Gas
Self-performers use anti-virus solutions

and complete the process on their own time. If
they are on a Microsoft operating system (OS),
they rely on patches from Microsoft and its antivirus provider, then test, validate, and deploy the
updates themselves. Depending on plant size,
this can be an onerous task. A plant with five
computers on the control network requires manual implementation on each computer individually; some industrial facilities in certain regions
have as many as 85 computers on the controls
network. Not only is the process more time consuming when managing individually, it is also
more of a liability for the organization as it introduces risk to the process.
Self-performers take 100% of the risk
themselves to manage patches and ensure all
computer systems are updated. If the patch
unexpectedly requires system shutdown, the
organization loses revenue due to unplanned
downtime. Additionally, many do-it-yourself
approaches still require a USB drive to transfer
the patches to each computer system.
According to a recent study of security behaviors from Raytheon and the Ponemon
Institute, more than half (52%) of survey
respondents plugged in a USB device that was
given to them by another person in the past
three months. The potential for insider threats
is a concern that reverberates through the oil
An oil and gas company calculated

that the failure of one control system
human-machine interface and
two-days of downtime would cost
an estimated $12 million in lost
production.
and gas and power generation sectors. Using

someone elses USB or leaving it in an unsecure
location may allow internal actors to manipulate
the portable device. Connecting a compromised
USB device to the controls network could introduce malware to the network and wreak havoc
on the system and operations.
When organizations rely on trusted security services and providers who take all necessary precautions to secure their supply chain
through update delivery, they substantially mitigate risks and transfer liability away from the
self-performer.
Validated patch management
Organizations can select a packaged solution or a comprehensive service when choosing a

third-party patch management approach.
www.controleng.com
Learn about the latest engineering trends

and technologies.
Check out our Control Engineering
webcasts on topics like
Internet of Things/Industry 4.0
Cyber Security
System Integration technologies
and strategies
Information Integration: controller
technologies and strategies
and more
Professional Development Hours
are available!
www.controleng.com/webcasts
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cover story
With a packaged solution, a vendor gathers

the necessary patches for a plant facility based
on the operating system (OS) software and hardware and shares the packaged updates with plant
operators to implement themselves. This option
reduces the work involved in identifying patches and combining them for one monthly update.
However, the organization is still responsible for
testing these patches and mitigating any adverse
impacts prior to deployment.
Untested patches are unreliable in the ICS environment because, without testing, operators cannot
predict how a particular system will respond to the
updates in its as is state. In 2014, 10 of 12 OS
patches issued for ICSs had to be modified for the
live industrial environment to avoid complications,
downtime, or vulnerabilities. With validated patch
management, the patch is run in a virtual environment on-site or a lab environment that mimics the
plant environment to identify any incompatibilities that may exist before the patch is applied. This
allows operators to determine what alterations need
to be made to ensure uptime and protection against
cyber security threats.
Virtual testing with vendor training is more
effective than not testing, but it is limited in its
capability to fully address all factors within the
plant environment. A secure external lab environment that has the physical hardware and software
in place for testing is the best method to guarantee industrial controls receive tailored patches monthly. This process helps keep ICSs secure
and up-to-date so malware and malicious attacks
cannot manipulate system vulnerabilities.
Failed patch strategies
Energy companies already have felt the repercussions of failed patch management strategies.
In one energy company, an HMI was using an
obsolete OS no longer supported by vendors
for continued patches. Malware was introduced
on this system, which, in turn, affected production. In addition to the lost production and forced
downtime, the company had to launch an investigation to identify the cause of the shutdown,
using more resources and lowering productivity. To avoid this scenario, organizations should
regularly patch systems using a validated patch
management system, while also managing outdated hardware and software; proactive lifecycle
management can avoid costly forced downtime.
Securing connected machines
As more technology is introduced into the

plant environment, there is greater need to
validate secure configurations and patches to
maintain a reliable control system network.
Securing connected machines in the industrial
Lab: Validated patch management testing is conducted in a cyber asset protection (CAP) testing lab. This process ensures the control system network stays
online and secure after implementing patch updates. Courtesy: GE Measurement
& Control, a division of GE Oil & Gas
sector has a unique set of complexities that are

very different from those related to protecting
a business data center.
Additionally, industrial organizations must
understand the challenges of and differences
between information technology (IT) and operational technology (OT) to execute a strong cyber
security strategy. The world of OT security needs
to be foundationally different from traditional
IT detection systems in existence today. As with
other industries, ICS cyber security will likely
transition into a managed service practice rather than an in-house or vendor-generated solution.
As energy organizations place greater emphasis
on cyber security, they must remember that successful patch management is the foundation for a
secure and productive enterprise. ce
- Dana Pasquali is a product management leader at GE Measurement & Control,
a division of GE Oil & Gas; edited by Mark T.
Hoske, content manager, Control Engineering,
mhoske@cfemedia.com.
Next article in this issue

covers wireless cyber security.
Consider this...
Are you waiting for an industrial control system
cyber security incident before seeking a budget to
match the risk?
www.controleng.com
Go Online
Online, also see the article, ICS
cyber insecurity: Not if, but when,
and others about patching.
For more on protecting control

systems, see Oil & Gas Engineering, if not with this issue, then
linked with this article.
cover story
Wireless security
basics, standards
Wireless has become the communications medium of choice for many people and
applications. However, without effective data security, wireless technology could not
grow and people would still be reliant on wired systems along with the cost and
inconvenience associated with them. Industries and businesses want to prevent
intellectual property and production from being compromised.
Key
concepts
Digital realm data
requiring protection
includes personal data,
intellectual property,
processes, passwords,
and confidential email
exchanges.
As the utility of wireless
LANs (WLANs) began to
become apparent, a means
for securing the network
needed to be found and
implemented.
Beginning with the
802.11i amendment,
robust security networks
(RSN) and robust security network associations
(RSNA) were introduced to
provide a framework for
secure wireless networks.
34
he subject of wireless security is a

combination of intrigue, hard work,
trial and error, and finally success.
The perfection of wireless security has allowed the technology to
evolve within two years from a novelty that was
untrusted and used only as a last resort to a technology that is becoming an essential part of the
fabric of data communication, and everyday life.
It is predicted that soon most people will have
a mobile smartphone as their primary computer.
Wireless has become the communications medium of choice for many people. However, without effective data security, wireless technology
could not grow and people would still be reliant
on wired systems along with the cost and inconvenience associated with them.
Digital security, wireless
What is security? We all have things we want

to protect. In the physical realm, we have homes
and cars; in the digital realm, we have personal data, like our social security numbers, online
passwords, and confidential email exchanges.
Industries and businesses want to prevent their
intellectual property as well as their means of
production from being compromised.
However, we see regular instances of ostensibly secure corporate networks hacked with
impunity. How do we protect treasures from
being stolen or compromised? This concern
has been with us since time immemorial. The
basis of security is to allow us to freely access
our possessions while restricting or preventing
access by others.
In the physical realm, we lock doors and use
a key to open them. In the digital realm, we enter
a combination of numbers or letters to access a
computer or data. At the bottom of it all, there

is a lock and key, a worthy analogy to keep in
mind. The key is unique to the lock; no other key
will open it. The lock can be picked, however,
or it can be physically destroyed (the brute force
approach); the key can be stolen or borrowed. All
security suffers from the same weaknesses, and
the analogy holds. The key will retain its essential meaning; however, the lock in this analogy
will take many different forms.
Digital access control
Wireless security can consist of several components depending on the individual or companys need for protection. Small systems, such
as small office/home office (SOHO) routers or
personal wireless LANs (WLANs), typically restrict access to the network by passwords.
Larger enterprise WLANs also require passwords, but in addition use methods of authentication and encryption that rely on authentication
servers to control access to a wireless network.
Larger systems also segregate traffic into specific roles, further segmenting traffic using virtual
LANs (VLANs) and other methods. These techniques give administrators control over the data
and who can access it based on need to know, job
roles, or department.
Wireless intrusion detection systems (WIDS)
also are used to discover and mitigate unauthorized users and monitor the network continuously; these systems are very effective in most cases,
but they are also very costly. Finally, and this is
often overlooked, there needs to be a security
policy regardless of the WLAN size. Most networks are compromised by what is called social
engineering. This term describes the process by
which a person reveals his or her credentials to
an unauthorized person as a result of fraud or

subterfuge. A solid security policy is effective in
teaching people how to avoid being coerced or
duped into revealing credentials.
Wireless security legacy, background
A wireless network segment used to be little

more than an expensive novelty and wasnt used
for anything critical. Open system authentication
(OSA) was the term used for the early methods
of network access and was little more than a simple query by the access point (AP) to the client
to ensure that the client device was IEEE 802.11
compatible. Wireless was used as an extension
to a wired network because wiring was costly
or impractical. As the utility of wireless LANs
(WLANs) began to become apparent, a means
for securing the network needed to be found and
implemented.
The first attempt at securing the network was
called wired equivalent privacy (WEP). The
intent of WEP was to provide an equivalent measure of data confidentiality to wireless networks
as was available in wired networks. WEP was
based on the Rivest Algorithm, otherwise known
as rivest cipher 4 (RC4), for encryption. WEP
used a 24-bit randomly generated initialization
vector (IV) and a 40- or 104-bit static key (for
64-bit and 128-bit WEP, respectively) to encrypt
plain text. The key must match on both the client
device and access point.
Combining the key, along with its integrity
check value (ICV), with the keystream, encrypts
a plain text message. Concatenating the secret
key with the 24-bit initialization vector (IV) and
applying the encryption algorithm, RC4, produce
the keystream. Concatenation is a logic function
creating a symbol or sequence by placing one
value after another, in this case the key with the IV
and the message with the ICV. At each round of
encryption, the IV would be incremented, producing a unique IV and keystream for each message.
WEP suffered from inherent flaws related to
key construction and IV reuse. The IV was transmitted plain text, and it was possible to determine the secret key using various techniques
exploiting IV reuse and collisions. The ICV was
based on CRC-32, which was not designed to be
secure; this provided another means of exploitation. Using commonly available tools, WEP can
be cracked in fewer than 10 minutes; WEP is no
longer used and should be avoided, even in small
office/home office (SOHO) environments.
Temporal key integrity protocol (TKIP) was
designed to remedy the IV reuse issue. TKIP provides data security while using existing equip-
Figure 1: The key must match on both the client device and access point.
When it is combined along with its integrity check value (ICV), with the keystream, it encrypts a plain text message. Figures 1-3 courtesy: Daniel E.
Capano, Diversified Technical Services Inc.
Figure 2 is an example of the IEEE 802.11 security tree. Beginning with the
802.11i amendment, robust security networks (RSN) and robust security
network associations (RSNA) were introduced to provide a framework for
secure wireless networks. Generally, a successful authentication indicates
that the parties to the transaction have mutually verified each others identities and have generated dynamic encryption keys to be used for secure data
transmission.
ment that could be upgraded through firmware

