Control Engineering June 2013

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The first Ethernet port is a real bargain since it comes embedded on the H2-DM1E CPU ($399) All Do-more CPUs also have one serial port built in to communicate with other control devices For more serial ports, add H2-SERIO-4 modules, with three ports per module ($176 each) Need more Ethernet? Segregate Do-more connection to Ethernet networks for security or isolation by adding an H2-ECOM100 module ($301 each)
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Name your devices Give your communication ports logical names and refer to those names in your program for ease and clarity. Define a custom protocol with an instruction set that lets you define a non-standard data exchange (serial or Ethernet!)
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JUNE 2013
Vol. 60 Number 6
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
39
Features
Courtesy: Control Engineering
26
35
26 Beyond automation: Humans as process controllers
While automated control systems can keep our processes running ef ciently, new variables are entering into the production equation that are beyond what we can expect from PID.
35 Mechatronic designs blend power, electronics, mechanical systems

Mechatronics pre-integrates power, electronic, and mechanical systems, using hardware, software and networks to simplify design, lower costs, and speed time to market.
39 Seven reasons to consider a non-Ethernet industrial network 45 2013 System Integrator Giants
Here are seven reasons non-Ethernet networks might be speci ed for an industrial project, to help determine if an Ethernet, eldbus, or a device or sensor-level network should be considered.
The 100 largest system integrators in the industrial automation businesswho they are and what they do.
CONTROL ENGINEERING (ISSN 0010-8049, Vol. 60, No. 6, GST #123397457) is published 12x per year, Monthly by CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Jim Langhenry, Group Publisher /Co-Founder; Steve Rourke CEO/COO/Co-Founder. CONTROL ENGINEERING copyright 2013 by CFE Media, LLC. All rights reserved. CONTROL ENGINEERING is a registered trademark of CFE Media, LLC used under license. Periodicals postage paid at Oak Brook, IL 60523 and additional mailing offices. Circulation records are maintained at CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Telephone: 630/571-4070 x2220. E-mail: customerservice@cfemedia.com. Postmaster: send address changes to CONTROL ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Publications Mail Agreement No. 40685520. Return undeliverable Canadian addresses to: 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Email: customerservice@cfemedia.com. Rates for nonqualified subscriptions, including all issues: USA, $ 145/yr; Canada, $ 180/yr (includes 7% GST, GST#123397457); Mexico, $ 172/yr; International air delivery $318/yr. Except for special issues where price changes are indicated, single copies are available for $20.00 US and $25.00 foreign. Please address all subscription mail to CONTROL ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Printed in the USA. CFE Media, LLC does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the material contained herein, regardless of whether such errors result from negligence, accident or any other cause whatsoever.
JUNE 2013 CONTROL ENGINEERING www.controleng.com
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JUNE 2013
C OV E R I N G C O N T R O L , I N S T R U M E N TAT I O N , A N D A U TO M AT I O N S YS T E M S W O R L D W I D E
Inside Machines
Starts after p. 57. If not, see www.controleng.com/archive for June.
M1
WindPower 2013: Fair winds in Chicago

The American Wind Energy Associations conference and exhibition showed how automation and controls help the manufacturing and use of wind-power technologies.
M3 M6 M7
Packaging company saves vacuum system costs

Energy audits estimate at least 25% reduction in annual operating costs for bagmaking machines after adding motor drives and a new monitoring system.
PC-based controls help packaging machines

Bag-in-box food packaging machines embrace modular concepts, adaptability, ease of maintenance, reliability, and universal high-performance control systems.
Powering reliable entertainment

Mission-critical entertainment may seem like a misnomer, until considering that commercial time for some venues exceeds $1 million per minute.
PRODUCT EXCLUSIVE
departments
8 Think Again
Im having a ball at work
news
20 Robots in diverse industries; setting system baselines; wireless control for carts; cyber security webcast; new book offers legal advice
10 Product Exclusive
Multi-purpose digital panel meters
12 Tech Update
Process risk assessment uses big data PRODUCTS
14 IT & Engineering Insight

Hacked without knowing it
products
67 Embedded PC; HMI software; pressure sensor; multi-touch PC/HMI; ultrasonic owmeter; PoE power injector; and more
16 International
Labor supply, demand bring changes to China manufacturing industries
18 Machine Safety
Severity, frequency, probability ISO 13849-1: 2006
96 Back to Basics
Selecting voltage-based pressure sensors
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The 2013 Sensors Expo & Conference returned to Chicago again. Read about some of the latest technologies at www.controleng.com, including a video produced by Control Engineering that takes you to the exhibit area where you can hear from the companies. To go there directly, scan the QR code to the right.
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Im having a ball at work
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Does that mean you are wearing a ball and chain, are juggling many things, or are having fun?
One gauge of a performance culture is to do a rough measure of how your teams are having a ball at work: Ball and chain, juggling many balls, and life is great. What percentage of each do you have? (40-4020% or 20-60-20%?) The goal is to get zero in the first ball and chain area. A high-performance cultural chain of impact results: Satisfied employees lead to satisfied customers, leading to satisfying business profits, time, cost, and quality. Make a strategic plan. Goals should be aspire and be realistic. Stretch. Set clear expectations, make ways to score progress, and set timing along the way. Test the results. Are you winning? How do you know? How do you know when youve accomplished success? Just crossing things off your to do list isnt good enough. Resource deployment differs depending on where in the game you are. If youre behind, but have a plan, that still can be a good response. In any organization, it has to be clear: How do you know when we accomplish success here? Garnett asked if things like Facebook, YouTube, or American Idol are necessities or optional. Take stock of your time. Set priorities. Do the right things. Stop guessing: measure and think again. Most people think they know how they spend their time, but they dont. Dont stop believing in the power of your people. ce
f you want something done, give it to a busy person. Truisms have truth in them, and results-oriented consulting derives from the core of this saying. Busy people often have an internalized system of accountability, methods for organizing, and the follow-through to get many things done, having fun along the way. SPEED Metrics was the title of Ted Garnetts session at the Control System Integrator Association (CSIA) Executive Conference in May. Garnett, president, Performance Resources Consulting, in Cedar Rapids, Iowa, explained that SPEED stands for structure, productivity, engagement, execution, and dependability (or due diligence). Examples follow. He started the session by challenging each person attending any meeting to teach the team, upon return, at least one thing of value from the meeting, or, better yet, one thing from each session. Researchers took two groups and asked each to write 100 life goals. One of the groups also was asked to practice various accountability techniques: track them, make plans, and tell others in their lives. Over time, the group asked to be accountable was 27% more likely to achieve the goals than the group who were asked only to make the list. One of Garnetts college roommates garnered laughter upon sharing, Im going to be an NFL quarterback. All the decisions and trade-offs aligned thereafter, until Kurt Warner got it done... and played for three NFL teams, was named to four Pro Bowls, and went to three Super Bowls, winning one. Doing what it takes? In your family, community, neighborhood, and company, are you doing what it takes to achieve your NFL goal? Leadership is a verb, not a position. The mission to get things done starts at the top, and having a performance culture can help get that done.
Contributing Content Specialists

Frank J. Bartos, P.E., braunbart@sbcglobal.net Jeanine Katzel jkatzel@sbcglobal.net Vance VanDoren Ph.D., P.E., controleng@msn.com Suzanne Gill, European Editor suzanne.gill@imlgroup.co.uk Ekaterina Kosareva, Control Engineering Russia ekaterina.kosareva@fsmedia.ru Marek Kelman, Poland Editor-in-Chief marek.kelman@utrzymanieruchu.pl Luk Smelk, Czech Editor-in-Chief lukas.smelik@trademedia.us Andy Zhu, Control Engineering China andyzhu@cechina.cn
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Go Online
At www.controleng.com/archive, June 2013, read this for more advice; see video summary. www.controlsys.org www.PScultureMatters.com
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EXCLUSIVES
Multi-purpose digital panel meters

Precision Digital introduces PD6080 and PD6081 Super Snooper Modbus Scanners capable of displaying 16 process variables, including Modbus registers and two analog inputs.
he PD6080 and PD6081 from Precision Digital are Modbus traffic, picking up specific registers being polled for dismulti-purpose digital panel meters capable of display- play and monitoring. Relays and a 4-20 mA output operate based ing 16 process variables, including Modbus registers, on selected process variables (PVs) in any mode. and up to two analog inputs. These are programmable Math functions may be applied to the 16 process variables. as Modbus RTU Masters, Slaves, or Snoopers (packet sniff- The displays, relays, and the analog output may be assigned to ers), and can accept both current and voltage signals. They are any of four math channels. Three of the front panel buttons can ideal for level, flow, temperature, or pressure Modbus trans- be custom-programmed for a specific operation. A digital input mitter applications, the company said. The PD6080 displays in is standard. The Super Snoopers connect to a Modbus network decimal format, while the PD6081 displays in feet and inches, with RS485 serial communications. including fractions of an inch. These are 1/8 DIN panel meters with NEMA Go Online As Modbus masters, the PD6080 and PD6081 4X front panels and also are available interead up to 16 slave devices, scale related data, www.predig.com grated into a fully approved FM, CSA, ATEX, and display the results. As slaves, they are conand IECEX explosion-proof products: the PD8 See more products at trolled by a master device, scaling and displaying www.controleng.com/products. 6080 and PD8-6081. These include Precision data sent to them. As snoopers, they listen to the Digital SafeTouch through-glass buttons. ce
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technology
UPDATE
Process risk assessment uses big data

Predictive, process risk assessment can use big data to assess risks dynamically and report automatically, empowering plant personnel to identify issues, taking necessary preventive measures to address them, avoiding a related shutdown incident or accident.
Ankur Pariyani, PhD; Ulku G. Oktem, PhD; Deborah L. Grubbe, PE
ts a typical Monday morning scene at a refinery: the team (plant manager, supervisors, and head operators) gets together to review the past weeks performance and the coming weeks plans. They talk about the industrial fluid-catalytic-cracking-unit and the key question, How was the catalyst stand pipes performance? The team answers are: Not great; there were more alarms than usual; and were not sure why. Plant management knows the regenerated catalyst stand pipe is prone to disturbances, which leads to frustrating operational hiccups (and trips) every now and then. Its one of the most profitable units in the refinery, with a best-inclass historian and manufacturing intelligence software. The systems generate hundreds of thousands of data points. Yet, the magnitude of risks and reliability associated with the stand pipe (and how they change dynamically) remains unknown, creating challenges in managing its operation for optimum efficiency. This type of scene plays out often in refineries across the globe and indicates a growing problem as equipment ages and experienced operators retire. With recent advances in control and monitoring systems, facilities are getting overloaded with data, without clear insights into process performance, especially development of process risks. Over the past few years, facilities have become data rich but information poor; this is typically referred to as the big data challenge. Big data is indeed big. Typically, more than 5 billion data points are recorded every 6 months in a plant Figure 1: Extended safety pyramid developed by Nearwith about 320 Miss Management LLC indicates two categories of tags, recording near-misses that are precursors to accidents. Courtesy: sensor measureNear-Miss Management ments every sec12
ond. It is often characterized by four Vs: volume, variety, velocity, and variability, which change with time. Lost in the big data flood are indicators that can help plants understand the dynamically changing risks and avoid some of the $10 billion losses the U.S. chemical and petrochemical industry experience annually (due to unexpected shutdowns). Research shows that taking a different-in-kind approach to harnessing big data (based on processing the information directly with advanced data mining techniques) creates a wealth of insights that were previously unavailable. This has significant potential to transform the way facilities operate, and to reduce unexpected disruptions. Current process risk analysis methods leave gaps in the risk assessment landscape. Predictive risk assessment can help facilities prevent accidents and unexpected shutdowns, and operate reliably with reduced risk profile.
Current risk analyses, gaps
Improved process risk management is the primary outcome of the widely used Process Safety Management (PSM) standard, which is promulgated by the U.S. Occupational Safety and Health Administration (OSHA) to maintain and improve safety, operability, and productivity of plant operations. Advances have been made in the process risk assessment area in the last decade, though significant gaps remain for some facilities. 1. Quantitative risk assessment (QRA). Typically, QRAs are conducted once every 3-5 years by most facilities. These use various data sources available to the industry, such as incident data, material safety data, and equipment and human reliability data, to identify incident scenarios and evaluate risks by defining the probability of failure and their potential consequences. They help users identify areas for risk reduction. Gaps: Because QRA mostly involves incident and failure data (excluding day-to-day process
and alarm data that contain information on precursor events), it has limited predictive power. The importance of using process-specific databases for objective risk analyses has been gaining recognition. 2. Safety audits. Many facilities conduct safety, health, and environmental audits using internal teams and large consulting companies, which require significant resources. The frequency and effectiveness of internal safety audits depend highly on resource availability of the facility. In most cases, safety professionals with some support from engineers, operators, and sometimes even managers periodically review operating procedures and safety records, and conduct limited number of interviews about safety practices. Gaps: Formal, in-depth safety audits are conducted periodically, with frequency ranging from once a year (in extremely rare cases more than once a year) to once in several years. These can not monitor changes in risk levels in real, or even near, time. 3. Operations management and manufacturing intelligence tools. Operations management and manufacturing intelligence software provide key performance indicators (KPIs) for performance monitoring of operations, and assessment of availability and effectiveness of equipment. They focus on trending, reporting, and visual analytics of a select data slice, which help users monitor the variability of different parameters in a time period (shift, day, week, etc.). Gaps: These systems fall short when it comes to big data analytics, particularly when users need insights on when parts of operation are becoming riskier and how anomalies are creeping in. With aging equipment and expected departure of many seasoned operators from the workforce, this handicap becomes even more considerable. 4. Condition-based monitoring tools. These tools identify abnormal situations in real- or near-time by comparing plant performance with its expected behavior and alerting the user when there is a mismatch. Both model-driven (based on quantitative process models) as well as data-driven tools (based on clustering and dimensionality reduction approaches) are available in the market that help operators take immediate corrective actions as real-time alerts are dispatched. Gaps: Because they are designed to monitor operations in real- or near-time, they do not focus on identifying how risks and likelihood of incidents evolve over a period of time (days, weeks, months). Although they provide smart alarms (superior to traditional alarms with fixed thresholds) that cater to the needs of operators on the floor, they are limited in scope when it comes to
assessing magnitude of process risks and performance, which is critical information for plant managers, engineers, and reliability personnel for strategic decision making.
In real time
Accidents are rare events that occur when a series of (unfortunate) failures of risk management barriers occur in Figure 2: Variation of likelihood of shutdown for succession, implying a a pressure differential variable over 4 months chance factor involved shows indicators at shutdown. Courtesy: Nearin their occurrences. Miss Management However, post-incident investigations show that there are several nearmisses that occur before these unexpected events that evolve (gradually or often, rapidly) to become abnormal situations (Phimister et al., 2003; Kleindorfer et al., 2003; Pariyani et al., 2010; Kleindorfer et al., 2012). This concept is captured in the well-known safeFigure 3: Variations of risk level for a key analyzty pyramid. Figure 1 introduces er variable are shown over 5 months. Courtesy: an extended version Near-Miss Management of the safety pyramid (developed by Near-Miss Management LLC), indicating two categories of near-misses that are precursors to accidents. Observable near-misses are typically noted by the operations team, such as Go Online equipment failures, leaks, etc. Hidden near-miss www.nearmissmgmt.com events can be detected only through rigorous data analysis and are typically not observable to the At www.controleng.com/ human eye. Finding such events in the process and archive alarm databases permits detection of operational June 2013, this article problems at their developing stages. Results can includes more gap details, be made accessible to all users (plant managers, two case studies, references, supervisors, engineers, reliability and maintenance and biographies. crew, as well as operators) to promote transparen- December 2012, the Prodcy among the operating team and to complement uct Exclusive explains how existing PSM, hazard identification, and quantita- Near-Miss Management LLCs commercial software, tive risk analysis activities. ce -By Ankur Pariyani , PhD, Ulku G. Oktem, Dynamic Risk Analyzer, PhD, and Deborah L. Grubbe, PE, Near-Miss analyzes process and alarm data to dynamically deterManagement LLC; Edited by Mark T. Hoske, mine risks of continuous content manager, CFE Media, Control Engineer- processes. ing, mhoske@cfemedia.com.
www.controleng.com
IT & engineering
INSIGHT
Hacked without knowing it

Cyber-criminals are stealing manufacturing companies intellectual property (IP). Is your lack of cyber security hardware, software, and best practices giving away millions of dollars of IP to unknown competitors without your knowledge?
I
Dennis Brandl President of BR&L Consulting
t is hard not to be afraid. Recent news articles and security analyst reports have listed the types of attacks and illicit information gathering directed against manufacturing companies, and they are not what you may expect. Much of the current press announcements are about stealing credit card information and social security numbers, but cyber-criminals are after something much more valuable in manufacturing companiestheir intellectual property (IP).
Advanced persistent threat
rity guards. Unfortunately, with cyber security there are no safe neighborhoods, so you have to protect yourself. This means that companies need to install firewalls for interior and exterior protection. Interior firewalls provide the same level of protection as locked interior doors and filing cabinets inside locked buildings. You dont want to make cyber-criminals jobs easier by giving them unrestricted access once they are inside the corporate network.
Access points
Information stolen includes product development data, test results, system designs, product manuals, parts lists, simulation technologies, manufacturing procedures, and more.
Go Online
www.brlconsulting.com At www.controleng.com/ archive, find more under this headline At www.controleng.com search cyber security See www.controleng.com/ webcast
14
Numerous manufacturing companies have been compromised by directed attacks, usually called advanced persistent threats (APTs). Information stolen has included product development data, system designs, product manuals, parts lists, simulation technologies, manufacturing procedures, and descriptions of proprietary processes. This is information that can be used to replicate production facilities. Many companies think that this information has little value outside their company, but it can be used by their competition to replicate products and processes at a fraction of the cost. Most of your competitors will not resort to using illicitly acquired information, but if your competition is based in a country with limited intellectual property rights, then you are at risk, and you may have already been hacked and not even know it. Intellectual property theft is done in a stealth mode. There is a saying among cyber security experts that there are only two types of companies: those that have been hacked, and those that dont yet know they have been hacked. If you dont want an unscrupulous competitor to use your standard operating procedures (SOPs), production processes, product definitions, and recipes, then it is up to you to ensure that your IT department is protecting your manufacturing IP. The IT department is probably already protecting its financial and personnel records, but it may not realize the value of your manufacturing IP. With physical security, a company can reduce risk by operating in a safe neighborhood, alarming all of its windows and doors, and hiring secu-
With physical security, windows and doors are the ways in and out. With cyber security, the ways in and out can be different. Many attacks are introduced through infected USB drives and email, but report back through Internet communications. IT departments should have procedures in place to monitor all outbound Internet traffic for suspicious and atypical behavior. Maybe you cannot always keep the bad guys out, but you can recognize when you have been hacked and you can keep the thieves from phoning home. With physical security, companies can employ security services to monitor alarms and provide guards to look for suspicious activity. For cyber security, you need to employ active measures to maintain security. These can be accomplished through port scans, checks of actual installed vs. approved programs and libraries, checks of actual vs. approved accounts, and checks of actual vs. approved scheduled tasks. IT departments can usually be very aggressive in checking production support systems without impacting direct production systems. Making your own safe neighborhood, locking and protecting your assets, and employing active measures to check for security breaches are the main tools for protecting your manufacturing IP. There are bad guys out there, and they want to break in. You should work with your IT department to make sure you can keep the bad guys away. ce - Dennis Brandl is president of BR&L Consulting in Cary, N.C. His firm focuses on manufacturing IT. Contact him at dbrandl@brlconsulting.com.
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Labor supply, demand bring changes to China manufacturing industries

Robotics and other automation are seen as competitive opportunities as labor costs increase in China, according to Control Engineering China.
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ne reason China has become a manufacturing power is that Chinas manufacturing enterprises can benefit from abundant labor resources and low labor costs. With the approaching end of the demographic dividend in China, this situation appears ready to change. Labor supply and demand are changing manufacturing enterprises in China. In the past two years, a tighter labor market has increased labor wages in China, especially in manufacturing-intensive areas, such as the Pearl River Delta and the Yangtze River Delta. Despite average annual wage increases of 10%, some factories find recruitment difficult.
In some factories in China, industrial robots do repetitive and high-strength work, countering higher labor costs in China industrial markets. Courtesy: Control Engineering China
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Many manufacturing facilities are exploring new measures to offset recruitment challenges. These include changing modes of employment (such outsourcing factory positions or functions) and using new equipment or technologies for manufacturing. These measures reduce dependence on permanent employees. Some decision makers also have been increasing the amount of automation used in factories. A textile processing factory in Suzhou, Kiangsu province, set up an automated stereoscopic warehouse system, using an information system to control inventory, taking the place of manual inventory management. The factory director said he followed the example of another factory in the same industry. The purchase of the system has significantly improved efficiency. In the warehouse, the system helped reduce labor costs and the number of errors in quantity of goods transferred, previously checked by warehouse work
ers and transport drivers. In some factories, industrial robots do repetitive and high-strength work. Robotic applications, previously used primarily for automobile manufacturing in China, are expanding into other industries. Foxconn, one of the largest electronic manufacturing groups, said it will add a large number of industrial robots into its production lines in China. Generally speaking, challenges often create opportunities. Changes brought by labor supply and demand may be a new driving force to develop Chinese manufacturing industries, and we also will be happy to see Chinese workers getting more value from their hard work. ce - Henry Qiao is an editor, Control Engineering China. This was translated from a recent edition of CE China.
Go Online
www.cechina.cn www.controleng.com/international
16
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SAFETY
From Individual Control Panels, To Complete Systems Integration
Severity, frequency, probability
ISO 13849-1: 2006
Standard ISO 13849-1 begins with the old qualitative approach to Performance Level required (PLr) for any safety function, looking at severity, frequency, and probability.
ew quantitative ry by severity, frequency, requirements for and probability. (Also see designing safetygraph.) related parts of What were the criteria the control system (SRP/CS) for the severity, frequency, have created many related and probability questions? discussions about machine Is severity weighted the safety. Even with these most because its the first new requirements from ISO question? Such as S = 50%, J.B. Titus, CFSE, 13849-1, the updated stanF = 30%, and P = 20%? Certified Functional dard begins with the same Or is probability asked old qualitative approach to Safety Expert (CFSE) last because of its greater determine the goal, (Perimpact? Such as S = 25%, F formance Level required - PLr), for any = 35%, and P = 40%? Or can all three safety function. The same three ques- questions be equally interchanged? ce - J.B. Titus, Certified Functional tions are still asked about severity, freSafety Expert (CFSE), writes the Control quency, and probability. EN954-1, in 1996, put more teeth Engineering Machine Safety Blog. Reach into determining a hazard level and him at jb@jbtitus.com. related mitigation for any recognized Go Online hazard. Each hazard required analysis by evaluating the related potential injury by Engineering interaction: Go to this blog at severity, frequency, and probability. (See www.controleng.com/blogs, for related articles: graph.) Confusion amuck, quantitative circuit design ISO 13849-1, in 2006, introduced versus qualitative risk assessment Performance Levels and the require Can end user companies comply with ISO ment to develop the PLr (the goal). Use 13849-1: 2006 without design engineering the qualitative approach to develop PLr resources? by evaluating the related potential inju-
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Robots serve diverse industries

