APR15 A&C Snipe (CE)_Layout 1 3/13/15 2:33 PM Page 1

l
ro
Co or
nt
& f
n d
io llie
at A
m k
to hin
Au T

www.controleng.com
 GREAT PEOPLE!

the #
* See our Web s

input #39 at www.controleng.com/information

 This .com is powered by
.awesomepeople
For over twenty years our sole focus has been customer service.
That takes many forms: great prices, fast delivery, and quality
products. But regardless of our product selection and other
tangibles like pricing, the intangible value of customer service
is something that cannot be faked, automated or glossed over.
Our team members here at AutomationDirect.com approach every
day with this one goal in mind - serve the customer. Its a simple
philosophy that many companies forget or make too complex and
fail at. If the answer to any decision is Yes, this is good for our
customers, then we do it.

Its that simple.

Should we have real upfront pricing online and realtime stock availability?
Yes, this is good for our customers.

Should we have FREE tech support before, during, and after any sale instead
of charging yearly fees for tech support?
Yes, this is good for our customers.

Should we oer FREE software on many products instead of charging

licensing fees?
Yes, this is good for our customers.

Should we have all our documentation online for FREE so people can access
anytime, even before they choose to purchase?
Yes, this is good for our customers.

Should we oer more selection by consistently introducing new quality

products with great prices monthly, sometimes weekly?
Yes, this is good for our customers.

Should we oer FREE shipping for orders over $49?

Yes, this is good for our customers.

All these internal discussions have had certain aspects of Can we

do that?, That will be hard to accomplish, and No one else is doing
that, how can we?. But if you bring it back to the simple answer, Yes,
this is good for our customers, then the perceived obstacles really
dont matter.
Our company has evolved dramatically since 1994 and its this type
of decision-making by all our team members over the years that
keeps our customers coming back and new customers checking us
out daily. So visit www.automationdirect.com to see what we have
to offer and we hope you give us an opportunity to serve you.

See what our current customers think:

www.automationdirect.com/reviews

#1 value in automation
ite for details and restrictions. Copyright 2015 AutomationDirect, Cumming, GA USA. All rights reserved. 1-800-633-0405 www.AutomationDirect.com
 What makes AutomationDirect the
#1 value in automation?
Great Products...
AutomationDirect offers tens of thousands
of high-value industrial automation products,
both name brand and private-labeled, that
are chosen for their best-in-class features,
price and quality. Our name-brand products
come from companies such as Fuji Electric, Programmable Universal Field I/O Software Operat
Cutler-Hammer, and Hubbell/Wiegmann. Controllers
We work with these multi-billion dollar
companies in order to provide you with
world-class quality products at low prices.
We also co-engineer many of our private-
labeled products with the manufacturer to
ensure our customers are getting the features
they ask for at prices they can afford.
Motors and Motion Control Power Transmission Pne

Great Prices...
Motor Controls

Saving you money on industrial control

products is what we do, and since 1994
our prices have been typically 50% less
than traditional suppliers. But you may be
wondering, How can AutomationDirect offer
great products at such a low price? Well, you
can be sure we dont sacrifice quality; in fact
Relays and Timers Sensors Pushbuttons, Termina
there are two main reasons for our low prices: Switches and Lights
We get great prices from our suppliers because of our
volume purchases, so that means we can oer very
attractive prices on everything from programmable AutomationDirect
PLC CPU and I/O Allen-Bradley
controllers to terminal blocks. Comparison Productivity2000 CompactLogix

With our direct business model and focus on eciency,

we have the lowest overhead in the industry. Keeping Base (if required) $69.00 N/A
P2-04B N/A
our internal costs down allows us to pass even more Power Supply $69.00 $414.50
savings and customer satisfaction on to you. P2-01AC 1769-PA4

CPU $255.00 $3,160.00

P2-550 1769-L33ER

AutomationDirect 16 AC Inputs $105.00 $286.00

Power Supplies Allen-Bradley P2-16NA 1769-IA16
RHINO
and Modules Price/Part Number Price/Part Number 16 24VDC Inputs $69.00
P2-16NE3
$244.00
1769-IQ16

60W 1-Phase AC/DC $42.00 $274.50 8 Relay Outputs $51.00 $301.50

Power Supply, 24VDC PSB24-060S 1606-XL60D P2-08TRS 1769-OW8I

180W 1-Phase AC/DC $152.00 $398.00

8 Analog Input
Channels (mA)
$199.00
P2-08AD-1
$713.50
1769-IF8
Power Supply, 24VDC PSM24-180S 1606-XL180B

ASCII Comm Module $0.00 $737.00

240W 3-Phase AC/DC
Power Supply, 24VDC
$127.00 $439.00 Built in to CPU 1769-ASCII
PSB24-240S-3 1606-XL240E-3
Modbus RTU
Comm Module
$0.00 $701.00
Redundancy Module
(20A output)
$35.00 $154.50 Built in to CPU 1769-SM2
PSB60-REM20S 1606-XLSRED Total System Price with
USB, Ethernet and Serial $817.00 $6557.50
Buffer Module
(20A output) $149.00 $417.00
PSB24-BFM20S 1606-XLSBUFFER 24
All prices are U.S. published prices. AutomationDirect prices as of 6/5/2015.
Allen-Bradley retail prices taken from www.plccenter.com 5/12/2015.
AutomationDirect
*All prices are U.S. published prices. AutomationDirect prices as of January 2016. Allen-Bradley retail prices taken from www.plccenter.com Hoffman
Hubbell/Wiegmann
1/6/2016. Prices may vary by dealer. Many other part numbers are available from all vendors.
Enclosures Price/Part Number Price/Part Number

NEMA 1 wall mount

24 x 24 x 08
$177.00 $348.10
N1C242408LP A-24N24BLP

NEMA 12 wall mount

20 x 16 x 08
$240.00 $460.79
N12201608 A-201608LP

NEMA 12 free-standing
mount 60 x 60 x12
$1,550.00
N12606012
$2,457.79
A-606012LP

NEMA 4 wall mount

20 x 20 x 06
$310.00
N4202006
$583.81
A-20H20ALP But most importantly...
NEMA 4X wall mount
20 x 20 x 06
$731.00 $1,345.32
SSN4202006 A-20H2006SSLP

NEMA 4/12 wall mount

36 x 24 x 08
$307.00
N412362408C
$584.68
C-SD36248

the #1 value in automation

*All prices are U.S. published prices. AutomationDirect prices as of March 2016. Hoffman prices are taken from www.newark.com 5/22/2015.
Prices may vary by dealer. Many other part numbers are available from all vendors.

* See our Web site for details and restrictions. Copyright 2015 AutomationDirect, Cumming, GA USA. All rights reserved. 1-800-633-0405 www.AutomationDirect.com
input #1 at www.controleng.com/information
 PLC
HMI
ALL IN ONE

Unitronics offers the

most cost-effective
answers
Rick Gallimore, Innovative Automation and Controls, Inc.

In the picture Packaging Machine controlled by 7"

Unitronics V1210 and SAMBA 4.3.
Bimetec BV, Netherlands.

4.3" 3.5"

On-Board I/Os CANbus Unitronics is a pioneer in the manufacture and

Digital and analog (Optional)
Full function PLC with onboard I/O
Integrated color-touch HMI
Ethernet
Unbeatable price-performance ratio USB programming port (Optional)
(RS232/RS485 in 3.5")
design of PLCs with integrated HMI and
on-board I/Os - rugged PLC product lines that
meet a diverse range of requirements. You
program your entire application in a single,
intuitive software environment, and benefit
from best-of-breed technical support,
both provided at no extra cost.

www.unitronics.com
input #2 at www.controleng.com/information

Unitronics, Inc. 1 Batterymarch Park, Quincy, MA 02169,

(866) 666-6033, Usa.sales@unitronics.com
 APRIL 2016

Vol. 63
Number 4

Features
Cover: System integration

28
Best practices and technologies to help
28 How system integrators, plant owners should collaborate
on an automation project COVER: When considering a plant upgrade or new project, the integrator and cus-
30 Financial benefits of combining automation and safety projects tomer must come to terms on which technologies will fulfill the overall objectives
best. Courtesy: Maverick Technologies
32 Industrial networking technologies add value
to existing infrastructure
34 Contextual mobility for monitoring and control
36 Two reminders and six steps to market to engineers

Virtualization virtues
38 Core-isolation enables virtualization for industrial applications
39 Distillery saves times and money with virtualization
40 Benefits of a virtualized power management strategy

41 Digital Edition Exclusive

20 years of CiA 401: Perhaps the most implemented CANopen
profile; Enabling business through safety, security

Cyber security advice 44

42 The whitelist: Finding the light in cyber darkness
44 Pay attention: Industrie 4.0 and ICS cyber security
45 Cyber security protection enters a new era

47 U.S. motor-driven system

energy savings
Motor-driven system regulations are changing in the U.S. to improve
efficiencies beyond individual motors. Considering the motion control
system can deliver more than six times the power savings compared
to motor efficiencies alone, according to NEMA committee members.
Power electronics are helping.
Hannover Messe Preview
51 Hannover Messe 2016
52 American manufacturing in the spotlight
53 Manufacturer builds for a global future
56 Universities bring knowledge, curiosity to Hannover
60 Product introductions: next wave of innovation Hannover
47
CONTROL ENGINEERING (ISSN 0010-8049, Vol. 63, No. 4, GST #123397457) is pub-
lished 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 2016 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. E-mail: customerservice@cfemedia.com. Postmaster: send address changes to
CONTROL ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Pub-
lications 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, $150/yr;
Canada/Mexico, $180/yr (includes 7% GST, GST#123397457); International air delivery
$325/yr. Except for special issues where price changes are indicated, single copies are
available for $30.00 US and $35.00 foreign. Please address all subscription mail to CON-
TROL 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, regard-
less of whether such errors result from negligence, accident or any other cause whatsoever.

2 | APRIL 2016 CONTROL ENGINEERING www.controleng.com

 Maximize Productivity of
Sensitive Remote Assets

In order to succeed in a highly competitive industry, you need every edge you can get. You can improve
productivity with intelligent analysis of real-time data from your remote assets, but you need to make sure
that you dont also expose those assets to unauthorized access. With industrial secure routers like
Moxas EDR-810, your operations are protected while remote assets collect, share, and act on data.
Its easier than you think. Find out more at www.moxa.com.

EDR-810
Industrial Secure Router

Ethernet Switches Wireless AP/Bridge/Clients Cellular Gateways

Secure Routers Gateways and Protocol Converters Media Converters
Serial Device Servers Multiport Serial Boards IP Cameras
Video Servers Remote I/O and Controllers Embedded Computing

linkedin.com/company/moxa @moxainc youtube.com/moxavideo facebook.com/moxainc

Moxa Inc. Tel: 1-888-669-2872 usa@moxa.com www.moxa.com

input #3 at www.controleng.com/information
Corey Stefanszak, Senior System Architect
Todd Williams, Vice President, Systems Integration

Optimize system functionalities.

Implement an energy roadmap.
Leidos Engineering is a trusted advisor for smart
facilities across the nation, with forward-thinking
solutions in systems engineering, energy management,
software development, and wired and wireless
infrastructure. Our experts help advance the enterprise
and take on whats next with the Internet of Things.

Activate Tomorrow, Today.

leidos.com/activate

input #4 at www.controleng.com/information
 APRIL 2016

Vol. 63
Number 4

Inside Machines
Appears after page 65; If not, see the Digital Edition:

M1
www.controleng.com/DigitalEdition

M1 Traditional and collaborative robots

working safely with humans
Traditional and collaborative robots, depending on the application,
may be used partially or fully in areas with human workers; new
standards can help improve safety capabilities.

M3 Improving robotics
with model-based control
Model-based control results in robotic systems moving faster
and more accurately, with greater throughput.

M7 Encoders for ultra-slow motion control

Encoders and speed sensors play a critical role for many motion
control applications, such as industrial test and measurement,
automation, security and surveillance systems, and others.
M3
Departments
8 Think Again
Integration, prediction, and a 2020 control room
Products
77 Chlorine analyzer; Encapsu-
10 Apps for Engineers lated dc/dc converters; Handheld par-
Maintenance apps ticulate pollution meter for hazardous
environments; I/O breakout boards;
12 Product Exclusive
Stainless steel faced sensors
IoT gateway starter kit for end-to-end data service

14 Research 78 Pressure sensors; Incremental

Cyber security encoder for functional safety;
Synchronous servo motors
16 Control Engineering International
Replacing humans with machines and saving jobs?

17 IT Insight
Manufacturing software development:
Bigger is not always better

18 Integrator Update
Integrated controls and information system adds
product consistency, quality

80 Back to Basics
Critical infrastructure specialists

News
20 Communication system assists human-robot teams

21 The evolution of the Internet of Things in field service

22 Industrial Internet groups agree to align architecture efforts;

Cloud for IoT services

23 Headlines online: Events, Top 5 articles, PMI is up, Conveyor model

www.controleng.com CONTROL ENGINEERING APRIL 2016 | 5

 More resources posted daily at:
APRIL
www.controleng.com

Trending New Products Control Systems Process Manufacturing Discrete Manufacturing System Integration Networking & Security Info Management Education & Training

Ensuring network cyber security On-demand

Theres a lot more to read online. Go to www.controleng.com/news webcasts
to read Control Engineerings exclusive Web content.
Control Engineerings
 Ladder logic 401: webcasts are always
Data acquisition and analysis available on de-
 Funding for energy-efficient mand at any time. If Webcasts
you need additional
electric motor programs
continuing education credits, you can
 Communication system assists meet your requirements at
human-robot teams www.controleng.com/webcasts.
 Software features for enhancing  Next-generation Industrial HMIs
collaborative robot.
 Industrial Internet of Things
Webcast Series 2016, Part One:
Effective Change Management

Oil & Gas Engineering

Newsletter: April issue
Process Instrumentation Oil & Gas Engineer-
& Sensors ing provides industry-
specific solutions de-
Support-focused enterprise control: signed to maximize
sensor actuation charts uptime and increase
Keep up with the latest industry news productivity through
by subscribing to Control Engineerings the use of industry
14 newsletters at best practices and
www.controleng.com/newsletters: new innovations,
increase efficiency
 Electric actuator technology prospers from the wellhead to
in production fields the refinery by imple-
 In hazardous areas, sensor safety menting automation
rating is crucial and monitoring strategies, and maintain
and improve safety for workers and the
 Solar-powered thermal mass flowmeters work environment. Read the digital edi-
operate in flare-gas monitoring system. tion at www.oilandgaseng.com.

Video tutorials Digital Edition

Marketing to Engineers The tablet and
At the 2016 CFE Media Marketing to digital editions of
Engineers event, Tracy Long, vice pres- this publication have
ident of marketing at Baldor Electric unique content for
Co. shared insights on how to develop our digital subscrib-
ers. This month has
and deliver engineering content across
digital exclusives on:
platforms to drive followers to a desti-
20 years of CiA 401:
APR15 A&C Snipe (CE)_Layout 1 3/13/15 2:33 PM Page 1

nation site and to create an experience Perhaps the most

that makes viewers want to stay. Con- implemented CANo-
l
ro
Co or
nt
& f

trol Engineering offers online videos at

n d

pen profile; Enabling

io llie
at A
m k
to hin

www.controleng.com/videos. business through

Au T

www.controleng.com

See a related article topic on page 36. safety, security.

6 | APRIL 2016 CONTROL ENGINEERING www.controleng.com

 Reliable Detection
For Your Application

You cant afford not to know. See it all at thinkallied.com/sensors

1.800.433.5700

Allied Electronics, Inc 2015. Allied Electronics and the Allied Electronics logo are trademarks of Allied Electronics, Inc. An Electrocomponents Company.

input #5 at www.controleng.com/information
THINK AGAIN automation applications
Integration, prediction,
2020 control room
Application examples: Machine data integration saves time, predictive
maintenance avoids unplanned downtime, and a control room designed
S
for 2020 attracts young engineering prospects, among other benefits.
Smart applications of automation
technologies save money, time, improve qual-
ity, decrease downtime, and, perhaps, in an
unintended benefit, can attract younger engi-
neers. These were among application presenta-
tions at the ARC Group Industry Forum, Feb.
8 to 11, in Orlando, Fla.
Shop-floor data network
Rocky Rowland, a Mazak production
manager, talked about how a shop-floor data
network in the Florence, Ky., Mazak manufac-
turing facility lead to an 8.5% increase in paint
line utilization in 4 months. The plant makes
114 computer-numerical control (CNC) lathes
and machine center models, more than 200
units per month, and recently completed a $30
million, 100,000 ft2 addition.
MTConnect networking technology pro-
vides a shop data network, using a royalty-free
software, including Bluetooth communi-
cations for manufacturing. Measurements
include overall equipment effectiveness
(OEE), quality, availability, and downtime. A
simple dashboard was created so the metrics
could be easily viewed and improved upon.
The program will expand, Rowland said, with
hardware expected to be offered on Mazak
machines for sale. Security is built in, and data
is processed on the edge, sending a report,
rather than a big-data stream.
Predictive maintenance
Keith Holliday is president and CEO of
Global Drilling Support, a manufacturer of
top drives, the large electric-motor that pow-
MORE
ADVICE
GO ONLINE
See 11 images and more details with the online ver-
sion of this column, plus Three control room design
tips and Five control room design challenges. Click
on the headline in the digital edition or search the
headline at www.controleng.com.
HMI webcast at www.controleng.com/webcasts.
8 | APRIL 2016 CONTROL ENGINEERING
ers oil rig drill bits. The company also repairs
and recertifies competitors drives, so Holliday
understands the high cost of unplanned down-
time for the 200 hp to 1,500 hp units. Equip-
ment usually is taken apart after 5 years, but
rebuilding based on actual wear rather than an
average, saves resources. Embedded sensors
help with warranty claims. The new system
uses a field agent, subscription service, cloud-
based server with analytical software.
Customers now want data, but dont know
what to do with it. This opens more oppor-
tunities for service contracts and better future
designs based on analysis, Holliday said.
Control room 2020
Michiel Tijsseling, Dow Chemical pro-
cess automation leader, worked on a control
room design for year 2020 for two units at
Oyster Creek OC-1001 Hydrocarbons Com-
mand Center, Freeport, Texas. The result was a
future-proof design for operations, since pro-
cess control is a function of the operator.
We use state-based control. If theres a trip,
the steps in-between are shown, along with
what happens automatically, to help the opera-
tor do whats needed, Tijsseling said. The new
design creates a reliable interface to the pro-
cess for control, and it is redundant in a smart
way, so any one component of failure doesnt
create outage, said Tijsseling. Within 30 sec-
onds, an operator can know plant status. The
design supports physical needs, lighting, noise,
temperature, and workflow.
What do I need to work here? asked one
student. An executive taking a tour brought
additional co-workers the next day.
Dont wait. To help quantify your next
automation application, think again about the
extended bottom-line benefits. ce
Julie Timbol, CT, DE, MD, ME, MA, NC, NH, NY, NJ, PA, RI, SC, VA, VT, WV, DC,
Mark T. Hoske, Content Manager
MHoske@CFEMedia.com
1111 W. 22nd St. Suite 250, Oak Brook, IL 60523
630-571-4070, Fax 630-214-4504
Content Specialists/Editorial
Mark T. Hoske, Content Manager
847-830-3215, MHoske@CFEMedia.com
Jack Smith, Content Manager
630-907-1622, JSmith@CFEMedia.com
Amanda Pelliccione, Director of Research
631-320-0655, APelliccione@CFEMedia.com
Joy Chang, Digital Project Manager
630-571-4070 x2225, JChang@CFEMedia.com
Chris Vavra, Production Editor
630-571-4070 x2219, CVavra@CFEMedia.com
Emily Guenther, Associate Content Manager
630-571-4070 x2220, eguenther@cfemedia.com
Contributing Content Specialists
Frank J. Bartos, P.E., braunbart@sbcglobal.net
Peter Welander, PWelander@CFEMedia.com
Vance VanDoren, Ph.D., P.E., controleng@msn.com
Suzanne Gill, Control Engineering Europe
suzanne.gill@imlgroup.co.uk
Ekaterina Kosareva, Control Engineering Russia
ekaterina.kosareva@fsmedia.ru
Wojciech Stasiak, Control Engineering Poland
wojciech.stasiak@trademedia.us
Luk Smelk, Control Engineering Czech Republic
lukas.smelik@trademedia.us
Aileen Jin, Control Engineering China
aileenjin@cechina.cn
Publication Services
Jim Langhenry, Co-Founder/Publisher, CFE Media
630-571-4070, x2203; JLanghenry@CFEMedia.com
Steve Rourke, Co-Founder, CFE Media
630-571-4070, x2204, SRourke@CFEMedia.com
Trudy Kelly, Executive Assistant,
630-571-4070, x2205, TKelly@CFEMedia.com
Elena Moeller-Younger, Marketing Manager
773-815-3795, EMYounger@CFEMedia.com
Kristen Nimmo, Marketing Manager
630-571-4070, x2215, KNimmo@CFEMedia.com
Brian Gross, Marketing Consultant, Global SI Database
630-571-4070, x2217, BGross@CFEMedia.com
Michael Smith, Creative Director
630-779-8910, MSmith@CFEMedia.com
Paul Brouch, Director of Operations
630-571-4070, x2208, PBrouch@CFEMedia.com
Michael Rotz, Print Production Manager
717-766-0211 x4207, Fax: 717-506-7238
mike.rotz@frycomm.com
Maria Bartell, Account Director
Infogroup Targeting Solutions
847-378-2275, maria.bartell@infogroup.com
Rick Ellis, Audience Management Director
303-246-1250, REllis@CFEMedia.com
Letters to the editor: Please e-mail us your opinions to
MHoske@CFEMedia.com or fax us at 630-214-4504.
Letters should include name, company, and address,
and may be edited for space and clarity.
Information: For a Media Kit or Editorial Calendar,
email Trudy Kelly at TKelly@CFEMedia.com.
Reprints
For custom reprints or electronic usage, contact:
Brett Petillo, Wrights Media
281-419-5725, bpetillo@wrightsmedia.com
Publication Sales
Patrick Lynch, ContentStream, Director of Content Marketing Solutions
630-571-4070 x2210 PLynch@CFEMedia.com
Bailey Rice, AR, IL, IN, IA, KS, KY, LA, MN, MO, MS, NE, ND, OK, OH, SD, TX, WI,
Central Canada
630-571-4070 x2206 BRice@CFEMedia.com
Iris Seibert, AK, AZ, CA, CO, HI, ID, MT, NV, NM, OR, UT, WA, WY,
Western Canada
858-270-3753 ISeibert@CFEMedia.com
Eastern Canada
978-929-9495 JTimbol@CFEMedia.com
Maggie Hatcher, AL, FL, GA, MI, TN, classified, product mart, media
showcase
630-571-4070, x2221 MHatcher@CFEMedia.com
Stuart Smith, International
www.controleng.com
Tel. +44 208 464 5577 stuart.smith@ssm.co.uk
 Advantech Control Industrial PC
Providing Computing, C
Connectivity
ty and Control
for Smart Factories

Advantech's APAX-5580 is a powerful control industrial PC with an Intel Core

i7/i3/Celeron processor. It features flexible I/O expansion, network capability through
various interfaces, real-time I/O control, and supports dual power input/UPS module
for maximum uptime.
High Performance Computing
Features latest Intel Core i7/i3/Celeron CPUs with open operating system
support including Microsoft Windows Embedded and Embedded Linux
Boundless Connectivity
Built-in Serial, USB, Ethernet, WiFi, and Fieldbus
Robust Control
Includes real-time distributed bus technology, hot-swappable I/O modules,
open software support including CODESYS IEC 61131-3

APAX-5580 APAX-5000 APAX-5435 CODESYS SoftLogic

High powered Control Full Range of I/O Wide variety of Control Software
Industrial PC with Intel modules including communication
Core i7/i3/Celeron AI/AO, DI/DO, T/C, interfaces including
processors RTD, Relay, and fieldbus, wireless,
Counter and I/O
www.advantech.com input #6 at www.controleng.com/information
 APPS FOR ENGINEERS data collection
www.controleng.com/appsforengineers

INCREDIBLY Mobile apps for

FASTER! maintenance
Maintenance mobile applications have potential to
help engineers do their jobs better. CFE Medias
The USB 3 uEye CP
Apps for Engineers is an interactive directory of
with ON Semiconductor
CMOS sensors engineering-related applications for Apple iOS and
Android operating systems from various companies.
Apps are organized by category, company, and type.
These are listed in the app as of April 2016.

Fit4Filter
iOS 4.0+, Android 2.3+
Cost: Free
Company: Rexroth Bosch Group
Website: www.boschrexroth.com
The Fit4Filter app helps find a replacement filter. The filter database is
periodically updated to ensure that the information is current and relevant.
Once a Rexroth filter element is found, the displayed technical specifications
and various links will aid in the ordering process.

PlanGrid
iOS 6.0+, Android 4.0+
Cost: Free
USB 3 uEye CP USB 3 uEye CP
Company: PlanGrid Inc.
PYTHON 500 PYTHON 1300
Website: www.plangrid.com
800 x 600 px 1280 x 1024 px PlanGrid is a free construction app that lets contractors, owners, and
575 fps 224 fps
architects collaborate with all project plans, specs, and photos on an Apple
iPad. Upload PDF drawings, and the drawings automatically sync in real time
USB 3 uEye CP USB 3 uEye CP to all iPads in use by the team. Any markups also can easily be shared with
everyone on the project.
PYTHON 2000 PYTHON 5000
1920 x 1200 px 2592 x 2048 px
165 fps 72 fps

Steam Tools Mobile App

iOS 3.0+, Android 2.3+
Cost: Free
More than 1000 fps with AOI. Company: Spirax Sarco
Learn more about the ultra Website: www.spiraxsarco.com
fast USB 3 uEye CP: The Steam Tools app enables quick and easy access to steam tables and
www.ids-imaging.com/usb3 saturated steam pipe sizing tools without need for the Internet connection, for
easy mobile access to references. The app links to steam engineering tutorials,
product literature catalogues, international website, and YouTube channels.

ecoInsight Audit App

iOS 6.0+
Cost: Free
Company: ecoInsight Inc.
Website: www.ecoinsight.com
The ecoInsight App for Apple iPad is an audit application for contractors, dis-
tributors, manufacturers, and energy professionals, to collect lighting and other
www.ids-imaging.com information on a walk-through. Uploaded data in ecoInsights online analysis and
proposal tools enables exports, specifications, upgrades, and proposals.

input #7 at www.controleng.com/information 10 | APRIL 2016 CONTROL ENGINEERING www.controleng.com

A better tomorrow is
driven by drives
5bn
people worldwide
will benefit daily
from Danfoss Drives
by 2025.

ENGINEERING
TOMORROW
is feeding a growing population
Feeding a growing population places stringent demands on hygiene, traceability and
cutting-edge control, while continuously pushing boundaries for system efficiency. We champion
your cause with intelligent product lifecycle services, complemented by a comprehensive range of
application-optimized variable frequency drives with global compatibility.

Discover how Danfoss is Engineering Tomorrow at www.danfoss.us.

input #8 at www.controleng.com/information
PRODUCT EXCLUSIVE starter kit for IoT

IoT gateway starter kit for

end-to-end data service
Advantechs IoT Gateway Starter is designed to provide end-to-end
data service, as well as a quick path to Internet of Things (IoT) inno-
vation. It includes a ready-to-run system, IoT server-side software
and platform service, a software development kit, technical support
service, and Microsoft Azure service certification and integration.

A
Advantechs IoT Gateway Starter is designed to provide
end-to-end data service and a quick path to Internet of Things
(IoT) innovation with a reliable platform and open gateway tech-
nologies. The package includes a ready-to-run system (Intel Cel-
eron J1900 platform and Microsoft Windows 7 Embedded), IoT
server-side software and platform service (WISE-PaaS), a soft-
ware development kit, technical support service, and Microsoft
Azure service certification and integration. With it, designers can
take their IoT innovation to market more quickly with a combined
hardware, software, and services package.
For IoT developers and system integrators, the Advantech IoT
Gateway Starter Kit gives the flexibility to create and deploy inno-
vative, cost-effective, and secure IoT products and services for
industrial applications. The Ultra Compact Gateway Starter Kit is
designed for space-saving applications, and the Multiple I/O Gate-
way Starter Kit has broad input/output (I/O) applications.
The kits withstand harsh environments with a temperature
range from -20 to 70 C (-4 to 158 F) and have good scalability for
networking and versatile I/O communication. They also connect
various existing thingsincluding machines, devices, and sen-
sors. They unify different protocols under MQ telemetry trans-
port (MQTT), the prevailing IoT unifying protocol, and then
empower IoT application development for applications, such as
intelligent alerting, big data, and predictive analytics. ce
Advantech, www.advantech.com
MORE Input #200 at www.controleng.com/information
ADVICE
ONLINE
www.controleng.com/products has additional products. Also see the product
section in the April 2016 print/digital edition of Control Engineering.
Interested in introducing a product to the world here? Contact Mark T. Hoske,
mhoske@cfemedia.com.