upgrades. TKIP was developed jointly by the
IEEE 802.11i task group and the Wi-Fi Alliance
to replace WEP. It became the basis of wireless protected access (WPA). This was an interim measure that provided a solution until a more
robust security mechanism could be developed
and put into place. TKIP uses dynamically generated and unique 128-bit encryption keys, or
temporal keys, as opposed to the static keys
used by WEP. A process called the 4-way handshake that takes place between an AP and a client device generates these keys. Each frame is
www.controleng.com
cover story
Recognizing
that the
adoption
of wireless
technology
was growing
exponentially,
the IEEE 802.11i
task group
developed
advanced
methods
of securing
wireless
networks.
also assigned a sequence number; a frame is

rejected if it is received out of sequence. In addition, the weak key and key reuse problem was
addressed by using a complex key mixing process to develop a stronger key stream. The TKIP
was designed to operate on legacy equipment
using WEP encryption; the RC4 cipher was also
used in TKIP. Finally, an enhanced data integrity
scheme was implemented, the message integrity
code (MIC). While the use of TKIP was mandatory in WPA, it is optional in WPA2, which mandates the use of CCMP-AES encryption.
IEEE 802.11 and CCMP/AES
Recognizing that the adoption of wireless

technology was growing at an exponential rate,
and that security was of paramount importance
in supporting this growth, the IEEE 802.11i task
group developed advanced methods of securing
wireless networks.
Beginning with the 802.11i amendment,
robust security networks (RSN) and robust security network associations (RSNA) were introduced to provide a framework for secure wireless
networks. Generally, a successful authentication
indicates that the parties to the transaction have
mutually verified each others identities and have
generated dynamic encryption keys to be used
for secure data transmission.
Wireless protected access 2 (WPA2) Is a
complex security method that draws on the federal information processing standard (FIPS)197, which introduced the advanced encryption
standard (AES). The WPA/WPA2 designation

was developed by the Wi-Fi Alliance and mirrors the IEEE standards, and is actually a certification, ensuring equipment adheres to a
common standard of security. WPA2 defines
two types of security: passphrase authentication
for small and small office/home office (SOHO)
networks, and 802.1X/EAP security for enterprise networks.
WPA2 mandates the use of a new protocol,
counter mode with cipher-block chaining message authentication protocol (CCMP). CCMP
uses the AES block cipher; replacing the RC4
cipher used in wired equivalent privacy (WEP)
and temporal key integrity protocol (TKIP).
A block cipher processes data in blocks, while
a streaming cipher like rivest cipher 4 (RC4)
processes data bit by bit, in a serial stream.
The encryption method is commonly referred
to as CCMP/AES. AES uses a 128-bit key and
encrypts data in 128-bit blocks. CCMP/AES uses
several enhancements, including temporal keys
(TK), packet numbers (PN), nonce [number or
bit string used only once], upper layer encryption, and additional authentication data (AAD).
It should be understood that AES is a standard
and not a protocol. The AES standard specifies
the use of the Rijandel symmetric block cipher
that can process data blocks of 128 bits, using
cipher keys of 128, 192, and 256 bits.
CCMP is a security protocol. It follows carefully designed steps that include the use of the
AES specified algorithm to encrypt sensitive
data. CCMP is made up of different specialized
components providing specific functions. It also
uses one temporal key for all encryption and data
integrity processes. ce
- Daniel E. Capano, owner and president,
Diversified Technical Services Inc. of Stamford,
Conn., is a certified wireless network administrator (CWNA), dcapano@sbcglobal.net. Edited
by Chris Vavra, production editor, CFE Media,
Control Engineering, cvavra@cfemedia.com.
Consider this...
Are your industrial wireless networks offering the latest
security capabilities, or are others listening in, looking for
vulnerabilities?
Go Online
Figure 3: Diagram of the cipher-block chaining message authentication protocol (CCMP) encryption process. CCMP uses the AES block cipher, which
processes data in blocks; the encryption method is commonly referred to as
CCMP/AES. AES uses a 128-bit key and encrypts data in 128-bit blocks.
36
www.controleng.com/blogs has more information and

images from Capano on these topics.
See the Control Engineering cyber security page:
www.controleng.com/networking-security/
cyber-security
Advance network security,

support system monitoring
5 defense-in-depth tips
faceted rules for communication between various network

segments and zones in the
ICS network.
2. Create demilitarized
zones from the established
firewall by grouping critical
components and isolating
them from the traditional
business IT network.
3. Deploy intrusion detection and prevention systems
that focus on identifying possible incidents in an
ICS network.
4. Establish well-documented and continuously
reviewed policies, procedures, standards, and
guidelines regarding IC network security.
5. Implement continuous assessment and security training to ensure the security of the ICS and
the safety of the people who depend on it. ce
Defense in depth is a strategy to establish

variable barriers across multiple levels in the organization to secure the ICS. These barriers include
electronic countermeasures such as:
1. Establish firewalls to add stringent and multi-
- Marty Aaron is product line manager, and Rick

Schear is a product manager at Eaton; edited by
Mark T. Hoske, content manager, CFE Media,
Control Engineering, mhoske@cfemedia.com.
yber security: Applications can improve

power reliability and reduce energy costs
by advancing network security and supporting system monitoring. Allowing network access
raises cyber security concerns. Five defense-indepth measures can help.
To make intelligent power management decisions that reduce energy consumption and
improve power reliability, it is critical to monitor and
understand how power is used, although collecting
and accessing that information can introduce cyber
security concerns. Monitoring via the industrial
control system (ICS) can be used to gain access
to equipment to prevent downtime, and see system parameters and diagnostics, creating a risk
of unauthorized information access or providing
unintended access to equipment operations and
settings to unauthorized users.
Mapping networked
assets and practicing defense-in-depth
strategies can lower
the risk of cyber security intrusion, while
allowing access to
important information,
such as energy use.
Courtesy: Eaton
2015
Mobility, Ethernet and Wireless

Turning research into insights makes for better business decisions
This study was conducted by Control Engineering to learn more
about integration, use, and spending for mobility, Ethernet,
and wireless technologies and how they help users of
automation, controls, and instrumentation to be more
productive.
Fifty-eight percent of respondents predicted that
productivity as it directly relates to mobility and
wireless technologies will increase within the
next 12 months.
Download the Control Engineering
Mobility, Ethernet and Wireless Research today!
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process control
A dual split-range control

strategy for pressure and
flow processes
Maintaining setpoint for two-mode or wide-range operations can be
much easier when there are two control devices.
Key
concepts
Some control problems
require more sophisticated
solutions than traditional
regulatory control.
Split-range control strategies are very well suited
for specific applications.
Syncrude Canada was
able to automate a difficult application that had
required a high level of
manual intervention.
plit-range control has been widely used in industrial processes for

controlling pressure, temperature,
and flow, and it is normally used to
control a two-mode operation. For
example, split-range control has been used to
maintain a vessel temperature where there are
both heating and cooling controls. When the
temperature (a single measured value) is below
the desired temperature setpoint, first the cooling valve is closed and then the heating valve
will start to open. When the temperature is
above the setpoint, first the heating valve is
closed and then the cooling valve will start to
open. Alternatively, split range control is used
to regulate two control valves to cover a wider
range of operation. One control valve controls
through the lower range and the second control
valve controls the upper range. In both applications we need a control valve in each of the
individual process lines.
Discussion and design below review how a

dual split-range control can maintain pressure
or flow rate in a three-pipeline process with two
lines having control valves and the third line
(flow line) having no control valve, and how
to coordinate between the pressure split-range
controller and the flow split-range controller.
P&ID for the example
The existing piping and instrumentation

arrangement has the main line with one control
valve A, which branches into two lines as shown
in Figure 1. Valve A is used to maintain upstream
process pressure measured by PT2 with a standard PID controller P2. The two branch lines
have two control valves, B and C, to maintain
downstream pressure measured by PT1 using a
pressure split-range controller P1 by opening and
closing control valves B and C through PC1A
and PC1B. PT1 is a pressure transmitter to measure the downstream pressure of valve A.
When upstream pressure PT2 is high, valve A
will open more to reduce the pressure. And when
pressure at PT2 is low, valve A will reduce its opening. In both situations, downstream valves B and C
will follow the changes in valve A to maintain pressure at PT1 by using split range controller P1.
When pressure at PT1 is high, P1 will open
valve B first to send gas to plant 1. When valve
B is fully opened and pressure is still high, P1
will open valve C to send gas to the flare header to control. On the other hand, when pressure
at PT1 is less than P1s setpoint, P1 will close
valve C and then valve B until pressure reaches
P1s setpoint.
Changing the process
Figure 1: Existing pressure process and control. All diagrams courtesy: Syncrude Canada Ltd.
38
Due to changes in the process, gas from

valve A is sometimes required to flow to plant
2. However, the line to plant 2 has only a

solenoid valve D with two operational states,
fully open or closed, and has a flow transmitter FT2 as shown in Figure 2. FX2 is the
compensated flow with temperature and pressure, which are not shown in the diagram.
The new process requires maintaining
pressure at PT1 when valve D is closed, and
maintaining a certain flow rate at FT2 when
valve D is open. The existing pressure splitrange control P1 has difficulty meeting the
two different control objectives. When valve
D is open and gas flows into plant 2, an operator manually adjusts pressure by trial and
error to achieve the required flow at FT2 to
plant 2. This results in delays and difficulty maintaining a steady flow to plant 2. For
example, when the inlet pressure in plant 2
changes, it will cause flow variation even if
the pressure at PT1 is maintained very well.
Thus, it needs continuous intervention by the
operators to maintain constant flow at FT2 if
only the split range controller P1 is used to
control flow.
Therefore, the existing control design does
not meet the operators expectation of having
continuous automatic control of both pressure
at PT1 and flow at FT2.
Figure 2: The new piping and instrumentation arrangement reflecting