With more than 40 live robotprogramming, three demos with ic demonstrations and 39 semithe high-speed FlexPicker includnars on robotic subjects, ABB ing the new 8 kg model, and two Robotics hosted a Technology demos with the IRB 120, ABBs Days event on May 15, 2013, for smallest 6-axis robot. current and potential customers Painting, with three demos at its North American headquar(basic to sophisticated), displayters and training center in Auburn ing systems for all sizes of paint Hills, Mich. A large exhibition operations, each providing thorfloor put robots through their ough and consistent paint coverpaces. General and application age for significant paint savings. specific information was provid Service and training, with Before: An ABB robot After: An ABB robot ed to help those considering use robotic cells dedicated to training, before refurbishing, after refurbishing, 2013 of robotic automation, and those live remote service demonstra2013 ABB Technology ABB Technology Day. looking to upgrade or expand tions, and robot reconditioning. Day. CFE Media images, existing robotic lines. Powertrain, covering robotMark T. Hoske ABB experts answered quesic automotive powertrain systems tions, attendees toured the 55,000-sq- set up an initial robotic welding opera- and tours. ft facility, and an open house educated tion, advanced laser welding and cut The lighter side, a 70-in. flatfamilies, youth organizations, and stu- ting technology, and a 10-axis robot screen was attached to the arm of a dents. Robotic demos included: system consisting of a smaller 6-axis robot, creating a unique viewer expe General applications, including robot attached to the arm of a larger rience by bringing virtually unlimitnew technologies in integrated vision, 4-axis robot for long reach applications. ed, 6-axis motion to the video media. robotic safety, machine tending, and Packaging, highABB RoboScreens gained simulated programming. lighting a three robot palprominence in 2010 as Go Online Welding and cutting, featuring letizing cell with new www.abb.com/robotics main stage props for the fully equipped cells for those looking to software for far easier Bon Jovi Circle Tour.
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Baseline your system or else

In a recent Automation System Integration blog post, Anthony Baker learns that the lack of data about how a system has been operating can create a moving target after an upgrade. A customer required an architectural change to a control system to support some new functions, a conversion from a two PLC (programmable logic controller) system to a three PLC system. All the old interlocks were mapped and moved, and new interlocks added between PLCs. All the DA (data administrator) servers, Invensys Wonderware ArchestrA objects and Wonderware InTouch HMI software tags were reconfigured for the new setup. In short, all items in the checklist were complete. The new architecture was installed Saturday morning, and many test cases were run over a three-day weekend. Everything looked good, so Monday night, its time start-up production again. And everything looked good in production too; just some minor tweaks here and there. On Tuesday evening the, client appears: Client: Were getting more products in wrong locations. Immediately questions start running through Anthonys head: What could be causing this? Are there mechanical issues? Is the system not setup correctly? Is there a communication or network issue? Why hasnt this been brought up earlier? Anthony cant identify a cause. Client: We still see more products in wrong locations. Anthony: I cant find any issues; how much more? Client: More than before. We usually get 120/160/180 per shift, and now we see 160/180, but last shift we got 300. Anthony: Well 300 seems like a lot more than usual.
Something else must have gone wrong. Client: Maybe it did. I dont know really. I just know were seeing more than before these changes were put in. By this point Anthony is tearing his hair out. Anthonys manager: Youre spending a lot of time on this. How are we going to know when were done? Anthony: I dont know. Ive fixed a bunch of things that would have existed before the change, but they keep telling me that its more than before, or its too much in general. Anthonys manager: Whats the target here? Do we know for sure what they had before? Anthony: They dont have historical data. I heard one guy say six per shift was expected... In the end, it got down to a count under 30 per shift, much lower than it was before, and the client was happy. Anthony fixed some things that had been in the code since nearly the beginning of the project, but hadnt come up before. Lessons learned: If youre going to be making a change or improvement to a system ensure you have baseline data on how it operated before, in production. Test cases wont always show all problems on a complex system. - Anthony Baker is a fictitious aggregation of experts from Callisto Integration. Andrew Barker, P.Eng., Callisto Integration, compiled the advice. www.callistointegration.com www.controleng.com/blogs
IT INFRASTRUCTURE
SOFTWARE & SERVICES

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NEWS
High-speed wireless control and monitoring for carts

Johnson Controls, an automotive up to 300 Mbps. industry supplier, is preventing breaks The technology was the best option in wired communications by eliminat- for wireless communication based ing wires and installing industrial wire- on the testing results and presale tech less technology for monitoring and con- support provided on-site, explained trols application resulting in half the Adrian Torres, Johnson Controls projdowntime for that application. ect leader. Adepi, the systems integraWhen most people hop into their tor, and Risoul y Cia, the distributor, new car for the first time, the first worked with engineers from the wirething they do is adjust the position of less provider to make the project sucthe drivers seat. Moving it forward or cessful and get past a hurdle involving backward, they either automatically or the data transfer rate and streamline manually adjust the installation. seat by pushing a butIt took only a 23 of 42 carts ton or two, or pulling couple of days to levers, to get it into a I/O are physically have it completecomfortable position. ly optimized, Hugo connected to an said. Many of those seats were manufactured by Adepi Engineer industrial wireless Joaquin Johnson Controls in Ortiz said radio with a Tlaxcala, Mexico. there have been sevIn Tlaxcala, Mexibenefits, includmaster connected eral co, 43 carts go through ing elimination of whats known as a wiring and not havto the controller urethane process as ing the master PLC platform. they move around inside the production a production caroucarousel. sel. Johnson Controls had difficulties with the wired communication sys- Half the downtime Downtime has decreased considertem, because the wires were starting to break, and when a wire broke, pro- ably with the wireless communication, duction was hindered until the wire approximately 50%, Ortiz said. Speed is now optimized, and browas fixed. This resulted in unexpected downtime. Johnson Controls wanted to ken communication wires are becoming improve the system and chose industrial a thing of the past at the Johnson Controls plant. With that, so is the downwireless communications. time that occurred as a result. Data Real-time requirements is transferred at a high rate of speed Johnson Controls had four require- between each of the carts and the conments of the new system, including troller platform. having capability for monitoring and The company plans to install wirecontrolling the process in real time; less on the remainder of its carts later obtaining seamless and robust com- this year. With the successful implemunication between carts and system mentation of the radios, Johnson Conmonitoring; and having the ability to trols is also looking at installing a simibring data to a PC in the field office lar solution at its U.S. plant. and to control the robot permission to - Victor Garcia is marketing writrun urethane injection based on infor- er with ProSoft Technology; edited by mation transmitted via radios. Mark T. Hoske, content manager CFE Johnson Controls system integrator Media, Control Engineering, mhoske@ and distributor chose fast wireless radi- cfemedia.com. os. Twenty-three out of 42 carts I/O are physically connected to an industriGo Online al wireless radio with a master connect- http://adepi.com.mx ed to controller platform. The radios www.prosoft-technology.com can transfer data at a high rate of speed
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22
WEBCAST: Cyber security survey results

Cyber security survey results and analysis and advice from two experts are available in a June Control Engineering Cyber Security Matt Luallen, webcast. An RCEP cyber security / ACEC Certified trainer and Professional Develconsultant opment Hour (PDH) with Cybati is available. Survey results update a 2009 Control Engineering survey to determine how industrial users perceive threats to their networks, and what steps theyve taken to defend against cyber attackers. The two industrial cyber security experts are: Matt Luallen, a cyber security trainer and consultant with Cybati and regular contributor to Control Engineering Tim Conway, who recently joined the SANS Institute Tim Conway, as technical directechnical tor, ICS and SCADA, director, ICS and prior director of and SCADA NERC compliance with SANS and operations techInstitute nology at NIPSCO. Peter Welander, Control Engineering content manager, moderated the discussion, which is available for archive viewing after the scheduled June 13 date. Participants offered situational analysis and suggestions based on survey responses. www.controleng.com/webcast
BOOK: The Automation Legal Reference provides legal advice with wit, wisdom
little or no understandLegal risk surrounds ing of what automation automation, robotics, companies do (mention and process industries the word software and projects, and The many will politely look Automation Legal Referfor the exit), but I also ence, by Mark Voigthave seen all too many mann and published by engineers (and, frankly, ISA, includes inspired automation company legal wisdom and wit executives) attempt to from years of writing navigate their way and speaking about through legal hazards legalities of automation. in what can only be Voigtmann, attorney with described as a penny Faegre Baker Daniels, The book, The Automawise but pound foolish expanded upon years tion Legal Reference by mannersaving a few of Control Engineering Mark Voigtmann, is availthousand on legal fees Legalities columns, able through the online ISA on the front end only to speeches, and other artiBookstore, and expands see a company-killing cles, and added illustraon Voigtmanns wisdom in problem arise as a result tions from Aaron Reiter, many Control Engineering of that inattention. in the 160-page book. Legalities articles. He further explains Its appropriate readthat legal risks awaiting for anyone involved ing those who venture out in the autowith control system integration, robotic mation world are by no means small. integration, and integration of process Although reading this book will not control projects, as well as customers, eliminate those risks, I hope it will at those funding the projects, and others least demystify themso that each new involved. project is begun with open eyes. Voigtmann said that in automation, A sampling of content is available. robotics, and process industries, lack For a brief preview of Voigtmanns style, of communication is a two-way probyou can look at two Control Engineerlem. Not only do most lawyers have
www.controleng.com
industry
NEWS
ing columns, which are expanded into chapters 5 and 6 in this book: - Beware The Dirty Dozen - Legalities: Want a good starting place for figuring out whether to accept another companys terms and conditions? Try looking for these Dirty Dozen contract flaws. - Legalities: 8 Ugly Contract Clauses - Legal risks for automation industry companies: Add these ugly 8 contract clauses to the dirty dozen to get 20 very serious legal risks. And, as Voigtmann advises, This book is intended as a general guide to legal risk in the automation realm and should not be relied upon as advice for any particular situation. The law applicable to any given circumstance can be nuanced. Please consult counsel. The book, The Automation Legal Reference by Mark Voigtmann, is available through the online ISA Bookstore. He spoke at the CSIA Executive Conference in May. www.controlsys.org www.isa.org/books
Mark Voigtmann, attorney with Faegre Baker Daniels, bundles and expands upon legal advice in a new book, The Automation Legal Reference, available through the online ISA Bookstore.
Go Online
At www.controleng.com/archive, June 2013, read this for links to prior Legalities columns.
CALENDAR
Shows, events, and conferences that may be applicable or of interest for Control Engineering readers include the following. Siemens Summit, New Orleans, June 24-27 www.usa.siemens.com/summit NIWeek (National Instruments), Aug. 5-8, Austin, TX www.niweek.com Pack Expo, Sept. 23-25, Las Vegas, www.packexpo.com
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Emerson Exchange 2013, Sept. 30-Oct. 4, Grapevine, Texas www.emersonexchange.org 25th National Robot Safety Conference, Oct. 14-16, Indianapolis, Ind. www.robotics.orgevents ISA Automation Week, Oct. 18-24 www.isa.orgevents Solar Power International, Oct. 21-24, Anaheim, Calif. www.solarpowerinternational.com AutomationFair (Rockwell Automation), Nov. 13-14, Houston www.automationfair.com SPSIPC Drives, Nov. 26-28 SPSIPC Drives, Nov. 26-28, Nuremberg, Germany www.mesago.deenSPS Industrial Automation Show 2013, Shanghai, Nov. 5-9 www.industrial-automation-show.com European Robotics Week 2013, Nov. 25-Dec. 1 www.eurobotics-project.eueuroboticsweekeurobotics-week-.html
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cover story
Humans as process controllers

While automated control systems can keep our manufacturing processes running efficiently, new variables are entering into the production equation that are beyond what we can expect from PID. In an interview, Peter Martin explains forces pushing a return to humans as controllers to accommodate these changes, at least for a while.
Beyond automation:
op contracts with their electricity suppliers for a year at a time, essentially relegating the price of electricity to a constant for the contract period. With the price as a constant, all you really needed to control was consumption, and by reducing consumption, it directly translated into profitability. With the opening of the power grid and deregulation, all of a sudden the price, not only the usage of electricity, but the price is changing more frequently than it ever has. In fact in the U.S., on the open marKey CE: Over the last year or two, ket, the price changes about every concepts you have made comments about 15 minutes. how process industries are changHistorically, weve applied con The number of variables that have to be considing, and suggested that you expect trol theory to the plant floor, and ered in a control strategy a larger role for humans in conweve applied management theois growing in a way that trol functions. With the growing ry to the business. That made some includes more businessimportance of automation, this sense because all of the critical related elements. seems counter-intuitive. Where business variables didnt change Control strategies that do you see this headed? within a given month. You could are adequate for running use monthly information from SAP the process may not be What we see going on is that or Oracle, and youd be getting capable of controlling automatic control (and manual measures of energy costs, materinew variables. control) have been applied to conal costs, and product value, all of Human controllers trolling the efficiency of plants for those things that were fairly stamay need to fill the gap between needs and capamany, many years. Its been going ble and could be managed with bilities on for a long time, and were pretmonthly data. Today with the openty good at it. Over the years, weve ing of the power grid and the dombeen able to replace human decisions with auto- ino effect that its caused, all of a sudden were matic decisions, especially in a more real-time seeing not just electricity costs, but the price world where automatic controls can make deci- for natural gas changes every 15 minutes. Simisions much better, more effectively, and more lar things are happening to some of the materiquickly. I dont see a reversal of that. What I do als used in production process, especially heavy see going on is that the critical business variables process industries. If you watch the price of critistarting to change in real time. So, for example, cal metals like copper, they might change mul15 years ago, companies used to be able to devel- tiple times per minute. If one of those is a raw
eter Martin, PhD, is vice president, business value solutions for Invensys Operations Management. He has emerged as something of a control strategy futurist, looking for how our concepts of process control need to evolve as business-related demands on manufacturing change. Control Engineering contributors Vance VanDoren and Peter Welander asked the questions.
26
material in your manufacturing process, thats a new dynamic introduced to your manufacturing processa high-speed change thats never been there before. And if youre going to play that correctly, perhaps the products that are being produced should be adjusted to reflect that and reflect market demand. The three critical business variablesproduction value, energy costs, and material costsare changing multiple times daily, and companies are still trying to manage them. Its not that I see a lessening of applying control theory on the plant floor, but rather I see controlling the business side of industry as more of a real time control problem than its ever been, and we believe that we have to apply real time control theory to those critical business variables. That said, its not easy to apply something like PID control because you dont get the natural periods of the loops in the business side that you get in the process side. Therefore, what we see going on is that humans have to jump in and be controllers of the critical profitability variable almost in the same way they were 100 years ago for the process variables. Back then we set operators on a hand valve looking at a gage, and we said to the operator, Look, when the needle goes this way, turn the valve this way, and when the needle goes the other way, turn the valve the other way. The interesting thing about it is that humans did a pretty good job. What I see going on, in terms of control theory, is that humans are getting involved more in controlling profit. A lot of people think, Youre talking about business managers. But no, Im talking about operators and maintenance people. When an operator changes the set point of a loop, lets say a temperature loop from 400 to 410 degrees, from a business point of view, that either added value or destroyed value. Theres no other alternative. That type of change is either creating or destroying economic value. Just like in the old days of manual process control, if we can stick operators in front of a gage that will show them what the impact is, in terms of the business, of every activity and action they take, then over time the operators can learn how to take actions and how to perform activities that will drive the most value. Thats where I see much more manual control than we would have seen 10 years ago, but not at the process level, its at the business level. But its the same peopleits the operators or the maintenance people learning how their actions and activities impact the profitability of the plant. In reality, that is feedback control. Its the difference between control and management. Management is when you cant control
Photo illustration by Mike Smith and Peter Welander
Therefore, what we see going on is that humans have to jump in and be controllers of the critical profitability variable almost in the same way they were 100 years ago for the process variables.
something. If you can control it, do. If you cant control it, manage it. Were getting to the point in business where the traditional management constructs, like using monthly reports to manage your business, are truly becoming obsolete. Its not that we dont need the monthly reports, but you cant use that same monthly data to manage the performance of your operations, because the operations are moving so fast that the speed of the business precludes running it monthly. So if you cant run it monthly, you have to run it in the time frame in which it changes, which is essentially becoming real time. Then the people that become the business managers, who are the manual controllers of profitability, are the operators, maintenance people, supervisors, and engineers.
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cover story
CE: But wont all these parameters taken together threaten to exceed the ability of human operators to keep up? Wont we have to develop some kind of automatic control at the management level just the way we did in the 1930s at the process level? I absolutely think that is going to have to happen. We all need to be looking for how to do automatic control of all these variables. Unfortunately, its not as simple as applying PID. We have to be looking for that automatic control algorithm. The good news is that in most parts
Were starting a new era for control engineers where theyre going to have to figure out how we can do predictive control or modelbased control of business variables.Youll have profit control cascading to efficiency control, and well have a new type of closedloop controller.
to the U.S. or wherever youre shipping it to be refined. During that trip its stuck in the pipeline for three days, and during that period the price of that crude may have changed 120 times, and theres not a thing a business manager can do about it. The whole concept around storage and inventory has to be altered along with the whole trend. I was at a Momentive Chemical plant in Deer Park, Texas, recently, and its fascinating: they have no on-site storage. They buy their raw material off a pipeline from the refinery next door. All of a sudden were finding more and more processes that are changing because the real-timeness of these variables. Everything is going to become faster and faster. I think were starting a new era for control engineers where theyre going to have to look at this problem and figure out how we can do predictive control or model-based control of business variables. Youll have profit control cascading to efficiency control, and well have a new type of closed-loop controller. There are some really fun challenges. CE: The tricky part will be finding the right control algorithm. You cant use PID because you dont have a natural period in the business variable loop. Weve come up with model-based control and other things that are really pretty sophisticated. Maybe some of these other algorithms, expert algorithms, or neural-net models may make some sense going forward. Down on the plant floor, you can always default to PID, and we do, because its relatively easy and effective. Maybe when we get up to business control, because you cant default to PID, we might see some of the great research thats been done over the last couple of decades show its applicability with business variables rather than process variables. One way might be to look at it as a realtime optimization problem of sorts, trying to balance production value, energy cost, and material costs that are constrained by safety and environmental considerations. The problem with linear or non-linear programming today is that you typically have to pick an objective function and relegate all your other objectives to constraint functions. Im not sure that will be dynamic enough. There is some new work being done in multi-objective linear programming and optimization that holds a lot of promise. Youre trying to balance three objectives, production value with energy cost and material cost, so that may be the direction for closed-loop business control.
of the world, governments have jumped in and regulated the time in which these variables can change. For example, if you look at the price of electricity on the open grid, in the U.S., it changes every 15 minutes. That interval is not because of any business or physical reality but because the government says, You cant change any faster because we cant keep up with it. When we first started looking at this, everybody said, Yes, this can happen for energy, but its never going to happen for raw materials because people have too much inventory, and the inventory itself will slow things down. That tends to be true. Inventory does add a capacity buffer effect, but what Im seeing going on now is business managers who understand whats going on have two dynamic problems: One is controlling the business, the second is controlling the physical process. We see a lot of people rethinking the physical processes themselves. North West Redwater Partnership is building a new refinery near Edmonton. We havent built a new refinery in North America in decades, so why are they doing that? Today, when you produce crude from the oil sands in the Athabasca range, you put it in a pipeline and pump it down
28
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CE: It will have to be some sort of iterative search optimization. Theres not going to be a neat tenth-order differential equation that relates inputs to outputs, which is the fundamental premise of regulatory control. The other issue when you start to look at multiple-objective control and optimization is historically, linear and non-linear programming with multiple constraint functions requires a lot of computing power to process things and come up with optimal settings. As the time gets shorter and shorter, how do you get that amount of computing power in a cost-effective way? If you think about it, there are some really fun challenges. I think the golden age of the control engineer is almost upon us. CE: I think the golden age will be when we can start to use some of these new techniques to control our processes, instead of following tradition and returning to PID as we have for the last 60 years. The thing that I worry about, and Im speaking in large generalities here, is if it truly is a cascade control structure, and we cascade profitability to efficiency, we have to remember the old concept that the secondary loop of a cascade controller has to be four times faster than the primary loop. As the business variables get faster and faster, we may find PID control of the process becoming a constraint. The process could become chaotic if the business variables move faster than the periods of the loops on the plant floor. That will be a fascinating thing. If that starts happening, well have no choice but to look at other methods of control. CE: Thats a natural extrapolation, but thinking in terms of costs and business variables changing faster than flow or pressure blows the mind. Put on a ticker for commodity prices some time. When you see the price of copper changing every 32 seconds, can you control a temperature loop much faster than that? So ask yourself, why dont we have a control problem right now, because some of these variables have gotten themselves to the speed where theyre actually breaking into the classical temperature and level domain, if not the flow and pressure domain. The issue ends up being that instead of worrying about the problem, were ignoring it and we buy our raw stock in bulk so the inventory gives us the buffering. We just dont worry about it. Where it will all blow up, I believe, is when
30
some business realizes that it can have a huge competitive advantage by playing the price of its raw materials effectively. When that one company does it, everybody else is going to say, Wait a second, in order for us to survive in this environment, we have to think differently. I dont think were far, time-wise, from that happening when I see sites like Momentive Chemical in Deer Park. No on-site inventory combined with real-time acquisition and distribution of product via pipeline. It fascinates me. Huge amounts of money are at stake. CE: This sounds interesting, but as a practical matter, how much leeway will, or can an operator have to change whats happening? If the plant is in a sold-out state and the objective is to create as much product as possible, when does it become practical to start trying to finetune the parameters? We have to look at the dynamics of the process itself, but I think the decision criteria could get complicated and it may be impractical if the dynamics of the physical process are slower than the business process. That could get into some very difficult things. The issue is this: Weve been working in a world of sold-out everything. The primary philosophy of business has been to make as much as you can in a given period of time, and life as we know it is good. Thats what everybody has been doing. The best example is the power industry. For years, the way the power industry worked was they had central station, coal-fired power plants that made as much power as they could 24/7. Pricing was regulated so they always made a profit, everything was good, and nobody could imagine anything different. Then what happened? They deregulated and the grid opened up. That means all of a sudden there were, by law, other power suppliers, such as windmills, photoelectric, and co-gen plants, all these sources of power, which if they wanted to send power onto the open grid, they had to be paid money, based on the current value of electricity on the grid. You went from a situation where you had a single producer producing for a series of users, to where you had multiple producers producing for multiple users, and the supply side is going up and down at a higher rate than anybody had seen it move. You might have a co-gen operation at your plant, and for the next three hours you dont need its output yourselves in the plant, so you put it out on the grid. Now the supply of electricity goes up and people have to adjust. Thats what the smart grid is all about. Were in a brand new dynamic environment,
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which is also fascinating because you cant store power. So with no inventory buffer, whats going on? Youve got real-time strategywe actually had to go to a new structure of the generators, the producers, the grid managers, and the consumers. All of a sudden you have a very dynamic environment. So what did the energy producers have to do? They built new types of plants. Combined cycle plants that could start up and shut down quickly, because if there was a demand on the grid, and the big energy companies couldnt provide enough power to meet the demand, they were penalized, so they had to
The day of the megascale coal-fired power plant is behind us. The day of the mega-scale refinery may be behind us. Our manufacturing philosophy has to change. Maybe we have to go to more localized micro-manufacturing to match the dynamics of the market place.
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n Read this article online at www.controleng.com to see a 2010 interview with Martin discussing the value of automation. n http://iom.invensys.com
32
have those combined cycle plants start up. Those plants produce energy at much higher cost than the coal-fired plants, so you see these big swings in price. In response, even at the home level, were going to see things like thermostats that read not just the temperature, but the current price of electricity. Youll put wet clothes in the dryer in the morning, and it will turn itself on when it sees that the price of electricity is low enough. The power industry is an extreme, but its where all industrial operations are going. Trucks, trains, and material in pipelines dont travel as fast as electricity, but the dynamics of these systems are going to drive a true reconstruction of how we manufacture. I can picture in the future, where instead of building megascale Texas City refineries, we start building smaller refineries that can be more agile, just like the combined cycle plants in the power industries. Hydrocarbon companies wont run a plant at a time; theyre going to be running their asset set across the entire value chain because if the price of crude is too high right now, so that I make gasoline at a loss, I should slow down production, even if Im in a sold-out condition.
If you cant play that game, youre going to lose money during these difficult periods. They are already hitting the power industry, and theyre going to hit the rest of our industries. The ones that can play that game are going to be profitable, and the other guys are going to be out of business. I believe this is where its going. The day of the mega-scale coal-fired power plant is behind us. The day of the mega-scale refinery may be behind us. Maybe our manufacturing philosophy has to change. Maybe we have to go to more localized micro-manufacturing in order to match the dynamics of the market place. Those are the kinds of things that were going to have to start thinking about. As an industry, we came up in the era where everything was sold-out, all you had to do was make as much as you can, and margins were huge. That time is behind us. Now, margins arent huge and everything isnt sold out. Some times of the day were making money, and other times of the day were losing money. The world has changed, and its going to require a different set of strategies. I think at least initially, some of these strategies will be to use the people in these production operations in a more effective way. Were going to see some manual controls involved in profitability, with the safety of the operation, and with the environmental integrity. As we learn more, those manual controls are going to have to be replaced with automatic controls, from a purely practical point of view, because theyre going to become too fast for humans to deal with. Heres another indication of how things are changing: When you think about the chemical industry, the average tenure of a CEO in a chemical company is somewhere between 13 and 20 months. Thats a frightening concept. That means that these people have 13 to 20 months to prove themselves. So what do they do? Everything is designed for short-term gains, and its driving them nuts. Its all going to catch up. Sooner or later, the group thats looking beyond that and looking for the root cause is going to become more profitable, and those people that are playing the short-term gain game are going to be left by the side of the road. I dont believe there are many instances on the plant floor that can be brought under automatic control where we should go back to manual control. We should be trying to control as much as possible in an efficient, automatic way, while at the same time involving people more and more in the operation because of the business dynamic. ce Edited by Peter Welander, pwelander@cfemedia.com.
APRIL 2013 CONTROL ENGINEERING www.controleng.com
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pre-integration
Mechatronic designs blend power, electronics, mechanical systems

