Automation & Drives
AUTOMATION & DRIVES
VOL 07 | APR-MAY 2014 | ` 100 www.AandD24.in
Automation & Drives
A U T O M AT I O N & D R I V E S
A comprehensive approach towards automation
Also available in China, Taiwan, Singapore, Malaysia, Thailand & Hong Kong
FOCUS Chemical & Process
P. 42, 48
ROUND-TABLE Revamping automation education & training P. 36 A&D - Interview
A&D - Interview
Jason Urso
Dr Oliver Vietze
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VP & CTO Honeywell International (p.34)
In association with
CEO & Chairman Baumer Group
(p.32)
Advt
APR-MAY 2014 I VOLUME 07
Better process-to-product Efficient Manufacturing management
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Unbeatable Control,
Precision, and Flexibility
Lowering cost, increasing productivity, and shortening design times are just some of the challenges industrial engineers face. The graphical system design approach combines productive software and reconfigurable I/O (RIO) hardware to help you meet these challenges. This off-the-shelf platform, customizable to solve any control and monitoring application, integrates motion, vision, and I/O with a single software development environment to build complex industrial systems faster.
>> Accelerate your productivity at ni.com/industrial-control-platform NI Systems (India) Private Limited Phone: 1800 103 9449 (Toll Free) Email: ni.india@ni.com Š2012 National Instruments. All rights reserved. LabVIEW, National Instruments, NI, and ni.com are trademarks of National Instruments. Other product and company names listed are trademarks or trade names of their respective companies. 07926
NI LabVIEW system design software offers ultimate flexibility through FPGA programming, simplifies code reuse, and helps you program the way you think–graphically.
e d i to r i a l
Maintaining high standards! Global competition, complexity, speed, accuracy, regulatory compliance, and customer demands are pressurising manufacturing companies to improve operating performance and at the same time keep the costs low. While automation has clearly been the perceived means to improve operating performance keeping the costs low, research indicates that implementation has been slow, and many times even claimed successes remain functionally fragmented. Many companies struggle even with internal connectivity among various functions, forget about end-to-end supply chains. What is needed to realise the full benefits of automation is to transform the fundamentals of functional connectivity and supply chain management and usher in new waves of collaboration, integration, optimisation, and communication across industries. It is also necessary to gain an understanding of the market drivers and transformational outcome of technological change. The Cover Story in this issue talks on the technological change in automation requirements and the considerations to be taken into account while adopting newage automation technologies or upgrading to new automation systems. I am happy to inform you that, with this issue, A&D India is entering into its 7th year of operation. We hope that you have enjoyed reading the magazine, and will do so in future as well, and you will continue to support our efforts to help us maintain the high standards. We would like to thank the members of our editorial advisory board, our contributors, associates and the advertisers who supported us in our success route. Best wishes!
MORE PRECISION. LASER SENSORS Largest selection worldwide from low-cost up to highest precision Measuring ranges from 2 to 1000mm
NEW High-End series optoNCDT 2300 49kHz; Outputs: Ethernet, EtherCAT, RS422 Handling via Web Browser
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Measuring ranges: up to 3000m
editorial advisory board
Shekhar Jitkar Publisher & Chief Editor shekhar.jitkar@publish-industry.net
Vijay Srinivasan Partner, Effectus Consulting LLP Anup Wadhwa Director – AIA (Automation Industry Association) P V Sivaram MD – B&R Automation Member – AIA Anant Maheshwari Managing Director Honeywell Automation India
Outstanding repeatability Fast response time Compact design
Ganapathiraman G Vice President & GM (South and South-East Asia) ARC Advisory Group Ravi Agarwal Director, Pepperl+Fuchs (Factory Automation) Raj Singh Rathee Managing Director Kuka Robotics India
Dr KLS Sharma Advisor Automation Education & Training Mandar Phadke CEO, Abhisam Software Former Head – Process Control Lanxess India Pvt Ltd Arcot Rajabahadur Automation Consultant
Jasbir Singh Vice President – Electrical & Instrument Essar Project Management Consultants
Thampy Mathew Chairman, Fieldbus Foundation India Regional Sales Director, Pepperl+Fuchs (Process Automation)
Overseas Partner: China, Taiwan, Hong Kong & South-East Asia
A & D I n d i a | A p r- M a y 2 0 1 4
www.micro-epsilon.in MICRO-EPSILON | 94496 Ortenburg / Germany Phone +49 85 42/168-0 | info@micro-epsilon.com Representative for India: IPS Integrated Process Systems | 600 004 3Chennai Phone +91 44 24981786 | www.ipsindia.in
CONTENTS
Market
Management
Focus
Chemical & Process 08 NEWS
32 “We strongly believe in local
42 PERVASIVE SENSING
management” 14 “innovations are coming from SME s ”
Interview with Tom Kindermans, Vice President - Asia Field Operations, ANSYS Inc
Interview with Oliver Vietze, CEO & Chairman, Baumer Group 34 “we help customers change the way
48 DOWNTIME FOR SAFE FUTURE OPERATIONS
they operate” 16 “FOCUS IS ON NURTURING INNOVATION”
Interview with Victor Mieres, Vice President - Emerging Markets, National Instruments
The article highlights the advanced measures used to make a plant modern, safe and environmentfriendly
Interview with Jason Usro, Vice President & Chief Technology Officer, Honeywell Process Solution International
The article briefs on planned factory shutdown by INEOS for cleaning, maintenance and inspection
18 “NEED TO DEVELOP EVOLVING SOLUTIONS”
Interview with Todd Graves, Vice President - Engineering & Technology, Allegion India 20 MARKET TRENDS
Focussing on optimising assets
A feature on adopting contemporary business practices through ALM models 36 ROUND-TABLE
Revamping automation education & training
The article proposes the various measures taken for making the young talent industry ready
Solutions for plant & machine safety
CONTENTS
Advt
Technology
Cover Story 24 BETTER PROCESS TO PRODUCT
64 SENSORS & ENCODERS
Building designer expertise
MANAGEMENT
The article talks on technology changes for upgrading new automation systems 52 SAFETY & INTEGRATION
A read into the latest sensor technologies that brings a revolution in the industrial system designs 68 EVENT PREVIEW
The languages of automation
The article focuses on user-friendly techniques for automation tasks that vary from stand-alone applications to the implementation of classic automation
Platform for automated processes A pre-event report on Automatica 2014 EVENT REPORT 70
Convention of global innovations
A post event report on the recently held Hannover Messe 2014
56 CONTROL & REGULATION
Designing via a new technology
An article on adopting new motion control technologies for better performance
74
Building an idea factory
A post event report on “Leveraging technology for quantum jump in business� by AIA 76 TECH-TALK
62 ENERGY MANAGEMENT
Taking eco-conscious decisions intelligently The article focuses on Energy Intelligent Software for achieving sustainability
Rough & tough cables
The article discusses the latest cable solutions used by the Indian tyre manufacturers
Cover image courtesy: SHUTTERSTOCK
New Products Automation solution for packaging; Energy measurement device; Terminal blocks to fight vibration; Safety light curtains 78 Engineering software tool; Test and evaluation kit for real-time Ethernet; Pneumatic rotary lift; Stripable control cable series 79 Light-weight laser profile scanner; Measuring light grid; Managed switches for Ethernet network 77
Columns 05 06 80 80
Editorial Contents Highlights - Next issue Company index
Advt
market | news
Schneider Electric partners with Ramco Systems
Enhancing deployment flexibility
Schneider Electric has partnered with Ramco Systems to offer advanced process control optimisation solution for cement customers. The partnership will see Ramco’s advanced process optimisation software, OPTIMA, become an important part of Schneider Electric’s solutions for the cement industry and strategically help explore business opportunities. With cement manufacturers The partnership will see Ramco’s advanced focusing their efforts on process optimisation software, OPTIMA, reducing energy and emissions, become an important part of Schneider improving overall performance Electric’s solutions for the cement industry and managing consistent product quality grade, plant operators are looking for solutions that stabilise the production process and maintain optimal operation point for minimal effect on the environment. It also expects to focus on optimisation of kiln and mill operations to its cement customers. It will support increased production volumes, promote ease & uptake of alternative fuels and support human operators for best decisions to change operating conditions.
Siemens PLM’s NX™ Software is now available in a cost-effective private cloud environment. The company has worked closely with NVIDIA Corporation to certify the deployment of NX in the private cloud using virtual desktop infrastructure (VDI) with NVIDIA GRID vGPU (virtual graphics processing unit) technology. This technology enables companies to use central servers with remote access and to host software on a virtual desktop. It also optimises IT resources, enhances deployment flexibility and further expands platform-of-choice option. “Virtual desktop infrastructure” certification enables successful NX deployment in private cloud. The new deployment option enhances flexibility and further expands the wide variety of platform choices available to NX customers. As a result, Siemens and NVIDIA are able to help one of their joint customers, Turkish Aerospace Industries Inc. (TAI) successfully to deploy NX in a private cloud environment. “By deploying Siemens’ NX in our private cloud using the NVIDIA graphics environment, we can optimise resources and eliminate strains on IT,” said Serdar Kaya, IT System Engineer, TAI.
> MORE@CLICK ADI03429 | www.AandD24.in
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Bringing advanced sensing technology to academic Institutions
HGS Automation ties up with Creaform
Pepperl+Fuchs along with Ajay Kumar Garg Engineering College (AKGEC) have recently established an advanced training set up for industrial sensing at Center of Relevance and Excellence, AKGEC Ghaziabad. It is expected to aid the institution in imparting education on relevant technology and provide a good platform to give hands on training to students for a deeper understanding of the subject through real life Industrial equipment. The It is expected to aid the institution training set up and course in imparting education on relevant material are unique and tailored technology to meet the growing needs of Indian industry and engineering education in the automation domain. It covers in-depth industrial scenarios and has complementing hardware which suggests and trains the best-fit technology and solutions. It aptly covers the domain of modern industrial sensing, bus based technology, RFID and positioning systems. Students can be trained in these areas on world class training kits too.
HGS Automation has recently announced a strategic alliance with Creaform. Under the agreement, HGS Automation will sell, integrate and commission fully integrated Metrascan-R solutions, which provide robot-mounted optical CMM 3D scanners for automated inspection on and off the production line. Based on the Metrascan 3D technology, the The turnkey solutions provide better R (robot) version offers high accuracy, quality, accuracy and repeatability portability and an intuitive interface to clients in need of 3D scanning devices for on-line measurements in the automotive and aerospace industries. Incorporating this technology, this solutions offer customers benefits like speed, fully configured and programmed versatility, high accurate measurements up to 0.085 mm in shop floor conditions, C-track’s dynamic referencing mode, automatic selfcalibration ensuring constant accuracy during the systems entire life cycle and continuous parameter monitoring such as temperature and accuracy, ensuring constant device accuracy during a systems entire life. The turnkey solutions provide better quality, accuracy and repeatability. Moreover, they reduce health and safety issues for repetitive tasks handled by humans.
> MORE@CLICK ADI03431 | www.AandD24.in
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A & D I n d i a | A p r- M a y 2 0 1 4
market | news
Emerson appoints Neoteric Infomatique as national distributor
Memex Automation partners in THINC
Emerson Network Power has recently announced that it has appointed Neoteric Infomatique as a national distributor for small and medium uninterruptible power supply (UPS) products in India. The company plans to address the growing demand from enterprises for innovative and technologically superior back-up power solutions devised for modern day IT requirements. “IT resellers in India will now have access to Emerson’s reliable and highly effective UPS solutions which can thrive in India’s power infrastructure,” said Sanjay Zadoo, Country Manager - Channel Business, Emerson Network Power, India. Emerson’s small and medium UPS product portfolio includes the online and line-interactive product range. “The company’s back-up power solutions enable enterprises to have reliable back-up power and thereby, protect their IT infrastructure. We will focus on on-boarding and enabling partners to provide Emerson’s state-of-the-art UPS solutions that facilitate real-time infrastructure optimisation,” said Rakesh Kaul, National Head-Sales, Neoteric Infomatique Ltd.
Okuma has recently announced the partnership of Memex Automation in THINC. Memex, which specialises in networking machine tools and administration computers allows productivity and other statistics to have the ability to be sent digitally anywhere in the world. The solution enables manufacturing execution system improving profitability, reducing waste and ensuring compliance with regulations. The RFID asset management shows asset information in real time and works hand-in-hand with OEE, Lean and Six Sigma. The merlin machine The solution enables monitoring typically increases shop floor manufacturing execution efficiency by 10%. Also, direct numerical system improving profitability, control allows simultaneous upload and reducing waste and ensuring download of multiple CNC controls. “We are compliance with regulations excited to announce our new partnership with Memex Automation. Their expertise and dedication to help manufacturers obtain the highest level of profitability possible through real time productivity information tools, makes them a great addition to partners in THINC.” says Jeff Estes, Director of Partners in THINC.