process changes.
Solving the challenge
In analyzing the challenge, it was clear that

there were three main objectives that would have
to be fulfilled simultaneously:
Use the flow and pressure controls to
maintain flow or pressure based on input
from the flow or pressure controller with
the new setup, but with no field control
valves in the flow control line
Figure 3: Dual (flow/pressure) split-range control scheme.
Smooth bump-less and procedure-less

transfer between flow and pressure
controllers, and
Avoid flare and pressure upsets when
the solenoid valve suddenly closes in
the third line.
Dual split-range control strategy
The new dual (flow/pressure) split-range

control scheme was configured in the control
systems with no additional field instrumentation
or valves, and is illustrated in Figure 3. F2A is a
flow split-range controller and PHS1 is a switch
used for operators to select between pressure
split-range control or flow split-range control.
Figure 4: Pressure/flow split-range control with open-close valve D status.
In the new control scheme, when valve D

is closed, the pressure split-range controller is
used to maintain pressure at PT1 in the same
way as before. When the valve D is opened,
the new flow split-range controller F2A will
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process control
Initial P1.OP = 100 [F2A.OP +

(FT2.PV / Maximum Flow Rate)*100]
Here, FT2 is the flow in the third line, and
the maximum flow rate is defined as the flow
in the first line when the controller P1 is fully
opened. This design can avoid the upset caused
by the sudden closing of the solenoid valve
D, which may cause flaring and disturb the
upstream operation.
Figure 4 shows the valve opening states of
valves B, C, and D for the cases of pressure
split-range control and flow split-range control,
respectively.
Actual results
Figure 5: The flow split-range control performance history.
Figure 6: The dual (flow/pressure) split range control performance history.
Go Online
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www.syncrude.ca
At www.controleng.com,
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articles on this critical topic.
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40
maintain the flow to plant 2 as monitored by FT2.

When the flow is less than F2As setpoint, F2A
will first close valve C. When valve C is fully
closed, it will start to close valve B until the flow
reaches its setpoint. In normal operation, it is
desirable to avoid sending gas to the flare.
To achieve smooth transfer between the flow
split-range controller and pressure split-range
controller, and to avoid a possible upsets or flares
when the solenoid valve is suddenly closed by
the trip functions, control logic is designed to set
the pressure or flow controllers opening initially.
For example, when the control is switched
from flow split-range control to pressure splitrange control by an operator or by the trip
logic, pressure controller P1 is set to its initial
opening value, which is defined in the following equation, and then controller P1 is set to
automatic control. P1s initial opening is calculated thusly:
This new dual split-range control strategy is

now in use for waste gas processing in our company. Figure 5 shows the control performance
using the flow split-range control for flow FT2.
The flow setpoint of FT2A was first increased
from 4 mscfd to 5.5 mscfd and then reduced to
4.8 mscfd. It is clear that the flow at FT2 followed setpoint changes well.
Figure 6 demonstrates the flow split-range
control for the flow at FT2 at the beginning and
for most part in the middle section, and with the
pressure split-range control for pressure PT1 at
the end.
It can be seen that when the control is
on flow, FT2 with the flow setpoint rapidly changed from 4 mscfd to 2 mscfd, the flow
FT2 tracked the flow setpoint very well, and
the header pressure PT1 changed without any
upset or pressure surge. When solenoid valve D
was suddenly closed, the DCS logic set a calculated initial opening to control valve B through
controller P1 and set a predefined setpoint to
controller P1 (15 psig), then switched the flow
controller to the pressure controller, which prevented a pressure upset and avoided the need
for possible waste gas flaring.
The dual split-range control discussed here
has been implemented at Syncrude Canada
Ltd. A properly designed dual split-range control strategy can maintain both pressure and
flow rate for a process that has three pipe lines,
two lines with control valves and the third with
no control valve. The results of this industrial
application satisfied all the control performance
criteria of the process. ce
- Xi (Chris) Sun, PhD, PEng, is senior associate, Control, PC&A; Ashish Shah, PEng, is team
leader, Technical, PC&A; and Joseph Amalraj,
PEng, MBA, is senior technical leader, PC&A,
for Syncrude Canada Ltd.
digital edition
EXCLUSIVE
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DE-1 CANopen provides distributed control functionality
Clear up these misunderstandings regarding the multi-master functionality of CANopen-based control systems. The CAN data link layer is a multi-master protocol, and each CAN node has the right
to request bus access at any time. Priority of the CAN data frame determines node timing.
DE-3 Six ways a mobile service app helps oil and gas businesses
improve field equipment performance
A mobile software service application can help manage and care for oil and gas rigs and heavy
equipment located in remote geographical locations.
DE-5 Need for better security: SCADA/HMI connecting

with mobile Internet
Control Engineering China interviewed Marcia Gadbois, vice president and general manager of
InduSoft, on SCADA/HMI development, factory intelligence, and the companys recent merger.
Go to www.controleng.com/digitaledition today!
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digital edition
EXCLUSIVE
CANopen provides
distributed control functionality
There are some misunderstandings regarding the multi-master functionality of
CANopen-based control systems. The CAN data link layer is a multi-master
protocol, and each CAN node has the right to request bus access at any time.
Depending on the priority of the CAN data frame, the node gets immediate bus
access or it has to wait.
Key
concepts
CANopen can be used
to design a network with
multiple host controllers. In this case, the host
controllers can share the
network to communicate
PDOs and SDOs.
The trend of modular
machine design will also
be adapted in industrial
and other machinery, such
as laboratory automation
and medical apparatuses.
CANopen provides all
necessary features for
such distributed control
architectures.
he CANopen application layer provides several protocols. The only

mono-master protocol is the network
management (NMT) protocol. There
is usually just one NMT master device that
sends the NMT message to control the other
CANopen devices. To avoid a single point of
failure, CANopen provides an optional NMT
Flying master functionality. This means that
there are additional CANopen devices in the
network that provide NMT master functionality, but this function is not yet activated. If the
active NMT master device loses connection to
the network, the remaining devices with sleeping NMT master functions start to negotiate
as to which one will act as the NMT master.

Each NMT master capable device has a unique
priority, assigned by the system designer. If a
temporarily disconnected NMT master-capable
device is connected it again, it requests the priority of the active NMT master and possibly
starts the above-mentioned negotiation process.
The NMT Flying master process comprises
four protocols.
The Heartbeat is a producer/consumer service. This means any node produces its Heartbeat to indicate that it is still in the network.
All other CANopen device may consume the
Heartbeat of others. The system designer can
configure this for each node differently. The
The basic CANopen

document (CiA 301) specifies a default assignment
of CAN-IDs for the different
communication protocols.
There are just four predefined CAN-IDs for PDOs
to be transmitted for each
node.
Figure 1: NMT Flying master protocols are used to negotiate which CANopen device will become
the active NMT master. Figures courtesy: CAN in Automation
DE-1
EMCY (emergency) message is also a producer/consumer service. The system designer can
configure the EMCY reception by means of
standardized parameters in the CANopen object
dictionary.
Process data objects (PDOs) also follow
the producer/consumer model, making it a true
multi-master system. They are sent in broadcast
to all connected nodes, and depending on the
implemented hard- and software message filtering, they are processed or ignored. One of the
misunderstandings comes from the pre-defined
CAN-ID connection set. The basic CANopen
document (CiA 301) specifies a default assignment of CAN-IDs for the different communication protocols. There are just four pre-defined
CAN-IDs for PDOs to be transmitted for each
node. Additionally, there are four pre-defined
CAN-IDs for PDOs to be received. This means
that there is a pre-configured set of PDOs normally consumed and produced by a host controller. But the system designer can configure
the CANopen devices in a way that the crosscommunicate PDOs, as well as multi-cast them,
making it is possible to configure a full-meshed
PDO communication.
Another misunderstanding is regarding the
default service data objects (SDO) communication. SDOs are used to write or to read the
parameters in the object dictionary. This is a
client/server communication. The client always
has the initiative, and the server responds to
the write or read request with a confirmation.
In case of reading, the SDO server provides the
requested data in the confirmation. The abovementioned pre-defined CAN-ID connection set
features just the Default-SDO communication,
meaning each CANopen node has just one predefined CAN-ID for receiving the request from
the SDO client and another one to transmit the
confirmation to the SDO client. Normally, the
host controller owns all SDO clients for all the
Default-SDOs of the other CANopen devices,
but it is possible to assign unused CAN-IDs to
not pre-defined SDO-channels. At the end, each
CANopen device can be the SDO client for
each other and vice versa. This would be a true
fully meshed SDO network.
CANopen can be used to design a network
with multiple host controllers. In this case, the host
controllers can share the network to communicate
PDOs and SDOs. Additionally, they can share the
connected other CANopen devices. For example,
an I/O module can communicate with one PDO its
inputs to one host controller and with another PDO
other inputs to another host controller. The I/O
module can even be host controller by itself.
Figure 2: CANopen devices may implement several SDO servers, so that several
host controllers can share the devices functionality.
One CANopen device can implement multiple SDO servers, so that different host controllers can configure it. Such real distributed
control systems may have a single-point of failure if no NMT Flying master functionality
is implemented. The subsea controllers make
use of redundant NMT masters, and some other
mission-critical applications implement the
NMT Flying master protocols. In the elevator
control business, multiple host controllers are
used, sharing the network and communicating
via the very same bus-lines with the assigned
CANopen devices. Multiple host controllers are
also used in CANopen-based rail vehicle applications. In industrial machine control systems,
most of the applications implement just one
big host controller collecting all input data
and transmitting all commands to the actuators.
In mobile machine control systems, sometimes
multiple host controllers are used. The trend of
modular machine design will also be adapted
in industrial and other machinery, such as laboratory automation and medical apparatuses.
CANopen provides all necessary features for
such distributed control architectures. ce
- Holger Zeltwanger is managing director,
CAN in Automation, a CFE Media content partner; edited by Anisa Samarxhiu, digital project
manager, asamarxhiu@cfemedia.com.
Go Online
Link to other CAN in Automation articles in the archives
www.controleng.com/archives
Learn more at the CiA website
www.can-cia.org
Consider this...
How would you use the multi-master functionality of
CANopen-based control systems?
www.controleng.com
CONTROL ENGINEERING APRIL 2015 DE-2
digital edition
EXCLUSIVE
Six ways a mobile service