Advanced Cooling Technologies, Inc. NE

W
Sealed Enclosure Cooling
Innovations in Action

Web-Based Selection Tools

Online Pricing & Ordering
Low Price - High Value
Compact & Low Profile
Indoor - Outdoor - Wet Locations
Stocked for Immediate Shipment
3 - Year Warranty
NEW at OTC 2016
May 2 - 5, Booth 13221
717-295-6061, www.1-ACT.com/Enclosure-Cooling
More to come...Heat Pipe Coolers...Active Coolers...Eco-Mode Coolers
input #9 at www.controleng.com/information
 NEW Jupiter Model JM4
Magnetostrictive Level Transmitter

MAGNETOSTRICTIVE
REDEFINED
Removable Transmitter Head Increased Signal-to-Noise Ratio Advanced Diagnostics Smart Probe with Auto-Conguration HART 7.0
310 Head Rotation Graphic Display EDDL Capable 0.05 Accuracy Environmentally Sealed Probe Local Echo Curve Capability
Remote-Mount Option PACTware/DTM Capable Dual-Compartment Enclosure High-Temp and Cryogenic Application Capability Automatic
Event-Based Echo Capture Stainless Steel and Exotic Alloy Construction Dual-Float Measurement Environmentally Sealed Electronic Module

The Next Generation is Here

The NEW Jupiter Model JM4 magnetostrictive
level transmitter combines the latest in advanced
features with the simplicity and reliability
of buoyancy-based level measurement. With
ground-breaking features, such as a removable
and rotatable head, Smart Probe technology,
and a graphical user interface with echo curve
capability, Orion Instruments continues a proud
tradition as a global leader in industrial level
measurement.

orioninstruments.com

input #10 at www.controleng.com/information

 Retrofitness

research
2015 SYSTEM INTEGRATION STUDY:

In-house system integrators

Thirty-eight percent of respon-
dents to the Control Engineering 2015
System Integration Study perform all
system integration work themselves, as
opposed to hiring a third-party system
integrator or providing system inte-
gration services to other companies.
Below are five additional findings from
this study as they relate to in-house
system integrators:
1. System integration projects: An
Get your machinery average of 16 system integration proj-
ects are worked on in house per year;
in shape with Delta and the average project size is $248,000.
2. Devices integrated: The top
Motion Controllers. devices these companies integrate in-
house are programmable logic con-
And use our versatile trollers or programmable automation
RMCTools software to controllers (72%); human machine
interface hardware or equipment,
strengthen productivity, operator interface, control panels,
alarms, annunciators, data acquisi-
quality and uptime. tion equipment, or data recorders or
plotters (64%); and process control
Get fit. Retrofit. Just call wired networking hardware, Ethernet
switches, cord sets, connectors, wire or
1-360-254-8688 or visit cable analytical instruments, or test or
calibration equipment (63%).
deltamotion.com
3. Project effectiveness: Fifty-four
percent of in-house system integrators
have found automation system inte-
gration to be highly effective in their
projects, compared to 38% moderately
effective, 6% somewhat ineffective, and
2% not effective.
4. Project effectiveness: More than
half of in-house system integrators
measure project success by the effect on
productivity, if the project was on bud-
get, and if the project was completed on
time.
5. Challenges: The top five chal-
lenged faced by these system integra-
tors are trouble with hiring engineering
talent for system integration (46%) as
well as industry expertise (40%); lack of
communication (31%); keeping up with
changing regulations, codes, and stan-
dards (30%); and making time for con-
tinuing education (26%). ce
View more information at
www.controleng.com/2015SystemIntegration.
Amanda Pelliccione is the research
director at CFE Media,
apelliccione@cfemedia.com.

RMC75 and RMC150 Motion Controllers Most recent system integration project
Schedule Budget
Don't know Don't know
Not on time 11% Not on budget 9%

Not on time Not on budget 8%

6%
but delay was but deviance
small and was small and
insignificant 54% insignificant 64%
15%
5% 24% 4%
1-2 Axis Multi-axis
Not on time Not on
but delay was budget but new
agreed upon On time budget was agreed upon On budget

Looking at their most recently completed system integration project, 54% of respon-
dents indicated an on-time delivery, and 64% were able to adhere to the budget initially
settled upon. Courtesy: Control Engineering
input #11 at www.controleng.com/information www.controleng.com/ce-research FOR MORE RESEARCH INFORMATION

14 | APRIL 2016 CONTROL ENGINEERING www.controleng.com

 BOA Spot
TM

NE
W Low Cost Integrated Vision Sensor
BOA Vision System Performance at Vision Sensor Affordability

Integrated light, lens and processing Built-in factory communications

Easy-to-use application interface 100% automatic inspection
Embedded vision tools for Low cost of ownership
matching, counting, feature
nding and measuring

View the BOA Spot Features Guide:

http://goo.gl/Y9p9FN

input #12 at www.controleng.com/information

 CONTROL ENGINEERING International
Replacing humans with machines
and saving jobs?
While automation and robotics will replace some jobs to keep manufacturing competitive, they
will create other positions in computers, mathematics, architecture, and engineering, according
to Control Engineering China, citing World Economic Forum information. Is manufacturing ready
A
for the transition?
Stone Shi is execu-
tive editor-in-chief, Con-
trol Engineering China.
Courtesy: Control
Engineering China
MORE
ADVICE
KEY CONCEPTS
While automation and robotics can
save manufacturers from shutdowns,
are workers prepared for a shift in
roles?
Wholesale layoffs because of
robots seem unlikely in the short term.
Are manufacturers and workers
ready if a faster shift to automation
is needed?
GO ONLINE
www.controleng.com/international
www.cechina.cn
www.controleng.com/robotics
CONSIDER THIS
Are countries and manufacturers
helping workers make the needed
transitions as manufacturers become
increasingly automated?
16 | APRIL 2016 CONTROL ENGINEERING
Are countries preparing for the shift
in education as more automation and robotics
make manufacturing more competitive?
The World Economic Forum stated recent-
ly that by 2020, the development of science and
technology will lead to net losses of more than
5 million jobs in 15 developed countries. These
countries include Australia, China, France,
Germany, India, Italy, Japan, U.K., and U.S.
Some statistical data indicates that the quanti-
ty of labor force in 15 major economic entities
accounts for approximately 65% of the global
labor force, which means that the development
of robots and artificial intelligence technologies
will lead to unemployment of about 10 million
people globally in the next 5 years.
The World Economic Forum also estimates
there may be 7.1 million fewer job posts through
layoffs and job elimination, automation, or dis-
intermediation, as 2.1 million new jobs will be
created. The new positions focus on more special-
ized fields, such as computer, mathematics, archi-
tecture, and engineering. The formation of these
new job posts may partially offset negative impact
brought by the reduction of job posts. However, if
not handled in advance, the advantages of such a
transformation may be fewer than expected.
While replacing humans with machines may
be the first thought, increasing use of robotics is
a growth area for many industries.
Timing for more robots?
For administrators in manufacturing enter-
prises, is replacing workers the greatest value of
industrial robots? Do workers need to be con-
cerned about layoffs in the short term?
While some have called for substituting
machines for humans, there is still a long way
to go before robots replace a large number of
workers. For many locations, the cost to pur-
chase and implement industrial robot systems
cannot be ignored. Most establishments seem
likely to choose incremental investments, rather
than large-scale implementations seeking quick
money.
In view of greater robotics and automation,
enterprises must have sufficient long-term
planning in place to train or hire more spe-
cialized personnel in engineering design and
equipment maintenance in enterprises. While
industrial robots may be considered the model
of intelligent equipment, in principle there
is little distinction between robotic intelli-
gence and highly automated production equip-
ment. As market demands accelerate, industrial
robot systems seem unlikely to meet continu-
ously changing production demands, with time
required for setup and debugging.
While the phrase replacing humans with
machines sounds an alarm, people should real-
ize that the primary cause of unemployment
is market competition rather than industrial
robots. This is almost an irreversible trend.
Orderly transition, not disruption
Klaus Schwab, founder and executive chair-
man of the World Economic Forum, said, If
no urgent and targeted action is taken today to
make planning of short-term transformation and
establish labor force with technology required in
the future, governments of various countries will
have to confront continuously increasing unem-
ployment rate, social inequality, and business
environment in which consumer groups increas-
ingly shrink in the future.
In other words, if we are faced with demands
to substitute machines for humans more urgent-
ly in rigorous competition, it may be difficult to
practically advance rapidly with lack of appro-
priate talent, technology thresholds, investment
costs, etc. This is the advanced warning many
Chinese manufacturing enterprises need. Are we
really ready? ce
Stone Shi is executive editor-in-chief, Control
Engineering China; edited by Mark T. Hoske,
content manager, Control Engineering, CFE
Media, mhoske@cfemedia.com.
www.controleng.com
with programmable controllers
at out-of-this-world prices
FREE Software FREE Tech Support
Download and install as Voted Best in Service 15 years straight.
often as you need. Give us a call and see for yourself.

PLC CPU
PLC CPU 5 comm ports Basic PLC Ethernet PLC
starting at starting at starting at
$299 $255 $69 $129

1-800-633-0405 | www.AutomationDirect.com
Weve never been traditional . . .
. . . and neither have our
Regardless of your project or system needs, AutomationDirect has a PLC to m
your specs and your budget. So whether youre building a simple process or
machine, you can count on us for affordable innovations you can rely on.

CLICK PLC BASIC PLC STARTING AT: $

FREE Programming Software and Tech Support for
Its amazing how we fit so much functionality into such a smal
with such a low price! Starting at $69, the CLICK micro-brick PL
simple, cost-effective solution for your application.
R
Stand-alone PLC units with discrete or discrete/analog I/O
Expandable up to 142 I/O points
NEW! CLICK Ethernet PLC units with built-in 10/100 Mbps Et
FREE, easy-to-use programming software
2 year warranty
See more at: www.automationdirect.com

Do more

Do-more PLC CPU STARTING A

FREE Programming Software and Tech Supp
What could be better than combining our time-tested
or Terminator I/O hardware with a next-generation co
a ton of memory, speed, and communication? How ab
unbelievably affordable price.
High-performance processor with over 1M bytes o
USB programming, serial, and Ethernet ports
Expandable up to 65536 analog, discrete and spec
FREE, powerful programming software with simula
1 year warranty
See more at: www.automationdire

Real-time data on temperature

and analog modules

2016

FINALISTS
 Just pay once . . . because once is enough!
With traditional suppliers the upfront Our programmable controllers include
prices. price is not always the price you pay.
The costs associated with service
many standard features that you would
pay thousands for elsewhere, but what
match contracts, software licenses, access to they dont include is the additional
r a complex online resources, etc. can make your PLC cost of ownership.
purchase a long and painful one. We are not a traditional PLC company
but we just might be what you need.
$69 Check us out.
r Life!
ll package, Traditional PLCs come with traditional costs
LC is a

$$$$$$
Additional
software licenses
Service
Initial contract
renewal
$$$$$
thernet port starting at $129 software Access to
costs online
Cost of Ownership Over Time resources
(forums,
$$$$

Service
m/clickplcs contract updates, etc.)
$$$$

Hardware
cost
$$$

FREE Software
AT: $299 FREE Tech Support
port for Life! NO software license fee.
d DirectLOGIC PLC Hardware Download as many copies for as
$$

ontroller, offering cost many computers as needed.

bout doing it for an

of memory (H2 models)

PLC Lifetime
$

Year 1 Year 2 Year3 Year 4

cialty I/O
ator!
Traditional PLCs AutomationDirect
Productivity Do-more CLICK
ect.com/Do-more-PLCs

And our newest programmable controller line . . .

Productivity2000 PLC CPU w/5 comm ports: $255
FREE Programming Software and Tech Support for Life!
The Productivity2000 PLC is our newest PLC and is designed to offer you the best
value and lowest cost of ownership in its class. Compared to the competition, the
Productivity2000 PLC has the features you want at a price they cant touch.
50MB of user memory with built-in data logging capability
OLED real-time data and diagnostic displays
5 built-in communication ports including USB programming, serial, and Ethernet ports
Communication protocols include EtherNet/IP and Modbus TCP
FREE, tag name based programming software
Mobile device access and remote visibility
2 year warranty
See more at: www.automationdirect.com/Productivity2000

See for yourself, and get more than you paid for
at www.AutomationDirect.com/plcs

1-800-633-0405 www.AutomationDirect.com
 #1 Value in Automation
The best values in the world . . .
Weve shopped around to bring you the most practical industrial control products
that are in-stock, ready to ship and at the right prices!
Ive been using Automation I have bought a touch panel and I like the website and user
Direct for a few years now. a PLC from automation direct. I friendly ordering. No problems
Their products are a great value am very satisfied with the level of in over 4 years with any
and their customer support technical support I have received. shipping or material.
is excellent. I love that I can It is great to see a company that Richard
get something Ive forgotten offers this level of support even to in WHEELER, TX
overnighted to my work site as clients that place small orders as
needed. I have. Technical Support best in class,
Thanks, Automation Direct! Every time I call for help the from detailed knowledge of
Annalisa technical support agents are very products to product selection
in SALT LAKE CITY, UT courteous and knowledgeable. of an upcoming project.
Javier ROB
in MONTREAL, QC in AFTON, MI

Programmable Universal Field I/O Software Operator Interface AC Drives

Controllers

Motors and Motion Control Power Transmission Pneumatics Process

Motor Controls

Relays & Timers Sensors Pushbuttons, Terminal Blocks & Wiring Safety
Switches and Lights

Communications Power Products Enclosures Circuit Protection Tools and Test Equipment

A quality product line, with FREE #1 rated technical support and quick shipping!
Call 1-800-633-0405 or visit us at: www.AutomationDirect.com
INSIGHT IT & engineering
Manufacturing software development:
Bigger is not always better
Manufacturing and IT insight: More lines of code in a software development project do not
mean that a project will be successful; there is more to effective software development than just
a sophisticated programming package. Software tools without proper programming training for
O
the right people only lead to major headaches down the road for everyone.
One of the advantages of partici-
pating in professional organizations is the oppor-
tunity to learn about successful and unsuccessful
automation programming projects. A recent proj-
ect proved the old saying, bigger is not always bet-
ter. While bigger may be better for bank accounts
and dessert servings, it is definitely not better when
applied to programming, system designs, and con-
trol designs. More lines of code in a software pro-
gram do not necessarily equate to better software.
Write fewer lines of code
The project involved fixing a custom report
package. The problem was that the engineer was
not a programmer and had never received any for-
mal training in software design, software engineer-
ing, or programming.
There were no established procedures for soft-
ware development and no policies for design
reviews. The result was a brute force approach,
which used a separate function for each specific
month and year and excessive code duplication,
with no documentation on the developed software,
no comments in the code, and no header descrip-
tions on any of the functions.
Predictably, the report failed, and no one
remembered how the software was intended to
work. A complete redesign and rewrite fixed the
problem and reduced the number of lines of code
from almost 10,000 lines to less than two hundred.
The lesson that should be learned from this
example was that a better process was needed to
develop software. No one would expect that giving
a chemical or electrical engineer a 3D modeling
tool would give him the skills needed to become an
automotive designer and develop a new car design.
However, too many managers and engineers
think that giving chemical, electrical, or mechani-
cal engineers a programming tool will make them
software engineers. There is more to effective soft-
ware development than just a sophisticated pro-
gramming package. Tools without training are just
engineers toys. Using tools without effective poli-
cies and procedures are just hobbies.
www.controleng.com
A key point to remember is that the ineffec-
tive design and development of software is a peo-
ple problem, not a technology problem. Improving
technology allows us to build software faster, but
that doesnt necessarily mean better. Without train-
ing, knowledge of the underlying solution space,
and some measure of experience, technology tools
are often wasted.
Four lessons of software development Dennis Brandl
The key lessons that should be learned in devel- President of BR&L
oping safe, supportable, and robust manufacturing Consulting
software are: 1) provide focused training on new
tools or provide the time to experiment and learn
the environment before using it in a production
solution; 2) develop comprehensive policies for
the review of all software designs before they are
committed to code; 3) write procedures on how to
conduct design reviews; and 4) write effective pro-
cedures for how to conduct code reviews.
The purpose of the design review procedures
is to uncover ineffective algorithms, not to judge
the designers. In his book Creativity, Inc. Ed Cat-
mull, president of Pixar Animation, discusses the
creative process and how it is iterative, and our
first, second, and even later attempts are often in MORE
the wrong direction. ADVICE
An independent viewpoint often points out the KEY CONCEPTS
flaws that we cannot see. The purpose of the code Establish procedures for software
reviews is to identify best practice implementation development and create policies for
design reviews.
weaknesses. Writers of code, just like writers of
Ineffective software design is not a
books and screenplays, need editors to review and technology issue; its a people issue.
correct mistakes that the authors cannot see. Mature policies and a strong training
The development of safe and reliable manu- program are vital for developing safe
facturing software, and especially any control sys- and reliable manufacturing software.
tem software, requires that there is a high level GO ONLINE
of maturity in training, policies, procedures, and Read this story online at
tools. When combined with good engineers, www.controleng.com for additional in-
these provide the winning combination for build- formation not found in the print/digital
edition issue of Control Engineering.
ing future successes. ce
CONSIDER THIS
What best practices and training
Dennis Brandl is president of BR&L Consulting in policies can companies use to cut
Cary, N.C. Edited by Chris Vavra, production edi- down on potential software develop-
tor, Control Engineering, cvavra@cfemedia.com. ment mistakes?
CONTROL ENGINEERING APRIL 2016 | 17
 INTEGRATOR UPDATE mixing controls
High Powered Wireless Products
for Measurement and Control Integrated controls
adds product
ZW-REC
consistency, quality
Starts at An automated integrated control and informa-
$
250 tion system helped Whitmore Manufacturing Co.
increase production capacity 28% with a nine-hour
decrease in cycle time, adding 150 batches per
year while increasing quality for one product line.

A fully automated integrated control and information

system helped decrease cycle time and increase product consis-
tency and quality for Whitmore Manufacturing Co., an industrial
lubricant manufacturer, using batch software, temperature control,
motor control for mixers, flow control, historian, and an enter-
High Power Wireless Receiver prise manufacturing intelligence (EMI) software with help from
Ethernet or Internet Connection system integrator Innovative Control Inc. Production capacity
increased 28%, and average cycle time decreased nine hours, add-
ing 150 batches per year to production for one grease line.

Many products, recipes

Lubricants, used in a range of industries, such as mining, rail-
ways, and space travel, keep gears moving, reduce friction, and
improve performance and longevity. For NASA, they help trans-
port space shuttles to the launch pad.
Whitmore Manufacturing. produces industrial lubricants, seal-
ants, coatings, cleaners, and oils. Lubricants produced amounts to
more than 16 million pounds per year, including biodegradable
and dry film lubricants, hydraulic oils, and tire sealants.
High Power Wireless Transmitters Ethernet or Internet Connection Whitmore manages lubrication production from research and
ZW-ED Series Starts at $175 development (R&D) through product formulation and appli-
input #13 at www.controleng.com/information cation services for customers globally. A recent $20 million,
120,000-square-foot expansion of headquarters and manufactur-
ing facility in Rockwall, Texas, included efforts to resolve challeng-
es related to labor-intensive, often manual, batch processes.
Whitmore engineers began working with Innovative Control
Inc., a system integrator, to build an integrated control and infor-
mation system using a platform with an integrated architecture.
The multi-year project began by installing a programmable logic
controller (PLC) that was integrated with motor control software

MORE
Digital Panel Meters
ADVICE
DPPt Series Starts at $150
KEY CONCEPTS
OMEGA Introduces Moving from a manual to an automated process reduced errors and increased
quality as production capacity increased 28%.
Technical Learning System integrator helped integrate software and control technologies.
Visit omega.com/technical-learning GO ONLINE
More details, another photo, and other batch control articles are linked to this
Contact Us Today article online. If reading the digital edition, click on the headline or search on the
headline at www.controleng.com.
1.888.826.6342 | omega.com CONSIDER THIS
Have you had a system integrator help with return on investment analysis of auto-

mating a manual process? In this issue, see the system integration series of articles.
Prices listed are those in effect at the time of publication and are subject to change without notice.
Please contact OMEGAs sales department for current prices.

|
Note: Models with wireless option are approved for use in the US, Canada and Europe only.
COPYRIGHT 2016 OMEGA ENGINEERING, INC ALL RIGHTS RESERVED 18 APRIL 2016 CONTROL ENGINEERING
 Historian software tracks key variables for
for the facilitys charging and temperature Whitmore Manufacturing, such as lubricant
control systems. temperature, weight, and mixing time for more
Manufacturing execution system soft- than 20 mixers. The historian information is fed
ware provides a full and accurate view into FactoryTalk VantagePoint EMI software from
into the newly automated lubricant charg- Rockwell Automation, which provides greater
ing and mixing systems with tight integra- accessibility to in-context data and trend reports.
tion with the PLCs and other plant-floor Electronic batch ticketing process to drive work
applications. flow. Each formula is programmed by engineers
Historian software tracks key variables, and requires signoffs before recipes are released
such as lubricant temperature, weight, and to production. Courtesy: Whitmore Manufacturing
mixing time for more than 20 mixers at
the facility. Operators can easily see where
modified batches originated by reviewing
historical and real-time data.
The historian information is fed into
EMI software, which provides greater
accessibility to in-context data and trend
reports and enables operators to analyze
multi-batch data more efficiently.
Whitmore engineers chart connec-
tions between average cycle times and pro-
duction rates. Dashboards allow operators
to monitor and troubleshoot the system
remotely or on a mobile device. The con-
trollers integrated platform and one pro-
gramming environment has minimized
operator interaction with materials.
Whitmore implemented an electronic
batch ticketing process to drive work flow.
Engineers program recipes and formulas in
batch applications, then sign off before rec-
ipes are released to production.

No downtime transition
Whitmore automated more than 20
mixers without downtime and automat-
ed the motor control and charging sys-
tems. Since the implementation of the
automated integrated control and infor-
Safety is not an option.
mation system, Whitmore has reduced
product variation significantly nearly
ACS880 Industrial Drives
eliminating human error.
For lithium-based greases, Whitmore
increased production capacity by 28%,
adding 150 batches per year, and reducing
cycle time an average of nine hours. The
new system has minimized work order
variancesincluding cost and materials
and yield is monitored and controlled.
Once the automation system is integrat-
ed with the enterprise resource planning
system, Whitmore expects even more ben-
efits, including real-time inventory control
and increased reporting. ce

Daniel Gassett is mechanical engineer with

Whitmore Manufacturing Co. Edited by
Mark T. Hoske, content manager, Control
Engineering, mhoske@cfemedia.com.

CONTROL ENGINEERING APRIL 2016 | 19 input #14 at www.controleng.com/information

INDUSTRY NEWS and events
Communication system
assists human-robot teams
Autonomous robots performing a joint
task send each other continual updates:
Ive passed through a door and am turn-
ing 90 degrees right. After advancing 2
feet Ive encountered a wall. Im turning 90
degrees right. After advancing 4 feet Ive
encountered a wall. And so on.
Computers, of course, have no trou-
ble filing this information away until they
need it. But such a barrage of data would
drive a human being crazy. At the recent
annual meeting of the Association for the
Communication system developed by
MIT researchers could make it easier to
design systems that enable humans and
robots to work together in emergency-
response teams. Courtesy: Jose-Luis Oli-
vares, MIT
For a full list of available enclosures
and participating dealers, please
visit www.rittalenclosures.com
Terms and conditions subject to change.
Advancement of Artificial Intelligence,
researchers at MITs Computer Science
and Artificial Intelligence Laboratory
(CSAIL) presented a new way of modeling
robot collaboration that reduces the need
for communication by 60%. They believe
that their model could make it easier to
design systems that enable humans and
robots to work together in, for example,
emergency-response teams.
We havent implemented it yet in
human-robot teams, said Julie Shah, an
associate professor of aeronautics and
astronautics and one of the papers two
authors. But its very exciting, because
you ... just reduced the number of com-
munications by 60%, and presumably
those other communications werent real-
ly necessary toward the person achieving
their part of the task in that team.
The work could have also have impli-
cations for multirobot collaborations that
dont involve humans. Communication
consumes some power, which is always a
consideration in battery-powered devices,
but in some circumstances, the cost of pro-
cessing new information could be a much
more severe resource drain.
In a multiagent system (the computer
science term for collaboration among
autonomous agents, electronic or other-
wise) each agent must maintain a model
of the current world state and a model
Rittal Wallmounts:
A good thing just got better.
Rittal Part # Size Hoffman Part #
JB060604HC 6x6x4 A606CHNF
WM201608NC 20x16x8 CSD20168
WM242408NC 24X24X8 CSD24248
WM201608N4 20X16X8 CSD20168SS
input #15 at www.controleng.com/information
of what each of the other agents takes to
be the state of the world. Agents are also
expected to factor in probabilities that their
models are accurate, then decide whether
or not to modify their behaviors.
In some scenarios, a robots decision to
broadcast a new item of information could
A new version permitted extensive
communication to complete tasks
between 2% and 10% faster.
force its fellows to update their models and
churn through all those probabilities again.
If the information is nonessential, broad-
casting it could introduce serious delays,
to no purpose. And the MIT researchers
work suggests that 60% of communications
in multiagent systems may be nonessential.
Shah and Vaibhav Unhelkar, a gradu-
ate student in aeronautics and astronautics
and first author on the new paper, creat-
ed a version of their system that permitted
extensive communication to complete the
tasks at a rate between 2% and 10% higher
than the prior version.
Edited from an MIT News Office story
by Larry Hardesty by Chris Vavra, pro-
duction editor, Control Engineering, CFE
Media, cvavra@cfemedia.com.
Saginaw Part # Rittal Price
(Mounting panel included)
SCE-606ELJ $24
SCE-20EL1608LP $122
SCE-24EL2408LP $145
SCE-20EL1608SSLP $318
 Reading the digital edition? Click on headlines for more details. See more news daily at www.controleng.com/news

The evolution of the Internet of Things in field service

T
he Internet of Things (IoT) has made quite a buzz the last few and spit out actionable feedback, manufacturers can produce
years, especially in the industrial realm. It was the most talked better products and provide more informed, proactive service to
about topic at the Consumer Electronics Show (CES) in January customers.
2016. And over the last couple of years, IoT has made its mark as a Salesforces guide, The Rise of Systems Intelligence, calls
leading technology guiding the future of field services. this influx of data the tsunami of information. Enterprises will need
The manufacturer can now offer a package of connected to figure out how to not only capture this data, but how to search,
equipment and related services that optimize overall results, said analyze, and visualize it ... The ultimate goal is the ability to perform

a recent Harvard Business Review article, How predictive analytics and real-time intelligent
Smart, Connected Products are Transforming decision making .... This is going to require an
IoT helps manufacturers
Competition. IT transformation from systems of record to
There are many opportunities to add to exist- be more knowledgeable systems of intelligence.
ing telemetry to power continuous analytics at
while making customers IoT for industrial equipment
the individual component or system level, Ven-

The IoT will continue to grow in functional-
tureBeat wrote in a recent article, IoT Mapped.
more efficient. ity and popularity among industrial equipment
IoT sensors allow manufacturers to monitor
businesses. Some of the future trends indus-
equipment at a granular level, see how systems
trial
. businesses will see in the coming years include:
are working together, or if an individual component on a generator
 Initiating tasks and communicating with other equipment
is working correctly.
 Tailoring user interfaces, recommendations, and movements to
By using information to guide business decisions, manufactur-
meet customer preferences
ers become more knowledgeable while making customers more
 Strengthening featuresand thus the benefits they provide
efficient.
customersthrough software improvements
IoT sensors allow service programs to be proactive rather than
 Learning how to lower operating costs
reactive. As the world enters an age where customers demand
 Optimizing yield and productivity
more from equipment and the services they receive, manufactur-
 Preventing accidents and failures during operation
ers are discovering the importance of gaining loyal customers and
 Taking action in uncertain or adverse conditions.
achieving ongoing service revenue by leveraging the power of
smart, connected equipment.
The IoT is the next frontier in product support, and manufac-
Information tsunami turers need to have the right tools to meet tomorrows service
As more field service things become smart, service firms will demands.
need a place to capture, organize, and make actionable the key
data their machines produce. Anybody can gather datasensors Joanna Rotter is content marketing manager at MSI Data.
are cheapits about what is done with the data. MSI Data is a CFE Media content partner. Edited by Chris Vavra,
With solutions that make sense of incoming machine intelligence production editor, Control Engineering, cvavra@cfemedia.com.

Low Price, High Quality. Now with Accessories and Stainless, too.
Youve known Rittal quality and durability in Wallmount Enclosures for years. Now, because weve
expanded our low pricing to Stainless and Wallmount Accessories, you can get even more of the
industrys highest-quality enclosures at a price so low Hoffman and Saginaw cant bear for you to see.
And, with our manufacturing plant located in the USA, local availability means you wont have to wait for
the perfect Rittal Wallmount enclosure you need for your facility today.
Industrys highest quality at low prices
Available in more than 100 standard sizes in both carbon and stainless steel
Now including a full line of accessories
UL Listed with foamed-in-place gasket, flange through collar and secure locking system

Get the FREE

Wallmount App for RITTAL SHIPS QUICK! www.RittalEnclosures.com
iOS and Android Made in the USA (800) 477-4000 One Class. Rittal Class.