> MORE@CLICK ADI03433 | www.AandD24.in
ABB substation to help reinforce Indian power grid
> MORE@CLICK ADI03434 | www.AandD24.in
MATLAB EXPO 2014 in Bengaluru and Pune
ABB has won an order worth around $18 million from Power Grid Corporation MathWorks' MATLAB EXPO 2014 will be hosted on July 10, 2014 in of India Limited (PGCIL) to construct a 400 kV gas-insulated switchgear Bangaluru and July 15, 2014 in Pune. It will bring together engineers, (GIS) substation at Kolhapur, Maharashtra. It scientists and partners to exchange ideas helps strengthening inter regional grid and explore the latest product capabilities between the Western and Southern regions. in MATLAB and Simulink. The EXPO will “This substation will boost power feature presentations by the company’s transmission to the Southern region and technical experts and customers in India increase inter regional transfer capacity” along with an exclusive exhibition area said Oleg Aleinikov, Head, Substations showcasing cutting-edge demonstrations. The substation will boost business, ABB. Key product supplies include Jason Ghidella, Technical Marketing power transmission to 400 kV GIS, shunt reactors, control and relay Manager, MathWorks, will present the the Southern region and panels based on IEC 61850 platform. The keynote address entitled ‘Directions in increase inter regional latest generation GIS has a compact, Technical Computing and Model-Based transfer capacity modular and eco-efficient design, enabling Jason Ghidella, Technical Design.” He will also discuss how MATLAB Marketing Manager, reduction in product volume, footprint and and Simulink are equipping engineers and MathWorks, will present the weight, while enhancing eco-efficiency. The project is scheduled for scientists to respond to challenges and keynote address entitled completion in 2016. ABB has previously supplied several GIS substations to opportunities arising out of mega technology ‘Directions in Technical PGCIL and has recently commissioned the 765/400 kV substation at trends such as Big Data, cloud and mobile Sholapur, ahead of schedule. The key node enabled the completion of the computing, internet of things, low-cost Computing and Model-Based Design Raichur-Sholapur transmission line, linking the Southern grid to the national programmable micro-processors, online transmission grid. education and more. > MORE@CLICK ADI03435 | www.AandD24.in
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A & D I n d i a | A p r- M a y 2 0 1 4
market | news
ANSYS honours engineering simulation teams
Launching SPS Automation India
ANSYS has recently honoured two teams competing in the BAJA SAEIndia all-terrain vehicle (ATV) development contest organised by the Society of Automotive Engineers (SAE) and presented an engineering simulation award. Team Nemesis from the College of Engineering at Pune University and Vellore Institute of Technology’s Team ANSYS congratulated two teams Kshatriya successfully leveraged competing in the BAJA SAEIndia ANSYS simulation for their individual ATV designs. They used ANSYS Mechanical™ to analyse its vehicle’s suspension components, chassis, gearbox casing and brake pedal to reduce the weight of its ATV while ensuring maximum strength. “ANSYS instituted the Engineering Simulation award in 2010 to recognise student competition teams and organisations who take advantage of simulation to optimise their designs, whether it’s an ATV or formula-type race car,” said Murali Kardiramangalam, Academic Program Director, ANSYS. “These contests are crucial to facilitate learning simulation outside the classroom and by providing software, training and support to these teams, the company is helping to nurture the next generation of innovative engineers,” he added.
Messe Frankfurt India Trade Fair confirmed its partnership with Pepperl+Fuchs to launch the edition of SPS Automation India. “P+F is glad to partner with SPS Automation India for its debut show and looks forward to displaying the existing range of products and technology trends in the field of sensing and measurement,” said Ravi Agarwal, Director, Pepperl+Fuchs. SPS Automation India, will take place on February 5-7, 2015 at SPS Automation India -Driving confirmed Mahatma Mandir Convention their partnership with Pepperl+Fuchs to and Exhibition Centre, launch the edition of SPS Automation India Gandhinagar, Gujarat which will be an ideal platform for this development while opening new avenues and business prospects for the participating companies. It will display a vast range of products & systems and also host a parallel seminar. “The alliance has strengthened our resolve to provide an international standard business & networking platform for the sector’s players, while focusing on modern automation solutions for the Indian market”, said Raj Manek, Managing Director, Messe Frankfurt India.
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Kollmorgen partners with Ruju Corporation
Lapp Group offers solutions for more efficient & flexible factory
Kollmorgen has expanded its presence in India. The motion control specialists completed a distributor agreement with Ruju Corporation at the recent SPS/IPC/Drives Expo in Nuremberg. "The partnership with Ruju is an important building block to enable our continued growth in a strong market," said Udo Panenka, Managing Director, Kollmorgen Europe. “Kollmorgen’s high level of The motion control specialists expertise in servo drive technology and completed a distributor motion control solutions immediately agreement with Ruju provides us with real benefits as a Corporation premier supplier of automation equipment in our country," added Hiren Joshi, owner & CEO, Ruju. "Based on our open and standardised product platform, and together with Ruju, we can develop well scaled motion and machine control applications for machine builders in India that are accurately tailored and implement faster," concluded Alexander Hack, Market Development Manager, Kollmorgen. These also include increased opportunities to effectively address the rising energy costs in India with efficient solutions.
Lapp Group has taken part in a number of research projects to offer solutions for more efficient & flexible factory. The research mainly focuses on the following questions: how could the work environment look in a factory of the future? What kind of tasks will factory workers undertake and how can they be supported in fulfilling their tasks? “This is important for understanding the entire production system, that is the plants and operators. We want to use our findings to develop solutions that are even more suitable for Siegbert Lapp, Member of the the factory of the future,“ explains Board, Lapp Holding AG briefs Siegbert Lapp, Member of the Board, on the research projects Lapp Holding AG. In addition to this, the taken by Lapp Group company is involved in the SmartFactoryKL initiative run by the German Research Center for Artificial Intelligence (DFKI). The SmartFactoryKL is a demonstration factory inside a laboratory, where researchers from the DFKI can use technologies for the intelligent factory of tomorrow in a production environment as close as possible to the real world.
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A & D I n d i a | A p r- M a y 2 0 1 4
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Answers for industry.
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market | interview
“Thoughtful engineers are the need of the future” Tom Kindermans, Vice President – Asia Field Operations, ANSYS Inc, details on engineering simulation as one of the biggest initiatives taken to empower SMEs and discusses the various strategic plans for the Indian market, during an interview with Srimoyee Lahiri. What are your company’s strategic plans for expanding the Indian market share? We are worldwide leaders in engineering simulation and the market is growing globally as companies look to us for simulation expertise, and the competitive advantage we bring to their business. Overall, we want to meet market needs by investing in product development, adding more partners and improving infrastructure by optimising our team & operations.
How does R&D work in your domain? How is ANSYS focused on empowering SMEs? Our R&D is driven by customer requirements and the availability of the latest technologies. We spend about 17% of our global revenue on R&D. Education and awareness about engineering simulation is one of the biggest ways to empower SMEs. We have observed that more innovation is happening at the SME level in India than a decade ago, and innovation is gradually moving to SMEs as they mature.
From which sectors are you witnessing major demand? Major demand is witnessed from aerospace & defence, automotive, oil & gas and electronics - the proportion of which however, varies by regions. We have worldclass expertise in each of these industries and are already adding a lot of value to several OEMs and suppliers.
Which technology trends have been witnessed in 2013? What are the expectations for 2014-15? In 2013, we saw SMB companies eager to learn more about engineering simulation and understand its value for their businesses. In 2014-15, we hope to see better investment climate that incentivises product development and innovation.
What are the new age applications that are being launched in 2014-15? Indian organisations today are facing complex (and sometimes competing) pressures like never before. There is a need to create the next ‘must-have’ products which are affordable, first time right and yet priced such that organisations make profit. Hence, multiphysics analysis becomes imperative while creating such products and we are witnessing customers adopting it rapidly across the globe. The company’s innovative multiphysics software offers a comprehensive and integrated structural, thermal, fluid and electromagnetic analysis under a single framework. What are the company’s expansion/investment plans in 2014-15? Automotive is in fact a very important area of potential for ANSYS in India and we have several ongoing initiatives with our existing auto customers. Aerospace & defence and oil & gas are two other important verticals for our India business. We are also connected with academia in several ways by supporting student competitions, sponsoring academic projects by funding and helping out professors.
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What are the challenges that are being witnessed in your domain? We are reaching a stage where every engineer needs to have an understanding of product development processes and engineering simulation. For a vast and diverse country like India there are challenges related to education policy, curriculum control and industry-academia connect. A lot is being done by the government and private institutions but our focus on engineering research still needs a boost. ANSYS is trying to contribute by providing software and sponsoring research projects. Well trained & thoughtful engineers are the need of the future. How do you align your market strategy with fluctuating demand scenarios? The fundamental strategy does not change dramatically. But of course, we do make adjustments depending on the current market scenario. ☐
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A & D I n d i a | A p r- M a y 2 0 1 4
market | interview
“Focus is on nurturing innovation” Discussing the emerging technology trends in industrial automation, Victor Mieres, Vice President - Emerging Markets, National Instruments, briefs on graphical system design for better functionality, during an interview with Srimoyee Lahiri Globally, what is the strategic importance of emerging markets for NI? From a global standpoint, emerging markets possess key elements that make it strategically important. We expect to see continual strong growth from the emerging markets as we focus on mining, semiconductor and manufacturing to deliver productivity to our customers and foray into new markets with our tools and technology. Your company is largely identified with LabVIEW. What are the emerging technology trends in the industrial automation domain? Through control design tools in LabVIEW, we can bring different models of computation such as simulation models, textual math and data-flow, thereby integrating it into hardware. Another interesting trend is the rise of cyberphysical systems. Most complex systems bridge the fields of computation, information technology and physics. An emerging field of science is the study and development of engineered systems that bridge cyber and physical worlds. They are engineered to continuously interact with their environment through the coupling of distributed computational and physical components. CPS applications are all around us and include smart grid, vehicle traffic networks, smart buildings, cooperative robots, telecommunications, automotive systems and avionics. Which steps can be taken to encourage innovation in the engineering domain? “Graphical system design” equips domain experts with hardware and software that is off-the-shelf and can be used to build complex engineering solutions easily because of the level of abstraction and flexibility that it provides to domain experts. This approach solves the challenge to learn multiple skills and tools to implement a system. The program focuses on nurturing local innovation through partnerships and supporting small & medium enterprises (SMEs), entrepreneurs and organisations building solutions that can contribute locally to the prosperity and sustainable development of emerging nations. Our academic program has initiatives such as collaborative research, LabVIEW academy and setting up centres for excellence that
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enable such industry institute collaboration in improving the teaching-learning process. Do you think the Indian mindset is open to experimenting with the latest hi-tech automation with better and more functionality? What are your views on the same? The graphical system design approach with its highly modular hardware and flexible software provide an ideal platform for Indian engineers as they design and build cyber-physical systems. Another area for growth is the big analog data, which is probably the oldest, fastest and biggest in the category of big data. It harbours great scientific, engineering and business insight. To tap this vast resource, developers are turning to solutions powered by tools and platforms that integrate well with each other through a wide range of other vendors. This area is growing in demand as it solves problems in key application areas such as scientific research, product testing & machine conditioning and asst monitoring. What are your strategic plans for NI for 20142015? In R&D innovation, we are redoubling our efforts to improve product offerings, especially for RF/wireless test applications and reconfigurable I/O portfolio using NI LabVIEW and FPGA technologies for test and control applications. We aim to increase NI technology adoption, by working with our stakeholders to create an ecosystem that combines hardware and software tightly integrated to create a standardised platform that can be shared across many applications to ensure customers’ success. On the business front, we will continue to invest in our regional infrastructure to guarantee technical and business support globally, extend our presence geographically in several cities in India as well as growing frontier markets in Africa and Asia. We are also collaborating with NGOs and international development agencies worldwide such as USAid and the World Bank to provide engineers and scientists with increased access to technology to achieve sustainable prosperity. ☐ > MORE@CLICK ADI03442 | www.AandD24.in
A & D I n d i a | A p r- M a y 2 0 1 4
market | interview