Mechatronics pre-integrates power, electronic, and mechanical systems, using hardware, software and networks to simplify design, lower costs, and speed time to market.
Mark T. Hoske
echatronics is the convergence of three areas: power, electronics, and mechanical systems, including related embedded software and hardware. Some automation products embed mechatronics functionality, making life easier for controls, electrical, and mechanical engineers, along with original equipment manufacturers (OEMs) that play in all three worlds, explained Chuck Edwards, president of Lenze Americas. Products designed using mechatronics principles pack more performance and opportunities for optimization into a smaller package, taking less real estate and offering more dynamic machine performance, Edwards said. Mechatronics-based designs, using pre-integrated systems, add engineering productivity, Edwards said, explaining that for most OEMs 25%-30% of the cost of the machine is in engi-
neering. Such products, which reduce engineering costs, help OEMs bring machines to market faster, breaking the risks associated with a common three-year design cycle (first year, design; second year, launch and production; and third year, financial returns). Simpler integrated designs also help make machine operation and maintenance easier for a workforce that may have less manufacturing experience and education than they once did. Engineering companies also need to work with area colleges to ensure applied engineering and mechatronics are part of four-year engineering curriculum, beyond theoretical engineering, Edwards advised. - Mark T. Hoske, content manager, CFE Media, Control Engineering, mhoske@cfemedia.com.
The Lenze 8400 motec frequency inverter drive integrates the gearbox, ac motor, and inverter in one compact design that allows machine builders to optimize machine performance at a high level. Courtesy: Lenze
Electromechanical manufacturing systems

A tightly integrated mechatronic system can reduce the machine footprint, shorten programming time, and eliminate dedicated hardware controllers.
Matt Lecheler
utomation architectures can use one controller, one network, and one software platform across one system architecture. Such a design can integrate a programmable logic controller (PLC), motion control, safety, communications, and robotics on an industrial PC (IPC) or embedded PC. With this approach, users can replace multiple expensive controllers and black box hardware with a more powerful centralized system. For machine and robot builders, this means engineering cost savings with process optimizations, and a significantly smaller footprint on the plant floor.
A key driving force for a unified architecture is a modern multi-core processor technology. As multi-core technology progresses, so too does the capability to add even more functionality. The rise of more integrated automation systems has also produced some very interesting innovations in the area of mechatronics.
Mechatronics demonstration
Consider this...
In project design: Think beyond automation to include power and mechanical systems Consider related software from the start
A modular linear drive that serves as a motion control system is exactly the kind of mechatronic advancement that takes full advantage of more powerful PC-based controllers and one architecture. A machine equipped with such a motion control system would leverage one stanwww.controleng.com
pre-integration
Beckhoff Automation XTS (eXtended Transport System), is an example of mechatronics design, at PackExpo, in Chicago, October 2012. CFE Media image by Mark T. Hoske
dard controls architecture (PC-based control), one software platform, and an industrial Ethernet network. By combining linear motor technology on a continuous motion track with straight and curved track segments, a machine designer can configure topologies that suit numerous applications. Typically, a linear motion system has a linear magnetic track and one active carrier. Motion is constrained to back-and-forth actions on one plane. A modular track, on the other hand, is like an inverse linear motor and is specially engineered for multiple carriers. The track contains the active coils and encoding, while each mover is composed of a passive set of magnets with encoder flag and roller wheels. The simple design delivers outstanding performance. Control software can abstract complex underlying control principles, to enable a controls
engineer to program against the movers absolute position. Movers are positioned using the same software function blocks as traditional rotary axes. Complex motion tasks are relatively easy to implement, such as electronic gearing and computer-aided motion (CAM) tables between movers or between the movers and external axes.
Integrated motion, robotics
A high-speed integrated robot-mover hardware and software system can run on one industrial PC, as demonstrated at Hannover Fair 2013. A tightly integrated mechatronic system can go a long way for engineers to reduce the machine footprint, shorten programming time, and eliminate dedicated hardware controllers. - Matt Lecheler is motion specialist at Beckhoff Automation.
Implementing mechatronics: Software engineers are different

Embedded software development, a component of controls systems and mechatronics, differs from other engineering, says Cambashi research.
Peter Thorne
Project development methodology

User requirements Site acceptance test (SAT) Factory acceptance test (FAT)
Go Online
www.lenzeamericas.com www.beckhoffautomation. com/xts www.cambashi.com At www.controleng.com/ archive, June 2013, read more on each: Mechatronics designs can decrease the 25% cost of engineering for OEMs Mechatronics: Electromechanical manufacturing systems Implementing mechatronics: Software engineers are different
36
Software has been an important component of control systems for many years. Control system software continues to grow in importance. For example, a faster processor in a control unit may allow a product to perform better and reduce costs by using simpler, lower-cost mechanical parts, but only if the sensor and actuator control software are good enough. Software intensive, networked electronics are becoming increasingly central to the performance of products of all kinds, from industrial to consumer. More engineering teams are facing questions about the best way to handle software development as a key part of product development projects. [This includes mechatronics-based design, those integrating mechanical and electronics, including embedded software. See many examples and details for future software development online.] Software development engineers, methods, and tools can be integrated into product development teams. Examples include industries and product types such as medical devices, radar subsystems, transportation equipment, production monitoring, aerospace, and communications. Some companies approaches can aid software development in new product introduction projects. Regulations affecting development methods exist in many industries; lowering the cost
Functional requirements
Design specifications Write software
System documentation Integration & test software
Source: Control Engineering with data from GAMP.
V-model project development methodology was originally formulated by the Good Automated Manufacturing Practice (GAMP) Forum and has been incorporated into the Best Practices of the Control System Integrator Association. Left half of the V shows the planning required for each testing step shown on the right half of the V. Courtesy: Control Engineering with information from GAMP Forum
of obtaining and maintaining the right certifications is high priority. More software reuse is needed, and this means modularity, standard interfaces, and use of external software components. Strategies such as common platforms are relevant to software (and hardware) to organize these efforts. ce - Peter Thorne is director, Cambashi Ltd.
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industrial networks
7 reasons to consider a non-Ethernet industrial network

Here are seven reasons non-Ethernet networks might be specified for an industrial project, to help determine if an Ethernet, fieldbus, or a device or sensor-level network should be considered.
John F. Wozniak
hy or when should non-Ethernet protocols be considered for an automation project? Seven reasons follow, showing when non-Ethernet networks might be specified for an industrial project. These can include simplicity, flexibility, familiarity, and consistency, even if logic might suggest otherwise. 1. Simplicity. For some automation engineers, it is the simplicity of fieldbus networks that tips the scale for them to decide to use one of these non-Ethernet-based fieldbus network instead of an Ethernet-based network. These non-Ethernet-based traditional fieldbus networks generally require less hardware and may be much less complex than Ethernet protocols. Fieldbus networks do not require switches to guarantee control system determinism, whereas some Ethernet-based networks require complicated Ethernet switches to guarantee determinism. 2. Flexibility. In addition, most fieldbus networks can be laid out in multiple configurations (line, tree, line-tree combination, and ring). Most Ethernet-based networks are much more restrictive in how they are laid out for a project. 3. Familiarity. Another reason non-Ethernet protocols should be considered is a situation when automation engineers and the maintenance staff on the project have used the same non-Ethernet-based network for quite some time, they are comfortable with this technology, it works for their current application, and they do not see the benefit of adopting a new Ethernet-based network for a new application. Perhaps a new Ethernet-based network would not provide them with a significant productivity boost, and the potential cost savings would not justify learning a new Ethernet-based network technology. With this information, the project leaders cannot justify adopting a new Ethernet-based network, so continue using the same non-Ethernet-based network. 4. Consistency for an incremental expansion. In another situation, application uses a non-
Ethernet-based network. Automation engineers are considering expanding that application to include more automation, and this expansion can usually be completed more cost effectively using the same non-Ethernet-based network by adding more stations to the current non-Ethernet-based network. Expanding an existing application using the same non-Ethernet-based network maintains consistency in the application and allows use of the same tools and current products without requiring operators and maintenance staff to learn a new system and how to use new tools. 5. Policy. A company also may say all projects must use a specific non-Ethernet protocol for all automation projects. Automation engineers and the maintenance staff may be comfortable with current technology, but automation engineers may understand that the benefits and potential cost savings would justify learning a new Ethernet-based network technology. Company management, however, has so much invested in the current specific non-Ethernet protocol that they continue to use the prior protocol. 6. Automation experience. A different situation where non-Ethernet protocols should be considered is when a company is new to automation networking. Using a fieldbus network may be easier to justify because that technology has been around longer and is deemed more reliable; or perhaps the engineers on the plant floor have been requesting some automation for years and have always requested a fieldbus network, because when they initially requested this new automation networking, Ethernet networking was not viable or available. 7. Equipment compatibility. In another projects investigation phase, it was discovered that not all necessary equipment would be available to communicate using an Ethernet-based network. To maintain and use one network for the automation project, an appropriate non-Ethernet-based network should be considered for communications among all equipment. - John F. Wozniak, PE, is a networking specialist with CC-Link Partner Association.
www.controleng.com
With the migration away from traditional point-to-point fieldbus, advanced networking architecture ensures connectivity, collaboration, and integration from the device level to enterprise business systems. Courtesy: Turck
The ease of configurability of wireless networks for new assembly lines makes wireless very attractive to the automotive industry, which often introduces new models every year. Courtesy: Honeywell Sensing and Control (S&C)
Go Online
www.CCLinkAmerica.org www.tricore.com
industrial networks
Industrial Ethernet alternatives

When choosing between an industrial network or another option, such as industrial Ethernet network or industrial wireless, sort out the cost and timing of legacy upgrades.
mens, along with other European manufacturers, developed a standard that eventually became Profibus. The AS-Interface is an open technology originally developed by a consortium of sensor manufacturers used for simple field I/O devices. Many other standards exist. Now that open standards are commonly available, why would we want to go back to our old proprietary ways? One reason is that our past is still alive and well in many of our manufacturing facilities. The choice of networking solutions comes down to how much of legacy stuff is in the existing automation infrastructure, and the effective remaining lifecycle of infrastructure components. Suppose, you have to upgrade a portion of your facility currently running AllenBradley 1771 series I/O on an RIO network platform.a legacy platform still supported by many control engineers and systems integrators. If the upgrade is small, and parts are still active, it will generally make the most sense to stay on this legacy platform for small projects. When circumstances are the same except that some components are designated as Silver Series, a term Rockwell uses to indicate a part is near the end of its lifecycle, then, even if the project is small, upgrade costs can be disproportionate to the amount of work at hand.
Legacy networks: Not if, but when
From RS-485 to Ethernet, we have had 50 years of industrial networking. Courtesy: TriCore
David McCarthy
Go Online
At www.controleng.com/ archive, June 2013, also read: Industrial wireless monitoring and sensing How wireless networks are changing industrial environments Industrial networking: One network for full enterprise connectivity Wireless www.controleng. com/wireless
40
ndustrial Ethernet in its various forms is beginning to dominate manufacturing networks globally as the solution platform of choice. Its a communications network; its a fieldbus; its highly interoperable; its the superman of networks. So does that mean it is the right solution for your application? Not always. Not long ago, industrial networks were mainly proprietary. Control devices were largely hardwired. Information crawled along at relatively low speeds, and network topologies came in a variety of configurations. Network cabling media was largely copper and often installed by an electrician rather than a network cabling firm. The desire to integrate real-time manufacturing information with business systems was present, but the state-of-the-art often fell short of the mark. Many proprietary industrial communication networks evolved including DH1, DH, and DH+; Modbus RTU; TiWay; and many, many more. Each controller manufacturer also had at least one proprietary device control I/O network, sometimes more. It was not uncommon to have multiple networks co-mingled on the same plant floor. In response to proprietary platforms was a push for open standards from a variety of sources. The IEEE 802 project led to the establishment of Ethernet for communications. In the I/O world, Allen-Bradley (now Rockwell Automation) developed a standard that eventually became DeviceNet and ControlNet, while Sie-
The same argument will go for any modification to a legacy system. You will always need to balance the extra cost and time of upgrading a legacy system to a modern platform, which could be quite significant, against the upgrade benefits. Keep in mind that eventually you will have no choice but to upgrade. Plan the migration rationally. In the short term, maintaining the legacy platform will often make the most sense. On the fieldbus side, recent trends have been away from some open platforms such as ControlNet, an open standard but with deployment mainly constrained to Rockwell Automation systems. In that case, trending has been toward industrial Ethernet solutions. AS-Interface is growing in acceptance and installations and plays nicely as a partner network with higher level fieldbus platforms including industrial Ethernet. ce - David McCarthy is president and chief executive officer of TriCore Inc.
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2 014 S Y S T E M I N T EG R ATO R O F T H E Y E A R C A L L F O R E N T R I E S
ARE DUE AUGUST 1,
ENTRIES
2013
System Integrator of the Year Awards

Who should enter?
If youre part of a contract engineering rm or an engineering division of a larger company that can design and implement computerized control systems for industrial machinery, manufacturing lines, or other automated facilities that produce either a commodity or a nished product, Control Engineering urges you to enter its 2014 System Integrator of the Year competition. The chosen System Integrator of the Year winner will receive worldwide recognition from Control Engineering. The winner also will be featured as the cover story of the 2014 Automation Integrator Guide, distributed in December 2013.
Control Engineerings annual
Dont miss your chance to enter. Entries must be received by Aug. 1, 2013. Questions? Contact Vance VanDoren, System Integration contributing content specialist for Control Engineering : controleng@msn.com (765) 296-7600
Whats in it for the winner?
How will the competition be judged?

Control Engineerings panel of judges will conscientiously evaluate all entries. Three general criteria will be considered for the selection of Control Engineerings System Integrator of the Year:
Business skills Technical competence Customer satisfaction
Tell us how you measure up in these three areas. Get the application at www.controleng.com/SIY
Top 100 System Integrators | More than $7 billion in revenue represented inside
Image courtesy of Beckhoff Automation, Saugatuck Brewing
Vance VanDoren, PhD, PE
System Integrator Giants of 2013

The 100 largest system integrators in the industrial automation businesswho they are and what they do.
n its second year of production, the 2013 System Integrator Giants (SI Giants) program has assembled the 100 largest system integrators based on system integration revenue for the most recently completed scal year. Compared to last years data, the 2013 metrics have signicantly increased in response to the number of participating rms, making the group even more giant in many ways. For 2013, all 2,387 system integrators listed in the Control Engineering Automation Integrator Guide (AIG) were asked to provide details about annual revenues, head count, client base, industries and areas served, technical skills, professional afliations, and product experience. They also were asked about the educational opportunities available to employees and
the biggest challenges they face as a company. Respondents reporting the largest system integration-related revenue are shown in the accompanying table (see pages 53 to 56). In the early days of the computer industry, it was said that no one ever got red for buying IBM, meaning that the largest vendor in the business was never a bad choice. Some would say the same is true in todays industrial automation industry when it comes to system integrators. Bigger integrators with more personnel and a broader geographic presence are arguably more adept than smaller competitors at implementing largescale automation systems spread over multiple locations. In practice, the advantages of hiring a larger integrator versus a smaller one probably depend on the particulars of each project, so the question of whether or not bigger is always better can never be denitively answered. Even the question of which integrators are the largest in the automation industry was a topic of debate before the 2013 System Integrator Giants survey. The biggest change from last year is the addition of M+W Automationthe No. 1 system integrator for 2013moving
System Integrator Giants: 2013 to 2012 revenue comparisons

Total gross revenue for scal year ($ U.S.) Total system integration revenue ($ U.S.) $1,238,430,068 $875,824,751 Change in total SI revenue among those ranked 41% % of revenue from system integration 17% 39% Median (50th ranked rm) total revenue $8,500,000 $5,000,000 Change in median (50th ranked rm) total revenue 70% Median (50th ranked rm): SI revenue $7,600,000 $4,400,000 Change in median (50th ranked rm) total SI revenue 73% % revenue from system integration 89% 88%
2013 2012 2012 vs. 2013
$7,097,250,184 $2,251,284,436 Change in total revenue among those ranked 215%
More rms with larger total revenue and larger system integration revenue replied to the SI Giants survey for 2013 than in 2012. Yearto-year total revenue increased 215% to $7.1 billion, and system integration revenue increased 41% to $1.2 billion. As a percent of total revenue, the revenue for system integration is less in 2013 at 17% compared to 39% in 2012. However, just excluding M+W alone (among new respondents with an unusually disproportionate amount of non-system integration revenue) increases the percentage of system integration income for 2013 to more than 30%.
46
Image above is from ABB Robotics 2013 Technology Day.
All charts, graphs, and data courtesy of CFE Media.
Staff Information
Total number of employees 25,580
Engineers (number, % of total) Automation and control engineers assigned primarily to system integration projects Technical staff other than engineers, managers, and executives Technical staff assigned primarily to system integration projects Managers and executives Managers and executives assigned primarily to system integration projects
Did your company acquire another company in 2011?