Magnetic Flow Meters
VMx Series
induQ VMx series are designed
Thefor commercial and industrial
applications that require accurate and reliable
measurement of water and other conductive
liquids over a wide flow range.
No moving parts = high reliability
Viscosity Independent Measurement
High Accuracy: 0.5-1% of reading
0.026 4,980 gpm range
1/8 8 standard sizes available
VMM
VMZ
VMI
Made in Germany www.sika-usa.com
Quality by tradition
input #16 at www.controleng.com/information
Power sources for
highest performance in
harsh environment.
input #17 at www.controleng.com/information
Reliable. Available. Now. tracopower.com
INDUSTRY NEWS and events
Industrial Internet groups agree
to align architecture efforts
Representatives of Plattform Industrie 4.0 (I4.0) and the
Industrial Internet Consortium (IIC) agreed to align their
architecture effortsrespectively, the Reference Architec-
ture Model for Industrie 4.0 (RAMI4.0) and the Industrial
Internet Reference Architecture (IIRA). Both sides recognize
the complementary nature of the two models, an initial draft
mapping showing the direct relationships between elements
of the models, and a clear roadmap to ensure future interop-
erability. Additional topics included collaboration in the areas
of IIC Testbeds and I4.0 Test Facility Infrastructures, as well
as standardization, architectures, and business outcomes in
the Industrial Internet.
Prof. Dr. Siegfried Russwurm, technical director of Platt-
form Industrie 4.0, CTO and member of the managing board
of Siemens AG, said, Collaborating with other initiatives is
important, especially for Germanys export-oriented econ-
omy. We are highly interested to cooperate intensively with
others in order to pave the way for global standards. Coop-
erating with IICand with other consortiais an important
step in the right direction.
Dr. Richard Mark Soley, executive director of the IIC, said,
The effort shows that smart technical people can bridge any
gap and find a way to solve problems that might otherwise
262.886.2695
have created barriers to entry in the adoption of IoT technol-
ogy for industrial applications. I applaud the participants and
thank them for their initial work and
look forward to a successful collabora-
tion moving forward.
The meeting constituted an informal
group, which will continue its work on
exploring potential alignment between
I4.0 and IIC.
Edited from an Industrial Internet
Consortium press release by CFE Media.
Company launches
cloud for IoT services
Bosch is launching the Bosch Internet
of Things (IoT) Cloud, web-based services
to run applications for connected mobility,
connected industries, and connected build-
ings. The first Bosch cloud, located in Ger-
many, includes technical infrastructure and
platform and software. It connects more
than 5-million devices and machines and is
for in-house use initially. In 2017, it will be
offered as a service to other companies.
Software identifies web-enabled objects,
orchestrates data exchange, and enables
services. Big data can be analyzed. Rules
for automatic decisions can be stored,
such as when patterns of wear should be
reported and preventive action taken.
- Edited by CFE Media from a Bosch
press release.
22 | APRIL 2016 CONTROL ENGINEERING
 Headlines online
Industry events
At www.controleng.com, on the right side, click on the events box
and scroll by month to see related industry events including:
 Hannover Messe 2016, Hannover, Germany, April 25-29
www.hannovermesse.de

 The AIA Vision Show, Boston, May 3-5

www.visiononline.org/mvo-content-adv.cfm?id=247

 Offshore Technology Conference and Exhibition, Houston, Texas, May 2-5

http://2016.otcnet.org

 Connect 2016, New Orleans, May 23-27

www.se-connect2016.com

 Rockwell Automation TechED, Orlando, Fla., June 12-17

www.rockwellautomation.com/global/events/ra-teched/usa/overview.page

 Honeywell Users Group America, San Antonio, Texas, June 19-24

www.honeywellprocess.com/en-US/online_campaigns/hug/Pages/
americas/americas.html

 Sensors Expo, San Jose, Calif., June 21-23

www.sensorsexpo.com/attend

 Automation Summit 2016, Las Vegas, June 27-30

www.industry.usa.siemens.com/automation/us/en/summit/Pages/
summit.aspx

Top 5 Control Engineering articles

Mar. 21-27: The most visited articles included PC-based control, the
2016 Engineers Choice Awards, heat exchanger control strategies, input #18 at www.controleng.com/information
ladder logic and PLC scanning, and data acquisition and analysis.

PMI rises for second straight month

The Institute for Supply Managements (ISM) Purchasing Manufac-
turers Index (PMI) rose for the second straight month to 49.5% as
the overall economic outlook remains more positive than it had been
in previous months.

Support-focused enterprise controls:

Best in class Motor Starting Solutions
conveyor application model
A support-focused control system must have the ability to enable Hannover Messe Industrie hall 14, booth K20
control system designers to model conveyor applications by providing
an object-oriented chart design environment that can enhance the
ability to monitor and interact with a conveyor control application.

Test bed for grid security launched

The American Recovery and Reinvestment Act of 2009 (ARRA)
provided the Energy Department with $4.5 billion to modernize the
electric power grid and transition it to a smart grid that is designed to
be more responsive to changing power needs.

Honoring manufacturings future

The annual CFE Media Engineering Awards in Manufacturing ban-
quet, honored Control Engineerings 2016 Engineers Choice Award
recipients, as well as the 2015 Engineering Leaders Under 40 and wered
Po

Plant Engineerings 2015 Product of the Year Grand Award and the
2015 Top Plant Award winner.
Controlled start current by IGE
L

Flying robots communicate, artificial intelligence

used for data analytics Reduction of mechanical stresses
Executives from Intel and IBM talked about disruptive changes in pur- Reduction of maintenance costs
chasing thanks to developments in robotics and the cloud. Examples Increase of system uptime
include unmanned robots flying in sync to Beethovens Fifth Sympho-
ny and IBMs Watson changing data processings nature from being IGEL Electric GmbH Industrieweg 1315 48324 Sendenhorst Germany
transactional to cognitive. Phone +49 (0)2526 9389-0 Fax +49 (0)2526 9389-22 info@igelelectric.de igelelectric.de

CONTROL ENGINEERING APRIL 2016 | 23 input #19 at www.controleng.com/information

 advertisement

Six Approaches to
Improve Operations Performance
Emerson Process Management

At industrial facilities worldwide, safety and process availability depend

on operators. Operators take the brunt of daily operation issues and
are often the first to address them. No matter the level of process
automation, operators must still make accurate and rapid decisions in
stressful situations. In striving for operator excellence, operating
companies use many methods: improving processes, integrating
best-of-class products, understanding human limitations and strengths,
applying knowledge to specific environments, and more.
Download the free eBook
This white paper series analyzes the challenges operation teams
are facing and the solutions they can leverage to achieve an
efficient and productive path to improve operations
performance. Explore six approaches using technology and
service innovations that can improve operational efficiencies
to reduce cost and run your plant more efficiently.

Topics include:
Cybersecurity Discover best practices to methodically
reduce cyber threats from your process.
Electronic Logbooks Drive more consistent processes
and minimize shift handover risk with electronic logbooks.
Alarm Management Use a configuration-free layer of
protection against alarm floods optimized to reduce
operator stress and increase situational awareness.
Batch Achieve flexibility for agile manufacturing to meet
real-time demands with consistent and integrated processes.
High Performance Graphics Improve business results and
simplify tasks with easy-to-use operator design and graphics.
Data Integration Attain a comprehensive integration platform to
manage a range of plant data including data from field devices and
enterprise business systems.

See how Emerson helps to improve your plants operations performance. automation.systems@emerson.com
Download the free eBook at http://bit.ly/1PXM4Ds. emersonprocess.com/operationsperformance

input #20 at www.controleng.com/information

 advertisement

Microstepping: Myths and Realities

MICROMO engineering | MICROMO

The lure of microstepping a two-phase stepper and reducing

motor may sound enticing, and although resolution resonances
will increase, accuracy will actually suffer. Before you problems. Although
make design commitments, consider some of the microstepping gives
myths and realities behind microstepping. the designer
more resolution,
The real compromise with microstepping is that as improved accuracy
you increase the number of microsteps per full step, is not realized.
the INCREMENTAL torque per microstep drops off
drastically. Few stepper motors have a pure sinusoidal Reduction in mechanical and electromagnetically
torque vs. shaft position and all have higher order induced noise is, however, a real benefit. The
harmonics that distort the curve and affect accuracy. mechanical transmission of torque will also be much
And although microstepping drives have come a gentler as will a reduction in resonance problems.
long way, they still only approximate a true sine wave.
This gives better confidence in maintaining
synchronization of the open loop system
and less wear and tear on the mechanical
transmission system.

In fact, taking an infinite number of microsteps

per full step results in two-phase synchronous
permanent magnet ac motor operation. Speed
is a function of the frequency of the ac power
supply. The rotor will lag behind the rotating
magnetic field until sufficient torque is generated
to accommodate the load.

Its also critical to note that any load torque will Download the paper at: http://goo.gl/l0E2bG
result in a magnetic backlash, displacing the rotor
from the intended position until sufficient torque
is generated.

Some of the other compelling reasons for

microstepping (besides high resolution) are reduced marketing@micromo.com
mechanical noise, gentler actuation mechanically, www.micromo.com

input #21 at www.controleng.com/information

 advertisement

Choosing the Best Camera

for Your Vision System
Glen Ahearn | Sales Engineer, Teledyne DALSA

So you need a camera.

Youre designing a vision system and know your

application, your performance expectations, and you
have a general idea of how that might translate into
camera specifications and cost. But there are a lot of
variables! There are so many ways to solve your
vision requirement.

The easiest way would be complete transparency

show a camera manufacturer your application and
ask them what you need. Unfortunately, you cant
always do that.

There are usually confidentiality requirements and

proprietary technology that you cant disclose. So if
you cant disclose everything, what do you need to
Linea Gig E line scan camera
tell a camera provider so they can help you get you
the best possible camera for your application?

Download the white paper at:

http://info.teledynedalsa.com/acton/fs/blocks/showLandingPage/a/14932/p/p-008e/t/page/fm/0

sales.americas@teledynedalsa.com
www.teledynedalsa.com

input #22 at www.controleng.com/information


Reliable VFD Cables Boost Productivity,
Minimize Downtime
John Gavilanes | Director of Engineering, Lapp Group NA
From fans and blowers to 24/7 production line
equipment, variable frequency drives (VFDs) are
a mainstay of the industrial world due to their
remarkable ability to improve the efficiency of
motor-driven equipment.
As part of a complete VFD package, high quality
cable is one of the most important components
in terms of achieving maximum productivity and
minimizing downtime. When designing a robust
VFD cable, the materials used in its production
are critical to ensuring that the cables electrical
properties will guarantee peak performance.
For system engineers and others involved in
specifying VFDs, cable quality should be one of
the most decisive factors.
ce201604_whitePpr_lappHlf.indd 1 input #23 at www.controleng.com/information
eNewsletters
Control Engineering covers relevant topical articles in a variety of
eNewsletters each and every month:
CEs Top 5 Reader Favorites
Energy Automation
IIoT Report
Industrial Networking
Industry News & Products
Automotive & Transportation
Chemical Manufacturing
Packaging
Information Control
Machine Control
Subscribe today by visiting
www.controleng.com/newsletters
CE_eNews_HalfHorizontal_2016.indd 1
advertisement
The cable itself is often considered the
most critical component of the VFD system.
In order to protect cables from power
distortions during rectification, the 2015
National Electrical Code (NEC) requires
the size of source power conductors to be
125% of the drives full load current.
Although filters, reactors and isolation
transformers can be added to the drive
to clean off harmonics, these can cause
additional voltage drops from the power
supply. Due to these and other issues,
cable materials can make a big difference
in the lifetime and reliability of the overall
VFD system.
New Products for Engineers Showcase
Oil & Gas Engineering
Planning and Design
Process & Advanced Control
Process Instrumentation & Sensors
Safety & Cybery Security
System Integration
Whitepaper Connection
Download the paper at:
http://landing.lappusa.com/
VFDWP2016_PE
sales@lappusa.com
www.lappusa.com
Products For Engineers
PE SHOWCASE
Control Systems Process Manufacturing Discrete Manufacturing
One Chip. One Company. All Your Network
Solutions.
The netX network controller chip
family from Hilscher integrates
fieldbus and industrial Ethernets
for transparent protocol
conversion. One chip, 12 networks,
24 protocol stacks. All stacks have
the same Driver Interface. Master
stacks include FDT-based
Configuration Tool.
Register to learn more.
One Chip. One Company. All Your Network
Solutions.
Solutions Direct offers discounted
prices on over 8,000 Electrical
Enclosures and Thermal
Management Products. Sizes range
from 2 x 2 to 86 x 187 and meet
NEMA/UL Ratings.
Click to learn more.
On-demand webcasts
It's never been easier to earn
continuing education credits! Attend
our 1-hour-long webcasts now
available on-demand.
Learn More.
2/22/2016 3:57:50 PM
3/7/2016 5:55:00 PM
System Integration Netwroking & Security
Wednesday, October 22, 2015
Info Management
Kepware Releases KEPServerEX V5.16
with New Local Historian Plug-In
The plug-in captures data at the
source to prevent data loss and
improve operational efficiency with
an easy to configure, flexible, open,
and cost-effective solution.
Download a free Demo.
Engineers' Choice Awards finalists
Official Engineers Choice ballots are
open for voting for Control
Engineering North American print
and digital edition qualified
subscribers. Based on your
experience, vote for the best
Engineers Choice finalists of 94
products in 26 categories.
Vote Now!
One Chip. One Company. All Your Network
Solutions.
The netX network controller chip
family from Hilscher integrates
fieldbus and industrial Ethernets
for transparent protocol
conversion. One chip, 12 networks,
24 protocol stacks. All stacks have
the same Driver Interface. Master
stacks include FDT-based
Configuration Tool.
Register to learn more.
 COVER STORY system integration

How system integrators, plant

owners should collaborate
on an automation project
When a plant owner and an automation system integrator are planning an automation project,
both sides have to agree on the direction, priorities, and expectations.

H
MORE
ADVICE
KEY CONCEPTS
Many automation projects become
more complex for a variety of reasons;
entering into an open discussion
goes a long way toward a successful
conclusion.
When disagreements occur, the
system integrator needs to decide
whether there is room for compromise
and to decide whether the changes
being asked are acceptable.
The most effective projects and
relationships are those where the plant
owner and system integrator cooperate
as trusted partners.
GO ONLINE
Go to www.controleng.com to see
more information with this article
posted online, including links to
related stories and sections about:
When DCS opinions clash
Long-term DCS collaboration
CONSIDER THIS
What other aspects of a project
should a system integrator consider
before deciding to embark on a project?
ere are two pitches for the same control
system integration project:
This new process unit will be a tech-
nological showcase: no control room
everything will work from hand-held
human-machine interfaces (HMIs); software in
the cloud and maximum connectivity via the web.
Wireless sensor networks will be everywhere.
Or perhaps: The unit must use tried-and-true
basic analog, hard-wired field devices, and standard
PC-based HMIs like the older systems on site. We
know and stay with what works.
Those two approaches represent extremes of
the technology spectrum. The question is, who is
making the suggestion for each? In most cases the
situation lands somewhere in the middle. Sepa-
ration must be resolved, and the technology gap
must be closed. Sometimes patience and compro-
mise is required from all, but when done well, it will
improve an automation project.
Some project discussions begin with the owner
taking a strong position and telling the integrator: I
am the customer, and its your job to do the project
the way I want. Here is the scope, fill it as described,
and charge appropriately.
This approach works for projects where the
scope is tightly defined, and few options exist for
forming an alternative solution. Many automation
projects, however, become more complex for a vari-
ety of reasons. Entering into a more open discus-
sion goes a long way toward a successful conclusion.
The table lists reasons for involving an integrator in
technology selection and implementation.
Choosing the DCS
The number of process plants launching major
control system upgrades, including full distributed
control system (DCS) replacements, is increasing.
Many companies trying to run plants using 30-year-
old systems find the risks and costs of nursing old
platforms intolerable. Breakdowns and replacement
part shortages interrupt production. Vulnerabilities
to outside cyber attackers pose major threats.
When a DCS must be replaced, the first hurdle is
supplier selection. For some companies, the choice
is simple: for reasons of history, supplier relation-
ships, corporate engineering policy, or whatever,
there is one choice: Supplier X. If this is the case,
any system integrator working on the project will
live with this decision or not accept the project.
For the owner, stating the selection at the out-
set might thin out the number of integrators bid-
ding on the project. An integrator unfamiliar with
Supplier X has to bow out or take the project believ-
ing it can train internal personnel quickly or hire
appropriate talent. In most cases, the integrator will
not be able to pass those extra costs to the client and
must look at it as an investment. Perhaps anoth-
er project will allow new skills to be used again. A
large, experienced integrator has an advantage and
only needs to assign the right people to the project.
If supplier selection is open to discussion, an
integrator can play a critical role. The process
begins with the plant owners engineers examining
operational needs: Here is what the system must be
do as a minimum, and here is what we would like it
to do to improve process control.
The integrators project team looks at the
requirements, and internal platform experts repre-
senting each DCS supplier draw on knowledge and
experience to make a case for why a particular sys-
tem best meets the owners requirements. When a
consensus is reached, the best one or two possibil-
ities are presented to the owner by the integrator
with an explanation of why. Often the integrators
cumulative internal experience plays a major role.
Experience of where a platform worked well or
poorly in particular applications guide the selection.
Having this unbiased experience is paramount
for such a decision. The internal engineers at a
given facility dont have the time to research prod-
ucts in necessary detail. Sales pitches from DCS
suppliers may not provide an entirely accurate
view. Because the integrator often has hands-on

28 | APRIL 2016 CONTROL ENGINEERING www.controleng.com


experience with the platform in a variety of appli-
cations, it is easier for the integrator to achieve a
higher level of objectivity than the owner alone.
If the integrator feels the customers selection
is not the best for the situation, the internal expert
for the specific platform will explain why. The
integrator will point out where gaps exist between
functionality needs and the systems capabilities.
If the owner accepts the evaluation, but sticks to
the original selection, the next step is to figure out
how to overcome the deficiencies. The integrators
role in this process is critical.
The integrators project leader may have to
explain problems to the DCS suppliers represen-
tative, allowing the company an opportunity to
resolve them. If the DCS supplier sees the plant
owner as a critical customer, it may be glad to work
to solve the problem and cement the relationship.
The alternative may be for the integrator offer a fix,
independently or with the DCS supplier.
The toughest DCS situation
The most difficult situation is when an entire
plant changes hands. The new owner and its engi-
neering staff had no prior involvement. Some prior
plant engineers may be around to help, but its hard
to depend on that over the long term.
An integrator working with a new owner is in
the same position of bewilderment at the outset.
The task is to make sense of what is there, identify-
ing which systems need help and how the automa-
tion infrastructure can be improved. The particular
plant may be unfamiliar, but if there are experts
within the integrators staff capable of working with
the major process units and automation systems,
moving through the learning curve more quickly.
The new owner and integrator need to analyze the
plant, processes, and supporting automation sys-
tems. Problems need to be prioritized by ability to
disrupt production. Those need to be fixed first.
www.controleng.com
COVER IMAGE: When
considering a plant
upgrade or new project,
the integrator and cus-
tomer must come to
terms on which technolo-
gies will fulfill the overall
objectives best. Courtesy:
Maverick Technologies
Reasons to engage a systems integrator in
automation system selection and implementation
Creates buy-in between owner and integrator
Integrator has more experience than owner with different automation systems
Integrator has more experience than owner with automation system supplier
sales tactics
Integrator provides a second set of eyes to evaluate technology selection
Integrator may be able to spot flaws in automation supplier offerings
Integrator can often provide fixes and workarounds to optimize automation system
performance
Integrator can provide better long-term support when it is involved with the
automation system selection process
Courtesy: Maverick Technologies
The next step examines where improvements
can improve throughput and gain efficiencies. An integrator
These often are incremental programs, a methodi-
cal march through systems while the plant remains can bring an
in production. New owners rarely shut down a facil-
ity to make all improvements at once. external view
The same guidelines for technology selection
also apply. The owner may decide to leave existing
combined
systems in place for cost reasons, or it might want with practical
to bring the new plant up to its current engineering
standards. Changes may balance costs and benefits. experience with
The ability to analyze and quantify steps is where an
integrator can bring an external view to the situa- similar plants,
tion combined with practical experience with other processes, and
similar plants, processes, and automation systems.
The most effective projects and relationships are automation
those where the plant owner and system integra-
tor cooperate as trusted partners, instead of just as systems.
a vendor and a customer. This partnering relation-
ship creates the highest value for both sides. ce
Tim Gellner, senior consultant, Maverick Technolo-
gies. Maverick Technologies is a CFE Media content
partner. Edited by Chris Vavra, CFE Media, Control
Engineering, cvavra@cfemedia.com.
CONTROL ENGINEERING APRIL 2016 | 29
 SYSTEM INTEGRATION safety integration
Save by integrating safety
and automation projects
Your company could be saving considerable funds by collaborating on seemingly disparate projects.
This case study demonstrates the benefits of departmental cooperation and system integration.
MORE
ADVICE
KEY CONCEPTS
Upgrading controls systems can
save companies more money over the
long term.
Operations should work with the
engineering department for better col-
laboration and long-term, cost-saving
initiatives.
GO ONLINE
Before and after diagrams of the
project are available with this article
online, plus another table and infor-
mation. Click on the headline in the
digital edition or search the headline
at www.controleng.com.
CONSIDER THIS
Could a lack of collaboration be
costing your company unnecessary
money loss?
30 | APRIL 2016 CONTROL ENGINEERING
A
lmost every mid- to large-sized man-
ufacturer has dedicated engineering
and environment, health, and safety
(EH&S) departments. Since the pur-
pose, goals, and objectives of these
departments have traditionally had very little over-
lap, its not too uncommon to find these depart-
ments working without knowledge of what the
other is doing. Engineers constantly work with
operations to find new ways to improve productiv-
ity and efficiency. Safety professionals are assessing,
reducing, and managing risks while juggling regu-
latory requirements. So its not a big surprise that
these two departments rarely cross paths in a year.
As more advanced technologies hit the market-
place, especially technologies designed to provide a
safer and more productive work environment, the
importance of cross-functional departmental col-
laboration becomes critical for survival.
Many companies dont realize how much money
the company could be saving by collaborating
even on seemingly disparate projects. One of the
biggest areas of financial impact for collaboration
between EH&S and engineering can be on every-
day projects that involve machinery and equipment.
Chances are projects involving machinery and pro-
cesses consume a majority of the companys capi-
tal budgets. Not collaborating could be costing the
company money when it isnt necessary.
Until recently, the primary method to reduc-
ing risk was to add physical guards to equipment
to prevent employee access to hazardous condi-
tions. Over the years, the industry has progressed
into developing risk reduction measures, which has
allowed easier access to equipment by replacing the
physical guards with intelligent safeguarding devic-
es. These devices were typically connected to a sin-
gle-purpose safety-rated logic device, independent
of the machines control system, to create a dedi-
cated safety system. At the time these safety devices
and systems were being installed, it really was the
only cost-effective option available. However, with
safety measures being integrated into standard auto-
mation devices, there are financial incentives for
EH&S and engineering to collaborate on corporate
strategies and future capital projects.
Collaboration case study
To determine the collaboration savings, a case
study was conducted by reviewing two project pro-
posals at a large food and beverage company. The
project proposal requests were within six months of
each other and were on the same pair of 15-year-
old depalletizers. The first projects purpose was to
upgrade safety systems on the depalletizers.
The driving factor for this project was the occur-
rence of a recent serious injury and the awareness
that the current safeguarding measures were insuf-
ficient. Since the scope of this project was only
upgrading the safety-related aspects of the machine,
a secondary control panel was needed to add the
additional safety control components. The scope
of the second project was to upgrade the original
(and now obsolete) control system and the opera-
tor station with a new programmable logic control-
ler (PLC) and modern human-machine interface
(HMI). Table 1 looks at project cost components as
originally proposed.
Cost analysis 1: combining projects
The first cost analysis exercise was to explore the
potential savings of combining these two indepen-
dent projects into one project. In developing a new
proposal to reflect the anticipated savings, it was
assumed that the scope and engineering for each
project would remain exactly the same. By keeping
the solutions the same, it was easy to determine the
added costs of keeping the projects separate. Table 2
shows that combining these projects to take place at
the same time would save more than $45,000.
Noteworthy discoveries in Table 2 were:
Project management savings (30%) were
achieved by reducing mobilization time (proj-
ect understanding, kick-off meetings, infor-
mation gathering, etc.) and management time
(scheduling, financial monitoring, etc.)
System integration savings (40%) were
achieved by reducing duplicate software pro-
gramming efforts, mainly eliminating unnec-
essary code changes on the safety project to
communicate with the original PLC.
Electrical design savings (35%) were achieved
by reducing in schematic modification
www.controleng.com
 Table 1: Separate projects, both depalletizers
Safety upgrade PLC upgrade with HMI
Project management $7,130 $5,060
System integration (software) $13,040 $18,400
and development time. The safety project Electrical design $30,520 $20,240
required modification of 12/15 existing draw- Mechanical design $4,800 $0
ings with the addition of 14 new drawings.
Electrical hardware $46,064 $30,954
The PLC project would have required modifi-
Mechanical hardware $40,000 $0
cation of 15/15 drawings with four new draw-
ings instead of 14. Installation (electrical,mechanical) $40,000 $9,000
Commissioning and start-up savings (25%) Commissioning, startup support $23,080 $15,640
were achieved through reduction in duplicat- Total $204,634 $99,294 SUM $303,928
ed site acceptance testing, I/O checks, system
debugging, and travel and expense time. Table 1: This table displays the cost breakdown for independent projects.
All tables courtesy: Grantek
Cost analysis 2: Re-engineering projects
When any engineering-related projects are
Table 2: Costs of combined projects, savings
combined into one project, there are potentially
additional cost savings options available through Combined project cost Savings
alternative solutions. Engineers are no longer Project management $8,533 30%
restricted to focusing on independent solutions System integration (software) $18,864 40%
which serve a single purpose. Instead, they are
Electrical design $32,994 35%
able to re-engineer solutions to be streamlined
Mechanical design $4,800 0
and simplified. For example, if a machines PLC is
being replaced as part of the upgrade, there would Electrical hardware $77,018 0
be no need to add a secondary control panel to Mechanical hardware $40,000 0
support a dedicated safety control system. Using
Installation (electrical, mechanical) $46,550 5%
a safety PLC simplifies engineering and design
efforts. Expanding on the first cost-analysis exer- Commissioning, startup support $29,040 25%
cise, an additional proposal was developed to Totals $257,799 15.2%
reflect a simpler re-engineered implementation.
Table 2: This table shows the cost of projects if done together, with
Project time spent on-site for installation is te
15.2%, $46,129, savings compared to the sum of the columns in Table 1.
single biggest savings. The new solution avoids hav-
ing a dedicated safety controller in a separate panel,
which provides a simpler, cleaner installation. Even Table 3: Re-engineering combined projects adds more savings
though a safety PLC itself is more expensive than
a standard PLC and separate safety controller, the Re-engineered totals
overall solution costs less to implement. Costs are Project management $8,533
lower for hardware, electrical design, system inte- System integration (software) $18,864
gration and wiring, and on-site labor. Electrical design $32,194 (2% less, $800 more savings)
Mechanical design $4,800
Operational benefits
Operational benefits from using an integrated Electrical hardware $76,018 (1% less, or $1,000 more savings)

safety solution include downtime reduction and Mechanical hardware $40,000

reduced exposure to hazards. Most of these bene-
fits are well advertised by all the hardware manu-
facturers. What is often not addressed as part of an
integrated safety solution is the cost associated with
making modificationseither change orders to the
existing project requirements or future changes
to the system. On a small project like the one men-
tioned earlier, the changes may not be as noticeable.
When a company is tackling a larger-scale safety
or control project, these costs can add up. Table 3
shows the anticipated cost savings on a larger proj-
ect associated with change order requests when uti-
lizing an integrated safety solution. The project for
this evaluation consisted of 84 packaging machines
with 51 change orders for the project (ranging from
simple programming tweaks to in-depth func-
tional changes). As high as this number of change
Installation (electrical, mechanical) $36,550 (21% less or $10,000 more savings
Commissioning, startup support $29,440
Total project cost, re-engineered $245,999 (19.1% total savings, $57,929)
Table 3: Re-engineering combined projects creates extra savings of $11,800, in
three (bold) of eight areas, for $57,929 total savings, or 19.1%, less than Table 1.
orders may sound, its on par with Lines between automation and
typical large-scale, multi-plant proj- safety are becoming more blurred
ects. With an integrated safety project, as time progresses; dont miss the
most requested changes are now capa- opportunity for savings through inte-
ble of being accomplished through gration. ce
programming, as opposed to physi-
cal changes, to the hardware. On aver- Jeff Winter, CSP, FS. Eng., is the direc-
age this reduces costs by about $3,500 tor of safety practice at Grantek Systems
per change order (averaged over the 84 Integration; edited by Control Engi-
machines). neering, controleng@cfemedia.com.