‘Need to develop evolving solutions’ Todd Graves, Vice President, Engineering & Technology, Allegion India, during this discussion with Sumedha Mahorey, addresses the safety and security requirements of the Indian manufacturing sector and its prospects in the coming years. Excerpts… What are the highlights of the global safety and security to specify the optimum solution from the beginning. The key is market? developing scalable solutions that can evolve as the customer’s In the manufacturing sector, as with other types of facilities, needs change and the use of open protocols & standards makes safety and security are dual requirements that demand a this evolution much easier. solution which balances the needs of both. Security is achieved when unauthorised people are kept out, while authorised How is R&D and innovation strategy implemented at people are allowed access quickly and easily, maintaining the Allegion? productivity of the workforce. In a manufacturing facility, We are committed to develop the most innovative safety and safety and security requirements are often paired with time & security solutions. We have invested in our R&D capabilities attendance, wherein workers “clock in” and “clock out” of their around the world, investing in people, tools and processes to shift concurrent with gaining access to the facility. get the innovations to market quickly. This is reflected not only in our long heritage of innovation, demonstrated by the fact Which are the evolving safety & security that Allegion invented many of the safety needs of the Indian manufacturing sector? and security devices in common use today, Security is a mechanical problem on its most but also in our investment in the India fundamental level. A physical barrier must Engineering and Technology Centre. We keep unauthorised people out, while quickly have created a world-class facility to house and easily allowing authorised people in. a highly-talented engineering team, along However, as mechanical solutions have evolved with development tools and test equipment with the addition of electronics, new levels to allow them to turn their creativity into of safety and security can be achieved. The innovative new products and solutions. addition of electronics further allows various Allegion created the Disruptive Innovation safety and security systems to communicate Centre of Excellence (DICE) to tap into the with each other with a central control creativity of our employees worldwide and system and database. Communications and turn their ideas into products quickly and connectivity are enabling novel capabilities effectively. DICE allows employees time apart to be added, increasing the productivity from their normal responsibilities to work of the facility to the levels that were not possible with purely on innovation, providing resources they need to collaborate mechanical solutions. freely. Our team in India is one of the most productive in terms of new innovations, reflected in large number of patent filings How is the Indian safety and security market likely to perform coming from our team here. in 2014-15? As a growing economy and market, India will see its safety and How will the new Bengaluru-based Engineering Centre help security needs increase over the next couple of years. Allegion tap the Indian market potential? Allegion’s Engineering and Technology Centre in Bengaluru What are the challenges and opportunities in the Indian develops products for all of our markets around the world. It is market? one of our largest engineering centres, and it plays a key role in With various markets across the world, Indian market is developing mechanical, electronic and software solutions that challenged with providing increased levels of safety and serve our global markets. The Indian team is highly skilled and security for end users for the industry migrates to more creative, and is in the lead by developing some of our most connected solutions. Growing markets like India have a unique important innovations, which improve safety and security opportunity because new facilities do not have an existing around the world. ☐ > MORE@CLICK ADI03443 | www.AandD24.in infrastructure to migrate, so the designer of the facility is free
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COMPETENCE IN COMMUNICATION
Ethernet to MPI/DP/PPI Converter for SIMATIC S7ÂŽ Highlights: ` Full access to PROFIBUS diagnostics and services in STEP7ÂŽ ` Parallel communication to 32 PLCs with up to 16 TCP connections ` Direct PLC to PLC communication, also as projected connection
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02.04.2014 09:37:07
market | trends
Focusing on optimising assets The article briefs on the traditional ALM practices on managing assets with a narrow vision on asset lifecycle that are becoming obsolete. As processes evolve there is an urgent requirement to shift gears and move from traditional to contemporary ways of doing business. ARC analysts have done an indepth research on this and designed an asset lifecycle management (ALM) model with a focus on improving and optimising assets throughout its lifecycle. Companies in India today realise that improving asset performance is a key component for success in the competitive market. Major global players have established their presence across most industry verticals in India, raising the benchmark for domestic companies to scale up in terms of productivity, quality and time-to-market. In this market scenario, it has become mandatory for companies to focus on reducing operational cost to remain competitive. On the other hand, due to expanding regulatory requirements and increased concerns about security, companies need to allocate budgets on features and aspects that doesn’t necessarily improve the
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Piyush Dewangan Analyst - India & South East Asia ARC Advisory Group PiyushD@ARCweb.com
G Ganapathiraman Country Manager ARC Advisory Group, India RamanG@ARCweb.com
bottomline. In addition, due to the present uncertain economic climate, companies are hesitant to invest more on creating new assets – and that adds further challenges of “doing more with less.” Hence, it is clear that better asset management is a pivotal business driver. Improved management of assets and its optimisation requires clear understanding of the asset lifecycle. The traditional ALM practices on managing assets with a narrow vision on asset lifecycle are becoming obsolete; as processes evolve it is important to shift gears and move from traditional to contemporary ways of doing business. ARC analysts have
A & D I n d i a | A p r- M a y 2 0 1 4
trends | market
done an indepth research on this issue and designed an asset lifecycle management (ALM) model with a focussing on improving and optimising assets throughout its lifecycle.
Traditional v/s new model for asset lifecycle management Traditionally most companies think of ALM in terms of a linear model. While this captures the major ALM activities from creation to disposal of a complex asset, it also has major drawbacks for understanding ALM information management challenges. The model explains ALM as three major processes: project performance management (PPM), asset performance management (APM) and asset & project portfolio management (APPM), which some might simply call planning. Capital assets: The traditional model represents a limited view of capital assets. Focus is solely on the physical plant while performance in real plants depends upon an extensive set of supporting resources. An appropriate view of a facility includes three classes of assets: physical, human, and virtual. The ALM model focuses on the importance of all these assets when it comes to asset performance. Physical assets play an obvious role, since no facility produces anything without some equipment. But, the quantity, quality and value of that output can be directly influenced by the organisation’s human assets. Likewise, the performance of both equipment and humans depends upon having high-quality information. In the end, these are all vital pillars of asset performance and care must be taken to ensure that they are always synchronised and balanced. Independent v/s interdependent: In the traditional model the major ALM processes and their relationships are represented as if they are sequential and independent activities. The reality is that certain activities repeat many times as the facility is upgraded. This leads people to make poor decisions in critical areas like staffing, training, partnering, investing in technology and information management. The model represents the relation between the major ALM activities. The three major ALM activities are interdependent and overlapping and require information sharing and
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collaboration. Linear v/s cyclic: The traditional model presents ALM activities as one-shot efforts. This is acceptable if companies are only focused on projects, but is misleading for someone who manages assets over their complete lifecycle. Real assets get old and have upgrade and modification projects that cause the process to repeat. Hence, with traditional approach, the lack of information on key asset health often leads to challenges on upgrades and other improvement programs. The model understands this cyclic nature of activities and hence major activities are represented in a circular manner rather than linear. The circular representation indicates that it is an ongoing activity which requires continuous improvements during the lifecycle of the plant. Hence, it is incumbent on the managers of each process to make sure that information and lessons learned in one project or plant are captured and made available for improvement on other projects and plants. Management responsibilities: The traditional model recognises that design & build is responsible for sourcing material and building the facility. But the new model highlights the fact that their responsibility also includes the management of all information created or collected in the following stages — making sure that spare parts are acquired in time for commissioning; that IT systems used to operate and maintain the facility are in place and initialised with all needed information; that procedures are available in time for operating and maintenance personnel to be trained before accepting the facility and others. ALM strategies can succeed only with proper information management; hence AIM is of vital importance.
Information management – an important tool for the success of ALM strategies An owner-operator’s capital assets is more than the physical equipment that one sees during plant visits. Human assets are needed as well to build, operate and maintain these facilities and they need require asset information to accomplish their tasks. Hence, information is an essential part of every asset investment. It forms the virtual asset that the ALM Team needs to understand and manage the physical and human assets at
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market | trends
Asset lifecycle management: Traditional vs ARC’s Model
each facility. It must be complete, comprehensive, accurate and granular enough to support queries about the asset’s creation, use and its care throughout its lifecycle. Asset information is good when it is trusted and used by people in their decision making across all of the ALM processes. To achieve these goals, its characteristics should comprise of complete - all information for every asset in every relevant category; accurate - with respect to the existing situation; consistent - across all documents and object instances; accessible - by authorised ALM stakeholders using reasonable knowledge, in a form that conveniently meets their needs and timely - reflects the current situation with reasonable measures of realtime. From a content perspective, this means that an organisation needs access to reference data for every asset’s functional capabilities, its physical design and how humans are supposed to assemble, operate and maintain the equipment in a safe and efficient manner. All of this reference data needs to be carefully managed for change to ensure that virtual representations always match reality. Some people will also have questions about asset performance and the root cause of problems and incidents. So, the content must also include activity records reflecting current status and the decisions and actions that occurred during the facility’s design, procurement, installation, use and maintenance. And, to be effective, all of this information, reference data and activity records, need to be cross-referenced. From a toolset perspective, these characteristics imply that the organisation has an asset information management technology strategy that supports diverse set of users, each with their own needs and preferred views of the virtual asset. This includes a general, yet powerful search capability that supports queries related to certain assets, issues, time periods, etc. Comparisons of information across different plants, different instances of a given kind of asset, different time
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periods, etc would also be possible. Users would likewise be able to view information in various formats, from a variety of devices and through various applications that support their individual workflows.
Better asset performance The value of better asset information management lies in its ability to improve asset performance, whether the asset is human or physical equipment. Better information about process parameters can improve a designer’s productivity and help them make better equipment selection decisions. The same information can help operators and automation systems optimise throughput and energy costs of a facility once it is operating. But these latter benefits will be lost if the information is not shared across asset lifecycle stages. There are two channels through which better asset information management improves performance of human assets. Firstly, it can directly impact the productivity of an individual or, better yet, a whole group of individuals. Secondly, it can enable better collaboration between people and groups, which indirectly improves everyone’s performance. In both cases, these improvements contribute to asset performance through lower capital costs, shorter project schedules, lower operating costs, etc. In a similar fashion, better asset information management can improve physical asset performance. It can be used to improve a facility’s functional performance in terms of throughput, yield, quality, and such others. It can also help in terms of increasing the facility’s availability for productive activity and extending equipment lifetimes. Finally, better asset information management can improve performance in critical areas like environmental, health and safety (EH&S). ☐ > MORE@CLICK ADI03444 | www.AandD24.in
A & D I n d i a | A p r- M a y 2 0 1 4
c o v e r s to r y | t e c h n o l o g y
A comprehensive approach towards automation
Better process-to-product management
B R Mehta Senior Vice President Reliance Industries Ltd
Image courtesy: Shutterstock
Automation may not limit itself to process controls, advance control and optimisation in one unit or one plant but seamless integration with ERP systems, Management Information System (MIS) shall be part of automation. The article talks on these technology trends, considerations for adopting automation technologies, and end-user expectations from automation solution providers.
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t e c h n o l o g y | c o v e r s to r y
The manufacturing value chain is moving towards efficiency and low cost of manufacturing globally. In purview of the changing world order after globalisation, economies of scale are tilting in favour of nations where there is great demand. This paves the way for countries like India and China, to secure their manufacturing capacity to meet dual demand of meeting the domestic market and that of the international market with lower cost of manufacturing. Automation will certainly have a major role to play to attain the goals of low cost of production in meeting the scale and the scope.
