better connections · dang sameto, apc engineer at ptfi, in a presentation about the mine’s...
TRANSCRIPT
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A SENSE OF OBSOLESCENCE
A TASTE FOR RASPBERRY PI
A KNACK FOR SMART MACHINES
better connectionsfor better maneuvers2 stories stacked with maximum motion
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FEATURESmachine input
The future of automation starts here3 industry leaders talk about the
direction technology is taking
manufacturing
Mike Bacidore, chief editor
18
cover story
Better connections for better maneuvers2 stories stacked with
maximum motion
Ray Marquiss, Valin; and Ryan Poethke,
Showman Fabricators
28
CNC
Greater return on CNCHow Spyder Manufacturing
climbed to the top
Dave Perkon, technical editor
38
CONTROL DESIGN, (ISSN: 1094-3366) is published 12 times a year by Putman Media, 1501 E. Woodfi eld Rd., Suite 400N, Schaumburg, Illinois 60173. (Phone 630/467-1300; Fax 630/467-1124.) Periodical post-age paid at Schaumburg, IL, and at additional mailing offi ces. Address all correspondence to Editorial and Executive Offi ces, same address. Printed in the United States. ©Putman Media 2019. All rights reserved. The contents of this publication should not be reproduced in whole or part without consent of the copyright owner. POSTMASTER: Please send change of address to Putman Media, PO Box 1888, Cedar Rapids IA 52406-1888; SUBSCRIPTIONS: To change or cancel a subscription, email [email protected] or call 1-800-553-8878 ext. 5020. To non-qualifi ed subscribers in the United States and its possessions, subscriptions are $96.00 per year. Single copies are $15. International subscriptions are accepted at $200 (Airmail only.) Putman Me-dia also publishes CHEMICAL PROCESSING, CONTROL, FOOD PROCESSING, PHARMA MANUFACTURING, PLANT SERVICES, SMART INDUSTRY and THE JOURNAL. CONTROL DESIGN assumes no responsibility for validity of claims in items reported. Canada Post International Publications Mail Product Sales Agreement No. 40028661. Canadian Mail Distributor information: World Distribution Services, Inc., Station A, PO Box 54, Windsor, Ontario, Canada N9A 6J5. Printed in the United States.
table of contents
ControlDesign.com / November 2019 / 5
product roundup
Make the connectionCables and connectors bring a
design together42
Volume 23, No. 11
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9 editor’s page
How to overcome obsolescenceMike Bacidore, editor in chief
11 live wire
A real, smarter control systemDave Perkon, technical editor
13 embedded intelligence
Not a PLC, but an automation complementJeremy Pollard, CET
14 technology trends
RFID 2.0Rick Rice, contributing editor
45 product showcase
50 automation basics
The brains in smart machinesDave Perkon, technical editor
COLUMNS
Allied Electronics .................................................................6
AshCroft ...............................................................................34
AutomationDirect................................................................2
B & R Industrial Automation ...........................................8
Beckho� Automation ........................................................4
Carlo Gavazzi......................................................................16
Digi-Key Electronics ........................................................52
Dinkle ....................................................................................24
Emerson Automation Solutions .................................51
Endress+Hauser ...............................................................10
FreeWave Technologies ................................................27
Hammond Manufacturing .............................................35
Hilscher North America..................................................12
HMS Networks......................................................................7
icotek North America ......................................................32
IDEC Corporation ..............................................................37
Measurement Computing ............................................41
Newark .................................................................................21
Novotechnik .......................................................................36
Pepperl+Fuchs ..................................................................25
Phoenix Contact ...............................................................31
SEW-Eurodrive ......................................................................3
SMC ........................................................................................23
Telemecanique Sensors ................................................17
Wago Corporation ............................................................15
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table of contentsVolume 23, No. 11
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ControlDesign.com / November 2019 / 9
PT FREEPORT INDONESIA (PTFI) was facing obsolescence of its Foxboro control system. The
mining company put together a comprehensive modernization plan that included maxi-
mizing value from existing automation investments.
“Our primary mine is the Grasberg surface mine in Papua, Indonesia,” explained Ben-
dang Sameto, APC engineer at PTFI, in a presentation about the mine’s various upgrades
at Schneider Electric’s Innovation Days in Austin, Texas. “It will be closed, and we will
move our mines underground. The crater is so wide it’s not feasible to mine from the
surface any more.”
This transition to a completely underground operation comes on the tail end of a
control-system upgrade that has already spanned 17 years. The operation includes crush-
ers and equipment to transport the crushed ore to stockpiles. After crushing and grinding
and converting to slurry, it’s then
transported to a pipeline, which car-
ries it to a dewatering plant portside,
where it’s readied to be sent by ship.
Average throughput topped out in
2001 and 2009 at 238,000 tons/day.
During that span, the oldest
workstations and software were
upgraded, and new enclosures were
added. The 12-node cable local area network (LAN) was upgraded to �beroptic. Controls
were upgraded from CP40A to the Field Control Processor 270 (FCP270) with Field Device
Systems Integrator (FDSI).
“We have 800 Fieldbus Modules (FBMs) installed,” said Ade Jaya, control systems leader
at PTFI. The Grasberg mine also includes 8,000 terminations of �eld wiring, 950 control
loops, about 6,000 calculation blocks and 730 operator graphic displays.
Refurbished workstations were purchased and older ones were upgraded to a common
standard with a system software upgrade, as well.
“We migrated from LAN to a mesh network, which can route around multiple faults,
unlike the A/B redundant network,” said Jaya. Additional nodes were brought on the mesh
network, and the �beroptic infrastructure was improved.
The older controllers and gateways were upgraded because of obsolescence and their
limited capabilities. “As I/O points increased and control loops have become more compli-
cated, some of these controllers have become overloaded,” said Jaya.
Foxboro’s current offering of controllers and workstations all require a mesh network,
he explained. “Establishing a good network design ensures total �exibility into the fu-
ture,” said Jaya. This also allowed PTFI to upgrade the FCP270 to FCP280.
How to overcome obsolescenceeditorial teameditor in chief
Mike [email protected]
technical editor
Dave [email protected]
digital managing editor
Christopher [email protected]
contributing editor
Rick [email protected]
contributing editor
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Lori [email protected]
columnist
Jeremy [email protected]
design/productionsenior production manager
Anetta Gauthier
senior art director
Derek Chamberlain
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Industrial Fans, Blowers
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Industrial Process Furnaces & Ovens 472
Machine Tools 2,110
Materials Handling, Conveyors
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The oldest workstations and software were upgraded,
and new enclosures were added.
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“WHAT ARE WE GOING TO DO with the technology?” asked Peter
J. Photos, Ph.D., chief scientist and executive vice president at
Streamline Innovations at the 2019 Ignition Community Con-
ference (ICC) in Folsom, California. He certainly laid out some
limitless possibilities, the theme of the ICC, during his session.
Photos’ discussion was really about the future. Using an oil-
and-gas process in his example, but it could be any machine or
process, there are many pieces of equipment used. However,
at the current stage of technology, Photos notes there is maybe
one PLC across a typical gas-process-
ing facility and about 40 I/O points
in each, similar to a station on an
assembly system.
“Imagine, in the future where all the
pieces in a gas-processing facility or
manufacturing system are smart; not
just controlled, but smart,” says Pho-
tos. “But here’s the problem. We all hear about what the future is,
what we’re going to be doing and all these great technologies that
people are on the edge of doing, but where is automation going?”
There are two options. “We could boldly go where no one has
gone before,” says Photos. “We could do all these incredible or
amazing things and build some super-high technologies that
are completely automated. Alternatively, we could go gentle
into that good night and make some incremental changes and
improvements to take little steps forward, so, in 20 years, we
are just slightly further ahead of where we are currently at.”
While its story is long, Streamline Technology is a startup
about two years old in San Antonio, Texas. It makes equip-
ment that uses a pure chemical reaction to remove hydrogen
sul� de, an extremely toxic gas, that is found in the natural gas
produced in about 40% of the wells. They design, build and
integrate equipment to remove this toxic gas as well as manage
these processes during operation.
The equipment uses two chemical reactions to remove
the hydrogen sul� de. One converts it to sulfur, and the other
converts the spent chemistry and regenerates it. Both reactions
need to be controlled very carefully, but the process equipment
is installed in remote locations, 50 miles from nowhere.
What’s Streamline’s secret sauce? “We have a control system
that we made smart,” says Photos. “And we have Ignition SCA-
DA by Inductive Automation in the middle with MQTT sending
the information to a cloud server and remote access.
“We had about 10 or 20 grand to create the control system,”
continues Photos. “The traditional setup includes a plant, a
PLC and an HMI, but there is a problem with this. We are doing
exquisitely tight control of chemical reactions. The PLC did an
okay job, but it was very inef� cient. And every time it went down
someone had to get in the car and drive an hour to restart it.”
The control system needed to get better. “We installed Igni-
tion, and we were in business,” says Photos. “We got real-time
data and immediate alerts as soon
as the system went down. But we
were missing a few things, we
needed better control of the system.
The process was still inef� cient.
The system needed brain power.”
Adding brain power was the
next step, so Streamline installed a
Moxa PC box, which was a cost-effective and capable embedded
computer and gateway with cellular support that runs Ignition
Edge. “And there was room on the device to run other things,”
says Photos. “We could write Python scripts to better control
the process. The calculations were not PLC friendly. It was not
just a PID loop or plus or minus output. It was a two-variable
linear algebra equation. Simple to solve on paper on in a script,
but not so simple in a PLC.”
The system collects and displays 300 to 400 real-time data
points. It has full historian data. There is also full, bi-directional
control available through an app on a mobile device, which can
start and stop the unit and change set points.
“But what’s cool is the system is smart,” says Photos. “When
it goes down, it sends a text message to the operator who can
restart the unit remotely. Cybersecurity aside, the control room
is my PC or an app on my phone. It’s the full HMI with access
to all the historian data that the users and operators can use.
There are also some canned reports and trends in the system to
help with day-to-day operations.”
With a little intelligence and bi-directional control using Igni-
tion Edge and Python script, Streamline made the control a little
smarter. “Our uptime went from 95% to 99% using this brain pow-
er, cloud data and remote access,” says Photos. “We take a middle-
size plant, we install a PLC, a Moxa box, Ignition Edge and now we
have some intelligence. And boy do we have room to grow.”
A real, smarter control system
live wire
The system collects and displays 300 to 400 real-time data points.
ControlDesign.com / November 2019 / 11
Dave Perkontechnical [email protected]
CD1911_11_LiveWire.indd 11 11/5/19 9:34 AM
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ControlDesign.com / November 2019 / 13
Jeremy [email protected]
embedded intelligence
THE RASPBERRY PI single board computer (SBC) has been
around for a long time. Arduino-based boards along with Beagle
boards have made it from the hobby workbench into industry.
You would be surprised as to where you might �nd these de-
vices working and lurking in the shadows.
But is it wise to employ a hobby-based technology in your
plant or OEM equipment where customer support would be al-
most non-existent? There is no programming software that the
user can plug in to see what’s going on in the brains like they
can with a PLC.
So I ran into a board that has been
‘industrialized’ by Embedded Micro
Technology. It uses the Raspberry Pi
compute module. The compute mod-
ule consists of the PI processor such
as the BCM2837 along with 1 GB of
RAM. There is an optional eMMC �ash
memory device available, as well.
The normal Raspberry Pi module has all the stuff you need to
implement a solution, but the compute module allows for an OEM
to build on top of the basic motherboard using an edge connector.
The embedded solution is very extensive. The integrator
board called MyPI looks to be very well laid out and manufac-
tured. It has built-in Ethernet, USB, HDMI and pin headers for
add-on cards and devices. It also supports a camera. There are
multiple options for mounting enclosures, as well.
One of the cool things it has developed is communication
solution add-on cards for RS-485/232, Modbus and Canbus along
with Mbus, the protocol to speak to utility metering that sup-
ports the protocol.
It supports analog and digital sensors for most small projects
but only for dc-based systems.
Various network protocols are supported, including Bluetooth
and Wi-Fi. Ethernet/IP drivers are available for the Pi.
The operating system (OS) that MyPI uses is Linux (Raspian),
which is the standard PI OS. It has been adjusted to support the
add-on cards and functionality of the MyPI Integrator board.
While home and/or hobby applications abound for the Rasp-
berry Pi, MyPI takes the hardware into the industrial space. One
of the most probable applications will be in the world of the
Industrial Internet of Things (IIoT) utilizing MQTT protocol.