www.controleng.com CONTROL ENGINEERING APRIL 2016 | 31

 SYSTEM INTEGRATION information sharing technologies
Industrial networks add value
to existing infrastructure
Todays Web-enabled, data-centric world is full of new technology that can be used to connect
things in new ways and share information across previously uncrossable boundaries.
MORE
ADVICE
KEY CONCEPTS
The Industrial Internet of Things
(IIoT) presents many new opportuni-
ties to provide value to existing
technologies, but they do require
users to update work habits and style
of thinking.
Integrating new devices is much
easier thanks to open platform com-
munications (OPC), data distribution
service (DDS), and the MQ telemetry
transport (MQTT) protocol.
Using the Internet of Things (IoT) is
cheaper than previous technological
leaps because it doesnt require huge
initial investments of capital expendi-
tures and labor to integrate things.
GO ONLINE
For more on IIoT, integrating devices,
and picking the right team, read this
article online at www.controleng.com.
CONSIDER THIS
What other processes can be
improved through the IIoT integrating
with other devices?
32 | APRIL 2016 CONTROL ENGINEERING
T
he landscape of process control systems
has completely changed in the last 5
years. The industry has moved forward
from where the state-of-the-art was
integrating process data with enter-
prise resource planning (ERP) systems and is now
pushing into the realm of completely connected,
distributed, and always-on systems to devices that
didnt even exist a few years ago.
Regardless of the namethe Industrial Internet
of Things (IIoT), Industrie 4.0, the digital factory,
or the connected enterprisethese developments
are here to stay. They present many new opportu-
nities to provide value to existing technologies, but
they do require users to update work habits and
style of thinking. What worked even five years ago
does not necessarily apply anymore. When imple-
mented correctly, though, these new technologies
give the companies who use them a deeper under-
standing of every aspect of their world.
Tracking, analyzing data, new sources
The world is comfortable with the idea of track-
ing as much data as possible. New apps are being
developed to send notifications, display the data in
useful ways, and give everyone information they
can use to optimize their lives. Why should the
manufacturing world operate differently?
Energy usage is an example of new data streams
available to users. Web-enabled power meters, gas
meters, and flowmeters allow access to get real-time
information on water, air, gas, electricity, and steam
usage. This information can be combined with util-
ity billing information to understand the most cost-
effective times of day to run a process and provide
a level of oversight for billing that previously would
have required a lot of manual calculation.
Technology from outside of the manufactur-
ing world such as beacons, geo-fencing, and smart-
phones with global positioning system (GPS)
capability can all be implemented at a processing
facility to provide a real-time view of where person-
nel are in the plant. The information can provide
location-specific alerts and allow, with appropriate
security, control of the process from mobile devices
in certain physical locations.
This can have huge impacts on health and
safety. The safety team can pull up a map of the
plant on a phone or tablet and see where everyone
is in the plant at any given time. This can save time
and resources required to account for everyone in
the event of a fire, natural disaster, or other event.
Integrating devices, systems
One of the most difficult hurdles to integrat-
ing IIoT-enabled devices is integrating them with
existing systems. Through the use of open plat-
form communications (OPC), data distribution
service (DDS), and the MQ telemetry transport
(MQTT) protocol, integrating new devices is
becoming as simple as adding them as a node
on an existing network. MQTT is an Internet of
Things (IoT) protocol built on a machine-to-
machine (M2M) architecture, which makes it easy
for a distributed array of devices to communicate
and share status and environmental readings.
The increasing number of companies developing
IoT-capable devices brings about a growing num-
ber of communication protocols. A group of devic-
es made by one manufacturer will likely be able to
communicate with each other, but not to devic-
es from another company. By using OPC, DDS, or
MQTT as a bridge between an existing system and
new devices, this problem is nearly eliminated.
Many existing systems use OPC or DDS, and
many of the major software vendors are releasing
MQTT communication links to enable compatibil-
ity between their systems and IIoT devices. Add-
ing this information brings more context to process
control and ERP, and other manufacturing execu-
tion system (MES) data adds more value to the sys-
tem. Staying ahead of the curve with technology
is easier than ever. Using the IoT is much cheaper
than previous technological leaps because it doesnt
require huge initial investments of capital expendi-
tures and labor to integrate things. ce
Alex Marcy, P.E., is the owner and president of
Corso Systems, a system integration firm based in
Chicago. Corso Systems is a CFE Media content
partner. Edited by Chris Vavra, production editor,
Control Engineering, cvavra@cfemedia.com.
www.controleng.com
 Valmet IQ
The smartest way to reach
your quality goals

The Valmet IQ quality management solution for the pulp and

paper industry is a comprehensive new product family that helps
you to reach your process and end product quality goals. Our products,
applications and services cover all your needs, from replacement of
individual equipment to building a full quality management solution. Each
Valmet IQ solution is always based on our extensive industry knowhow and
designed to move your performance forward.
www.valmet.com/iq

input #24 at www.controleng.com/information

 SYSTEM INTEGRATION mobile HMI
Contextual mobility
for monitoring and control
Infrastructure to support contextual mobility is needed. Mobility solutions used to monitor,
diagnose, maintain, and control buildings and energy management systems (EMS) are now
being modified by advances in contextual mobility and benefit and operations.
Figure 1: Tablets and
smartphones, with an
enabling underlying sup-
port infrastructure, can
provide contextual mobil-
ity. All figures courtesy:
PcVue Inc.
MORE
ADVICE
KEY CONCEPTS
Advances in contextual mobility
Mobility infrastructure
Benefits to deploying a mobility
infrastructure.
GO ONLINE
More benefits, diagrams, and
links to other articles about building
automation systems and EMS are
found with this article online.
CONSIDER THIS
A mobility infrastructure without
appropriate procedures, processes,
and technologies may increase the
risk of a security breach.
34 | APRIL 2016
M
obility is associated with smart
devices, most notably phones
and tablets. They are increasing-
ly the preferred communications
method for engineers and tech-
nicians on the move. Interaction with mobile
devices differs from the way in which peo-
ple interact with laptop and desktop comput-
ers. Historical approaches to mobility solutions
used to monitor, diagnose, maintain, and con-
trol buildings and energy management systems
(EMS) are being revolutionized by advances in
contextual mobility.
In the distributed environment of monitoring
and control, typically, independent servers are
available for each physical area or zone of con-
trol. A zone may refer to all of the equipment in
an area, such as a floor in a facility, or it may refer
to a specific automation system.
Those responsible for automation systems are
increasingly required to be on the move. They
typically use smart devices to access equip-
ment and other assets located in each zone.
They must know how to connect to the control
server responsible for that zone to get relevant
information and controls. Due to many publish-
ers of control server software, it is unlikely that
the zones will organize information in a consis-
tent way or have a common user interface. This
greatly complicates access and increases the time
required for mobile workers to carry out their
responsibilities.
The responsibilities of mobile workers are
defined by their organizational roles and may
vary by the zone of control. For example, a per-
son responsible for operating equipment in one
zone may only monitor equipment in another.
Likewise, within any given zone, operators may
need different information than maintenance
personnel. The required information and con-
trols are therefore in the context of the persons
role and location. What is needed is a system that
is proactively and securely presenting the right
contextual information, to the right person, at the
right location, and at the right time.
CONTROL ENGINEERING
There is a dire need for a new infrastructure
to serve contextual mobility. The mobility infra-
structure (MI) embraces the smart mobile device
to increase the value and capability of the system.
It consists of indoor positioning systems (IPS)
deployed in zones of control, a proximity services
application on the mobile devices, and a mobil-
ity server responsible for evaluating the appro-
priate contextual requirements and handling the
communications needed to monitor and control
equipment and other assets (see Figure 1).
Proximity services for contextual mobility
IPS and the global positioning system (GPS)
are standard features of todays mobile devices.
Using IPS or GPS, the mobile device can deter-
mine its own current location. When an app on
the device validates and maintains the users cre-
dentials, the device can determine the role of
the user and location in real time. In addition,
using the same IPS technology, the app can sense
nearby mobile assets along with the location
and profile of the user and can synchronize this
information with the mobility server.
The mobile device is connected using stan-
dard wireless network connections. Geo-tags,
including bluetooth low energy (BLE) beacons,
near field communication (NFC) tags, and QR
codes, are used along with Wi-Fi access point
triangulation and other emerging technolo-
gies to determine the micro geolocation of the
mobile device. In similar fashion, geo-tags may
be applied to mobile assets for enhanced prox-
imity services. As the user is on the move, the
picture changes, creating a movement history
that may be recorded by the mobility server as
allowed by privacy considerations.
Mobility server, contextual logic
The mobility server and its contextual logic
engine (CLE) provide a cornerstone for the infra-
structure. The mobility server determines the
appropriate actions and distributes information
and control elements to mobile workers in the
context of where they are and their responsibilities
www.controleng.com

at that location. The information may include real-
time status or control of the equipment. It may
suggest additional resources (drawings, schemat-
ics, etc.) needed by workers in the performance of
their duties (see Figure 2).
When the CLE determines that conditions
require new information and actions to be pro-
vided to the mobile user, they are automatically
sent to the smart device. Some examples are:
 Graphical human-machine interface
(HMI) with status and ability to command
 List of measurement values
 Trend chart of key values
 Display and/or modify a schedule of events
 Manage alarms
 Launch a Web page, display a docu-
ment, or invoke other operating system
resources.
The CLE also may make environmental com-
fort adjustments or provide access control.
Securing the mobile device
Cyber security concerns are paramount in
any information system and as in any network,
it is important to provide a full range of security
measures such as firewalls and active user rights
management. Additional considerations must
be thought through when deploying a mobility
solution.
Specific features within the framework of the
mobility infrastructure include: 1) User sign-on
to use the smart app; 2) Re-authenticate before
control actions are performed; 3) Validation
before critical actions are performed, including
validating proximity of the user to the device
with wearable sensor, such as a BLE beacon,
and confirming validity via geo-tag attached to
equipment, such as a QR code (see Figure 3).
The rise of smart mobile devices now famil-
iar to most workers has created an opportu-
nity to improve mobility for monitoring and
control. This trend moves away from manag-
www.controleng.com
Figure 2: Mobil-
ity infrastructure
interacts with
mobile tools,
such as tablets
and smart-
phones, and
existing systems.
ing from a central control room to a distribut- Figure 3: Validator tags
ed model of personnel on-the-move. The way determine user rights
in which users interact with their mobile device within zones. A worker
compared to how an operator works in a control who might have rights
room requires a mobility infrastructure to opti- to change settings or
mize efficiency, safety, and security. even programming might
With the standardization of geo-location and have view-only rights in
micro geo-location capability on mobile devices another area.
it is possible to monitor mobile personnel loca-
tion and drive contextual information and con-
trols to their smart device based on credentials
and location without specialized equipment.
The mobility infrastructure results from the
desire to use the rapid growth and availability of
smartphones and tablets. Incorporating proxim-
ity services with a mobile app and mobile server
enables world-class mobility solutions for super-
visory control and data acquisition (SCADA) and
building management system (BMS) projects. ce
Edward Nugent is the chief operating officer of
PcVue Inc. of Woburn, Mass., Edited by Emily
Guenther, associate content manager, CFE Media,
Control Engineering, eguenther@cfemedia.com.
CONTROL ENGINEERING APRIL 2016 | 35
 SYSTEM INTEGRATION integrated marketing

Two reminders and six steps

to market to engineers
Engineers welcome the technology side of integrating controls systems and may avoid
taking the same methodical approach about marketing, which can be as integrated as the
product lifecycle. Have a marketing plan; a modern, optimized website; high quality content;
and track progress, to refine along the way.

MORE
ADVICE
KEY CONCEPTS
Information about the product and
its lifecycle can be included in the
marketing lifecycle of the product.
Marketing workflow can be as
methodical as engineering.
Make a plan, market, and measure.
GO ONLINE
More advice from Geier, Ask 5
questions to create a content plan
and links are available with this
article online, under April, at
www.controleng.com/archives.
See also
www.controleng.com/ContentStream
CONSIDER THIS
Compelling information about a
product should be integrated as part
of the product and its lifecycle.
E
ngineering and scientific business lead-
ers often dont know where to invest in
technology marketing to get the great-
est return, theyve tried a do-it-yourself
approach that they werent able to follow
through on because of all the hats theyre wearing,
or they have unrealistic expectations about return
on investment (ROI) and timeframe to achieve
results. So they lose confidence and often give
up too quickly perhaps believing that marketing
doesnt work with technical audiences like control
and plant engineers. To help engineers with market-
ing, two reminders and six steps follow.
Two engineering marketing reminders
1. Marketing in this space has to be as smart
as the people it targets. It takes time and intention-
al planning to do marketing effectively. The scien-
tific instrumentation and control market shows the
importance of accuracy; the spirit of sharing infor-
mation, research, and educating; and the skepticism
that engineers have for slogans and slick brands.
By taking a methodical, measured approach and
following the steps in the book, marketing can be
smart and effective.
2. It is a marathon, not a sprint. Marketing
has transformed over the past 20 years, and now
the buyer is in charge. In research by Trew Mark-
ing and CFE Media (Control Engineering publisher)
hundreds of engineers said the leading place they
go for work-related information is search engines,
primarily Google. With buyers in control, the chal-
lenge (and opportunity) as marketers is to get found
where and when the technical buyer is searching.
This takes time and a long-term commitment to
publishing high-quality content.
If marketing is done intelligently, with content at
the heart, through perseverance, you will get found,
build trust with prospects, and drive demand.
Six steps for marketing technology
Six steps to help engineers improve how they
market technology follow.
1. Say no to grow. Its important to be clear and
focused in technical markets because engineers and
scientists are working on critical applications; they
need expert advice and proven solutions, not gen-
eral engineering direction. To prove trustworthi-
ness, have a clear position and message and be able
to prove it. Do the hard work to determine what
makes what is being marketed unique and articu-
late it consistently across channels in a way that is
differentiated.
To achieve differentiation, make trade-offs to
focus, and be as specific as possible. If growth is
desired, say no to a generalist approach, stop react-
ing to one-off opportunities, and say yes to a more
differentiated and focused position.
For product companies seeking to differenti-
ate, often the issue they face is a market adoption
challenge. They are looking to move across the
chasm and beyond the early adopters to get bell
curve adoption. This can be either for a young, one-
product company, or established companies that
are introducing a new product or targeting a new
segment. After getting past early adopters, revisit
or refine the messaging to get to the early and late
majority; this requires clear differentiation as well as
content that proves the product.
2. Develop a marketing plan to get an edge
over competitors. Many technical business lead-
ers are too busy to stop, focus, debate, and agree on
a comprehensive strategic marketing plan. Instead,
they go down a reactive marketing road that leads
to mediocre results and higher costs in time, money,
stress, and frustration.
Its not that most people dont want a plan.
Everyone would prefer to know where theyre
going, and how theyre going to get there. I believe
instead this is because they are unsure where to
start, what should be included in that plan, and how
to measure success of the plan.
Having a plan provides an edge over competi-
tors, for the three practical benefits of 1) Intention,
2) Measurement, and 3) Efficiency. Those being
intentional with marketing know exactly what they

36 | APRIL 2016 CONTROL ENGINEERING www.controleng.com

 Engineers most valued content sources

The most-valued content

sources for engineers are search
engines (87%), supplier and vendor
websites, trade publications, trade
publication websites, and industry
association websites, according to
CFE Media research, in cooperation
with Trew Marketing. Graphics cour-
tesy: Rebecca Geier, Trew Marketing

plan to do and target and define

goals and objectives with timelines
and a budget.
3. A website is the most important market- 5. Treat content like
ing investment. A website serves many roles in an a product. At the heart Marketing budget as a
organization, such as company storefront, customer of successful marketing percentage of gross revenue
support resource, and a recruiting center, to name a is content. In the past,
few. It is the marketing hub of all activities and the messages were pushed to
main vehicle for creating an online branding experi- people at certain times.
ence, marketing content, and generating leads. Today, it is primarily
Building an effective website requires many ele- through content that new
ments, such as a clean and mobile-friendly design; people find a company
intuitive navigation; informative graphics; clear from searches; its also
company positioning; well-structured code and the companys position
sitemaps for search engine optimization (SEO); and and thought leadership;
compelling, succinct, up-to-date, and optimized how prospects are edu-
content. Whether its a company ad campaign, a cated and compelled to
trade show exhibit, or social media communication, complete lead forms; and
all channels lead back to the website and content. ultimately its how trust
Without an optimized, well-designed, and respon- is built between a busi-
sive website with engaging content, much if not all ness and prospects and
of the investment spent in those promotional activi- customers.
ties will be lost. Content can include
4. Get found on Google. With Google, buy- creating high quality
ers are now in control of what, when, and how they technical content, such
search for information to help them do their jobs. as white papers and case
Engineers can search and search onlineand as studies, and treating content like a product, which Target and annual
research shows, they search much deeper than the has three aspects: optimize, amplify, and repurpose. marketing budget of
average Google userwithout being interrupted or Just like launching and marketing a product, compa- 4% to 12% of revenue
bothered. With engineering buyer personas (target nies need to consider high-value content as products. based on company size,
audience profiles) now in control, the challenge 6. Create a content plan along the funnel. margins, past marketing
and opportunityfor marketers is to get found Marketing to a technical audience requires an investment, the economy,
where and when the technical buyer is searching. understanding of the types of content engineers and revenue forecasts, as
Building a website and adding content will get need and where, why, and how they look for and the chart shows.
traffic, but the right traffic derives from having the use this content during the buying cycle. Learn how
right content optimized with the right key terms. engineers find, use, and engage with content. High-
Defined customers groups (personas) need to find quality, accurate content is important to attract
a companys website when they are searching key- technical target audiences and build trust and cred-
words related to that companys solutions. ibility. Among more than 700 engineers, nearly 75%
SEO takes time, patience, and trial and error. said they are more likely to do business with a com-
Google and other search engines are very partic- pany that regularly produces new and current con-
ular (and quiet) about what they allow to rank in tent, according to the Marketing to Engineers 2014
the search engine results page (SERP). Take a spe- study by Trew Marketing and CFE Media. ce
cific and strategic approach to SEO that will help
you gain the search engine visibility that a website Rebecca Geier is CEO and co-founder of Trew Mar-
deserves. Remember the target audience, and follow keting. Edited by Mark T. Hoske, content manager,
a methodical approach. Control Engineering, mhoske@cfemedia.com.

www.controleng.com CONTROL ENGINEERING APRIL 2016 | 37

 VIRTUALIZATION multi-core flexibility

Core-isolation enables virtualization

for industrial applications
For managing servers and other applications, virtualization has become a major tool in the IT
space that provides huge benefits; core-isolation can minimize the amount of physical hardware
that must be purchased as well as provide additional automation benefits to users.

MORE
ADVICE
KEY CONCEPTS
Virtualization generally manifests
with virtual desktops or virtual servers
running on centralized hardware.
Multiple complex operations can be
executed on one powerful multi-core
PC while maintaining the determinis-
tic performance of the application.
Software modules can be combined
with higher level modules to create
more complex machine units, up to
a complete machine controlled from
one CPU.
GO ONLINE
Find more information and links in
the online version of this article, in
April, at
www.controleng.com/archives.
Read this story online at
www.controleng.com for more
information not found in the print/
digital edition.
CONSIDER THIS
What other techniques can be
used to improve a networks security
apparatus from potential attacks?
V
irtualization is a term most often
associated with information tech-
nology (IT) departments, generally
manifesting with virtual desktops or
virtual servers running on centralized
hardware. An example of a virtualization appli-
cation is core-isolation, which includes migrat-
ing servers from running on their own central
processing units (CPUs) and hardware in a rack
to running several instances of those servers on
one piece of hardware in the rack. This minimiz-
es the amount of physical hardware and operating
costs, and does a better job of utilizing the hard-
ware. Doing the work of multiple, previously sepa-
rate devices from one piece of hardware is growing
in popularity in all kinds of industries and appli-
cation areas as more companies adopt centralized
control strategies.
This type of virtualization typically uses a man-
agement layer of software between the hardware
and the running application/operating system (OS).
For managing servers and other applications, virtu-
alization has become a major tool in the IT space
that provides huge benefits. Similar parallels can be
found in modern industrial control systems (ICSs).
For industrial operations systems should be real-
time capable, which is not achievable in a tradition-
al virtualized OS environment. Most virtualization
applications cannot fully replicate an entire pro-
grammable logic controller (PLC). With advanced,
real-time, PC-based control system architectures,
this is possible and somewhat commonplaceit is a
function of the robust, modular nature of industrial
PC systems and the associated software. Advanced
PC-based automation software platforms provide
a framework for real-time calling of modular soft-
ware elements. By modularizing the components
within this real-time environment, multiple PLC,
C++ or Matlab/Simulink modules can be executed
independently on one piece of hardware.
An architecture, combining many controllers
running on one PC facilitates access to many com-
munications methods from these running software
modules. One real-time software control module
can access fieldbuses A and B, others can access
fieldbuses C, D, E, and F, while other modules com-
municate via independent protocols to ERP, M2M,
or even cloud systems. Multiple complex operations
can be executed on one multi-core PC while main-
taining the applications deterministic performance.
With a multi-core processor and core-isolation
technology, individual functions, assemblies, or
machine units can be regarded as modules; each
should be as independent as possible and struc-
tured hierarchically. Individual control modules can
be put into operation, extended, scaled, and reused
independently. The system can use the IEC 61131-
3 Programming Languages standard, including the
object-oriented extensions. The architecture can
serve robotics, advanced measurement, condition
monitoring, and cloud-based systems for the Indus-
trial Internet of Things (IIoT) and Industrie 4.0. ce

Daymon Thompson is automation product spe-

cialist, Beckhoff Automation. Edited by Chris
Vavra, production editor, Control Engineering,
cvavra@cfemedia.com.

While 36 cores arent needed for a virtualization

application, high-powered, PC-based control options
provide greater flexibility for virtualization applica-
tions, as this Beckhoff Automation display at Pack
Expo 2015 shows. Courtesy: Mark T. Hoske, Control
Engineering, CFE Media

38 | APRIL 2016 CONTROL ENGINEERING www.controleng.com

VIRTUALIZATION upgrade without rip and replace
Distillery saves time and
money with virtualization
Midwest Grain Products (MGP) saved an estimated $3 million with an upgrade
using virtualization, compared to a rip-and-replace alternative.
T
hose who have worked with a virtual-
ized system would not want to go back
to conventional control because of cost
savings, increased quality, consistency of
process, and more efficient use of time.
The automation vendor involved helped create a
three-step migration path using virtualization that
would ultimately save more than $3 million over
the rip-and-replace option with another vendor.
Midwest Grain Products (MGP) rye whiskey
distillery in Lawrenceburg, Ind., produces the bulk
straight rye whiskey with a 95% mash bill, popular
with bottlers and consumers. Demand continues to
grow. There isnt time for interruptions in the plants
continuous, 24/7 operation. MGPs Lawrenceburg
facility produces 40,000 to 50,000 proof gallons a
day of brown goods and an additional 16,000 per
day in grain neutral spirits, all parts of nationally
recognized whiskeys, bourbons, gins, and vodkas.
The control system at the distillery has been
upgraded several times to keep up with demand.
The system needed an upgrade to continue growth
as the distributed control system (DCS) lifecy-
cle was ending, and the human-machine interface
(HMI) program was no longer available or support-
ed. Considering that downtime costs five figures per
hour, keeping the plant running was a top priority.
Virtualized migration
Virtualization, possibly the most important part
of migration, is often overlooked. Virtualization
approaches control from the information technol-
ogy (IT) side. Operations, engineers, and mainte-
nance deal with physical clients and are comfortable
working with physical wires. Virtualization elimi-
nates the need to control through physical elements
and emulates the hardware, operating systems, data
storage, and networks through virtual operating
systems within a host operating system. The virtu-
alization system uses software that runs on the main
host server with process control system.
Virtualization allows multiple operating systems
to share one host server. The client-based virtual-
ization controls the host processor and efficiently
allocates server resources, while allowing each sys-
tem, or virtual machine, to operate independently
in its own shell while communi-
cating with each other. Virtual-
ization software allows users to
aggregate separate physical com-
ponents into a pool of sharable
resources that can be dynami-
cally delivered to applications
when and where needed. The
virtual machine sits on top of the
hypervisor, is independent, and
focuses only on its own needs.
Multiple virtual machines run
on top of the physical host.
Migration pays off Sitting atop the hypervi-
The migration strategy using virtualization sor, a virtual machine oper-
is well underway and on track for completion in ates independently and
2020. The migration focused first on areas of high- focuses on its requirements
est vulnerability to the least, starting with HMI without taxing the server.
and ending with input/output (I/O) connections. The system uses a VMware
Boiler/utilities and dryers are migrated. 2016 will Sphere hypervisor on a main
address the fermenter and yeast rooms, and next host server with Siemens
year cooker and stills will get an upgrade. Simatic PCS 7, allowing
Migration began in 2014 and includes upgrading multiple operating systems
200 HMI screens. Now underway is replacement of to share one host server.
eight prior DCS controller nodes with redundant Courtesy: MGP Inc.
process control system controllers.
The migration will end with Ethernet or device MORE
communications to 7,300 I/O points, replacing more ADVICE
than 260 I/O cards. A process historian and an infor- KEY CONCEPTS
mation server will support long-term archiving and Virtualization allows orderly DCS
reporting needs this year. Virtualizing the plant has migrations without rip-and-replace
shutdowns.
reduced costs because of fewer computers to man-
Less hardware is required with
age and repair. A central location administers con-
virtualization; design saves time.
trol systems.
The instrumentation and controls specialist can GO ONLINE
Learn more about DCS migra-
take care of anything in the plant from the office, tion with this article online: more
and about 20% less time is spent working on hard- diagrams, a photo, an article about
ware. It has helped to improve control-system lon- products used, and cyber security tips
gevity; life span increased from 5 to 7 years to 10 to in Virtualization benefits and chal-
lenges. If reading the digital edition,
15 years before software needs to be modified. ce
click on or search on the headline at
www.controleng.com.
Jason Singleton is instrumentation and controls
CONSIDER THIS
specialist at MGP Inc., Lawrenceburg, Ind. If virtualization can make DCS
Edited by Mark T. Hoske, content manager, migration less painful, havent you
Control Engineering, mhoske@cfemedia.com. waited long enough?
CONTROL ENGINEERING APRIL 2016 | 39
VIRTUALIZATION power management
Benefits of a virtualized
power management strategy
Power monitoring and management are complex and essential to maintaining continuous
uptime at engineering facilities; a virtualization management system and a specialized power
monitoring and management solution can help.
Integrating virtualiza-
tion technology with stra-
tegic power management
solutions ensures critical
power systems stay up
and running. Major virtual-
ization platforms, such as
VMware vCenter Server,
Microsoft System Center
Operations Manager, and
Citrix XenCenter Server
enable users to view and
control many physical and
virtual machines while
adding power manage-
ment capabilities. Live
migration programs, such
as VMware vMotion, help
move virtual machines
from host servers running
on battery power to unaf-
fected network servers in
the cloud.
Courtesy: Eaton
40 | APRIL 2016 CONTROL ENGINEERING
I
n todays virtualized industrial landscape,
more services are running on less hardware,
which means that ensuring those services stay
up and running is more vital than ever. Gen-
erally speaking, no one solution offers all the
features needed to keep critical power compo-
nents and backup devices operating at peak effi-
ciency. Ensuring uptime of critical power systems
requires combining virtualization management
technology with a strategic power management
strategy.
Deploying the right power management and
monitoring solutions can help expand the capa-
bilities of a virtual platform while also creating a
cohesive, maximized asset. Implementing a vir-
tualized power management strategy offers key
benefits and opportunities.
Integration, virtualization
Major virtualization platforms enable users
to view and control many physical and virtu-
al machines while adding power management
capabilities.
Many of todays power management solutions
can seamlessly integrate with virtualization man-
agement technology, enabling users to administer
backup power and power distribution assets, which
include uninterruptible power supplies (UPSs) and
power distribution units (PDUs), in sophisticated
ways on one virtual management console.
Better command, control
Virtualization management solutions allow
technicians to extend UPS battery life during util-
ity outages by shutting down virtual machines and
consolidating them onto fewer host devices.
Live migration programs also let data cen-
ters move virtual machines from host servers
running on battery power to unaffected servers
elsewhere on the network or in a co-location data
center in the cloud.
No other type of information technology (IT)
and facilities management solution can perform
these types of critical functions.
Real-time remote monitoring
In a perfect world, someone would be able to
monitor system IT infrastructure equipment con-
stantly, ensuring critical applications are continu-
ously powered and running efficiently. But thats
not realistic, as teams have more to tend to than
just the IT environment. Thats where a compre-
hensive monitoring and management platform
can make a big difference, helping to act as a sec-
ond set of eyes on vital equipment.
More uptime
Power monitoring and management are com-
plex tasks, but they are essential to maintaining
continuous uptime at engineering facilities. To
perform these tasks effectively, a virtualization
management system, along with a specialized
power monitoring and management solution,
are needed. Operators seeking to prevent utili-
ty outages and power system malfunctions from
disabling mission-critical IT applications should
ensure they have the right set of onsite technol-
ogies and remote monitoring services for their
environment. ce
Arthur Mulligan is a Raleigh-based product line
manager for Eatons U.S. power quality service orga-
nization. Jim Tessier is an Eaton product manager
for IT hardware and software products. Edited by
Mark T. Hoske, content manager, Control Engi-
neering, mhoske@cfemedia.com.
MORE
ADVICE
KEY CONCEPTS
Virtualization and power management strategies can be
integrated.
For greater uptime, live migration can move virtual machines
to unaffected areas on the network or to the cloud.
GO ONLINE
For related resources, click the headline in the digital edition
or type the headline in the search box at www.controleng.com.
CONSIDER THIS
Why not integrate power management and virtualization?
www.controleng.com
 More resources posted daily at:

www.controleng.com

digital edition
Exclusives, Online Extras: Benefits of the Control Engineering Digital Edition include
tablet-friendly viewing (HTML5), exclusive content in every issue; headlines link to the
longer version posted online; links are live where a URL is provided; and an email link
arrives when ready. In addition, link to additional Online Extra articles.