Optimising automation subsystems Virtualisation: Nowadays, manufacturing automation systems are heading towards virtualisation of operator system interface (Level-3 applications), with running multiple operating system, on single physical machine by dividing system recourses between virtual machines; isolating fault and security at hardware level with advance recourse control preserve performance; migrating any virtual machine to any similar or different physical service, which gives hardware independence; and optimum utilisation of servers through recourse utilisation. Through virtualisation, high cost related to maintenance, network and disaster recovery plan can be reduced. It also helps in creating centralised system management. Asset management: From an instrumentation and control perspective, equipment such as instrument and control can be considered as instrument assets which need to be maintained and managed to derive the value for planned duration/life cycle of the equipment or instrument. The equipment such as instrument needs to be maintained for proper operation due to its contribution/criticality while deriving the value to the production as a whole. As the ability to self-diagnose device health and integrity improves, available information is too valuable to ignore. For example, standard temperature measurement options offering hot backup redundancy are being expanded into detecting sensor drift and predicting when a temperature sensor will fail. Pressure transmitters now detect plugged impulse lines and inform the operator when an apparently good measurement is, in fact, not valid. Control valve diagnostics and the ability to execute partial valve stroke test or generate valve signatures for online diagnostics allow many valve problems to be easily isolated and remedied without the cost associated with pulling a valve out of service and unnecessarily rebuilding it. All of these developments in device diagnostics help processing facilities practice more preventive and less reactive
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maintenance. With approximately 50% of the work accomplished in most organisations being reasonably preventable maintenance, potential cost & savings from utilising device diagnostics data are tremendous. In the process control industry, instrument assets range from field devices to hardware/software based control solutions. In order to maximise the output of an industrial facility, all instrument assets need to be maintained at certain intervals — i.e. monitored, serviced, refurbished or replaced. Instrument asset management assists in determining these intervals through continual asset condition monitoring, which predicts time-to-service, detailed diagnostics with guidance of required service actions and system-supported planning and execution of service tasks. The goal of an instrument asset management solution is proactive rather than reactive maintenance, wherever possible. High performance HMIs: Some benefits of better optimising on HMIs include better handling of abnormal situations and effective response, effective alarm and event management. Since humans recognise shapes and colours faster than numbers, use of Pattern Recognition Objects (PRO) will provide effective graphical overview of simultaneous process conditions. Shapes/colours will change to alert onset of abnormal condition for operator to take quick corrective actions. Also, superimpose pre-captured patterns with realtime patterns and real-time performance feedback & KPI for selected parameters will help.
Implementing automation systems At times, different vendors are used for implementing the overall control system plan. This is done to harness the core competency of different solution providers. Open control system architecture plays a major role in tightly integrating the different modules of control system, and makes them work in unison. It is never an easy task to fulfill all requirements of process control and safety. Seamless integration of DCS & ESD and integration of various systems with DCS like machine condition monitoring, compressor control systems, analyser management, fiscal and allocation metering systems, automatic tank gauging systems, PLCs for large mechanical packages is always a challenging task. To design & implement safety instrumented systems and mitigation layer system like fire & gas system is also very critical in nature.
Automation @ Reliance Industries In a refinery, there are various process systems like advance
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c o v e r s to r y | t e c h n o l o g y
Diagnostics based on NAMUR 107 standard can provide pin pointed data to operation and maintenance person on health of instruments
process control, tank farm management system, ESD system, F&G system, oil movement system and blending & optimisation system, terminal automation system, among others, all working in tandem and in perfect synchronisation. The mission of automation in Reliance Refinery was to achieve operational excellence in monitoring, controlling & managing process and business; optimum level of integration between process control, operation & business support systems; and showcasing corporate image of Reliance Industries providing next generation control systems. The objectives achieved by us with the implementation of Foundation Fieldbus technology and new smart devices include inter-operatable products & systems; elimination of proprietary protocols; technology enabling innovation by manufacturers; device diagnostics; lower installation costs; more information from the valves; multiple inputs from one device; new instrumentation easier to add later; reduced wiring; reduced terminations; reduced commissioning time and reduced control room space. Process control systems were traditionally closed systems designed for functionality, safety and reliability where the prime concern was one of physical security. Increased connectivity via standard IT technologies has exposed them to new threats which they are ill-equipped to deal with (for example, worms, viruses and hackers). As this process control networks continue to increase in numbers, expand and connect so the risks to the process control systems from electronic threats continue to escalate. Commercial off-the-shelf software and general purpose hardware is thus being used to replace propriety process control systems. Such software and hardware often does not match the uniqueness, complexities, real-time and safety requirements of the process control environment. Many of the standard IT security protection measures normally used with these technologies have not been adopted into the process control environment. Consequently, there may be insufficient security measures available to protect control systems and keep the environment secure. Additionally, software and hardware applications are difficult to upgrade in a control system network. This acts as one of the challenges industry is facing. Also, securing control systems may not be perceived as
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economically justifiable. Industry is facing security challenges from internal as well as external world. The internal threats include disgruntled employee, viruses and worms, accidental system changes and malicious users. While external threats include cyber hackers, viruses and worms, spyware (trojans), and terrorist attacks. Ideally, integrated security solutions for preventing illegal entrance, viruses and cyber-attacks or financial loss must be infallible. Although no single technology can claim to be completely flawless, layering multiple security technologies can leverage the capabilities of each technology, overcoming the limitations of any single technology. Moreover, threats to system vary in nature, so different technologies provide different solutions for different type of threats.
Expectations from automation solution providers End-user expectations for reliability and speed have grown dramatically as more and more users have come in contact with wider arrays of software applications. End user inputs to vendor are precious because it brings future into the present and avoid becoming insular. As end users, we expect, life cycle excellence from the concept to optimisation; single integration architecture; enterprise integration; cyber security protection; application integration; productivity & profitability through technology and services; shortening delivery times & reducing time of start-up; reducing the “four Cs” – cost, commissioning, customisation & coordination; smart service capabilities; value-added services for maximisation in profit; least cost of ownership of the control systems; Mean-Time-To-Repair (MTTR) to be minimum which can be achieved by service centre at site. Apart from this, the application developer tool should be user-friendly and easily upgradable without calling for a process shutdown. The application programs should be easily scalable to meet any capacity growth.
Considerations for new technology deployment Normally, while selecting the new technology like Foundation Fieldbus, we consider three major aspects – the
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c o v e r s to r y | t e c h n o l o g y
Many unnecessary checks can be avoided which is about 63% of the time spent on investigation of problems which do not exist
future of process automation, proven technology and openness. We consider benefits which come during the life cycle of the project which is typically engineering, construction, commissioning & start-up, operation & maintenance. We ensure that the infrastructure is neutral; standard based, provides end-users with a common framework to implement and manage the strategies & are continuously improving. We also learned that it is non-proprietary, open, interoperable & continuously evolving with vendors coming in with various innovations.
Drivers for industrial automation There are five major identified driving forces most likely to impact on industrial automation businesses. These forces are the transition from – transactional to real-time business environment; process to product management; labour workers to performance managers; an island to a holistic business perspective; and from rigid to agile operations. Any automation manufacturer has to come-up with innovation, latest technology, and cost-effective solutions to remain leader in the market. Also, in place of standard offerings they should offer value-added solutions/offerings to end-user. Many of the manufacturers today compromise on environmental and health aspects and thereby, harm the community at large. They use obsolete technology to produce the product with the just acceptable quality but not meeting the other standards of production which calls for efficiency and lesser environmental impact. To subjugate this problem, various manufacturing forums as well as government statutory bodies should effectively help legislate and implement laws that would address not only product quality issues but also production quality issues without jeopardising the profits. This will trigger new wave of automation within the automation sector. Manufactures should work as a stakeholder of the society rather than working in their silos. Advanced automation technologies can certainly add more value in this process of reform in the industry within India.
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Involvement of the expert team from projects, operation and maintenance from the early days of projects and effective interaction with selected vendors and other end-users has made the automation technology of refinery ‘future proof ’. We have immensely benefited after implementation of Foundation Fieldbus technology. This has enabled us to prioritise various process and system alarms as per the latest automation standard and trends in the process industry. Device monitoring and information during the service fault and other diagnostic information has helped in predictive maintenance. Real-time Plant Asset Management (PAM) has given us access to plant health field devices and automation system; and ability to add new devices with reduced time, wiring and termination. Technology has built-in standard safety functions such as device failure, function check and maintenance request with single operator display. Since display is digital, it eliminates conversion such as analog to digital which has improved accuracy and reliability. We can integrate certified products from different suppliers to selected system uniformly with standard features which will allow for interchangeability. More IT tools are integrated with process automation software with high level of system security and integrity that will help process, automation end-user in many ways.
New age technology developments The bottleneck in technology advancement shuttles between hardware and software periodically and is being continuously addressed by the automation world. A radical change coming from the fundamental research in physics can bring in a disruptive change in the automation world, just as it came after the advent of semiconductor technology. The future of automation will go hand-in-hand with the IT industry. Automation industry has been evolving very fast with the advent of microprocessor technology that offered flexibility of implementing our process control strategy. There have always been spillovers from consumer technology within
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c o v e r s to r y | t e c h n o l o g y
High performance HMI helps in detecting abnormal situation before alarm occurs
the automation world. For example, advancement in IT and telecommunication technology has widely influenced the automation industry. There is a definite shift from the age old proprietary hardware and software systems towards more open universal hardware and software systems, which offers better interchangeability of automation products. The differentiation points are the application layer and the hardware at the I/O level, with better availability and Mean-Time-Between-Failures (MTBF) figures. Another concept getting popular in process automation is Remote Operation Management (ROM). Due to rising operating cost, the plant operations are becoming more geographically dispersed. The traditional approach now do not work with dynamically changing supply and demand; tighter production specification and environmental norms; challenge in identify skilled and qualified human recourses. In order to counter-act such difficulties in present scenario, concept of ROM comes as solution. ROM can be used by conventional method of collecting data from systems and analyse the data as per the end-user requirement. Another ROM concept which is not popular in process industry, but used for the smaller size automation application, is cloud-based ROM. In cloud-based ROM, the data is collected and stored in remote server through various communication gateways such as serial communication, Modbus RTU, or GPS; this stored data is accessed through secured network such as Ethernet IP, GSM or GPRS for end-user through customised online display. Recent development on ROM concept is being thought of by integrating wired infrastructure, remote I/Os and ISA wireless infrastructure, into FF infrastructure data management. This will enable real time operation management through more effective use of various data structure, data quality, in turn increase reliability and availability with predictive maintenance strategy. Control has already shifted to field with the maturing of the Fieldbus technology. Recent developments in wireless technology have offered
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flexibility in monitoring points; less capital and operational cost; freedom from cables, JBs, isolators, marshaling cabinets and DCS I/Os; reduction in commissioning and engineering efforts; employed for monitoring of steam traps, relief valve leakage; vibration applications for cooling tower motors, fin fan coolers, rotary valves and non-critical pumps to support predictive maintenance. Other benefits include non-critical parameters monitoring and ease of addition of new devices with minimum engineering efforts. Wireless technology will also facilitate to achieve sustainability, monitoring health of steam traps; detecting safety valve passing or leaking; flare gas recovery unit load monitoring; managing effluent treatment plant (ETP) for better environment.
Future trends in automation technologies In the future, mega scale manufacturing plants/complexes are expected to take advantage of scales of production at single location. To maximise operational efficiencies and yield & to achieve faster ROI, mega plants shall have to be equipped with maximised automation. Automation may not limit itself to process controls, advance control and optimisation in one unit or one plant but seamless integration with ERP systems, MIS shall be part of future automation. Nanotechnology may be used in developing tiny, low power, highly accurate sensors which will showcase direct impact on low cost of production in the future. Cloud computing may also be used to optimise costs. Automation shall have a maximum impact in future projects in terms of scope, cost, schedule and manpower. A comprehensive and integrated approach towards safety is essential to achieve higher level of plant safety. And such an approach must include securing the process control network, responding quickly and accurately to abnormal situations, early detection of defects, proactively monitoring asset health, moving the plant assets into safe state and managing emergency situation quickly and efficiently. � > MORE@CLICK ADI03445 | www.AandD24.in
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Delta has applied its knowledge and technology in automatic control and electric power to expand its automation products, systems, and solutions for application in a broad range of industries including packaging, textiles, chemicals, electronics, printing, and pharmaceuticals. As a leading industrial automation brand, and as a reliable partner to worldwide customers, we provide efficient and reliable solutions in factory automation, process automation, and machine automation for many major companies. For details and enquiries please mail us at automation@delta.co.in
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www.deltaelectronicsindia.com
IABU Monday, April 07, 2014 5:27:41 PM
management | interview
“We strongly believe in local management� ...says Dr Oliver Vietze, CEO & Chairman, Baumer Group, in an exclusive interview with Shekhar Jitkar and Srimoyee Lahiri. Briefing on the acquisition of Waaree Instruments in India and sharing insights on implementation of Six Sigma/Lean techniques, not only in production but also in all aspects of business, Dr Vietze elaborates on how average customer have become more techno-savvy and demand more intelligent sensors. What are your strategic plans for India in terms of market positioning, expansions, manufacturing activities and tie-ups, if any? Baumer started its active direct presence in India through its wholly owned subsidiary in 2007 set up at Pune under the name Baumer India Private Limited. The company has established itself in the last five years and has significant market leadership in certain segments of factory automation market. The acquisition of the Waaree Instruments, three years ago has boosted our activities in the Indian subcontinent with manufacturing set up. It complements the international expansion strategy of the company. It is also an excellent opportunity to strengthen our process instruments business.