This would therefore qualify as an edge device. So imagine
any device that is remote that can be sensed using dc or analog
and have wireless or cell communication over MQTT using MyPI
can be done although you will have to learn some new skills to
utilize this solution.
I asked my community about applications and by far and
away it is data acquisition and display. Gathering data using the
GPIO header on a standard Pi is fairly easy to do for those who
know Linux; thus there is a learning curve for those who don’t.
But wait. Can’t I run Windows on a Pi? Well, Angela, yes you
can. Windows IoT can be installed
on the Pi compute module, and now
you would be in familiar territory.
Having said that, Automated Solu-
tions has released a library for .NET
and Linux environments to com-
municate with all major PLC brands
including Rockwell Automation and
Siemens. I can see many applications coming to light simply based
on this since involving PLC communications is the mainstay of
all data acquisition projects. This is not to say the MyPI cannot
be used exclusively and with its myriad I/O cards. It is saying you
don’t need a PLC at all for control and/or system monitoring.
Having the ability to have inexpensive data acquisition is price-
less. There are sample projects on the Internet that basically build
an SQL database to hold the said data. While I was unable to �nd
one for store and forward client server, it won’t be far behind.
Applications that use wireless, such as remote water treat-
ment facilities and wells require data to be stored on a timely
basis. Should the communications go south for a time, then
the data will have holes in it, and regulatory bodies don’t take
kindly to that. So a store-and-forward functional system built
on MQTT, MyPI and Windows 10 IoT would be perfect for the
application. The MyPI is industrial by design. The power supply
is better �ltered and has been oven-tested for temperature vali-
dation. Shock issues aren’t a problem since all devices and I/O
cards are physically secured making it a good choice for many
applications. Is MyPI the new PLC? No I don’t think so, but it is a
darn good complement to your automation solutions.
Not a PLC, but an automation complement
Involving PLC communications is the mainstay of all data
acquisition projects.
JEREMY POLLARD, CET, has been writing about technology and
software issues for many years. Pollard has been involved in control
system programming and training for more than 25 years.
CD1911_13_EmbedIntel.indd 13 11/5/19 9:35 AM
14 / November 2019 / ControlDesign.com
technology trends
Rick Ricecontributing editor
IN AN INDUSTRY like automation, the fast-paced growth can
sometimes leave great ideas in the rearview mirror on the
highway of life. One technology that has been around for years,
radio frequency identi�cation (or RFID), has withstood the test
of time by reinventing itself from time to time.
RFID works on the concept of information stored on data carri-
ers attached to objects that are then exposed to an antenna that
extracts the information. It is basically a wireless identi�cation
system. To create an RFID system, one needs RFID tags, a read/
write device and a host system. The
RFID system writes data, provided by
the host system to the tag using the
write function of the read/write device.
Data on the RFID can be read back to
the host system and, importantly, data
on an RFID is re-writable, meaning it
can be overwritten by new data.
The primary uses of RFID technology is in destination
determination and historical tracking. An example of destina-
tion determination might be an RFID tag attached to a bin on a
conveyor sortation system. As the bin passes speci�c challenge
points (just like intersections on a road system), the informa-
tion contained on the data puck attached to the bin provides
information related to the desired destination of the contents of
the bin. Asset management is a good example of the use of RFID
for historical tracking purposes. An identi�able asset, like a hy-
draulic pump or a horizontal milling machine, has a permanent
RFID tag attached to it. Throughout the lifetime of the asset, the
RFID tag is scanned any time part is replaced or a service order
is opened. The tag is also scanned as a machine goes in and out
of use. The resulting data can be used to determine uptime/
downtime, as well as reliability analytics.
Another example of the use of RFID tags can be in a manufac-
turing process where a part can be tracked as it makes its way
through the various workstations from raw material to �nished
product. Picture an engine block as it starts out in the foundry
and stops at the various stations along the path to a �nished
engine assembly. In this method of tracking, the base object can
be taken in and out of the main process with all of the history
of the object kept with it.
The use of radio technology means that RFID tags can employ
each of the �ve radio frequencies: low (LF), medium (MF), high
(HF), very-high (VHF) and ultra-high (UHF). Radio waves are
transmitted in a straight line. High-frequency radio waves are
shorter in length, meaning that more data can be transmitted
in a shorter time. Low-frequency waves can be transmitted over
greater distances because they “string out” their data pack-
ages over a longer wave length and are less impacted by terrain
(or obstacles). Generally, HF technology is better in conditions
where obstacles to “line of sight” might be present but the de-
sire to get great data sent over a short burst (time) is necessary.
RFID systems use one of three
methods of transmission: electro-
magnetic coupling, electromagnetic
induction and radio transmission.
Coupling uses the lowest frequen-
cies, induction the mid-range
frequencies, and radio transmission
the highest frequencies. Electro-
magnetic coupling is limited as it isn’t good at short range from
tag to antenna (less than 150 mm). Electromagnetic induction
improves transmission at distances of more than 150 mm up to 1
meter, while radio transmission has effective transmission up to
10 meters. To summarize all of this, electromagnetic transmis-
sion methods hold up better under “dirty” environments, such as
automotive and metal-processing plants, while radio transmis-
sion is better where the environment is cleaner, giving the ability
to mount the antenna farther away from the tag.
The traditional features of RFID technology help to keep it at
the forefront of industry. A tag can be read from and written to
without physical contact. This helps to keep the antenna at a safe
distance from the process. The combination of an object and its
pertinent data means that large data doesn’t have to reside on a
data concentrator. The information resides on the tag itself, and
the antenna simply accesses that data long enough to determine
the next stop in the trip or, alternately, add to the data stream for
the object as it moves along the road to the next destination.
At this point in the discussion, it would make sense to bring
up some talking points about another identi�cation technology,
barcodes. Barcode technology is based on the reading of dark and
light regions that are coded to represent numbers and/or letters.
Early scanners used oscillating mirrors to de�ect light across a
coded bar where the receiver would decode the regions of dark
and light into an alphanumeric string. Unlike RFID, early bar
RFID 2.0
Tags can come in a variety of shapes and sizes to suit the
application.
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technology trends
codes were one-dimensional (or linear) and could be used for little
more than a pointer to data that must be stored and retrieved on
another device or medium. A common medium was paper, where
information was added by means of pen or pencil and a reference
code somewhere on the paper record would tie that information to
a matching code af� xed to the object being tracked.
The need for more prompted the creation of two-dimensional
bar codes. These codes combine horizontal and vertical lines to
embed data within the code, much like an RFID tag. One very
popular 2D code is a QR code. These can be found on products at
the retailer and also show up in trade magazines and on ID tags at
trade shows. Much like RFID tags, 2D codes can store information
relative to the product or person that they are attached to, but,
unlike an RFID tag, a 2D bar code only contains information avail-
able at the moment that the code is printed. No other information
can be added to the code once it is on the package or label. For
this reason, you will � nd 2D bar codes that, when scanned, can
automatically direct a smart phone to a Web browser landing on a
manufacturer’s website or to an electronic wallet program.
Barcodes rely on data contained in the one-shot printed code
to make a connection to a product or service whereas an RFID
tag is a read/write device that can grow dynamically to the lim-
its of the embedded memory storage media. Like a prize � ghter,
RFID keeps coming back for more. With 2D bar codes somewhat
leveling the playing � eld, new technologies have taken RFID to
even higher heights, perhaps described best as RFID 2.0.
Unlike barcodes that rely on the coding of 1s and 0s, space-
transmission technologies provide a level of data integrity that
can’t be reached by barcodes and data protocols speci� c to RFID
transmission results in error detection of less than 1%. Sixteen-
bit CRC is added to the data as it is transmitted, adding to the
security and accuracy of the data package. RFID doesn’t employ
mechanical devices, so the probability of physical malfunction
is practically eliminated.
Unlike a barcode that depends on the physical interpreta-
tion of coded data, RFID is much more impervious to physical
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The RFID tracking solution that easily integrates with
your existing network.Need to track individual objects moving through your operation? Need an access control system that easily identifies employees with varying access privileges? The best RFID solutions are those which seamlessly integrate into the network your company has already established. And because Telemecanique Sensors’ RFID readers are compatible with worldwide tag standards, our system should easily fit...into yours.
Who should you trust for your RFID solutions?
CD201911-Telemecanique-2.indd 1 10/22/2019 8:10:40 AMCD1911_14_17_TechTrends.indd 16 11/5/19 9:45 AM
contamination of the tag and antenna. The effects of dirt, water
or oil do not impact the capability of the system. Only metal
contamination can impact the transmission of data. Because of
these qualities, direct line of sight or precise alignment of tag
and antenna is not necessary to effectively use the technology.
Some RFID systems even employ antennas that are capable
of communicating with multiple tags at the same time, within
a similar range to the antenna. This improves the ef� ciency of
the application and eliminates the need to provide a signi� cant
range of separation between adjacent objects utilizing RFID tags.
Tags can come in a variety of shapes and sizes to suit the
application. Tags can be read-only (RO), write-only, read-many
(WORM) or true read/write (R/W). An example of an RO tag would
be a tag embedded in a piece of hardware, a WORM tag would be
a tag con� gured with a unique tag within a � eet of tags (like a
sorting bin) and an R/W tag could be an asset management tag.
One sector that makes great use of RFID tags is safety guard-
ing. Noncontact guard switches employ RFID to turn what
traditionally would have been a proximity switch into a safety
device that can only be triggered by the close proximity of an
RFID tag that can only be read by an RFID antenna that is look-
ing for the speci� c data programmed to the read-only tag. En-
hanced RFID guard switches can be employed that required the
deployment of a tag and antenna that are speci� cally matched
to each other only. Unlike a general RFID guard switch where
any antenna in the safety loop can read any matching tag in the
same family of antenna/tag pairs, and enhanced RFID tag can
only be read by its matching antenna. The code on the tag and
in the antenna is unique only to each other.
One � nal method of employing RFID technology that has
gained great general use is key fobs used to permit employee
entry to the place of employment or a speci� c area or room in
the place of employment.
RICK RICE is a controls engineer at Crest Foods (www.crestfoods.com),
a dry-foods manufacturing and packaging company in Ashton, Illinois.
Simply easy!XG RFID Systems communicate usingEthernet/ IP, M odbus TCP/ IP, M odbus R TU,Uni-Telway, and Profibus-DP networks. www.tesensors.com/EasyRFID
The RFID tracking solution that easily integrates with
your existing network.Need to track individual objects moving through your operation? Need an access control system that easily identifies employees with varying access privileges? The best RFID solutions are those which seamlessly integrate into the network your company has already established. And because Telemecanique Sensors’ RFID readers are compatible with worldwide tag standards, our system should easily fit...into yours.
Who should you trust for your RFID solutions?
XG RFID Systems communicate usingEthernet/ IP, M odbus TCP/ IP, M odbus R TU,
CD201911-Telemecanique-2.indd 1 10/22/2019 8:10:40 AMCD1911_14_17_TechTrends.indd 17 11/5/19 9:45 AM
18 / November 2019 / ControlDesign.com
DR. HEINER LANG recently expanded his responsibilities to
include three of Bosch Rexroth’s business units. In August,
Lang joined the executive board of Bosch Rexroth, Lohr a. Main,
Germany. In his new role, Lang will also be responsible for the
three Bosch Rexroth business units that constitute the factory
automation division: automation and electri�cation solutions,
assembly technology and linear motion technology. He will
retain his role as general president of the automation and elec-
tri�cation solutions business unit.
Lang became general president of the automation and elec-
tri�cation solutions business unit at Bosch Rexroth in July 2017.
Before this new role, Lang started his career at Bosch Rexroth as
the head of technology for the industrial applications business
unit in January 2017.
Beckhoff Automation hired Mark Ruberg as packaging
industry manager in a move meant to strengthen its presence
among U.S. packaging and processing OEMs and manufactur-
ers of consumer packaged goods (CPGs).
Ruberg now oversees sales efforts and application sup-
port for new and existing Beckhoff customers focused on the
packaging and processing of goods across the United States
(Figure 1).
Beckhoff has accelerated the introduction of automation
technologies for packaging applications in recent years, such
as with the mechatronic eXtended Transport System (XTS).
Ruberg’s experience in packaging and plastics most recently
involved serving as a regional sales manager for Conair Group
and before that includes seven years at packaging machinery
company ProMach.
Yamaha Motor USA‘s Intelligent Machinery (IM) Division re-
cently welcomed Shinji Kuroda as sales manager for its Factory
Automation Product Line. Kuroda was previously of Yamaha
Robotics in Japan and joined the team to further expand robot
sales in the Americas.