8,761, 34%
No
Yes
9%
91%
5,038, 20% 3,908, 15% 1,966, 8% 1,417, 6% 631, 2%
Was your company acquired by another company in 2011?
No
Yes
4%
96%
Engineers represent about 34% of staff totals for the 2013 SI Giants, down from about 38% in 2012. This years 100 list includes a higher proportion of larger rms.
More integrators reported acquiring other companies than were acquired, suggesting a net gain of capital and resources for the industry.
last years leader, Wood Group Mustang, to No. 2. Everything about M+W Automation is, well, giant. Its 800 automation and control engineers outnumber the entire staff at 96 of the other SI Giants, and its $150 million integration-related revenue accounts for more than 12% of the $1.2 billion system integration revenue reported by all 100 SI Giants combined. M+W Automations parent company, M+W Group, is even larger, with 2,000 engineers, 7,500 employees overall, and $3.5 billion in overall corporate revenue, nearly equal to the $3.6 billion overall revenue reported by the other 99 SI Giants. The average size of the SI Giants also grew between 2012 and 2013, though mostly from the addition of several larger companies to the mix more than the growth of those returning this year. The average integration-related revenue gure rose from $876,000 to $1.2 million, the average engineering staff rose from 52 to 88 (with 50 automation engineers on average versus 36 in 2012), and the average revenue per employee rose from $187,000 to $280,000. The median income for automation system integrators in general (as represented by the other 2,287 integrators listed in the AIG) remained in the $5 million to $10 million range. See the stafng information chart (top-left) for employee counts in other categories, all of which are higher for 2013.
On the other hand, survey results do show some evidence of actual growth in the automation system integration industry, at least in the sense of larger companies forming from mergers and acquisitions. More integrators reported acquiring other companies (9%) than were acquired (4%), suggesting a net gain of capital and resources for the industry. As the professional afliations chart on page 48 shows, this years SI Giants have also demonstrated a signicant increase in involvement with the various professional and trade organizations that focus on automation-related skills and industries that use automation. And like last year, the survey results show that SI Giants tend to join these organizations more readily than other automation system integrators do. For example, in 2013 more than half of the SI Giants (57%) reported being members of the Control System Integrators Association (CSIA), up from 43% in 2012. CSIA membership also grew among automation system integrators in general, but not nearly as much. This year, 18.5% of other integrators cited the CSIA as a professional afliation, up from 17% last year. It comes as no surprise that an association dedicated to control system integrators would have a signicant following
Professional af liations
47
Professional and Third-party Af liations

Control System Integrators Association Underwriters Laboratories International Society of Automation National Fire Protection Association Project Management t Institute National Society of f Professional Engineers Control Systems Society (IEEE) International Society of f Pharmaceutical Engineers Institute of Electrical & Electronics Engineers American Society of f Mechanical Engineers Instrumentation and Measurement Society (IEEE) Industry Applications Society (IEEE) American Institute of f Chemical Engineers Society of Manufacturing Engineers OPC Foundation Fieldbus Foundation American Water r Works Association American Petroleum Institute Robotic Industries Association
57% 39% 34% 25% 24% 24% 20% 18% 17% 17% 13% 13% 13% 7% 6% 6% 5% 5% 3%
The 2013 SI Giants are more involved in professional and trade organizations focusing on automation-related skills and industries that use automation. Majority of respondents belong to CSIA; RIA has the largest growth opportunity among the 2013 SI Giants.
among both SI Giants and automation system integrators in general, but exactly why the CSIA should appeal so much more to larger rms is not altogether obvious. There was a time that the CSIA required a minimum annual revenue before a prospective member could join, but that requirement has been lifted. Perhaps smaller integrators still think of the CSIA as an organization just for the big guys. The organization for robotic system integrators, the Robotics Industry Association (RIA), was cited by 3% of both
SI Giants and other integrators. At the 2013 Automate Show, the vast majority of system integrators exhibiting were RIA members (the event was sponsored in part by the RIA), yet only one belonged to the CSIA. Control system integration and robotic system integration industries seem to have little overlap, even though both cover industrial automation. This divide is also evident in engineering specialties performed by the 2013 SI Giants (see table on page 52). Robotics (32%), vision systems (33%), and automated assemblies (33%) are the three least-common specialties performed, while automation and control engineering (95%), installation and start-up (93%), and HMI and operator interfaces (92%) round out the top three. Among automation system integrators in general, automation and programmable logic controller (PLC) skills were not so dominant (56% and 63%, respectively), but still well ahead of robotics and vision systems (32% and 30%, respectively). Other professional organizations that gained popularity among the SI Giants included Underwriters Laboratories (UL), the Project Management Institute (PMI), and the National Society of Professional Engineers (NSPE). Comparing the 2012 and 2013 SI Giants data, UL increased from 19% to 39%; PMI increased from 11% to 24%; and NSPE increased from 10% to 24%. The International Society of Automation (ISA) remained in the top ve as the third most-cited professional afliation, with 34% in 2013 vs. 38% in 2012. Rounding out the top 10 afliations were the National Fire Protection Association (NFPA, 25%), the Control Systems Society (CSS, 20%), the International Society of Pharmaceutical Engineers (ISPE, 18%), the Institute of Electrical & Electronics Engineers (IEEE, 17%), and the American Society of Mechanical Engineers (ASME, 17%). Most of these professional/third-party organizations are dedicated to the practice of various technical disciplines, which makes sense considering what automation system integrators do for a living. The list of most-cited professional afliations among other integrators was similar: ISA, IEEE, CSIA, UL, CSS, NFPA, ASME, NSPE, and PMI. ISPE was the 2013 SI Giants only top 10 professional afliation associated with a specic industry. It did not make the top 10 list for automation system integrators in general, but even for that group, ISPE was still the most popular of all professional organizations that focus on an industry rather than a technology. Ironically, pharmaceuticals as an industry
Industries served
Robotics vs. controls
48
Monday
Tuesday
Wednesday
Thursday
Friday
Saturday
How do you manage change? Invensys and its Partner Ecosystem help.
Invensys MES software, coupled with its Partner Ecosystem, bring you unmatched capabilities to meet any manufacturing challenge. Solutions to meet quality, safety, or compliance needs are just a call away. For more information, visit wonderware.com/partnersolutions.

Copyright 2013. All rights reserved. Invensys, the Invensys logo, Avantis, Eurotherm, Foxboro, IMServ, InFusion, Skelta, SimSci-Esscor, Triconex and Wonderware are trademarks of Invensys plc, its subsidiaries or affiliates. All other brands and product names may be trademarks of their respective owners.
Industries Served - Big 6

Food, beverage, and allied industries (including baking, confections, and snack foods) ....... 10% Oil and gas (including exploration, production, transportation, and distribution)........................ 8% Chemicals and petrochemicals (products and processing) .............................................. 6% Automotive (components and manufacturing)................................................................... 6% Water and wastewater .............................................................................................. 6% Pharmaceuticals manufacturing................................................................................ 5%
Business from Existing Clients

What percentage of business in 2012 was from existing clients? (not rst-time clients)
44%
Food and beverage, oil and gas, chemicals and petrochemicals, automotive, and water and wastewater are the top ve industries for the 2013 SI Giants.
30% 9% 3% 3%
12%
was not as popular with the 2013 SI Giants or the other integrators listed in the AIG. Only 5% of the 2013 SI Giants serve the pharmaceutical manufacturing industry (see the chart on page 50), up 2% from 2012. Despite the industrys increased popularity, pharmaceuticals still only accounted for half as much revenue as the most-served industry on the list: food and beverage (10%). The formerly most-served industry, oil and gas, dropped from 11% in 2012 to 8% in 2013. Rounding out the top ve were chemicals and petrochemicals (6%), automotive (6%), and water/wastewater (6%), about the same as last year. It is interesting to note that only one of these top ve industries served, automotive, is discrete, and of the top 10, theres only one more, material handling (4%). The remaining industries are process or hybrid industries: metals (4%), consumer products (4%), and processing (3%). Perhaps the simplest explanation is that the reneries, foundries, and processing plants of process industries generally operate on a much larger scale, with the exception of automotive plants of discrete industries, requiring the largest system integrators. The divide between the SI Giants and robotic system integrators came up again when the SI Giants were asked about vendors products they have integrated in the past 12 months. The most-cited robotics vendors were ABB with 55% popularity and Mitsubishi Electric Automation with 32%. But even those results are probably overestimates of the SI Giants involvement in robotics since ABB and Mitsubishi offer other automation products, and the product experience question did not specify divisions. Which brands proved popular with the SI Giants? The Product Experience table (only online at www.controleng. com/giants) shows that Rockwell Automations Allen-Bradley brand from 71% in 2012 to 92% this year. The Rockwell
0-10%
11-30%
31-50%
51-75%
76-90%
91-100%
More than half (56%) of 2013 SI Giants derive 76% to 100% of current business from existing clients.
Automation brand itself increased to 89%, and Rockwell Software completed the Rockwell hat trick at 86%, up from 55% in 2012. While the defending champion, Siemens Industry, fell to beneath the three Rockwell Automation brands with 79% this year, that popularity score improved from 71% in 2012. Invensys Wonderware also increased to 80%, up from 68% last year. The biggest gainers in this years product experience list were Microsoft (82%) and Dell (81%). Last year, they were 53% and 42%, respectively. These results would suggest that the SI Giants have become even more partial to product vendors offering PLCs, HMI software, and the personal computers (PCs) required to program PLCs and host HMI software. The Engineering Specialties table on page 52 indicates that HMIs (92%) as a speciality are only slightly more selected by the 2013 SI Giants than PLCs (91%). Only the more generic skills of automation and control engineering (95%) and installation/start-up (93%) placed higher. Ironically, the SI Giants did not identify PCs as a particularly popular engineering specialty, in spite of their afnity for Dell and Microsoft. In 2013, only 58% of rms listed PCs as an engineering specialty, up 30% from 2012. Keeping consistent with the 2013 SI Giants top ve ranking of PMI, project management is an engineering speciality offered by 90% of the rms, up from 52% in 2012.
Product experience
Engineering specialties
50
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Structured as a Main Automation Contractor, Prime Controls provides customers a sole source solution for Industrial Automation challenges.
Along with all of these services, we are focused on safety, quality, and improving our customers efciencies and protability, giving them the competitive advantage. Why choose Prime Controls?
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Our experience and focus: Oil and Gas Production and Distribution Water and Wastewater Semiconductor Fabrication Critical Infrastructure and Utilities Food and Beverage General Manufacturing applications Services include: System Design Application Engineering DCS / PLC Programming Equipment Installation 24/7 Maintenance Services
As a dedicated systems integrator, Prime Controls is professionally staffed with over 250 employees to supply the customer with all aspects of their Instrumentation and Control needs. Headquartered in Dallas, TX with ofces throughout the South Central US, Prime Controls successfully executes projects throughout the United States. Want to learn more? Visit www.prime-controls.com
Tel: 972.221.4849 | Fax: 972.420.4842 | sales@prime-controls.com | www.prime-controls.com

Engineering Specialties
95% 93% 92% 91% 90% 90% 87% 85% 85% 85% 82% 82% 81% 81% 80% 79% 79% 79% 79% 77% 75% 74% 74% 72% 70% 59% 59% 59% 58% 49% 42% 33% 33% 32% Automation and control engineering (including designs and implementation) Installation and start-up Human-machine interfaces and operator interfaces Programmable logic controllers (including installation and programming) Process control and automation Project management Data collection and reporting (including historians) Control panels (including fabrication, installation, and UL listing) Networking and communications (including eldbus, Ethernet, and telemetry) Systems engineering (including design and integration) Computer engineering - software and programming SCADA (supervisory control and data acquisition) Instrumentation and data acquisition Training and education Turnkey systems Discrete and sequential control Factory automation Field service Motors, drives, and motion control (including ac, dc, and variable frequency drives) Batch control (including recipe management) Project planning and consulting CAD/CAM, drafting, and documentation Data processing and database management (including SQL programming) Supervisory control Designs and speci cations (including P&ID development) Distributed control systems (DCSs) Electrical/electronics engineering (including electrical contracting) Product tracking and identi cation (including bar codes and radio frequency tags) Personal computers (PCs) Machine design and controls Water, wastewater, and groundwater systems Automated assembly Vision systems (including image processing and OCR) Robotics
Automation and controls, PLCs, installation and start-up, HMIs and operator interfaces (OIs) are among leading engineering specialties for the 2013 SI Giants.
The 2012 SI Giants top 10 engineering specialties were virtually identical as were the 2013 top 10 engineering specialties cited by other integrators in the AIG, though this years popularity scores for SI Giants were considerably higher than both. These results also were consistent with the SI Giants afnity for the CSIA and Rockwell Automation. All of the top 10 engineering specialties are integral to the practice of automation system integration, Rockwell Automation has signicant market share for the products involved (at least in North America), and the CSIA is the control system integrators most popular association, just as its name implies. In a open-ended response, by far the challenges most often cited by the surveys respondents focused on nding, training,
and compensating the skilled labor they need. Last years top issue, the economy, came in a distant second for 2013. This result seems to reect the overall optimism about the economy in general and the automation industry in particular as reported by the CSIA in its own recent survey. (See System integrators worldwide expect revenue growth in 2013 at www.controleng. com.) Business seems to be so good that business-growth issues barely registered in respondents comments this year. Perhaps the 2013 SI Giants already have their hands full, but theres a hidden danger in complacency. In response to a separate survey question, the SI Giants estimated their business percentage from existing clients, which showed that a whopping 86% of all respondents rely on existing clients for at least half of their revenue, and 12% rely on existing clients almost exclusively. Repeat business is desirable, but what happens when projects run out? Presumably, there must come a time when even the most loyal client nds that everything that can be automated has been. But only three of the 2013 SI Giants cited nding new customers as a current challenge. Apparently, the rest of the SI Giants plan to cross that bridge when they come to it. Another challenge was geographical expansion. One SI Giant expressed interest in offering more services in more places, compared to 21 in 2012. It could be argued that trying to cover additional territory without opening new ofces could be futile since clients would rather hire an integrator that can be on site within a matter of hours rather than days. (See the Areas Served charts online at www.controleng.com/giants.) In conclusion, after two years worth of data collection from the System Integrator Giants, it remains apparent that system integrators continue to be a key component in the everevolving industrial manufacturing landscape. ce - Vance VanDoren, PhD, PE, edits the Control Engineering Automation Integrator Guide. Patrick Lynch, project manager, provided data collection/analysis. Edited by Mark T. Hoske, content manager, Control Engineering, mhoske@cfemedia.com and Amanda McLeman, project manager.
Go Online
At www.controleng.com/archive: Take a survey about system integration with this article June 2013 See more tables, read more from system integrators about challenges See the SI Giants for 2012 at www.controleng.com/giants A no-cost listing in www.controleng.com/integrators is the first step for any automation, controls, instrumentation system integrator to be considered for SI Giants in 2014.
Challenges and opportunities
52
In the second year of CFE Media SI Giants, 65 companies that didnt respond last year are ranked in the 2013 list of 100 largest by automation system integration revenue, providing a much larger set of companies, overall. Until the 94th ranking, all the 2013 rms have greater system integration revenue than those in the 2012 list. Only those ranked 96-100 had less system integration revenue than those 2012 rankings.
2013 SI Giants (by system integration revenue)

ra nk Ow * ne rs hi p ty pe To ta lg sc ro al ss ye re ar ve ( $ nu US e fo To ) r ta re l sy ve st nu em e i ( $ nt Pe US egr rc ) ati fro en on m tag sy e o st f em re in ven te ue Co gr rp at io or n at e ad dr es s 20 13 Co ran m k pa ny na m e ad dr es s W eb
www.mwgroup.net www.mustangeng.com www.mavtechglobal.com www.prime-controls.com www.optimation.us www.manganinc.com www.ekb.nl www.callistointegration.com www.avanceon.com www.averna.com www.intechww.com www.matrixti.com www.avtron-ia.com www.premier-system.com www.enengineering.com www.etech-group.com www.saic.com/engineering www.Testengeer.com www.conceptsystemsinc.com www.ace-net.com www.masmec.com www.thermosystems.com www.bwdesigngroup.com www.indicon.com www.interstates.com
1. 2. 3. 4. 5. 6. 7. 8.
M+W Automation Wood Group Mustang ** Maverick Technologies ** Prime Controls L.P. Optimation Technology Inc. Mangan Inc. ** EKB Callisto Integration (Aseco **, PS2 merged) Avanceon Averna 6 4 11 1 3
20 12
Private Public Private Private Private Employee Public
$3,500,000,000 $102,000,000 $80,000,000 $65,235,302 $61,208,000 $52,000,000 $36,976,989
$150,000,000 $95,000,000 $64,800,000 $45,956,701 $45,500,000 $41,600,000 $36,976,989
4% 93% 81% 70% 74% 80% 100%
Lotterbergstr. 30, 70499 Stuttgart, Germany 16001 Park Ten Pl., Houston, TX, 77084, USA 265 Admiral Trost Dr., Columbia, IL, 62236, USA 815 Of ce Park Cir., Lewisville, TX, 75057, USA 50 High Tech Dr., Rush, NY, 14543, USA 1500 W. Carson St., Ste. 100, Long Beach, CA, 90810, USA Wijkermeerweg 31, 1948 NT, Beverwijk, The Netherlands
Private Private Private Private 10 22 Private Public Private 14 Private Private
$32,000,000 $32,000,000 $37,000,000 $38,124,319 $29,006,654 $35,000,000 $29,500,000 $62,300,540 $17,000,000
$30,000,000 $24,000,000 $24,000,000 $23,447,318 $23,205,323 $20,000,000 $19,800,000 $17,078,045 $17,000,000
94% 75% 65% 62% 80% 57% 67% 27% 100%
635 Fourth Line, Unit 16, Oakville, Ontario, L6L 5B3, Canada 180 Sheree Blvd., Ste. 1400, Exton, PA, 19341, USA 87 Prince, Montreal, Quebec, H3C 2M7, Canada 4903 W. Sam Houston Pkwy., North, Ste. A-100, Houston, TX, 77041, USA 1760 Indian Wood Cir., Maumee, OH, 43537, USA 7555 E. Pleasant Valley Rd., Bldg. 100, Independence, OH, 44131, USA 140 Weakly Lane, Smyrna, TN, 37167, USA 28100 Torch Pkwy., Ste. 400, Warrenville, IL, 60555, USA 5530 Union Centre Dr., West Chester, OH, 45069, USA
9. 9.
11. Intech Process Automation 12. Matrix Technologies Inc. ** 13. Nidec Avtron Automation Inc. 14. Premier System Integrators 15. EN Engineering LLC 16. E-Technologies Group 16. SAIC Energy, Environment & Infrastructure LLC ** 16. Testengeer Inc. 19. Concept Systems Inc. ** 20. Applied Control Engineering Inc. 21. Masmec SpA 21. Thermo Systems LLC 23. Barry-Wehmiller Design Group 24. Indicon Corp. 25. Interstates Control Systems Inc. **
48 13
Private Employee Private
$659,075,000 $26,000,000 $16,700,000
$17,000,000 $17,000,000 $16,700,000
3% 65% 100%
9400 N. Broadway, Oklahoma City, OK, 73114, USA 3777 Hwy. 35 South, Port Lavaca, TX, 77979, USA 1957 Fescue St. SE, Albany, OR, 97322, USA
16
Private Private Private
$15,900,000 $15,700,000 $25,500,000
$15,900,000 $15,700,000 $15,700,000
100% 100% 62%
700 Creek View Rd., Newark, DE, 19711, USA Via dei Gigli, 21, Modugno, 70026, Bari, Italy 84 Twin Rivers Dr., East Windsor, NJ, 08520, USA
Private Private
$196,544,057 $38,000,000
$14,163,937 $14,000,000
7% 37%
8020 Forsyth Blvd., St. Louis, MO, 63105, USA 6125 Center Dr., Sterling Heights, MI, 48312, USA
19
Private
$18,500,000
$14,000,000
76%
444 12th St. NE, Sioux Center, IA, 51250, USA
2012 rank notes 1 - as Mustang Automation & Control 22 - as Avtron Industrial Automation
53