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The Indian operations have improved our ability to meet local customer requirements, speed up local delivery and to react timely to the dynamic and growing Indian market. Our manufacturing locations are spread across Western Europe including two in Switzerland, six in Germany, one location each in Denmark, Venezuela, France. We globally cover five segments including sensor solutions, motion control, process instrumentation, vision technology and gluing systems, finding applications in diverse range of industry segments such as print graphics, packaging, pharmaceutical machinery, food/beverage wind energy, cranes, steel, metal and material handling, among others. Our expansion plans are based on making the best use
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interveiw | management
“The sheer size of the Indian market makes it imperative that no global strategy can be worked out ignoring India. We see India contributing significantly to our global business” Dr Oliver Vietze
of the available local talent. We strongly believe in local management. Indian unit is integral part of our global strategy to build products catering to high technology requirements at sustainable price. Where do you see your Indian operations leading to in the next five years among Baumer’s global network? The integration of the Indian market is essential part of the international growth strategy of Baumer. The sheer size of the Indian market makes it imperative that no global strategy can be worked out ignoring India. We see India contributing significantly to our global business.
efficiency (using ‘Six Sigma’) have become the key aspects of success. Would you like to comment on the acquisition of Waaree Instruments in India? How is it running, so far? Baumer acquired Waaree Instruments three years ago. This was purely Indian company and within the last three years we have done lot of fundamental work on the organisation. We have worked on people and technology front. This is to bring new Baumer Technologies India at par with international Baumer quality.
With constant pervasive changes in technology & market How do you look at the trends in the sensor business, requirements, how can organisations design/plan the change technology & market? Where do you see the potential management process and product development strategies? Would you like to give any examples from Baumer? coming from, geography & sector? Sensor business is driven toward offering many high Baumer runs continuous program to improve organisation, performance features within standard products. Utmost processes and people competence. The company makes product reliability and safety features integrated into products extensive use of Six Sigma/Lean techniques not only in and component sale coupled with application know-how and production but also in all aspects of business. Baumer consultation are some of the trends. Manufacturing efficiency Business Systems (BBS) is a global program wherein all becomes more important under trying economic environment. Baumer companies worldwide participate to exchange knowGlobally, major growth will come from the emerging markets how and experience to ensure value addition at each stage of organisational activity. Moreover, as an open culture company, in Asia, Africa and South America. we facilitate know-how transfer at multiple levels and are not There has been an increasing trend in the sensor business restricted to top driven actions. which points at miniaturisation, precision, safety & measuring speed. How does Baumer take care of these What kind of innovations/technology breakthrough is expected from your company in the coming years? demand expectations? These may have become the latest buzzwords, but for Baumer We are one of the leading companies in sensors and sensing we have been offering these features on customised basis technologies. We want to maintain the focus on sensor working closely with our OEM customers from Switzerland development. Sensor technology is a growing field in and Germany for last several decades. Technologically speaking automation in every industry vertical. We feel the trend towards this is not new for Baumer. The change however is that some use of sensors in each product and commodity will continue. of these special features have to be incorporated in the new With average customer becoming more techno-savvy, there is product ranges we offer for the general market. That is where more and more demand for intelligent sensors. ☐ > MORE@CLICK ADI03446 | www.AandD24.in innovation in product design and emphasis on manufacturing
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management | interview
“We help customers change the way they operate� Elaborating on cyber security, Jason Usro, Chief Technology Officer, Honeywell Process Solutions & Vice President and Chief Technology Officer at Honeywell International, highlights the recent technology advancements for a better control system and the recently designed solutions to enhance process safety & security, during an interview with Srimoyee Lahiri. Honeywell has several new technologies that are likely to transform control rooms of the future, including an advanced dashboard to help industrial plants better manage control system cyber security. Please elaborate. Today, plants need to be highly automated. Hence, we have introduced several new technologies that will transform control rooms of the future in the way they implement, operate and maintain their control & safety systems. These technologies have been designed to make operators more effective in their daily tasks and decision-making. Technologies like OneWireless extends control room to the field, where industrial handheld devices that are linked together through wireless technology can free control room operators from their consoles and allow them to be more productive and autonomous; or cyber security
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management systems like the Cyber Security Dashboard that focuses on removing risk from the control system environment. It can be customised to help industrial plants better manage control-system cyber security; and collaboration solutions like Experion Collaboration Station that enables faster responses to both routine and emergency situations by displaying a common view of how distributed assets at multiple locations are functioning. In which areas of automation technology do you expect to see significant levels of automation in the coming years? Honeywell Experion Orion console is a futuristic console that reduces operator fatigue with an improved, ergonomic design featuring a larger display and alarm lighting. We
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i n t e r v IE w | m a n a g e m e n t
“Our objective is to engage with the customers beyond supplying just products and simple point solutions and become a trusted advisor to help them achieve their critical business goals” Jason Usro
have also introduced Collaboration Station that allows Control System (DCS) architecture, including field instruments, industrial organisations to monitor and manage operational SCADA, plant historians and other advanced control functions activities across multiple facilities from anywhere within a such as simulation software and advanced process control and network of sites, helping plants better leverage their expertise optimisation applications. between locations, mitigate staffing issues associated with remote locations and maximise production and optimise How are you planning to drive the growth of your company operations. Core process industries such as oil & gas, refining, in India? What are your strategies to enhance the market petrochemicals, power and chemicals can significantly benefit share in India. from advanced automation technologies too. We are well-positioned to grow our business in India, and help drive the growth of the Indian economy with innovative In the current uncertain economic situation, what would technologies. We will continue to expand our footprint in you advise to manufacturers for investment in automation Asia Pacific. We work with our customers, listen to them, technologies? understand their challenges and then come up with solutions. Our technology is oriented toward helping customers become This means we help customers change the way they operate more profitable. In terms of advance control and optimisation, making them more flexible and productive. It also means we can reduce customers’ energy costs or improve throughput that we change how they make decisions, the speed of those without requiring additional capital being invested. On the decisions, and even the place that the people need to be when other hand, technologies like alarm management helps to making those decisions. Our objective is to engage with the provide information to the operators so they can better address customers beyond supplying just products and simple point process problems before reducing production and finally solutions, and become a trusted advisor in helping them shutting down the plant. achieve their critical business goals. We understand the demands of our customers and hence Currently, what are the innovation themes that your have a strong commitment toward developing and delivering company is working on? solutions that are relevant and competitive for the local We develop cutting-edge technologies that address global macro market. For example, PlantCruise by Experion, a proven DCS trends such as safety, security and energy efficiency across helps maximise users’ production uptime, improves safety, different industries therefore helping customers. For safety & reliability & efficiency and reduces investments and operating security within plants, we have designed solutions that enhance costs. It is a product that is designed and developed based on process safety & security and allow customers to operate in a customer inputs from the region; or SmartLine transmitters safe manner while reducing the number of incidents that occur that is designed to enhance communication abilities, improve within plants. We are also innovating on energy efficiency. To operational efficiency and reduce lifecycle costs for process ensure maximum optimisation benefits, we integrate advanced manufacturers. ☐ > MORE@CLICK ADI03447 | www.AandD24.in energy solutions with the customer’s existing Distributed
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m a n a g e m e n t | r o u n d - ta b l e
Revamping automation education & training With the automation industry becoming the backbone in major manufacturing verticals, Indian institutes and colleges have been gearing up and updating their syllabus to suffice the demands of the industry. This feature analyses the challenges on this front, and the various measures being taken to make young talent industry-ready. The Indian automation industry is the backbone of the manufacturing sector which has been a major contributor to the growth of Indian GDP. But this industry has been facing a serious dearth of young talent, despite the country producing lakhs of young engineering graduates every year. This feature provides insights into the human resource & talent acquisition challenges in the automation industry. Suggesting feasible solutions for the automation industry and the academia for young talent development are industry stalwarts Anup Wadhwa, Director, Automation Industry Association (AIA); Dr KLS Sharma, Advisor, Automation Education and Training; S S Prabhu, Professor (Emeritus), Advisor, IIITB; Renukaprasad Belgur, Business Mentor & Advisor, MentorWise Advisors, President of ISA (Bangalore Section) and Former Executive Director, Avasarala Technologies; Girish N Ayya, Consultant – Industrial Automation & Corporate Trainer and Co-Founder, Avadhoot Automation; and Sukumaran Mathoor, Senior Member – ISA & President Elect – ISA Bangalore Section and
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Sumedha Mahorey Deputy Editor sumedha.mahorey@publish-industry.net
General Manager – Operations, Pepperl+Fuchs (India), Process Automation Division.
Creating a right mix of theory, practice & training There are many reasons for the gap between industry and academia even though industry and academia are continuously striving together to bridge the gap in areas such as education, training, research, development, etc. Highlighting these issues, Dr Sharma avers, “The industry keeps adopting latest and diverse technologies quickly to stay in business, but the academia faces difficulty in keeping pace with the industry. The syllabus update process in academia is very slow for procedural reasons; also, text and reference books on latest technologies are non-available in the market as the same remains with the industry, and its percolation into public domain is slow and restricted. Qualified, experienced, trained teachers and state-of-art laboratories to introduce the latest
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r o u n d - ta b l e | m a n a g e m e n t
“The human resource departments in automation sector industries can & must learn from IT organisations on how to attract young talent”
Sukumaran Mathoor, President Elect - ISA Bangalore Section and GM – Operations, P+F Process Automation (India)
products, systems, and solutions are also not available.” The above leaves a gap between the fresher’s knowledge level and industry’s expectation. This affects induction (recruitment, placement, deployment, and absorption) of fresh graduates into industry, as reasonable comfort level does not exist between the fresher and industry. “With this, many freshers perceive industry is not for them and many industries perceive freshers are not for them. This leaves freshers losing good employers and industry losing good freshers. This exists in all areas and automation industry is no exception,” he points out. Addressing these issues, Wadhwa suggests, “Active engagement with automation industry would help create curriculum relevant to a globalising country. A suggested mix for the institutions that want to produce globally competent automation engineers should have 40% classroom learning, 20% practical (automation labs), 20% digital self-learning through webinars and videos (class learning/individual learning), 20% exposure through internship/hands-on experience in manufacturing unit, guest lectures & discussions with professionals from automation industry and user industry. This will help students to connect with the real world of science and technology, develop critical and analytical thinking about processes and also nurture their entrepreneurial spirit and ideas for innovation.” Adding on Wadhwa’s thoughts, Mathoor asserts, “Faculty Development Programs can be organised by academic institutions, in which experts from the automation industry can share their experience. This will help faculties from academic institutions to update their knowledge and skills, interact with the industry experts and revise their syllabus accordingly. Faculties from academia can attend special training courses offered by automation system manufacturers/ other organisations like ISA, which will help meet this objective partially. Institutes can also look at hiring professionals from industry as consultants, who can support these activities. Conventional instrumentation laboratories in engineering colleges need to be upgraded by installing latest technology, automation products & systems as well as engineering tools & software used by industry.” Addressing the issue at hand, Ayya says, “Industry academia interactions on a regular basis by way of seminars, technical events, road shows, technical quiz, etc to connect the students to the industry will also help majorly.” Giving his perspective on the challenges in automation education & training, Prabhu shares a practical viewpoint. “Engineering education has been changing in the recent times.
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“With new technologies coming up in automation, we can keep the passion of an engineer alive” Anup Wadhwa, Director, Automation Industry Association
This is because of the enormous changes taking place in various technology areas, new technologies emerging, interdisciplinary nature of technologies, the presence of computing and communication technologies in almost all engineering systems, etc. The effort is to convey the broad sweep of modern engineering systems, give students a reasonable background in computing and communication, and enable them to study particular areas of interest through elective course concentrations. Increasingly, project work in small groups is encouraged. It is unrealistic to assume that engineering education will prepare graduates who are ‘industry ready’ for any particular industry. They will, however, have strong background and preparation to pick up engineering practice of relevance to their specialisations in a very short time.” Providing suggestions on overcoming the many challenges education institutes are facing, Dr Sharma elaborates, “Certain steps can help bridge the gap between industry and academia and make engineers industry-ready. These include introduction of a new discipline with the name ‘Industrial Automation’ and making it open to all electrical science students at pre-final and final levels in under-graduate program; introducing a basic course addressing the philosophy, technology, terminology, and practices of modern automation to serve as a platform for all the subsequent courses in automation and domain related areas (supporting and advanced) and tailoring the subsequent domain supporting courses (Electronics, Communication, Information technology, etc) to address automation related issues, rather to keep them general in nature followed by advanced courses in automation.”