Yamaha’s Robots are seen in production lines around the
globe, with a strong market share in each of three main robotic
product lines: Cartesian (X-Y-Z), SCARA and six-axis robots.
What are three key things that a machine builder, system integrator or manufacturer should know about your company?
Shinji Kuroda, sales manager, factory automation, Yamaha Motor
USA (www.yamaha-motor-im.com), At Yamaha Intelligent
Machinery (IM), we design and produce a wide range
of industrial robotic products, single axis linear actuators,
cartesian robots, SCARA, articulated robots, and more. We offer
a wide range of available solutions so that our customers can
�nd products best suited to their applications. We have more
than 30 years’ experience in the Factory Automation market
worldwide. At our company, we have preserved our own unique
skills developed through this experience, and we pass them
down from generation to generation. We conduct diligent
research to understand the demands of the market and develop
appropriate solutions well ahead of our competitors.
Mark Ruberg, packaging industry manager, Beckho� Automation
(www.beckho�.com), First, Beckhoff has based its
automation platform on PC technology since the
market entry of the �rst PC-based machine controller in 1986.
PC Control continues to provide important technological
momentum for manufacturers and machine builders across all
industries. This is especially true for packaging, which has
largely remained locked in traditional architectures for too long
and is really starting to embrace revolutionary technologies.
Second, the EtherCAT industrial Ethernet system, which
Beckhoff introduced in 2003, is still the fastest �eldbus in the
automation world. Furthermore, Beckhoff has made EtherCAT
technology open to the world as one of the founding members
of the EtherCAT Technology Group (ETG). ETG has more than
5,500 member companies worldwide at the moment. EtherCAT’s
distributed clocks, high speed and ability to support 65,535
devices on a single network allow for a truly deterministic �eld-
bus that has no limitations in terms system architecture.
The future of automation starts here3 industry leaders talk about the direction technology is taking manufacturing
by Mike Bacidore, chief editor
machine input
CD1911_18_26_MachineInput.indd 18 11/5/19 9:50 AM
ControlDesign.com / November 2019 / 19
Third, TwinCAT 3 automation software from Beckhoff turns
the PC-based system into real-time controllers with many
PLC, NC, CNC and robotic runtime solutions. Both the engi-
neering environment and runtime execution reside in the
universal TwinCAT software. Complete automation program-
ming solutions are done within TwinCAT, including machine
control logic, motion control, HMI, TwinSAFE integrated safety,
high-end measurement technology, condition monitoring, im-
age processing/vision, machine learning and more. TwinCAT
supports all IEC 61131-3 programming languages, ladder logic,
structured text, function blocks, object-oriented programming,
PackML, C++ and MATLAB/Simulink. Optimized for 64-bit
operating systems, TwinCAT future proofs applications and
supports multi-core and many-core CPUs.
Dr. Heiner Lang, board member, Bosch Rexroth (www.bos-
chrexroth.com), First, Rexroth, a Bosch company, is
international. We think and act globally and solve
challenges unique to our local markets. We have 50 production
locations, sales and service hubs in more than 80 countries and
we are the market leader in motion and control.
Second, customer focus is key to us, and we see change as an
opportunity to serve our customers. Customer integrity and in-
timacy means more than being a good supplier. It means serv-
ing as a valued partner, and our more than 30,000 associates
are focused on that. This enables us to set trends and provide
game-changing technology that helps our customers succeed.
Finally, technology and innovation are in our DNA. No one can
match our portfolio or Rexroth’s deep industry knowledge. We are
Display of waresFigure 1: Technology has accelerated the introduction of automation technologies for packaging applications in recent years.
(Sou
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CD1911_18_26_MachineInput.indd 19 11/5/19 9:51 AM
20 / November 2019 / ControlDesign.com
leaders and set the industry standard in hydraulic applications,
whether it’s mobile equipment or industrial hydraulics. In factory
automation, we set the innovation pace with electrical drives and
controls as easy to use as a smartphone and linear guideways
connected to the cloud for condition monitoring, and we are
developing autonomous guided vehicles like the Active Shuttle,
which is an intelligent alternative to the conventional milk run.
What new technologies are driving your product development and why?
Dr. Heiner Lang, board member, Bosch Rexroth (www.boschrexroth.
com), The development of new technology and the speed
of innovation is increasing. What drives us across all
technologies is electroni�cation, electri�cation and connectivity,
from a digitalized hydraulic pressure valve in a bulldozer to
machines with sensor-equipped ball screws to connected motion
platforms, like those integrated into an opera stage.
Electroni�cation means we add bits and bytes to the product,
integrate sensors and enable logic and smart function features
connected and controlled by electronic automation and enter-
prise networks. This approach is transforming many technolo-
gies: for example, hydraulic components are far more customiz-
able to the desired application and can be engineered to capture
and communicate historical data for life-cycle monitoring.
Electri�cation is expanding in all industries, and Rexroth is
the pioneer in combining electric drive systems with hydraulic
and mechanical solutions. For many years, our servo-hydraulic
solutions have empowered complex machines, such as simula-
tor platforms, to perform their functions with much greater
dynamics and precision. Currently, we’re developing hybrid
systems for construction machines, an area where combustion
engines and hydraulic drivetrains are still dominant. Recently
for example, we worked with a customer to downsize a rehan-
dling excavator’s diesel engine by 30 percent using a Rexroth
servo-hydraulic power unit. The new power unit saves fuel,
reduces CO2 emissions and produces less noise.
Finally, connectivity, with and without cables, �nds its way into
industrial equipment. We plan to have all Rexroth products able
to be digitally connected to information systems by 2022. The ac-
tive exchange of information about device and system factors like
status, demand and functional behavior increases transparency
and uncovers optimization potential. Our CytroBox, for example,
is apparently a hydraulic power unit, but with its integrated sen-
sors and connectivity, its operating condition can be monitored,
and proactive service tasks can be obtained to optimize OEE.
Shinji Kuroda, sales manager, factory automation, Yamaha Mo-
tor USA (www.yamaha-motor-im.com), Although we cannot
disclose speci�c details about our ongoing develop-
ment, we are nevertheless working diligently in many differ-
ent �elds including collaborative robots (cobots), AGV, AI and
more. We have planted many seeds, so to speak, that when
they develop will meet our customers’ growing demands.
That’s our Monozukuri, a state of mind, the intense spirit to
produce not only excellent products but to also to constantly
improve the production system. Monozukuri is a very unique
Japanese manufacturing style.
Mark Ruberg, packaging industry manager, Beckhoff
Automation (www.beckhoff.com), OEMs and end users
continue to develop data-driven initiatives to
empower continuous improvement efforts and productivity
gains. Data analytics deliver actionable information, but
this new information age in automation is really still in its
early stages.
The data needs of machine builders and manufacturers
have driven Beckhoff to extend EtherCAT’s record speeds by
announcing EtherCAT G and EtherCAT G10, which will offer
communication rates of 1 Gbit/s and 10 Gbit/s, respectively.
On the software side, the algorithms for condition monitor-
ing, predictive maintenance, analytics and machine learning
are being realized now and will continue to evolve. These
technologies are data intensive, but combined with the excep-
tional bandwidth increases of EtherCAT G, they will unlock
productivity gains that deliver dramatic increases in OEE.
How does the Industrial Internet of Things �gure in your business strategy?
Dr. Heiner Lang, board member, Bosch Rexroth (www.bos-
chrexroth.com), IIot is an essential part of our business.
After many years of sophisticated industrial
approaches, from Industry 4.0 to China 2025, we developed our
Factory of the Future vision to present a clear picture about our
strategy: going forward, the only thing in a modern, Industry
4.0 factory that is �xed in place is the building itself; the
technology and production equipment is �exible to meet
ever-changing demands.
It’s an ambitious vision, and to reach it—and make it easy
for both our customers and Rexroth to begin—we focus on
sensors, software and services. The Factory of the Future
machine input
CD1911_18_26_MachineInput.indd 20 11/5/19 9:51 AM
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22 / November 2019 / ControlDesign.com
is data-rich and uses I4.0 sensors sitting somewhere in
the industrial environment to capture that data, such as a
machine or tightening power tool. Without data, the key
ingredient in IIoT, you cannot build a factory of the future.
The rest is hard work, which means developing analytical
software around the data that separates unnecessary data
from the important stuff and provides the right data in the
right way: the indication, trend, signal, alert, etc. that is
needed to make real-time decisions to improve operating
performance. The real value comes from the services that
are wrapped around the sensor and software to optimize
time, money and space.
A very good example is the sense-connect-detect (SCD)
sensor. The device, sensor, costs less than $100. It’s de-
signed for tough industrial environments and can detect ac-
celeration, temperature, magnetism and light. Our custom-
ers use it with a smartphone app, software, that can display
sensor data as well as analyze and collect data. The alarm
function, service, tells the customer when a certain value
has exceeded its limit or notifies the operator or mainte-
nance staff that a check is needed. The sensor provides
manufacturers with an easy, inexpensive and proactive way
to leverage IIoT technology.
Mark Ruberg, packaging industry manager, Beckho�
Automation (www.beckhoff.com), I feel that Industry 4.0
is more comprehensive than IIoT. The initiative is
integral with our product development. Industry 4.0 cohabi-
tates with the world in which our products reside. Of course,
big data is only meaningful if analytics deliver actionable
intelligence. Beckhoff’s people and products are fundamen-
tally familiar with operations, creating a deep understanding
of production realities. This understanding positions
Beckhoff to deliver on the promises of advanced analytics.
Shinji Kuroda, sales manager, factory automation, Yamaha
Motor USA (www.yamaha-motor-im.com), Our robot
controllers are on the leading Edge of actuators
working in the production lines and on the machines. Our
controllers will play a very important role in the IIoT. Using
the abovementioned technological ‘seeds’ that we have
planted, our robotics solutions will lead advanced IIoT in the
exploding robotics market.
How will machine automation and controls alter the way companies staff their operations in the future?
Shinji Kuroda, sales manager, factory automation, Yamaha Motor
USA (www.yamaha-motor-im.com), Machine automation
has, perhaps surprisingly, been done only for very
limited operations and applications such as those that are easily
automated, or those that are perceived to be able to provide a
good return on investment in a short time. Yet meanwhile,
automation is about to be commoditized, and as such, machine
automation will change. It will change not only for such partial
automation as mentioned, but even the factory itself, or the
automotive product itself will become automated and un-
manned. Investment in mass-optimization will be the most
important factor upcoming for all companies, all industries, and
for all applications ultimately. And yet this macro automation,
and the real automation, is needed in the market. Facilitating
this, the most important consideration is the know-how,
supported by experience and reliability. Yamaha has such
know-how thanks to our experience as a robot manufacturer in
such challenging applications as 24/7 factories.
Dr. Heiner Lang, board member, Bosch Rexroth (www.bos-
chrexroth.com), Manufacturing processes will become
more digitalized and connected, while people’s
skillsets will emphasize mind over muscle. If robots and
algorithms take over monotonous, dif�cult or even dangerous
work in factories and of�ce, human workers can focus on
creative and demanding tasks. Designing the processes and
adding human creativity will remain key for machine automa-
tion and control. Success will depend on people’s capabilities to
combine industrial processes and digital systems.
Mark Ruberg, packaging industry manager, Beckho� Automation
(www.beckho�.com), Companies must rethink their
target audience and job descriptions. The most
disruptive technologies (for example, self-driving cars, drones,
robots/cobots, automation, augmented reality, arti�cial
intelligence and so on) are training amazing programmers in
new methods that more traditional automation specialists
might not consider. Controlling the machine is only a portion
machine input
Big data is only meaningful if analytics deliver actionable intelligence. - Mark Ruberg
CD1911_18_26_MachineInput.indd 22 11/5/19 9:51 AM
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CD1911_FPA.indd 23 11/5/19 11:28 AM
of the control needs. Smart factories
require communication horizontally up
and down production lines as well as
communications vertically with
business enterprise systems. Companies
are rapidly exiting the server business
and moving to cloud-based solutions.
So where do companies look for
automation, controls and operations
programmers? For example, consider
more IT-oriented programmers who
know C, C++, object-oriented program-
ming and abstraction layers. These ap-
proaches are far more common in most
current university curricula than ladder
logic programming. We � nd that some IT
students and gamer types get extremely
excited when introduced to automation
technology only after they see that their
software programs can actually manipu-
late and control real-world objects.
How is the development of software solutions impacting your requirements for hardware?