DIGITAL EDITION EXCLUSIVES

DE1 20 years of CiA 401:
Perhaps the most implemented CANopen profile
CiA 401, the CANopen device profile for generic I/O modules, was released in 1996 and
has been consistently used by manufacturers. Future plans for CiA 401 include mapping
for 64-byte process data objects (PDOs) and enhancing interoperability, with discussions
underway about safety and security.

DE3 Enabling business through safety, security

With enough knowledge of a facility such as an oil platform, refinery, or pipeline network, a cyber attack
that used distributed malware could lead to physical damage and serious losses of revenue.

ONLINE EXTRAS (Click on the headlines or search www.controleng.com.)

Support-focused enterprise controls: conveyor application model

A support-focused control system must have the ability to enable control system designers to model conveyor
applications by providing an object-oriented chart design environment that can enhance the ability of support
personnel to monitor and interact with a conveyor control application.

Farming and shipping industries powering IIoT revolution

The Industrial Internet of Things (IIoT) revolution is in full swing, with the agriculture and transport sectors
leading the way as enterprise technology becomes more and more important for manufacturing.

Five tips for hiring the right talent

Dont lose the war for engineering talent. Staffing plans facilitate company growth.

Cyber security attacks against oil and gas

organizations increasing
According to a report sponsored by Tripwire and conducted by Dimensional Research in November 2015,
82% of oil and gas industry respondents said their organizations registered an increase in successful cyber
attacks over the past 12 months.

The skills gap is a misnomer

The reported skills shortage can be greatly alleviated with the new productivity best practices and by new
definitions of the old work augmented with better shop practiceswhich produce more productive teams
with new tools to apply to old tasks.

Human resources will make or break your company this year

You cannot grow your company until your human resources is an effective executive team member
pushing your organization to more marketplace success. For that to happen, you must hold HR
accountable to be more employee-centered with a business strategy focus.

www.controleng.com CONTROL ENGINEERING APRIL 2016 | 41

DIGITAL EDITION exclusive
20 years of CiA 401:
Perhaps the most implemented
CANopen profile
CiA 401, the CANopen device profile for generic I/O modules, was released in 1996 and
has been consistently used by manufacturers. Future plans for CiA 401 include mapping
for 64-byte process data objects (PDOs) and enhancing interoperability, with discussions
underway about safety and security.
T
he CAN in Automation (CiA) 401
profile specification was developed
by the Esprit project developing the
CAL-based communication profile.
After handing over to CiA for further
development and maintenance, the profile for
modular input/output (I/O) devices was released
internally as version 1.3 in 1996 and imple-
mented by several companies. In those times,
CiA members edited the specifications. Today,
CiA engineers do it. Developments continue to
enhance interoperability, and discussions are
looking at safety and security.
The CiA profile supports different digital I/O
granularities. Besides the mandatory 8-bit digital
process data, 16-bit or 32-bit access was speci-
fied as well as a bit-wise access. For analog I/Os,
the profile provides 16-bit resolution (mandato-
ry) as well as 32-bit, floating point, and manu-
facturer-specific data types.
DE1 | APRIL 2016 CONTROL ENGINEERING
Process data objects
Version 1.4 pre-defined just two process data
objects (PDOs). Version 2.0 used already pre-
defined PDOs. The first PDO-transmitted digi-
tal inputs respectively received digital outputs.
The other three PDOs contained four analog
I/O values. In case of other I/O port capabili-
ty, the devices need to be configured. To avoid
this, CiA 401 version 3.0 introduced the M-bit
in the device type object (index 1000h), which
indicates that a manufacturer-specific PDO
mapping is implemented.
Since version 3.1, the profile is split into
two parts. Part 1 specifies generic I/O mod-
ules; part 2 describes several joystick imple-
mentations with dedicated PDO mappings and
some specific parameters. There is also the CiA
852 recommended practice for CiA 401-based
operator environment sub-systems developed
for construction and mining machines.
However, the recommen-
dation has not been imple-
mented very often. In fact, the
CiA 401 generic profile is one
of the most used and imple-
mented I/O specifications. In
particular, the second part of
CiA 401 has been improved
and specifies additional joy-
stick PDO mappings.
There are many modu-
lar CANopen I/O devices
on the market, and there
are more CiA 401 imple-
mentations. Some of these
Eaton_XN300: Eatons
XN300 device family comes
with a CiA 401-compliant
interface. Courtesy: Eaton
www.controleng.com
 Designed for rail-vehicle applications, the Selectron Smartio is a CiA 401-compliant device.
Courtesy: Selectron
implementations such as I/O devices in IP65-
rated enclosures are very specific. Many of the
CANopen suppliers for construction machines
and off-road vehicles provide I/O modules
compliant to CiA 401. There are also micro-
controllers with pre-programmed CiA 401
compliant software available. These I/O chips
are designed to simplify the device design of
CANopen I/O modules.
The future of CiA 401
Although CiA 401 is 20 years old, there are
some enhancements under development. The
PDO mapping is going to be updated due to
the longer data frames (up to 64-byte) provid-
ed by the CAN FD data link layer. There is also
demand to improve the interoperability between
host controllers and CiA 401 modules, which
could be achieved by device classes using ded-
icated mappings specified in CiA 852. Another
option is combining analog and digital I/O data
in pre-defined PDOs, which hasnt been done in
the past. CiA members are also discussing add-
ing functional safety and security features in the
longer PDOs. ce
Holger Zeltwanger is managing director, CAN in
Automation (CiA). CAN in Automation is a CFE
Media content partner. Edited by Chris Vavra,
production editor, Control Engineering, CFE
Media, cvavra@cfemedia.com.
www.controleng.com
Part 1 specifies generic I/O
modules; part 2 describes several
joystick implementations. A CiA
852 covers operator environment
sub-systems developed for
construction and mining
machines.
MORE
ADVICE
KEY CONCEPTS
The CiA 401 profile for modular input/output (I/O) devices was
released internally as version 1.3 in 1996 and implemented by
several companies.
There are many modular CANopen I/O devices on the market,
and there are more CiA 401 implementations designed for
specific applications such as micro-controllers.
Future plans for CiA 401 include updating the PDO mapping to
accommodate 64-byte data frames provided by the CAN FD data
link layer.
GO ONLINE
Go to www.controleng.com to see additional stories from CAN
in Automation.
CONSIDER THIS
What other updates should be added to CiA 401 and what
benefits could they provide?
CONTROL ENGINEERING APRIL 2016 | DE2
 DIGITAL EDITION exclusive
Enabling business
through safety, security
With enough knowledge of a facility such as an oil platform, refinery, or pipeline network, a cyber
attack that used distributed malware could lead to physical damage and serious losses of revenue.
MORE
ADVICE
KEY CONCEPTS
Good security is more than just
stopping the bad guys; it increases
productivity and improves the bottom
line.
A company could realize a 5% gain
in productivity if theyre committed to
their safety program.
There is a business justification
that having the right safety and
security program will enable the
business to run more efficiently and
productively.
GO ONLINE
Read this story online at www.
controleng.com for more informa-
tion about cyber security programs
and how they can positively impact
businesses.
CONSIDER THIS
What security measures has your
company undertaken that has proven
to be effective?
DE3 | APRIL 2016
A
n oil platform stood in the Gulf of
Mexico waves a short time ago and
unbeknownst to workers on the rig
and those offshore, malware was
on board turning that facility into a
potential floating time bomb. Malware, downloaded
via satellite and through USB drives, had incapaci-
tated computer networks and left the rig lifeless and
unable to perform any duties for a period of time.
While the rig eventually came back on stream
after workers fixed the locked up system, it turned
out a worm was flooding their network. Had this
incident been a targeted attack, the rig could have
sustained major problems. With enough knowl-
edge of a facility like an oil platform, refinery, or
pipeline network, a cyber attack that used distrib-
uted malware could lead to physical damage and
serious losses of revenue.
There is no explaining how many millions of
dollars that unplanned downtime cost the oil com-
pany. In todays tight economy, companies, big or
small, cannot afford to lose that kind of money to
any kind of safety or security incident.
Uptime remains critical
The cost of unplanned downtime is just one
case to show management there is a solid busi-
ness proposition behind employing solid safety
and security programs. The idea pushing forth in
the industry today is safety and security are not
just insurance policies to protect against an inci-
dent or bad guys, but rather a business enabler
that keeps the network and system up and run-
ning, productive and profitable.
The insurance justification doesnt always
work, said Farshad Hendi, industrial automa-
tion safety industry manager at Schneider Elec-
tric. People will say I worked at this plant for
the past 15 years and we have never had an inci-
dent. It is true you didnt have an incident in 15
years, but that does not mean you will not have
an incident tomorrow. Uptime and operational
stability is something that resonates with people
very quickly. If your plant is down for one week
CONTROL ENGINEERING
you can quickly determine the cost and you can
quickly determine how much investment I need
to put in and how much gain I will get.
When talking about safety or security users need
to consider metrics such as improving the efficiency
of operations, reduction in time to detect incidents
and return on prevention. But Wait a minute, a
senior manager could say, we have never been
hit before, so why should I pay for something that
doesnt generate revenue? The simple answer is,
safety and security can pay big dividends.
It is an interesting conversation to have, said
Joshua Carlson, industrial automation manager for
cyber security in North America at Schneider Elec-
tric. The challenge is getting users to understand
we are not just looking at the risk model and figur-
ing out the probability. With cyber security, it is not
a matter of if, but a matter of when. The challenge
becomes at some point when are you going to have
an incident and how much is it going to cost you?
Mature vs. dynamic force
Safety has evolved over the years to where
manufacturers think safety first. But security is
an entirely different beast. With its constantly
changing dynamic force, it isnt about hardening
a system to keep bad guys out any more, it is now
about being situationally awareunderstanding
what is happening within a system at any given
time. And if the senior manager thinks attacks
arent happening, think again.
Just look at the numbers in Fiscal Year (FY)
2014, the Industrial Control Systems Cyber Emer-
gency Response Team (ICS-CERT) received and
responded to 245 incidents reported by asset own-
ers and industry partners. The energy sector led all
others again in 2014 with the most reported inci-
dents at 79 or 32%, followed by critical manufac-
turing at 65 or 27%. Of all the incidents reported
to ICS-CERT, 55% involved advanced persistent
threats (APT) or sophisticated attackers.
While the numbers reported to ICS-CERT may
seem low, in reality, the vast majority of companies
dont report incidents, but instead, keep news of
www.controleng.com
the attacks to themselves. When it comes to safe-
ty, the numbers in dollars and cents can numb the
mind, because in the U.S. major industrial inci-
dents cost an average of $80 million each, accord-
ing to a report from the Center for Chemical
Process Safety (CCPS).
Focus results in savings down the line
If a company is truly smart about safety and
focuses on what they have to do, remains vigilant
and is a top-tier organization, they could realize a
five percent gain in productivity, according to CCPS
statistics. In addition, a company employing a solid
safety program could see a three percent reduction
in production costs, five percent reduction in main-
tenance costs, 20% reduction in insurance and a one
percent reduction in capital budget.
In the security realm, costs continue to rise with
the average consolidated cost of a data breach is
$3.8 million up from $3.5 million the previous year,
which is a 23% increase in the total cost of a data
breach since 2013, according to a Ponemon Insti-
tute study of 350 companies spanning 11 countries.
In addition, malicious attacks can take an aver-
age of 256 days to identify while data breaches
caused by human error take an average of 158 days
to identify, the report said. On top of that, in a sepa-
rate study the Ponemon Institute found the average
annual cost of cybercrime per large U.S. company at
$15.4 million, an increase of 19% from $12.7 mil-
lion a year ago. It also represents an 82% jump from
Ponemons first study six years ago.
Turning a profit for safety and security
We now consider security as part of the opera-
tional lifecycle especially when we are talking about
critical infrastructure, said Jay Abdallah, indus-
trial automation EMEA cyber security manager at
Schneider Electric. We are seeing things such as
performance monitoring capabilities to proactive-
ly see when a company would experience an out-
age based upon the available statistics. He said that
looking at condition monitoring and management
of safety functions in the field can help.
I have developed a little return on investment
(ROI) calculator that has a questionnaire and we
ask the user some basic questions about metrics,
said Sven Grone, industrial automation TMC busi-
ness development at Schneider Electric. We ask
with your process and practices how long would
it take to do a certain project. We then we show
them with the solution, we can do it in .01 times X.
We do that in a series of activities associated with
the management of functional safety. In the end
we crunch some numbers and say if your plant has
a revenue stream of $5 million a day and it costs
www.controleng.com
you $150 and hour for an engineer and this system
is $200,000 to put in, we can show you a return
on investment in three months. The user can then
take that tool that has their own metrics and show
it to management to justify the cost.
Whether it is a ROI calculator or an Ouija
board, users can look at the technology all they
want, but they also need to look at factors associ-
ated with the risk of a cyber security incident. The
impact of a cyber security incident could have a
significant negative perception on the organiza-
tion, impact the reputation, and potentially cause
a financial impact to the company or facility. If
the company or facility appears to be a risk for a
loss of financial information, the environment, or
safety, the company or facility could take a finan-
cial hit from fines, or penalties, or lawsuits.
Threat levels and costs
Whether it is a major cyber We have never been
attack or a safety incident or
a malware downloaded onto hit before, so why pay for
an oilrig in the Gulf, there is a
business justification that hav- something that doesnt
ing the right safety and securi-
ty program in place will enable generate revenue? Safety
the business to run more effi-
ciently and productively. and security can pay
The threat level is chang-
ing and with every shut down big dividends.
it is costing more money, said
Nasir Mundh, industrial auto-
mation global director of modernization at Schnei-
der Electric. Because the plants are getting more
complex and the processes are getting more com-
plex, where at one point people were getting one or
two products out of their feedstocks now they are
getting multiple derivatives out their feedstocks.
With the situation becoming more complex, the
stakes are higher for every day a shutdown occurs.
The investment users put into making their
systems secure or making them safer is very little
compared to any shutdown they may have, which
may not end up in a catastrophe, but would still be
a financial loss, Mundh said. By putting in these
safeguards if you can prevent one shutdown, that
is a tremendous saving. ce
Gregory Hale is the editor and founder of Industrial
Safety and Security Source (ISSSource.com), a news
and information website covering safety and secu-
rity issues in the manufacturing automation sector.
This content originally appeared on ISSSource.com.
ISSSource is a CFE Media content partner. Edited by
Chris Vavra, production editor, Control Engineer-
ing, cvavra@cfemedia.com.
CONTROL ENGINEERING APRIL 2016 | DE4
 CYBER SECURITY industrial control systems
The whitelist:
Finding the light
in cyber darkness
Attacks on critical infrastructure and energy organizations are becoming more frequent and a threat
from a safety and financial standpoint. Application whitelisting can be an effective strategy in limiting
what programs can run on a computer, which can limit the potential for a cyber security attack.
MORE
ADVICE
KEY CONCEPTS
Cyber security attacks pose risks to
human safety and physical equipment
and are very expensive for companies.
Application whitelisting is an
administrative process designed to
limit what applications can run on a
computer.
Many vendors have developed
whitelisting mechanisms to determine
the validity of software processes run-
ning in a control system.
GO ONLINE
See additional stories about the
industrial control systems (ICSs)
online at
www.controleng.com.
CONSIDER THIS
What other protocols and methods
can companies use to lower the risk
of a cyber security attack?
42 | APRIL 2016 CONTROL ENGINEERING
A
ttacks on critical infrastructure and
energy organizations are becom-
ing more frequent and costly from
financial and shareholder perspec-
tives. These attacks are calculated,
sophisticated, and persistent to achieve the end
goalwhether they access data or damage the
operational technology (OT) environment. This
has spurred energy organizations to be aware of
existing cyber vulnerabilities and seek solutions
to improve their security posture, maintain best
practices, and prevent the next major disruption
to operations.
Because these attacks are most often aimed
at the industrial control system network, they
have the potential to cause catastrophic damage
in comparison to information technology (IT)-
specific incidents.
These attacks pose risks to human safety,
physical equipment, and are very expensive. In
2015, the average annual cost of cyber crime
for energy and utility companies was $12.8 mil-
lion, which led all industries in highest cost aside
from the financial sector. Its not exactly a com-
petition anyone wants to win, but a reality faced
in industrial environments.
The rising costs are associated with the ris-
ing number of threats. Attacks on critical infra-
structure have increased dramatically in the last
few years, up 20.4% in 2015 compared to 2014
according to an ICS-CERT report, but they
have not been as widely reported as IT breaches
because they arent as pervasive and remain con-
tained within the organization.
In some cases they may not even be rec-
ognized as a cyber attack until months later.
According to the 2015 SANS industrial control
system (ICS) security report, 34% of industri-
al organizations surveyed believe their systems
have been breached more than twice in the past
year, and 44% were unable to identify the source
of the infiltration.
The uncertainty and lack of transparency
surrounding cyber attacks in industrial sectors
have made them difficult to not only prevent and
mitigate, but also to understand. When hackers
hijacked the systems of two power distribution
companies in Ukraine, 80,000 customers lost
power. The illusive critical infrastructure cyber
attack became a reality for everyone.
To help guide organizations, the U.S. Depart-
ment of Homeland Security (DHS) recent-
ly issued its Seven Steps to Effectively Defend
Industrial Control Systems, which identified
the implementation of application whitelisting
as the most effective strategy to mitigate poten-
tial cyber threats. Application whitelisting has
traditionally been challenging to configure in
ICS networks, but recent innovations and shift-
ing business strategies toward a managed secu-
rity service model have enabled much easier and
cost-effective adoption.
What is application whitelisting?
In the IT environment, application whitelist-
ing is an administrative process designed to
limit what applications can run on a com-
puter. Similarly in an OT, industrial envi-
ronment, application whitelisting runs on
human-machine interface (HMI) computers
and designates the specific applications that are
allowed to run on the ICS network.
This strong layer of protection for a net-
work that is overlaid on physical assets helps
detect and prevent cyber attacks in the form of
malware that could directly impact the opera-
tion of those assets. By ensuring that only gen-
uine firmware code is capable of running on
the secured controller platforms, application
whitelisting protects servers from malware and
zero-day attacks.
One downside to application whitelisting
has been the complexity and cost surrounding
implementation and maintenance within orga-
www.controleng.com
nizations. More vendors, however, are offering
implementation as part of the investment in the
ICS software and accompanying cyber security
solutions. The techniques effectiveness provides
value for the vendor and industrial customer by
protecting the ICS layer of the network. DHS
recommends that ICS operators collaborate with
their vendors to baseline and calibrate applica-
tion whitelist deployments to guarantee secure
set-up and proven protection.
To ensure the success of a strong application
whitelisting practice, training and education
must be implemented throughout the organi-
zation. To maintain the application whitelisting
mechanism, operators must have an understand-
ing of cyber vulnerabilities and what applications
are safe to run on the network. As a large portion
of the energy workforce is nearing retirement, The average annual cost of cyber crime for energy and utility companies
operators with a background in engineering and in 2015 was $12.8 million. Courtesy: GE Oil & Gas
cyber security are a scarce commodity and con-
tinue to be highly sought after.
Industrial organizations will need to become
more aggressive about providing training pro-
Blacklistings role in cyber security
grams and opportunities for continued educa-
tion to develop the workforce it requires and
help nontechnical staff understand how their
T raditional firewalls and antivirus software are not enough to prevent against
advanced attacks. A more predominant method in the energy space, black-
listing, has been a standard practice in virus protection and intrusion detection/
actions impact security. To supplement the need
prevention systems but has failed to meet the constantly evolving threats that are
many vendors offer to maintain the application
whitelisting as a service. This helps alleviate being manipulated and adapted to penetrate unique industrial environments.
the talent gap by providing the technology and Blacklists rely on signatures for known threats that are part of a threat-centric
expertise to support cyber security requirements model in which known threats are blocked from running while all other unlisted
and needs, which is particularly beneficial when programs are allowed to run. The downside is there is no inherent protection
an organization is not set up to manage this
against zero-day threats that are not yet known to be potentially damaging, and its
undertaking internally.
impossible to keep up with the growing volume of malware today.
Light: Policy-based control One of the more known malwares, BlackEnergy, has been active in the energy
A strong cyber security strategy for an ICS industry since 2007. Like the flu virus, BlackEnergy has evolved in several variants
today includes a granular, policy-based con- to become more effective in propagation. BlackEnergy 3 was found in the recent
trol of the application layer to enable industrial Ukraine hack and may have been introduced through spear phishing. The variant in
operators to eliminate the systems attack surface
this case was the inclusion of a KillDisk component. It is believed hackers gained
size by only opening doors to trusted software
and applications. Many vendors have developed access to the networks, and once on the networks, took over the operator stations
whitelisting mechanisms to determine the validi- to control the breakers and shut down power. Blacklisting would not have recog-
ty of software processes running in an embedded nized the BlackEnergy 3 variant to prevent the initial access to the network.
control system and ensure that only the genuine Blacklisting also tends to require more server updates to keep pace with the
released software is allowed to run.
proliferation of malware. When aging digital assets, such as gas turbines and
This comprehensive approach to safeguarding
against attacks prevents the execution of mali- compressor controls, have a life span of a decade or longer and require continu-
cious programs, malware, or other software pro- ous operation, they are more vulnerable than other machines that receive regular
cesses deemed to be security risks. All of this is updates and patching during frequent maintenance shutdowns.
critical to safeguarding a critical infrastructure These assets are safest when they are either completely shut down or fully
or energy organizationand its customersand operational. For this reason, frequent updates pose a greater risk of introducing
is particularly important when these risks are
cyber threats. Rather than protect against the known threats, operators must rely
more prevalent and destructive. ce
on the trusted applications and block everything else through whitelisting. As
Dana Pasquali, product management leader, GE additional applications are identified as safe, operators can modify the whitelist to
Oil & Gas. Edited by Chris Vavra, production edi- include or remove applications when needed without taking the asset offline.
tor, Control Engineering, cvavra@cfemedia.com.

www.controleng.com CONTROL ENGINEERING APRIL 2016 | 43

 CYBER SECURITY industrial control systems
Pay attention: Industrie 4.0
and ICS cyber security
Industrie 4.0 is propelling organizations and their production and service delivery capabilities far
beyond steam power and factory electrification, and industrial control systems (ICSs) can provide
a vital layer of protection to keep networks safe.
G
reater attention to industrial con-
trol system (ICS) cyber security is
required with greater connectivity
and information flow in manufactur-
ing and in process plants. The Inter-
net of Things (IoT) refers to the billions of smart
connected devices, from simple sensors to complex
machines, that affect business locally, regionally,
and globally, with personal behavior.
The IIoT and Industrie 4.0 plat-
forms are comprised of cyber-physical
systems with connected devices that
collectively make up the smart fac-
torya facility or operation with the
technical advantages of self-prediction
and self-awareness in the processes
used to make and move products and
services. When the network is recog-
nized as a means to deliver value and
as a conduit to bring new risk to a con-
trol system, the importance of indus-
trial network monitoring and anomaly
IIoT brings both benefits as well as risks detection becomes apparent.
that will take a toll on those who dont For the electricity sector, for
make proactive investments and establish instance, assuring the reliability of
a comprehensive security program and the bulk power system and mitigating
culture. Courtesy: NexDefense risks associated with the ever-expand-
ing network connectivity, the North
MORE American Electric Reliability Corp. (NERC) devel-
ADVICE oped critical infrastructure protection (CIP) stan-
dards. The standards even call out the importance
KEY CONCEPTS
Industrie 4.0, the next manufacturing
of network monitoring for protecting electron-
revolution, brings cyber-security risk. ic security perimeters and aid in system security
Proactive planning and the use management, incident response, vulnerability, and
of continuous network monitoring change management.
can help alert engineers of abnormal Despite the power that comes with negative
events and other breaches. reinforcement of regulatory fines for noncompli-
GO ONLINE ance, NERC CIPs positive effects can only come
See more on IIoT and Industrie 4.0 from industry participants that adopt a security
with this article online; search on the
headline at www.controleng.com.
culture that extends beyond a check-the-box men-
tality that regulations can often drive. IIoT brings
CONSIDER THIS benefits and risks that will take a toll on those who
What other risks could Industrie 4.0
bring to the plant floor and what can dont make proactive investments and establish a
you do to offset or minimize those comprehensive security program and culture.
risks? A recent cyber security assessment published by
44 | APRIL 2016 CONTROL ENGINEERING
the Snohomish Public Utility District (SnoPUD)
is a prime example of how convergence has killed
the air gap. As the largest public utility in the state
of Washington, the facility had robust security in
place on the corporate network to presumably pre-
vent adversaries from gaining access to its ICS net-
work. Although the facility had corporate security
and was NERC CIP compliant, assessors gained
access to the ICS network within 22 minutes and
then found zero security tools in place.
Its an example of how complexity results in risk
as well as how regulatory compliance doesnt nec-
essarily equate to security. It reinforces the impor-
tance of effective network anomaly detection for
ICS systems that can identify unusual events as
early as possible and notify responders and trigger
other security controls to protect critical systems.
Monitoring the ICS network
Despite the industrys best efforts, there like-
ly will never be standards or federal regulations
advanced enough to keep up with the proliferation
of IIoT and the risks associated with a connected
infrastructure. The burden falls largely on each
organization to maintain asset integrity. One way to
do soakin to how corporations have secured their
IT infrastructureis to monitor the industrial net-
work at all times. With the evolution of a connected
enterprise, theres an interdependence of informa-
tion and operational technology functions in orga-
nizations because systems often are integrated.
With the array of activity on control system net-
works today, organizations need visualization into
communications to determine what is approved,
malicious, or accidental. Monitoring control system
network infrastructures can aid with identifying a
newly connected or failed device, misconfiguration
of a system, unauthorized activities and changes to
the networks health, and highlight the first indica-
tors of potential cyber attacks. ce
Doug Wylie, CISSP, vice president of product mar-
keting and strategy, NexDefense. Edited by Chris
Vavra, production editor, Control Engineering,
cvavra@cfemedia.com.
www.controleng.com
CYBER SECURITY software code
Cyber security protection
enters a new era
Watch for a backdoor cyber security assault. The Juniper Networks incident in December 2015
changed how industry looks at device security as hackers exploit deliberate weaknesses being
installed into software. End users, integrators, and device manufacturers need to adapt and
prepare for this new reality. Follow these new cyber security steps.
A
software engineer is trying to com-
plete a major block of code, but his
boss cut out a large section includ-
ing some open-source routines down-
loaded from the Internet. Replacing
those routines will add days to the project. He runs
to his boss office and pleads: I need to use that
software in the system!
You cant use it. Its been compromised.
The engineer nods, having anticipated that reply.
Yes, its open-source and came from the Web, but
weve used it before. I also talked with the software
engineers, and they will do a line-by-line review of
the source and object code.
The boss looks up and glances at his award for
years of service at an undisclosed location. You can
never be sure something isnt in there, he says.
That brief scene might sound like something
from a suspense movie, but the situation could be
very real given recent events in the cyber security
community. Most think of software as something
that does what its supposed to most of the time and
therefore sometimes neglect lurking danger.
Software engineers trying to write code for
devices and industrial systems want to avoid re-
inventing the wheel. If someone has already writ-
ten code to do a certain job, and it works, they dont
want to write it again. Theyd rather save time by
downloading freeware and open-source code off
the Web. Or, they could pick up existing code from
earlier products with a proven track record. All of
this gets cobbled together and loaded into a new
device. As long as it does what its supposed to,
nobody needs to know or care where it came from.
This has been the working assumption for quite
a while, but the landscape is changing. The cyber
security world is becoming more confusing with
nation-states, hacktivists, and cyber criminals mak-
ing their presence known. Hackers and their efforts
reflect a wide spectrum of skill levels. Some are
clumsy and easy to spot. Others are more insidious
and undetectable by all except the most sophisticat-
ed forensic cyber specialists.
www.controleng.com
While the engineer streamling a project means
well, the boss is correct: unsecure code can lurk
within such software. Sometimes it can be found
and removed, but a recent example of a cyber
security breach proves that the threat can be well
camouflaged.
The password is <<< %s(un=%s) = %u
Those of us old enough remember hearing the
Password game show announcer whispering the
key word for viewers. Nobody could guess this pass-
word, but it is changing the threat landscape.
In December 2015, Ars Technica published a stun-
ning report: On Dec. 17 [2015], Juniper Networks
issued an urgent security advisory about unauthor-
ized code found in the operating system (OS) used
by some of the companys NetScreen firewalls and
secure service gateway (SSG) appliances. A patch was
issued to the affected device OS, and forensic investi-
gation determined the unauthorized code acted as a
backdoor into the device, the report said.
Forensic investigations determined the admin-
istrator password used to evade normal authen-
tication was <<< %s(un=%s) = %u. Security
researchers looking at this bit of gibberish might
recognize that it was crafted to appear as debugging MORE
or test code within a software source code file. This ADVICE
suggests two conclusions:
KEY CONCEPTS
1. The unauthorized backdoor was put there Cyber security methods that worked
in the past no longer work because
intentionally. of the new and sophisticated attacks
being implemented.
2. It was carefully designed to evade detection. End users, integrators, and device
manufacturers need to rethink how
We seem to be moving into an era where vul- they approach software development.
nerabilities are built into software deliberately and GO ONLINE
then carefully hidden. Attackers aware of the hid- Find more network vulnerabilities
den codes function can use planted vulnerabilities with this article online, and links to
other articles; if reading the digital edi-
when they like. tion, click on the headline or use the
search box at www.controleng.com.
What to Do: End users CONSIDER THIS
Review device patch statusObviously, the What additional safeguards can
first thing any organization should do is start on companies take to avoid breaches?
CONTROL ENGINEERING APRIL 2016 | 45
CYBER SECURITY software code
an organizationwide
review of vulnerable
and potentially vulner-
able network devices.
This should be done
not only for Juniper
hardware, but also
for all other network
gear vendors. Begin by
assuming devices from
all vendors are similar-
ly compromised.
Patch or attempt
to patch all network
devicesAfter the
review, patches should
be applied to all cur-
rent devices, even in
advance of approved
patches for non-Juniper
equipment. The reason
The chart explains for this is two-fold: to identify which devices are in
when to patch a cyber particularly critical areas (such as industrial control
security network based systems) and to find those too old to be updated.
on whether its practi- Create a risk matrixThe results of the first
cal and how critical the two steps will generate information, which can
situation is. Courtesy: help define the attack surface. This matrix should
Yokogawa have two axes: The first is capability of patch-
ing, running from impossible due to age to easy
thanks to cooperation from the vendor. The sec-
ond is operational importance, running from
high for critical 24/7 industrial networks to low
for a small branch office switch. An unpatchable
device in a critical operation should be replaced.
Following this analysis will help your organiza-
tion stay one step ahead of the inevitable disclo-
sures of other network gear being compromised
by these types of hacks.
Create a plan to change your attack surface
vulnerabilitiesThe matrix should guide any
efforts to lay out a patching plan. With all this
information, security personnel can provide a
burn-down list with percentage-based metrics
showing the risks posed by new network gear vul-
nerabilities as they emerge. The matrix also pro-
vides a good plan of action if the worst happens: a
new and exploitable network vulnerability is dis-
covered with zero-day malware.
Increase network and configuration moni-
toringIf an organization is using Snort, Fox-
IT already has IDS signatures to help detect this
attack. An organizationwide effort should also be
implemented to bring all network gear under con-
figuration control. Periodic security audits should
not only verify the configuration of network gear,
but also assess the actual live network configura-
tion by testing traffic patterns.
46 | APRIL 2016 CONTROL ENGINEERING
What to do: Integrators supplying
network gear
Review lab device patch status and implemen-
tation guidesIntegrators should patch any lab sys-
tems and then update their implementation guides
to reflect the change in network gear configurations.
For example, Juniper now has a code-signing step
for firmware updates. Implementation personnel
should be prepared as other network gear vendors
are discovered to have similar issues.
Patch or attempt to patch all network devic-
esIntegrators should patch all devices with
their clients and end users as soon as possible.
There also should be frank discussions explaining
to clients how this is a new generation of threat,
emphasizing the importance of preparing for
more patching and monitoring over the long term.
Characterizing this as another Stuxnet-type event
is not an exaggeration.
Integrators can offer solutions and services
to increase device monitoringSystem integra-
tors should lead the effort to inform customers
of this new threat and craft solutions and servic-
es to ramp up monitoring of security and network
devices. There is good reason to push customers
to consider services aimed at determining network
configuration control and implementation levels
of network patches.
What to Do: Device manufacturers
(including industrial control devices)
Review development and implementation
lab device patch statusA device manufactur-
er should patch any development and lab systems
immediately. Security policies and procedures
should be updated to reflect the change in network
gear configurations. Controls should be tightened
on devices and software migrated into develop-
ment environments.
Re-examine development lab and develop-
ment office architecturesDevice manufacturers
need to be more paranoid about how development
networks are connected to other networks. Juniper
will likely spend many resources finding out how
the backdoor appeared in its device software. You
can also be sure Juniper will be investing in more
development configuration control and rethinking
its development network security to include great-
er auditing and monitoring.
Read this article online for other vulnerabili-
ties and 13 tips for re-examining software devel-
opment policies and procedures. ce
Jeff Melrose, CISSP-ISSEP, GICSP, principal tech-
nology strategist for cyber security at Yokogawa
Corp. Edited by Chris Vavra, Control Engineering,
CFE Media, cvavra@cfemedia.com.
www.controleng.com
EFFICIENCY motor-driven systems