www.vfd.com www.champtechnology.com www.industrialsystems.ru www.hollandertechniek.nl www.icshealyruff.com www.i2r.com www.kahlerautomation.com www.jmpeng.com www.getmatrixed.com www.mlr.de www.faithtechnologies.com www.spiratec-solutions.com www.avidsolutionsinc.com www.innovativecontrols.com www.tricore.com www.ausenco.com www.aesolns.com www.SuperiorControls.com www.atcss.com www.a-cc.com www.theescogroup.com www.calbay.com www.direct-automation.com www.zarpac.com www.malisko.com www.cotmacelectronics.com
26. Five Star Electric 27. Champion Technology Services Inc. 28. Insist Avtomatika 29. Hollander Techniek 29. ICS Healy-Ruff 29. Integrity Integration Resources (I2R) ** 29. Kahler Automation Corp. 33. JMP Engineering ** 34. Matrix Design Inc. 35. MLR System GmbH 36. Faith Technologies 37. SpiraTec 28 8
20 12
Private
$68,000,000
$13,600,000
20%
4729 Shavano Oak, San Antonio, TX, 78249, USA
20 17
Private Private Private Private
$22,720,000 $14,837,000 $85,241,278 $15,000,000
$12,950,000 $12,218,741 $12,000,000 $12,000,000
57% 82% 14% 80%
11824 Market Place Ave., Baton Rouge, LA, 70816, USA 18-1A Marx St., Omsk, 644042, Russia Boogschutterstraat 30, Apeldoorn, 7324 AG GLD, The Netherlands 13005 16th Avenue North, Ste. 100, Plymouth, MN, 55441, USA
Private Private Private Private Employee Private Private/ Employee Private Employee Private Public Private Private Private
$29,500,000 $14,000,000 $19,245,000 $11,200,000 $15,641,333 $261,000,000
$12,000,000 $12,000,000 $11,850,000 $10,990,000 $10,948,933 $10,535,000
41% 86% 62% 98% 70% 4%
4001 E. Plano Pkwy., Ste. 500, Plano, TX, 75074, USA 808 Timberlake Rd., Fairmont, MN, 56031, USA 4026 Meadowbrook Dr., Unit 143, London, Ontario, N6L 1C9, Canada 1627 Louise Dr., South Elgin, IL, 60177, USA Voithstrasse 15, Ludwigsburg, 71640, Germany 225 Main St., Menasha, WI, 54952, USA
$12,185,000 $15,236,000 $104,000,000 $10,173,595 $633,500,000 $29,000,000 $9,400,000 n/a
$10,525,000 $10,281,000 $10,200,000 $10,173,595 $10,120,544 $9,396,000 $9,000,000 $8,800,000
86% 67% 10% 100% 2% 32% 96% n/a
1839 Ygnacio Valley Road, #390, Walnut Creek, CA, 94598, USA 2875 Ridgewood Park Dr., Winston-Salem, NC, 27107, USA 624 Reliability Cir., Knoxville, TN, 37932, USA 6921 Mariner Dr., Racine, WI, 53406, USA 1320 Willow Pass Rd., Ste. 300, Concord, CA, 94520, USA 250 Commonwealth Dr., Ste. 200, Greenville, SC, 29615, USA 135 Folly Mill Rd., Seabrook, NH, 03874, USA 2080 Nelson Miller Pkwy., Louisville, KY, 40223, USA
38. Avid Solutions 39. Innovative Controls 40. TriCore Inc. 41. Ausenco 42. aeSolutions 43. Superior Controls Inc. ** 44. Alliant Technologies 45. Automation & Control Concepts Inc. 46. ESCO Automation 47. Cal-Bay Systems 47. Direct Automation LLC 47. Zarpac Inc. 50. Malisko Engineering Inc. 51. Cotmac Electronics Pvt Ltd. 40
37 18
Private Private Private Private Public Private Private
$8,353,000 $38,100,000 $8,000,000 $10,000,000 $11,000,000 $8,500,000 $37,735,849
$8,353,000 $8,100,000 $8,000,000 $8,000,000 $8,000,000 $7,600,000 $7,547,169
100% 21% 100% 80% 73% 89% 20%
1310 Papin St., St. Louis, MO, 63129, USA 3450 3rd St., Marion, IA, 52302, USA 3070 Kerner Blvd., Ste. B, San Rafael, CA, 94901, USA 408 N. Hwy. 77, Dell Rapids, SD, 57022, USA 1185 North Service Rd. East, Oakville, Ontario, L6H 1A7, Canada 707 N. 2nd St., Ste. 650, St. Louis, MO, 63102, USA S-168, MIDC, Bhosari, Pune, Maharashtra, 411026, India
54

www.rdcustomautomation.com www.cougar-automation.com www.dynamicdesignsolutionsinc.com www.pattieng.com www.stratusauto.com www.iastech.com.br www.automationgroup.com www.integro-tech.com www.advancedintegrationgroup.net www.itac.us.com www.nexjen.com www.cogentind.com www.PhantomTechnical.com www.customcontrol.net www.mikrokontrol.rs www.ecn.com.mx www.merteknc.com www.optimacs.com www.trimaxsystems.com www.machinevc.com www.lomancsi.com www.aaronct.com www.indpg.com www.pro-at.nl
52. R+D Custom Automation 53. Cougar Automation Ltd. 54. Dynamic Design Solutions Inc. 55. Patti Engineering Inc. ** 56. Stratus Automation 57. IASTech Automacao de Sistemas Ltda. 58. Industrial Automation Group 59. Integro Technologies Corp. 60. Booth Welsh 61. Advanced Integration Group Inc. 62. Industrial TurnAround Corp. (ITAC) 63. Nexjen Systems LLC 64. Cogent Industrial Technologies Ltd. 65. Phantom Technical Services Inc. 66. Custom Controls Technology Inc. 84 67. Mikro Kontrol Doo. 68. Electro Controles del Noroeste, S.A. de C.V. 69. Mertek Solutions Inc. 70. Optima Control Solutions Ltd. 71. Trimax Systems Inc. 72. Machine Vision Consulting Inc. 64 73. Loman Control Systems Inc. 74. Aaron Associates of Connecticut Inc. 75. Industrial Process Group LLC 76. Pro-AT BV 68 76 53 55 38 41
20 12
Employee Private Private Private Private
$8,200,000 $8,253,968 $6,150,000 $6,700,000 $7,260,000
$6,970,000 $6,603,174 $6,150,000 $5,900,000 $5,780,000
85% 80% 100% 88% 80%
23411 W. Wall St., Lake Villa, IL, 60046, USA Birch House, Forest Rd., Waterlooville, Hampshire, PO7 6XP, U.K. 3565 Centre Cir., Fort Mill, SC, 29715, USA 2110 E. Walton Blvd., Auburn Hills, MI, 48326, USA 22613 68th Ave S., Kent, WA, 98032, USA Rua Sansao Alves dos Santos, 76 - 4 andar - Brooklin Novo, Sao Paulo, SP, 04571-090, Brazil 1340 Coldwell Ave., Modesto, CA, 95350, USA 305 N. Lee St., Salisbury, NC, 28144, USA
$7,500,000 $7,400,000 $5,500,000 $22,700,000
$5,625,000 $5,600,000 $5,500,000 $5,150,000
75% 76% 100% 23%
First Ave., Stevenston Industrial Estate, Ayrshire, KA20 3LR, Scotland www.boothwelsh.co.uk
Private
$7,082,560
$5,052,000
71%
1 McCormick Rd., McKees Rocks, PA, 15136, USA
Private Private
$42,000,000 $5,500,000
$4,600,000 $4,500,000
11% 82%
13141 N. Enon Church Rd., Chester, VA, 23836, USA 5933 Brookshire Blvd., Charlotte, NC, 28216, USA Unit 180 - 13091 Vanier Pl.,
$4,400,000 $3,896,536 $4,275,250 $7,800,000
$4,400,000 $3,896,536 $3,785,900 $3,600,000
100% 100% 89% 46%
Richmond, British Columbia, V6V 2J1, Canada 111 Outerbelt St., Columbus, OH, 43213, USA 705 W. 20th St., Hialeah, FL, 33010, USA Vase Pelagica 30, Belgrade, 11040, Serbia Boulevard Paseo Rio Sonora Sur No. 69, Hermosillo, Sonora, 83270, Mexico 3913 Hawkins Ave., Sanford, NC, 27330, USA Blakewater Rd., Blackburn, Lancashire, BB1 5QR, U.K. 565 Explorer St., Brea, CA, 92821, USA 69 Milk St., Ste. 217, Westborough, MA, 01581, USA 143 E. 28th Division Hwy., Lititz, PA, 17543, USA
Private Employee Private Private Private Private
$19,400,000 $4,000,000 $3,336,000 $5,199,518 $3,200,000 $3,900,000
$3,560,000 $3,500,000 $3,336,000 $3,328,239 $3,200,000 $3,128,000
18% 88% 100% 64% 100% 80%
74
Private Private Private
$3,330,000 $3,738,644 $3,200,000
$3,000,000 $2,845,185 $2,800,000
90% 76% 88%
478 W. Main St., Waterbury, CT, 06723, USA 111 E. Mildred St., Logansport, IN, 46947, USA Kubus 70, Sliedrecht, Zuid-Holland, 3364 DG, Netherlands
55

www.processplus.com www.riverconsulting.com www.adaptiveresources.com www.synsysinc.com www.control-associates.com www.jordansynergist.com www.kaier.net www.nextautomation.com.br www. tchcompany.com www.smithcontrols.net www.georgethall.com www.apexmfgsolutions.com www.cqsinnovation.com www.genesyscontrols.com www.auto-eng.net www.northwindts.com www.agatos.com www.projectweb.it www.plantwerx.com.sg www.synergetech.com www. owdynamics.net www.esr-systemtechnik.de www.kccsoftware.com www.avisonelectrical.com
20 12
87 97
Private/ 77. Process Plus LLC 78. River Consulting LLC 79. Adaptive Resources Inc. 79. Synergy Systems Inc. 81. Control Associates Inc. 82. Jordan Engineering Inc. 83. Kaier Engineering 84. Next Automation Focus Solution Group 84. The Fitch Company 86. Smith Controls 87. George T. Hall Co. Inc. 88. Apex Manufacturing Solutions 89. CQS Innovation Inc. 90. Genesys Controls Corp. 91. Automation Engineering 92. NorthWind Technical Services 93. Agatos Software Engineering Pte. Ltd. 94. Project S.R.L. 95. Plant Werx Pte. Ltd. 96. Synergetech Co. Ltd. 97. Flow Dynamics and Automation 98. ESR-Systemtechnik GmbH 99. KCC Software 100. Avison Electrical Private Private Private Private Private Private Private Private $2,500,000 $1,300,000 $1,200,000 $2,000,000 $8,000,000 $1,950,000 $225,000 $850,000 $1,300,000 $1,000,000 $960,000 $500,000 $400,000 $300,000 $225,000 $90,000 52% 77% 80% 25% 5% 15% 100% 11% 91 81 63 Employee Private Private Private Private Private Private Private Private $3,600,000 $4,100,000 $2,900,000 $15,500,000 $1,963,747 $2,300,000 $3,500,000 $6,294,586 $2,600,000 $2,200,000 $2,200,000 $1,980,000 $1,900,000 $1,842,730 $1,650,000 $1,500,000 $1,434,820 $1,350,000 61% 54% 68% 12% 94% 72% 43% 23% 52% Av Angelica 2223, So Paulo, 01227-20, Brazil 631 Hammond St., Bangor, ME, 04401, USA 1839 Route 9H, Hudson, NY, 12534, USA 1605 Gene Autry Way, Anaheim, CA, 92805, USA 408 E. Parkcenter Blvd., Ste. 200, Boise, ID, 83706, USA 2390 Pipestone Rd., Benton Harbor, MI, 49022, USA 1917 Olde Homestead Ln., Lancaster, PA, 17601, USA 100 North Main, Hackett, AR, 72937, USA 2751 Antelope Rd., Sabetha, KS, 66534, USA Blk 67, Ayer Rajah Crescent, #07-18, Singapore, 139950, Singapore Via Don Lorenzo Perosi, 50, Firenze, 50127, Italy 51 Bukit Batok Crescent, #09-02, Singapore, 658077, Singapore 31/65 Moo 6 Pracharaj Rd., Taladkwan, Muang, Nonthaburi, 11000, Thailand 1024 11th Court West, Birmingham, AL, 35204, USA Waiblinger Strasse 56, Fellbach, 70734, Germany 830 Eldorado Ave. SE, Huntsville, AL, 35802, USA 592 Collins Dr., North Bay, Ontario, P1B 8G3, Canada 67 Employee Private Private Private Employee Private Private $16,100,000 $27,392,098 $3,500,000 $3,100,000 n/a $2,316,361 $3,000,000 $2,660,757 $2,591,479 $2,500,000 $2,500,000 $2,400,000 $2,316,361 $2,250,000 17% 9% 71% 81% n/a 100% 75% 1340 Kemper Meadow Dr., Cincinnati, OH, 45240, USA 445 Hutchinson Ave., Ste. 740, Columbus, OH, 43235, USA 104 Broadway St., Carnegie, PA, 15106, USA 1982 Ohio St., Lisle, IL, 60532, USA 20 Commerce Dr., Allendale, NJ, 07401, USA 4516 Mountainview Rd., Beamsville, Ontario, L0R 1B3, Canada 106 Commerce Blvd., P.O. Box 503, Lawrence, PA, 15055, USA
Notes * 2013 rank could be lower and system integration revenue higher: 65 names are new to the ranking in 2013. See the 2012 SI Giants listing at www.controleng.com/giants. ** Control Engineering named three rms System Integrator of the Year annually since 2007 in three revenue classes; 12 are included here.
After deadline, two rms asked that their total revenue not be reported. Firms not allowing requested data points will not be included in the 2014 ranking.
ONLINE: More graphics, links to related content at June 2013, www.controleng.com/archive Not here? Process starts with a listing at www.controleng.com/integrators. System Integrator of the Year deadline is Aug. 1: www.controleng.com/SIY
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WindPower 2013:
Fair winds in Chicago

The American Wind Energy Associations annual conference and exhibition, WindPower 2013, showed how automation and controls help the manufacturing and use of wind-power technologies.
indPower 2013, at Chicagos McCormick Place, May 5-8, discussed policies, technologies, and benefits related to wind power. Speakers at WindPowers opening general session included Gov. Terry Branstad of Iowa, who understandably conveyed enthusiasm for wind energy, given the states enviable position of having the third largest installed capacity of wind power in the U.S., after Texas and California. Iowa also claims the highest average electricity generation from wind power of any U.S. state, currently running at 24.5%. Gov. Branstad said Iowa Go Online accounts for an estimated 7,000 wind-energy related jobs, ranking the state No. 1 in that catAt www.controleng.com/ archive, read this article for egory. Branstad added that policy stability and more details and links to: predictability are key requirements for the wind industrys long-term success. n Direct-drive wind turbines flex muscles Tom Kiernan, incoming CEO of the American Wind Energy Association (AWEA), stressed the n U.S. Department of Energy need to create a fresh long-term plan for the wind interactive Wind Manufacturing Map power industry and AWEA. Kiernan begins his tenure with AWEA on May 28. n www.windpowerexpo.org Approximately 600 companies exhibited n 8 related organizations products at WindPower 2013. One of the scientific sessions Innovative Wind Turbine Components R&D, moderated by Dr. D. Todd Griffith, offshore wind technical lead at Sandia National Laboratoriesfocused on turbine blades, gearboxes, and sound mitigation. Experimental and Wind power encompasses various technologies Computational Study besides the turbine. Among these technologies, of Dynamic Transient represented at WindPower 2013, were motors, Loads in a Wind Turdrives, control subsystems, switch gear, generators, bine Gearbox was converters, transformers, electric substations, and the topic from Zhiyu grid connections. Courtesy: ABB. www.abb.com Jiang, PhD candidate,
Frank J. Bartos, PE
M1
Norwegian University of Science and Technology (NTNU). The paper covered research on gearbox modeling and testing by the Gearbox Reliability Collaborative project of the National Renewable Energy Laboratory in the U.S. and the NTNU. One project objective was to evaluate gearbox response under field conditions. Current work has expanded into field-test measurements and greater emphasis on gearbox transient eventsafter validation of dynamometer test measurements performed earlier, according to Zhiyu Jiang. Two cases of gearbox transient events examined were start-up and emergencystop. The gearbox was heavily instrumented with sensors to measure strains and loads; however, only planetary bearing loads were measured, he noted.
Gearbox standard
Brian McNiff, owner of McNiff Light Industry, reviewed A New International Wind Turbine Gearbox Standard. Under development for 6 years, a new international standard on wind turbine gearing has been published. The new International Electrotechnical Commission standard is IEC 61400-4 Ed. 1.0, Wind turbines - Part 4: Design requirements for wind turbine gearboxes. IEC 61400-4 applies to enclosed speed-increasing gearboxes for horizontal-axis wind turbine drive trains with power rating greater than 500 kWincluding onshore or offshore installations. IEC 61400-4 includes greater analysis of gearbox structures; dynamometer testing of any new or modified gearbox design; recommendations for lubricant performance, including filtering and cleanliness requirements; and cooling requirements. IEC 61400-4 provides guidance on gearbox design, performance, manufacture, and testing specifically for wind turbine application. AWEA runs various programs and events nationally. WindPower 2014 is scheduled for May 5-8, 2014, in Las Vegas, Nev. ce - Frank J. Bartos, PE, is a Control Engineering contributing content specialist. Reach him at braunbart@sbcglobal.net.
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Automation 3200 Motion and PLC
Packaging company saves thousands on vacuum system costs

Energy audits estimate at least 25% reduction in annual operating costs for bag-making machines after adding motor drives and a new monitoring system.
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High performance Advanced controls for superior contouring, in-position stability, move and settle, and velocity control Reduced setup time Integrated calculators and extensive diagnostics Ease of use One software environment: .NET, C, G code, LabVIEW, or AeroBasic input #30 at www.controleng.com/information Ph: 412-963-7470 Email: sales@aerotech.com www.aerotech.com Dedicated to the
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he Trinity Packaging plant in Pueblo, Colo., converts blown film into retail plastic bags and wanted to increase the efficiency of doing so. The converting facility has a variety of specialized equipment to create bags with complex features, such as multi-colored printing or airtight closures. The project began with the goal of improving the efficiency of wicket-style bag-making machines. Five wicket style bag making machines use aluminum arms with vacuum holes to grab the bag after it has been cut. The vacuum holes then stack the bag on a conveyor. Roots blowers develop the required vacuum pressure; they are multistage blowers with several fans stacked together. The goal was to cut costs and increase efficiency by improving the vacuum system. When the project started, each bagging machine required two centrifugal blowers, each using a 10 hp motor running at full rated speed to create the required vacuum. Two blowers per machine were used. The pumps sucked much of the petroleum waste released into the air as a result of the bag cutting and sealing process. As residue builds up on the blowers, the vacuum suction would weaken, making the blowers very inefficient. There was no way to accurately monitor the machines to assess the amount of residue buildup, so two blowers had to run all the time to ensure sufficient vacuum. Moreover, blowers couldnt be shut down when the machines werent running, because the amount of residue
buildup would often cause the pumps to lock up and trip the control system at start-up. Furthermore, the motors always ran at full speed even when the process didnt need that much vacuum.
Maintenance, total costs
A pilot project on one machine aimed to improve efficiency and overall operations. The first step was to install vacuum pressure transmitters at the inlet of the pumps. Five transmitters were installed to measure the actual vacuum pressure at the pump and send an analog signal to the input card in the machines programmable logic controller (PLC). Alarms provide notification when the pressure increases too high, a sign that filters need to be changed. A low-pressure alarm means the pump lost its belts. A temperature transmitter monitors the drive enclosure to turn the cooling fans off and on. Upon switching to the new system, it seemed as if there was a problem with the controls because one line showed very high pressure. Examination of the machine showed that one vacuum hose had come off and sucked several bags in, a problem that would have gone undetected by the previous system. Moreover, improved monitoring helped with creation of a precise cleaning schedule based on data collected by the transmitters. That information allowed use of the second blower as a backup, instead of having it run all the time, significantly reducing overall equipment and maintenance costs. After being cleaned, the blowers run more efficiently, so motors require less
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These pumps create the required vacuum pressure for the wicket-style bag-making machines. Courtesy: AutomationDirect
power. However, without a variable frequency drive, blower motor speed could not be reduced. A blower was fitted with a drive, and results were monitored for approximately six months. Results showed that when everything is clean, the motor only needs to run at half speed. Now, based on vacuum transmitter readings, the drive increases motor speed automatically as the arms get dirtier to maintain the required vacuum pressure, which increased energy efficiency significantly. The pilot expanded to all wicket-style bag-making machines.
Products used
Enhanced Displays
New blower motor drives dramatically reduce energy costs by allowing motors to run at less than full speed, depending on machine requirements. Courtesy: AutomationDirect
Clarity, Accuracy And Simplicity
The control and monitoring system includes vacuum pressure transmitters, PLCs, and variable frequency drives. Better pressure and vacuum monitoring along with the variable speed motor drives supplied useful data, so an HMI touchscreen panel was added to the control system to display and help interpret data. An Ethernet card in the PLC communicates with the touchscreen HMI. Data can be monitored on the panel or remotely, which speeds response to any possible issues. Drives communicate directly with the HMI using the Modbus protocol. Use of Modbus protocol eliminated a wiring and associated costs, avoiding the need to buy analog sensors to send current, rpm and other readings to the HMI, which transmits that information digitally from each drive to the HMI. It was very easy to program the HMI using the Microsoft Windows-based graphical editor. Creating alarm parameters only required entering setpoints for
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low and high pressure. When an alarm is triggered, it automatically appears on the screen, and an e-mail is sent. Hours of operation for each pump is monitored; an alarm tells when to change the oil to increase operating efficiency and machine life span. If any drive fault, belt failure, or pressure fault occurs, the PLC opens the backup gate and turns the backup pump on. The system then e-mails the event tag from the HMI. This happens instantly and automatically, allowing production to continue as if the event never occurred. As the project progressed, images and specifications for every component used in the system were saved from vendors website. This information was converted into bitmaps, and then imported into the HMI. Now, when information is needed
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This HMI screen displays information from a variable speed drive and associated valving, allowing more precise monitoring and control of machine operation. Courtesy: AutomationDirect
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on any part, it can be pulled up immediately on the plant floor from the HMI touchscreen. The new automation system greatly reduced the amount energy used and cut the number of blowers needed for regular operations in half. This has significantly decreased overall operating costs on these machines. As energy prices continue to rise, the increases have been offset by running the blowers only as needed to maintain sufficient vacuum pressure. The old system needed two 10 hp motors running at full rated speed for the two centrifugal blowers to successfully operate each machine. Removing the need for a second full-time blower on each machine has eliminated approximately one week of maintenance for each pump on the five machines. The load on the remaining motor also has been reduced because the drive can adjust motor speed to deliver only Go Online the amount of vacuum needed to hold the bags in place. At www.controleng.com/ An outside firm hired to perform an archive June 2013, see more energy audit and calculate the overall about the products used. savings used, as a basis, a total annual www.trinitypackaging.com operating cost of $49,000 per year for www.automationdirect.com the wicket bag making machines. The Consider this... audit said operating costs will decrease by $13,000 a year, more than a 25% What efficiencies are you missing by not retrofitting? reduction. A new project using the latest PLCs is underway to upgrade older equipment in other parts of the plant. ce - Charles Landry is maintenance manager, Trinity Packaging Corp. Edited by Mark T. Hoske, content manager CFE Media, Control Engineering and Plant Engineering, mhoske@cfemedia.com.
M5
JUNE 2013 CONTROL ENGINEERING
inside machines
PC-based controls help packaging machines