Mark Ruberg, packaging industry
manager, Beckho� Automation (www.
beckho� .com), Beckhoff recently
introduced the eXtended Transport
System (XTS) to the U.S. market. This
mechatronic system creates design
� exibility that allows engineers to
consider solutions previously not
possible. Machine vision, image
processing and machine learning
software solutions are being introduced
into the TwinCAT engineering environ-
ment. TwinCAT 3 provides expansion
capabilities to protect our customers’
intellectual property in the dynamically
changing technology world.
These technologies require controls
and industrial networking to handle
much greater amounts of data. Ether-
CAT has held its position as the fastest
� eldbus in the market since 2003. Now
EtherCAT G and G10 provide even more
bandwidth to handle the increasing data
needs created by technological advances
machine input
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in vision systems and the most demanding motion control appli-
cations. Most importantly, these are fully compatible extensions
that will integrate into standard EtherCAT networks with an
innovative branch controller model, rather than replace them.
EtherCAT is and will continue to be on protocol version 1.0.
Shinji Kuroda, sales manager, factory automation, Yamaha Motor
USA (www.yamaha-motor-im.com), Originally, hardware was
planned and developed � rst, and then software was
developed to maximize the features offered by the hardware,
but now that whole approach has been turned on its head.
Nowadays we � rst consider how we want to automate the entire
system in view of the software. Then we develop the hardware
to realize and implement what was planned in the software.
Dr. Heiner Lang, board member, Bosch Rexroth (www.bos-
chrexroth.com), By the end of this year, Rexroth will
launch its new automation platform, ctrlX Automa-
tion, manufacturing’s answer to the smartphone. This innova-
tive development is a hardware and software solution for factory
automation, connecting the IT with the OT world and bringing a
consumer-like user experience to the shop � oor. To make it
future-proof, we decoupled the hardware from the software,
allowing ctrlX Automation to run software independently from
the hardware. Thus our development is now focused on basic
software solutions such as motion or IoT functions, while at the
same time we have prepared the framework to run customer
speci� c software, customized function blocks or open source
software on our new automation platform.
As engineering and IT continue their convergence, which one is and/or will be making your products better, faster and easier to use?
Dr. Heiner Lang, board member, Bosch Rexroth (www.bos-
chrexroth.com), The ef� ciency of convergence in
engineering and IT comes from the integrated
Ensuring process availability.Providing flexibility.Challenging expectations.
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CD1911_18_26_MachineInput.indd 25 11/5/19 9:51 AM
26 / November 2019 / ControlDesign.com
digital work�ow. Our customers can start with their applica-
tion, and our design and sizing software will suggest a
solution that can be tweaked and tuned jointly. A modern web
technology offers ease of use and can be run continuously
from the ideation up to the commissioning and operating
process. With our app technology, customers can download
functionality from different sources (that are packed in
so-called containers) and can be executed on the control
(snap-technology). This system gives customers the speed
and �exibility to, for example, adapt to new circumstances or
download crucial security updates. Most importantly, our new
products come with the simplicity and intuitiveness of a
smartphone experience.
Shinji Kuroda, sales manager, factory automation, Yamaha Motor
USA (www.yamaha-motor-im.com), Without question, IT is
making life a lot easier. But without engineering, IT
cannot create technological breakthroughs. Thus, they are
working closely together.
Mark Ruberg, packaging industry manager, Beckho� Automation
(www.beckho�.com), Historically, business functions
have been classi�ed into departmental areas — IT,
OT, engineering, accounting, sales and marketing, for
example. This model resulted in “over the wall” issues,
territorial con�icts and power struggles. The information age
blurs the lines between departments while promoting
collaboration through better data. Data-driven organizations
will test the leadership skills of upper management, more
than ever before, to align resources and rewards for achieving
the organization’s desired outcomes.
Looking into the future, how will technology change your company over the next �ve years?
Shinji Kuroda, sales manager, factory automation, Yamaha
Motor USA (www.yamaha-motor-im.com), We can expect
that people’s values will become increasingly
diverse throughout the world as we move forward, and that
issues surrounding the global environment and society will
become more serious and complex. In response, Yamaha
Motor applies its cultivated technology and sensibility to
human-like concerns and the goal of expanding human
possibilities. In this way we believe that we can respond to
the needs of society. The phrase “Art for Human Possibili-
ties” has been created with this concept in mind. Our
company’s aims of expanding human possibilities and
building better lives with society are re�ected in our ideals
of “Advancing Robotics” and “Rethinking Solutions - Taking
on social issues according to the unique style of Yamaha,”
and “Transforming Mobility.”
Mark Ruberg, packaging industry manager, Beckho� Automation
(www.beckho�.com), Among the many advances
Beckhoff is bringing to manufacturers and OEMs, we
can envision machines without control cabinets by utilizing
smart HMIs, distributed and machine mounted I/O, motors
with integrated drives and One Cable Technology (OCT).
Moore’s Law continues to hold true, which gives PCs increasing
power to control multiple machines or entire lines.
After 40 years in the machinery business, I have little doubt
that nearly everything that we can imagine today can be real-
ized in the future. Embracing STEM education and revolutionary
technologies is the only path for future success. Evolution or
extinction is the choice. At Beckhoff, there are unprecedented
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so we can ensure our customers thrive today and in the future.
Dr. Heiner Lang, board member, Bosch Rexroth (www.
boschrexroth.com), We embrace technology as well as
innovation because they’re in our DNA. They’ve led
our company to be more competitive in product performance,
quality and cost. Increasingly, timing has become very
important. Development cycles are becoming shorter and
technologies are merging. This has impacted our organization
and how we work together. It remains important to under-
stand what can be done, how it can be applied and most
importantly: Is there a substantial need and ROI? I am
convinced that digitalization and connectivity will change our
company most in the years to come.
For example, Rexroth uses technology to accurately create
the conditions our products experience over their lifetime. We
correlate the nominal condition of the product with its real
condition before delivery in order to keep a �ngerprint at zero
hour. Connectivity helps — if the customer agrees — to update
on the operational condition. Then we can back trace changes
and jointly �nd ways to optimize the operations, product
design or even guarantee or sell availability. By the end of the
day, this will drive Rexroth to go from a hardware-only com-
pany orientation to a software and service provider on top. We
are prepared for the challenge new technologies will bring.
machine input
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CD1911_FPA.indd 27 11/5/19 11:07 AM
MOTION CONTROL IS critical to manufacturing,
testing and almost any function. These two
stories illustrate how motion control plays a
pivotal role in these companies’ successes.
28 / November 2019 / ControlDesign.com
cover story
CD1911_28_36_CoverStory.indd 28 11/5/19 10:14 AM
In manufacturing, it’s necessary to ensure that parts or
subsystems meet performance criteria before they are sold
or used in larger systems. This type of testing can range
from very simple to extremely complex. However, the complex-
ity of the test doesn’t always correlate with how routine it may
be to accomplish. For instance, as part of a larger assembly,
one of my customers manufactured an array of small pushbut-
ton switches. Before the parts were sent to the next step in the
process, speci�c tests for functional operation had to be per-
formed. One way to do it would be to have workers push all the
buttons while monitoring an indicator, but that is extremely
monotonous work. Furthermore, the customer was concerned
that defects might be missed due to human error.
Testing requiredThe customer wanted to create an automated test �xture that
would be capable of testing the switches better, faster and more
reliably than human testing would. In addition, it wanted the
ability to make minor changes to the testing parameters to ac-
commodate future changes in the product.
The switch operation was tested to ensure the contacts on
the switch closed after a predetermined press distance. The
force used to press the button was also tested to con�rm it did
not exceed a setpoint limit. Finally, testing was performed to
ensure that the contacts opened when the button was released.
For product safety during the test cycle, it was necessary to
limit the force to assure the system wouldn’t break any part
of the assembly if pushed too hard. This was needed in case a
switch had been mounted incorrectly.
There was a possibility that the testing parameters might
change in the future, and the customer wanted to plan for
these changes. These included the push force, distance to
push and the physical positions of the buttons in the array. In
other words, the number of buttons in an individual array or
the number of button arrays may change in the future, and the
customer needed to be prepared.
By the time the customer engaged us, its engineering team
had developed a pretty solid concept that involved plugging
multiple switch arrays into a �xture electrically connected to a
programmable logic controller (PLC). Through the �xture, every
button was connected to an input point on the PLC, so each
button pressed would turn on unique input.
The PLC would command the automation to move to a but-
ton’s x-y coordinate position and then push the button while
monitoring that both the button-pushing mechanism and the
button operated correctly closing the switch contact at the
proper push distance. This way, the customer could reliably
record a pass-or-fail result for every single button.
ControlDesign.com / November 2019 / 29
Communication simplifies test system designAutomation of product testing with IAI hardware and EtherNet/IP communication successfully
eliminates monotonous manual labor and human error
By Ray Marquiss, Valin
3-axis push button testerFigure 1: Motor-driven actuators and motion controllers were designed and pack-aged into a simple and capable test system.(SOURCE: INTELLIGENT
ACTUATOR)
CD1911_28_36_CoverStory.indd 29 11/5/19 10:15 AM
A 3-axis motion solutionUsing electric, motor-driven actuators
and motion controllers from one of
our vendors, Intelligent Actuator (IAI),
I helped the customer specify three
very simple motor-driven ball-screw
actuators and appropriate controllers
(Figure 1). Two of the actuators would
be for the x and y movement that would
position the third small, low operating
force electric actuator over each button
where it then moved in the z direction
to push the buttons.
To keep costs down, each axis had its
own simple driver/indexing controller.
Typically, the simple driver/indexing
controllers can be controlled using digi-
tal I/O to recall preprogrammed posi-
tions and command movement to them,
but, with three controllers, that would
be a lot of wiring to design, implement
and troubleshoot. The customer’s PLC
had the capability of using EtherNet/
IP, an industrial Ethernet � eldbus that
allows devices from different vendors
to communicate with each other. The
use of EtherNet/IP had the advantage
of simplifying the connection to the
PLC, reducing the amount of program-
ming that needed to be done in each
controller, and providing more detailed
feedback from the controllers for the
PLC to capture.
The controllers’ connection to the
PLC used common Ethernet cables and
unmanaged Ethernet switches with no
I/O wiring. This networked connection
allowed the PLC to send all the target-
position data to the controllers before
each move, so there was no need to pre-
program move data into each controller.
This had the added bene� t of making it
easier to change positions due to product
changes. The current position variables
and alarm and move completion status
bits could all be passed back to the PLC
over the network connection. This ad-
ditional feedback about each move was
used by the customer to better error-
proof and validate the test.
The z-motion actuator used to push
the buttons was a challenge because the
test required movement to a predeter-
mined position using a preset push force.
If too much push force was required to
actuate the button, it would indicate a
failed button test. However, it shouldn’t
be an alarm or error that would stop
further testing. In addition, the actuator
movement was less than 25 mm, which is
very small for a motor-driven, lead-screw
or ball-screw actuator.
The buttons needed about 3 lbf to
operate, and the actuator speci� cation
was approximately 5 lbf maximum.
The motion controller allowed the PLC
to de� ne moves that not only had the
usual target position, speed and accel-
eration/deceleration, but also allowed
the setting of a maximum push force.
All the available motion settings helped
to determine good switches from bad.
For example, the maximum push force
could be set to 3lbf (60% of max) for
the button-pressing move. If the target
push force was exceeded before the tar-
get position, then the PLC would know
that the button was defective. At the
same time, if the target position was
reached but the button contacts didn’t
close, as determined by the PLC I/O, the
button would be considered defective.
The customer used a PC with SCADA
software as the HMI, which included
data collection and storage for the test
� xture (Figure 2). It also included the
graphical tools, device drivers and data-
base needed. The PC communicated with
the PLC via Ethernet, which in turn com-
municated with the motion controllers.
The operator could use the PC to enter
test-con� guration data, which included
number of switches and number of
cycles per switch, and to start the test.
Next, the test results were stored on the
PC upon completion. A visual display
could indicate the pass/fail status clearly
to the operator so that bad parts were
easily removed.
In the end, the customer was very
happy with the way the system
worked. The number of button tests
completed in a shift increased dramati-
cally, and the reliability of the testing
increased. Furthermore, the time to
build the controls for the test � xture
and the customer learning curve were
both reduced because it could use the
SCADA software and PLC brand that it
was already familiar with because of
the EtherNet/IP interface on the Intel-
ligent Actuator controllers.
Ray Marquiss is senior
applications manager for
Valin (www.valin.com)
in San Jose, California.
Contact him at 800/774-5630.