U.S. motor-driven system

energy savings
Motor-driven system regulations are changing in the U.S. to improve efficiencies beyond
individual motors. Considering the motion control system can deliver more than six times the
power savings compared to motor efficiencies alone, according to NEMA committee members.
Power electronics are helping.

E
lectric motor system efficiency and
power electronics are impacting future
energy saving opportunities as attention
moves from motor efficiency to motor-
driven system energy savings. In the
U.S., the first move was to apply motor efficiency
regulation. Next is addressing the system. Focus-
ing on the motion control system can deliver more
than six times the power savings compared to just
looking at motor efficiencies.

Stage 1: motor as a component

U.S. motor efficiency regulation began in
1992. At this time the motor already includ-
ed efficiency data on each name plate. The U.S.
Congress drafted legislative language that includ-
ed definitions of products to be included as well
as referencing test methods and efficiency levels.
The motor community began a journey into fed-
eral regulation that continues today.
In 2001 motor manufacturers created a premi-
um efficiency level that raised the efficiency lev-
els above the federal requirement (NEMA Table
12-12). In 2010 this new level was added to a sec-
ond round of regulation bringing the markets great-
er savings to a select category of motors know as
Subtype 1, required to meet NEMA Table 12-12,
and Subtype 2, required to meet table 12-11. These
categories impacted approximately 40% of the units
sold each year. In 2014 a third round of regulation
was released that will take effect June 1, 2016. This
latest round of regulation essentially covers all poly-
phase motors from 1 hp (0.75 kW) to 500 hp (375
kW). This latest round of regulation was carefully
constructed to expand the scope of products to be
covered while paying particular attention to unin-
tended consequences that would defeat the ener-
gy saving goal of the rule. The motor community
worked diligently with the energy advocates and
the U.S. Dept. of Energy to create a regulation that
took into account mechanical and electrical issues
that would undermine the regulation if an effi-
Figure 1: The graph from Michael Turner, Nidec U.K. Technology Center,
provides a visual to help explain motor energy loss (red) versus useful motor
energy (blue). Minimum efficiencies of 4-pole, 50 Hz motors start around 85%
for fractional motor output power and increase to more than 95% for motors
with 200 kW output power, according to EN60034-30. Courtesy: NEMA
ciency level were to be increased to a point that trig- MORE
gered any or all of the following 10 consequences. ADVICE
KEY CONCEPTS
Higher efficiency risks
U.S. regulation is moving from motor
There were 10 areas considered by the group as to motor-driven system.
potential consequences or risks to raising efficien- A third round of motor efficiency
cy levels beyond the NEMA Table 12-12 (IE3) levels regulation starts June 1.
in existing rules. European Union (EU) began looking
at the motor system in EN 50598,
1. Torque necessary to start loads may be com- published in December 2014.
promised potentially requiring a jump to a GO ONLINE
higher motor horsepower rating. See related articles linked to this
online. If reading the digital edition,
click on the headline. If reading on
2. Power factors may diminish, forcing utility paper, search the headline at
or plant modification to correct. www.controleng.com.
Also see www.nema.org.
3. Inrush currents may increase, requiring CONSIDER THIS
cable and switch gear replacement. Would six times the power savings
be attractive in motor systems?

www.controleng.com CONTROL ENGINEERING APRIL 2016 | 47

EFFICIENCY motor-driven systems

8. Motor testing and lab variance may be out-

side their ability to accurately measure such
small gains with necessary repeatability.

9. The amount of active material such as cop-

per, magnetic steel increases dramatically for
an extremely small gain in efficiency (such as
11 kW motor needs about 60% to 70% more
material to gain 1.3% efficiency increase).

10. The investments needed to redesign and

reconfigure production facilities would be
better applied to the power drive system
(motor + variable frequency drive) which
delivers much greater energy savings than
regulation in isolation of the motor as one
component.

Figure 2: The illustration shows all components that make up the system.
Work continues on establishing energy efficiency levels for entire systems. It
becomes clear that the motor is a critical part of this system, but it only makes
up a small percentage of the losses in the Stage 2 energy saving opportunity.
Courtesy: NEMA
Figure 1, from Michael Turner, Nidec U.K.
Technology Center, provides a visual that helps
explain motor energy loss (red) versus useful
motor energy (blue). By continuing to peruse effi-
ciency of the motor, the challenge would be to
reduce losses, which in this example, are less than
5% the kW loss, exposing the motor user to one or
more of the 10 issues discussed above. The great-
est opportunity for energy saving (reduction in
kWh) is achieved by adding the power converter
to the motor-driven system to optimize the sys-
tem and reduce the kW loss by 30%, 40%, 50%,
or more. When seen in this perspective it becomes
clear that the addition of the power converter to
the motor-driven system has distinct advantages.

Avoid dampers, throttling

Figure 3: The system
standard establishes a
series of 8 points that
can be used to evalu-
ate the energy savings.
These are shown in load
points for loss evalua-
tion. Courtesy: NEMA
4. Mechanical sizes may increase, eliminating
retrofit ability.
5. Repair of failed motors as an alternative may
increase, placing previously unregulated
product back in service for many more years.
6. Motor supplier resources will be used to
overcome design and application issues that
are better applied to power management
solutions.
7. The remaining efficiency gains of the motor
are extremely small when measured under
controlled conditions. Under actual uses that
include power quality and varying load con-
ditions, the efficiency gain in industrial and
commercial applications are questionable.
In the past many motors ran without the benefit
of electronic speed control devices. Therefore, the
control of the output volume of the pump, fan, or
compressor had to be throttled by closing the valve,
dampers, or vanes. Though this will adequately con-
trol the flow, this is by no means an efficient meth-
od. There are significant losses generated in the
throttling mechanism and the motors efficiency
drops significantly at the lower operating speeds.
Next generation of savings, called Stage 2 here,
for sake of discussion, will change the current met-
ric from efficiency, expressed as a percentage, to
energy savings (kWh) by employing power elec-
tronics within the power drive system to eliminate
mechanical flow control devices. The European
Union (EU) began looking at the system in EN
50598, which was published in December 2014.
This was an excellent start in establishing a guide-
line for energy savings as it relates to the entire
system.
This work is taking place today in an interna-
tional standard Working Group (WG) 18 within the
International Electrotechnical Commission (IEC).

48 | APRIL 2016 CONTROL ENGINEERING www.controleng.com


WG 18 is creating the international standard IEC
61800-9-1, 2, which establishes the needed method-
ology and necessary metrics.
The work continues on establishing energy effi-
ciency levels for entire systems. Figure 2 shows all
the components that make up the system.
Stage 2: power drive system
The second stage is to create standards that
quantify energy saving delivered by a power drive
system. It becomes clear that the motor is a crit-
ical part of this system, but it only makes up a
small percentage of the losses in the Stage 2 ener-
gy saving opportunity.
Stage 2 will leverage the motor, inverter, and
controls system referred to here as the power
drive system (PDS). Also, in consideration are
the starters, torque transmission devices, and of
course the load (pump, fan, compressor) which
is now referred to as the extended product. While
moving forward on this topic, it was discovered
that it was necessary for a metric to move to loss-
es versus efficiency. The reduction in losses as a
result of process control through the use of a PDS
delivers the reduction in kWh.
It is necessary to use loss reduction versus effi-
ciency when considering total system energy sav-
ings. Considering an extreme case where the
application requires a period of operation within
its duty cycle at or near zero speed where the effi-
ciency is 0% it becomes a little clearer that efficien-
cy is no longer a meaningful metric.
The work that is now ongoing in WG 18 (work-
ing group 18) is to establish the losses generated at
various operation points and determine the savings
in energy as a result of using a PDS which includes
the extended product. The system standard estab-
lishes a series of 8 points that can be used to evalu-
ate the energy savings. These are shown in Figure 3.
These points have been developed to represent
every possible application, but not all load points
will be required for every application. For example,
a variable torque application such as a centrifugal
pump may only find three of the points relevant; PL
(100,100), PL (100, 50), and PL (50, 25).
Reference losses of typical equipment now in
operation are used as the basis for loss reduction.
These reference losses have been established for the
complete drive module (CDM), motor, and PDS.
The CDM can now have IE levels established
based on the loss reduction from a reference CDM
which is defined in the standard. The motors
already have IE levels established in 60034-30-1.
The IE3 level established in 60034-30-1 is in har-
mony with premium levels in NEMA MG1, Table
12-12, regulated in the U.S. With this standard it
will be necessary that the motor and inverter man-
ufacturer provide the losses at all the required load
www.controleng.com
RELATED NEWS: $25 million in funding
for motor efficiency advances
T
he U.S. Dept. of Energy (DOE) announced, on March 11, up to $25 million in avail-
able funding aimed at advancing technologies for energy-efficient electric motors
through applied research and development (R&D). It is part of the Obama Administra-
tions Mission Innovation effort to double clean energy R&D investments over the next
5 years. The effort will fund innovative technologies that will significantly increase
the efficiency of electric motors, which use approximately 70% of the electricity con-
sumed by U.S. manufacturers and nearly a quarter of all electricity consumed nation-
ally, according to the statement from DOE Office of Energy Efficiency and Renewable
Energy (EERE). With this online article, link to more information.
Edited by CFE Media from DOE EERE information.
points as requested by the system integrator who
will be combining the entire system. The stan-
dard also provides a methodology for calculat-
ing or testing for all the losses of the inverter and
supporting CDM equipment. It has been deter-
mined that the motor losses at any load point can
be extrapolated from 7 points that can be provided
by the motor manufacturer.
This method for extrapolation will be covered
in detail in IEC 61800-9-2 and in IEC 60034-30-2.
Methods for testing or calculating the losses for the
motor at these load points are cov-
ered in the motor standard 60034-
2-3 still in progress. Users suggest code
Using the methodology cov-
ered in the future IEC standard interoperability sounds
61800-9 series, the system inte-
grator now has the tools to accu- good but is hard to
rately predict losses of the system.
If the losses are equal to the loss- implement.
es of the reference PDS then the
system is an IE 1, but if the losses are 20% lower
than the reference losses of the PDS then it is an
IE2 PDS. Even more important, the system inte-
grator can now look at the extended product and
compare the losses of the extended product ver-
sus the losses that would have occurred without a
CDM by just throttling the load. The system inte-
grator can then accurately establish the energy sav-
ing of the entire system. Considerably more energy
savings can be achieved when evaluating the entire
system rather than just the individual compo-
nents. Incorporating the PDS advantage in stage 2
can increase the power saved by over six times the
amount that could be saved by relying solely on
the motor component efficiency. ce
NEMA Motor Generator Section member representa-
tives authors are: Rob Boteler of Nidec Motor Corp.
(chairman NEMA Energy Management Committee),
Bill Finley of Siemens, and Tim Schumann of SEW
Eurodrive. Edited by Mark T. Hoske, content manager,
Control Engineering, mhoske@cfemedia.com.
CONTROL ENGINEERING APRIL 2016 | 49
 Cant make it to the show?
Keep tabs on whats happening: Hannover Messe 2016

The worlds most important industrial

fair, Hannover Messe, kicks off April 25,
2016. But, if you cant be there, dont
worry: we have a full complement of
social outlets where you can keep
up with the latest from the show.

Phoenix Contact will be there, too, with

our wide range of electronic components
and solutions, valuable insight on IIoT,
Industrie 4.0, and more.

Dont miss a thing: #HM16USA

@hannover_messe
@SelectUSA

PhoenixContactUSA

Phoenix Contact USA

To learn more:
Integrated Industry Discover solutions! www.phoenixcontact.com/GoMesse
Hannover Messe, April 25-29, 2016. input #25 at www.controleng.com/information

2016 PHOENIX CONTACT

THE ROAD TO
HANNOVER MESSE2016

American manufacturing
on a global stage

American manufacturing is ready

for its close-up on the worlds
largest industrial trade show
in Hannover, Germany.
CFE Media

www.controleng.com CONTROL ENGINEERING APRIL 2016 | 51

THE ROAD TO
HANNOVER MESSE2016
American manufacturing
in the spotlight
Partner Country status lets U.S. trumpet its industrial leadership.
I
By Bob Vavra t leads the world in manufacturing output
Content Manager, CFE Media and helped lead the U.S. economy out of
recessionso it is a well-earned celebration
of U.S. manufacturing that will begin April
24 when President Barack Obama delivers
the keynote at Hannover Messes opening
ceremony. The designation of the United States
as the 2016 Partner Country at Hannover Messe
will bring the largest-ever U.S. contingent to
the worlds largest industrial trade show. Its
an effort to build bridges for U.S. companies
looking to expand into Europe and beyond, as
well as a way for global manufacturers to learn
more about the U.S. manufacturing innovations.
The weeklong event is expected to draw more
than 200,000 attendees, and the presence of
President Obama has added an air of excite-
ment to this years festivities. The real work at
Hannover Messe for U.S. manufacturing leaders
will occur in meetings at the U.S. Investment
Pavilion and among the state economic develop-
ment departments, industry leaders and more
than 350 U.S. companies making the journey
to Hannover Messe.
The United States is home to the most inno-
vative and forward-thinking companies in the
world. But in todays global economy, it is not
enough to simply be the best. We must also
let the world know that America is open for
business, said U.S. Commerce Secretary Penny
Pritzker. Hannover Messe is a unique opportu-
nity for American companies to showcase their
products and capabilities to thousands of global
advanced-manufacturing representatives.
Hannover Messe is a perfect platform for
small to midsized manufacturers looking to
reach potential global buyers, partners and
investors, said Deputy Assistant Secretary for
U.S. Operations for the Department of Com-
merce Antwaun Griffin. This is a great show
to connect to the latest digital manufacturing
trends, and to meet some of the strongest com-
panies and innovators in the United States and
around the world.
52 | APRIL 2016 CONTROL ENGINEERING
Going global
At the press preview for Hannover Messe
2016 in January, fair officials and German
industry leaders were thrilled with the pros-
pect of the U.S. as the Partner Country, and
with the attendance of the President. In the
70 years since Hannover Messe was first
staged in 1947, this will be the first time the
United States will be the Partner Country.
The key question over the last six months
had been, Is he coming, or isnt he? It was
actually fantastic news, said Jochen Kck-
ler, the member of the managing board of
Deutsche Messe AG responsible for Han-
nover Messe, at the press preview. It also
is fantastic for the international character
of Hannover Messe. Weve been waiting 70
years to welcome the U.S. as Partner Coun-
try.
U.S. Ambassador to Germany John B.
Emerson also addressed the preview and
said the excitement over the U.S. status at
Hannover Messe was mutual. The United
States is honored to be the Partner Country
for the 2016 Hannover Messe, and I know
that Commerce Secretary Penny Pritzker and
our boss, President Obama, are excited to
be coming here in late April, Emerson told
more than 100 media members from around
the world who attended the preview.
Emerson touted the expanded U.S. pres-
ence at Hannover Messe, including represen-
tatives from 40 state and regional economic
development groups at the U.S. Investment
Pavilion in Hall 3 on the fairgrounds.
Emerson also focused on the existing
cooperation between Germany and the
United States around trade issues. As
you may know, last year the United States
became Germanys largest customer; and
Germany is Americas largest trading part-
ner in Europe. The ambassador said. In
Continued on page 28
www.controleng.com
 Right at home
On both sides of the Atlantic, Block builds for a global future.
By Bob Vavra, Content Manager, CFE Media

V
erden is just an hour away on the German Autobahn from distributor network and its existing relationship with compa-
Hannover. So when Block, an electrical engineering and nies such as Wago and Rockwell Automation, where Block is an
manufacturing company, tucked into this German city of Encompass Partner.
27,000 residents in the center of Lower Saxony, travels to We are expanding, Wesner added, The first step is to get
Hannover Messe each spring, company officials feel right at home. Blocks products into engineers hands.
Its the worlds biggest industrial trade fair and its right at
our front door, said Christoph Wesner, who heads standards
and approvals for the 77-year-old company that designs and
manufactures transformers, power quality devices and electri-
cal filters. For more than 40 years, weve visited Hannover
Messe. Its our home.
Block also has a home in Franklin Park, Ill., a Chicago
suburb near OHare Airport, whose history also centers on
industrial manufacturing. Block opened its first U.S. manu-
facturing and sales center in Franklin Park in 2015 and looks
to expand its growing reputation in the United States.
So with the U.S. as the Partner Country at Hannover Messe
2016, Block officials see the year as a chance to celebrate its
history and its future. The American market has great inter-
est for us, said Wesner. The drives and automation market Headquartered in Verden, Germany, but with a new manufactur-
is a very big market for Block. We are doing local production ing facility in the United States, electrical engineering company
and we can better meet the U.S. market requirements by Block has set its sights on global growth. Image courtesy: Block
building locally.
Growth curve
Expansion into the U.S. After Wolfgang Reichelt, chairman and CEO of Block, took over
The growth of Block as a global manufacturer with U.S. roots the company in 1971, hes helped set the company on a course of
will enable the company to expand on its philosophy of being a growth and expansion.
custom manufacturer that can meet the individual needs of their In a company interview, Reichelt noted the company is at that
customers. unique intersection between manufacturing and family. People
More than 80% of our work is customized, said Udo Leonhard are our most important resource, he said in the interview. Even
Thiel, who heads up Blocks research-and-development efforts. if you have state-of-the-art machinery, it will only give you the
They start out asking for standard products, but in the end, they edge over your competitors if its operated by motivated and com-
have their own needs. If were talking about drive manufactur- petent employees. We must find innovative ways of ensuring our
ers, they want accessories like filters that will match their system employees are ready to face future challenges with us.
perfectly. We can put them in different enclosures, and just make The global expansion of Block is part of those challenges. The
slight modifications of a standard enclosure. challenge is meeting the domestic electrical standards with locally
To have that kind of manufacturing flexibility, Blocks manu- manufactured products while also providing U.S. machine build-
facturing operation focuses on hands-on quality control in the ers and OEMs with access to European standards.
plant. The companys Verden facility does its own metal cutting That growth potential is why Block officials see this particular
and bending for enclosures, and transformers are wrapped by Hannover Messe as particularly exciting. It brings both the com-
hand as well. panys traditional home-field advantage as a Hannover neighbor
Its a philosophy Block will bring to its growing manufacturing together with the U.S. Partner Country presence.
operation in the U.S. We want U.S. production supported by Were looking at sensible growth for Block USA and a stronger
German manufacturing know-how to meet U.S. product require- U.S. market share of the Block brand, said Wesner. Were also
ments, said Wesner. We have new ideas for new products with reaching out to U.S. customers in Germany. Were showing Ger-
additional support through the German headquarters to meet man and U.S. know-how by having worldwide products.
the extended market requirements in the U.S. Hannover Messe is where the industrial world comes together,
Ultimately, Wesner said, the growth in the U.S. market, in which he added. If you have a specific problem, or if youre in need of
Blocks name is still becoming known, will be built through its a resource, youll find the resource at that show. PE

www.controleng.com CONTROL ENGINEERING APRIL 2016 | 53

THE ROAD TO
HANNOVER MESSE2016
The strong connection
between the U.S. and Ger-
man manufacturing sectors
will be on display at Han-
nover Messe 2016 starting
April 24. All images cour-
tesy: Hannover Messe
54 | APRIL 2016 CONTROL ENGINEERING
Continued from page 26
other words, Germany and the United States
have a huge stake in the health and vitality of
each others economies. President Obamas
presence illustrates how important this show
will be for both the U.S. and German busi-
ness communities.
From the U.S. point of view, it offers a
unique opportunity not only to showcase
American innovation and ingenuity, but to
strengthen the trans-Atlantic partnership at
a critical juncture, Emerson added.
Trans-Atlantic partnership
The Trans-Atlantic Trade and Investment
Partnership, or TTIP, has been a point of
discussion for many years at Hannover
Messe. The trade deal, which supporters
say would reduce trade barriers between
the U.S. and the European Union, has been
stalled in Congress for more than two years.
With or without TTIP, however,
there has been a steady stream of
manufacturing commerce going
on between the U.S. and Europe.
That includes foreign direct invest-
ment on both sides of the Atlantic,
something the U.S. economic devel-
opment agencies from around the
country hope to continue to foster.
For German-based companies,
the need to not just sell to the U.S.,
but also to locate manufacturing on
U.S. soil, has long been a strategic
imperative.
As an example, Festo is an inno-
vative manufacturing and robotics
company based in Germany, but
it sees a vital partner in the U.S.
market.
(Festo) has been investing in
the U.S. market for more than 40
years and is a reliable partner for
American enterprises, which now
not only require machinery and
production facilities, engineering
expertise, software and supplier
components for the establishment
and modernization of their pro-
duction locations, but above all
technical education, the compa-
ny said in a press release. In these
times of increasing automation, the
company is thereby securing jobs
and salaries as well as facilitating
industrialization in Germany and
America.
Festo has opened a $45 million
production and logistics center in
Mason, Ohio, that employs 150
workers and gives the company a
distribution and manufacturing
hub closer to its customers.
Major German industrial and
consumer manufacturers all have
significant facilities in the U.S. Sie-
mens, for example, has more than
www.controleng.com
 Visit Beckhoff at Hannover Messe 2016
in Hall 9, Booth F06!

input #26 at www.controleng.com/information

THE ROAD TO
HANNOVER MESSE2016
Industrial Internet of Things
(IIoT), and its German
equivalent Industrie 4.0, is
a central topic for Hannover
Messe 2016.
56 | APRIL 2016 CONTROL ENGINEERING
700 individual facilities in North America.
Auto manufacturers, such as Volkswagen
and BMW (a past Plant Engineering Top
Plant award winner), have placed significant
investments in the U.S. market.
But those investments have worked both
ways. A 2014 Hannover Messe presentation
on German-American trade relations noted
there are about 1 million U.S. jobs dependent
on German-owned companies and approxi-
mately 600,000 German jobs dependent on
U.S.-owned companies.
It is the United States reputation as a
global manufacturing leader that moved
Hannover Messe to pursue the U.S. as this
years Partner Country, and the U.S. delega-
tion is doing all it can to deliver a presence
that will not just last the week, but also will
foster relationships for the future.
A case in point: Ohio
A decade ago, Ohio was one of the few
U.S. states to send a delegation to Han-
nover Messe. Then-Ohio Gov. Bob Taft was
interviewed by Plant Engineering at Han-
nover Messe in 2006, and he mentioned the
importance of getting out there to tell the
story of all his state had to offer.
In 2006, there was a Republican in the
White House and a Democratically con-
trolled Congress, but Tafts message was
strikingly similar to the environment today.
Its concerning to hear Congress talking
about controls on foreign investments in the
U.S., Taft said that
year. We have 960
foreign companies
investing in Ohio.
Manufac tur ing is
one of our healthiest
sectors. Our manu-
facturing exports are
growing, and weve
got a lot of jobs tied
to exports. Ohio is
an integral part of
the world economy.
Wer e f e e l i n g
terrific competitive
pressure, Taft added
in that inter view.
We have to go out
and tell the story.
To d a y, O h i o
boasts more than
2,200 foreign com-
panies533 f rom
Germany aloneand more than $12 bil-
lion on research-and-development invest-
ment in the state from public and private
companies. At Hannover Messe 2016, Ohio
will come with another large contingent of
civic, business and governmental leaders and
will participate in a dozen lectures, partner
events, and receptions.
Embracing IIoT
What is called Industrie 4.0 in Germany and
the Industrial Internet of Things (IIoT) in
the U.S. is the realization of an integrated
industry. That also is the theme for Han-
nover Messe 2016, and Kckler said during
the press preview the acceleration of that idea
is driving new growth in manufacturing.
Integrated industry is still at an early
stage, he said. I believe no other topic
established itself so quickly and has had
such a huge impact. We need to implement
integrated industry. We get more and more
excited with each year.
Exhibitors, who embraced the Industrie
4.0 concept at Hannover Messe 2015, plan
even more examples of application cases and
product offerings to offer fair attendees. Hall
9 is the center of the Industrial Automation
pavilion, and every vendor onsite in 2015
was promoting the Industrie 4.0 content,
including from the Hannover Messe per-
spective. In 2016, that presence should be
amplified as customers look to learn more
about the technology. PE
www.controleng.com
HANNOVER MESSE
25 29 April 2016
Hannover Germany
The USA will be highlighted at the worlds largest industrial
technology trade fair. To explore opportunities at HANNOVER
MESSE, call +1 (773) 796-4250 or visit www.hannovermesse.de.