Bag-in-box food packaging machines from Pattyn Packing Lines embrace modular concepts, adaptability, ease of maintenance, reliability, high ease of operation, and universal high-performance control systems.
ackaging machines, as with mechanical engineering in general, are subject to increasingly higher customer requirements for higher speed, more flexibility, and competitive costs. Machine manufacturers must keep step with respective market developments to survive. Belgian packaging machine manufacturer Pattyn Packing Lines relies on a high degree of automation for its advanced food packaging machines. The company balances performance and cost using PC-based control technology. Requirements for packaging machines follow general mechanical engineering trends for modular concepts, adaptability, ease of maintenance, reliability, high ease of operation, and universal high-performance control systems. Over and above that, a packaging machine must integrate itself seamlessly into the production process so that no goods tailbacks occur, which would lead to bottlenecks, explained Joeri Haegebaert, software manager and quality inspector at Pattyn Packing Lines. With the new Ceflex-21, Pattyn combines the proven technologies of carton forming by vacuum suction and bag insertion into one machine, combining two processes. First the carton is isolated, fixed by vacuum suction, and opened, and the base flap is folded over and glued. Film grippers pull the bag off the roll, open it, and place it precisely inside the carton. The controlled bag enables the reduction of bag dimensions for film savings of up to 30%. The Ceflex-21 has a production capacity of 12 cartons per minute. The integrated bag-in-box packaging machine
Packing machine: compact, efficient
is controlled by an embedded PC with directly connected I/O terminals for EtherCAT Ethernet protocol. Stepper motor terminals control the stepper motors. The machine benefits from the modern drive and control solutions. The rigid compressed-air driven systems for carton forming and the opening and insertion of the bags are replaced today by flexible systems driven by stepper motors. The stepper motor exhibits a favorable torque behavior for such applications, explained Haegebaert. The compact packaging module can be integrated easily into the automated Pattyn packaging line or an existing packaging line. Pressure on machine manufacturers is continually growing. Increasingly complex functions must be implemented with ever increasing efficiency. In addition, it is important to find the correct price-to-performance ratio. That can only be achieved with a high degree of automation, said Haegebaert. Other vendors systems and devices can be integrated without problems and openness of the PC controller makes it easier for us to manufacture custom machines. Also, our customers value the possibility to log directly into a PC environment. After several years, Pattyn decided to standardize on the technology, including touchscreens in the future, said Haegebaert. ce - Information from Beckhoff Automation, edited by Control Engineering.
www.controleng.com
In this Pattyn Packing Lines application, mechanical grippers pull the film bag off the roll, open it, and place it precisely inside the carton. Courtesy: Beckhoff Automation
Go Online
n www.pattyn.com n www.beckhoff.com At www.controleng.com/ archive, June 2013, find more details and photo with this article online.
CONTROL ENGINEERING JUNE 2013 M6
inside machines
Powering reliable entertainment

Mission-critical entertainment may seem like a misnomer, until considering that commercial time for some venues exceeds $1 million per minute, meeting or exceeding downtime costs for many major manufacturing sites.
Greg Hookings
Saunders Electric generator provides quiet reliability using Mitsubishi Electric controls. Courtesy: Mitsubishi Electric Automation
Mitsubishi Electric GT16 Interface screen has an extended viewing angle, enabling operators to be more mobile while the power system is in use. Courtesy: Mitsubishi Electric Automation
Go Online
n www.saunderselectric.com n www.meau.com At www.controleng.com/ archive, read this for more.
M7
aunders Electric, which has been supplying the broadcast industry with reliable power solutions with studio-quiet generators since the early 1990s, knows that in the entertainment business, failure isnt an option. The company actively refines its products and in 1994 began using a rack-style, modular programmable logic controller (PLC) to synchronize generator and landline power sources. This helped create a power signal that more closely replicated the main grid supply. With a higher quality power signal, Saunders Electric can better support the hypersensitive media equipment used in the film and broadcast industry without interruption or degradation of signal during grid outages. Power outages or failures at home or work can create frustration but rarely affect show business. Entertainment industry special events demand perfection, requiring reliable power. As the saying goes: The show must go on. Broadcast and entertainment industry companies rely on portable, temporary power services to eliminate grid outages and brownouts. Saunders Electric has provided products and services to entertainment events, such as: the Academy Awards, the Emmys, the Grammys, the American Music Awards, ESPN college basketball, and others. Saunders Electric upgraded to a new control platform and new human-machine interface (HMI) for improved performance and a more intuitive, visual operator experience. The new generator control system added features and performance available in todays automation controllers. During the selection process, Saunders Electric considered a variety of new automation and control options. However, in an industry where power failure is unacceptable, a track record for outstanding reliability goes a long way in the decision process. After years of using a control system without failure, upgrading to the
next generation was a logical choice. The new controller provides other performance benefits and advantages such as faster processing speeds, advanced analog control, more flexible graphical interface, and a significantly smaller hardware footprint, increasing space in the cabinet for other devices. Saunders Electric benefited from a short implementation time, completing the transition to the new control system in one month. This short implementation period kept costs down, and the company was able to see a return on investment (ROI) more quickly. Adding to power quality, high-speed, digital-to-analog signal conversion permits faster response times when matching generator speed to the grid power signal. This minimizes the effect of overshoot, providing a cleaner power signal for broadcasting equipment. Operator effectiveness was also greatly improved. Extended HMI viewing angle enables operators to be more mobile while the power system is in use. Design software helps create more intuitive screens, improving setup and monitoring efficiencies. Continued reliability was essential to the system upgrade. A hardware and software quality control program provided assurance that the Saunders Electric synchronous power system will keep running, providing highly dependable, temporary power services to the broadcast industry. Hardware includes the CPU, analog module, input module, output module, Modbus master, and HMI. The system provides strong-build quality, high-speed sampling, and intuitive HMI screen designs with greater viewing angle, for higher reliability, improved power quality, and greater operator effectiveness. Saunders Electric cited using the same control systems on our load command systems since 1994 and never had a live show go off the air. ce - Greg Hookings is marketing communications manager, Mitsubishi Electric Automation Inc.
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& software
HMI software platform aims at OEM applications to shorten development time

Eaton has introduced Galileo 8.0, a new software platform for its XV Series of HMIs. Already available in Europe, the software is designed to help OEMs expedite time to market with an easy-to-learn operator interface project design environment. In addition to Galileo, Eaton is introducing six new XV models. The software platform provides project design tools and functionality without graduated restrictions on tags and screens. The software features data bridge functionality and multiple PLC communication driver support. The new XV HMI models are now available with 3.5, 5.7, and 7.0 in. screen sizes. Eaton
www.eaton.com
Enhanced pressure transmitter incorporates features from more advanced models

Yokogawa Corporation of America announced its enhanced DPharp EJA series pressure/differential pressure transmitters, one of its core sensor products, which will be produced in its Newnan, Ga., manufacturing facility to support the North American market. Enhancements include signicantly improved performance and functionality, incorporating the same high-speed response and multi-sensing functionality available with the high-end DPharp EJX series. For safety applications, the enhanced transmitters now comply with the IEC61508 international safety standard on the functional safety of electrical/electronic devices and are certied for use in safety integrity level (SIL) 2 applications as stipulated by the IEC. Yokogawa
www.yokogawa.com/us
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software &
PRODUCTS
Digital panel meters support flow, level, temperature, and pressure applications
Precision Digitals PD765 Trident series digital panel meter is a process meter that features two relays, a 4-20 mA analog output, and a 24 Vdc power supply all in one meter. It is housed in a 3.6 in. deep, 1/8 DIN enclosure that features a NEMA 4X front panel. Two display heights are available: the Trident 0.56-inch (14.2 mm) display, and the Trident X2 1.2 in. (30.5 mm) display pictured. Each display is adjustable to lighting conditions, including direct sunlight, allowing easy reading from up to 30 ft. These can handle a wide range of level, ow, temperature, and pressure applications. Units can be eld programmed to accept process voltage (0-5 V, 1-5 V, etc.) inputs, current (4-20 mA) inputs, 100 Ohm RTDs, and J, K, T, and E thermocouples. Precision Digital Corp., www.predig.com
Multi-touch panel PC designed for manufacturing control, building automation, and HMIs
Advantechs TPC-1840WP is an 18-in. widescreen multi-touch panel PC specically designed to provide easier operation and boost productivity in manufacturing control environments, building automation, and other HMI applications. It features a widescreen 16:9 aspect ratio with multi-touch capabilities to provide high levels of control and viewing information using Advantechs SUSIAccess and WebAccess management software. The TPC-1840WP uses an AMD dual-core processor with an independent graphical processor to support Microsoft Windows 8 and DirectX11 so it can handle more complicated and detailed graphics. Advantech, www.advantech.com
The biggest thing in signal conditioning is only 6 mm wide

The 3000-series of converters and isolators packs the next generation of microprocessor technologies into an ultra-slim 6 mm housing. Featuring exceptionally high signal reliability with 0.05% accuracy and a broad temperature operation range, the 3000 series is the ideal solution for multiple applications in factory automation and the process industry. You can also count on its high safe isolation for excellent process reliability day in and day out. Experience the 3000 factor, only from PR electronics. Learn more on www.prelectronics.com
Ultrasonic flowmeter with measurement redundancy designed for marine and offshore applications
Emerson Process Managements Daniel 3818 liquid ultrasonic owmeter for liqueed natural gas applications is specically designed for reducing ow measurement uncertainty throughout the LNG value chain. This meter is ideal for many marine and offshore applications, including custody transfer and allocation measurement. It provides a linearity within 0.15% and a meter factor uncertainty of 0.027% due to its multi-plane British Gas design, fast signal processing, and advanced transducer technology. With a redundant four-path, multi-plane conguration, the unit utilizes two independent transmitters, one for each set of four chordal paths. This ensures complete measurement redundancy and the ability to poll each four-path meter separately. Emerson Process Management
www.emersonprocess.com
Gigabit high-power injector transmits 60 W for Power over Ethernet devices

Moxas INJ-24A Gigabit high-power PoE+ Injector transmits data and up to 60 watts of power to any PD or PoE (Power over Ethernet) device, allowing devices on 10/100/1000 networks to operate safely with twice the power of conventional PoE+. The unit can adapt quickly to different power standards. By adjusting a DIP switch, the operator can select different power standard modes and even which wire pairs to deliver power on. This allows the INJ-24A to supply power to nearly any PoE device with minimal compatibility obstacles because it can be recongured to match the devices settings. It can transmit data even with potential hazards like power uctuations, static electricity, and other sources of electromagnetic interference. The built-in 24/48 Vdc booster enables the injector to operate on either 24 or 48 Vdc. Moxa, www.moxa.com
PRODUCT & LITERATURE SHOWCASE

More Models, More Protection, Less Noise, Lower Cost
580+ different 5B, 7B, and 8B signal conditioners provide accurate, isolated Instrument Class performance to ensure the integrity of your industrial automation, data acquisition, process control, and quality assurance systems. Custom modules available.
0.03 to 0.05% Accuracy 1500Vrms Isolation Up to 240Vrms Input Protection ANSI/IEEE C37.90.1 Transient Protection 3- to 6-Pole Low-Pass Filtering -40C to +85C Operating Temperature CSA C/US Certified & ATEX Compliant (5B, 7B) C-UL-US Listed (8B)
5B / 7B / 8B Signal Conditioning Solutions
Acromag Signal Conditioners & Ethernet I/O We have the experience to help you solve your process monitoring and control challenges. Get our new product guide today.
NEW! USB Transmitters & Ethernet I/O 4-20mA Isolators and Splitters Ethernet, Modbus, Profibus Remote I/O
877-295-7057 www.acromag.com
I
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Allied Electronics . . . . . . . . . . . . .19 . . . . . 13 . . . . Antaira Technologies LLC . . . . . . .10 . . . . . .7 . . . . . ASCO Valve, Inc. . . . . . . . . . . . . . .29 . . . . . 19 . . . . AutomationDirect . . . . . . . . . . . . .C2 . . . . . .1 . . . . . Baldor Electric Company . . . . . . .9 . . . . . . .6 . . . . . Banner Engineering Corp. . . . . . .25 . . . . . 18 . . . . Data Translation Inc. . . . . . . . . . . .34 . . . . . 22 . . . . CFE Media LLC . . . . . . . . . . . . . . .43 . . . . . . . . . . . . Control Engineering E-Newsletters . . . . . . . . . . . . . . . .66 . . . . . . . . . . . . Eaton Corp. . . . . . . . . . . . . . . . . . .16 . . . . . 10 . . . . Eaton Corp. . . . . . . . . . . . . . . . . . .33 . . . . . 21 . . . . Festo Corporation . . . . . . . . . . . . .22 . . . . . 15 . . . . HELUKABEL . . . . . . . . . . . . . . . . .23 . . . . . 16 . . . . Invensys . . . . . . . . . . . . . . . . . . . .49 . . . . . 26 . . . . Kepware Technologies . . . . . . . . .38 . . . . . 24 . . . . Magnetrol . . . . . . . . . . . . . . . . . . .37 . . . . . 23 . . . . MECHATROLINK Members Association. . . . . . . . . .C3 . . . . . 61 . . . . Moore Industries - Intl. Inc . . . . . .4 . . . . . . .4 . . . . . Moxa Technologies . . . . . . . . . . . .3 . . . . . . .3 . . . . . National Instruments . . . . . . . . . .7 . . . . . . .5 . . . . . Omega Engineering Inc . . . . . . . .1 . . . . . . .2 . . . . . OPTO 22. . . . . . . . . . . . . . . . . . . . .17 . . . . . 11 . . . . Otek Corporation . . . . . . . . . . . . .57 . . . . . 28 . . . . Phoenix Contact . . . . . . . . . . . . . .15 . . . . . .9 . . . . . PI North America. . . . . . . . . . . . . .11 . . . . . .8 . . . . . PR electronics . . . . . . . . . . . . . . . .68 . . . . . 36 . . . . Precision Digital Corp. . . . . . . . . .41 . . . . . 25 . . . . Prime Controls . . . . . . . . . . . . . . .51 . . . . . 27 . . . . Prosoft Technology Inc . . . . . . . . .24 . . . . . 17 . . . . Rittal Corporation . . . . . . . . . . . . .20-21 . . 14 . . . . SEW Eurodrive Inc . . . . . . . . . . . .C4 . . . . . 62 . . . . Siemens Industry Inc . . . . . . . . . .C1, 31 . . 20 . . . . Solutions for Engineers . . . . . . . .42 . . . . . . . . . . . . System Integrator of the Year Awards . . . . . . . . . . . .44 . . . . . . . . . . . . Unitronics . . . . . . . . . . . . . . . . . . .67 . . . . . 35 . . . . Vecoplan LLC. . . . . . . . . . . . . . . . .18 . . . . . 12 . . . . Inside Machines Aerotech Inc . . . . . . . . . . . . . . . . .M3 American Industrial Systems (AIS) . . . . . . . . . . . . . . . .M4 B & R Industrial Automation . . . .M8 Beckhoff Automation LLC. . . . . . .M2 Solutions Direct . . . . . . . . . . . . . .M5 Triangle Research Intl Inc . . . . . . .M5
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CFE Media Contributor Guidelines Overview

Content For Engineers. Thats what CFE Media stands for, and what CFE Media is all about engineers sharing with their peers. We welcome content submissions for all interested parties in engineering. We will use those materials online, on our website, in print and in newsletters to keep engineers informed about the products, solutions and industry trends. www.controleng.com/contribute explains how to submit press releases, products, images and graphics, bylined feature articles, case studies, white papers, and other media. * Content should focus on helping engineers solve problems. Articles that are commercial in nature or that are critical of other products or organizations will be rejected. (Technology discussions and comparative tables may be accepted if non-promotional and if contributor corroborates information with sources cited.) * If the content meets criteria noted in guidelines, expect to see it first on our Websites. Content for our e-newsletters comes from content already available on our Websites. All content for print also will be online. All content that appears in our print magazines will appear as space permits, and we will indicate in print if more content from that article is available online. * Deadlines for feature articles intended for the print magazines are at least two months in advance of the publication date. Again, it is best to discuss all feature articles with the appropriate content manager prior to submission. Learn more at: www.controleng.com/contribute
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We proudly salute manufacturing innovation and invite you to explore and celebrate the success stories of these participating manufacturing innovators:
Allied Electronics ASCO Valve, Inc. Automation Direct Beckhoff Automation Data Translation Inc. Eaton Festo Corporation Invensys Kepware Technologies Lenze Americas Moore Industries Inc. Moxa Americas Inc. National Instruments Omega Engineering Inc. Opto 22 Otek Corporation PMD Corp. Phoenix Contact PI North America Precision Digital Corporation Red Lion Controls SEW-EURODRIVE Siemens Industry, Inc. Yaskawa America, Inc.
Look for the special Innovations videos at: www.controleng.com/innovations
Allied Electronics Celebrates 85 Years of Innovation

For 85 years, Allied Electronics has built an enviable reputation as a distributor of electronic components. Since our conception in 1928, our main pursuit, and now our legacy, has been providing excellence through innovative products and customer service. We were one of the first to sell electronics through a catalog, and we were the first electronics distributor to offer the catalog on CD-ROM. Today, customers can not only browse our 2,200-plus page catalog, but they can easily access more than three million parts at alliedelec.com. We offer first-class customer service, same-day shipping, next-day delivery and a local sales rep is just a phone call away.
A Top 500 e-Retailer

For three consecutive years, Allied Electronics has been named a Top 500 e-Retailer by Internet Retailer, a national business monthly magazine. Allieds 2012 ranking is 126, up three places from last year.
Offering the Best in Automation & Control

Allied Electronics stocks the top brands for automation and control under one roof. From Phoenix Contact and Schneider Electric to Omron Automation and Safety, Allied has the brands customers trust. For two consecutive years, Allied Electronics has been voted as a go-to source for automation and control products by Automation World magazines Leadership in Automation program. The program invites automation professionals to vote for their favorite automation and control vendors through a year-long poll with unaided recall. Allied is one of the few distributors to make this list each year.
The Top 500 Guide is an authoritative ranking and a comprehensive analysis of North Americas 500 largest e-retailers. The rankings are based on annual Internet sales, researched by Internet Retailer,, and confirmed by retailers. This report includes company financial, operational and performance data, as well as vendors in key categories. Learn more about Allied Electronics at www.alliedelec.com, or contact your local sales rep at 1.800.433.5700.
Find us on Facebook: www.facebook.com/alliedelectronics | Follow us on Twitter: @alliedelec Subscribe to our YouTube channel: www.youtube.com/alliedelectronics
New Low-Power Valve Technology Changes the Rules of the Game

ASCO offers new line of .55 watt power consumption solenoid valves
Process plants worldwide often place considerable reliance on low-power solenoid valves. They are used as pilot valves to open and close larger ball or butterfly valves, or on control valves (installed between positioner and actuator) for fail-safe air release if theres a loss of power. A new generation of even lower-power valves is now changing the rules of the power consumption game for project specifiers in the refining, upstream oil and gas, chemical, pharmaceutical and life sciences, food and beverage, and power industries. ASCO is leading the development of low-power solenoid valve technology with a new line of products offering .55 watt power consumption while providing highly reliable operating performance.
Ideal solution for renewable energy-powered applications

The new solenoid valve is an optimal solution for applications powered by renewable energy sources such as solar panels. Its low-power consumption permits the use of smaller battery packs and enables extended operation on the existing back-up energy source. The low-power valve is designed to be wired directly into a plants bus network without the need for auxiliary power source. This means two to three times more devices can be installed on a network segment. In addition, the need for an additional relay is eliminated, plus a smaller power supply can be used reducing the installation and operating costs. The highly flexible valve comes in multiple options for flow efficiency and maximum and minimum temperature and pressure ratings. It has ATEX, FM, CSA, and UL approvals and is SIL-3 certified.
on the market delivers higher performance per watt.
No other solenoid valve
ASCOs new low-power valve is an attractive choice for project and application engineers designing processing systems in remote locations or who want to install more devices directly on their bus networks, said Robert W. Kemple, Jr., Executive Vice President, Sales and Marketing Americas, ASCO Numatics. No other solenoid valve on the market delivers higher performance per watt.
For more information, contact ASCO at 800-972-ASCO, by e-mail at info-valve@asco.com, or visit www.ascovalve.com/lowpower.
Award-winning services satisfy customers

AutomationDirect has always maintained a huge inventory, allowing us to ship 99.7% of orders complete the same day. We were among the first to offer free 2-day shipping, available for any order over just $49. Shipment confirmations and any backorder status and estimated delivery information is communicated electronically to keep you informed. Our online store is one of the most exhaustive in the industry all technical documentation can be downloaded free of charge, as well as software and firmware updates. Hundreds of instructional videos are available for viewing without registration.
AutomationDirect Headquarters, Cumming, Ga
AutomationDirect takes the best ideas from the consumer world to serve industrial market
As a direct seller of industrial automation products for over 18 years, AutomationDirect has led the industry in offering many customer services not typical with traditional distributors. We created a print catalog, and later an online store, that provides complete product information and pricing so that customers can make informed decisions on their automation purchases quickly and independently. AutomationDirects standard for products is that they are practical, easy to use, and offer a low cost of ownership. We offer quality products at prices up to 50% lower than those of more traditional distributors. Most of our products programming software is free, requiring no initial or upgrade costs, and no software maintenance contracts.
99.7% orders shipped complete the same day
Online access to your account includes viewing and changing account information, viewing order history and making payments. Customers can also obtain return authorizations online for quick and easy product returns or exchanges. Our phone technical support staff has garnered top honors in service from industry magazine readers 12 years in a row. And with tens of thousands of active customers, our online technical forum taps into that knowledge base by encouraging peers to help each other with applications and other questions.
Practical automation products, including programmable controllers
Other online help includes frequently asked questions, application examples, and product selection guides.
www.automationdirect.com | Email: sales@automationdirect.com | Phone: 1-800-633-0405

