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CTL1205_Cover_V4msFINAL.indd 2 5/2/12 5:02 PM
Features:
1.2" x 1.2" x 1.7" deep
1/8" NPT process connection for: air, non-corrosive gases,
non-flammable gases. (NOT for use in liquid applications)
Repeatability +/- 3% of full scale
Two digital outputs (NPN or PNP) which may be set individually, and a 4-20 mA analog output
Two vacuum to pressure ranges (-14.5 to 14.5 psi and -14.5 to 145 psi)
Three operation modes: Easy, Window and Hysteresis
3-color digital LCD display
6 pressure unit conversions
Lockable keypad
Unit parameters are easily copied to other pressure switch units
Selectable response times to eliminate output chattering
Fast zero reset
Optional panel mount and bracket kits
Agency approvals: cULus (E157382), CE, RoHS
2-year warranty
ProSense Digital
Pressure Switches/Pressure
Transmitters
Designed for air, non-corrosive gas and
non-flammable gas applications, these small
(1.2" by 1.2" by 1.7" deep) digital pressure
switches/pressure transmitters have a 3-color
LCD display and provide digital pressure control
via two digital outputs and one analog output.
These compact pressure switches are easy to install
and are ideal for use as pneumatic pressure switches or vacuum
pressure switches.
Current Sensors
Solo Process
Controllers
Signal
Conditioners
Also Available
www.automationdirect.com
1-800-633-0405
Go online or call to get complete information,
request your free catalog, or place an order.
www.automationdirect.com/digital-pressure-switches
Pressure
Switches
1205-ControlEngineering-ProcessSensorDigital-MAG:sensors-digital 4/16/2012 1:31 PM Page 1
input #1 at www.controleng.com/information
CTL120501-MAG_Ads.indd 2 5/1/2012 6:23:19 PM
COPYRIGHT 2012 NEWPORTELECTRONICS, INC. ALLRIGHTSRESERVED.
e-mail:info@newportUS.com
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MAY12-Shipping Ad (CD).qxd:Sensors Ad 4/11/12 10:32 AM Page 1
input #6 at www.controleng.com/information
CTL120501-MAG_Ads.indd 9 5/2/2012 11:50:33 AM
10 MAY 2012 CONTROL ENGINEERING
EXCLUSIVES EXCLUSIVES
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T
o apply the best interactive dis-
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these units to its Control Panel series,
introduced in 1995. The redesigned pan-
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bining elegance with a robust design.
Panels are available in landscape or
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Five-finger touch with work gloves
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more online at www.controleng.com.
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CTL1205_ProdExcl_V3msFINAL.indd 10 5/2/12 2:29 PM
input #7 at www.controleng.com/information
CTL120501-MAG_Ads.indd 10 5/3/2012 9:34:36 AM
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CONTROL ENGINEERING MAY 2012 11
T
he new MAQ20 Industrial Data
Acquisition and Control System
from Dataforth Corp. is said to
be a high- performance, highly
flexible system for factory, process, and
machine automation; military and aero-
space; power and energy; oil and gas;
and environmental monitoring.
The initial MAQ20 system offering is
a family of DIN rail-mounted, program-
mable, multi-channel, industrially rug-
ged signal conditioning input and output
modules and communication modules.
Modules mount on the industry standard
35 x 7.5 mm gull-wing DIN rail; a back-
bone mounts within the rail to provide
power and communication interconnec-
tions between the communication mod-
ules and each I/O module.
Bill McGovern, national sales man-
ager. One communication module can
interface to up to 24 I/O modules to con-
struct a system with a maximum of 384
channels that fits within a standard 19-in.
instrumentation rack.
MAQ20 modules include two com-
munication modules, analog input mod-
ules (process voltage, process current,
thermocouple, RTD, strain gage, fre-
quency), analog output modules (process
current, voltage output), and discrete
input/output modules with five channels
of input and five of output per module.
Key features include: ReDAQ Shape
monitoring and control software; 1500
Vrms channel-to-bus isolation; 0.035%
accuracy; -40 C to +75 C operating tem-
perature. System power comes from a
7-34 V dc power source connected to the
communication module; for more power,
load-sharing power boost modules can
be installed in standard I/O module slots.
ReDAQ Shape for MAQ20 software
enables users to easily create, save, and
open graphical user interface projects for
test, process, data collection, and data
analysis applications.
Dataforth
www.dataforth.com
Industrial data acquisition
and control system
Dataforth MAQ20 Industrial Data Acquisition and Control
System: DIN rail-mounted, programmable, multi-channel,
rugged signal conditioning I/O and communication modules
CTL1205_ProdExcl_V3msFINAL.indd 11 5/2/12 2:29 PM
input #8 at www.controleng.com/information
CTL120501-MAG_Ads.indd 11 5/3/2012 9:38:12 AM
12 MAY 2012 CONTROL ENGINEERING www.controleng.com
Social media for engineers, such as Linke-
dIns Automation & Control Engineering Group,
provide a platform for automation and control
engineers to share ideas, opinions, and solutions.
CFE Medias Control Engineering manages and
monitors this discussion platform. Some insights
follow, with more posted online.
Will cloud computing technology be adopt-
ed in process control and automation systems?
Majed Al Braik, an oil and energy profes-
sional in the United Arab Emirates and control
engineering section leader at ADMA OPCO,
wondered this out loud to fellow members of
LinkedIns Automaton & Control Engineering
Group and drew an array of insights.
Cloud computing is the way to go, noted Al
Braik, for high-level applications of industrial
control such as historians, human-machine inter-
faces, training systems, and asset management.
Adopting this technology at these levels pro-
vides beneficial and optimum hardware solutions
for offshore applications where space may be
limited, he said, but security threads may be of
concern if the cloud is exposed to a dirty network
(for instance, the Internet). With a limited local
cloud, security threads on my process control
system may be controllable with appropriate pro-
tection and mitigation measures. Some robust
cloud-computing software may become available
for process control, he suggested.
Group members remarks varied. It may well
happen, said John Blackburn, design engineer
at KAS Paper Systems LTD, Milton Keynes,
UK, but I think it would be a bad move. Too
many people are too inventive in ways to put
data at risk. You have no idea where critical
data are, who is responsible for keeping the data
secure, or what the motivation is of those who
are keeping the data secure. Cloud computing
proponents may tout security technology used
to protect a system, but Ive heard it all before.
In Blackburns view, controls engineers
should keep their hardware and software systems
under their purview.
Dave Hellyer, vice president, channel sales,
Tatsoft LLC, Dixon, Ill., said cloud strategies
can offer lower investment requirements in hard-
ware, software, infrastructure, and maintenance
personnel. It is not a requirement that all clouds
be public. Companies looking to modernize their
infrastructure and gain these advantages are
implementing their own private clouds. Anoth-
er advantage to implementing cloud strategies is
that software leveraging cloud technologies pro-
vides an engineering environment where multi-
ple engineers can work on the same project from
many locations simultaneously, using engineer-
ing resources more efficiently and productively.
Alarm priorities
The alarm management discussion was equal-
ly productive. Initiated by Morgan Wilson,
project engineer, Streat Automation, Christ-
church, New Zealand, this forum focused on
finding effective ways to present alarmsespe-
cially critical onesto plant operators. Alarm
lists get out of control quickly, said Wilson.
Hundreds can swamp a system. We reduce them
by planning carefully and setting severity lev-
els, she said, but acknowledge fever can still
impact some operators. In addition, she went
on, pop-up style alarms can be overly intrusive
when run on the same SCADA that the opera-
tor uses for control. Does anyone have any other
ideas for SCADA-based alarming?
Carl Lemp, contract automation engi-
neer, Pfizer, Lincoln, NE, USA, said key issues
include: An overwhelming number of alarms;
operators uncertain of what to do when a new
alarm occurs; Acknowledge fever, or confu-
sion from too many alarms at one time.
Trying to find a better system to manage
alarms after they are generated is like trying
to manage spam after it is in your inbox, said
Lemp. It will always be a struggle. If possible,
he said, develop an alarm strategy and decide
which alarms can be eliminated. Once unneces-
sary alarms are removed, those remaining can
be streamlined and more easily managed by the
existing systems alarm management features. ce
-Jeanine Katzel, contributing editor to Con-
trol Engineering, is at jkatzel@sbcglobal.net.
w
SOCIAL MEDIA
w
SOCIAL MEDIA
engineering
Cloud computing,
alarm management
Jeanine Katzel
An alarm
strategy can
help decide
which alarms
can be
eliminated.
What topics are hot in the LinkedIn Automation & Control Engineering Group?
Cloud computing and alarm presentation provoke lively dialogue. Read more online.