Sign up for free tickets: www.hannovermesse.events/cfemedia

Get new technology first

input #27 at www.controleng.com/information

THE ROAD TO
HANNOVER MESSE2016
Universities bring knowledge,
curiosity to Hannover
U.S. schools will showcase their research, look to develop new partners.
T
he Massachusetts Institute of Technology (MIT) in
Cambridge invented GPS, developed Doppler radar
and is a pioneer in 3-D printing. Carnegie Mellon
University, Pittsburgh, Pa., created the navigation
software used by NASAs Mars rovers, built robots
that can walk on water and is a birthplace of artificial
intelligence. Together, the two universities boast more than 100
Nobel laureates. In 2016, both will exhibit at Hannover Messe
in Germany for the first time.
Carnegie Mellon and MIT are two of Americas most storied
research universities. Their participation further spotlights the
innovative power of Partner Country USA at Hannover Messe,
said Marc Siemering, senior vice president of Hannover Messe.
The two universities join leading German institutions such as the
Fraunhofer Society and the Karlsruhe Institute of Technology.
MIT and Carnegie Mellon will exhibit at the U.S. Pavilion
in Hall 2. MIT will emphasize the universitys commitment to
Mens et Manus training, which leads to commercialization
and entrepreneurship as well as how MIT promotes technology
transfer. Carnegie Mellon will showcase research innovations in
robotics and additive manufacturing with a focus on emerging
university startup businesses in these fields.
An educational process
More than 20 of the United States top universities and industrial
technology institutes will take center stage in the U.S. Pavilion
at Hannover Messe 2016. In the Research and Technology trade
fair in Hall 2, exhibitors will showcase groundbreaking research,
business startups and global partnerships that line up with the
fairs emphasis on the Industrial Internet of Things (IIoT) and
the German initiative, Industrie 4.0.
As part of the United States Partner Country status at Han-
nover Messe 2016, U.S. academic and technology institutes will
showcase faculty members, student talents and research programs.
American universities are leading the way in research and
innovation, and in partnering with industry to bring innovations
to market, said Deputy Assistant Secretary of Commerce for Ser-
vices Ted Dean. Hannover Messe presents a prime opportunity to
show the world how U.S. research universities are creating global
solutions that are revolutionizing how ideas become a reality.
For example, Virginia Tech will showcase its groundbreaking
research and the innovative partnerships it has formed with global
business and industry. Specifically, the Blacksburg, Va.-based
school will showcase its Smart Infrastructure Laboratory, which
examines the use of sensor information to improve the design,
monitoring and operation of civil and mechanical infrastructure
to investigate how humans interact with built environments. These
58 | APRIL 2016 CONTROL ENGINEERING
researchers insights into the performance of concrete materials
are producing safer, less costly construction methods and a longer
life for bridges and other structures across the United States.
Virginia Tech is a partner with the German university Tech-
nische Universitt Darmstadt (TUD). Together, the institutions
offer a unique dual bachelors degree in mechanical engineering.
In this program, U.S. students complete their senior year at TUD
and German students finish at Virginia Tech, earning degrees
from both universities simultaneously.
Virginia Tech has a long history of working with businesses
throughout the world, said Guru Ghosh, the universitys vice
president for Outreach and International Affairs. These part-
nerships tap into practical applications of knowledge, allowing
businesses to solve problems, create new products, recruit high-
quality employees and develop new markets. We look forward
to sharing the best of Virginia Tech with the global audience at
Hannover Messe.
Partnering with business
Arizona Technology Enterprises (AzTE)the Scottsdale-based
IP management and technology transfer organization for Arizona
State University (ASU)is bringing several startups to Germany.
Joining the delegation will be Fluidic Energy, an ASU spinout com-
pany that is partnering with Caterpillar Inc. and PLN, Indonesias
state-owned electricity company, on a project to provide power to
500 remote villages throughout the island nation. The program
will deliver reliable, renewable power to 1.7 million people through
solar panels paired with Fluidics metal-air batteries.
Arizona State Universitys interdisciplinary approach to research
and entrepreneurship delivers truly novel solutions to persistent
societal and market challenges, said Annette Kleiser, PhD, the
AzTEs business development consultant. She will present Inno-
vation and Impact: Facilitating Use-Inspired-Research Into the
Marketplace at Hannover Messe Hannover Messe 2016 is an
important global showcase for this work, and were very excited
to be part of the USA Research & Technology Pavilion.
As the largest recipient of U.S. federal government research fund-
ing, the University of California is attending Hannover Messe to
showcase the depth of its research related to energy and climate
solutionsto attract industries interested in collaborating with
researchers to create innovations that will help address this global
challenge.
School officials will demonstrate the U.S. governments commit-
ment to leveraging its resources and talents to create global solutions
for the challenges of energy sustainability and climate change.
The University of California is proud to be part of U.S. par-
ticipation in Hannover Messe, said William Tucker, interim
www.controleng.com

Researchers work in Virginia Techs Thomas M. Murray Structures Laboratory.
Virginia Tech researchers insights into the performance of concrete materials are
producing safer, less costly construction and a longer life for the nations bridges
and other structures. Image courtesy: HFUSA/Virginia Tech
vice president for Research and Graduate
Studies at the university. As the worlds
largest public research university and a
global leader in the search for solutions
to the challenge of energy sustainability
and climate stability, we want to share
our commitment to this cause and use
Hannover Messe to seek out other govern-
ment, academic and industrial partners
to join us in this mission.
Growing global learning
As one of the United States leading insti-
tutes for research and commercializa-
tion, Georgia Tech, Atlanta, will highlight
its leadership in advanced manufactur-
ing, robotics and energy. The university
will also showcase its basic and applied
research in manufacturing, trade and
logistics that is supported by its strengths
in materials and management.
Georgia Tech continues to be a leader
in establishing global innovation portals
and partnerships, research and education
hubs, and select branch campuses like
Georgia Tech Lorraine in Metz, France.
Through the use of distance learning
and other technologies to deliver educa-
tional and research products to students,
researchers, governments and businesses
around the world, Georgia Tech will show-
case its global impact.
Georgia Tech is in the fortunate posi-
tion of being one of a few global institu-
tions continually called upon by univer-
sities, companies and governments from
around the world to assist in their efforts
to grow science, business and technolo-
www.controleng.com
NEW
Single-channel
eBreakers
Line
reactors
All-pole
Make it perfect
sine filters
gy in an increasingly innovation-centric
economy, said Georgia Tech President
G.P. Bud Peterson. We are proud to
join the U.S. Department of Commerces
SelectUSA initiative at Hannover Messe to
highlight the many advantages the United
States offers as a location for business and
investment.
Tech Parks Arizona, a unit of the Uni-
versity of Arizona based in Tucson, will be
showcasing Global Advantage, a unique
business development program designed
to assist fast-growth international technol-
ogy companies entering the North Ameri-
can market. The program offers assistance
in market access, product development,
testing and demonstration, business
development and advanced manufac-
turing. Global Advantage also connects TRANSFORMERS
companies to the University of Arizona, POWER SUPPLIES
REACTORS
a premier research university located in
Phoenix, and to its research parks, the
largest technology parks located along
the U.S.-Mexico border.
Tech Parks of Arizona recruits small
EMI FILTERS
and midsized high-growth technology
companies to Southern Arizona in six Visit us at Hanover Fair on April 25-29,
industry sectors: advanced energy, min- 2016 to experience our newest innova-
ing technology, defense and security, bio- tions for Advanced Manufacturing.
science, arid lands agriculture and water.
These specializations make Tech Parks
Hall 13
Arizona a prime choice for companies in
Booth C34
cross-cutting industry sectors, such as sus-
tainability, optics and imaging, advanced
manufacturing and informatics. PE
Compiled from Hannover Messe press input #28 at www.controleng.com/information
releases.
CONTROL ENGINEERING APRIL 2016 | 59 blockusa.com
THE ROAD TO
HANNOVER MESSE2016
Industrial security solutions
Siemens and Intel Security are expanding their collaboration to help protect industrial automation systems from
increased cyber threats. Siemens experts leverage Intel Security solutions such as anti-virus software, whitelisting and
security information and event management (SIEM) within the framework of plant security services. These tools are
designed to help detect security incidents promptly, enabling Siemens experts to notify plant operators without undue
delay and allowing them to implement counter-measures. The two companies are coupling their expertise in the area
of industrial automation and cyber security to provide industrial
plants with products and services designed to help minimize
cyber risks, while increasing system availability. Siemens offers a
range of plant security services that include carrying out security
assessments, implementing security, and continuous monitor-
ing of industrial infrastructures. The offering now encompasses
Intel Security solutions including McAfee VirusScan, McAfee
Application Control, McAfee ePolicy Orchestrator (ePO) as well
as McAfee Enterprise Security Manager, the security information
and event management.
Siemens
www.siemens.com

Intelligent learning
The DUPLOcator camera follows the assembly of a struc-
ture from model building blocks. The robot is now able to
use its modern robot arm and build the recognized struc-
ture on its own.
Fraunhofer
www.fraunhofer.org

Technology test kit

The Smart Factory Starter Kit allows manufacturers to test
smart manufacturing technologies quickly and easily. It
provides a fast-to-implement Manufacturing Intelligence
solution that can help calculate and indentify ways to
improve overall equipment effectiveness (OEE) and to
monitor factory performance globally in real time?
FORCAM
www.forcam.com

60 | APRIL 2016 CONTROL ENGINEERING www.controleng.com

 PRODUCTS
Superconductor applications
Festo is showcasing three new concepts for the industrial applica-
tion of superconductor technology at the Hanover Messe 2016.
With these exhibits, superconductors enable the contact-free
transfer of carrier plates in the horizontal plane and their transport
across a surface of water, and they allow a gripper to be used in sus-
pension and an object to be moved within an enclosed liquid-filled
tube. The unique characteristics of superconductors come to the
fore here by making low-energy, efficient motion possible in sus-
pension even beyond walls or through media.
Festo
www.festo.com

Integrated solutions
Integrated solutions based on Industry 4.0 are at the heart of Sicks presentation at Han-
nover Messe 2016, with production applications presented in four different exhibits. Sick
displays will demonstrate how the intelligent use of sensor data is already boosting flexibil-
ity and productivity today. The data is also aggregated in a cloud in a live demonstration,
while various Web services show the possibilities of fully integrated solutions online.
Sick
www.sick.com

Our Heart Is Set On

Your Productivity!

FORCAM Never misses a Beat.

Hannover Fair 2016
April 25 29 I Hall 7 I Booth A11

Winner
2015

We Deliver Results In Productivity

www.forcam.com input #29 at www.controleng.com/information
THE ROAD TO
HANNOVER MESSE2016 PRODUCTS
Air conditioning units
The Blue e+ air conditioning units feature up to
75% energy savings compared to traditional ac
units for enclosure climate control. The Blue e+
hybrid process uses two parallel cooling circuits
working together, depending on temperature
difference. The integral heat pipe dissipates
heat from the enclosure as soon as the ambient
temperature falls below the setpoint, provid-
ing passive climatization. Active climatization
is achieved via the compressors cooling circuit
with speed-controlled components for demand-
based cooling. This unique inverter technology
provides cooling output that is always exactly
the amount needed at the time. Not only is ener-
gy consumption far less than with conventional
technology, but the improved cooling leads to
longer service life of the components inside the
enclosure and the cooling unit itself. All Blue e+
units provide multi-voltage capability to connect
to all standard power grids worldwide.
Rittal
www.rittalenclosures.com

Linear position sensors

The E-Series of linear position sensors
support the IO-Link communication pro-
tocol (as outlined within the IEC 61131-9
standard. The IO-Link protocol offers
simple bi-directional point-to-point com-
munication with both signal transmission
(at rates of up to 230.4 kbps) and power
delivery being handled. It enables con-
sistent communication between sensors
and the controller, as well as providing
access to valuable diagnostic data that will
ensure ongoing reliable operation. These
sensor devices have a maximum stroke
length reaching up to 2,540 mm. They
exhibit a high degree linearity, keeping
deviation to within a margin of less than 0.02% (full scale).
MTS Sensors
www.mtssensors.com

62 | APRIL 2016 CONTROL ENGINEERING www.controleng.com

 Visit Azima DLI
& WATCHMAN:
Digital Factory
Hall 7 E12
Delivering a robust solution for effective
25-29 April 2016
machine condition monitoring Hannover, Germany

Six key reasons to add

Total TRIO to your PdM
strategy:
Advanced PdM vibration
diagnostic technology
Performance assurances
in service and support
PdM cloud services for
low cost infrastructure
Performance analytics to
ensure compliance
Expert analysis to support
ASK ABOUT EXPERTALERT your team in the field
ADVANCED VIBRATION DIAGNOSTICS FOR YOUR PROGRAM
Lower cost of total
ownership

CALL TODAY:
+1 781.938.0707
sales@AzimaDLI.com
PDM MONITORING SERVICES

input #30 at www.controleng.com/information

Diagnostics // Analytics // Cloud Services w w w. A z i m a D L I . c o m

THE ROAD TO
HANNOVER MESSE2016
Smart factory demonstrations
At the Beckhoff main booth in Hall 9, visitors can explore the expanded Industrie 4.0/ Industrial Internet of
Things (IIoT) forum. Beckhoff will demonstrate foundational technologies and ready-to-use products for the
smart factory. TwinCAT Analytics records industrial data synchronously with the process cycle and serves as
the basis for comprehensive analytics.
To enable enables easy-to-configure
connections between the Internet of
Things (IoT) and the Internet of Ser-
vices, TwinCAT IoT supports com-
mon protocols used in cloud com-
munication. In addition, visitors can
see the EtherCAT IP and TwinCAT
HMI, and I/O terminal technology
that integrates high-end measurement
technology.

Process control mappings, which

can be generated from the control
technology, make it easy for the user
to assess connected machines and
systems. The smart factory also intro-
duces numerous requirements regard-
ing online and offline state analysis,
predictive maintenance, pattern recognition, machine optimization and long-term data archiving. This requires
data capture to be as continuous as possible and in sync with the processing cycle. Beckhoff developed Twin-
CAT Analytics software of that all process data can be provided as needed, either locally or as a cloud-based
solution on a server, whether on an internal corporate network or in a public cloud.
Beckhoff
www.beckhoff.com

Frequency inverters
The i500 frequency inverters can be tailored to a wide
variety of machine application and industrial environ-
ment. Compliant with efficiency class IE2, the i500
inverters feature a peak energy efficiency in the 0.33 to
60 hp (0.25 to 45 kW) power range. It features a lower
housing depth along with a sophisticated cooling sys-
tem to reduce heat losses and allow side-by-side instal-
lation with minimal wiring in a smaller control cabinet.
Inverters for control cabinet installation feature IP20
and IP31-rated protection. It also contains different
forms of field bus communication, including Ethernet,
multiple I/O interfaces, and plug options for a keypad,
a USB interface or a wireless LAN module.
Lenze
www.lenze.com

64 | APRIL 2016 CONTROL ENGINEERING www.controleng.com

 PRODUCTS
Industrial connectors
Molex is focused on communication and connectivity for automation at Hannover
Messe and will be featuring a complete range of industrial automation solutions.
Featured new products/solutions include Brad M23 Signal and Power Connectors
and MXMag Gigabit Single-Port RJ45 Magnetic Jacks. In addition, the company
will showcase its Flamar cable assemblies, GWconnect Heavy Duty Connectors
(HDC), FCT mixed layout connectors, Brad MX-PTL M12 Cordsets, CC-Link
network interface cards, EtherNet/IP Protocol Stacks, CIP Safety Protocol
Stacks, and SST CompactLogix Modules for Rockwell Automation. A live
demonstration will showcase Molex capabilities in protocols that include
EtherNet/IP, Profinet, CC-Link, and IO-Link.
Molex
www.molex.com

Cloud gateway
The Simatic IOT2000 is designed for industrial IT solutions that
acquire, process and transfer data directly in the production envi-
ronment. For example, it can be used to connect the production to
a cloud-based analysis of machine and production data. This gate-
way can also be retrofitted in existing plants, where it then harmo-
nizes communication between different data sources, analyzes the
data, and passes it on for evaluation in, for example, a cloud. The
Simatic IOT2000 complements the MindConnect Nano cloud
gateway from Siemens. This is already on the market, and is spe-
cifically designed for MindSphere and SAP Hana. The hardware
of the new Simatic IOT2000 gateway is based on rugged, reliable
and long-lasting industrial technology and has a compact design.
The device is suit-
able for mounting
Ethernet cables on a standard rail,
and is equipped
Increased automation in production pro- with a power-
cesses requires the volume of data transmit- saving Intel Quark
ted to be much greater. Since movement processor x1020
also plays a role in modern production (+Secure Boot),
processes, special Ethernet cables have 1 gigabyte RAM,
been designed to ensure reliable move- battery-backed real
ment and reliability. There are 27 cables time clock (RTC)
in the product range, from the chainflex and a large num-
CF888 with a guaranteed service life of up ber of interfaces,
to five million strokes to the new chainflex including two x
CFROBOT8.052, the first robot cable that Ethernet and two x RS 232/485 ports. Simatic IOT2000 can be
complies with the CAT7 standard. easily expanded for tailor-made solutions with Arduino Shields
Igus and miniPCIe Cards. It also supports Yocto Linux and many other
www.igus.com options for programming in high-level languages.
Siemens
www.siemens.com

www.controleng.com CONTROL ENGINEERING APRIL 2016 | 65

 INSIDE MACHINES collaborative robots

Traditional and
collaborative robots working
safely with humans
Traditional and collaborative robots, depending on the
application, may be used partially or fully in areas with
human workers, and there are new standards and
applications designed to improve their safety capabilities.

MORE
ADVICE
KEY CONCEPTS
Traditional and collaborative robots
have their own unique features and
roles on the plant floor, but recent
technological developments are
allowing each robot to behave more
like the other.
Technology developments are
allowing robots and humans to work
together safely and allowing robots
and humans to use their individual
strengths to create a true partnership.
GO ONLINE
Go to www.controleng.com to see
additional stories about collaborative
robots and worker safety.
CONSIDER THIS
What safety features and develop-
ments need to be made to make robot
and human interaction on the plant
floor safer?
W
hile robots are catching on
as a viable and efficient
option on the plant floor,
making sure they can oper-
ate safely with humans is
still a challenge. Robots generally have no idea
humans are around. Thus, they can cause great
harm if humans enter their work path. Find-
ing the right application can be difficult, but it
is imperative. Traditional robots typically work
in fenced areas where humans cannot interact
with them. Collaborative robots, depending on
the application, may be used partially or fully
in areas with human workers, because sensors
alert the robot to humans and slow them to safe
speed and torque.
Traditionally, fenced and collaborative
robotic applications each have unique charac-
teristics and specific roles to play on the plant
floor. However, some traditional robots are
being designed to achieve the same benefit as
a collaborative robot thanks to safety software
and sensor technology developments. This
used to be unthinkable with previous itera-
tions because of the software and technologi-
cal developments and the fact that traditional
robots were kept away from humans while
they operated.
A semi-collaborative subset of applications
has become popular as a result of improved
reliability of safety scanner technology cou-
pled with robot safety systems. These applica-
tions allow a traditional industrial robot to be
used and provide the same benefits as a col-
laborative robot. In addition, it provides for
an increase in payload and speed, as well as a
reduction in costs.
Technology developments have also
changed plant floor real estate and how it is
A fenceless robotic solution, from JMP, a
Fanuc Authorized System Integrator, uses safety
sensors and robot safety software. In this case, the
robot is not surrounded by guarding, but for safety
reasons, its motion is monitored and stopped
when people are located within its work envelope.
Courtesy: JMP Engineering
used. High-speed vision systems and LIDAR
sensors allow for traditional robot fencing
to be minimized or eliminated. This pro-
vides better visualization on the plant floor.
As a result, equipment can be packed closer
together, and individuals can work easily with
a robot, allowing for quicker troubleshooting
of issues that arise.
Over the years, the strengths and weak-
nesses of robots and humans have been better
understood. While robots are dependable, reli-
able, and consistent in throughput, they can-
not think and problem solve like humans can.
A true partnership between individuals and
robots lends itself to one of the best manufac-
turing processes. This partnership incorpo-
rates the best of both worldsthe consistency
and throughput of robots and automation, and
the ability to think, problem solve, and han-
dle variability instinctively. Recent technologi-
cal and safety developments are making such
a concept become reality rather than a pipe
dream. ce
Ken McLaughlin, general manager, automa-
tion, JMP Engineering. Edited by Chris Vavra, CFE
Media, Control Engineering, cvavra@cfemedia.com.

M1 | APRIL 2016 CONTROL ENGINEERING www.controleng.com

 EtherCAT Terminals Bus Terminals EtherCAT Box
(IP 20) (IP 20) (IP 67)
Servomotor 50 V, 4 A W
50 V, 4 A, OCT W
Stepper motor 24 V, 1.5 A W W
50 V, 5 A W W W
DC motor 24 V, 1 A W W
50 V, 3.5 A W W
50 V, 5 A W

input #31 at www.controleng.com/information

 INSIDE MACHINES smarter robots

Improving robotics
with model-based control
Model-based control helps robotic systems estimate torques and forces on the robot during movement
and prevent excessive torque, increasing robot speed and reducing oscillations and settling times.

D
ynamic modeling of
robotic manipula-
tors has been a known
methodology in aca-
demic circles for many
MORE years. It commonly serves as a tool
ADVICE in robotics and engineering labora-
tories for research and development
KEY CONCEPTS of humanoid robots and advanced
Robots can move faster and
smoother when model-based algo- control algorithms, motion simu-
rithms predict needed responses with lations, and other academic pur-
speed, load, robot type, and position. suits. Dynamic modeling involves
Robot paths are optimized using the development of mathematical
dynamic modeling. formulas that describe the dynam-
Models with smooth movement ic properties of the robotinertia, mass, center of
reduce wear and maintenance.
mass, and other characteristics that cannot easily
GO ONLINE be measured. Use of dynamic modeling to improve
For more about optimized paths, and robot control has been mostly overlooked by devel-
links to other robot and motion control
articles see this article online. opers and manufacturers of industrial robots.
www.controleng.com/robotics. Potential of dynamic modeling was considered
to resolve performance issues experienced by a
CONSIDER THIS
Smarter software can increase
manufacturer of high-speed delta robots used in the
throughput and reduce robot main- semiconductor industry. The solar wafer handling
tenance. applications in which the robots were employed
The delta robot poses a risk of damage to itself and its load. Servotronix first
considered the potential of dynamic modeling to resolve performance issues expe-
rienced by a manufacturer of high speed delta robots used in the semiconductor
industry. Servotronix engineers adopted and enhanced a dynamic model whose
origins were rooted in academic research.
Servotronix obtained accurate values
by developing additional algorithms and a
process for automatic identification of kine-
matic and dynamic parameters while the
robot is moved randomly. Servotronix also
developed dynamic models for other types
of robots, such as SCARA robots, 4-axis
traverse arm robots, and the 5-axis Galileo
Sphere Robot Light (shown), resulting in
faster settling time and better trajectory-
following motion control. All images
courtesy: Servotronix Motion Control
demanded high acceleration and extreme preci-
sion. With its inherently fragile structure, the delta
manipulator was highly susceptible to breakage. It
posed the threat of impacting and damaging expen-
sive loads and production materials.
Reduce risk of robot damage
The study of delta kinematics is based on
mechanical parallelograms connected by ball-
joints, in some systems, to the moving platform
and the arm links. If certain positions or angles are
exceeded, the force needed to break apart the robot
decreases drastically, and the robot can easily dis-
assemble if a collision or strong jerk occurs. These
breaking points are typically at an outstretched
position, with a strong risk of hitting an obstacle. If
an impact is left undetected after the robot breaks,
the potential for even more damage increases.
To overcome disadvantages and provide better
control of the delta robot, engineers adopted and
enhanced a dynamic model with origins in aca-
demic research. The model, or set of algorithms that
describe the delta robot, is half the story.
The model is generic. Parameter values vary
because robots differ in size and mass. Although
the robot kinematics is the same, physical proper-
ties are different. Even in a manufactured series, the
physical properties of each robot may vary slightly
and affect performance differently for each robot.
After modeling the robotic system, accurate val-
ues of the dynamic parameters need to be obtained.
This was achieved by developing additional algo-
rithms and a process for automatic identification of

M3 | APRIL 2016 CONTROL ENGINEERING www.controleng.com

input #32 at www.controleng.com/information
INSIDE MACHINES smarter robots

kinematic and dynamic parameters.

The computed torque values almost exactly predict the filtered torque, as
indicated by the torque error. Model-based control is an embedded feature in Ser-
votronix softMC multi-axis controllers. EtherCAT allows the Servotronix softMC
multi-axis controller to update drive values every millisecond; in each sample, soft-
MC sends and receives from the drive commanded and feedback torque values,
with standard position and velocity values.
While some parameters, such as the geometric
dimensions of the robotic arm links, are easily mea-
sured and inserted into the formula, other parameter
values, such as the center of mass of each link, are
determined by automatic identification.
During the identification the robot is moved ran-
domly, and the dynamic parameter values are deter-
mined by identification algorithms. Internal and
external factors, such as shape, material, cables, and
friction, are figured into the calculations. Dynamic
models were developed for other robot types, such as
selective compliance assembly robot arm (SCARA)
robots, 4-axis traverse arm robots, and a 5-axis spheri-
cal robot. Dynamic modeling resolves greater demand
for higher output, faster speeds, and lower costs.
Using the dynamic models, customers have
achieved faster settling time and better trajectory-
following motion control. A side benefit is the detec-
tion of wear on the system through changes over
time in mechanical parameters, particularly the fric-
tion constant. Model-based control is embedded in
some multi-axis controllers. ce
Mirko Borich is softMC project manager, Servotronix
Motion Control; edited by Mark T. Hoske, content man-
ager, Control Engineering, mhoske@cfemedia.com.

ENGINEERED FOR E T HE RISK

SAFETY
D UC

OF
RE

Nonmetallic Enclosures & Premium Accessories

K
Allied Mouldeds new HMI Cover Kits are designed to provide protection
AR

C OC
for instruments or electronics requiring routine attention or detail. Use of FL H
such a cover kit reduces the risk of arc flash by eliminating the need to fully ASH & S
open an enclosure to view electronics or perform maintenance on a system.

The cover kit features a strong and rigid design, mounting securely to the outside of
any enclosure, and makes accessibility to electronic components easy.
Available in two sizes, HMI Cover Kits are UL recognized and maintain
a NEMA Type 4X seal, and are well-suited for outdoor applications.
Multiple cover latching options are also available, including
a hinge screw, tamper proof screw, and snap latch model.
All are available in solid opaque or polycarbonate
thermoplastic clear covers. Scan the QR code
to learn more! input #33 at www.controleng.com/information
222 North Union Street Bryan, Ohio 43506
Ph: 800-722-2679 Fx: 800-237-7269

2016 Allied Moulded Products, Inc. www.alliedmoulded.com

 t i n g integrated
c h i t e c h
A r intouch bu mi
Solutions ndles

Applicat
Superior ion
Assista
Technical nce
Support Acceler
Speed- ated
To-Mar
ket

Wonderware
Distributor
Wonderware Distributors Possess Powerful HMI
and SCADA Capabilities for your Automation Projects
Wonderware Distributors have been known to pull off some heroic automation
feats for their customers. One of their most powerful capabilities include the
integrated, InTouch HMI Bundle a pre-packaged and ready-to-go solution for
real-time success in plant operations. North American locations include:
NorCal norcal.wonderware.com 866.966.3376
PacWest wonderwarepacwest.com 888.449.0494
West wonderwarewest.com 713.209.8884
Great Plains logic-control.com 913.764.4400
Midwest wonderwaremidwest.com 866.826.9725 2016
Canada East wonderwarecaneast.ca 905.829.9300
Cincinnati atrdistributing.com 513.353.1800 WINNER

North wonderwarenorth.com 877.900.4996

Southeast insource.solutions/wonderware 877.467.6872

Ask about our Integrated

InTouch HMI &
Hardware Bundle
input #34 at www.controleng.com/information
 INSIDE MACHINES motion control

Encoders for
ultra-slow motion control
Encoders and speed sensors play a critical role for many motion control
applications, such as industrial test and measurement, automation, security
and surveillance systems, as well as many other applications.

MORE
ADVICE
KEY CONCEPTS
Tight control of slow speed is
important for many motion control
applications.
Inductive encoders offer high-
resolution, noncontact measurement
in tough operating environments.
GO ONLINE
Read this story online to link to
other encoder and motion control
stories at www.controleng.com.
CONSIDER THIS
What other applications could
benefit?
W
hen design engineers use the term
motion control, the first reaction
may be to think of high-speed sys-
tems with rapid changes in direc-
tion and speed. High-speed and highly dynamic
motion control applications have technical chal-
lenges, but this is also true at the other end of the
spectrum with very slow speeds. Tight control of
slow speed is an important issue for many motion
control applications, such as industrial test and
measurement, automation, and security and sur-
veillance systems.
In applications today, it is not uncommon for
high zoom optical systems to focus clearly on a
target object 20 km away. When that distant target
object moves, things start to get tricky because the
field of view is limited, and the target will quickly
disappear from view if it is not followed smoothly.
If the target is moving at 20 km/hr at a range
of 20 km this equates to a rotational speed of 0.05
rpmextremely slow. To keep the target within the
users central field of view, this low speed needs to
be controlled accurately and responsively as the tar-
get objects speed and direction changes. To main-
tain a central position in the field of view, equivalent
to 0.3 m at a range of 20 km then >200 k encoded
points are required or 18 bits of encoded position.
To maintain smooth motion 20 bits is required, four
times more than the example mentioned.
The traditional approach would be to use an

Introducing the FAST App

TM

The Festo Mobile App gives you quick and easy

DFFHVVWRRXU)$67FDWDORJZKLFKIHDWXUHVD
FRPSOHWHOLQHRIDXWRPDWLRQFRPSRQHQWVZLWK
Same Day, 3 Day and
5 Day availability.

q On-the-go access to the FAST catalog

q Tracking and managing orders
q 1RWLFDWLRQRIVKLSPHQWV

Download today and get started!