About: Beckhoff Automation

Ethernet fieldbus technology), TwinSAFE safety solutions, servo drives and motors. Another advanced solution from Beckhoff is TwinCAT 3, which represents a convergence of automation and the IT world; this is referred to as eXtended Automation Technology (XAT).
Feature-Laden Solutions
While supporting all IEC 61131 programming languages and providing active support of multicore systems, Beckhoff advances leading edge automation solutions that deliver high performance at a low cost. This includes Scientific Automation, which merges automation, PLC and motion control with advanced condition monitoring and precise measurement technologies. This can be handled all on one powerful, PC-based automation controller and cost-effective EtherCAT Terminals, eliminating the need for many expensive black boxes.
Beckhoff Automation is a provider of advanced and open automation products based on proven industrial technologies. Manufacturers and machine builders can implement high performance Beckhoff control systems more efficiently and at a lower overall cost than traditional PLC and motion control systems. Beckhoff has been a long-time proponent of open controls architectures, full system interoperability, seamless machine-to-machine communication and lean automation solutions. As more technology companies are calling for these types of cost-efficient solutions, Beckhoff is wellpositioned today to support them. Beckhoff sales and service are handled directly, with no intermediaries involved for exceptional customer service and consultation.
Worldwide Presence
Beckhoff Automation North American headquarters is located in Savage, Minn. (Minneapolis area). At this location, administration, product and engineering management, warehousing and training occurs. There are also regional technical centers located in Chicago, San Diego, Calif.; Charlotte, NC; Mill Creek, Wash.; Fond du Lac, Wisc. and Mississauga, Ontario. Beckhoffs global headquarters, including product design and assembly facilities, is located in Verl, Germany. Between direct owned subsidiaries and worldwide co-operation with partners, Beckhoff is represented in 60+ countries.
Problem-Solving Technologies
Beckhoffs product range includes PC-based control, Industrial PCs, Embedded PCs, programmable automation controllers (PACs), PLCs, operator interfaces, I/O compatible with over 15 different fieldbuses, EtherCAT (next generation
Contact: beckhoff.usa@beckhoff.com | 1-877-TwinCAT | www.beckhoffautomation.com

Data Acquisition to Meet Your Needs

About Data Translation Inc.
Data Translation Inc. (www.datatranslation.com), founded in 1973 and headquartered in Marlboro, Massachusetts, is a leading designer and manufacturer of high performance data acquisition solutions for the test and measurement market. With expertise in the design of high-accuracy, high-quality hardFred Molinari, ware and application software, Data Founder, President Translation partners with end users and CEO of and OEMs to achieve their test and Data Translation Inc. measurement goals. With more than forty years of experience, customers have come to rely on Data Translation for its world-class software, design proficiency, high-quality manufacturing, and customer service. Data Translation has a worldwide presence, with offices in the US and Europe and distribution in more than 40 countries. Data Translation products are manufactured in the company headquarters ensuring complete quality on all products. Additionally, 5-day standard delivery is guaranteed on most shipments, along with free comprehensive technical support.
All product design, manufacturing and sales take place at Data Translations Corporate Headquarters located In Marlboro, MA.
Data Translation Inc. offers a wide range of USB and Ethernet data acquisition modules and supporting software for any application or budget. Engineers, Scientists and Designers requiring temperature, voltage, sound and vibration measurement and analysis tools can choose from over 150 modules from low cost to high performance, each offering high quality results. All of Data Translations modules are supported by a range of software and are LabView and MATLAB compatible.
Product Innovation
Data Translations MEASURpoint is an ultra-accurate instrument for measuring any combination of voltage, temperature, or RTD inputs in harsh environments. MEASURpoint incorporates proprietary ISO-Channel technology that makes measurements almost indestructible and eliminates any common mode noise and ground loop problems under all environmental conditions. On-board galvanic isolation ensures high signal integrity by providing isolation up to 3500V continuously or 5000V for transients, making it ideal for application in noisy environments. In addition, up to forty-eight configurable input channels (depending on the model) offer ultimate flexibility to the user. USB and Ethernet versions are offered and guarantee superior isolation and reliability to the user.
The DT8875/6 Ethernet Measurement Instrument offers channel-to channel galvanic isolation up to 3500V.
Contact: www.datatranslation.com | 800-525-8528 | info@datatranslation.com

At Eaton, powering a world that demands more inspires us. With over 100 years experience in electrical power management, we have the expertise to see beyond today. Thats why, when a high-end German auto manufacturer posed the challenge of expanding its existing operation in China, we leapt at the opportunity. A newly designed conveyor system had to be powered to transfer auto bodies to multiple welding stations. As well as integrate into the existing plant automation structure. The complexity of the project inspired us. A tremendous
number of signals had to be processed across multiple stations. Motor drives and sensors had to be monitored and controlled centrally. The system had to be tuned to intricate quality control algorithms. Over 1,200 motors had to be protected. This was no ordinary project. It demanded extraordinary thinking. Eatons custom solution started with revolutionary SmartWire-DT technology.
By looking beyond the now, Eaton powered the conveyor system with never-beforeseen flexibility, efficiency and speed. As well as flawlessly integrating into the existing plant automation structure. Looking into the future, the auto manufacturer is looking to Eaton to energize more innovative power management solutions for even greater productivity. At Eaton, we power businesses with reliable, efficient and safe electrical solutions. Combined with our personal service, support and bold thinking, we are answering tomorrows needs today. Follow the charge with Eaton.
Eaton SmartWire-DT cuts wiring effort by more than 60%.
SmartWire-DT makes traditional point-to-point wiring obsolete. It also enables conventional motor control to be incorporated into systems effortlessly. SmartWire-DT cuts wiring effort by more than 60%. Which in turn cut the projects installation time by 22 business days.
Visit eaton.com/followthecharge
2013 Eaton. All rights reserved.
Supporting Advanced Automation As No One Else Can!

With a comprehensive line of automation components, custom components and complete electromechanical and pneumatic motion controlled multi-axis systems... Festo can support your most complex automation requirements. Festo Assured Shipping Time Program With Same Day and 3 Day availability of 1000s of Festo automation components, the FAST program enables designers and manufacturers to: Festo is a leading global manufacturer of pneumatic and electromechanical systems, components and controls for process control and factory automation solutions, with more than 55 national headquarters serving more than 180 countries. With over 40 years of innovation in the United States and over 80 years globally, Festo has continuously elevated the state of manufacturing with innovations and optimized motion control solutions that deliver higher performing, more profitable automated manufacturing and processing equipment. Our dedication to the advancement of automation extends beyond technology to the education of current and future automation and robotic designers with simulation tools, teaching programs, and on-site services. Festo is globally recognized as a symbol of expertise in factory automation and process control. We can help decrease process costs by engaging Festo as an extended workbench and benefitting from our expertise with regard to pre-assembled pneumatics, customized product designs, and system solutions. Festo enables its partners to obtain more intelligent automation solutions from a single source. In addition to tried and tested pneumatic drive units, Festo also provides both servo-pneumatic and electric drive units. Our intelligent systems for status monitoring and machine diagnosis (condition monitoring solutions) are made up of sensors, software, controllers and visualization. These solutions can greatly reduce maintenance and servicing costs. lower inventory costs reduce time-to-market for prototype and production equipment invest inventory savings and time savings in growing their business.
FAST Program
The selection of FAST industry automation components available for same day shipment include: Pneumatic Cylinders and Actuators, Pneumatic Valves, Air Preparation Units, Fittings, Tubing and Sensors. FAST custom length Cylinders and Actuators, combination Air Preparation Units, and Valve Manifolds ship in 3 days.
Its on time or its shipped free!

Festo will reimburse the shipping charges for qualifying orders which do not meet the shipment times specified by the FAST Program. Learn more at: www.festo.com/us/fast.
Festo Corporation | Tel: 800.99.FESTO | Fax: 800.96.FESTO | E-mail: customer.service@us.festo.com | www.festo.com/us

A leading provider of global solutions

integrate these products and services to help clients collaborate across systems and enterprises in real time, extracting critical data to make faster, better decisions and synchronize their operations from the plant floor to the executive offices, aligning production goals with business objectives. Invensys Software Businesses are comprised of three brands: Avantis, SimSci-Esscor, and Wonderware. The Avantis Enterprise Asset Management solution forms the core of our Asset Performance Management solution set. These maintenance repair and operations solutions provide maintenance management, spares and inventory management and a complete procurement capability. When coupled with the powerful Avantis Condition Manager solution, Invensys is uniquely positioned to offer customers real-time answers to help reduce costs while continuing to maximize asset reliability and performance. The overall solution set helps customers to realize outstanding return from all their assetspeople, processes and equipment, thereby enabling true Asset Excellence. Wonderware is the market leader in real-time operations management software. Wonderware software delivers significant cost reductions associated with designing, building, deploying and maintaining secure and standardized applications for manufacturing and infrastructure operations. Our solutions enable companies to synchronize their production and industrial operations with business objectives, obtaining the speed and flexibility to attain sustained profitability.
Invensys is a leading provider of automation and information technology, systems, software solutions, services and consulting to the global manufacturing and infrastructure industries. Headquartered in Houston, Texas, its solutions are used by more than 40,000 clients around the world in more than 200,000 plants and facilities.
SimSci-Esscor simulation software has assisted in the design, operation, and optimization of processes across numerous industries since 1966, providing professional simulation tools for: Improved process designs resulting in lower capital and operating costs Dynamic studies and operator training simulators (OTS) resulting in safer operation Process optimization and process simulation resulting in improved performance SimSci-Esscor engineering software that yields improved profitability throughout the entire plant lifecycle.
Invensys offerings are delivered under several prominent industry brands, including Avantis, Eurotherm, Foxboro, IMServ, InFusion, SimSci-Esscor, Triconex and Wonderware. The companys approximately 9,000 employees and its global partner ecosystem
To learn more about Invensys, visit iom.invensys.com.

Kepware Technologies Enhances Communications Security

Users that want to apply a more robust security strategy to new or existing applications will nd that we have created an intuitive and easily implemented solution for what is often considered to be a complex challenge, states Tony Paine, President and CEO of Kepware Technologies. Regardless of your organizaPresident and CEO tions approach to security, certain characteristics of the security strategy are undeniable: it should be implemented with the least amount of impact on performance, able to be modied on-the- y without requiring a system restart, and provide the tools needed to deploy a tested solution into production. The KEPServerEX platform and Security Policies Plug-In make all this possible.
Tony Paine
Kepware Technologies, Portland, Maine
Solving a Market Need

The ability to securely move information between software applications and hardware appliances is critical to any automated process. To make this possible, an interoperable communications platform must be layered into the control system. This approach ensures that critical information will not be deciphered by non-authorized applications for malicious use. This approach also limits the scope of activities that each authorized user is allowed to do and/or access in the system. Systems must be able to provide the information necessary to each stakeholder so that they may perform their responsibilities; however, by appropriately limiting access to information that the stakeholders do not require, administrators can minimize unintentional mistakes that may cause downtime or impact safety.
About Kepware Technologies

Kepware Technologies, established in 1995, is a private software development company headquartered in Portland, Maine. Kepware has been developing, testing, and delivering advanced communications and interoperability software solutions for the Automation industry for nearly 20 years. Kepwares exible and scalable solutions help customers connect, manage, monitor, and control disparate automation devices and software applications.
The KEPServerEX Platform

Kepware recognizes the importance of security at both the interface and user levels. Although standard interfaces have enabled Kepware to develop secure communications between components, the company had not previously developed a solution for role-based security. With KEPServerEX version 5.12 and the introduction of the Security Policies Plug-In, Kepware provides a complete solution to this market problem.
207-775-1660 | sales@kepware.com | www.kepware.com

The best machines and production facilities around the world use Lenze
L-force Engineering the solution
Demands are increasing all the time. In the future, key challenges will lie in the areas of cost efciency, time-savings, and quality improvements. Faster project planning and commissioning, improved performance and increased exibility in production are expected. New ideas are therefore needed for the machines of the future. Lenze has risen to this challenge and, with L-force, we can offer you an innovative family of drive and automation products, and a comprehensive portfolio of solutions and engineering software tools that are driven by: Innovation New ideas for new possibilities Flexibility High degree of scalability for individual solutions Usability Simple solutions, even for complex applications Compatibility Universal products and solutions Straightforward engineering- Simplifying the planning process
As a global specialist in Motion Centric Automation, Lenze offers you products, drive solutions, complete automation systems and engineering services and tools from one single source. We are able to support the entire development process for your machine - from initial idea to after-sale, from control systems to drive shafts.
Engineering made easy

In order to deliver the ideal solution for your machine tasks, Lenze advises and supports you through all ve phases of the engineering process: Developing ideas Drafting concepts Producing solutions Manufacturing machines Ensuring productivity
Lenze Americas, based in Uxbridge, MA , is a subsidiary of Lenze SE in Germany. As a global manufacturer of electrical and mechanical drives, motion control and automation technology, Lenze products can be found in many industries, including automotive, packaging, material handling, logistics, robotics and commercial equipment (pumps/fans). A global network of distributors and representatives makes Lenze Americas perfectly positioned to meet the motion control needs of customers worldwide.
From helping you choose the best drive components to full engineering services, our sales and applications engineers work with you to develop the optimum solution for your machine requirements. With Lenze, you have an expert at your side for choosing the best products, providing energy efcient drive dimensioning, project planning, implementation and commissioning.
Visit Lenze Americas at www.Lenze.com Call us at 508-278-9100 or toll-free 800-217-9100 | Email us at marketing@lenzeamericas.com
Moore Industries STA Safety Trip Alarm

STA Safety Trip Alarm Effective Alternative to Safety PLCs
The flagship product in Moore Industries FS FUNCTIONAL SAFETY SERIES is the STA Safety Trip Alarm, a standalone safety system logic solver that has undergone critical testing by TV and exida and approved for 61508/61511 compliance, including single use in Safety Instrumented Systems up to SIL 2 with firmware approved for use in SIL 3 systems.
Moore Industries FS FUNCTIONAL SAFETY SERIES addresses concerns of plant engineers and operators relating to the safety and reliability of their processes in hazardous settings. In many situations, a single fault or error can lead to a chain of devastating events within a process control system. Using a Safety Instrumented System (SIS) that implements one or more Safety Instrumented Functions (SIF) to return a process to a safe state after abnormal operational conditions protects against potential catastrophes. The FS FUNCTIONAL SAFETY SERIES products from Moore Industries give engineers a level of confidence in their safety systems and overall reliability. They are designed and built in compliance with the latest leading worldwide safety standard IEC 61508 and have also been audited and approved for use in safety systems by exida, an industry leading consulting, product testing and assessment agency with expertise in functional safety. exida-certified FMEDA reports are available on the products, enabling a functional safety practitioner to determine the products applicability in safety-related applications.
The STA is easier to use and significantly more affordable than a typical safety PLC and can work as an extension of a larger control system or perform localized operation in safety settings. It acts as a single loop logic solver that performs these functions: Warning of and acting on unwanted or potentially hazardous process conditions Providing emergency shutdown in Safety Instrumented Systems Providing on/off control and traditional alarm trip functions Locally displays and retransmits PV status The STA is part of the ever-expanding FS FUNCTIONAL SAFETY SERIES, which includes a range of products designed to enhance safety in Safety Instrumented Systems and traditional process control settings. For more information visit www.miinet.com/AdditionalContent/SafetySeries.aspx.
Contact info@miinet.com | (818)894-7111 | www.miinet.com

Making Industrial Networks Smarter, Tougher, and More Reliable

for signal recovery and renegotiation, there is absolutely no interruption or delay in data transmission.
Hardened Power over Ethernet (PoE) Switches for Heavy Duty Requirements
On Moxas EDS-P510A-8PoE industrial PoE switch, 8 Ethernet ports supporting 802.3af (PoE), and 802.3at (PoE+) are available to supply up to 36 watts to heavy-duty PoE devices, such as IP surveillance cameras with wipers/heaters, high-performance wireless access points, and rugged IP phones. With built-in management functions, Gigabit SFP fiber ports, and a rugged wide-temperature design, it is an ideal solution for outdoor PoE installations that have demanding requirements for power, reliability, and bandwidth.
25 Years of Experience with Industrial Networking Technology

Since 1987, Moxa has been designing and manufacturing hardened networking and communication equipment for mission-critical applications. Our Ethernet switches, wireless access points, IP cameras, computers, and more are specially designed and tested to ensure highly reliable operation and connectivity for industrial users and harsh environments.
Easy Monitoring and Management of Industrial Ethernet Networks

Moxas MXview software allows industrial users to see their entire Industrial Ethernet network in a glance, with live status for every MXview Industrial Network Management Software switch and connection. It is designed for high flexibility and interoperability with other hardware and software, and new functionality is regularly introduced through free software updates. Key features include the following: Simple graphic network visualization and event log list on one screen Automatic network topology mapping with drag and drop adjustment Automatic OPC tag generation and new group tag for overall network health Event recording and playback of network events Interoperability with other NMS through SNMP traps Native support for other Moxa networking devices (serial, I/O, and fieldbus)
Concurrent Dual Radio Technology for Highly Reliable Wireless Connections

On Moxas AWK-5222 and AWK-6222 industrial wireless access points, concurrent dual-radio technology is used to establish an exceptionally stable wireless connection that is practically immune to interference. Two RF modules simultaneously transmit duplicate packets on separate wireless channels. Instant and seamless failover occurs if one channel experiences wireless interference or other disruption. Since no additional time is required
Contact usa@moxa.com | 888-MOXA-USA | www.moxa.com

Committed to Engineers and Scientists

Embedded Systems Outlook 2013
The Embedded Systems Outlook highlights important technologies and methodologies making a large impact on the embedded systems market. By interacting with over 35,000 companies worldwide, National Instruments has formed strategic partnerships with many key customers and leading technology providers including Analog Devices, Intel, and Xilinx, to identify market trends and industry best practices.
National Instruments makes a positive impact by doing what it does bestapplying engineering expertise to critical societal issues and equipping engineers with tools that accelerate productivity, innovation, and discovery. NIs graphical system design approach provides an integrated software and hardware platform that simplifies the development of any system that needs measurement and control.
From Design to Test With a Standard Technology Platform

NI offers graphical system design tools to engineers and scientists
Learn more about the most pressing trends and challenges facing design teams building embedded control and monitoring sytems. Visit ni.com/eso
who develop next-generation control and monitoring systems within industries such as energy, industrial control, life sciences, and transportation. NI reconfigurable I/O (RIO) hardware and NI LabVIEW system design software provide an off-theshelf platform to meet demanding control and monitoring tasks. This NI platform-based approach gives smaller design teams the confidence to build innovative embedded systems without wasting development time and cost on custom design. Visit ni.com/embeddedsystems to learn more.
Download the 2013 outlook to explore the most pressing trends, opportunities, and challenges influencing todays design teams that are building embedded control and monitoring systems. Download at: www.ni.com/eso/
Reconfigurable Heterogeneous Architectures - When faster CPU cores fall short, embedded system designers combine heterogeneous processing elements to meet application needs. Democratization of Embedded System Design - Design teams are abandoning larger specialized teams for smaller groups focused on translating domain expertise into realized innovation. Total Economic Profitability - More companies are adopting a comprehensive approach that considers not only cost benefit analysis but also factors like flexibility and risk. The Digital Energy Revolution - Digital technologies are changing the way we manipulate, move, control, and store energy. Embedded Vision - The incorporation of visual data is taking embedded systems to new levels of performance.
Phone: 888-433-3488 | Email: info@ni.com | www.NI.com

A Force in Domestic Manufacturing

Because Omega Engineering offers over 100,000 products, many customers have the erroneous impression that the company is simply a catalog house, distributing products made by others. Actually, Omega is a major manufacturer in its own right, making over 80% of the products it offers, with this percentage continuously increasing.
Wire Production
Manufacturing at Omega starts near the bottom of the supply chain. The company actually produces its own thermocouple wire at a manufacturing operation that turns out tens of millions of feet per year. Starting with bare wire stock in a wide range of compositions and diameters, finished cable is made for a myriad of Omega products. Specialized machines turn out braided, extruded, glass-wrapped, shielded, single conductor, multi-conductor, twisted shielded pairs, Kapton coated, and PFA coated cable in both solid and stranded styles.
Thin Film Fabrication

RTD elements used in temperature sensors and probes are made in Omegas own thin film fabrication facility located in a class 10 clean room. Here the RTD elements are created on substrates, 2000 at a time.
Omega is a major manufacturer in its own right, making over 80% of the products it offers
Temperature Probes
Omega boasts an automated probe manufacturing facility that is unequalled. Starting with coils of flat metal stock and a wide range of wire types, a highly automated production line fabricates probe sheath, with wiring enclosed, in coils which can be hundreds of feet in length. Sheath sizes range from an incredibly thin 0.010 inches up to a robust 0.375 inches. While other manufacturers make the probes individually to a specific length, Omega can make any desired length by simply cutting it from the probe coil.
Benefits of In-House Manufacturing

Omega products are used in many critical applications in manufacturing, food processing, medicine, aerospace, and science, to name a few. By making the individual components within the company, Omega can achieve a measure of control not possible when critical parts are supplied by a variety of vendors with a variety of reliabilities. This is key to the high esteem Omega enjoys among its customers and its reputation for highly consistent, top quality products.
For sales and service call 1-888-826-6342 | email: sales@omega.com | www.omega.com

groov from Opto 22 changes the way you think about HMIs. Forever.
Its all you need to build effective HMIs for any device
With groov, its simple to build high-performance HMIs using only a web browser. No plugins; no software to install; no servers to commission; no licenses to buy. groov is completely web-based, and everything you need is in the groov Box. Just drag and drop touchscreen-ready indicators and controls onto the screen. Gauges, buttons, labels, even live video all scale gracefully to match the device.
Imagine what you can do

Monitor machine status on a web-enabled HDTV mounted in the factory. Check a live security video feed. See production figures on your phone. Control equipment in hard-to-reach areas from a laptop. Use a tablet as an operator interface for your machine. Just imagine what you can do with an operator interface you can use on any authorized tablet, smartphone, or computerany size, any manufacturer, anywhere. Just imagine what you can do with groov.
Explore new best practices for HMIs that work

What makes one system easy to monitor and control, while another suffers downtime, waste, and accidents? Often its the HMI. groov was designed from the ground up with highperformance HMI principles in mind. So groov helps you build an HMI that works. Read more about effective operator interfaces in our white paper: op22.co/HMIwhitepaper. Then build your own in groov.
About Opto 22
groov comes from Opto 22s 40 years of experience pushing the boundaries in industrial automation, remote monitoring, and data acquisition. Like all our products, groov is based on open standards, built by engineers, and manufactured and supported in the U.S.A. Get your groov today and see what you can do. Learn more at groov.com.
systemseng@opto22.com | 800-321-6786 | www.groov.com

Are Technological Innovations Destructive?

happened to all the displaced workers? They relied on their distinctly human instinct to improve or die and learned new skills and technology. Dr. Fest postulates that Its much easier to improve than to be replaced by a better mouse trap. Benjamin Franklin stated it best when he said When you finish changing, youre finished! A great example of the destructive, yet beneficial, power of technological innovation is captured by Oteks new model NTT. The NTT (New Technology Transmitter) takes the traditional analog meter invented in 1893 by Sir E. Weston (signal powered) and combined it with a traditional 4-20mA current loop transmitter. However, thats all thats traditional in the NTT! The NTT is variation of Oteks new Loop Powered Display/Controller series LPD. The NTT is a 100% loop/ Model LPD-0 signal powered bar-meter to which Otek added its patented isolated 4-20mA transmitter, but kept the LPDs powerful firmware and hardware. The NTT has isolated serial I/O (USB, 485, Ethernet), math functions, polynomials, X-Y tables, Log/Anti-log, scale tare, offset, relays, isolated 4-20mA output and numerous algorithms including PID. In addition, the NTT Model LPD-3 accepts over 30 input signals (TC, RTD, S-G, pH, RMS, etc.) and is even isolated 4-20mA loop powered on the front end. All of the NTT functionality is accessible via the serial port. This means that the NTT can work stand alone or become part of DCS/SCADA for complete process automation control (PAC). The automatic tricolor bargraph and high resolution digital display keep supervisory personnel informed of the process status and can even be used to send text to the operator. This frees up the PAC for other functions. The more efficient your automated process, the less human oversight is needed-just one more destructive innovation by mankind!
Dr. Otto Fest, President and Founder of Otek Corporation
Most people who work in the technical field find advances in technology to be extremely exciting. New innovations and inventions are often the topic of many lunch room discussions. However, lets take a moment to ponder whether or not technological innovations are beneficial, destructive or both. According to Dr. Otto Fest, the President and Founder of Otek Corporation, one of the leading manufacturers of state-of-the-art digital panel meters and bargraphs, cutting edge innovation is both destructive and necessary but ultimately beneficial. Innovations partially destroy the existing labor force. When the printing press was invented, thousands of workers across the globe suddenly became irrelevant. The industrial revolution replaced the slow, inefficient and mistake-ridden worker with fast, highly efficient and accurate machines. If you watch the TV show how its made, you will be amazed at how millions and millions of items are produced without the interference of a human hand! Most goods are now produced using a form of Process Automation and Control (PAC). Yet, how can a displaced work force afford to consume the goods produced by the PAC? While the PAC technology has destroyed some of the workforce, Dr. Fest feels that these innovations are absolutely indispensable for society to advance. What
Visit www.otekcorp.com | Tel: 520-748-7900 | Fax: 520-790-2808 | email: drfest@otekcorp.com.