30 / November 2019 / ControlDesign.com
cover story
HMI supports communicationFigure 2: The customer used a simple SCADA/HMI software package with all the graphical tools, device drivers and database needed to connect, communicate and operate all the devices.(SOURCE: OMRON AUTOMATION AMERICAS)
CD1911_28_36_CoverStory.indd 30 11/5/19 10:15 AM
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While not your typical, grey-metal industrial auto-
mation application, industrial strength controls
are needed to raise and lower custom lighting
pieces onto the TV studio stage set. At Showman Fabrica-
tors, a studio set designer/builder, we created a solution that
controlled and con�gured 20 separate servo motors that were
mounted on the ceiling, 25 feet up.
What made this a dif�cult application was that, for each
automated lighting/scenery con�guration, 20 separate motors
and their programmable logic controllers (PLCs) needed to be
reprogrammed over USB, using PC software. Making the matter
worse, USB communication is a short-range, maximum16-foot
connection. The use of a laptop—on a scissor lift—every time a
change had to be made in the studio set was unacceptable.
Stagecraft solved this problem using SEH Technologies USB
device servers to connect serial devices, the integrated servo
motors, over a TCP/IP network. This gave show set designers
and other industrial automation providers more options when
mounting these servo motors and other USB communication
devices in hard-to-reach places.
Setting the sceneWhen we talk about industrial automation, we tend to think �rst
about such things as factories and oil pumps, not entertainment.
But the electrics team at Showman Fabricators (www.showfab.
com) makes what I like to call “the weird and the wonderful.”
Founded more than 30 years ago, Showman Fabricators
designs and creates custom sets and environments, using all
kinds of materials and shape-building techniques. Whether
it’s the glitzy set of a TV show or a Broadway play, a replica of
an historical street in a museum, or a unique retail or public
space, this company builds 3D structures, as well as associated
electronics, graphics and mechanical parts in a state-of-the-art
facility in Bayonne, New Jersey.
Showman is riding a wave of innovation in theater technol-
ogy. In general, this is due to developments in industrial auto-
mation including IP-enabled motion control and 3D printing.
An example of this innovation can be found in an automated
scenery system we created for a new TV studio in New York
City. The project involved 20 ClearPath integrated servo motors
from Teknic. Each motor was used to raise and lower an illumi-
nated scenery piece. Adjusting the elevation of the set lights is
common function as it changes the size and the feel of the set,
as seen through the camera.
Motor control, setup, monitoring Hanging from the studio ceiling 25 feet up, the servo motors
hoist these scenic elements—large light rings containing LEDs
that shine in multiple colors—on command to speci�ed posi-
cover story
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Motor control when hanging from the ceilingShow-biz sets up the scenery using industrial automation control system hardware, motors and USB communication device servers
By Ryan Poethke, Showman Fabricators
CD1911_28_36_CoverStory.indd 32 11/5/19 10:15 AM
tions above the studio’s �oor. These posi-
tions are pre-programmed into PLCs, the
brains behind many industrial automa-
tion systems. The commands are sent
over Ethernet, strung up into the ceiling,
from the stagehand’s touchscreen opera-
tor station at �oor level to the motors
above (Figure 1).
The integrated servo motors must be
calibrated, monitored and programmed
through Teknic’s ClearPath motor setup
program (MSP) software running on a
PC. This PC-to-motor communication
is needed to commission and tune the
servo motors with such parameters as
the weight of the scenery element they
lift, which may change. And that, in
turn, requires a one-to-one USB connec-
tion, with a cable length limit of 16 feet
between PC and servo motor. The Clear-
Path software is also used for system
monitoring and possible troubleshoot-
ing, to ensure the precision of those
positions and movements.
Problems working above the scene Manually plugging each of 20 ceiling-
mounted motors into a PC via a USB-
cable connection, presumably while
standing on a scissor lift, was not going
to work. The only practical way that
the Showman Fabricators team could
ef�ciently tune servo motors that were
mounted on the ceiling was by simulat-
ing that direct USB connection over the
existing Ethernet network.
This was only the second project in
ControlDesign.com / November 2019 / 33
Technology in the studioFigure 1: Ceiling-mounted servo motors with USB connectivity over Ethernet raise and lower lighting elements in the new studio using an automated system run by PLCs.
(SO
URC
E: S
EH T
ECH
NO
LOG
Y)
SEH Technology in the StudioBringing USB Connectivity to Ceiling-Mounted Motors
CD1911_28_36_CoverStory.indd 33 11/5/19 10:15 AM
which we used these particular servo
motors. In the previous project, the mo-
tors were installed at �oor level, so acces-
sibility was not an issue. This is the �rst
time we wanted to put them up in the air,
which led us down this design path.
That path led me to a PLC-programming
discussion forum, where I picked the
brains of generous fellow engineers. I
asked forum members to recommend a
solution with crash-resistant software,
as rebooting devices hanging from the
ceiling to reestablish connectivity was
also a non-starter. I also required easily
customized addressability, so that each of
20 devices would have logical and easy-to-
understand names. The control system al-
ready had a 24 Vdc supply I also requested
a solution that required no separate sup-
ply and that was DIN-rail mountable.
We needed a way to communicate
over Ethernet with the servos, so we
needed to do USB communication over
our Ethernet TCP/IP network, which is
how I posed the problem. Ethernet was a
logical choice for us, as we already had a
network in place for PLC-based control of
the automation system.
Forum responders came up with sev-
eral USB device servers for me to try.
A connected solutionSEH Technology’s INU-100 USB device
server was chosen for several reasons.
Importantly, they were able to con�rm
lead time for a relatively large quan-
tity, 20 units. Equally important, test
samples are a standard service at SEH,
something other vendors were unwill-
ing or unable to provide.
SEH Technology sent a sample INU-100
for testing with the servos. This was criti-
cal, as Showman management wouldn’t
commit to purchasing 20 USB device
servers with the chance there would be
incompatibilities. Testing was needed.
I set it up on the test bench with my
laptop and had the thing talking to the
servo in about 10 minutes. The servo’s
USB port was cabled to the INU-100, and
the INU-100’s Ethernet port to the exist-
ing Ethernet local area network (LAN)
cover story
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19 April Control Design 015-5815.indd 1 3/21/19 4:17 PMCD1911_28_36_CoverStory.indd 34 11/5/19 10:15 AM
switch. Then, using the software tool,
SEH UTN Manager, to establish, manage
and organize access to the USB device,
the motor was assigned a meaningful,
friendly name.
Testing showed the INU-100 USB
device servers from SEH Technology
worked well converting USB communi-
cation for transport over Ethernet, and
testing proved it worked with the previ-
ously installed Ethernet network used by
the PLC and human-machine interface
(HMI). It’s nice because I can have 20 of
these things sitting on the network and
just talk to the motor that I need to set
up. I’ve played with a couple of other
device servers over the years, and these
were certainly the most user-friendly to
set up and very stable.
Fabricating the solutionOur automation & electrics department
team built a Showman-Fabricators-
branded control cabinet, called a Light
Ring Winch Controller, for each of the
20 servo motors (Figure 2). Each cabinet
exterior is also labeled with two IP ad-
dresses: one for the PLC controlling the
motor’s routine operation and one for
the USB device server for con� guration
and programming of the servos.
Each double-sided cabinet, built with
a center backplane for compactness
Polyester
Die-cast Aluminum
StainlessSteel
IndustrialWall-mount
Polycarbonate
Scene motor control cabinetFigure 2: For each of the 20 scenery-lifting mo-tors, Showman Fabricators assembled this light
ring winch control cabinet with external controls, which also includes two internal control panels. (S
OU
RCE:
SEH
TEC
HN
OLO
GY
)
CD1911_28_36_CoverStory.indd 35 11/5/19 10:15 AM
and serviceability, houses all the con-
trol hardware. One back panel contains
the motor power and con�guration
hardware, as well as the scene light
control (Figure 3). This includes the
motor braking resistor, LED dimmer,
power supply, circuit breakers and the
INU-100 device server that bridges the
integrated servo motor controller’s USB
port to the Ethernet TCP/IP network
and then its ClearPath MSP software
installed on a separate PC.
The other side of the light ring winch
controller cabinet contains the PLC that
directs the motor to move the lighted
scenery and related control relays and
power supplies. It also includes an Eth-
ernet switch.
We used AutomationDirect BRX PLCs
and Teknic ClearPath servo motors com-
municating via Ethernet. The externally
mounted ClearPath servo motor is an all-
in-one, compact package that includes a
matched motor and drive.
A key piece of control hardware was
the SEH Technology product that con-
verts USB signaling for transport over
Ethernet TCP/IP. As noted, while the
servo motors can be controlled by the
PLC via Ethernet, to bring the motors’
USB connectivity for con�guration and
programming from the ceiling down to
stage level, we installed INU-100 USB
device servers from SEH Technology into
the control cabinet of each motor.
I can easily foresee future orders for
more such device servers, as freedom
from scissor lifts and the possibility
of remote access using a VPN gives
me added design �exibility for future
projects involving moving parts or other
USB-accessed hardware.
This is especially true if we use these
Teknic servo motors again and need to
mount them where they’ll be inacces-
sible. I can de�nitely see us using the
device server again. Just being able to
talk to the motor over a network with-
out having to be directly attached via
USB to it or the control cabinet is very
helpful for us.
Ryan Poethke is an
automation and electrics
designer at Showman
Fabricators, based in
Bayonne, New Jersey. Contact him at
718/935-9899.
cover story
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Power and communicationFigure 3: The back panel contains the motor power, LED dimmer and configuration hardware including SEH Technology’s device.(S
OU
RCE:
SEH
TEC
HN
OLO
GY
)
CD1911_28_36_CoverStory.indd 36 11/5/19 10:15 AM
C
M
Y
CM
MY
CY
CMY
K
IDECFlushMtAd_ControlDesignR2FAOLprint.pdf 1 10/25/19 10:50 AM
CD1911_FPA.indd 37 11/5/19 11:08 AM
THE RESURGENCE OF Spyder Manufactur-
ing (www.spyderman.com) in Placentia,
Californiz, illustrates how the fate of a
shop can be tied to its machine-tool in-
vestment decisions. It’s also the improb-
able story of how this second-generation
company stumbled upon a business
breakthrough: CNC that is intuitive and
empowering (Figure 1).
A second chanceOriginally a manufacturer of lawn and
garden parts and accessories, Spyder
Manufacturing has been through several
transformations. Once employing more
than 30 people, the company experi-
enced a sharp decline when global com-
petition forced a downsizing of produc-
tion, employees and pro�ts.
Back then, Gary Monnig would often
say that the machines owned by Spy-
der were so old and rudimentary that
the company “maintained a stable of
hamsters just to power them.” Spyder
was spending thousands of dollars for
outsourced machining, both locally
and overseas, especially for more
complex parts.
38 / November 2019 / ControlDesign.com
CNC
Regeneration Figure 1: Gary Monnig and sons Justin, Matt, Nathan, and Jacob have revitalized their manufacturing operations by achieving game-changing returns on their CNC investments.
by Dave Perkon, technical editor
Greater return on CNCHow Spyder Manufacturing climbed to the top
(Sou
rce:
Spy
der M
anuf
actu
ring)
CD1911_38_41_Feature.indd 38 11/5/19 10:18 AM
“There was nothing advanced about
the shop,” Matt Monnig recalls. “So I
asked my dad if I could look into how in-
vesting in CNC-based machining might
revitalize our shop. He said absolutely,
and, no more than �ve minutes later,
entirely by coincidence, a CNC machine
tool dealer walked in the door.”
A fever for changeSoon, a new Fryer MC40 milling ma-
chine, sporting a Siemens 840D control
was delivered and installed on the
company’s shop room �oor. There it
stood, awaiting the arrival of Fryer’s �eld
service engineer to instruct the staff on
its operation.
After graduating from high school,
Matt had helped his dad run the com-
pany, but he had only dabbled in the
machining side of things. “I didn’t know
anything about machining when the new
machine arrived,” he candidly recalls. “I
didn’t even know how to turn it on.”
Not soon after, Fryer Machine Sys-
tems’ �eld service engineer, Trever Lowe,
arrived to begin what was scheduled to
be four days of training. However, almost
at the outset, Matt Monnig said he was
feeling lightheaded and nauseated and
“needed to lay down for a little bit �rst.”
What they didn’t know was that
Monnig had the �u. He was taken to a
hospital emergency room, pumped with
�uids and given two days of care. When
he returned to the shop at the end of
the week, he was ready to learn CNC
machining. But now there were less than
four hours of scheduled instruction re-
maining—hours that would prove to be a
turning point for the company.