app helps oil and gas
businesses improve field
equipment performance
A mobile software service application can help manage and care for oil and gas rigs and
heavy equipment located in remote geographical locations. A mobile service app can help
oil and gas industry service providers, and their customers, in six ways.
Key
concepts
Oil and gas businesses
seek to increase field
equipment performance
and make servicing equipment more efficient.
Rig and drilling equipment service providers
can use a mobile service
application to track, alert,
and manage service needs
for field technicians and
back office workers.
or oil and gas companies, mobile soft- 2. Ease meter readings with
ware applications can augment services e-inspection forms
Oil and gas service businesses need to
to help ensure the equipment used to
drill, pump, and deliver the goods to inspect equipment regularly to capture meter
customers stays in top shape. Todays oil and readings to ensure safe and efficient condigas companies must manage the complex pro- tions. To ease and standardize the inspection
cess of drilling, measuring, shipping, and sell- and meter reading process, businesses can
ing oil and gas, and ensure the equipment they build and centrally modify field e-forms, and
automatically sync informause is in top shape so theres
no downtime or inefficienWith detailed insight tion collected in the field
with the back office. With
cies during the process.
into key performance
a standard process in place
With improvements in
field service management indicators like equipment and immediate reporting,
readings and inspections
software and mobile apps for
performance, energy
can be more accurate, and
oil and gas service departoutput levels, or autothe need for data reentry
ments, the task of servicing
and performing regular main- alerts when a part needs and archaic paper filing will
be eliminated.
tenance through service conreplaced, companies
tracts has become much more
3. Measure equipment
manageable. Because oil and
see if equipment is
performance
gas rigs and heavy equipment
functioning at peak
Service businesses can
are located in many geoperformance
levels.
use an integrated mobile app
graphical locations, a mobile
to monitor equipment perforsoftware application can help
manage and care for equipment in remote loca- mance in the field while workers are on/off-site.
tions. Here are six top ways a mobile service app With detailed insight into key performance indicators such as oil rig performance, energy output
helps ease that process:
levels, or auto-alerts when a part needs replaced,
1. Split service work orders
oil and gas companies see if their equipment is
into segments
functioning at peak performance levels.
Sometimes the work that technicians need
to do is complicated and may require mul- 4. Track inventory
Field workers need access to the parts and
tiple tasks or technicians to get the job done.
A mobile segments feature allows the user to inventory information theyll need to serseparate work orders into phases or groupings vice or maintain pieces of equipment. With
that relate to important components of the field- a mobile app, field workers have constant
work taking place. Tracking work order phases access to the parts for any job to which theyre
through segments allows the user to document assigned. Field techs can also use such an app
to collect data and use parts analytics to plan
productivity at a meaningful level of detail.
DE-3
inventory purchasing, stocking, and allocation

to improve inventory efficiency planning going
forward.
5. Manage preventive maintenance

contracts
Instead of waiting for a piece of equipment

in the field to break down and halt production,
oil and gas companies can schedule preventive
maintenance (PM) contracts to keep equipment
at peak performance. A mobile app auto-schedules these recurring maintenance orders and
keeps technicians in the loop by sending alerts
when PM orders are coming up. The app also
provides full access into service and equipment
history, inventory information, and knowledge
sharing resources for each PM order on the
technicians schedule.
6. Improve scheduling efficiency
This is helpful if the equipment is spread out

because a technician wont have to worry about
driving hours out of the way to get there.
Oil and gas businesses of all shapes and sizes
are looking to increase field equipment performance and make servicing equipment more efficient. Stay on top of rig and drilling equipment
needs with a mobile service application to track,
alert, and manage service needs for field technicians and back office workers. ce
- Joanna Rotter is content marketing manager at MSI, a CFE Media content partner. Edited by Anisa Samarxhiu,
digital project manager, Control Engineering,
asamarxhiu@cfemedia.com.
Go Online
www.controleng.com/AppsForEngineers
Sign up for the free Oil & Gas Engineering e-newsletter.
Mobile apps for service technicians are

automatically connected to centralized service
scheduling software, helping schedulers make
rapid decisions and assignments based on actual
technician location, availability, and skill set.
www.controleng.com/enewsletters
Consider this...
How could a mobile software application help your
business better serve customer?
Engineering is personal.
So is the way you use information.

CFE Media delivers a world of knowledge to you. Personally.
To do your job better
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digital edition
EXCLUSIVE
Need for better security:

SCADA/HMI connecting
with mobile Internet
Control Engineering China (CEC) interviewed Marcia Gadbois, vice president
and general manager of InduSoft, on SCADA/HMI development, factory intelligence,
and the companys recent merger.
Key
concepts
Intelligent factories raise
new demand for SCADA/
HMI products, due to the
connection of various kinds
of data as well as stronger
mobility.
Network security is not
only a technical issue but
also involves education and
training.
Acquisition of InduSoft
by Invensys brings together
the medium-end and highend markets.
DE-5
CEC: Factory intelligence is

widely discussed in the manufacturing industry. How can
we make the development of
SCADA/HMI products fit the
demands of future intelligent
factories?
cation training in places like

Wuhan.
CEC: Will Invensyss acquisition of InduSoft have an impact
on InduSofts future mediumand long-term development?
Gadbois: Indeed, the vision

Gadbois: This acquisition is
of intelligent factory raises new
a win-win choice for both Indudemand for SCADA/HMI prod- Marcia Gadbois, vice pres- Soft and Invensys. We all know
ucts. The demand comes from ident and general manager,
that Invensys has a big influence
the improving connection of InduSoft. Courtesy: Control
on the process control field.
various kinds of data as well as Engineering China
Also, the SCADA/HMI prodstronger mobility. More compatucts of Invensys and InduSoft
ibility with data sources and stronger support complement each other due to market orientafor mobility will be needed. For example, a web tion. InduSofts strength is the software applistudio should integrate functions and require no cation in the embedded Microsoft Windows CE
loading of any plug-in modules. It should be platform, while Invensys is not good at this.
released from original PC project to webpage Besides, InduSofts software targets the medifor browser or mobile phone remote monitoring um-end market and below, which is significantwithout secondary development.
ly different from the high-end market Invensys
focuses on concerning product orientation
CEC: When we talk about data connection and planning. After InduSoft was acquired by
and mobile Internet, people always worry about Invensys and Invensys was acquired by Schneinetwork security because the most important der Electric, InduSoft is now able to leverage its
elements for factory production are safety and unique inner advantages. ce
- Edited by Joy Chang, digital project manreliability. Whats your point of view?
ager, Control Engineering, jchang@cfemedia.
Gadbois: I couldnt agree more on the impor- com, from an article supplied by Control Engitance of network security. Network security is neering China. www.cechina.cn
not only a technical issue but also an education
and training issue. Many potential industrial
Go Online
network security risks are not about techniowner Invensys acquires InduSoft is availcal protection but about the operators, who Wonderware
able by searching atop www.controleng.com.
are supposed to operate according to standards
www.controleng.com/international
and procedures. If the operators fail to do so,
it results in the failure of due function of net- has additional global news.
work security.
Consider this...
InduSofts education and training center
Does your organization have an educational program to
established by ICP DAS in Asia already has
improve network security?
begun to organize the InduSoft OEM certifi-
stay
informed
Stay current
with technology and trends
in electrical, mechanical,
instrumentation and
automation.
To subscribe, visit
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PID for motion control
Feed forwards
augment PID control
In closed-loop motion control applications, it is common to multiply the target speed and
target acceleration by the velocity and acceleration feed forwards to generate the feed
forwards contribution to the control output. Feed forward augmentation is a prediction
technique that estimates the output from a proportional-integral-derivative (PID) control
algorithm without waiting for the PID algorithm to respond. Feed forward reduces the error
faster or keeps the error smaller than relying on the PID algorithm alone.
Key
concepts
Feed forward estimates
proportional-integralderivative (PID) control
algorithm output without
waiting for the PID algorithm to respond.
Feed forward can reduce
the error faster or keep the
error smaller than relying
only on the PID algorithm.
When setpoints or load
change and error must be
minimized, feed forwards
always should be considered.
eed forward augmentation is a prediction technique that estimates the

output from a proportional-integralderivative (PID) control algorithm
without waiting for the PID algorithm
to respond. If the feed forward prediction can
estimate the control output closely, the PID
algorithm, whose job it is to minimize the error
between the current state of the system and the
desired state, will need to do less to correct the
error. This reduces the error faster or keeps the
error smaller than relying on the PID algorithm
alone. Feed forward control outputs usually are
calculated using the setpoint value and its derivatives (based on target velocity and acceleration
values) and multiplying each one by a gain. In
closed loop motion control applications it is
common to multiply the target speed and target acceleration by the velocity and acceleration
feed forwards to generate the feed forwards
contribution to the control output. (Online, see
a typical control loop diagram with feed forward terms added to the conventional P, I, and
D terms.)
Motor PID example
As a simple example, consider a motor that

will move 1 in. per second if 1 V is applied, 2 in.
per second when 2 V are applied and so on, such
that applying 10 V will result in a speed of 10 in.
per second. In this case the feed forward value
would be proportional to the velocity: the velocity feed forward value is 1 volt per inch per second. This means that if the setpoint (that is, the
target velocity of the system) is 8 in. per second,
the output from the velocity feed forward term
would be 8 V.
42
In a motion control application the velocity setpoint is ramped up to the final setpoint
smoothly so the feed forward term ramps up
smoothly to avoid sudden changes in the control
output that would shock the system.
Also, a motion control application usually has
an acceleration feed forward that is multiplied by
the rate of change in the velocity setpoint to give
the motor an extra boost when accelerating to the
final position and a little braking while decelerating as the final position is reached.
Temperature control applications generally perform well without using feed forwards because the
process is relatively slow and the integrator gain
term has time to do most of the work. However,
there are cases where the load changes rapidly.
Feed forward story problem
For example, consider a baking application