ONLINE
More of these discussions
http://bit.ly/IgKN3v
U.S. Manufacturing: Engineer-
ing Social Media - Is Industry
Returning to the U.S.?
http://bit.ly/wzNbvG
Has social media combined
with process control systems
yet? Were you fooled?
http://bit.ly/HPAl6I
Social media for Engineers:
LinkedIn Automation & Control
Engineering Group Click the
link atop
www.controleng.com.
CTL1205_Social_V3msFINAL.indd 12 5/2/12 2:30 PM
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input #9 at www.controleng.com/information
CTL120501-MAG_Ads.indd 13 5/2/2012 11:56:02 AM
14 MAY 2012 CONTROL ENGINEERING www.controleng.com
O
ne of the classic books of soft-
ware engineering deals with project
management. Unfortunately, many
automation engineers and project
managers are not familiar with the work. The
book is The Mythical Man-Month: Essays on
Software Engineering by Frederick P. Brooks.
Originally published in 1975, updated in 1982
and again in 1995, it is based on a series of IBM
development projects.
One of the primary lessons taught in the book
is that adding manpower to a late software
project makes it later. This simple and timeless
lesson is often forgotten in the rush to complete
projects, especially if a project is in trouble late
in the development cycle.
The reason for this non-intuitive lesson, also
known as Brooks Law, is that software proj-
ects, including automation software projects,
have inherent integration requirements. Pieces
must fit together, with no errors, for the system
to work correctly. Yet software is not visible or
easily reviewable until the pieces are ready for
integration. To make a reliable system, communi-
cations among architects, developers, managers,
and users must be plentiful.
As people are added to a project, the com-
munication paths increase nonlinearly, while the
benefit of the additional people increases lin-
early, at best. In addition, there are other costs
to adding people to a project, such as additional
training, additional systems and tools, and addi-
tional coordination meetings.
When a project is behind schedule, upper
management sometimes has a desire to throw
resources at the project hoping that it will fix the
problem. In some projects teams, outsiders will
descend on the project team to help, often only
getting in the way, creating more paperwork, and
taking valuable time in getting up to speed on
the project. These activities delay the project and
make the already late project even later.
How to avoid more delay
There is a way around this dilemma by adding
resources that meet very specific requirements
and by having a project organization that is
designed for the late addition of personnel. If you
are adding people late in the project, then you
must minimize their interactions with other team
members. This means that people you add must
be already trained in the system being used, must
understand the policies and procedures in place
for the project, must work on a very specific and
well-defined task, must be able to work indepen-
dently with minimal direction, and must not be
allowed to redefine requirements, designs, or
implementations that have already been agreed
to. You need experienced people who will not
step outside their immediate work area.
The second way to add people late in a project
and not make it even later is also discussed in
Brooks book under the chapter titled The Sur-
gical Team. If your project team can be orga-
nized using the surgical team model where every
member has a very special and well-defined role,
then communication paths are reduced and learn-
ing is reduced. A simple rule of thumb that can
be derived from Brooks Law is the maximum
number of people on a project is dependent on
the number of independent subtasks in the proj-
ect. The more tasks are subdivided because of
extra help, the longer it will take to complete
the subtasks.
Make sure that when you call all-hands-on-
deck to help finish a late project, all of the extra
resources dont further sink your project. If using
extra people at the end of the project, apply them
to independent subtasks, use experienced people,
and organize work to minimize required intra-
project communications. ce
- Dennis Brandl is president of BR&L Con-
sulting in Cary, N.C., www.brlconsulting.com.
His firm focuses on manufacturing IT. Contact
him at dbrandl@brlconsulting.com.
INSIGHT INSIGHT
IT & engineering
Project management: All hands
on deck may sink the project
Dennis Brandl
Simple and
timeless lesson:
Adding personnel
late in a software
project can make
the project even
later.
When you call All hands on deck! to help finish a late project,
ensure that all of the extra resources dont further sink the project. If
adding extra people at the end of a project, apply them to independent
subtasks, use experienced people, and organize work to minimize
required intra-project communications.
ONLINE
Use this link to see a longer
version of this article:
http://bit.ly/JRotyr Or search
on Brandl or project man-
agement atop
www.controleng.com.
Project management: All
hands on deck may sink the
project
What are your manufacturing
IT project principles?
CTL1205_Insight_V3msFINAL.indd 14 5/2/12 2:32 PM
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input #10 at www.controleng.com/information
CTL120501-MAG_Ads.indd 15 5/2/2012 6:32:23 PM
A
re the skilled trades persons entering
industry over the past 10 years equipped
to evaluate and trouble shoot 40-year-
old control systems without any connec-
tion for plugging in a lap top computer?
Clearly, 1970s technology pre-dated todays
advances in microprocessors, software, diag-
nostics, and Apple iPads. Almost everything in
an architecture involved hard wired components
and relay-based machine control. As technologies
advanced with PLCs, application software, and
diagnostics through the 70s, 80s, and 90s so did
the training for skilled trades persons. These folks
grew with the technology curve and had skill sets
to maintain and troubleshoot older systems. They
could maintain and troubleshoot the architectures
safety layer, required to stay hard wired, by indus-
try standards.
Fast forward to 2012 where the safety layer can
now be re-integrated with the rest of the machine
control system. This re-integration began in 2002
when NFPA 79, Electrical Standard for Industrial
Machinery, allowed Safety PLCs and safety com-
munication busses to be used for safety functions.
Since 2002 industry has seen skilled trades person-
nel leave the work force and new skilled trades
personnel enter. These young employees have gone
through school with electronic text books, high
tech systems in their labs, the internet as a basis for
communication, and iPads for daily use. What hap-
pens when a newly hired skilled trades person faces
a 40-year-old machine with a control system of 300
relays with one welded point? Theres no place to
plug in a lap top or IPad to diagnose the fault.
Is training the answer? Is there any place to get
training for 40-year-old control systems?
Do we have a skills gap in our trades personnel?
We still have a ton of old machine control systems
(including machine safety) and a shrinking pool of
skilled trades personnel with know how to main-
tain and trouble shoot these systems. People tell
me its hard to find qualified personnel capable to
revert to old schematics, analog meters, or even a
primary understanding of engineering basics. Ears
used to be a primary diagnostic tool. What are your
experiences?
Functional safety compliance
Who has the steps identified for anyone con-
sidering moving their machine safety compliance
to functional safety for their organization? Lets
assume for this discussion that functional safety
means being compliant with EN ISO 13849-1.
The general steps usually recommended for
engineers designing machine control systems are:
1.) Specify the safety functions
2.) Specify the required Performance Level(s)
(PLr) (goal)
3.) Technically design the safety circuit(s) to
achieve the safety function(s)
4.) Determine the specification of the Perfor-
mance Level(s) & their quantitative value
5.) Verify
6.) Validate
7.) Document
There may be variations to the above, and wed
certainly like to hear from you and your ideas.
However, does this really answer the question?
If youre the CEO, owner, or plant manager,
these steps dont even come close. Nothing here
addresses the business case, the cost benefit analy-
sis, the existence of a possible mandate, the impact
on employee injuries, or how to maintain compli-
ance with existing machines while adopting and
evolving over time to the new functional safety
approach. Might a plant manager want his supplier
of choice to provide a simple 5x7 card comparing
PL to Cat certified components? This would obvi-
ously be needed to replace a Cat component with
a PL component in an existing safety circuit. Cer-
tainly EN ISO 13849-1 considers that doesnt it?
Maybe not. Lets look at our domestic appli-
cation safety standards. Does anybody know of a
domestic machine safety standard that addresses
this issue? Will all suppliers (domestic and inter-
national) continue certifying safety components to
Cat while adding PL? If so, maybe the 5x7 compar-
ison card will not be required. Has anyone listed all
the business steps for moving to and adopting func-
tional safety for machine safety compliance? ce
- J.B. Titus, Certified Functional Safety Expert
(CFSE), writes the Control Engineering Machine
Safety Blog; jb@jbtitus.com; www.jbtitus.com.
w
SAFETY
w
SAFETY
machine
Old systems require more than
iPad skills; compliance
Is theres a machine safety trouble-shooting skills gap for older
systems? Functional safety compliance in the U.S.: Not even close.
JB Titus, CFSE
ONLINE
www.controleng.com/
blogs
Machine Guarding
trouble shooting old
systems is doomed with
iPad skills.
Machine Safety: Func-
tional safety and the
steps to be compliant in
the U.S.
Cost savings opportuni-
ties in machine safety
16 MAY 2012 CONTROL ENGINEERING www.controleng.com
CTL1205_Safety_V3msFINAL.indd 16 5/2/12 5:39 PM
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2012 MAVERICK Technologies, LLC.