The power of intuitive CNCHaving earned a living as a tool and die
maker, Trever Lowe may be among the
last of a dying breed. He joined Fryer
Machine Systems because he wanted
to work for an American machine tool
manufacturer. And he wanted to teach.
One of his �rst assignments with Fryer
was to travel to Spyder Manufacturing
to teach Matt Monnig how to set up,
program and operate their new Fryer
machining center.
“When Matt returned to the shop after
being hospitalized for two days, I realized
that we had about four hours of sched-
uled instruction time left,” Lowe recalls.
“So far, we had only walked through how
to create tools and basically move the
machine around. But now we’d run out of
training time. So I decided to go right into
the complex stuff—contour milling.”
Calling upon his many years as a
machinist, Lowe understood that what
his new student needed to learn was the
one thing that every future machinist
needed to learn.
“Today’s machine tool and manufac-
turing market needs more than button
pushers,” Lowe says. “Intuitive CNC is
the �rst step. Fryer Machine Systems
machines enable the machine opera-
tor to shine. They can start to write
their own programs at the control.
Other companies try to compete in
the conversational market, but Fryer
Machine Systems chose Siemens CNCs
because they are truly intuitive, �rst
and foremost.”
When learning to program a Fryer
machine, if you can understand the com-
plex stuff, then in time you will �gure
out the simpler stuff, Lowe concludes.
“So that’s what I did. In less than four
hours, I showed Matt the most complex
programming.”
In the span of a few hours, Matt
needed to learn to use a CNC machine
for the �rst time. Not only that, but he
was learning on one of the world’s most
powerful controls, the Siemens Sinu-
merik 840D, to program complex contour
milling, right at the machine.
ControlDesign.com / November 2019 / 39
At the displayFigure 2: Matt Monnig programming contour milling at the machine using machine step programming.
(Sou
rce:
Spy
der M
anuf
actu
ring)
CD1911_38_41_Feature.indd 39 11/5/19 10:18 AM
“After those few hours of training,
I left with doubt in my mind. I � gured
nothing would work, that he would crash
the machine and it would be a complete
catastrophe,” Lowe recalls. “But that’s
not how it went. It went completely the
opposite. Ever since, when customers ask
me how much training time is needed
on one of our machines, I tell them we
schedule 16 hours. Then I tell them about
Matt, someone who didn’t know anything
about CNC, but who in less than a day
picked up enough CNC know-how to
relaunch his business (Figure 2).”
Programming at the machineAhead of Lowe’s arrival, Matt was a
restless student in waiting. In� uenced
by conventional wisdom, he had in-
vested more than $4,000 in CAD/CAM
programming software.
“I bought and trained on the soft-
ware,” Matt admits. “But I never used it,
because it turned out that the Siemens
control has something called ‘conversa-
tional programming.’ That’s what Trever
showed me during our short training
session. I just found it so much easier to
understand and to work with than the
complicated off-line software.”
Lesson learned, say both men. The
ability to program at the control brings
a competitive advantage to a shop. It em-
powers both the operator and the shop
owner to ef� ciently produce more than
they could otherwise. Instead of waiting
for a CAD/CAM programmer to feed a G-
code program to a machine, an operator
can quickly set up the next program and
keep production rolling.
CNC-driven innovationSpyder Manufacturing is also the story
of how a greater return on CNC can
mean a greater return on a shop’s work-
force, enabling a business to leverage the
skills and knowledge of its people to cre-
ate new opportunities for the company.
Matt Monnig recalls how, from the
earliest days of the company, Edward
Jones was an especially resourceful
machinist. Called upon for his hands-on
perspective, Jones found ways to create
new product ideas, using whatever were
the tools of the day, long before the
dominance of CNC machining.
As Matt recounts, “Not long after we
bought our � rst Fryer machine, I drew
up an improved version of our climber
product. But the immediate feedback I
got was, ‘No. That will never work.’ But
then I showed the sketch to Edward, and
he said, ‘Let me make a sample.’ And so
he handmade a sample, and we looked
at the tools and what the new Fryer ma-
chines could do, and we all said, ‘Wow,
that will work.’”
The new product design was soon vali-
dated by the CAD/CAM capabilities of the
40 / November 2019 / ControlDesign.com
CNC
(Sou
rce:
Spy
der M
anuf
actu
ring)
New-generation millingFigure 3: With no G-code language barriers in the way, the shop could conceive, design and produce a new generation of products.
CD1911_38_41_Feature.indd 40 11/5/19 10:18 AM
Siemens control. Using highly intuitive,
graphically guided functions such as the
contour calculator, the shop could readily
conduct design for manufacturability
re�nements right on the machine. And at
the same time, they were establishing the
program to produce it. With no G-code
language barriers in the way, the shop
could conceive, design and produce a new
generation of products (Figure 3).
Optimizing resourcesToday, Spyder Manufacturing is a com-
pany transformed. For Gary and Matt
Monnig, achieving a greater return on
their CNC investments includes tak-
ing greater control of their business,
enabling their people and operations to
become increasingly ef�cient.
Now the company produces parts for
customers overseas, rather than the other
way around. Spyder is also able to bring
next-generation products to market and
ef�ciently keep pace with the demand for
those products. Including products made
possible by bridging old-world machinist
skills and knowledge with creative leader-
ship to capitalize on the most intuitive
and powerful CNC available.
“The Fryer machines have paid for
themselves many times over,” Matt Mon-
nig says. The company owns three Fryer
MC40 milling centers, all equipped with
Siemens Sinumerik 840D controls.
Before the company’s investment in
Fryer and Siemens, it took the shop a
month to produce 50 sets of tree climb-
er products. Now the shop produces
nearly 500 sets each month.
Higher production capacity and ef-
�ciency have brought a near tenfold
increase in the sale of the company’s
�agship product, the same product
whose evolved design was �rst thought
never to work.
Looking back, Gary Monnig and his
son Matt consider themselves fortunate
to have stumbled upon the best possible
strategy for revitalizing their busi-
ness. Looking ahead, they plan further
investments in Fryer-Siemens machines,
knowing that anything is possible given
the right set of circumstances: the
managerial desire to ask what if, the
strength of a machinist’s imagination to
see the way, and the power of intuitive
CNC to make it happen.
Bring Your Pi to WorkThermocouple Measurements on a Pi
The MCC 134 thermocouple measurement HAT providesbest-in-class, professional-grade accuracy.
Up to eight MCC DAQ HATs can be stacked onto one Raspberry Pi® allowing users to create multifunction DAQ
solutions based on this low-cost computer.
MCC 134 DAQ HAT• Four thermocouple inputs• 24-bit resolution• 1 second update interval• Supports most thermocouple types• Complete SW library for easy programming• Full set of examples in C® and Python™
www.mccdaq.com/DAQ-HAT
©2019 Measurement Computing Corporation, 10 Commerce Way, Norton, MA 02766 • [email protected]
CD1911_38_41_Feature.indd 41 11/5/19 10:18 AM
PCB push-in design connectorsThe 0150 series PCB pluggable terminal block is a connector
for servo driver applications. It has rated voltage and current
up to 600 V/20 A. The plugs have a clamp-designed lock �ange
directly beneath the housing to minimize the overall width,
which not only helps to save space and makes it easy to plug,
but also allows fast and stable wiring. The push-in mecha-
nism’s spring cage structure
allows solid wires or stranded
wires with ferrules, suitable
for wires up to 12 AWG. The
release tool is an optional
accessory that helps with
single-hand wiring operation.
Dinkle / 832-539-4703 / www.dinkle.com
Cable grommet with built-in plugs and installation jacksWith the AT-M cable grommet, the built-in plugs and installa-
tion jacks are integrated directly into cable entry strips KEL,
KEL-U or KEL-ER. The cable grommet is well-suited for inter-
facing to signal, data, power or hybrid connectors by screwing
them into the grommet’s threads. Even
hose �ttings or pressure compensa-
tion elements can be screwed to the
AT-M. The grommet is built on the basis
of a large AT cable grommet with an
integrated polyamide body. The AT-M
is available with inner threads of M12 x
1.0, M16 x 1.5, M20x1.5 and M25 x 1.5.
Icotek / www.icotek.com
IP67-sealed sensor cable assembliesThe Amphenol Sine PowerBOSSlite series sensor cables are IP67-
sealed and feature a positive key alignment that reduces
the possibility of mismating. These UL-listed
factory-molded industrial patch cords come
in multiple lengths and can be used in
power applications with high cur-
rent ratings up to 23 A per contact. Its
vibration-resistant ratcheting coupling design prevents loosen-
ing in high-vibration applications, and its wire gauge range from
16 to 12 AWG is well-suited for wire-to-board applications.
Newark / www.newark.com
Flexible cablesMachFlex products are engineered speci�cally for dynamic
industrial applications and rated up to 14 million �ex cycles.
These cables can withstand moderate
to continuous �exing movements in
harsh industrial environments with
their oil-resistant and wide operating
temperature ratings. More than 400
unique standard �ex cable construc-
tions are available.
Belden / www.belden.com
POC cables for industrial applicationsSpeci�cally designed for use in welding areas, POC cables are
resistant to weld slag and extreme temperatures. They can
withstand high mechanical stress and temperatures up to
150 °C. This allows the cables to be used in areas where other
cables cannot tolerate the heat, such as weld cells in the au-
tomotive and steel industries.
With a long service life and
reduced downtime, the cables
add an extra degree of reliability
in harsh environments.
Pepperl + Fuchs / 330-486-0002 /
www.pepperl-fuchs.com
Compact M12 connectors and cables for high-power applicationsThese M12 power cables and connectors make it easy to power
drive motors, fans, lighting and other distributed control boxes,
even in tight spaces. The UL-listed products were tested under
UL 2237 and can handle currents up to 16 A or voltages up to
600 Vac/63 Vdc. The full M12 power range includes cable assem-
blies, �eld-wireable connectors and panel-mounted receptacles
Make the connectionCables and connectors bring a design together
42 / November 2019 / ControlDesign.com
product roundup CONTACT US [email protected]
CD1911_42_44_Roundup.indd 42 11/5/19 10:19 AM
with a quick-disconnect system.
Because they are designed for a com-
mon 16-mm panel knockout, these
additions help to simplify panel
upgrades. The M12 connectors come
in both shielded and unshielded ver-
sions and are available in �ve cod-
ings (T and L for dc and S, K and M for ac) to prevent mismating.
Phoenix Contact / 800-322-3225 / www.phoenixcontact.com
Splicing connectorsThe 221Series Lever-Nuts Ex has the features of the 221 Lever-
Nuts, now for extreme and hazardous applications. The splicing
connectors obtain AEx (Class 1, Zone 1) rating when used in
conjunction with the mounting carrier, whether clamped onto a
DIN rail or fastened to a smooth sur-
face. The 221 Ex series is UL-listed
for use with solid, stranded, �exible
and tin-bonded wire with a range
of 24-12 AWG. When connectors are
�ush together within the carrier,
the working voltage is 275 V. For ap-
plications working with voltages up to 440 V, the connectors are
inserted so there is a visible space between each connector.
Wago / www.wago.com/221/us
Continuous �ex tray-rated servo cableThe FD 7TCE is a one-cable solution. Its ultra-�ne copper wiring
and high-strand count make it highly �exible, providing easy
installation in cable chains with tight bending radii, as well as
longevity up to several million
bending cycles. With additional
tray rating, this single-cable
solution goes from tray to cable
track. It meets approval for UL
and cUL CIC.
Lapp USA / www.lappusa.com
M12 food and beverage cablesThese UL-listed Food & Beverage Pro cables are suitable for use
in food processing facilities. In areas where system compo-
nents could come into contact with the food being handled
or re-entering the processing operation, the materials do not
absorb or contaminate the food being
processed. Made of highly-resistant
and robust polypropylene and V4A
stainless steel, these M12 cordsets
satisfy cleanability requirements set
by the EHEDG and FDA. They have an
extended temperature range of -40 to
105 °C, are resistant to high-pressure
cleaners (IP69K-rated) and feature an ice blue jacket color that
helps to identify contamination.
Murrelektronik / 770-497-9292 / murrinc.com
Cut-to-length heavy-duty DLO power cableDLO heavy-duty cable is a 2 kV-rated �exible power cable with
a variety of applications, including industrial control panel
power distribution, power feeds for variable frequency drives
(VFDs) and motor leads in non-
drive-related applications. With
RHH and RHW-2 ratings, these
cables are suitable for use in
both wet and dry locations and
can be used in conduits, ducts,
troughs and control panels. The
maximum rating for continuous use is 90 °C (194 °F) wet or
dry. The cable is oil-, heat-, �ame-, abrasion- and sunlight-re-
sistant and is �exible with a tight bend radius that allows easy
installations in tight spaces.