where material being heated moves through the
oven on a conveyor. Assume that the time the
material must be in the oven is constant, but the
oven temperature can be varied, and the difference in the rate of baking can only be due to
the density of the material being heated. As the
material leaves the oven, it removes heat; material leaving the oven at a higher rate will make for
a greater heat loss. To compensate for these factors, some mechanism would be required to estimate the density of the material going through
the oven, which could be used to calculate the
required variations in oven temperature.
Typically, the greater the volume or number
of items going through the oven, the higher the
oven temperature should be. If the oven is long
and has many zones, then a queue needs to be
implemented so each zone can respond to dif-
ferent amounts of material in it. There may even

need to be a look ahead feature in the queue
to account for dead time between items being
baked.
In theory, feed forwards should be able to predict the correct control output so there would be
no error, making the use of a PID control algorithm unnecessary. In reality, the feed forward
gains will not be perfect due to the real-world
reactions of the plant being nonlinear, changing
loads, or time constants relating to the process
that arent really constant.
So a PID is still required to correct the error.
However, if the feed forwards can estimate the
control output within 10% of the actual control
value required, then the PID only needs to do the
last 10% of the work. This will result in a faster
response and less error over time, and presumably lower costs and higher productivity for the
manufacturing process.
Figure A: This shows a system with no feed forward terms in the control
equation. The integrator is attempting to compensate is a plot of perfectly
tuned motion using feed forwards. (B has a velocity feed forward and C
shows the motion with no feed forward terms in the control loop.) All figures
courtesy: Delta Computer Systems Inc.
Calculating feed forward gains
Feed forward gains are actually the inverse

of the plant model (a mathematical model of
the operation or process being controlled). If the
plant model was some function Gp(s), the feed
forwards would be FF(s) = 1/Gp(s). This fact is
useful because when controlling a system, the
process variable [PV(s), the measured state of the
process] should be equal to the setpoint SP(s). In
math terms, feed forward control is:
SP(s)*FF(s)*Gp(s)=PV(s)
Since the feed forwards are the inverse of the
plant, Gp(s)*FF(s) = 1, so the equation above
simplifies to
SP(s)=PV(s)
The process variable is the same as the setpoint, so there is no error. This is the desired goal.
As mentioned above, the only problem is
that typically the plant designers neglect to provide a plant model, so the feed forward gains
must be tuned manually. This isnt as hard as it
seems if the person doing the tuning has access
to the integrators gain contribution to the control output.
It is best if the integrators gain contribution can be plotted on a trend or captured in
a plot. The reason for this is that if there is an
error in the feed forward gains, the integrator
gain will try to compensate for the error (see
Figure A).
Figures A, B, and C show three tuning plots.
Figure B: This shows a system with velocity feed forward in action. In this
case, the integrator term goes to zero through most of the motion sequence.
The yellow plot line in each represents the integrator term. Red and light blue are actual and
target position. Blue and magenta are actual velocity and target velocity, and green is
the control output to the valve. The goal is for
the actual and target axis positions to precisely
overlap at every point in time (horizontal axis).
By looking at the plot or trend, the cause of
the error can be determined. Then, to reduce
the error, a feed forward gain can be calculated
as a function of whatever caused the error. For
www.controleng.com
PID for motion control
Figure C shows a perfectly tuned system

with the feed forwards doing all the work.
Linear motor model
Finally, as stated above, the feed forward

gains provide the coefficients for the plant model
because the feed forward terms are the inverse
of the linear plant model. A simple linear motor
model may be:
Gp(s) = (K)/(s+1)
So the feed forward gains are:
1/(Gp(s) = (s+1)/K = (s/K)+(1/K)
...where:
K is the gain of the motor with load
Figure C: This shows a perfectly tuned system with feed forwards doing all
of the work (PID terms only act to eliminate unforeseen errors in positioning).
instance, if the motor discussed earlier is told

to move at 10 in. per second, the motors actual
speed will lag behind the target speed until the
value of the PIDs integrator component winds
up enough to increase the control output to 10
in. per second.
Changing the target velocity caused the
error, so the first step is to calculate a feed forward term as a function of velocity. Using the
numbers from the example above the integrator value would need to increase enough to contribute 10 V to the control output, causing the
system to go 10 in. per second. Now the person
tuning the system can divide the speed by the
control output to easily arrive at a velocity feed
forward term.
Acceleration, deceleration
Assuming the velocity feed forward is now

correct, there should be very little, if any, error
while the system is traveling at constant velocity (see Figure B). However, there will most
likely be some error during acceleration and
deceleration. During acceleration the integrator output will tend to increase a bit to keep
the actual velocity from lagging the target
velocity. Since the target acceleration also
can be plotted, the amount of integrator windup during acceleration can be divided by the
peak acceleration to get a good estimate of the
acceleration feed forward gain. This should
reduce the following error during the acceleration phase and when deceleration goes to zero.
44
is the time constant of the motor with load

s is the Laplace operator
1/K is the velocity feed forward term
s/K is the acceleration feed forward term
Reminder: Laplace transform is a mathematical device used to make a round trip from
the time to the frequency-dependent complex
variable(s) domain and back. A Laplace operator is a differential operator given by a functions gradient.
Hydraulic cylinder model
A linearized model for a hydraulic cylinder and load is more complicated. The cylinder
and load can be modeled as a mass between two
springs, so it is an underdamped two-pole system. A linear model is:
Gp(s) = (K*2)/(s2+2***s+2 )
Invert to find the feed forward gains:

1/Gp(s) = (s2+2***s+2)/(K*2 ) =
1/(K2 ) + (2**s)/(K*) + 1/K
...where the additional term is the damping
factor, and is the natural frequency
1/K is the velocity feed forward term
(2**s)/(K*) is the acceleration feed
forward term and
1/(K2 ) is the jerk feed forward term.

Notice that there is an extra power of (s) and a
corresponding feed forward term. This is the jerk
feed forward gain that is multiplied by the current target jerk generated by the target generator.
Refer to Figure 1 (with this article, online;
search on the headline at www.controleng.com
or click on the headline in the digital edition) to
see how all the terms combine in the control loop
structure.
Feed forwards are relatively easy to tune or
determine empirically and can reduce errors and
improve response times significantly. Feed forwards always should be considered when setpoints or load change, yet the error must be
minimized. ce
- Peter Nachtwey is president of Delta Computer Systems Inc.; edited by Mark T. Hoske,
content manager, CFE Media, Control Engineering, mhoske@cfemedia.com.
Feed forward gains

are actually the inverse
of the plant model
(a mathematical model
of the operation or process
being controlled).
Go Online
At www.controleng.com, search on this headline and

scroll to the bottom to link to two related articles.
Using PID for motion control, robotics
Back to Basics: Relearning terms, concepts for
process control
Also see a typical control diagram for a motion controller
shows how feed forwards can be incorporated into the
control loop.
Consider this...
Do you have open loops that could benefit from feedforward predictions applied to PID motion control?
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inside machines
Feedback for
machine motion
Closing servo-motor loops with feedback devices improves performance, but care
must be taken with design and installation. Closing the loop improves monitoring,
measuring, and controleven when outside forces cause deviations to the desired
setpoint. A one supplier system should be considered first, with escalation to a custom
system only when off-the-shelf systems cannot meet performance demands.
nderstanding issues and basic

design techniques for closing the
feedback loop on servo motors can
help alleviate many of these issues,
Feedback loop on servo
especially when purchasing premotors should consider
basic system design.
configured systems. Specific design guidelines
and installation techniques also can help close
Closed-loop servo motor
the loop and improve performance.
control improves position,
The primary advantage of closed-loop convelocity, and/or torque
control for automated
trol for servo motor systems is a self-adjusting
equipment.
output that improves position, velocity, and/or
torque control within automated equipment. In
Using elements from
other words, closing the loop improves monitorone supplier can simplify
system integration.
ing, measuring, and controleven when outside
forces cause deviations to the desired setpoint.
Subtracting the actual condition (process variable) from the desired setpoint and applying the
difference to the control loop forces the error
to zero, enabling
machines to adjust
for changing conditions.
While
open-loop
servo-motor systems
save money and
design effort for
a variety of applications, these systems will usually
be less repeatable
and less accurate
than
closed-loop
systems.
Position feedFigure 1: Choosing from among preconfigured and
back or closedtested motion control solutions, such as this Rockloop control can
well Automation Kinetix 6500 drive, can provide a
be implemented in
quick path to precision machine motion. All images
many ways, but all
courtesy: Dave Perkon
serve the same func-
Key
concepts
M1
tions. The output of a servo controller (Figure 1)

drives a motor, which affects the controlled position. A digital encoder (Figure 2) or an analog
feedback device reports the actual position back
to the controller.
The controller compares the requested position with the actual measured position to calculate position error. The controller then adjusts
the position-output command to eliminate the
error, therefore closing the loop. This is in contrast to an open-loop system where the position
or angle of the load is not measured, eliminating
the opportunity to correct for error.
Making the right connection
Motion control systems are some of the more

complex applications on automated equipment,
and there are usually several options to attain
the desired result. Once the general approach is
selected, theres a choice to design a custom system, or to purchase a preconfigured and tested
system from one supplier. Although some very
complex applications may require customization
using components from multiple vendors, most
can be implemented using the much simpler single-supplier approach.
With a custom system, the designer must
specify all the servo, controller, and feedback
components. This may provide optimal performance, but can also open the door to a variety of
motion feedback and control issues as listed in
the list on page M5 and discussed below.
To start, there is a heavy design cost. Those
who have done it know that combining a servo
controller from vendor A with a servo motor
from vendor B with hookup cables that must be
designed and integrated can be a long and difficult
road. Both vendors may need to work together to
make the system successful, and this can cause
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inside machines
Figure 2: Absolute encoders, available in many configurations such as these Allen-Bradley from Rockwell Automation, enable
accurate feedback of rotary position for precise servo system control.
issues. Just understanding where to install the