11-MV-0181_ad_DCSNxt_steve_control_engin.indd 1 2/14/12 10:58 AM
input #11 at www.controleng.com/information
CTL120501-MAG_Ads.indd 17 5/2/2012 11:59:02 AM
18 MAY 2012 CONTROL ENGINEERING www.controleng.com
F
rom cathode ray tube (CRT) displays to
cold cathode fluorescent lamp (CCFL)
backlit liquid crystal displays (LCDs),
and now white light-emitting diode (LED)
backlit LCDs, touchscreen HMIs or operator
interfaces have come a long way since introduc-
tion in the early 1990s. Flat-panel displays have
become popular in the automation industry with
industrial computers and human machine inter-
faces (HMIs) connecting to PLCs and embedded
controller boards. HMI backlighting has evolved
significantly for applications in automotive, med-
ical, packaging, pharmaceuticals, food and bev-
erage, transportation, and many other industries.
Parameters such as display life, picture qual-
ity, and display brightness help determine which
HMI will best suit an application and its envi-
ronment. Modern HMIs LCDs have a backlight,
responsible for the light
emanating from the
screen. When flat-pan-
el LCDs replaced the
older CRT displays like
the ones used in older
panel-based operator
interfaces, CCFL back-
lights enhanced the
quality, brightness, and
life span of the HMIs as
compared to the old CRT displays. CCFL back-
light for LCDs began with a life span of 5,000 hr,
improving over time from 10,000 up to 50,000
hr of backlight life. Life span for CCFL backlit
LCDs depends on the HMI ambient tempera-
ture and humidity. CCFL backlit LCDs for more
expensive thin-film transistor (TFT) LCDs oper-
ating at 25 C (77 F) normally last about 50,000
hr, but the backlight life span changes with tem-
perature. If the temperature of the LCD rises to
about 40 C (104 F), CCFL backlight life deterio-
rates to roughly 20,000 hr (see graph).
As for relative humiditys effect on life span,
the wet bulb temperature of a CCFL back-
lit HMI is 39 C (102.2 F). Once a CCFL back-
lit LCD reaches its maximum humidity rating at
a given temperature, the backlight will give up
(see graph). CCFL challenges relate to how they
work. The CCFL light source is classified as an
electronic component, and is a gas-discharge light
source, which produces output from a stimulated
phosphor coating inside the glass lamp envelope.
The typical CCFL is a hollow glass cylinder,
coated inside with a phosphor material composed
of rare earth elements and sealed with a gettered
UPDATE UPDATE
Backlights evolution for human
machine interface (HMI) panels
technology
White LEDs show high-temperature advantages for touchscreen HMIs or operator
interface backlighting compared to cold cathode fluorescent lamp (CCFL) backlit
liquid crystal displays (LCDs).
ONLINE
Read more on this topic, with
additional diagrams at
http://bit.ly/JD8Jlu
Also see:
www.uticor.net
www.avg.net
http://flash.ezautomation.net
Comparison of CCFL vs.
white LED backlight life
measured against tem-
perature. Courtesy: AVG
Automation
White LED backlighting
from AVG Automation is
available in 4, 6, 8, 10,
and 15-in. Uticore and
EZTouch touchpanel
PCs; 15-in. shown.
Courtesy:
AVG Automation
Relative humidity tolerance of CCFL backlit
HMIs. Note: The area under the curve represents
safe region, and over the curve is the unsafe
region of CCFL backlit HMI operation. Courtesy:
AVG Automation
Relative humidity tolerance of white LED backlit
HMIs. Areas under the plot represent a safe
region whereas areas over the plot represent
unsafe regions of operation for white LED backlit
HMIs. (Compare to the smaller safe region for
CCFLs in Figure 2.) Courtesy: AVG Automation
Continued on p. 26
CTL1205_TechUpdate_V3msFINAL.indd 18 5/2/12 2:42 PM
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User-friendly HMI and SCADA
Energy-efficient drive technology
Open PROFINET communications
Integrated safety technology
Single software environment in
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A complete solution makes the
best machines
2
0
1
2
S
i
e
m
e
n
s
I
n
d
u
s
t
r
y
,
I
n
c
.
input #12 at www.controleng.com/information
CTL120501-MAG_Ads.indd 19 5/2/2012 12:26:55 PM
SOFTWARE & SERVICES POWER DISTRIBUTION ENCLOSURES CLIMATE CONTROL IT INFRASTRUCTURE
Thousands of enclosures
Hundreds of options
Designed and delivered in 10 days
(206-A-10155)-15.75x3.5.indd 1 4/17/12 4:46 PM
input #13 at www.controleng.com/information
To identify the most energy-effi-
cient pneumatic and electric automa-
tion, a technology-neutral comparison
is required. After considering differ-
ent alternatives, a German automotive
components supplier adopted a ready-
to-install energy-efficient handling
system. When consumers look for an
energy-saving washing machine, they
simply buy the device with the best
energy-efficiency rating. For manu-
facturers of washing machines, things
are more difficult. If they want the
most energy-efficient production facil-
ity, they realize that no certification of
energy-efficiency classes is available.
Energy efficiency in automation
is dependent on the industrial applica-
tion in question, explained Festo ener-
gy-efficiency expert Dr. Axel-Andreas
Gomeringer.
The only reason it is possible to
classify washing machines into ener-
gy-efficiency classes is that the usage
scenario of a washing machine as a
closed system is precisely known. For
example, all devices can be compared
easily on the basis of their standard
cotton program with a 60 C wash tem-
perature. For machinery and installa-
tions, however, the system parameters
are not clear. Should only the drive be
assessed, or the control chain, or the
entire factory?
Define tasks clearly
Any industrial application has its
specific requirements for technical
criteria such as speed, load capacity,
power to weight ratio, accuracy, control
behavior, rigidity under load, and effi-
ciency or robustness, and also for eco-
nomic criteria such as the purchase cost
(price, commissioning, installation) and
operating costs (maintenance, durabil-
ity, energy costs). In any application,
energy efficiency depends on the spe-
cific task. The task must be clearly
defined before the user chooses a drive
technologyelectric, pneumatic, or
a combination of the two, explained
Gomeringer, head of innovation and
Efficiency needs a system approach,
depends on individual applications
NEWS NEWS
industry
Tiny details matter
http://bit.ly/IT9jsv
...or HMI?
http://bit.ly/ITCR7D
CSIA record
http://bit.ly/KPiJIs
Real world engineering Video game... System integrators
High rigidity and low moving mass: The
pyramid-shaped, enclosed design makes
the robot highly dynamic. At the same
time, the handling unit is more accessible
and allows faster production. One mil-
lion relays a year are produced reliably
in different shifts using the Delta robot.
Courtesy: Festo
CTL1205_News_V5msFINAL.indd 20 5/2/12 5:42 PM
technology management at Festo.
With engineering software, a com-
mon dimensioning process for mechan-
ical drive and transmission components
and motors prevents a duplication of
safety factors, which would result in
oversized electric drive systems and
a waste of energy. Calculations have
shown that, with consistent use of siz-
ing software, energy costs can be
reduced by as much as 70%.
Often success stories about ener-
gy-optimal solutions really get started
with complete handling systems and
control technology. Supplied ready-to-
install and fully pretested, lightweight
handling systems such as a high-speed
handling robot can be delivered directly
to users applications. The low weight
of the robot, with its rod kinematics
made up of standard electromechani-
cal components and ultralight carbon
fiber rods, ensures the efficient use of
drive technology. With a gantry design
with wide dynamic motion, stationary
motors for the X- and Y-axes ensure
lower moving masses. In control tech-
nology systems, for example, a double
motor controller with coupled interme-
diate circuits exploits braking energy
for recovery purposes.
The Tripod robot design needs
less space and design time than a han-
dling gantry and is also faster than a
SCARA (selective compliant articulat-
ed robot arm). That is how Gerd Ulmer,
general manager of G. Ulmer Automa-
tion GmbH, summarized some advan-
tages of the new handling system. He
has installed two Tripod handling units
on an assembly machine for the auto-
motive components supplier.
On a machine that assembles safe-
ty relays for diesel engines, two Delta
robots equip the relay bodies with
seven to nine contacts, depending on
the type of relay required. The compo-
nents were previously produced abroad
and are nowprimarily in the interests
of better qualityto be produced on a
fully automatic machine which includes
automatic test stations, explains the
client, a special machine builder. The
machine comprises 24 stations and was
ordered from Ulmer by a component
supplier to the automotive industry.
ONLINE: Photos, details on qual-
ity, teach-in, controlers and other
technologies at Ulmer Automation
- Christopher Haug is with Festo.
www.festo.com
www.ulmergmbh.de
Smart sand
http://bit.ly/ITDcqX
M. Scott Brauer photo courtesy of MIT News Office
Micro robotics
Video: Tips for
engineering service
contracts
Service and maintenance agreements
are important for engineers and system
integrators who can provide those services.