Small is the big news in motion amplifiers from PMD.

Introducing the ATLAS Digital Amplifiers
They might be as small as a paper clip, but ATLAS Digital Amplifiers the latest innovation from Performance Motion Devices pack an amazing amount of output power in the ultra-compact design. These single-axis amplifiers provide high performance torque control of DC brush, brushless DC, and step motors. And, despite their modest size, they offer up to 1 Kilowatt of total output powerall without breaking the bank.
Key Features
Total power output up to 1 Kilowatt Digital high-performance torque control Ultra-compact solderable design (1.5 x 1.5 x 0.6) Low cost and extremely efficient Programmable control Utilize standard through-hole pins for all connections
High Performance in an Ultra-Compact Package

ATLAS digital amplifiers are used for direct control of motor torque, or in conjunction with higher level controllers for velocity or positioning applications. Their very compact size and high power output make them ideally suited for applications such as laboratory automation, scientific instruments, general purpose motion control, HVAC, fan & pump controllers, and industrial motor control applications. ATLAS amplifiers are provided in both vertical and horizontal mounting configurations, and with and without heat sink attachment tabs.
Flexibility
The ATLAS family has been designed to work seamlessly with PMDs Magellan family of motion Processor ICs. Alternatively, they can be used with dedicated FPGAs, digital signal processors, or general purpose microprocessors. Communication is via SPI (Serial Peripheral Interface) using a simple, packet-oriented protocol. For step motors, in addition to the SPI format a pulse & direction input mode is provided.
Programmability
ATLAS digital amplifiers provide many advanced control features including user-programmable gain parameters, performance trace, field oriented control, and I2 t current management. ATLAS amplifiers are powered from a single supply voltage, and provide automatic protection from overcurrent, undervoltage, overvoltage, overtemperature, and short circuit faults.
About PMD
PMD provides innovative and high performance chip, card and drive-based motion control solutions to OEMs worldwide. With over 5 million installed axes, PMD has the motion control expertise to simplify customers designs and lower overall costs.
www.pmdcorp.com | 978.266.1210 | motion-control@pmdcorp.com

Phoenix Contact Provides Connectivity, Security and Safety

decoupling devices improve the life of the power system and safeguard against loss of redundancy due to unexpected load current demands.
Industrial Network Infrastructure and Security

Phoenix Contact offers full lines of industrially rated managed and unmanaged Ethernet infrastructure components for connectivity in the most demanding of industrial Ethernet processes. When traditional wired networking is not possible, industrial Wi-Fi, cellular or proprietary wireless technologies can be used to bridge this gap. The mGuard protects industrial Ethernet networks with a stateful inspection firewall and IT-compatible remote access, including secure communications over an IT-approved virtual private network (VPN). Todays automation systems need to be flexible and user-friendly, but not at the expense of safety or security. Phoenix Contacts wide range of automation infrastructure components provides connectivity, security and safety in virtually any industrial application.
Analog and Digital Interfaces

Bridging the gap between a controller and the field devices is a vital task in constructing any control cabinet. Phoenix Contact offers a wide range of innovative solutions designed to easily and quickly establish reliable connections to field analog and digital signals. From interposing relays, signal isolators and converters, to system cabling solutions and motor control devices, Phoenix Contact offers reliability and flexibility for any control system.
High Tech Power Solutions

Reliability is key for low-voltage control cabinet power solutions, and state-of-the-art technology meets this demand. Innovative AC to DC power supplies eliminate the need to purchase oversized power supplies to ensure that circuit breakers will properly trip. These power supplies provide critical early warning indications before applications experience downtime. For systems with mission critical power requirements, an intelligent UPS can communicate with the battery pack and allow the control system to actively monitor the percentage of life or capacity remaining. Advanced
About Phoenix Contact

Phoenix Contact develops and manufactures industrial electrical and electronic technology products that power, protect, connect and automate systems and equipment for a wide range of industries. Learn more about our comprehensive range of products at www.phoenixcontact.com.
Email: info@phoenixcon.com | Phone: 800-322-3225 (Technical Service)

PI North America supporting the worlds most used fieldbus and Industrial Ethernet
About PI North America
PI North America is a non-profit, member-supported automation organization for fieldbus and Industrial Ethernet, specifically PROFIBUS and PROFINET. It is dedicated to supporting the discrete and process industries in achieving beneficial results using these networks. PI North America also assists device manufacturers in the development and marketing of PROFIBUS and PROFINET products. It is one of 27 regional associations that make up the global PI community. Established in 1989, PI has more than 1,400 members, who have developed and now supply more than 2,500 devices.
PROFIBUS
To date, more than 45,000,000 PROFIBUS devices have been installed. PROFIBUS is the worldwide standard when it comes to networks in industrial automation. With a majority share of the fieldbus market, PROFIBUS has grown to become the unequivocal leader in this industry. Via a single cable, PROFIBUS links controllers or control systems with decentralized field devices (sensors and actuators) on the field level and also enables consistent data exchange with higher ranking communication systems. The consistency of PROFIBUS is enabled by utilizing a single, standardized, application-independent communication protocol which supports fieldbus solutions both in factory and process automation as well as in motion control and safety-related tasks.
PROFINET
The total number of PROFINET devices installed now exceeds 6,000,000. PROFINET, the all-encompassing Industrial Ethernet for advanced manufacturing, is the standard for industrial networking in automation. It connects devices, systems, and cells, facilitating faster, safer, less costly and higher quality manufacturing. It easily integrates existing systems and equipment while bringing the richness of Ethernet down to the factory floor. Here are some advantages of working with PROFINET at the I/O level: Freely scalable open architectures Reliable and high performance network Maintenance and servicing from anywhere Lower costs for production/quality data monitoring Comprehensive diagnostics built into the protocol Increased uptime with bumpless redundancy Learn more online at: us.profinet.com
16101 N 82nd Street Suite 3B Scottsdale, AZ 85260 Phone: 480-483-2456 | Fax: 480-483-7202
Replace Your Old Meters for Modern Conveniences

Transmitter Remote Displays Have Evolved
Established in 1974, Precision Digital Corporation manufactures a modern, comprehensive line of digital display and control instrumentation. Precision Digital has vastly improved the process industrys archaic, difcult to program 7-segment 1/8 DIN or undersized eld enclosed displays. At Precision Digital, instrumentation has evolved to improve convenience, productivity, and safety with features many plant engineers are still unaware of.
Bigger is Better
The PD765 Trident X2 optimizes traditional 1/8 DIN digital panel meters and with huge 1.2 inch digits readable in direct sunlight. For applications such as water ow rate or temperature indication, this meter provides a larger, brighter, and easier to read display than those of dirty or damaged meters that have spent years in a plant or outdoors. If a process is worth measuring, it is worth using a large, modern, accurate display that makes the reading stand out.
Dual-Input Meters Do the Math For You

The dual-line PROVU and ProtEX-MAX dual-input meters and rate totalizers provide more than just dual inputs to display two variables, units, and tag. Math functions can be performed on the two inputs, including sum, difference, ratio, percent, and more. For applications requiring this kind of math, let the meters do the math for you and increase accuracy and efciency while decreasing errors.
Measure Level in Feet & Inches

Why display level in milliamps, hundredths of feet, or hundreds of inches when you can display it in feet and inches. The PD6801 explosion-proof feet and inches level meter does just that. The ability of an operator to understand important level data at a glance is critical, especially in hazardous areas. The feet and inches display, equipped with custom units and a useful bar graph indicator, is much more informative than using a traditional one-line seven-segment display.
Replace Your Old Meters

Transmitter displays and digital panel meters are a crucial part of process monitoring. Features like pump alternation control and safety interlocks using digital inputs allow the display to be at the heart of the process monitoring system, whether your process involves ow, level, temperature, or pressure. If your instrumentation is hard to understand or lacking features, consider modern innovative replacements to improve your processes.
To speak to a representative or to place an order, contact Precision Digital today at 1-800-343-1001 or email sales@predig.com. For more information please visit our website at www.predig.com.
RED LION - Industrial Automation & Networking

As the global experts in communication, monitoring and control for industrial automation and networking, Red Lion Controls has been delivering innovative solutions for over forty years. Our award-winning technology enables companies worldwide to gain real-time data visibility that drives productivity. The following industrial automation products collect, present and process data anywhere, anytime: Controllers: PID controllers, signal conditioners and data acquisition devices for machine and process control Protocol Conversion: extensive protocol library connects otherwise incompatible devices on wired or wireless networks HMIs: combine protocol conversion, data logging and web server capabilities with visualization functionality for PLCs, motor drives and more Panel Meters: a wide range of models and sizes with expansion capabilities that easily adapt to changing requirements Visual Management: enables the display of real-time KPI data and Andon messages on large televisions to drive productivity RTUs & I/O: provides a simple yet powerful monitoring and control system for remote sites
For over forty years, customers and partners around the world have relied on Red Lion Controls. Our industrial automation and networking products provide critical information and controls to improve productivity, working with numerous devices and diverse protocols to access data.
We are a company that people trust.

Our company invests in research and development. Our company manufactures reliable, high-quality products. Our company stocks product that can ship today. Our employees care.
Our products solve problems.

Our products are high performance and dependable. Our products interoperate to create systems. Our products provide business insight. Our products improve productivity to increase the bottom line.
Our new industrial networking portfolio includes:

Unmanaged Switches: compact IEEE 802.3 Layer 2 industrial switches with automatic speed, duplex and cable sensing Monitored Switches: enable Layer 2 network performance monitoring via N-View software Managed Switches: provide Layer 2 and Layer 3 networking in a rugged package PoE Switches: designed to transmit power and/or data over an Ethernet network Wi-Fi Radios: IEEE 802.11a,b,g,n hardened radios support data bandwidths up to 300 Mb/s Cellular M2M Routers: provide uninterrupted, secure communication for remote sites
For more information, please visit www.redlion.net/together, email sales@redlion.net, or call Red Lion Controls at +1 (717) 767-6511
A trusted leader in the field of drive technology

Engineering excellence and customer responsiveness distinguish SEW-EURODRIVE, a leading manufacturer of integrated power transmission and motion control systems. SEW-EURODRIVE solutions set the global standard for high performance and rugged reliability in the toughest operating conditions. With its global headquarters in Germany, the privately held company currently employs over 15,000 employees with a presence in 45 countries worldwide. U.S. operations include a state-of-the-art manufacturing center, five regional assembly plants, more than 63 technical sales offices and hundreds of distributors and support specialists. This enables SEW-EURODRIVE to provide local manufacturing, service and support, coast-to-coast and around the world.
MOVIGEAR
The MOVIGEAR Mechatronic Drive System for horizontal materials handling from SEW-EURODRIVE sets new standards in terms of efficiency and functionality. MOVIGEAR not only combines the gear unit, motor and drive electronics within one highly reliable, efficient, and hygienically designed unit, it also reduces total start-up cost and annual operating costs in your material handling systemby as much as 50%! Remember, any opportunity to save energy is not only an important contribution to conserve the environment but also pays off financially.
PT Pilot Drive Selection Tool

Compatible with smartphones and tablets! TIME = MONEY. That is why SEW-EURODRIVE developed PT Pilot. This online program quickly provides a complete quote with options, parts lists, and 2D/3D CAD drawings for a gear unit or gearmotor. The entire process is intuitive from start to finish and completely paperless. It is accessible via a standard web browser no special software or plug-ins. Plus, PT Pilot is now compatible with smartphones and tablets so it can be accessed anytime, anywhere! PT Pilot contains a special section for design engineers. Its engineering calculator automatically sizes a drive for conveyors, travel cars, and hoists with or without an inverter. Just enter the design parameters and let PT Pilot do all the work. SEW-EURODRIVE . . . Driving the World
U.S. Headquarters Lyman, SC | Telephone: 864-439-7537 | cslyman@seweurodrive.com www.ptpilot.com | www.seweurodrive.com

Siemens Industry, Industry Automation Division

The Siemens Industry Automation Division supports the entire value chain of its industrial customers from product design to production and services with an unmatched combination of automation technology, industrial control technology and industrial software. With its software solutions, the division can shorten the time-to-market of new products by up to 50 percent. Industry Automation comprises several Business Units: Industrial Automation Systems, Control Components and Systems Engineering, and Sensors and Communications.
How does Totally Integrated Automation drive maximum productivity?

Totally Integrated Automation (TIA) has been the core intelligence of over 100,000 automation products (drives, motor control centers, energy management and control, PROFINET/PROFBUS networking, and much more) for nearly 15 years. This is the foundation for open flexible technology and maximum interoperability across multiple devices to transform them into a totally integrated automation system. TIA, when synchronized with customer requirements, optimizes factory, machine and process operations allowing you to not only produce more, more efficiently, but increase Raj Batra, Vice President, your innovation and Siemens Industry competitiveness. Automation Division
TIA Portal one engineering framework for all automation tasks.

Siemens has redefined engineering with the Totally Integrated Automation (TIA) Portal. The TIA Portal is the most intuitive, efficient, and proven engineering framework, enabling you to integrate PLC, PC-based control, HMI, Drives and Network configuration in a single engineering environment. This ground breaking innovation can shorten your engineering cycle, save commissioning time, reduce maintenance costs, and reduce your total cost of ownership. This has resulted in up to 40% reduced engineering time, thus reducing your time to market. See how TIA Portal has significantly benefited our customers, visit the website at www.usa.siemens.com/ tia-portal-awards.
Safety Siemens Safety Integrated increases safety and reduces complexity.

The SIMATIC Safety Integrated solution provides proven technology, as part of your overall safety program, to save lives. This safety solution blends seamlessly into Totally Integrated Automation and lowers initial and operating costs, reduces down-time, increases productivity and much more. This results in savings up to 30% in total cost of ownership.
www.usa.siemens.com/automation
Yaskawa Quality: More than a Measurement... Its an Experience.

We take quality personally at Yaskawa. Our drives and servo packages offer the highest MTBF in the world. The relationships we have with our customers ensure mutual bene ts. The partnerships we cultivate with our distributors add value to the way we work with you. We hire great people and continuously train them to be able to serve your needs better. We deliver product on time. It works out of the box. We answer questions promptly and never back down from challenges. To us, quality means doing everything we can to make our customer, partner and employee experiences great ones. We commit to that philosophy every day. We make it happen. We can because, to us, ITS PERSONAL. Were the only industrial drives and motion control manufacturer to win the Deming prize the most prestigious quality award in manufacturing. But we know that tells only part of the quality story. What about innovative design, knowledgeable, responsive engineers who understand your business, and superior support and training? Those crucial assets are a vital part of how a company is ultimately judged and what we mean by the Yaskawa Quality Experience. At Yaskawa, Quality is more than numbers, more than awards its the total experience of purchasing and owning Yaskawa products and working with Yaskawa people.
Motion Control Products:

Our broad product range of servo systems includes rotary, linear, and direct drive motors , matched with digital SERVOPACKS. These best-in-class servo systems can be matched with our single or multi-axis machine controllers for a system solution with the best quality and reliability in the industry.
Variable Frequency Drives:

Yaskawa low voltage industrial AC drives offer the greatest selection of size and performance, with power ranges from fractional HP to 2250 HP. Yaskawa Commercial AC drives for HVAC applications combine reduced size and cost with step changes in performance and quality. They feature extensive parameter selection to enhance energy efciency and closed loop control.
Yaskawa America, Inc. | Drives and Motion Division | 2121 Norman Drive South | Waukegan, IL 60085 1-800-YASKAWA | www.yaskawa.com
back to
BASICS
Selecting voltage-based pressure sensors

While most process instrumentation uses 4-20 mA current loops, there are situations where pressure sensors using voltage loops can operate with much lower power levels.
Karmjit Sidhu, Greg Montrose
is on short supply, pressure sensors that use one of a variety of voltage output options can reduce consumption significantly.
Where power
Go Online
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hile the bulk of process instrumentation has standardized on 4-20 mA current loops, this approach depends on having 24 Vdc with a few amperes available. Where power is on short supply, pressure sensors that use one of a variety of voltage output options can reduce consumption significantly. While the differences between the various voltages may seem minor, each option offers its own unique features and benefits for specific use cases and different user groups. The key is to match output with available system operating voltage. Lower-power systems are becoming more common, particularly in wireless environments thanks to lower installation cost features, along with remote device clusters that depend on solar panels and/or lithium batteries. In these situations, the need to conserve power takes on paramount importance. In such systems, voltage availability typically ranges from 7-12 Vdc, with currents in the 2-3 mA range to power the transducer. The only solution here is to use a voltage output approach, such as 0.5-4.5 V ratiometric with 5 Vdc supply, or 1-5 V sensors with 7-12 Vdc systems. Upstream and midstream oil and gas applications are driving this today where power is not freely available in remote areas. For battery-powered and pulsed systems, the sensor unit is often energized for a short time between sleep periods for monitoring, such as a tank level application. Such systems operate at 3.3 V, so the sensor uses less than 1 mA excitation with 0.5-3 V output. Here, the need to maintain battery life for two years or more is essential. The next most popular powering approaches are fixed 5 V or unregulated 6-12 V systems. These are typical with lithium and solar cell combinations. For these, sensors use 0.5-4.5 V outputs with maximum current limited to 2 mA or less so that the system can work for many years. This is particularly important in higher northern or southern latitudes where sunlight is limited for several months of the year. Finally, land-based systems with generator power or some other permanent supply run at
8-28 V. These situations allow several options for output signals, including 0-5 V, 1-5 V, 1-6 V, and 0-10 V. Here current consumption is less than 10 mA, so it is well below a 4-20 mA loop. The downside of a voltage loop is the limit on cable length between the transducer and controller such as a plc or computer.
Low level or no signal?
The main disadvantage of any zero-based output signal is that there is no signal with zero pressure. If the transducer has a cut wire, broken sensing element, or electronics that received an over-voltage, the sensor will produce no signal, thus, no way to provide an output. The controller cant tell if pressure is actually zero or if the unit is simply inoperative. For example, if used in water pressure measurement, the controller might signal a pump to act when the sensor detects pressure has crossed a threshold. If there is no pressure in the line, the transducer will produce a 0 V signal. Similarly, at fault conditions, the sensor continuously provides a 0 V signal. Since the reading is the same at actual zero pressure and fault conditions, there is no way for the controller to distinguish between the two. In a worst-case scenario, the pump would not know to run and could cause a flooding condition. As industrial pressure transducers become smarter with advances in electronics and microprocessors, sensors are available with a factory-set fault condition. Transducers can be programmed to rail or send output below the lowest point or above the highest point to indicate to the controller that there is an issue. For example, if a pressure spike in the system causes the sensor diaphragm to break, the output signal on a 1-5 V output signal can be programmed to drop the output below 1 V or above 5 V by about 10%. In a pump application, it can help prevent flooding, the pump from running dry, or extra wear. ce Karmjit Sidhu is vice president of business development and Greg Montrose is marketing manager for American Sensor Technologies.
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