feedback deviceat the motor, the gearbox output, or the loadcan be difficult.
Hooking up the encoder to the servo drive and
motor can cause problems if any wiring is incorrect. If theres one connection mistake, turning
the power on and enabling the drive
can cause the motor to accelerate danAbsolute encoder
gerously. If the motor, with coupling
feedback application, attached, is sitting on a table, the motor
can actually jump and rotate so fast the
where position data is coupling will break off and fly through
the air.
not lost when power

is cycled, one must
pay close attention
to encoder resolution,
output signal, output
type, and voltage.
Rotary servo, absolute encoder
In another example, a rotary servo

motor with hall-effect commutation
from one vendor, connected to a drive
controller from another vendor with
encoder feedback from yet another
vendor, can be a difficult integration
task. After a potentially difficult process to determine the correct power
wiring, the hall-effect commutation
connections must be dealt with.
Not only can the hall-effect sensor feedback
be commutated in three different ways, the halleffect feedback signals to the motor must be
correctly connected to provide the proper commutation sequence with the correct phase. The
servo drive must then be configured to use these
feedback signals to get the servo turning without
faulting the drive controller.
The encoder feedback must be scaled, with
the pulses converted to engineering units. With
M3
preconfigured hardware, one can just pick an

appropriate level of resolution and move on to
developing the application. With custom applications, chasing the proper scaling values and then
having to measure and confirm via actual measurements can delay project completion.
In an absolute encoder feedback application,
where position data is not lost when power is
cycled, one must pay close attention to encoder
resolution, output signal, output type, and voltage. Specifications such as pulses per revolution
(PPR) to values of 1024 PPR or more are common, as is a supply voltage of 5 V dc, 12 V dc,
or 24 V dc. Open collector, line driver, and single-ended signals can provide gray code or binary position data to a variety of controllers.
These issues can be avoided by purchasing
a preconfigured and tested servo system from a
single supplier, but other problems are common
to both custom and preconfigured systems.
Good design practices
Common feedback problems include missing

pulses or noise in the feedback signals. If encoder
counts are being lost, its often due to mechanical coupling slippage at the servo motor, gearbox,
or ball screw actuator mimicking missed signals.
This can also be confused with noise.
Searching for intermittent problems, such as
noise or missing pulses on a feedback signal,
can be a very time-consuming process. While
differential, line-driver signals can help reduce
noise, good practice demands that feedback signals be kept separate from noisy power signals.
That way, if there are feedback errors, effort can
inside machines
While
differential,
line-driver
signals can
help reduce
noise, good
practice
demands that
feedback
signals be
kept separate
from noisy
power
signals.
Figure 3: Using a single-supplier solution in common applications, like this food packaging line, simplifies and speeds design, test, and commissioning.
be focused on finding an open circuit or shorted

wires in the feedback cable, instead of chasing a
noise problem.
Other failures are more easily avoided with
proper installation. Installing encoders with an
improperly aligned coupling or too much tension
on an encoder drive belt can quickly turn feedback into a troubleshooting exercise to locate a
worn-out bearing.
Preconfigured advantages
Many off-the-shelf single-supplier solutions include motors matched to servo drives

along with power and encoder cables of various lengths. This is a true plug-and-play solution, which greatly simplifies motor and encoder
feedback hookup as the supplier has matched the
servo motor to the controller. For many applications, such as the food packaging line shown in
Figure 3, theres no need to look further.
With a servo motor and controller purchased
from and preconfigured by one supplier, all
parameters are set to commonly used default values, allowing quick operation out-of-the-box. Of
course, these parameters can be readily adjusted
as needed to make the servo system suitable for a
very broad range of applications.
Using one supplier also can simplify cabling.
Designing a 20-pin connector for interfacing the servo motor encoder to the controller is
Go Online
not a trivial task. By contrast, using a factorywww.controleng.com/archives, made and tested cable provides easy connection
to motor, brake, and encoder without required
in April, this article links to
related coverage on feedback. design and testing.
M5
Custom servo systems: common issues
Motor not matched correctly to controller

Wiring errors
Motor runaway at initial startup
Incorrect scaling of engineering units
Incorrect voltage specified for external
encoder
Sensing feedback at incorrect location
Incorrect mounting of encoder
Improper feedback device accuracy or
resolution
A single-supplier solution alleviates many of
the potential issues discussed above in design,
implementation, and test. As such, these solutions should be considered first, with escalation
to a custom system only when off-the-shelf systems cannot meet performance demands. ce
- Dave Perkon is an independent machine
automation consultant with experience in custom automated equipment development, system
engineering, project management, sales, controls design, and programming. Edited by Eric R.
Eissler, editor-in-chief, Oil & Gas Engineering,
eeissler@cfemedia.com
Consider this...
Have you seen an open-loop servo-motor system save
in capital cost but eat up profits because its less
repeatable and accurate than a closed-loop system?
inside machines
Six debugging techniques

for embedded system
development
Learning and propagating various debugging techniques reduces bug count and
increases code quality. Here are six techniques that can go a long way in assisting
the debugging process. Reset software coding expectations and get better results
for embedded systems development.
Key
concepts
Learning and propagating various debugging
techniques is crucial.
Try having more experienced engineers create
a short course on techniques and having younger
engineers learn from them.
With the right tools and
techniques, along with resetting expectations, the
debugging process can
be fun.
olid design practices (such as low

coupling, well-defined interfaces)
will go a long way to help reduce
bug counts. After that, systems must
be, or, depending on attitude, get to
be debugged. We tend to be irritated and even
surprised by the existence of bugs. It doesnt
have to be that way. Its just another facet of
problem solving. With the right tools and techniques, along with resetting our expectations, the
debugging process can actually be fun.
Learning and propagating various debugging
techniques reduces bug count during development and increases code quality. Try having your
more experienced engineers create a short course
on techniques and having the younger engineers
learn from them.
Although not an exhaustive list, these six
techniques can go a long way in assisting the
debugging process:
1. Simplify complex data: Substitute complex analog inputs with digital, synthetic, known,
and repeatable data. If a counting pattern does
the trick to start, use a counting pattern. For algo-
rithms with coefficients (such as filters), replace

the production coefficients with a simpler set of
coefficients (such as all zeros except one fullscale coefficient). See Figure.
2. Divide and conquer: Home in on the location of the problem as much as possible before
trying to understand it. This can save significant
time in simulation and in the lab on hardware in
the long run. To elaborate, lets call a chained set
of processing-intensive signal processing algorithms A, B, C, D. A problem emerges when stimulating A and observing D. If the input to C looks
fine, but the output of C is bad, the bug is likely
within C, which strips away the added complexities of A, B, and D.
This concept works from a bottom-up perspective. Verify that the lower level functions work first,
then work up through the layers of abstraction. For
example, look at an analog data logger algorithm.
Start by verifying the low level A/D interface, physical memory interface, and physical communication
bus interface. Then move up a layer to verify functions like data handlers and routers. Finally, verify
the top level of the data logger.
With the right tools and techniques, along with re-setting our expectations, the debugging process can actually be fun.
Courtesy: David LaVine, Viewpoint Systems
M7
3. Slow the process down: Slow down

clocks and data rates. Perhaps some timing
requirement isnt being met. Maybe one algorithm isnt synchronized with another. Perhaps
one of the algorithms that needs to be data-driven was accidentally coded to be clock-driven.
Or maybe one device is trying to push data too
quickly to another.
4. Only change one variable at a time:
When there are multiple inputs, it can be valuable to isolate them and only change one input
at a time, observing the system response. The
trick here is to identify all the inputs that induce
a change in the output of the system. This is
related to fault isolation and activation.
5.
Create off-line models: These models

should match the real-time algorithm, for bit-level comparison. This is most useful for non-intuitive transformations (such as matrix operations)
where its too challenging to understand what
the output should look like relative to the input.
If the real-time algorithm is fixed-point and the
off-line algorithm is floating-point, there may be
small discrepancies.
Co
ntr
ol
XL
6. Start from a known-good state: Slowly tune the input until something breaks, and the
bug is observable. This can be helpful for scenarios where overflow may be occurring. For example, if bit wrapping is suspected, slowly increase
the amplitude at the input until the problem is
observed. Similarly, if there are buffers in use,
start by feeding a small amount of data into the
algorithm and slowly increasing until the suspected condition occurs. Alternatively, maybe
a control loop that breaks with large transients
may appear fine with smaller deviations around a
steady-state condition.
After looking at the problem alone for a
while, a second set of eyes can certainly help as
well, so dont be afraid to have an outsider take
a peek. ce
- David LaVine is a business development
engineer at Viewpoint Systems, with knowledge and experience in the domains of systems engineering, electrical engineering, and
digital engineering. Edited by Joy Chang, digital project manager, Control Engineering,
jchang@cfemedia.com.
Go Online
See related debugging articles with this online at
www.controleng.com.
Consider this...
Whats your standard
debugging process? Do
you have the right tools
and techniques to solve
the problems?
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Companies, universities
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The Organization of Machine Automation and Control