AutomationDirect / 800-633-0405 / www.automationdirect.com
Plug-in and play readychainsCompletely assembled and quickly installed readychains help
to accelerate productivity for machine and plant manufactur-
ers. Users can con�gure
their own readychains
by choosing from 90,000
e-chain parts, 1,354 cables
and 3,500 electrical com-
ponents. The company will
assemble and deliver the
tailor-made chain in as
few as 3-5 days, and it can be installed at the customer’s plant.
Readychains are maintenance- and lubrication-free and offer
extended durability.
igus / 800-521-2747 / www.igus.com
ControlDesign.com / November 2019 / 43
CD1911_42_44_Roundup.indd 43 11/5/19 10:19 AM
M12 �eld-wireable connectors with push-in terminationThe technology behind the M12 �eld-wireable connectors with
integrated push-in termination allows for fast and safe manual
�eld-wireable assembly without the use of tools. No soldering
iron or screwdriver is required. The customer inserts a stripped
conductor end into the color-coded contact area and closes the
locking mechanism to establish an electrical connection. When
the conductors are terminated, the cable gland is screwed on,
allowing for quick and reliable mounting. The connectors can
be adapted to unique requirements
in the �eld and simplify installation
wherever cable lengths cannot be
estimated in advance. Flammability
class is according to UL 94 V-0.
Turck / www.turck.com
Made-to-order cables in 5 days or lessMade-to-order cables—including M8, M12 and splitters—are
available in �ve days or less through
domestic production. The cable
portfolio is tailored to meet a variety
of industries and applications and
includes features such as consistent
and accurate IP ratings, a range of cable
jackets (TPE, PVD and PUR), overmold con�gurations and high-
quality rugged materials.
Balluff / www.ballu�.com
M12 industrial Ethernet connectors and cordsetsM12 automation technology is available in A-, D- and X-code
industrial Ethernet connectors and cordsets. The connectors
and cordsets deliver high-speed transmission up to 10 Gbps
with overmold tools, cable �ex rating, jacket material, color
and inside and outside usage with cordset lengths up to 90
m. M12-A locking connectors are used for industrial networks
needing power or signal using
CAN, CANopen, Pro�bus PA and
DeviceNet devices. IP67 �eld-
attachable D-coded connectors are
designed for EtherNet/IP, Ether-
CAT and Pro�net devices. X-coded
connectors are well-suited for
industrial network applications in
harsh environments. All cordsets are available in standard 2-,
5- and 10-m lengths.
Binder USA / www.binder-usa.com
RJ45 �eld plugThe �eld-assembled RJ45
�eld plug pro can be used for
structured cabling in indus-
try or data centers with high
data transmission rates up
to 40 GBit/s. Available in 180° straight and 360° angled four- and
two-pair versions, it has a zinc die-cast housing and protected
latch for industrial use. It is designed for �eld assembly without
the need for special tools and is suitable for Power over Ether-
net (PoE, PoE plus, UPoE and 4PPoE), HDBaseT or other multi-
media applications as well as for industry standards such as
Pro�net and EtherNet/IP. A compact design makes the connec-
tor multiport-capable while being fully shielded.
Metz Connect USA / 732-389-1300 / www.metz-connect.com
Cable entry system for light to medium-duty applicationsThe Cable�x X entry system is designed to simplify cable
installation and offer space and time savings. This cable entry
system achieves Type 4X, 12 and 13 with a protection class
of IP65. It is available with 12 or
23 entry points and requires only
one enclosure cut-out. It can be
installed with four mounting bolts
onto enclosures of any wall thickness. A snap-in mounting op-
tion is available for enclosures with a wall thickness of 1.5 mm.
Lutze / 800-447-2371 / www.lutze.com
Stainless steel cord gripsThese stainless steel cord grips are
reliable for all types of harsh and
demanding applications. Both 304
and 316 stainless steel is available
for cord grips, conduit hubs, Liquid-
tight conduit �ttings and jacketed MC cable connectors. They are
UL-listed and IP68- and NEMA 4X-rated from ¼ to 3 in. Connec-
tors also can be custom-ordered.
Remke / www.remke.com
44 / November 2019 / ControlDesign.com
product roundup
CD1911_42_44_Roundup.indd 44 11/5/19 10:19 AM
Three-phase monitoring relaysThe DPB and DPC three-phase
monitoring relays feature an upgraded
switch mode power supply, which
provides a wider input voltage range
to cover different mains voltages while
reducing heat dissipation. The DPB series has an input voltage
range of 208 to 480 Vac, while the DPC series has an input volt-
age range of 208 to 690 Vac. The relays feature an expansive
frequency range of 50 to 400 Hz; noise, harmonics and tran-
sient �ltering; and DIN rail mounting. Three-phase monitoring
relays help to protect motors from severe damage that can
result from loss of a phase, phase imbalance or phase reversal.
Carlo Gavazzi / 847-465-6100 / www.gavazzionline.com
Synchronous servo motorsThe Kollmorgen VLM servo motor series is designed to �ll the
gap between stepper and high-performance servo motors. The
synchronous servo motors have a torque range of 0.5 to 4.5 Nm
continuous and 16 Nm peak, with speeds as high as 6,000 rpm.
They provide a �exible con-
�guration and are well-suited
for many applications in which
stepper or asynchronous motors
are pushed to their limits but
the expense and unused dynamics of high-performance servo
motors is not desirable. The motors are available with standard
frame sizes of 60 mm and 90 mm or NEMA 23 and 34.
Servo2Go / 877-378-0240 / www.servo2go.com
Plug-and-play electromagnetic �owmeterThe smart plug-and-play Picomag electromagnetic �owmeter has
been updated to measure the �ow of electrically conductive �uids
and process temperature and conductivity. It enables commis-
sioning with Bluetooth using the SmartBlue App and seamless
integration with IO-Link technology. It can be installed into any
pipe up to 2 in- diameter, even in con�ned spaces. For this pur-
pose, various process connection adapters
are available, such as NPT thread, R thread,
internal thread, Tri-Clamp or Victaulic.
The �owmeter can be used in applications
in which the focus is on high repeatability
(±0.2% o.f.s.) and reliable measured values.
Endress+Hauser / www.us.endress.com
Modular hybrid motor startersContactron pro is a hybrid motor starter that simpli�es wiring
and safety integration. It has a T-bus backplane system that
rapidly distributes 24-V power, bridges the e-stop enable signal
and adds auxiliary contact modules. These modules allow mo-
tor state feedback and implementation of self-sealing motor
circuits. When used with the PSR-MC38 safety
relay, the motor can permit a SIL 3/PLe group
of emergency shutdowns via one interface.
The modules incorporate Phoenix Contact’s
hybrid technology, which offers three-phase
motor switching up to 5 hp. It has a service life
of up to 30 million switching cycles.
Phoenix Contact / 800-322-3225 / www.phoenixcontact.com
Wrist-connected couplingI/O Coupling is designed to elimi-
nate the need to run an external
cable along a cobot arm. It directly
connects any of Robotiq’s adaptive
and vacuum grippers to the wrists
of major cobot models, including Omron, TM Techman and
Universal Robots. It stores four presets or default setting options
for gripper parameters, including position, force and speed for the
adaptive grippers and automatic vs. manual modes and vacuum
levels for its vacuum grippers. Manufacturers can change these
presets within the user interface by connecting the I/O Coupling
to a PC. The device features industrial-grade components capable
of withstanding harsh work environments and intensive use.
Robotiq / robotiq.com
Optimized data intelligence on the plant �oorTo optimize data intelligence further, the Crimson develop-
ment environment has been updated to allow the use of
expressions in �lters for SQL queries. This allows operators
to pull a subset of data from
the SQL database based on
dynamic search criteria. This
feature can deliver improved
ef�ciencies and process con-
trol, shortening response time
by accessing the right data faster. This is critical when trouble-
shooting production or operations work�ow.
Red Lion / www.redlion.net
ControlDesign.com / November 2019 / 45
product showcaseCONTACT US [email protected]
CD1911_45_48_Showcase.indd 45 11/5/19 10:20 AM
Intelligent position measuring system for absolute linear feedbackThis intelligent displacement sensor provides not only the
absolute position signal for the stroke travel of a piston via
IO-Link but also information about the sensor status and the
current ambient conditions. It monitors the sensor temperature
and the number of starts and issues warnings when a con�gu-
rable limit value is violated. An internal counter monitors the
operating hours over the sensor’s entire life continuously, both
since the last service and the last start-up. This
makes it possible to plan for a possible needed
replacement at the next service interval.
The integrated IO-Link interface enables
fast format changes because of its
parameterization functions.
Balluff / www.ballu�.com
Compact hydraulic/pneumatic position sensorsTM1 series magnetostrictive linear hydraulic and pneumatic
position sensors have a compact housing. A magnetic ring-
shaped marker is af�xed to an application’s moving cylinder
and moves up and down the TM1 rod without contact. The se-
ries offers stroke lengths from 50 to 2,000 mm in 25-mm steps.
Operating pressure is up to
5,076 psi (350 bar) with peaks
to 6,526 psi (450 bar). Both
plug-in and screw type �ange
models are available. Other
speci�cations include absolute
linearity of ≤0.04% F.S. (min. 0.3 mm) and repeatability of ≤±0.1
mm. Ingress protection is to IP69K, and the operating tempera-
ture range is to -40 to 105 °C.
Novotechnik U.S. / 508-485-2244 / www.novotechnik.com
Greater sensing distance ultrasonic proximity sensorsSU, UK, UT and TU series round body and UQ series cubic plas-
tic ultrasonic distance sensors are offered in sensing distance
ranges from 60 to 8,000 mm, in
metal or plastic housings and
M18 (18 mm) and M30 (30 mm)
barrel or head sizes. Discrete and
analog output sensors and mod-
els with both analog and discrete
switching outputs are available.
Discrete models are available with adjustable sensitivity; one
sensor can be standardized for many materials. Operating
voltages are 10 to 30 Vdc; temperature ranges up to 70 °C are
offered on some models. Most sensors provide LED status
indicators and have 2-m output cable or M12 quick-disconnect
connection options.
AutomationDirect / 800-633-0405 / www.automationdirect.com
Customized mounting features of LVDT and LVRT sensorsLVDT linear position sensors and LVRT inductive half-bridge
sensors include mounting features such as blocks or �anges to
�t into the existing footprint of steam turbines, eliminating the
need for turbine operators to update or replace costly legacy
equipment including mounting equipment, brackets and me-
chanical indicators. LVDTs and three-wire LVRTs are installed in
various locations on the steam turbine to track turbine vibration
for health monitoring and maintenance prediction and provide
feedback on the open/close status of steam inlets and governor
valves. As the LVDTs and LVRTs
often are exposed to high vibra-
tions on the steam turbines, the
stainless steel blocks and �anges
are welded to the sensors so footing
remains rugged.
NewTek Sensor Solutions / 856-406-6877 /
www.newtesensors.com
I/O modules for temperature control applicationsThese three groov Epic I/O modules meet precise requirements
for temperature control applications. They include designs
for mixed signal types, signal isolation and channel density.
GRV-IDCSW-12 has discrete input, 12 channels and dc contact
switch status; monitors the open/closed status of dry contact
switches; and provides the necessary excitation voltage to
power the circuit. GRV-IVI-12 has 12 isolated channels, each
con�gurable to one of eight ranges from ±1.25 to ±160 V. It
eliminates the need to segregate I/O signals
over multiple modules. GRV-IRTD-8 with
analog input, eight channels and tem-
perature/RTD or resistor increases
options for accuracy and I/O density
in temperature applications.
Opto 22 / 951-695-3000 / www.opto22.com
46 / November 2019 / ControlDesign.com
product showcase
CD1911_45_48_Showcase.indd 46 11/5/19 10:20 AM
Absolute safety rotary encoderThe WH58MR absolute safety rotary encoder can be �tted with
a hollow shaft of 10 to 15 mm open on one side as an option.
It has an external diameter of 58 mm. The rotary encoder is
�exible when it comes to the type of connection. In addition
to the M12 plug (single or with BUS IN/BUS OUT), variants are
available with a cable outlet or customized plug
connectors. The encoder also offers high shock and
vibration loads, UV resistance, an optional
salt spray-resistant housing and protec-
tion type IP67. It’s operating tempera-
ture range is -40 to 85 °C.