ZZZIHVWRXVPRELOHDSS

input #35 at www.controleng.com/information

 Bring Your Machine
Example of a pan
and tilt system tracking
To Life With
a distant moving target.
All images courtesy:
Zettlex UK Ltd.
Custom Drives
Ad va n c
ed C
Al go r ont
i t h m ro l
s

Ethernet
Connectivity

Automation
Controller
Custom
Drives

Custom Motor
Design
Examples of the new gen-
eration of inductive encoders
Custom
that are designed for hazard- Software Vision
ous conditions.

encoder on the systems drive motor and to multiply its counts Aerotech can partner with you to design
per rev through a reduction gearbox connected to the motor. The a custom automation solution for your
higher the gear reduction, the greater the multiplying effect. This specific application at a minimum price.
also means a greater amount of backlash and a less responsive
servo system overall. Such a system would have limited dynam- In our concept machine above, Aerotechs
ic range and typically would be unable to track a quickly moving drive packaging can be customized to fit
object at modest distances of less than a kilometer, as it would lack into the wasp body with special algorithms
the required performance at higher rotational speeds. developed at the firmware layer for flight
The alternative, more modern approach is to use a high-reso- control.
lution position encoder on the output shaft of the gearbox, which
helps avoid backlash effects while maximizing the servos dynamic
Aerotech can accommodate your custom
performance. This approach has been more widely used as high- automation controller needs by using
resolution encoders are less expensive. our plug-in architecture for specific
Because traditional high-resolution position sensing tech- algorithms such as 2D bar code, interfaces
niques have limitations, design engineers are turning to a new type to non-standard sensors, signal outputs
of sensor. The sensors may be thought of as a new generation of synchronized to servo sample time, and
inductive encoders that offer especially high-resolution measure- more. If you have a need for custom
ment of up to 4 million counts per rev (22 bits). Inductive encod- hardware or firmware in your drive
ers use the same basic physics as resolvers, and this allows them to package, contact Aerotech today.
offer high resolution, noncontact measurement in tough operating
environments. Operating in dirty or wet environments allows the
design engineer to eradicate the seals, bushes, or O-rings for opti-
We customize Aerotech automation for you
cal or capacitive encoders.
Hardware Software HMI Firmware
Rather than the traditional wire wound transformer con-
Packaging I/O Motors Electronics
structions found in resolvers, encoders use printed circuits as
their principle components. This decreases form factor, axial
height, and allows for a large bore. The design makes it easy for Global sales, service, and support
The Americas Europe Asia-Pacific
cables, shafts, and pipes to pass through the middle of the sensor.
Encoders offer a simple electrical interface featuring a dc supply Contact our Control Systems Group
at 412-967-6839 or
and an absolute, digital output. ce sales@aerotech.com to
discuss your application today,
Mark Howard, general manager, Zettlex UK Ltd. Edited or see go.aerotech.com/csg59
by Chris Vavra, production editor, Control Engineering, AH1214A-CSG

cvavra@cfemedia.com. input #36 at www.controleng.com/information

Dedicated to the
CONTROL ENGINEERING APRIL 2016 | M8 Science of Motion
 MEDIA SHOWCASE FOR ENGINEERS
Your place for new products, literature, Apps, Videos, Case Studies and White Papers.

ISO5167 Multivariable
Mass Flow Computer

The Industrial Internet of Things:
Its Here, It Works, Its Ignition


IIoT & SCADA on One Platform

Unlimited Licensing
Streamline Your Data Pipeline
Mass flow measurement under
ISO5167 standard for orifice plates,
Web-Based Deployment
nozzles and venturi tubes.

Arian Flow Cad software with fluid
physical properties based on:
NIST Standard Reference Database,
IAPWS-IF97, AGA 8 DC92.
Reliable in tough environments.

more information:
www.arian.cl/flow



Learn more at
inductiveautomation.com/iiot

Input #100 at controlengineering.hotims.com Input #101 at controlengineering.hotims.com Input #102 at controlengineering.hotims.com

MULTI-CONTACT
ad2_10.indd 1 2/12/2016 5:51:14 AM

connectors
With Silver Nickel Butt Style Contacts
for Maximum Performance & Durability NorCal
stay
Serving Northern California
informed
Ask About Our
InTouch HMI Stay current
Contact us for all your challenging HMI,
with technology and
SCADA and Automation projects. trends in electrical,
Industry Leading HMI Hardware Bundle mechanical,
FEATURES AVAILABLE Supporting Customers for 25 years
instrumentation
Knowledgable and Experienced Tech Staff
7 to 37 contacts Application Assistance and Best Practices and automation.
4mA to 150A per contact Architecting Solutions
Easy-to-wire contact terminals
Web: norcal.wonderware.com
meltric.com Email: sales@norcal.wonderware.com
800.433.7642 A company of MARECHAL ELECTRIC GROUP Phone: 866.966.3376
Input #103 at controlengineering.hotims.com Input #104 at controlengineering.hotims.com Input #105To subscribe, visit
at controlengineering.hotims.com
www.controleng.com/subscribe
74 | APRIL 2016 CONTROL ENGINEERING
AIS Norcal-CE0-040116.indd 1 4/1/16 5:07 PM
www.controleng.com
MEDIA SHOWCASE FOR ENGINEERS
Your place for new products, literature, Apps, Videos, Case Studies and White Papers.

TM
2 IN 1
PLUG / RECEPTACLE
Loop Powered 4...20ma
Isolating Conditioners

& DISCONNECT SWITCH

Line of Sight
Disconnect Switch
Meets NEC
requirements
Up to 200A
BOA Spot
TM

NE
W 600V, 75hp
Safe and reliable inputs for PLCs.
Low Cost Integrated Vision Sensor Protects from surge voltages and
eliminates ground potential
BOA Vision System Performance differences.
at Vision Sensor Affordability
OFF
Button 4kV and 10kV isolation.

5 years guarantee.

distributors wanted, more information:

View the BOA Spot www.arian.cl/din
Features Guide:
http://goo.gl/uVwkfN FREE SAMPLES

meltric.com
800.433.7642 A company of MARECHAL ELECTRIC GROUP

Input #106 at controlengineering.hotims.com Input #107 at controlengineering.hotims.com Input #108 at controlengineering.hotims.com

eNewsletters
ad4-2.indd 1 R 2/12/2015 7:03:37 AM

Studio
Control Engineering covers relevant topical articles in
a variety of eNewsletters each and every month:

CEs Top 5 Reader Favorites

Energy Automation
IIoT Report
Industrial Networking
Industry News & Products
Automotive & Transportation
Chemical Manufacturing
Packaging
Information Control
Machine Control
New Products for Engineers Showcase
Oil & Gas Engineering
Planning and Design
Process & Advanced Control
Process Instrumentation & Sensors
Safety & Cybery Security
Single-environment
System Integration
Whitepaper Connection PLC software reduces
programming time
Subscribe today by visiting
www.controleng.com/newsletters

Learn more at
www.unitronics.com
Input #109 at controlengineering.hotims.com Input #109 at controlengineering.hotims.com Input #111 at controlengineering.hotims.com

www.controleng.com CONTROL ENGINEERING APRIL 2016 | 75

 ED ! CFE Medias

D A T Global System
U P
Integrator Database
CFE Medias Global System Integrator Database is an interactive community of
global end-users and system integrators hosted by Control Engineering, Plant
Engineering, and our global partners in Asia and Europe.

The newest version of the online database is even easier to use. Features and updates:
More search results can now be seen on the screen
Relevancy score indicates how closely an integrators qualifications
match a users search criteria
Users can now preview the most pertinent data of an SI before clicking
to view the full corporate profile
New feature allows an end-user to request a quote for a project directly
from the database site
The most relevant data about an integrators engineering services appear
on one page on their corporate profile other details are organized by tabs.

Find and connect with the

Start searching the Global System
most suitable service provider
Integrator Database now!
for your unique application.

www.cfemedia.com/global-si-database
NEW PRODUCTS and software
See more products daily at www.controleng.com/products.

Chlorine analyzer for water monitoring, treatment processes

The TC-80 Total Chlorine Analyzer from Electro-Chemical Devices (ECD) is
designed for process and municipal applications such as water monitoring and treat-
ment. The TC-80 Analyzer monitors total chlorine in drinking water, rinse water, cool-
ing water, or other fresh water samples. The TC-80 features a panel mount design that
incorporates a constant head flow control device, a pH sensor, a chlorine sensor, and an
analyzer/transmitter. The analyzer is available with either 110 to 240 V ac or 24 V dc
power. The TC-80 graphically displays both the total chlorine and pH allowing for trend
analysis. The standard configuration has two 4 to 20 mA outputs and three alarm relays.
Electro-Chemical Devices (ECD), www.ecdi.com
Input #201 at www.controleng.com/information

Encapsulated dc/dc converter series Handheld particulate pollution meter

AutomationDirects Rhino PSE Series of encapsulated
dc/dc converters are designed to provide power for sen-
sitive loads in industrial
process controls, facto-
ry automation, and other
industrial environments
for equipment exposed
to harsh conditions. They
have input voltage rang-
es of 9.5 to 36 V dc and
18 to 75 V dc and also fea-
ture remote on/off control, input polarity protection, and
overload protection. The PSP Series of plastic slim-line
case converters are available in both 25 and 60 W models.
AutomationDirect
www.automationdirect.com
Input #202 at www.controleng.com/information
for hazardous environments
Omegas HHTP21 handheld particulate,
humidity, and temperature meter is designed
to measure fine and course particle pollu-
tion that comes from many different types of
sources. The HHTP21 is designed for moni-
toring particulate pollution in burning plants,
petrochemical facilities, thermal power plants,
restaurants, hospitals, mining facilities, and
metal refineries. Other features include tem-
perature and humidity measurements and a
health index detection and alarm. It also has a six-color LED
indication for air quality and a preset warning point. Addition-
ally, it has manual data memory, read function, and an operat-
ing temperature range of -20 to 60 C (-4 to 140 F).
Omega Engineering, www.omega.com
Input #203 at www.controleng.com/information

I/O breakout boards for simplified wiring

Opto 22s Snap-UDC-HDB-G4 and Snap-UDC-HDB breakout boards are designed to boost the capa-
bilities of 32-point Snap digital I/O modules, simplify field wiring, and save panel space for origi-
nal equipment manufacturers (OEMs) and machine builders. With the Snap-UDC-HDB-G4
breakout board users can connect 32-point Snap digital I/O modules to higher loads for fused
outputs and isolated inputs. These modules can provide up to 3 amps current switching or
sensing per point, fused outputs, isolated inputs, and per-point LED indicators, depending on
the G4 modules selected. For example, using G4 digital output modules on the breakout board
allows a 32-point module switch up to 12 times its regular current load of 0.25 amps. Spring-clamp
connectors secure field wiring and reduce installation time.
Opto 22, www.opto22.com
Input #204 at www.controleng.com/information

Stainless steel faced sensors

Turcks 2-wire, dc stainless steel faced sensors with an extended sensing range
are designed to be used as substitutes for traditional plastic faced sensors in appli-
cations where the sensors are damaged by impact. The one-piece housing is made
from high-grade stainless steel, which resists corrosion and is rated IP67 against
moisture ingress. The standard temperature rating for the line is -25 to 70 C (- 13
to 158 F). The rugged construction and design of the stainless steel sensor line
allow it to fit the needs of a wide variety of applications. PTFE or WeldGuard
coating is available upon request.
Turck, www.turck.com
Input #205 at www.controleng.com/information

www.controleng.com CONTROL ENGINEERING APRIL 2016 | 77

NEW PRODUCTS and software
See more products daily at www.controleng.com/products.

Pressure sensors for industrial applications

Curtiss-Wrights range of robust pressure sensors are designed for pressure sensing appli-
cations for industrial applications such as factory automation, process control, automotive and
specialty vehicles, hydraulics, pneumatics, and environmental systems. Featuring thin-film and
diffused-silicon sensing elements, the piezo-resistive sensing technology is small and robust with
stainless-steel body construction. Thin-film polysilicon resistors are applied to a stainless-steel dia-
phragm that deflects under pressure from the measured media, providing a varying voltage that can be
converted into other electrical outputs. Benefits include long-term stability exceeding 0.1% per annum
and compatibility with a wide range of gas and fluid media, that operate at 0 to 4,000 bar.
Curtiss-Wright, www.curtisswright.com
Input #206 at www.controleng.com/information

Incremental encoder for Synchronous servo motors for positioning tasks

functional safety applications
Sicks DFS60S Pro incremental encoder for functional
safety is designed for mobile and stationary applications
that require safe motion monitoring. The DFS60S Pro
incremental encoder is a certified safety product up to SIL2
(IEC 61508), SILCL2 (EN 62061), PL d (EN ISO
13849), Category 3 (EN ISO 13849). It is designed
to integrate safe motion into machine safe-
ty architecture by reducing work required for
verification, validation, and safety engineer-
ing. The DFS60S Pro features IP65 enclo-
sure rating, wide temperature range, and
wide set bearings for enhanced durability.
Sick, www.sickusa.com
Input #207 at www.controleng.com/information
Lenze Americas MCM synchronous servo motors are designed for
a range of positioning tasks including robotics, packaging equipment,
and handling systems. The modular MCM motors feature IP65-rated
protection class housings for food processing and other applications.
The motors are equipped with a resolver feedback system and can be
optionally supplied with multi-turn, sine-cosine encoders for high pre-
cision. SpeedTec connections with rotary connector boxes simplify
and expedite installation, maintenance, and replace-
ment. The Lenze MCM motor series is available in three
sizes with power ratings of 0.27 to 3.35 hp (0.2 to 2.5
kW). The MCM motor drive solutions are
capable of achieving torque ranges from
5.31 to 233.66 in-lb (0.6 to 26.4 Nm).
Lenze Americas, www.lenze.com
Input #208 at www.controleng.com/information

PRODUCT & LITERATURE SHOWCASE Acromag Signal Conditioners & Ethernet I/O
We have the experience
to help improve reliability,
5B / 7B / 8B Signal Conditioning Solutions increase productivity, &
More Models, More Protection, Less Noise, Lower Cost reduce your costs.

580+ different 5B, 7B, and 8B signal conditioners provide accurate, isolated Instrument Get your new product guide today.
Class performance to ensure the integrity of your industrial automation, data acquisition, 4-20mA Isolators and Splitters
process control, and quality assurance systems. Custom modules available. Ethernet, Modbus, Profibus Remote I/O
0.03 to 0.05% Accuracy ANSI/IEEE C37.90.1 Transient Protection
1500Vrms Isolation 3- to 6-Pole Low-Pass Filtering
Up to 240Vrms Input Protection -40C to +85C Operating Temperature 877-295-7057 www.acromag.com/ce

Input #101 at www.controleng.com/information

CSA C/US Certified & ATEX Compliant
(5B, 7B)
C-UL-US Listed (8B) Sensor Brackets
softnoze com

and so much more...

Please request your...

Call 800-444-7644 or visit www.dataforth.com
Input #100 at www.controleng.com/information
2D / 3D CAD Files
Catalogs
Stock & Customs
Place your Classified, Literature
Showcase or Product Mart ads today!
Contact: Iris Seibert at 858-270-3753 or ISeibert@CFEMedia.com Mount | Apply | Position | Protect
TM

WInput #102 at www.controleng.com/information

ORLD LEADER IN SENSOR INTEGRATION COMPONENTS
TM

78 | APRIL 2016 CONTROL ENGINEERING www.controleng.com

 Advertising Sales Offices
ContentStream
Patrick Lynch,
Director of Content Marketing Solutions
630-571-4070 x2210
PLynch@CFEMedia.com

AL, FL, GA, MI, TN

Maggie Hatcher,

ad index
Classified, Product Mart,
Media Showcase
630-571-4070, x2221
MHatcher@CFEMedia.com
Company Page# RSN Web
AR, IL, IN, IA, KS, KY, LA, MN, MO,
ABB Drives and Controls . . . . . . . . 19. . . . . . . . . . 14 . . . . .www.abb.com/drives
MS, NE, ND, OK, OH, SD, TX, WI,
Advanced Cooling Central Canada
Technologies, Inc. . . . . . . . . . . . . . . 12 . . . . . . . . . . 9. . . . . .www.1-ACT.com/Enclosure-Cooling
Bailey Rice
ADVANTECH . . . . . . . . . . . . . . . . . . .9 . . . . . . . . . . . 6. . . . . .www.advantech.com
(630) 571-4070 x2206
Allied Electronics . . . . . . . . . . . . . C1, 7 . . . . . . . . . 5. . . . . .www.alliedelec.com BRice@CFEMedia.com
AutomationDirect . . . . . . . . C2, OFG, IFG, 16A-16B . . . 1, 39 . . . .www.automationdirect.com
AK, AZ, CA, CO, HI, ID, MT,
Azima DLI . . . . . . . . . . . . . . . . . . . . 63 . . . . . . . . . 30 . . . . .www.AzimaDLI.com
NV, NM, OR, UT, WA, WY,
Beckhoff Automation LLC. . . . . . . . 55 . . . . . . . . . 26 . . . . .www.beckhoff.com
Western Canada
BLOCK USA, Inc . . . . . . . . . . . . . . . 59 . . . . . . . . . 28 . . . . .www.blockusa.com Iris Seibert
CFE Medias Global System (858) 270-3753
Integrator Database . . . . . . . . . . . . 76 . . . . . . . . . . . . . . . . .www.cfemedia.com/global-si-database
ISeibert@CFEMedia.com
Control Engineering
E-Newsletters . . . . . . . . . . . . . . . . . 27 . . . . . . . . . . . . . . . . .www.controleng.com/newsletters CT, DE, MD, ME, MA, NC,
Danfoss . . . . . . . . . . . . . . . . . . . . . . 11. . . . . . . . . . . 8. . . . . .www.danfoss.us NH, NY, NJ, PA, RI, SC, VA,
Delta Computer Systems Inc . . . . . 14 . . . . . . . . . .11 . . . . .www.deltamotion.com VT, WV, DC, Eastern Canada
Emerson Process Management. . . 24 . . . . . . . . . 20 . . . . .www.emersonprocess.com/operationsperformance Julie Timbol
(978) 929-9495
FORCAM . . . . . . . . . . . . . . . . . . . . . 61 . . . . . . . . . 29 . . . . .www.forcam.com
JTimbol@CFEMedia.com
HANNOVER MESSE . . . . . . . . . . . . 57 . . . . . . . . . 27 . . . . .www.hannovermesse.events/cfemedia
iDS . . . . . . . . . . . . . . . . . . . . . . . . . . 10 . . . . . . . . . . 7. . . . . .www.ids-imaging.com/usb3 CFE Media Contributor
IGEL Electric GmbH . . . . . . . . . . . . 23 . . . . . . . . . 19 . . . . .www.igelelectric.de/en Guidelines Overview
Inductive Automation. . . . . . . . Bellyband . . . . . . . . . . . . . .www.inductiveautomation.com/iiot Content For Engineers. Thats what CFE
Lapp Usa . . . . . . . . . . . . . . . . . . . . . 27 . . . . . . . . . 23 . . . . .www.lappusa.com Media stands for, and what CFE Media is all
about engineers sharing with their peers.
Leidos . . . . . . . . . . . . . . . . . . . . . . . .4 . . . . . . . . . . . 4. . . . . .www.leidos.com/activate
We welcome content submissions for all
MICROMO . . . . . . . . . . . . . . . . . . . . 25 . . . . . . . . . 21 . . . . .www.micromo.com interested parties in engineering. We will use
Moxa Technologies . . . . . . . . . . . . . .3 . . . . . . . . . . . 3. . . . . .www.moxa.com those materials online, on our website, in
print and in newsletters to keep engineers
Omega Engineering Inc . . . . . . . . . 18 . . . . . . . . . 13 . . . . .www.omega.com informed about the products, solutions and
ORION INSTRUMENTS . . . . . . . . . 13 . . . . . . . . . 10 . . . . .www.orioninstruments.com industry trends.
www.controleng.com/contribute explains
Phoenix Contact . . . . . . . . . . . . . . . 50 . . . . . . . . . 25 . . . . .www.phoenixcontact.com/GoMesse how to submit press releases, products,
Rittal Corporation . . . . . . . . . . . . .20, 21 . . . . . . . . 15 . . . . .www.rittal-corp.com images and graphics, bylined feature articles,
Servotronix Motion Control Ltd. . . 23 . . . . . . . . . 18 . . . . .www.servotronix.com case studies, white papers, and other media.
* Content should focus on helping engi-
SEW-EURODRIVE, Inc. . . . . . . . . . . C4 . . . . . . . . . 38 . . . . .www.seweurodrive.com neers solve problems. Articles that are com-
SIKA USA . . . . . . . . . . . . . . . . . . . . 22 . . . . . . . . . 16 . . . . .www.sika-usa.com mercial in nature or that are critical of other
products or organizations will be rejected.
Teledyne DALSA . . . . . . . . . . . . . .15, 26 . . . . . . . 12, 22 . . .https://goo.gl/Y9p9FN (Technology discussions and comparative
TRACO POWER . . . . . . . . . . . . . . . . 22 . . . . . . . . . 17 . . . . .www.tracopower.com tables may be accepted if non-promotional
and if contributor corroborates information
Unitronics . . . . . . . . . . . . . . . . . . . . .1 . . . . . . . . . . . 2. . . . . .www.unitronics.com
with sources cited.)
Valmet . . . . . . . . . . . . . . . . . . . . . . . 33 . . . . . . . . . 24 . . . . .www.valmet.com/iq * If the content meets criteria noted in
Yaskawa America, Inc. . . . . . . . . . . C3 . . . . . . . . . 37 . . . . .www.yaskawa.com guidelines, expect to see it first on our Web-
sites. Content for our e-newsletters comes
from content already available on our Web-
Inside Machines sites. All content for print also will be online.
Aerotech Inc . . . . . . . . . . . . . . . . . . M8 . . . . . . . . . 36 . . . . .www.aerotech.com All content that appears in our print maga-
zines will appear as space permits, and we
Allied Moulded Products, Inc. . . . . M5 . . . . . . . . . 33 . . . . .www.alliedmoulded.com will indicate in print if more content from that
American Industrial article is available online.
Systems (AIS) . . . . . . . . . . . . . . . . . M6 . . . . . . . . . 34 . . . . .www.aispro.com * Deadlines for feature articles intended for
the print magazines are at least two months in
Beckhoff Automation LLC. . . . . . . . M2 . . . . . . . . . 31 . . . . .www.beckhoff.com
advance of the publication date. Again, it is best
Festo Corporation . . . . . . . . . . . . . . M7 . . . . . . . . . 35 . . . . .www.festo.com to discuss all feature articles with the appropri-
WAGO Corp. . . . . . . . . . . . . . . . . . . M4 . . . . . . . . . 32 . . . . .www.wago.us ate content manager prior to submission.
Learn more at:
www.controleng.com/contribute
REQUEST MORE INFORMATION about products and advertisers in this issue by using
the http://controleng.com/information link and reader service number located near each.
If youre reading the digital edition, the link will be live. When you contact a company di-
rectly, please let them know you read about them in Control Engineering.
www.controleng.com CONTROL ENGINEERING APRIL 2016 | 79
 BACK TO BASICS cyber security
The need for critical
infrastructure specialists
Specialized experts for specific critical infrastructure projects are becoming more
common as projects become more complex and more demanding.
Those needing
to protect
critical
infrastructures
using operation
technology
(OT) cannot rely
on information
technology
(IT) security
specialists.
MORE
ADVICE
KEY CONCEPTS
Information technology (IT) and
operational technology (OT) experts
use computers differently.
Ask mission critical device manu-
facturers about cyber attack testing.
Specialized expertise is a must
for companies looking to secure
operational assets and reduce
compliance penalties.
GO ONLINE
Read this story online at
www.controleng.com for more
information about cyber security
programs and how they can posi-
tively impact businesses.
CONSIDER THIS
What other ways can operational
technology expertise help with
cyber security protection?
80 | APRIL 2016 CONTROL ENGINEERING
I
Its becoming very important for those
needing to protect refineries, power grids, health-
care institutions, traffic systems and other solu-
tions that are run by automated controls to use
specialized security researchers to perform site
assessments and, later, certifications. Those need-
ing to protect critical infrastructures using opera-
tion technology (OT) cannot rely on information
technology (IT) security specialists. Both use com-
puters but work in different environments.
Just as someone would not ask the plant man-
ager to fix the flaw in a Microsoft Windows sys-
tem, the IT director cant be expected to have all the
answers to protecting the OT system. IT special-
ists strive to protect data; OT environments work to
keep machines producing. Therefore, the byprod-
ucts of IT versus OT attacks are also different.
During the 2015 RSA security conference,
Wurldtechs Frank Marcus, director of technol-
ogy, led a peer discussion that underscored the
heightened profile of cyber security in the age of
the Industrial Internet. Addressing the audience of
global critical infrastructure experts, Marcus spoke
about the evolution of threats against critical infra-
structure. While enterprise cyber attacks may grab
bigger headlines, cyber attacks on physical infra-
structures can have greater consequences, includ-
ing environmental damage and human safety.
Protecting these types of attacks are not the
focus of IT departments. While the primary goal
in IT is to protect data, OT security strives to keep
processes running. Whether from outside threats,
like hackers or state sponsored actors, or inside
threats, like human error, in an environment
where companies are operating drills, electric
grids, MRIs or locomotives, unplanned downtime
is simply not acceptable.
This is especially true for industries such as oil
and gas, energy producers, health facilities and
transportation systems in which even a couple
minutes of downtime can yield tens of thousands
of dollars lost.
Developing OT specialists
In the real world, Wurldtech began with white
hat hackers who recognized there is an incred-
ible amount of risk in our critical infrastructure.
In-house hackers tested all the possible ways these
machine-to-machine (M2M) networks could be
infiltrated to identify where vulnerabilities exist and
determine how to protect against them.
With enough data, the team created a compre-
hensive cyber security solution to help provide crit-
ical infrastructure protection against the persistent
and dynamic cyber threats that challenge produc-
tion environments, transportation systems and
healthcare operations. If a system is successfully
hacked, it is possible to help stop that attack from
getting to the internal Internet where it can wreck
havoc on the factory, grid or drilling station.
Once it is installed, a security and quality testing
service that simulates attackers challenging the sys-
tem is needed to make sure that the user is control-
ling who is talking to whom. Such a service imitates
attackers challenging the companys system.
Ask about repelling attacks
Also, be sure to ask the mission critical device
manufacturers if they have been tested to repel
cyber attacks. Have they had their products mon-
itored to network and operational parameters,
allowing vulnerabilities to be discovered and faults
to be reproduced, isolated, identified and resolved
before these products are introduced to the mar-
ket? Are they certified to be secure?
In addition, management needs assurance the
security experts they hire are not only highly cer-
tified and trained to carefully assess, design and
implement OT security but to do so in their indus-
try environments. For instance, oil management
needs to assure that the security experts they hire
are certified and trained to carefully assess, design,
and implement OT security in offshore and
onshore environments. If the goal is to help secure
operational assets, reduce compliance penalties, and
enforce supplier security, specialized expertise is abso-
lutely needed. ce
Nate Kube founded Wurldtech Security Technologies
in 2006 and, as the companys chief technology offi-
cer. This content originally appeared on ISSSource.
ISSSource is a CFE Media content partner. Edited by
Chris Vavra, production editor, Control Engineer-
ing, CFE Media, cvavra@cfemedia.com.
www.controleng.com
 ENTER THE
MATRIX

Using complicated systems

for low harmonics or power
regeneration?
Try the efficient way with the
U1000 Industrial Matrix Drive.
Our greenest drive ever, the
U1000 goes beyond the
performance of conventional
drives. Enjoy extremely low
harmonic distortion and
regeneration in a space-saving
design, completely without the
need for additional components.

12/18-PULSE
SYSTEM
U1000 INDUSTRIAL
MATRIX DRIVE
12/18-Pulse Input Standard
Transformer Fuses Drive

ACTIVE
COMPONENT
SYSTEM U1000
Input Fuses LC Filter Active Standard
Rectifier Drive

For more info:

http://budurl.me/YAI886
input #37 at www.controleng.com/information

YASKAWA AMERICA DRIVES & MOTION DIVISION YASKAWA.COM 1-800-YASKAWA

 Less is more.
Are you under pressure to reduce costs? We can
help! The MOVIGEAR Mechatronic Drive System
from SEW-EURODRIVE substantially reduces your
inventory with its ability to cover a broad range of

gear ratios with a single unit. Independent research

has also proven that the MOVIGEAR reduces
start-up and operating costs in material handling

by 20-30%. So, relax...we got this!

input #38 at www.controleng.com/information

movigear.com / 864-439-7537