Those involved should carefully define war-
rantees, scope, deadlines, and payment
structure.
Mark Voigtmann, general counsel for
Control System Integrator Association
(CSIA), and attorney with Faegre Baker
Daniels, outlines key points to remember
when considering maintenance and service
contracts for automation, controls, or oper-
ations engineering. Voigtmann made the
comments after a presentation on the same
topic at CSIA 2012, the 19th Annual Execu-
tive Conference, in May, in Scottsdale, Ariz.
http://controleng.com/videos
(About 3:00 minutes.)
- Mark T. Hoske is content manager, CFE
Media, Control Engineering.
www.controlsys.org
Search Legalities atop http://contro-
leng.com for more from Voigtmann, includ-
ing the articles below.
Legalities: Not All Automation Standards
Are Equal
Legalities: 8 ugly contract clauses
Legalities In Automation: Know Your
Project Delivery Method
CTL1205_News_V5msFINAL.indd 21 5/2/12 5:42 PM CTL120501-MAG_Ads.indd 20 5/3/2012 9:41:27 AM
SOFTWARE & SERVICES POWER DISTRIBUTION ENCLOSURES CLIMATE CONTROL IT INFRASTRUCTURE
Thousands of enclosures
Hundreds of options
Designed and delivered in 10 days
(206-A-10155)-15.75x3.5.indd 1 4/17/12 4:46 PM
To identify the most energy-effi-
cient pneumatic and electric automa-
tion, a technology-neutral comparison
is required. After considering differ-
ent alternatives, a German automotive
components supplier adopted a ready-
to-install energy-efficient handling
system. When consumers look for an
energy-saving washing machine, they
simply buy the device with the best
energy-efficiency rating. For manu-
facturers of washing machines, things
are more difficult. If they want the
most energy-efficient production facil-
ity, they realize that no certification of
energy-efficiency classes is available.
Energy efficiency in automation
is dependent on the industrial applica-
tion in question, explained Festo ener-
gy-efficiency expert Dr. Axel-Andreas
Gomeringer.
The only reason it is possible to
classify washing machines into ener-
gy-efficiency classes is that the usage
scenario of a washing machine as a
closed system is precisely known. For
example, all devices can be compared
easily on the basis of their standard
cotton program with a 60 C wash tem-
perature. For machinery and installa-
tions, however, the system parameters
are not clear. Should only the drive be
assessed, or the control chain, or the
entire factory?
Define tasks clearly
Any industrial application has its
specific requirements for technical
criteria such as speed, load capacity,
power to weight ratio, accuracy, control
behavior, rigidity under load, and effi-
ciency or robustness, and also for eco-
nomic criteria such as the purchase cost
(price, commissioning, installation) and
operating costs (maintenance, durabil-
ity, energy costs). In any application,
energy efficiency depends on the spe-
cific task. The task must be clearly
defined before the user chooses a drive
technologyelectric, pneumatic, or
a combination of the two, explained
Gomeringer, head of innovation and
Efficiency needs a system approach,
depends on individual applications
NEWS NEWS
industry
Tiny details matter
http://bit.ly/IT9jsv
...or HMI?
http://bit.ly/ITCR7D
CSIA record
http://bit.ly/KPiJIs
Real world engineering Video game... System integrators
High rigidity and low moving mass: The
pyramid-shaped, enclosed design makes
the robot highly dynamic. At the same
time, the handling unit is more accessible
and allows faster production. One mil-
lion relays a year are produced reliably
in different shifts using the Delta robot.
Courtesy: Festo
CTL1205_News_V5msFINAL.indd 20 5/2/12 5:42 PM
technology management at Festo.
With engineering software, a com-
mon dimensioning process for mechan-
ical drive and transmission components
and motors prevents a duplication of
safety factors, which would result in
oversized electric drive systems and
a waste of energy. Calculations have
shown that, with consistent use of siz-
ing software, energy costs can be
reduced by as much as 70%.
Often success stories about ener-
gy-optimal solutions really get started
with complete handling systems and
control technology. Supplied ready-to-
install and fully pretested, lightweight
handling systems such as a high-speed
handling robot can be delivered directly
to users applications. The low weight
of the robot, with its rod kinematics
made up of standard electromechani-
cal components and ultralight carbon
fiber rods, ensures the efficient use of
drive technology. With a gantry design
with wide dynamic motion, stationary
motors for the X- and Y-axes ensure
lower moving masses. In control tech-
nology systems, for example, a double
motor controller with coupled interme-
diate circuits exploits braking energy
for recovery purposes.
The Tripod robot design needs
less space and design time than a han-
dling gantry and is also faster than a
SCARA (selective compliant articulat-
ed robot arm). That is how Gerd Ulmer,
general manager of G. Ulmer Automa-
tion GmbH, summarized some advan-
tages of the new handling system. He
has installed two Tripod handling units
on an assembly machine for the auto-
motive components supplier.
On a machine that assembles safe-
ty relays for diesel engines, two Delta
robots equip the relay bodies with
seven to nine contacts, depending on
the type of relay required. The compo-
nents were previously produced abroad
and are nowprimarily in the interests
of better qualityto be produced on a
fully automatic machine which includes
automatic test stations, explains the
client, a special machine builder. The
machine comprises 24 stations and was
ordered from Ulmer by a component
supplier to the automotive industry.
ONLINE: Photos, details on qual-
ity, teach-in, controlers and other
technologies at Ulmer Automation
- Christopher Haug is with Festo.
www.festo.com
www.ulmergmbh.de
Smart sand
http://bit.ly/ITDcqX
M. Scott Brauer photo courtesy of MIT News Office
Micro robotics
Video: Tips for
engineering service
contracts
Service and maintenance agreements
are important for engineers and system
integrators who can provide those services.
Those involved should carefully define war-
rantees, scope, deadlines, and payment
structure.
Mark Voigtmann, general counsel for
Control System Integrator Association
(CSIA), and attorney with Faegre Baker
Daniels, outlines key points to remember
when considering maintenance and service
contracts for automation, controls, or oper-
ations engineering. Voigtmann made the
comments after a presentation on the same
topic at CSIA 2012, the 19th Annual Execu-
tive Conference, in May, in Scottsdale, Ariz.
http://controleng.com/videos
(About 3:00 minutes.)
- Mark T. Hoske is content manager, CFE
Media, Control Engineering.
www.controlsys.org
Search Legalities atop http://contro-
leng.com for more from Voigtmann, includ-
ing the articles below.
Legalities: Not All Automation Standards
Are Equal
Legalities: 8 ugly contract clauses
Legalities In Automation: Know Your
Project Delivery Method
CTL1205_News_V5msFINAL.indd 21 5/2/12 5:42 PM CTL120501-MAG_Ads.indd 21 5/3/2012 9:41:44 AM
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Construction of Vogtle unit 3 turbine building foundation basement continues
in this March 5 image. Courtesy: Southern Company.
news
22 MAY 2012 CONTROL ENGINEERING www.controleng.com
The first new operating license in 34
years was approved in early February
2012 by the U.S. Nuclear Regulatory
Commission (NRC) for two reactors at
Southern Nuclear Operating Co.s Vogtle
power plant located near Augusta, Ga.
Other license approvals are pending. The
industry is at a crossroad with positive
and negative developments.
On Feb. 9, 2012, the NRC approved
a new era combined operating license
(COL)which is a construction permit
and operating license in onefor the
first of two reactors at Southern Nucle-
ar Operating Co.s power plant locat-
ed in east-central Georgia, near Augus-
ta. (Southern Co. heads a consortium of
utilities operating in the region.)
The new construction is on the site of
the companys two-unit Alvin W. Vogtle
electric generating plant. Westinghouse
Electric Co. (a unit of Toshiba Corp.) is
the supplier of the two AP1000 pressur-
ized-water reactors (PWRs), each with
1,100 megawatt (MW) net output. The
reactors represent advanced Generation
III+ design. Commercial operation of
Vogtle Units 3 and 4 is expected in 2016
and 2017, respectively.
A number of new nuclear plant appli-
cations are being processed but approv-
al has slowed due to renewed safety
concerns and economic and political
issues. Response to safety and reliabil-
ity concerns is key to approval of any
new reactor design. AP1000s reliabil-
ity enhancements include various pas-
sive safety systems that do not require
operator actions to mitigate design-basis
accidents, according to Westinghouse.
Gravity, natural circulation, and com-
pressed gas are used to actuate functions
of the safety systems. That eliminates
the need for ac power, diesel generators,
pumped cooling water, or other active
safety-support systems inherent to a typ-
ical nuclear power plant. If plant power
is lost (or a safeguards actuation sig-
nal is received), AP1000 is designed
to automatically align and actuate a few
basic valves, which start up the safety
systemsusing only Class 1E battery
power (Ref. 2, online).