Siko Products / sikoproducts.com
Pressure and level sensors for IoT applicationsThe IoT sensor product line includes pressure sensors and
transmitters, differential pressure sensors and level transmit-
ters that provide either analog or digital output signals suitable
for IoT applications. These rugged IoT sensors can to operate in
harsh environments. These pressure sensors and transmitters
feature high accuracy at both low and high pressure ranges;
isolated construction that enables measurement in
various liquids and gases and in a wide operat-
ing temperature range while providing tempera-
ture compensation; and span and zero correc-
tion. The stable level transmitters are fully
sealed, allowing them to act as submersible
level transmitters.
L-com / www.l-com.com
Integrated motor/actuatorThe GTX100 incorporates the patented inverted roller screw
technology, a high-power density and compact form factor,
making it a suitable replacement for hydraulic cylinders. The
actuator offers the power, precision and programmability of a
servo system while minimizing the maintenance dif�culties of
hydraulics. It has continuous force ratings up to 15,392 N (3,460
lbf), speeds up to 953 mm/sec (37.5 in/sec) and stan-
dard stroke lengths from 150 mm (5.9 in) to 300 mm
(11.8 in). It also includes IP65S (min.) envi-
ronmental protection, seamless integration
into many motion control architectures
and a removable front seal bushing.
Exlar / www.exlar.com
Noncontact RFID safety switches with diagnostic capabilitiesThe SI-RF series safety switches are designed to monitor doors,
gates, and other moveable machine safeguards. The switches
use RFID technology to monitor mechanical guards separat-
ing personnel from a hazard. They can be deployed alone to
safeguard a single machine access point or in a cascade series
to simplify the safeguarding of multiple access
points. Cascade models can be connected in
a series of up to 32 switches using a standard
four-wire cable, T-adaptors, an end plug and just
two terminals on a safety controller. Used alone
or in a series, the switches achieve Cat. 4, PLe,
or SIL CL3 safety ratings.
Banner Engineering / www.bannerengineering.com
Standalone accessory card to prevents false alarmsThe CMC series standalone accessory card provides an adjust-
able current limit alarm for any dc motor controller, prevent-
ing false alarms from predictable increases in current draw.
Compatible with any dc motor controller, the card is wired in
series with a dc motor using a jumper to set a
base current limit trip point. An onboard
OFFSET trim pot can �nely adjust the
trip point, while a TIME DELAY trim
pot establishes how long the motor’s
amperage draw must exceed the trip point
before determining that a fault has occurred.
American Control Electronics / www.americancontrolelectronics.com
Four-port antenna with horizontal/vertical polarizationThe four-port OMNI antenna can be used for WISP, cel-
lular and �xed wireless applications. It has 13 dBi of gain
and can deliver increased capacity offered by 4x4 MIMO.
It provides horizontal and vertical polarization and
operates on the 5.15- to 5.85-GHz frequency range. This
360° omnidirectional antenna features two vertically
stacked OMNI arrays in a single radome enclosure with
one mounting point. It supports one 4x4 MIMO or two
2x2 MIMO radios. This antenna is ideal for minimiz-
ing operator investment in low-density macro or
micropop deployments by having to mount only
one antenna and radio.
KP Performance Antennas / www.kpperformance.com
ControlDesign.com / November 2019 / 47
CD1911_45_48_Showcase.indd 47 11/5/19 10:20 AM
Modular data collection gateway for Edge IoT applicationsThe WISE-710 data gateway is well-
suited for connecting legacy equip-
ment to new mesh networks. Aimed
at harsh industrial environments as
well as in-cabinet applications with limited space, the terminal
features a compact form factor measuring 100 x 70 x 36 mm and
a wide operating temperature range of -20 ~ 55 °C. To enable
remote management, it supports Wi-Fi, 3G, 4G/LTE and NB-IoT
wireless modules that facilitate long-distance data transmis-
sions, over-the-air (OTA) updates and real-time communication.
The gateway is equipped with WISE-PaaS/EdgeLink protocol-
conversion software, which supports more than 200 communi-
cation protocols to enable data collection from legacy devices.
Advantech / www.advantech.com
Linear dc motorsTwo linear dc motors have been added to the LVCM series. Both
are 2 in (50.8 mm) in diameter, and the housings are 5 in (127.0
mm) long. The LVCM-051-127-02 features a longer stroke of 1.75
in (44.5 mm) with a continuous force of 13.8 lb (61.5 N) and a
peak force of 43.7 lb (194.4 N). In comparison, the LVCM-051-127-
03 has a higher continuous force of 22.4 lb (99.5 N), a
peak force of 70.7 lb (314.5 N) and a stroke
length of 1 in (25.4 mm) for applica-
tions with a higher force-to-size ratio.
Moticont / 888-785-1804 / www.moticont.com
Direct Modbus connection to PLCsGSM-PRO2 series communication modules feature a Modbus
RTU (RS-485) interface that enables easy data exchange with
other controllers. The modules operate in slave mode and can
provide a PLC with added functionality via a
plug connection to the RS-485 port directly on
the C-type mounting rail. The GSM-PRO-CON
extension module makes wiring even simpler.
Plugged into the GSM-PRO2 module, it offers
front-access terminals for connection to the
controller. Parameterization software can be
programmed to send a text or email fault mes-
sage to speci�ed recipients when the PLC input
status changes.
Conta-Clip / www.conta-clip.com
Space-saving integrated servo motorThe MDX integrated servo motors provide design modularity
and simplicity for a range of applications. The servo motors
house control electronics at the back, near the feedback device.
No other external electronics package is required to drive or
control the motor. The back of the motor also contains connec-
tors for power, communications and I/O. The onboard controllers
use the same command interfaces as external motor controllers,
including CANopen, RS-485, Modbus and Ethernet
connections as well as discrete I/O interfaces
such as pulse and direction. Command
signals from a robot or machine’s central
processing unit can be wired directly to
the integrated servo motor.
Applied Motion Products / 800-525-1609 /
www.applied-motion.com
Dual rail positioning systemThe DRS-206-05-012-01-EX dual rail positioning stage is de-
signed for applications that require long travel distances. It
uses a cog-free brushless linear motor to generate a continu-
ous force of 12.4 lb (55.6 N) and a peak force of 37.4 lb (167 N)
with a total stroke length of 210 in (5,341 mm). The noncontact
1-micron resolution encoder allows for precise positioning.
The stage is capable of speeds in excess of 200 ips (5 m/s). It is
guided by dual rigid recirculating ball linear bearings. The
entire stage is assembled on a single piece of
aluminum extrusion, thus reducing
overall system weight.
H2W Technologies / 888-702-0540 /
www.h2wtech.com
Antenna with extended frequency rangeThe ultra-thin ceiling-mount omnidirectional IOSE antenna offers
a wide frequency range of 600 to 3,800 MHz in a single unit. The
low-PIM (-153 dBc) device is available with a plenum 4.3/10 female
connection or a plenum N female connection. The TrueConnect
antenna reduces helps to simplify in-building installations. It pro-
vides coverage in low-signal areas when installing 600 MHz, 700
MHz, cellular, PCS, AWS, 2.5, CBRS DAS in-building
systems. At 8.38 in (213 mm) in diameter, it is low
pro�le, with a maximum thickness of only 0.73
in (18.5 mm) in the center.
Wireless Supply / www.wirelesssupply.com
48 / November 2019 / ControlDesign.com
product showcase
CD1911_45_48_Showcase.indd 48 11/5/19 10:20 AM
publishing teamgroup publisher & vp, content
Keith Larson [email protected]
vp, sales & publishing director
sales teamnortheastern and mid-atlantic regional manager
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Foxboro, Massachusetts 02035
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John M. Cappelletti
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reprintsFoster Reprints • www.fosterprinting.com
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866-879-9144 ext. 194
The only magazine exclusively
dedicated to the original equipment manufactur-
ing (OEM) market for
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CD1911_49_SOO.indd 49 11/5/19 10:22 AM
IS A PLC smart? It’s smart like a reptile, and it can reliably and
robustly control the many things connected to it using its
programmed functions. However, there are different levels of
intelligence needed to keep automated machines, systems or
critical parts operating. For smart machines, the PLC is just a
type of machine intelligence. Several types of control need to
communicate and combine to make a truly smart machine.
Much of these basics on smart machines were discussed by
Peter J. Photos, Ph.D., chief scientist and executive vice president
at Streamline Innovations at the 2019
Ignition Community Conference in
Folsom, California. Photos discussed
several smart communication meth-
ods and types of smart control during
his breakout session about building
intelligent systems of the future.
A typical system starts with the
machine or process controlled by a PLC with a human-machine
interface (HMI), but a smarter machine may remove the HMI and
replace it with an Ethernet cable and supervisory control and
data acquisition system (SCADA). The HMI becomes a client of
the SCADA system viewed on a smartphone. It may also elimi-
nate the thousands of wires entering a control room and replace
it with an Ethernet cable. Smart machines are also monitored
and controlled remotely reducing the need to visit a site.
“Smarter” means easy connection to the cloud, and building
a server and sending data to the cloud adds intelligence. There
are many cloud services out there, and some bit-size cloud-ser-
vices options are scalable such as DigitalOcean. These services
can make deploying, managing and scaling cloud infrastruc-
ture and applications easier.
These smart machines should present the data neatly,
organized and ready for use by a data scientist or modeling
software. Smart machines now and in the future will require a
model and analytics that predict real-time and future opera-
tion. The system should also monitor the data and provide a
text message or email warning, for example, when needed.
So what is a smart machine, or, more simply, what is smart?
“Making machines smart is similar to how humans are smart,
in theory,” says Photos. “Build a pump skid, install a Moxa PC,
install Ignition Edge for an edge-of-network HMI with Web
and data functionality, and it’s smart. Then develop a screen
quickly, add a control program and use off-the-shelf parts and
it’s smart and cost-effective.”
From a conceptual standpoint, some theories discuss four
major areas of your brain; the amygdala, reptilian brain, limbic
system and neocortex. The amygdala is the oldest part of the
brain—the lizard brain. It’s designed to keep you alive with
food, � ght and � ight type reactions. It’s an alarm system that
gets you out of danger with its fast evaluation and response
system to keep the person safe, but it may not always be accu-
rate without additional analysis.
The reptilian brain is your primi-
tive part that keeps you alive as
well. The primitive brain is respon-
sible for the most basic survival
functions such as heart rate and
breathing and orientation in space.
It has very consistent control
mechanisms and has priority over other systems of the brain.
You have little or no control over your heart rate and rarely is it
necessary to think about or control your breathing.
A complex part of the brain is the limbic system or mam-
malian brain. It controls emotions and communication to your
limbs so all parts are in communication to your brain.
A � nal part is the neocortex or the smart brain—the part
that makes you human. It provides the high order conscious
activities including language, abstract thought, creativity, solve
equations, analyze trends and think outside the box.
“Why not structure our control systems in plants using the
same analogy,” asks Photos. “There are some signi� cant com-
parisons. The amygdala keeping you alive and out of danger is
an emergency-stop safety circuit. The reptilian brain perform-
ing second-to-second tasks keeping your heart and breathing
correct is the reliable PLC. The limbic system communicating
to all the parts and ensuring relevant areas stay in touch is the
SCADA software such as Ignition. And � nally, the neocortex is
where we can have fun and get really smart. It’s a high-level,
general-purpose programming language such as Python.”
For smart machines, think about what part of the brain is to
do what and when. “It can speed the development of control
systems for machines and processes,” says Photos. “It’s brains vs.
brawn. Put the brain in a computer next to the PLC and let it do
the advanced calculations.”
The brains in smart machines
50 / November 2019 / ControlDesign.com
Dave Perkontechnical editor
automation basics
For smart machines, think about what part of the
brain is to do what and when.
CD1911_50_AutoBasics.indd 50 11/5/19 10:21 AM
Emerson’s outcome-optimizing controllers, like the PACSystems RX3i CPL410, enable you tomake better decisions by bringing together real-time data and advanced analytics capturedat the edge of your machines. Our next generation control solutions incorporate safety, securityand reliability that give you peace of mind while helping you realize higher performance in youroperations. Work with experts who can help you influence outcomes, generate opportunities, and improve results by bringing you to the leading edge of Industry 4.0.
Turn to the machine control experts who can help you find the edge you need. Visit Emerson.comor reach out to at [email protected] to learn more.
Outcome-Optimizing Controlsat the Leading Edge of Industry 4.0
The Emerson logo is a trademark and service mark of Emerson Electric Co. ©2019 Emerson Electric Co.
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