(OMAC) hosted a two-day industry forum on Standard for
Exchange of Product model data (STEP) for manufacturing,
which demonstrated and discussed technologies, projects,
and developments by companies and universities. STEP
enhancements aim to streamline use of machine tools and
digital manufacturing. Savings of 15% to 50% are expected
in various stages of the machining lifecycle.
pen
staning an integrated model
Key
dards
in
for the complete product
concepts
manufaclifecycle. The model is
turing are
known as STEP, and SC4
OMAC is working with
expecthas recently released an
companies and universied to save 15% to 50%
extension that adds Geoties on STEP-Manufacin various stages of the
metric Dimensions and
turing and encouraging
machining
lifecycle,
Tolerances (GD&T) to the
collaboration.
according to the Organizapreviously defined nomi STEP-Manufacturing
tion of Machine Automanal geometry and assemis a subcommittee of the
tion and Control (OMAC).
bly data.
International Standards
OMAC hosted a two-day
STEP-Manufacturing is
Organization (ISO) and is
industry forum on STanalso developing enhancedeveloping an integrated
model for the complete
dard for Exchange of Prodments to STEP to enable
product lifecycle.
uct model data (STEP) for
digital manufacturing. The
manufacturing in Orlando,
standards it manages include:
Companies and universiFlorida, during the 2015
ties often collaborate on
STEP developments and
ARC Forum. OMAC is
ISO 10303-219 Meainnovations.
an industry group of end
surement and Inspection
users, technology providers, original equipment manufactur ISO 10303-224 Process Planning
ers (OEMs), and academics.According
and Manufacturing Features
to the Manufacturing Workgroup area
of the OMAC site, the goal is to create
ISO 10303-238 Integrated Comflexibility through greater openness and
puterized Numerical Control
interoperability.
STEP-Manufacturing meets twice
ISO 10303-21 e3 File format for
per year and is a subcommittee of Interdistributed product models.
national Standards Organization (ISO)
Technical Committee (TC) 184/Sub
Collectively, these standards are
Committee (SC), 4 which is develop- known as STEP-Numerical Con-
M9
trol (NC), and they enable the direct control of

manufacturing machines using digital product, process, and resource data. This helps process solutions to be shared and optimized more
easily. When fully deployed, OMAC believes
that STEP will lead to a reduction of machining costs by 15% or better through the deployment of more intelligent control applications.
OMAC also projects a reduction in process planning costs through developed cloud services by
at least 35% and reduced supplier errors through
virtual machining by at least 50%.
In the deployment, manufacturing machines
will use STEP-NC to define the input, and
MTConnect to define the output.
ca demonstrated a Virtual CMM prototype

that measured the results of a STEP-NC
machining for conformance to the GD&T
defined by an AP242 product model. The
company is also going to test the accuracy
of its Virtual CMM by measuring virtual
and physical results for the circle diamond
square (CDS) part.
n Robot machining. Integration of machining

and measurement to enable manufacturing
using less rigid devices.
During the meeting, STEP-Manufacturing

agreed to continue working on the following
projects.
n Networked manufacturing. The group

agreed to develop new protocols to enable
safe, seamless sharing of product model
data across the supply chain.
Other OMAC developments
During the meeting, a number of companies

demonstrated their developments and innovations. Among them were:
Bring Your Machine To Life

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Aerotechs standard controllers are flexible
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From the simple motion of this mechanical
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Boeing and
GE are going
to test the
interoperability
of STEP-NC
by sharing
process model
data for an
engine bracket
on the 737.
n Machining cloud services, which is

designed to enable third-party development
and optimization of machining solutions.
Upcoming projects
n The Virtual CMM, which is a coordinate

measurement machine that predicts results
by measuring machining simulations for
conformance to the GD&T of a product
model. At the meeting, Mitutoyo Ameri-
A d va n
A l go
ce d
Co
nt
rit h
m s ro l
Ethernet
Connectivity
Intelligent Drives
Automation
Controller
Custom Motor
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AH1214A-CSG
Dedicated to the Science of Motion

AH1214A-CSG-WASP-Automation Controller-7x4_625.indd 1
2/26/2015 1:05:27 PM
inside machines
Penn State
University is
using DARPAs
Advanced
Vehicle Make
(AVM) results
to implement
a cloud
service for NC
Generation.
STEP-NC provides complete data exchange across

the machine process chain.
A 2006 article from Control Engineering explained how STEP-NC (using an AP-238 file) aims to
Engineering
streamline data flow fromControl
computer-aided
manufacturing (CAM) software to computer numerical controls programming, preserving and simplifying information. It eases selection of the machine that will
most efficiently run a job. Link to that article and an OMAC PDF, online. Courtesy: Boeing, OMAC
4.76
Sandvik Coromant and Iscar Metals

showed the automated assembly of highly accurate 3D cutter models from ISO
13399 data. In a related project, Penn State
is developing a manufacturing plan so the
companies can recommend best-in-class
cutters for machining.
Vanderbilt University also demonstrated
a very fast web viewer for product model
data. It was able to reduce the data volume
and download times of an XML viewer
by a factor of 100 by replacing the XML
technology with JSON. In addition, STEP
Tools is going to share the source code of
its STEP to XML translators with Vanderbilt so that they can build a very fast, Webbased visualization system for product
model data.
Penn State University is using the results
of the DARPA Advanced Vehicle Make
(AVM) program to implement a cloud service for NC Generation.
STEP-NC output translators exist for
CATIA v5 and Mastercam, and one is
being developed for NX.
STEP Tools Inc. demonstrated an MTConnect interface and showed virtual machining results in Orlando for a part that was
being machined in Troy, N.Y.
Makino is developing an interface that may
make it possible to track the coordinates
of in-process machining jobs to one thousandth of an inch.
Boeing and GE are going to test the
interoperability of STEP-NC by sharing
process model data for an engine bracket
on the 737.
Consider this...
If programming were
interoperable among
machine tools, how much
time might that save in
coding and in workflow
flexibility?
The next meeting of STEP-Manufacturing

will be in November. ce
- Edited from meeting notes provided by Sid Venkatesh, associate technical fellow, advanced factory
systems, Boeing Research and Technology; edited by
Chris Vavra, production editor, Control Engineering,
cvavra@cfemedia.com.
Go Online
www.omac.org
www.omac.org/content/machine-tool-working-group
Read this article online for added links.
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Telephone: (314) 881-5410
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Email: smalyszko@malisko.com
Website: www.malisko.com
Founded: 1994
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For more information on Malisko Engineering and to view

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PRODUCTS
software &
Solid-state interface relays for DIN-rail

mounting support varied wiring options
IDECs RV8S solid-state interface relays are suitable for DIN-rail mounting, and
have UL/c-UL and CE ratings as well as IP20 protection, which allow them to safely
operate in temperatures from -20 to 60 C and in humidity from 5% to 85%. The RV8S
supports exible wire termination options including screw terminal and spring clamp
models. The RV8S features 100 mA to 3 A switching capability in a compact 6 mmwide space. Other features include high switching cycles, extended operating life, and
high-speed load switching. It can also be used as an interface device between a PLC or
other controller outputs and a load with high power requirements.
IDEC Corp., www.idec.com
Input #200 at www.controleng.com/information
Miniature magnetic encoders for embedded OEM applications

Renishaws RLS series of three high-performance miniature magnetic encoders for embedded OEM motion control applications are designed for high-volume medical applications, optics
positioning, robot control, 3D printers, gimbals, and handheld devices. The miniature encoders
come in four different shapes and provide linear resolution up to 0.244 m. The encoders consist
of a miniature sensor and a magnetic scale or a ring. The sensors are available in a potted housing
or as PCB board level sensors. Position information can be output in incremental quadrature TTL
or RS422, as well as parallel in SSI and BiSS-C formats, with the option of a unique or periodic
reference mark.
Renishaw Inc., www.renishaw.com
Programmable CAN to USB interface

and datalogger
PCIe Gen3 carrier board

includes temperature sensor
VadaTechs AMC104 is a PCIe
Gen3 carrier board that allows highperformance commercial video or other
boards to be used in a MicroTCA system. The AMC104 provides the versatility of using high-end commercial
graphics cards, which typically have
short shelf lives, as removable mezzanines. By providing a carrier, users
can upgrade their PCIe GPGPU or
other video board as needed to serve
their needs. The AMC module comes
in a double module, full size. It routes
PCIe Gen3 to the backplane as x4 or
x8. Other features of the AMC104
include a temperature sensor, DIP
switches for IPMI functionality, and a
management RS-232 port.
VadaTech, www.vadatech.com
60
Kvasers Memorator Pro 5xHS 5-channel high-speed controller area network (CAN) to USB interface and datalogger is
designed to allow users to monitor and log data from multiple
CAN channels using just one device. It time synchronizes
the data transmitted and received across all ve buses as
well as automatically synchronizes with other Kvaser
interfaces connected to the same PC. The Kvaser Memorator Pro 5xHS has a 26-pin HD DSUB that connects to
a splitter with ve 9-pin DSUBs, and one USB connector
that easily links to any USB port on a host computer.
Kvaser AB, www.kvaser.com
Web-based visualization software

for operating and monitoring
Pilzs PASvisu is a web-based visualization software package for operating and monitoring. The
company has developed a platform-independent
visualization package that can use HTML5, CSS3,
and JavaScript. The software enables visualization
projects to be created and congured simply using
the PASvisu Builder. Access to all the data in an
automation project, including all process variables
and OPC namespaces, means there is no need to enter and assign variables manually. Selectable styles via CSS3 provide a uniform, consistent image across the project
at the click of a mouse. Predened graphic input and display elements, called tiles,
already provide all the relevant properties, such as prex, sufx, and error status.
Pilz, www.pilz.us
See more products daily at www.controleng.com/products.
Communications interface
option for CNC systems
Dual level power terminal

blocks have high wire
densities
Weidmullers WDK 10 dual-level
power terminal series is designed for
use in machinery, process, and power
generation applications. They are only
10 mm wide and have high wiring
densities in screw terminals for power
distribution applications requiring
6 AWG conductors. The WDK 10
terminal congurations include duallevel grounding, neutral, dual-level
with ground, feed-through, 5-wire
pre-assembled, and power distribution, 5-wire pre-assembled blocks.
The pre-assembled terminals feature
a single part number for ease of
ordering and handling. Weidmullers
WDK 10 terminal blocks integrate
two independent circuits within one
terminal and include corresponding
jumpering channels to accommodate
the connection of screw-down jumpers
to adjacent terminals.
Num Corp.s NumConnect is a communication

interface option that complies with the open MT
Connect interoperability standard. MTConnect is an
open, royalty-free communications standard designed
to improve the use of real data in manufacturing
industries. NumConnect is designed to be tted
to new or existing systems and simplify the
integration of CNC machine tools with thirdparty manufacturing management software.
The NumConnect software interface comprises two main components: an MTConnect
adapter and an MTConnect compliant information provider
or lightweight webserver known as an Agent. The adapter collects data from
the CNC system, lters out any duplicates, and then pushes the data to the Agent,
where it is held in a buffer store until overwritten by fresh information.
Num Corp., www.num.com
HVAC matrix drive provides