Structuring automation training for freshers Despite education institutions taking the above measures, it is apparent that automation engineers who have already passed out and are deployed on-job should be provided the relevant knowledge & content on the continuously evolving
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“The industry keeps adopting latest & diverse technologies quickly to stay in business, but the academia faces difficulty in keeping pace with the industry” Dr KLS Sharma, Advisor, Automation Education and Training
technology environment. Bringing forth the issues on this level, Dr Sharma affirms, “Fresh graduates, many a times, may not feel comfortable with subject and/or industry during initial learning days. Due to this, they may even leave the company for new jobs. Also, training, absorption, and deployment of freshers is expensive, time consuming, and requires a lot of effort. Thus, training should be offered by in-house experts. But these trainings are generally not adequate as the trainers do not find sufficient time for preparing and delivering good training due to their normal work pressure. Another issue lies with smaller companies which outsource training. These trainings may not be of good quality or match with freshers’ needs.” Suggesting steps to address this, Wadhwa highlights, “The competency gap can be overcome by creating a network of brand agnostic centres; our industry is ready to support aspiring educational institutions to fulfill this role as well. Adding his thoughts, Mathoor elaborates, “The knowledge & skill set required for fresh engineers to work in industry in each sector are different. For example, when we think about process automation, we mainly look at skills needed with regard to DCS, PLC, SCADA, AMS, MES, SIS, F&G, Field Instrumentation, Final Control Elements, etc used in process industries. We should be aware that there are several organisations involved in development, engineering, project implementation and final use of instrumentation and automation systems for process industry, such as end user; design & engineering consultant; project management consultants; EPCs; main automation company (DCS/PLC/ PAC); OEMs; system integrator; safety instruments/system manufacturers; field instrument/final control element/drives manufacturers; cable manufacturers; enclosure manufacturers, among others. Similar classifications are there for other areas of automation sector such as factory automation, building automation, etc. “Unlike IT, we do not find training institutes who offer specialised courses which can provide necessary skill sets and make engineers industry-ready. Hence, need-based training programs should be arranged in-house by these organisations. These training programs should include sessions to make the beginners understand how their customers derive value from using their products or services,” Mathoor adds. Sharing his thoughts, Belgur notes, “The training in industry has to start from internships during breaks as a part of the curriculum. Another way is to put them though a specific
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“The automation industry must deem it to be its duty to reach out to ‘engineers-in-the-making’ in colleges” S S Prabhu, Professor (Emeritus), Advisor, IIITB
finishing school process after completion of the curriculum and then to offer these students to the industry. The main competition would come again from the software units, who absorb students a year before they complete their curriculum.” Elaborating further he points out, “In my opinion, the policy group on education must insist that no company goes to any institution for campus recruitment. They all must have their internal assessment at their premises, so that students from all institutions get an equal opportunity.”
Attracting young talent With the craze toward happening sectors like IT, management and other engineering verticals, how can the automation industry attract young talent? Highlighting on this front, Prabhu explains, “Career attraction depends on opportunities. The current student perception is that there are not many jobs in automation industry; these jobs are not wellpaying; growth prospects are limited and job mobility to other areas becomes difficult since those who join the automation sector will be considered to have overly specialised experience and therefore, are not quite suited for other type of jobs. Unless this perception changes, it is difficult to make automation sector attractive.” Belgur adds, “The only way one can do this is to stop the policy of all software companies of coming to campuses and make them conduct their tests internally. The students need to be educated of the opportunities that exist for them in various sectors. Most students are unaware of their potential areas, where they can work.” Highlighting the existing opportunities, Ayya says, “Today, opportunities available in Indian automation across various industry segments are growing due to various factors. One of the major contributing factors is that job opportunities in
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m a n a g e m e n t | r o u n d - ta b l e
“The policy group on education must insist that no company goes to any institution for campus recruitment. They all must have internal assessment at their premises” Renukaprasad Belgur, Business Mentor & Advisor, MentorWise Advisors and President of ISA (Bangalore Section)
automation are available due to capacity expansions in the manufacturing segment to meet the growing market demands. Another factor is that the addition/up-gradation of automation systems needs engineered manpower.” Commenting on the subjects in automation, Mathoor avers, “Instrumentation Technology – the name used in engineering colleges for this branch needs to change to represent today’s automation sector. The knowledge and skill set for today’s automation sector is not limited to instrumentation technology alone. It covers a broad spectrum of electrical sciences including electrical, electronics, digital communication, instrumentation, wireless technology, etc. So, why not use ‘Automation systems technology’ instead? The human resource departments in automation sector industries can and must learn from IT organisations on how to attract young talent. Clarity on career growth opportunities, campus selection and higher salary packages for beginners are few measures to start with.” Awareness about the integrated world of data and machines, challenging work environment and need of critical and analytical thinking are biggest attraction and strength of automation sector today. Wadhwa explains, “We need to show students how a smart manufacturing facility runs, the speed and reliability that automation technologies bring in and the operational analytics that give engineers and managers total control. This will give them excitement to join automation sector. We all know that a talented engineer wants to deal with physical processes, simulation and analytics. They want to apply their skills across multiple domains to deliver the best impact. Our industry offers challenging goals to make processes more efficient, robust and competitive. With new technologies coming up in automation, we can keep the passion of an engineer alive.”
Making industry-institute collaboration more productive With education and training requirements taking the centrestage in the Indian automation industry, is there an enhanced need for industry-institute collaboration to be made more productive? Answering this, Wadhwa suggests, “We have to understand that both are part of a larger ecosystem. Educational environment and inputs are different from industry environment and inputs; so there must be a dialogue
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“Job opportunities in automation are available due to capacity expansions in the manufacturing segment” Girish N Ayya, Consultant – Industrial Automation & Corporate Trainer and Co-Founder, Avadhoot Automation
to bring about an open sharing of resources. The biggest challenge for automation industry is to have people with crossdisciplinary skills. Institutes are usually department led, so the concept of open electives can be tried for teaching automation. By working with each other, we can solve this problem and produce competent engineers which are suitable and well accepted by both automation industry and user industry.” Wadhwa provides the roadmap for industry-institute collaboration. It includes creating a balanced and brand agnostic industrial automation course that lays the foundation for engineers from different disciplines; creating opportunities for industry exposure; developing a network of colleges and industry partners that allow co-sharing of facilities; advocacy with AICTE and University Academic Councils to upgrade the core curriculum and assessment criteria; industry and colleges get linked through the creation of Competency Development Centres and on-line portal. On a similar thought, Ayya adds, “To make the industryinstitute collaborations more productive, the curriculum must address the basics regarding industrial measurements, control and process applications; all types of automation products like sensors, controllers, PLC, DCS, IT and automation integration, various automation standards used in the industry and industry standard communication protocol. Regarding the practices, the institutes can set up the labs using industrial products, so that the students can be exposed to industrial environments during the academics. During the degree/diploma courses, the integrated training programmes can be embedded to the respective semesters/years, so that the students can become well versed with the ongoing industrial scenarios.” Prabhu also suggests that the automation industry must deem it to be its duty to reach out to ‘engineers-in-the-making’ in colleges. ☐ > MORE@CLICK ADI03448 | www.AandD24.in
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chemical & process | Focus
Pervasive sensing Plants are being modernised with additional measurements, partly for the plant operator, but mostly for personnel outside the control room. The information helps increase reliability, energy efficiency, make the plant more environmentally friendly, and a safer place to work. Jonas Berge Director, Applied Technology Emerson Process Management Jonas.Berge@emerson.com
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Focus | chemical & process
Your parents’ car likely had only four sensors: speedometer, are eliminated by WirelessHART transmitters, thus reducing the temperature gauge, fuel gauge, and oil pressure warning. the risk of damaging the installation and saving time. An Modern cars have multiple digital communication networks electrician need not get involved either. A WirelessHART with dozens of sensors onboard for the drivetrain and brakes, network only requires a gateway at the edge of the plant area. for information, and for climate control. Most of the sensor WirelessHART transmitters form their own infrastructure, a data is aggregated into diagnostics used by the mechanic mesh network, also eliminating the need for expensive servicing the vehicle in the repair shop. Modern plants should backbone routers and their associated power and network cabling. Intelligence wireless sensors form a web of powerful be no different. Plants face challenges such as personnel safety, field devices, a digital architecture for the plant to improve environmental regulations, and energy costs. These challenges performance - an industrially hardened version of the which are important to run the plant but are outside of process “Internet of Things” (IoT). WirelessHART transmitters give the plant the agility to control and functional safety are referred to as ‘business freely add measurements because they can be deployed when critical’. To solve these problems, plants are being modernised with required with little or no risk.WirelessHART is a digital signal, additional measurements, partly for the plant operator, but communicated in engineering units. A measuring range need mostly for personnel outside the control room. The not be configured in the transmitter or control system and information helps increase reliability, energy efficiency, make there is no need to perform a 5-point loop check since there is the plant more environmentally friendly, and a safer place to no 4-20 mA signal. Non-intrusive sensors: Non-intrusive sensors mean no new work. process penetrations are created, reducing the risk and cost, and pipefitters need not get involved. For example, temperature Challenge sensors clamp onto the pipe. Acoustic sensors for steam trap Plants already have a wired “primary layer” of automation failure, relief valve release, and passing valves are strapped for the process critical control and functional safety on the onto the outside of the pipe. Position sensors for bypass and P&ID, providing operators at the DCS and Safety Instrumented other valves bolt onto the outside. Vibration sensors are System (SIS) consoles the data they need to run the plant screwed or bonded to the equipment body. Fittings for pressure gauges are instead used for wireless pressure sensors. efficiently and safely. Because applications beyond the P&ID are not as However, the reliability, maintenance, HS&E, and energy disciplines only get some of the data they need. There is a lot demanding as the safety and control on the P&ID, clamp-on of “missing measurements” beyond the P&ID they have to temperature sensors are adequate in such applications. collect manually or don’t receive at all, principally in the areas Similarly, a vibration transmitter is sufficient for non-critical of asset monitoring for reliability, energy conservation measures for energy efficiency, and HS&E monitoring to reduce risk.
Measurement agility Traditionally, many improvement projects do not get approval because adding sensor requires running signal and power wires for the transmitter risking to damage existing wires. Moreover, cutting and welding the pipe or vessel, could only be done during a plant turnaround. Wireless transmitters: The need for signal and power wires
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Table 1: Areas of modernisation Essential Asset Monitoring (EAM)
Air cooled heat exchangers, blowers, compressors, cooling towers, heat exchangers, pumps
Energy Conservation Measures (ECM)
Chiller water, compressed air, heat exchanger fouling, steam, steam trap failure
Health, Safety, and Environmental (HS&E)
Gauges, sight glasses, variable area flowmeters, and dip sticks, grab sampling, manual and bypass valves, passing valves, relief valves, safety showers and eye wash stations, vibration, temperature, acoustic testers
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Figure 1: Data from WirelessHART transmitters go to the control system and the AMS
temperature, level, and flow transmitters that take the place of manual rounds with the clipboard. Energy consumption for each unit to track conservation initiatives is useful to the energy officer who would also want to know if process Beyond the control room equipment is fouling reducing their energy efficiency. The The DCS is not ideal for most measurements collected raw data from multiple sensors is aggregated into simple through pervasive sensing for the maintenance supervisors, indicators of process equipment health and fouling to reliability engineers, the HS&E officer, energy manager, and maintenance personnel for planning turnarounds and the steam trap service company because they do not sit in the schedule daily maintenance. Measurement agility includes ability to freely add a new control room. For them to disturb the operators to get their measurement on the computer screen at somebody’s desk. data and reports would be inconvenient for everyone. System engineers are cautious with changes. There are Because the AMS applications situational awareness, energy policies and rigorous management of change procedures to efficiency, and asset monitoring, are not process critical they get the control system configured to integrate a new and are much more flexible and open to changes than the safety display measurement due to the process critical nature. It may and control system. On the AMS, the disciplines make the be necessary for the system vendor’s service engineer to come modifications themselves to suit their needs. Sensors can freely be installed, and the AMS configured to get the data to make the addition. onto a screen without disturbing the system engineers. Steam traps: Raw data from acoustic transmitters on critical Asset management – the second system steam traps throughout the plant is aggregated in steam trap Most pervasive sensing measurements are not process monitoring software providing an overview of their health critical control or safety and therefore, do not go to the DCS enabling the steam trap service company to quickly tend to and operators. Instead, plants deploy a second separate Asset steam traps before trapped condensate damages equipment or Management System (AMS) with a suite of specialised energy is wasted blowing steam. applications for asset monitoring, energy management, and Reliability: In the reliability office, machinery health HS&E. Personnel from these disciplines access data from their monitoring software enables analysis of vibration in pumps, own offices. Going to the control room to get the data or motors, conveyors, and fans, etc from a WirelessHART vibration transmitter by reliability engineers using the same disturb the operators is not necessary. Activation and health of safety showers and eye wash software used to manage critical turbines and large stations as well as relief valve releases, status of bypass valves compressors. and other valves, etc is useful to the HS&E officer. Which Maintenance, energy efficiency, and HS&E: For simple valves are passing, and to see data from vibration and applications, standalone HMI software can be used. temperature transmitters which take the place of handheld 1) Maintenance: Passing valves, high vibration or temperature testers is useful to maintenance staff. Same goes for pressure, of equipment like pumps, fans, agitators, conveyors, and pumps and other equipment which don’t need an extensive monitoring system.