After the March 11, 2011, came the
accident at J apans Fukushima Daiichi
nuclear power plant created repercus-
sions. An indicator of stronger regulatory
oversight is NRCs March 2012 authori-
zation to issue three orders to U.S. com-
mercial nuclear reactors to implement
several reactor safety recommendations,
based on Fukushima lessons learned.
Order 1 requires the plants to improve
protection of safety equipment installed
after the 9/11 terrorist attacks and to
have enough equipment available to sup-
port all reactors at a given site simulta-
neously. Order 2 mandates installation
of enhanced equipment to monitor water
levels in each plants spent fuel pool.
These orders affect every U.S. commer-
cial nuclear power plant. Order 3 applies
only to boiling-water reactors (BWRs)
with Mark I or II containment design.
These reactors must improve their vent-
ing systemsand in the case of Mark II
reactors install new venting systemsto
help prevent or mitigate core damage in
case of a serious accident.
Read more: http://bit.ly/IVfLNO
Frank J. Bartos, PE, is a Control
Engineering contributing content spe-
cialist. Reach him at braunbart@sbc-
global.net.
www.nrc.gov
www.westinghousenuclear.com
U.S. nuclear power update
CTL1205_News_V5msFINAL.indd 22 5/2/12 5:42 PM CTL120501-MAG_Ads.indd 22 5/3/2012 9:43:28 AM
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www.controleng.com CONTROL ENGINEERING MAY 2012 23
Imagine you are in a meeting with your companys chief
financial officer, and he says spending must increase at a sig-
nificantly slower rate than you expected this year. Now what
do you do about those process improvements? The good news
is that despite the economy, there are a number of core trends
that will help you be more selective with spending in 2012
and can help you optimize your role in the company.
One: Wireless technology -- If you havent already
invested in wireless technology, now is the time to do so to
reduce plant costs and to improve business productivity.
Two: Phased migration -- The drive to replace aging
equipment and technology continues to be a key trend among
manufacturers in the U.S.
Three: Upfront engineering -- Best-practice organiza-
tions use database-driven controls hardware and software to
seamlessly move through all stages of the design and manu-
5 control market trends for 2012: Wireless, migration...
facturing process; identifying errors up-front costs less.
Four: Energy usage management -- Energy consump-
tion is a rising percentage of the overall cost of goods.
Five: Safety -- Risk evaluation is an ongoing trend for all
manufacturers.
- Larry Turner is president and chief executive officer of
Hannover Fairs USA.
A plant manager involved in manufacturing
success, a top manufacturing analyst, and presi-
dent of a manufacturing group will deliver key-
notes at the 2012 Industrial Automation Summit,
presented by CFE Media and Hannover Messe and
sponsored by Beckhoff, Sept. 12-13, part of the first Indus-
trial Automation North America show at the 2012 IMTS Show,
Sept. 10-15 in Chicago. The 2012 Industrial Automation Sum-
mit keynote speakers are: Billy Taylor the plant manager at
Goodyear Tire and Rubber Companys Fayetteville, NC plant,
Karen Kurek, who heads McGladreys National Manufactur-
ing Industry consultancy, and Douglas Woods, the president
and CEO of the Association for Manufacturing Technology.
See more at www.imts.com/education/ianaSummit.html
Diverse voices to keynote
Industrial Automation Summit
Correction In the Control Engineering North American print edition, April 2012, p. 8,
Peter Herzhoffs name was spelled without an h.Control Engineering regrets the error. See
extended online article: http://bit.ly/ITxGVi.
CTL1205_News_V5msFINAL.indd 23 5/2/12 5:42 PM
input #14 at www.controleng.com/information
input #15 at www.controleng.com/information
CTL120501-MAG_Ads.indd 23 5/3/2012 9:50:45 AM
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24 MAY 2012 CONTROL ENGINEERING www.controleng.com
Control Engineering International
CFE Media asked engineers for
global engineering project advice.
Paul Bearn, PE, electrical services
engineer, KlingStubbins, Philadelphia:
Cultural differences become apparent
quickly. One is quickly warned that to
drink water during Ramadan would be
insultingeven during an all-day pre-
sentation. Stories about presentation
of business cards in China and J apan,
now clich here, still hold true. For-
eigners are usually afforded more lee-
way with such slips of social etiquette
than natives. Theres typically interest
on both sides to learn more about each
others culture and language. Exploring
differences can build relationships and
put everyone at ease. Areas of greater
concern.[include] differences in whats
implied by a contract. An American
project manager [may discover] that a
contract signing is only a formality, sig-
nifying the start of renegotiations.
Erin McConahey, PE, LEED AP,
principal, Arup, Los Angeles: Local
codes and practices; generally a proj-
ect refers to a specific countrywide
code like the British Standards (BS),
or European standards (EN), etc., but
little is stated or written of what local
authorities may expect and/or require.
Sometimes multiple codes are stipulat-
ed which may conflict with other codes.
Mehdi Jalayerian, PE, LEED AP
BD+C, executive vice president, glob-
al practice, Environmental Systems
Design Inc., Chicago: Often... local
codes and standards cannot be effec-
tively applied to modern projects envi-
sioned. Lack of applicability of local
codes presents a challenge [and] oppor-
tunity to help the local community of
building authorities, utility companies,
fire brigades, contractors, and owner-
operators to become familiar first-hand
with solutions, typically outside the
scope of local codes and experience.
ONLINEMore in a World of Dif-
ference tutorial, via Consulting-Speci-
fying Engineer. http://bit.ly/IFdj0m
Global engineering tips
While engineering is a language spoken globally, this advice
can help when working on your next international project.
Energy, data management, and
effective maintenance were three over-
arching themes from the 2012 Han-
nover Messe in Germany April 23-27.
The strength of U.S. manufacturing
global leadership was highlighted in
the 5-day event. With Europe strug-
gling to gain a more solid financial
foothold and Asia wrestling with qual-
ity, safety, and productivity issues, the
focus of the worlds admiration was on
the United States. The countrys ability
to emerge from recession and the rela-
tive strength of its economy were the
envy of global manufacturers at Han-
nover Messe this year.
When you look more in-depth
at the business, the patterns have
changed, said Michael Ziesemer,
COO and board member of German-
based Endress+Hauser. The U.S. busi-
ness climate is absolutely great.
As the 2012 Partner Nation at Han-
nover Messe, China attracted much
attention. Chinese premier Wen Jiabao
said, in part, China is confronted
with major challenges and problems
with industrialization, including an
inefficient model for industrial devel-
opment, lack of market competitive-
ness, weak capacity for scientific and
technological innovation, and low effi-
ciency in the use of resources.
Hannover officials said more than
25% of show attendees came from
outside Germany.
U.S. manufacturing
renaissance
The 2012 Hannover Messe focused on
energy and data management, but the
underlying strength of U.S. manufactur-
ing also was a major topic.
CTL1205_News_V5msFINAL.indd 24 5/2/12 5:42 PM
input #16 at www.controleng.com/information
CTL120501-MAG_Ads.indd 24 5/3/2012 10:02:06 AM
letter.indd 1 2/17/2012 5:02:10 PM
input #17 at www.controleng.com/information
CTL120501-MAG_Ads.indd 25 5/2/2012 12:45:56 PM
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26 MAY 2012 CONTROL ENGINEERING www.controleng.com
(impurity-free) electrode at both ends.
A CCFL backlit LCD requires a sup-
ply voltage of more than 1000 V, typi-
cally 1,200-1,500 V. A power-hungry
inverter board drives the CCFL back-
light. Despite the name, cold cathodes
dont remain cold as they operate; they
can get painfully hot. High backlight
temperatures reduce life span and can
cause erratic operation. HMIs in India,
Mexico, China, and the Middle East are
subject to ambient temperatures of 45 C
(113 F) with 95% humidity. For longer
life and higher reliability, high-end man-
ufacturers are turning to high-efficiency
white LEDs, solid-state devices.
Unlike CCFLs, white LEDs do not
have gases and phosphors requiring
high voltages but can operate in the
range of 5 V to 24 V without an inverter
board, generating less heat than CCFLs.
White LED backlit LCD displays gen-
erally last twice as long as CCFL back-
lights75,000-100,000 hr without
temperature effects (see first graph).
CCFL backlit LCD displays have 25
C operating temperatures; white have
LED-based backlights capable of operat-
ing up to 60 C (140 F) in humidity up to
95% (see last graph).
LED-based lighting has high effi-
ciency as measured by light output per
unit power input. Brightness is often
measured in NITS (lumens / sq meter).