low harmonic distortion
www.weidmuller.com
Yaskawas Z1000U HVAC Matrix Drive is designed to provide

low harmonic distortion in a space-saving design without the need
for countermeasures like passive lters or multi-pulse arrangements. The matrix technology employs a system of 9 bi-directional switches that are arranged in a matrix to convert a three-phase
ac input voltage directly into a three-phase ac output voltage. It
eliminates the need for a rectifying circuit and a dc bus that are
used in traditional ac drive inverters. Additionally, reduced distortion is designed to improve displacement power factor to 0.98
through the entire load and speed range, reducing energy costs.
Yaskawa America Inc., www.yaskawa.com
Weidmuller
Firmware updated for router

designed to enhance cyber
security
Moxas EDR-810 industrial 10-port secure router has received a rmware update
designed to enhance cyber security. The
rmware provides support for transparent
rewall functionality and the providing of
real-time event notication. To monitor
industrial networks more efciently, the
rmware upgrade also includes comprehensive VPN/rewall/DoS event logs and
SNMP traps for real-time event notication or
historical analysis. The EDR-810 is an integrated industrial
multiport secure router with Firewall/NAT/VPN and managed
Layer 2 switch functions. It is designed for Ethernet security
applications in sensitive remote control or monitoring networks
of critical cyber assets like pumping/treatment systems in water
stations, distributed control system (DCS) in oil and gas applications, and PLC/SCADA systems in factory automation.
Moxa Americas Inc., www.moxa.com
Software update includes email notification,

build interface development
Opto 22s groov 3.0 is an update to the platform with
added features like email event notications, enhancements
to the interface development environment, and the ability
for users to select the right platform for an application. The
enhanced event notication allows end-users, system integrators, and machine OEMs to receive
immediate email messages when a
connected machine or system needs
attention. The build interface development environment makes it easier to
position, align, and group on-screen
objects. groov 3.0 also offers the users
the ability to select a platform for an
application depending on how many
Modbus/TCP-ready devices or SNAP
PAC controllers will be connected and
if an OPC UA server will be used.
Opto 22, www.opto22.com
www.controleng.com
PRODUCTS
software &
Robot with elevated payload

The Smart NJ 650 by Comau has an elevated payload
to complete its range of high payload robots. The Smart
NJ robot can
handle a payload of up to 650 kg, a
maximum horizontal reach of 2.70
m, and ISO 9283 repeatability
from 0.15 mm. The Smart NJ 650
is designed for multiple industrial
applications including handling, spot welding
of large body parts for the automotive sector,
and the manipulation of heavy components
for machine tending operations. It can also
be used for palletizing, deburring and
polishing, packaging, and machining in
general. It can be deployed in the food and
beverage industry, foundry operations, and in
many other industrial sectors.
Comau, www.comau.com
Solenoid and pneumatic valve series for

clamping and locking operations
Festos VS series of piston-spool
solenoid and pneumatic valves and
valve manifolds are designed ideal
for simple clamping and locking operations in semiautomatic
assembly, end-of-line packaging, conveying, painting, open-pit
mining, woodworking, and other applications. The valves can be
applied in explosive environments and can be modied to meet
the IP67 standard for dust and immersion resistance. The VS
series is composed of VUVS solenoid valves, VUWS pneumatic
valves, and VTUS valve manifolds. VS series ow rate ranges
from 700 to 2,000 l/min. Pressure ranges from 0-10 bar and from
2.5-10 bar for internally piloted valves. Valve types include 3/2,
5/2, and 5/3, and widths range from 20 to 30 mm.
Festo, www.festo.com/us
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ABB Inc . . . . . . . . . . . . . . . . . . 15. . . . . . . . . . . 9. . . .www.abb.com

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IGEL Electric GmbH . . . . . . . . 26. . . . . . . . . . 15 . . .www.igelelectric.de

Inductive Automation. . . . . . . Bellyband . . . . . . . . .www.IgnitionBuild.com
Kepware Technologies . . . . . . 29. . . . . . . . . . 17 . . .www.kepware.com
Leidos . . . . . . . . . . . . . . . . . . . 21. . . . . . . . . . 12 . . .www.leidos.com/activate
Moore Industries - Intl. Inc . . . 4. . . . . . . . . . . . 4. . . .www.miinet.com
Moxa Technologies . . . . . . . . . 3. . . . . . . . . . . . 3. . . .www.moxa.com
National Instruments . . . . . . . 7. . . . . . . . . . . . 5. . . .www.ni.com
Omega Engineering Inc . . . . . 23. . . . . . . . . . 13 . . .www.omega.com
PI North America. . . . . . . . . . . 9. . . . . . . . . . . . 6. . . .www.PROFINETuptime.com
Rittal Corporation . . . . . . . . . . 24, 25. . . . . . . 14 . . .www.rittal-corp.com
SEW-EURODRIVE, Inc. . . . . . . C4 . . . . . . . . . 27 . . .www.seweurodrive.com
Unitronics . . . . . . . . . . . . . . . . 1. . . . . . . . . . . . 2. . . .www.unitronics.com
Yaskawa America, Inc. . . . . . . C3 . . . . . . . . . 26 . . .www.yaskawa.com
Inside Machines
Aerotech Inc . . . . . . . . . . . . . . M10 . . . . . . . . 23 . . .www.aerotech.com
Allied Moulded Products, Inc M8 . . . . . . . . . 21 . . .www.alliedmoulded.com
American Industrial
Systems (AIS) . . . . . . . . . . . . . M2 . . . . . . . . . 18 . . .www.aispro.com
Beckhoff Automation LLC. . . . M4 . . . . . . . . . 19 . . .www.beckhoff.com
PI (Physik Instrumente) LP . . . M12 . . . . . . . . 25 . . .www.pi-usa.us
P M D . . . . . . . . . . . . . . . . . . . . M9 . . . . . . . . . 22 . . .WWW.PMDCORP.COM
RGB Spectrum . . . . . . . . . . . . M11 . . . . . . . . 24 . . .www.rgb.com
WAGO Corp. . . . . . . . . . . . . . . M6 . . . . . . . . . 20 . . .www.wago.us
www.controleng.com
back to
BASICS
Why team communications fail

Communications issues between team members or customers delay projects
and increase frustration levels. See tips on how to address popular engineering
miscommunications and how to avoid them in the future.
nless you are a one person team, you

will always have problems with team
communications during projects. Even
if you are a one person team, you will
have problems with customer communications
during projects. After 45 years of projects, I cant
remember a project without communications
issues. Patterns emerge that point to underlying
causes of miscommunication.
The unmet,
Everybody does it that way
unvoiced
expectation
syndrome is
probably the
most common
communications
failure, and not
just at work.
Everybody does it that way is one of the

prime sources of miscommunication mainly
because it stops communication. The person with
the knowledge that other people need assumes
that they dont need to state the requirement to
do it a certain way because the other people will
automatically do it that way. The obvious trap
here is that most engineering problems dont
have a right answerthey have a spectrum of
answers that solve the problem, and the person
doing the answering will usually pick their version of how everybody does it again without
stating thats how theyre going to do it.
Tips: If you are the one having work done,
always tell those doing the work what is expected and how it should be done. Or, if youre the
person doing the work and you havent been told
the expectations for execution, then tell the customer how you plan to do the work.
Hundreds of e-mails a day
Go Online
www.controleng.com/blogs/
real-world-engineering
The Real World Engineering blog has other articles
from Maverick Technologies
including:
Automation resource
taxation
Advanced regulatory versus
model-predictive control
64
I get hundreds of e-mails a day, sounds

like the modern version of the I didnt get to
your letter, yet, syndrome of 30 years ago.
This creates a different class of miscommunication because the necessary communication may
have happened but the recipient hasnt read it, so
they dont know that theres an issue they might
need to address until the deadline to address it
has passed, or they dont know the issue was
resolved with part of the team and so offer a different solution than whats already been chosen.
This syndrome can cause confusion because
something the team thinks is already handled
is suddenly back open for discussion. Also the
late responder may feel set upon when the team
pushes back on the solution.

Tips: Request a return receipt from the e-mail
program so youll know when the e-mail has
been opened. The other tactic is to set a deadline, then call the person to ask for their input.
Another solution to this problem is to call before
sending the e-mail to alert them that something
requiring their immediate input is about to arrive.
This last tactic is almost required for people who
are chronically overloaded, which seems to be a
growing group.
Unmet, unvoiced expectation
The unmet, unvoiced expectation syndrome

is probably the most common communications
failure, and not just at work. This is a superset of
the everybody does it that way syndrome since it
encompasses all things that people expect whether
or not they are part of the deliverables. This often
identified by hearing: I expected or I would
have expected followed by an expression of an
expectation never heard before. These can be best
described as disappointments over something you
either did or didnt do and can include: I expected
a more professional job.
Tips: Like the earlier syndrome, this one could
be corrected by ensuring that anything anyone
expects is put down in writing at the start of the
project and that list is kept updated as the project
progresses a monumental task at best. Clearing up
this miscommunication can be very difficult since
even the person with the expectation may not be
completely aware of it until the mine blows up. One
tactic that can work is asking lots of questions and
particularly open ended questions so the responder
has to think about their expectations. This is also a
great place to play the little kid and asking Why?
until youve uncovered as much as possible.
This is by no means an exhaustive list of why
communications break down but hopefully it will
help. How have you addressed these issues? ce
- Bruce Brandt is a principal engineer at Maverick Technologies, an automation solutions provider and a CFE Media content partner. Edited
by Joy Chang, digital project manager, Control
Engineering, jchang@cfemedia.com.
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recent study of Yaskawa servos: a quality rate of 99.993% in an industry where 500 failures per 100,000 is the
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and motion control as well as servo motors. Then factor in consistent, balanced and expert advice, plus the
experience gained from manufacturing 20 million inverters, 10 million servos and more than 300,000 robots.
The result? Levels of productivity, reliability and automation success that defy the imagination.
Want a stronger installed base? Call Yaskawa today.
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APR15 A&C Snipe (CE)_Layout 1 3/13/15 2:33 PM Page 1

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