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chemical & process | Focus
Figure 2: Steam trap monitoring software
Figure 3: The AMS monitors process equipment like pumps
motors etc are flagged in standalone HMI software in the maintenance office. Readings previously taken manually from gauges, sight glasses, variable area flowmeters, and dip sticks, etc are collected automatically and printed in reports, eliminating rounds with the clipboard. The health of pumps, heat exchangers, cooling towers, air cooled exchangers, and blowers, etc is computed using multiparameteric algorithms from raw data from sensors on each piece of equipment. This enables a data-driven maintenance paradigm. The work processes for maintenance personnel is to check the software first, before going to the field. 2) Energy: In the energy office, software reports the consumption of steam, compressed air, and chilled water, etc for each plant unit to track energy conservation initiatives. Equipment fouling information is used by the energy efficiency officer to improve energy efficiency. 3) HS&E: Standalone HMI software is ideal for displaying plant data in the HS&E office, used to reduce risk and help meet regulatory requirements. Software alerts when a safety shower or eye wash station is activated and keeps records of function testing. Relief valve releases are tracked. Similarly, open bypass or dyke valves, or other valves are flagged.
Easy modernisation WirelessHART coverage throughout process units and areas are now being installed in many plants to meet these business critical needs. Plant modernisation is adding automation where it didn’t exist before, and doesn‘t require system migration. New process critical data is integrated to the existing DCS while most data from the new sensors integrate with the AMS or historian. Plant modernisation using wireless sensor networks for a second layer of automation is a new business opportunity for EPC.
Don’t build your new plant old Traditionally only process critical safety and control is automated in a plant. However, new plants should be built from the very beginning to support business critical needs, including an AMS with specialised applications and underlying wireless sensor networks. Do not build a new plant the old fashioned way.
The future for aging plants
Modern cars have been made more reliable, more fuel efficient, more environmentally friendly, and safer, using the many more sensors now networked onboard. Diagnostics Plant historian – the third system derived from most of the additional sensors is used by the A Plant Information Management System (PIMS) aka mechanic in the repair shop who has a different dashboard for “historian” is used for data collection in many plants. The servicing. Similarly, existing plants should consider deploying plant historian is suitable for the pervasive sensing a second layer of automation for other business critical needs. measurements. Algorithms can be created in the historian A second system beyond the control room can assist the plant’s that aggregate raw data into actionable information for energy run and maintain organisation in making the plant more consumption tracking and asset monitoring, etc. “Big Data” environmentally friendly, more energy efficient, more reliable, refers to the historian’s tremendous capacity for data collection, and a safer place to work. ☐ long-term data storage and analytics. > MORE@CLICK ADI03449 | www.AandD24.in
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Downtime FOR safe FUTURE operations A turnaround of two months is the most extensive chemical plant shutdown to date at the INEOS location in Cologne. Every day roughly 1,250 people work at the site, cleaning, maintaining and inspecting the extremely complex cracker plant. TÜV SÜD Chemie Service accompanies this mammoth project from the world of testing and inspection…
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A visit to the INEOS location in Cologne reveals labyrinthine futuristic structures tower in the distance. A closer look reveals hundreds of steel scaffolds serving as temporary, movable support structures and enveloping the 15-hectare chemical plant. The scaffolding provides entry to areas that are not normally accessible via stairs or fixed access ladders, including reactors, columns, heat exchangers, pressure vessels, control valves and other valves, and the many kilometres of piping systems. When in service, the plant processes or “cracks” naphtha, the crude-oil derivative used in the production of plastics for consumer products. Now, the entire plant has come to a standstill – completely emptied, cleaned and opened for maintenance, servicing and inspection activities that cannot be carried out during normal operation. The turnaround covers all processing equipment, columns, vessels and piping systems as well as electrical safety devices and lifting equipment.
Biggest shutdown of all times
Hohnroth, Turnaround Manager. “As time is money, we have planned every day of the shutdown, defining an exact route along which we walk the test engineers to the prepared components.” Preparations include dismantling and cleaning valves and vessels, uncovering and opening manholes, completion of any repairs that may be necessary and application of the defined test pressure to the heat exchangers so that the inspection engineers can get down to work without delay.
The turnaround No matter who enters the plant, everybody first needs to be instructed on the necessary safety precautions and don the required personal protective equipment, including safety goggles and helmets, safety footwear, gloves and fire-resistant work wear. People who have attended the safety instructions are identified by a clearly visible sticker affixed to their safety helmet. In addition, everybody accessing the cracker plant needs an electronic ID security card which they must wear visible at all times. The inspection tour starts at a sort of container village near the plant. There, partner companies and clients have their own infrastructure including offices, storage rooms, communal rooms and rest areas. Tools and personal protective equipment too are handed out there.
About 2,000 INEOS employees and another 4,000 staff from partner companies work around the clock. TÜV SÜD Chemie Service also has up to ten experts from various disciplines at the plant every day. “With a total investment volume of €100 million including a modernisation programme, this is the biggest turnaround that our Cologne site has seen so far”, says Dr Anne-Gret Multiple backup documentation as a safety net Iturriaga Abarzua, Communications Manager, INEOS. Every The atmosphere in the conference room of TÜV SÜD five years, the plant is shut down for servicing and inspection. The experts from various disciplines then have just under two Chemie Service is focused and concentrated as inspection months to inspect all process-engineering equipment, columns, engineers and turnaround managers are discussing which vessels & piping systems and the electrical safety devices and parts and components will be next for testing and inspection. lifting equipment. In every plant turnaround, the experts also Around 1,000 items must be “checked off ” over the next six focus on identifying and realising additional opportunities for weeks. To complete this workload on time, the experts are working days, nights and weekends. “We inspect every single improvement. component”, explains Klaus-Dieter Peschel, Head – Plant Safety & Inspection, TÜV SÜD Chemie Service’s Dormagen Complex detailed planning location. The inspection engineer is in-charge of the team of Realising such an extensive plant turnaround requires experienced experts that work at the cracker plant. “We accurate planning to make sure that all activities, including maintain a second documentation list in parallel to that of our the start-up procedures, are completed smoothly, without any client, to ensure no test item will be overlooked,” Peschel frictional losses. The turnaround of this cracker plant required continues to explain. However, this is not all; the experts also 75,000 hours of planning. The entire turnaround process, review the list internally at the end of each day of the from rough outline to detailed schedule, is meticulously turnaround, thus extending the “two-man rule” to a “threeorchestrated. “Nothing is left to chance”, reports Marcel man rule”.
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Visual inspection of a raised manhole
Continuing through the container village, passing the catering tent and arriving at the plant check-in, all individuals entering the plant are registered at a computer terminal with the help of their ID security cards. Given this, the number of people currently in the plant can be determined at the click of a button. A security guard is waiting for us at the entrance to accompany us through the plant. There is a general air of bustle; everywhere we look, workers are grinding, welding or assembling parts. Everybody knows exactly what to do, and where and how long to do it. “In time-critical processes, wellcoordinated maintenance and inspection schedules are imperative”, explains Peter Löffler, Inspection Engineer, TÜV SÜD Chemie Service. “By offering computer-aided management of inspection intervals and electronic access to inspection reports, we reduce costs and efforts incurred by plant owners/operators”.
Although the inspected and approved heat exchanger is on the small side, at a length of just under 4 m and a diameter of 70 cm it still weighs over 1.6 tonne. The weight is caused by the 80 tubes it comprises. By way of comparison, in other heat exchangers the number of tubes (known as the “bundle”) may amount to up to 10,000, easily bringing the total weight of the heat exchanger up to over 100 tonne. These types of component can only be moved by heavy-duty cranes. However, cranes are also needed for transporting smaller components to the right place. Given this, up to 40 cranes are in use at the cracker plant on any one day during the turnaround. A red crawler crane that can lift over half of its 927-tonne dead weight is particularly impressive. With a hook height of 188 metres, the crane is higher than Cologne Cathedral, and has warning lights on top to warn aircraft of its location. The crawler crane is the largest crane ever to be used in a turnaround on INEOS premises.
Functioning order
Modern test methods
Drizzle is now falling on the inspection engineers. Having inspected the inside of a vessel jacket, they are moving on to a heat exchanger connected to hoses and pumps. The hydrostatic test pressure briefly rises to 13 bar, and the expert from TÜV SÜD Chemie Service notes, “Component E-1050 withstands the test pressure, is tight and does not reveal any safety-critical deformation.” Once this has been determined, the engineer scrutinises connections, welds and particularly vulnerable spots. “The heat exchanger is in good condition. However, final approval must cover the component as a whole. Where are the hoods of the heat exchanger?”, the engineer asks the turnaround manager. After a quick call, the engineers proceed to a storage area where heat-exchanger hoods are lined up in a long and orderly row. There the experts find the hood they have been looking for.
Before proceeding to a stop valve, the engineers inspect another heat exchanger. At every component, the questions investigated by the experts are the same: Are there any indications of a corrosive attack or other damage? If so, what actions have to be taken? Does the component have to be replaced, or can its safe operation be guaranteed for another five years? What is the condition of other elements of the components, such as supports and insulation? Is there a risk of condensation developing? Have the necessary repairs, if any, been completed expertly? Sometimes special questions arise, necessitating further tests and inspections. “The technical progress made in non-destructive testing of surfaces by ultrasonic methods or digital radiography is providing new answers”, says Peter Löffler, TÜV SÜD Chemie Service. The methods supply high-resolution images of possible
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Focus | chemical & process
inhomogeneities in, say, welded materials, plant components or complex geometries. Depending on the diagnosis, they enable measures to be used that are better targeted to the specific problem on hand and that equally take into account the aspects of safety and cost-efficient maintenance.
TÜV SÜD Chemie Service. At the end of this day of the turnaround, the experts have found all components to be in perfect order. However, when they detect components that have to be repaired, time is of the essence. In this case, the plant professionals from TÜV SÜD Chemie Service provide further services – from defining the scope of repairs, providing the necessary calculations and Long-standing expertise approving the inspection and test plans to monitor the repair. The inspection engineers rely on their expertise and their All experts are working to one goal, ensuring the deadline for longstanding and specific experience. Having accompanied the startup of the cracker can be met. previous large-scale turnarounds of the naphtha cracker plant, When the day of the startup finally comes, the pressure in they are familiar with the individual components and able to the plant is built up again and the cracker is brought to identify possible changes. operating temperature. Fluids and gases flow into the system. Starting from their in-depth familiarity with the plant, the Everything looks as if there had never been any large-scale engineers can also support the plant owners in other aspects turnaround at all. The tangle of support structures and during the turnaround, such as life-cycle or plant-expansion scaffolding is dismantled, the cranes have moved on, and the projects. “As third-party service providers, we not only take chemical plant goes back to producing the basic chemicals for care of plant safety, but also help to maintain the value of the the world of tomorrow. ☐ plant in the long term.” Our extensive experience with large- Courtesy: TÜV SÜD Chemie Service scale turnarounds enables us to offer high-quality, one-stop > MORE@CLICK ADI03450 | www.AandD24.in services to the chemical industry”, says Klaus-Dieter Peschel,
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s a f e t y & I N TE G R AT I O N | T E C H N O L O G Y
The languages of automation User-friendliness is the key to acceptance of automation solutions. But as the challenge of making operation clear & simple grows, automation tasks become more sophisticated. In terms of engineering, it’s not just the hardware but the software implementation that’s particularly important – and if possible this should be in the user’s native language. Users aren’t the only people to benefit: design engineers can also reduce their effort significantly. In today’s centrally configured programmable logic controllers (PLC), changes in individual plant sections have far-reaching consequences at control level, because program structures at central points in the control system have to be modified. In terms of flexibility, re-usability and userfriendliness, classic automation architectures with centralised PLC controllers can no longer meet future requirements. That’s why the automation of the future demands solutions that can distribute control intelligence but also guarantee that the necessary networking of multiple control systems remains easy for the user to handle.
systems of various performance classes. Process or control data, failsafe data and diagnostic information are exchanged and synchronised via Ethernet. For the control function, it makes no difference where the respective program section is processed. Instead of a centralised control system, the user has a program distributed in runtime within a centralised project. All network subscribers are configured, programmed and diagnosed via this software.