An HMI with white LED backlights nor-
mally exhibits roughly 500 nits, com-
pared to the CCFL backlit LCD displays
at roughly 200-300 nits. White LED
backlight life span increases twofold,
and brightness increases.
Redundancy helps. When a CCFL
bulb fails, the LCD goes dark. With the
white LED backlit HMI, if one of many
LEDs burns out, the display dims in pro-
portion, but it still can be used. Read
more at http://bit.ly/J D8J lu ce
- Edited by Mark T. Hoske, content
manager, CFE Media, Control Engineer-
ing, with information from Vikram Aditya
Kumar, vice president, AVG/Uticor.
UPDATE UPDATE
technology
Inception: Retrofit engineering a
white LED for backlighting
I
nspiration for white
LEDs throughout an HMI
product line had a hot
beginning.
Shalabh Kumar, AVG
Automation CEO, said, I
got the idea for [LED back-
lighting] when landing in
Ahmedabad, India, and
the pilot said it was 42 C
[108 F] at 7:30 p.m. I asked
what the temperature was
during the day, and it was 48 C [118
F]. In a manufacturing plant, a panel
can easily be subjected to 60 C [140
F], which rapidly decreases operating
life. Then we talked to manufacturers
whose machines use operator inter-
faces using CCFL displays. A year and
a half life for a screen is not unusual.
While some screen manufactur-
ers try to make the bulbs easy to
replace, no one we talked to actu-
ally replaces them in the field. They
replace the entire operator inter-
face [OI], which adds considerable
expense, Kumar said.
Operator panels using white LEDs
last up to 6 years, com-
pared to 1.5 to 3 years maximum for
CCFLs, with a much higher operating
temperature range; in rugged environ-
ments, especially in high-temperature
areas, the higher initial cost is eas-
ily made up by avoiding multiple OI
replacements during the same operat-
ing period, he suggested.
Kumar said, in the March 14 inter-
view, that AVG is the only company in
the world that offers white LED back-
light as standard, throughout its Uticor
Tough Panel line of HMIs.
- Mark T. Hoske is content manager,
CFE Media, Control Engineering.
http://controleng.com/hmi
Shalli Kumar, AVG Auto-
mation CEO, shows a cold
cathode fluorescent lamp
(CCFL) removed from a
backlit liquid crystal display
(LCD), which is then retro-
fit with an LED array for a
Uticor Tough Panel HMI.
CFE Media photo by Mark
T. Hoske
Continued from p. 18
CTL1205_TechUpdate_V3msFINAL.indd 26 5/2/12 2:42 PM
input #18 at www.controleng.com/information
CTL120501-MAG_Ads.indd 26 5/3/2012 10:05:54 AM
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ctl201204_eNewsLtr_fillerHLF.indd 1 3/21/2012 11:47:49 AM
pose, he says. An OEM thinks, Im
going to build 200 of these this year. I
know what my I/O looks like, I know
how many I/O points,
and I know what my
screens look like.
Thats when this kind
of device fits perfect-
ly with the right price
and performance
ratio.
While all types of
users are cost con-
scious, OEMs have to
be especially aware
of how much cost any com-
ponent or manufacturing step adds to a
product. An integrated unit offers a very
effective way to avoid the labor costs
related to mounting a larger number of
components and buying those items. A
single unit can be installed more quick-
ly, probably in a smaller enclosure, and
avoid the need for additional cables and
accessories.
When you look at how an OEM
prices up a machine, theyre going to
count every little item, every cable,
every wire tray, everything that they
have to do, because they all add to the
cost, Krajewski says. At the end of the
day, its the economics that drive these
decisions.
The limits of practicality
As mentioned earlier, integrated units
tend to be at the lower end of the func-
tionality spectrum. As applications move
into higher I/O counts and greater pro-
gramming complexity, the practicality of
offering an off-the-shelf unit that fits such
an application is much smaller and suppli-
ers dont see the benefit. Still, some pro-
ducers feel they have yet to see the full
extent of the market.
Schuy believes there is still room to
expand the product line. Maple Systems
initial integrated offerings have used rela-
tively small screen sizes of 3.5- and 5.7-
in., while the companys separate HMIs
go as high as 15-in. New integrated units
with 7- and 10-in. screens are being eval-
Integrating HMIs with PC-based control
is also a growing trend. The concept
of a soft PLC built into an industrial PC
can provide much versatility. Courtesy:
Siemens.
Integrated control devices
CTL1205_F1_Integrating_V3msFINAL.indd 38 5/2/12 2:52 PM CTL120501-MAG_Ads.indd 38 5/3/2012 10:22:53 AM
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CONTROL ENGINEERING MAY 2012 39
uated, but he thinks those are pushing
useful limits. Once you get into the larg-
er screens, the cost difference between
conventional components and a combi-
nation HMI/PLC gets closer together, he
says. The majority of the cost is in the
display itself. Thats the most expensive
part. If a customer wants a larger screen,
say 10-, 12-, or 15-inch, theyre probably
going to go ahead and do it separately.
I/O options are also limited. A user
that wants to install a system in a pro-
cess manufacturing plant using smart
instrumentation via HART or a fieldbus
network will find few if any integrated
options. The greater availability of I/O for
discrete sensors reflects the slant toward
discrete applications.
Other types of integration
As Elswick already mentioned, Sie-
mens finds it easier to integrate I/O and a
PLC without the HMI. Invensys and Sie-
mens both see growing opportunities for
integration of HMIs with PC-based con-
trollers rather than more traditional PLCs.
Krajewski reports more OEMs are ask-
ing for HMIs that can be laid on top of
those controllers, now that technology
has caught up with the concept of using
soft PLCs. We had entered the PC-based
control market back in the late 1990s with
the Wonderware InControl product, and at
that time it was too early. There werent
embedded operating systems and those
kinds of things. Back then we were talk-
ing about Windows 95 and 98, and people
didnt trust those for control.
Evolving technologies are going in
a wider variety of directions than ever
before, so users can select an offer-
ing precisely aligned with the needs of
a given application. The greatest chal-
lenge is often sifting through the dizzy-
ing range of choices. ce
Peter Welander is a content manag-
er for Control Engineering. Reach him
at pwelander@cfemedia.com.
When the display is
large enough, a touch
screen allows for
the most flexibility of
virtual knobs and but-
tons. However, these
have minimum space
requirements for
practicality. Courtesy:
Invensys Operations
Management
Its a matter of
knowing the market
that youre trying
to address with an
integrated unit.
A hybrid
approach
keeps the
mission-critical
engineering
skills in-house
and outsources
more general
purpose
services.
Play an active
role every step
of the way, with
team members
focused
on clearly
defined project
results.
services
CTL1205_F3_ServicesV3msFINAL.indd 46 5/2/12 2:55 PM
www.controleng.com CONTROL ENGINEERING MAY 2012 P1
T
he industry debate over the vir-
tues of distributed control systems
(DCSs) versus programmable logic
controllers (PLCs) has been going
on for at least the past four decades.
However, as the technologies have evolved, so
has the discussion. The choice used to be more
clear-cut, but as the functionality differences nar-
row and price points align, the arguments for and
against each system have become increasingly
murky.
Central to understanding the argument
between the two is grasping the fundamen-
tal differences between the two platforms. For
instance, DCS architecture originated from an
overall system approach with a focus on dis-
tributing control on a network so that operators
could monitor and interact with the entire scope
of the plant. Coordination, synchronization, and
integrity of process data over a high-performance
and deterministic network are at the core of DCS
architecture.
PLC architectures, on the other hand, focus
on very flexible and fast local control, and recent
advancements in PLC technology have added
process control features. When PLCs and HMI
software packages are integrated, the result looks
a lot like a DCS but is still very much a do-it-
yourself (DIY) approach, meaning engineers
must oversee the assembly of their system from
the ground up. While this is a flexible approach
to control, the DIY option usually comes with
increased technical risks in networking and per-
formance as well as added costs that are not
Tim Sweet
Buy or Build Your
Process Control System
One DCS supplier makes the case for buying a comprehensive control system to run
your process unit rather than a do-it-yourself PLC-based approach.
inside process
ONLINE
www.honeywellprocess.com
At www.controleng.com/
archive, read the story of a
water utility that built a DIY
system and liked it: Water
Treatment Plant Upgrades
Automation, Nov. 2011.
CTL1205_InsideProc01_V7msFINAL.indd 1 5/2/12 2:58 PM
Oil & Gas exploration
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Times have
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Across
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manufacturing
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risen while the
purchase price
of a DCS has
decreased.
In a system
where the
control and
operator
environments
are designed
and built
together, often
90% of what is
needed to run
a process plant
can be made
standard.
3
5
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input #27 at www.controleng.com/information
CTL120501-MAG_Ads.indd 5 5/2/2012 5:56:49 PM
P6 MAY 2012 CONTROL ENGINEERING www.controleng.com
ing, trending, and history in the HMI are
easy to find and configured in one loca-
tion. Its no longer necessary to con-
figure these parameters to populate the
HMI configuration.
Application software
In the 20- to 30-year lifespan of an
automation system, its important to con-
sider how often typical users will need to
expand or modify their systems and how
often they will want to add a new control
technology to them.
In the world of DIY, its possible to
find all the applications needed to run a
plant merely by looking through catalogs
from PLC and HMI vendors and plac-
ing an order. Licenses, DVDs, down-
loads, and other usable content will
begin to arrive shortly after that, provid-
ing an array of materials. However, its
easier to order one model number and
receive everything needed at once via
the same content. One license can sup-
ply all the controlware, a data historian,
trend objects, business integration soft-
ware, and graphics needed to run a pro-
cess plant. With the capabilities of DCS
architecture, all control applications
load correctly, are guaranteed to be the
correct version, and are tested to work
together.
Data management
When the DIY DCS is pieced togeth-
er, multiple data models can spawn
multiple data elements representing the
same piece of information. And when
piece parts are brought together to form
a system, the various data models must
be synchronized and maintained. A bur-
den exists on application engineers and
system administrators to accomplish
this task.
In the world of the DCS architec-
ture, the entire data model has been
conceived to cover all parts of the sys-
tem. Hence, one data owner can provide
a piece of information to any applica-
tion or service anywhere in the system.
The issue here isnt the number of data-
bases. The key is having a single data
model so that no matter where a data
element resides, it can be used by any
element of the architecture and that par-
ticular data element is never duplicated.
A comprehensive data model doesnt
necessarily mean one database, but it
does mean only one location for any
given element of data.
Batch automation
The comprehensive nature of DCS
architecture has long been a favorite for
batch automation projects. More than
anywhere else, batch requires careful
coordination between phases, units, rec-
ipes, formulas, and so on. Even classic
DCS architecture has been challenged
to provide a complete packaged solution
because of all the various and diverse
elements in a batch environment. For
this reason, many batch automation proj-
ects have resorted to a myriad of packag-
es brought together to form the solution.
However, the batch-data model is no
longer as daunting as it once was, and
inside process
A large-scale DCS, regardless of the
manufacturer, should offer versatility for
control strategy along with an ability to
communicate with all manner of field
devices and networking strategies. The
final installation should be straightfor-
ward, both physically and functionally.
CTL1205_InsideProc01_V7msFINAL.indd 6 5/2/12 2:59 PM
input #28 at www.controleng.com/information
CTL120501-MAG_Ads.indd 6 5/3/2012 10:47:34 AM
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Cognex vision systems perform rigorous tasks that are practically impossible for people to do reliably and consistently.
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MIR_EasyFastSafe Ad_8.375x10.875.indd 1 05/12/2011 10:49
input #29 at www.controleng.com/information
CTL120501-MAG_Ads.indd 7 5/2/2012 6:02:20 PM
P8 MAY 2012 CONTROL ENGINEERING
It is also important to choose the con-
trol solution that will allow a seamless
addition of enterprise solutions onto the
control layer. Because information-rich
applications will most likely be expect-
ed right around the corner, it is important
to consider elements like manufacturing
execution systems (MES), asset man-
agement, reporting packages, statistical
process control (SPC), downtime track-
ing, or a variety of other enterprise layer
solutions.
Simulation technology
Control strategies need a thorough
ringing out before they are deployed
to control the actual process. Because process control is so
focused on repeatability, it is necessary for a simulation envi-
ronment to run the control strategy without alteration. Timing
is essential in process control, and a simulator must replicate
the process execution timing in a faithful manner.
With that in mind, DCS suppliers offer advanced simulator
technology to support improved performance throughout the
lifecycle of a plant. This ranges from off-line use in steady-
state design simulation, and control check-out and operator
training, to online use in control and optimization, performance
monitoring, and business planning.
Process history
Thorough process improvement relies on good process data,
which means that history collection must be coordinated with
the plant automation system functioning so it does not inter-
fere with more urgent control requirements. Yet, if it becomes
necessary to suspend the collection of history, the history must
be recovered since incomplete history is unacceptable. Plants
need a reliable solution for archiving history data, and also for
retrieving it for use in trending and quality analysis.
With this in mind, most current DCS platforms now include
robust process history functionality built in directly, enabling
engineers and plant management to analyze performance of the
entire operation from a single location. Redundant data collec-
tion mechanisms also ensure speedy fail-over to a secondary
collector upon loss of a primary.
Making the decision
Every plant, of course, will have unique requirements when
it comes to automation and control, and neither a DCS nor
PLC will be a catch-all solution for every facility. Ultimate-
ly, specific applications and operational needs must be con-
sidered carefully when determining which technology is most
appropriate for process control. There is a growing case to be
made, though, for the value of a DCS, even in smaller applica-
tions. Taking into account the possible issues examined above
can give operators and engineers a blueprint of DCS and PLC
capabilities and provide deeper understanding of what to con-
sider when choosing between the two. ce
Tim Sweet is solutions manager for small systems for Hon-
eywell Process Solutions.
the various aspects of a batch automa-
tion solution can now be captured in a
single DCS data model. For instance, all
elements needed for batch management
and execution are run in the process con-
troller, or a redundant pair of controllers
when robustness is desired. This means
that there is no longer a need for a PC
operating as a batch server. Because all
batch elements are handled in the control-
ler, batch execution is faster, cycle times
are reduced, and throughput is increased.
Further, operators learn one consistent
environment for alarms, security, and dis-
plays so that fewer errors are made. From
an engineering and maintenance perspec-
tive, the advantage is in learning and supporting one tool with
no duplication.
Open connectivity
Rarely are todays process plants run by a single brand of
controller. Thats why classic DCS architecture also serves to
bring third-party devices into the same data model employed
by the DCS. This incorporation of existing controllers means
that operators can view information from various brand con-
trollers in a consistent fashion.
inside process
Because process
control is so focused
on repeatability,
it is necessary
for a simulation
environment to run
the control strategy
without alteration.
www.acromag.com
Acromag_CE_ProdLitShowcase2.indd 1 5/31/2011 5:25:27 PM
Input #101 at www.controleng.com/information
Fluke Corporation, a manufacturer
of portable electronic test and mea-
surement technology, has released its
430 Series II, three-phase power qual-
ity analyzers. The company is charac-
terizing these as the rst tools to use a
patented algorithm to measure energy
waste and quantify its cost. The series
helps facilities reduce electrical power
consumption and improve the performance and lifespan of
electro-mechanical equipment by providing ROI justica-
tion to mitigate power quality distortion. Electricians, utility
technicians, electrical engineers, eld service technicians,
and energy consultants can automatically determine how
much power is being wasted and calculate exactly what the
extra consumption costs are with a single handheld tool. For
example, this analyzer allows facilities to assess the impact
of new energy-efcient, electronically-driven systems. While
these new systems consume less energy as individual installa-
tions, they can increase the level of power quality disturbance
in the overall electrical system, increasing waste energy due
to harmonics and reducing the total potential energy savings.
The analyzer calculates the cost of that waste energy.
Fluke
www.uke.com
Input #204 at www.controleng.com/information
Alpha Wire has added industrial Ethernet to its grow-
ing family of Xtra-Guard cables. The new Cat 5e cables
enable Ethernet communications with the durability and
temperature range of Alphas Xtra-Guard 4 jacket, for
demanding applications. These cables are available in a
choice of unshielded, foil shield, or Supra-Shield foil/
braid. Alpha Wires Supra-Shield uses a combination
aluminum, polyester, aluminum foil, and tinned copper
braid that offers excep-
tional EMI performance
and exibility. Addition-
ally, the cables are UV and
uid resistant, meet UL
1666 Riser and CSA FT-4
ame tests, and are suit-
able for use in NFPA 79
applications. This connec-
tivity cable is available in
a temperature range of -50
to 125 C on FEP-insulated conductors and -50 to 105 C
on polyethylene-insulated conductors. The TPE jacket is
available in black with standard lengths of 500 and 1,000
ft. Other colors, including red and teal, are available as
special orders.
Alpha Wire
www.alphawire.com
Input #205 at www.controleng.com/information
Power quality analyzers
measure energy wasted in
electrical systems due to
power quality issues
Industrial Ethernet cables have wide
temperature ranges, meet NFPA 79
application requirements
62 MAY 2012 CONTROL ENGINEERING www.controleng.com
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CTL1205_Products_V4msFINAL.indd 62 5/2/12 4:34 PM
AD INDEX
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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.
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how to submit press releases, products,
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neers solve problems. Articles that are com-
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Aaxeon Technologies, LLC . . . 33. . . . . . . . . . 19 . . www.aaxeon.com
ABB Inc - Safety Systems. . . . 25. . . . . . . . . . 17 . . www.processautomationinfo.com/24
Allied Electronics . . . . . . . . . . 9. . . . . . . . . . . . 6 . . . www.alliedelec.com
AutomationDirect . . . . . . . . . . C2 . . . . . . . . . . 1 . . . www.automationdirect.com
B & B Electronics . . . . . . . . . . 24. . . . . . . . . . 16 . . www.bb-elec.com
B & R Industrial Automation . 15. . . . . . . . . . 10 . . www.br-automation.com
Baldor Electric Company . . . . 4. . . . . . . . . . . . 4 . . . www.baldor.com
Beckhoff Automation LLC. . . . 39. . . . . . . . . . 23 . . www.beckhoff.com
CFE Media Educational Video
Series Sponsored By Eaton . . 22. . . . . . . . . . . . . . . www.controleng.com/educationalvideos
Eaton Corp. . . . . . . . . . . . . . . . 36. . . . . . . . . . 21 . . www.eaton.com
E-Newsletters . . . . . . . . . . . . . 38. . . . . . . . . . . . . . . www.controleng.com/newsletters
Industrial Automation
North America at IMTS 2012 . 27. . . . . . . . . . . . . . . www.ia-na.com
ITSENCLOSURES . . . . . . . . . . 11 . . . . . . . . . . . 8 . . . www.itsenclosures.com
MathWorks . . . . . . . . . . . . . . . C4 . . . . . . . . . 37 . . www.mathworks.com/accelerate
Maverick Technologies . . . . . . 17. . . . . . . . . . 11 . . www.DCSNext.com
Mitsubishi Electric
Automation Inc . . . . . . . . . . . . 35. . . . . . . . . . 20 . . www.meau.com
Moxa Technologies . . . . . . . . . 3. . . . . . . . . . . . 3 . . . www.moxa.com
National Instruments . . . . . . . 7. . . . . . . . . . . . 5 . . . www.ni.com
Newport. . . . . . . . . . . . . . . . . . 1. . . . . . . . . . . . 2 . . . newportUS.com
Rittal Corporation . . . . . . . . . . 20, 21. . . . . . . 13 . . www.rittal-corp.com
Schneider Electric . . . . . . . . . . 13. . . . . . . . . . . 9 . . . www.SEreply.com
Schweitzer Engineering Labs 10. . . . . . . . . . . 7 . . . www.selinc.com/mspsc
Sealevel Systems Inc . . . . . . . 37. . . . . . . . . . 22 . . www.sealevel.com
Siemens Industry Inc . . . . . . . C1, 19. . . . . . . 12 . . www.sea.siemens.com
Turck Inc. . . . . . . . . . . . . . . . . . 23. . . . . . . . . . 14 . . www.turck.com
Unitronics . . . . . . . . . . . . . . . . 23. . . . . . . . . . 15 . . www.unitronics.com
Vecoplan LLC. . . . . . . . . . . . . . 26. . . . . . . . . . 18 . . www.viccontrols.com
Yaskawa America Inc . . . . . . . C3 . . . . . . . . . 36 . . www.yaskawa.com
Inside Process
Cognex Corp . . . . . . . . . . . . . . P7. . . . . . . . . . 29 . . www.cognex.com/makeitright
Data Translation Inc . . . . . . . . . P5. . . . . . . . . . 27 . . www.DATATRANSLATION.COM
FLEXIM AMERICAS
Corporation. . . . . . . . . . . . . . . P2. . . . . . . . . . 24 . . www.flexim.com
Fluke Corp . . . . . . . . . . . . . . . . P3. . . . . . . . . . 25 . . www.fluke.com
Load Controls Inc.. . . . . . . . . . P4. . . . . . . . . . 26 . . WWW.LOADCONTROLS.COM
Maple Systems Inc . . . . . . . . . P6. . . . . . . . . . 28 . . www.maplesystems.com
Pepperl & Fuchs Inc . . . . . . . . P13. . . . . . . . . 34 . . www.pepperl-fuchs.us
Rockwell Automation . . . . . . . P9. . . . . . . . . . 31 . . www.RockwellAutomation.com/go/ce12
Solutions Direct . . . . . . . . . . . P8. . . . . . . . . . 30 . . www.solutionsdirectonline.com
Testo Inc. . . . . . . . . . . . . . . . . . P12. . . . . . . . . 33 . . www.testo.us/transmitters
TriCore Inc . . . . . . . . . . . . . . . . P11. . . . . . . . . 32 . . www.tricore.com
Winsted Corporation . . . . . . . P14. . . . . . . . . 35 . . www.winsted.com
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64 MAY 2012 CONTROL ENGINEERING www.controleng.com
Peter Welander
Paul Baran
was a visionary
and imagined
systems like the
Internet long
before most
people did.
O
ne of the things we take for granted
every time we look at something on
the Internet or an industrial control
system is that our networks can send
and receive data from any number of sources at
the same time and it all seems to work. It wasnt
always like that, and we have the technology of
data packets to thank for it.
In the early days of digital computing, devices
communicated with each other using point-to-
point serial communication. Basically the data
flowed from device A to device B like water
flowing through a pipe when both ends open the
appropriate valves. It was crude, but it worked
within its limitations. Early on that was tolerable
because there were so few computers that had to
communicate.
By the early 1960s, computers were becom-
ing more numerous and the kind of data that was
being communicated more critical. Paul Baran,
who was working for the Rand Corporation, con-
cluded that if data could be broken into chunks
rather than a continuous flow, it could support
a more robust system that could tie together far
more devices via a common network. It might
even be capable of withstanding a nuclear attack,
which given that Cold War era, was a valid con-
cern. Baran was a visionary and imagined systems
like the Internet long before most people did.
What is a packet?
To return to the water flowing analogy, instead
of sending water down a pipe, if you put it in a
bottle, you can send it anywhere. Others compare
data packets to letters, where a message is put in
an envelope and carried by the post office.
A packet is a framework of a spe-
cific size and structure. It has a header
and trailer at the beginning and end
that identify who sent it, where its
going, etc. In the middle there is a
space for the message itself, or pay-
load. For a given type of network,
the payload has a length limitation
so a longer message may have to be
broken into multiple packets. If the
message is short, the other parts of the
packet dont get any smaller. Various
networking protocols do the details
differently, but the basic concepts are
largely the same. Applications on the
sending and receiving ends put the data in packets
for transmission and unpack it when it arrives.
Networking protocols are rated on their effi-
ciency, or the amount of message payload com-
pared to the overall packet size. If too much
of the packet size is taken up with the header,
trailer, and other overhead, that protocol is con-
sidered inefficient. Part of the argument against
using Ethernet for field instrumentation is the
idea that it has too much overhead for the small
amount of data these devices generate.
One of the benefits of breaking larger data
into smaller units is that it is possible to verify
the accuracy of a message using an error check-
ing protocol such as a cyclic redundancy check
(CRC). In basic terms, all the information in the
message in a given packet has a numerical value
attached to it. The protocol adds up all those val-
ues and divides the sum by another number. The
remainder from the calculation is assigned to that
message. The receiver does the same calculation
and verifies that it got the same remainder value.
If it didnt, it knows that some of the data in the
message contained in that packet must have been
corrupted and it flags that packet.
Ethernet application
Ethernet communication depends on pack-
ets, or as they are more typically called, frames.
Many variations have been created, but there are
typically seven parts to a complete frame:
Preamble (used for bit synchronization)
SFD (start of frame delimiter)
Destination MAC address
Source MAC address
Length or specific type
Message or data payload, and
FCS (frame check sequence).
The size of each of these elements is fixed,
except for the payload. This can vary as need-
ed for the information being sent, but there is a
maximum of about 1.5 kB. This article, set in
plain text, would likely require three packets to
transmit.
As technologies go, its difficult to think of
one that has been used and adapted in so many
ways, and one that we depend on in so many
applications. ce
Peter Welander is a content manager for Control
Engineering. Email him at pwelander@cfemedia.com.
BASICS BASICS
Data Packets
back to
Putting data in packages is basic to virtually all our networking concepts.
ONLINE
At www.controleng.com,
follow the system integra-
tion channel for networking
coverage.
Ethernet frame
62 bits
Preamble used for bit
synchronization
2 bits Start of frame delimiter
48 bits
Destination of Ethernet
address
48 bits
Source Ethernet
address
16 bits Length or type
46-1,500
bytes
Data payload
32 bits
Frame check
sequence
CTL1205_BackBasics_V4msFINAL.indd 64 5/2/12 4:34 PM
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