Transferring functions to the software
The transfer of functions to the software brings users flexibility and scalability, reduces the variety of hardware types and simplifies maintenance and diagnostics on automation Pilz developed the automation system PSS 4000. Whereas solutions. The question as to whether software can be used in classic automation a standalone, centralised control system efficiently depends essentially on the user interface and the monitors the plant or machine and processes all the signals, available languages – both in terms of human language and the PSS 4000 allows control functions to be distributed programming language. PSS 4000 meets these challenges with consistently. In detail, the automation system consists of the software platform PAS4000. Various editors and blocks are hardware and software components as well as the real-time provided, which can be used for automation as well as safetyEthernet SafetyNET p and various programming editors related tasks. In PAS4000, the tools for configuration, designed for use in different sectors, with their application- programming, commissioning and operation are closely oriented function blocks. The hardware includes control compatible.
Centralised view of a distributed system
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s a f e t y & I N TE G R AT I O N | T E C H N O L O G Y
The automation system PSS 4000 is suitable for all automation tasks: from stand-alone applications to the implementation of classic automation with a central control system, through to the consistent distribution of control functions to the periphery
The ability of users to use their normal native language is important in terms of acceptance. As a result, the PAS Editors in the automation system PSS 4000 are available in multiple languages other than English and German. One of the editors available to users in PAS4000 is the simple, block-based Program Editor PASmulti. PAS4000 also provides established editors for programming. These include editors for PLC programming (in accordance with EN/IEC 61131-3) for Instruction List (PAS IL) and Structured Text (PAS STL), as well as the new editor for Ladder Diagram (PAS LD). This can be used to create safety-related programs, programs for automation tasks or a combination of the two.
have a standardised language. PSS 4000 also supports the diversity of language from a technical perspective: the control systems PSSuniversal PLC in the automation system PSS 4000 support the various communication protocols used depending on country and region, for example, the Profibus protocol, which is particularly widespread in Europe; Ethernet/IP, which is frequently used in the USA and Asia, as well as EtherCAT, CANopen and Modbus TCP. As a result, there is no problem exchanging data with the widest range of third-party control systems.
Simplifying the learning process
Different countries, different languages
The increasing challenges faced by automation can be met using systems that can distribute intelligence but at the same The individual editors are used to varying degrees, time are user-friendly to control. As a result, the cost of depending on the country or region. While instruction list or engineering, commissioning and maintenance can be structured text is frequently used for programming in Europe, significantly reduced. The system’s openness and the wide structured text is usually favoured in Australia. Programmers range of languages make it easier to use in automation projects in USA and Japan, for example, prefer to use ladder diagram. around the world. If local users can configure their machine in Within the Pilz automation system, the new Editor PAS LD can their native language and in their familiar programming be freely combined with the other EN/IEC 61131-3 PLC environment, it simplifies the learning process and tool programming languages, so that even complex automation handling enormously, as well as increasing acceptance. For tasks can be handled simply and consistently. All PAS Editors machine builders it brings the additional benefit of using one and programming languages have been classified as an LVL hardware structure, and a software program that needs language (Limited Variability Language) by TÜV Süd, enabling generating once only, to create automation solutions that can users to resolve not only automation tasks but also safety- be used anywhere in the world. related tasks, without functional restrictions. So for the first With the automation system PSS 4000, the control functions time, machine builders can create safety-related application are fully distributed and transferred to the periphery. Control programs using their usual development process. data, failsafe data and states are exchanged and synchronised via the real-time Ethernet SafetyNET p. Plants can be broken down into manageable, independently functioning units. As a Open for all protocols result, the cost of engineering, commissioning and maintenance In addition to the interfaces for man-machine is significantly reduced. ☐ communication, data exchange within the automation project Courtesy: Pilz also has an important role to play. The same applies – the more > MORE@CLICK ADI03451 | www.AandD24.in complex and extensive the project, the more important it is to
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C O N T R O L & R E G U L AT I O N | T e c h n o l o g y
Designing via a new technology The article details on breaking traditional boundaries and adopting new technologies for a machine builder by combining full feature sets and performance of fixed function devices High performance machines often require specialised control algorithms and advanced synchronisation with sensors & vision systems. These requirements can be difficult to achieve with fixed function motion controllers & drives and turning to custom design often isn’t feasible. Thus, fully reconfigurable motion control architecture based on the combination of a FPGA, real-time processor and modular I/O can be used to implement specialised high performance systems more effectively than traditional approaches.
Motion control system architectures: reconfigurable vs traditional Fixed function controllers and drives ship with firmware that implements behaviour which cannot be modified by the end-user. These controllers and drives could be optimised for a very specific purpose such as driving a CNC end mill spindle, or designed with the intent to be as generic as possible. As long as the operation is conducted within the designed use case, these fixed function controllers & drives are usually most effective for implementing an application because one can take advantage of all the design work and feature definition of that product, such as advanced filtering, auto tuning, test panels,
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diagnostic tools, and so on. The problem with fixed function controllers arises when the user, as a machine builder, steps outside the capabilities of a motion controller and drive firmware. Unfortunately, he may complete 95% of the application with a traditional controller or drive, but the remaining 5% abandons the entire design and so he searches for a new solution. These scenarios become more common as machines become more specialised and increasingly sophisticated. Machine builders can also choose custom design. With a custom built motion controller or drive, builders can define their preferable behaviour from the system. However, custom design is costly, time-consuming and has its own set of limitations. They can be very challenging to build and manufacture with a full team of engineers with specific skills. They also include the burden of creating revisions for life-cycle management due to bugs or part availability which perhaps become the most important limitation. The result is a continuous cycle of custom design that is difficult to break, especially for smaller companies that need to be as agile and lean as possible in their operation. Alternatively, design and manufacturing can be outsourced to a third-party company, but it is expensive and exposes the specialised IP.
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C O N T R O L & R E G U L AT I O N | T e c h n o l o g y
The combination of a programmable real-time processor, programmable FPGA and modular I/O packaged into an off-the-shelf system adds much of the needed flexibility for building control and measurement systems
So, to combine full feature sets and performance of fixed function devices with customising them as needed for specified applications, one needs a persistent framework that can be developed through fixed function device with testing and iterative feature improvements. But since it is a modular approach, progression of computing technology and reconfigurable embedded design tools (specifically FPGA technology) solves the problem. The combination of a programmable real-time processor, programmable FPGA and modular I/O packaged into an off-the-shelf system adds much of the needed flexibility for building control and measurement systems. Taking this concept to software is also important. The ability to reconfigure a standard framework; customising where necessary but still utilising the rest is essential for machine builders. In this software architecture, motion tasks are disaggregated to choose where to run a particular task to meet the needs of the application. Furthermore, each task or block is open to modify the functionality down to a very low level. Finally, machine control software packages should be modularly constructed to modify the specific tasks and customise it without largely impacting other blocks in the system. This approach is to a large extent hardware agnostic, so that one can mix and match components to come up with the HW system that meets the axis count, processing power, integration with other I/O subsystems and level of customisability.
Specialised control algorithms For systems that require non-standard control, having a reconfigurable system can make a difference between a simple
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code-change and costly redesign. This is relevant at the drive firmware level in FPGA, as well as at the supervisory control level in the real-time controller. One FPGA related example involves replacing common velocity or position loop with a loop running closed-loop force control. This can be done to test material strength, measure button quality or simulate a finger press on a touch panel. A modular design not only enables to use the control algorithm of your choice, but supports easy integration of a force sensor and any necessary signal conditioning. Other examples could include replacing hall-effect sensors with a custom startup routine for a brushless motor, or replacing a standard PID function with a more advanced control algorithm. For realtime controller, a modular design allows a developer to easily program their own inverse kinematics equations for nonstandard coordinate spaces in addition to using the traditional trajectory generator. The real-time controller could also be used for other advanced tasks like using a model-based control algorithm.
Advanced synchronisation with I/O and vision High performance machines will mostly require some synchronisation with other subsystems and this can take many different forms. Test systems may need to correlate data acquisition to specific real-world positions. Control systems often need to setup custom triggering based on a variety of conditions to perform tasks in real-time. Implementing motion on a platform with modular I/O means that one can mix and match specific I/O to meet system requirements without necessarily having to incur the cost of integrating a separate
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C O N T R O L & R E G U L AT I O N | T e c h n o l o g y
RIO architecture for motion control
tool chain for the measurement I/O. Having an RT system with an ecosystem of available components means easier integration of motion, vision and I/O system components. Having a programmable FPGA allows custom hardware level triggering and signal analysis beyond what is capable on standard motion and automation platforms. Perhaps the most common benefit FPGA provides in this architecture is the ability to define custom triggering based on information from the motion controller. For example, if one tries to precisely trigger a large collection of valves for precise durations at specific positions & features when implementing a printer-like application. This would likely be impossible with traditional motion architecture. However, once you combine modular IO with a high-speed FPGA that is aware of current position, the problem becomes relatively easy to solve. A growing use-case for this synchronisation with real-time processors is vision-guided motion. The real-time processor can process image data, calculate positions and command those positions to motors configured in a coordinate space. This motion opens the door for a wide variety of exciting possibilities.
Integration of disparate motor/drive/control/ feedback types For lower level control, basically at the drive firmware level, one has the ability to use FPGA for a variety of common motion control tasks. These include control loops and commutation schemes, motion I/O like an encoder read, reading limit switches, implementing filters and so on. One
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can dig in and customise just the pieces that one needs. By targeting specific portions of FPGA code for modification, one can achieve the needed flexibility and still get an application up and running very quickly. The flexibility this approach provides is very powerful. One can use it to easily to achieve coordinated motion with a FPGA controlled drive and an external smart drive from two different manufacturers. One could also coordinate many different types of motors and use a different type of feedback for each, all without changing the existing trajectory generation or move profile software. Essentially, any functionality provided from modular I/O and an FPGA can be integrated into an axis of motion that can be integrated with other axes of wildly different configurations. This technology is not always the best choice for every application; if the application is straightforward and it falls within the uses cases the large fixed function controller and drive manufacturers design for, one can probably design the system at a lower cost and more quickly using traditional motion systems. However, if one is pushing the edge with a high performance machine that needs to be better, faster, smarter than the previous designs, one will probably run into cases where advanced I/O, custom synchronisation, specialised control algorithms is needed or to integrate disparate or nonstandard subsystems. Thus, one steps outside the boundaries defined by traditional devices and in doing so, a reconfigurable architecture becomes the most effective way to implement these systems. � Courtesy: National Instruments > MORE@CLICK ADI03452 | www.AandD24.in
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ENERGY MANAGEMENT | technology
Taking eco-conscious decisions intelligently A read into Energy Intelligence software that helps companies to achieve sustainability and energymanagement objectives by delivering data across the enterprise
A variety of industry forces are driving the need among industrial companies for a comprehensive energy management system, but its profitability is motivating much of this activity. Organisations are realising that sustainability initiatives alone cannot drive profitability. They are finding that energy management efforts must be combined with efficient operations to effectively drive long-term financial growth. However, two key challenges â&#x20AC;&#x201D; lack of visibility into key performance indicators (KPIs) and a legacy manufacturing IT environment are preventing many companies from achieving their financial and operational goals. Investing in Energy Intelligence software, which includes data collection, visualisation software and analytical tools, is one way in which organisations are beginning to address their challenges. In many cases, this software supplements existing and planned manufacturing operations management (MOM) software and automation investments. However, these technologies traditionally neglect to collect and manage energy data in context of operations, so many companies are beginning to deploy Energy Intelligence strategies to gain insight into the role of energy within their operations â&#x20AC;&#x201D; from procurement through production. In addition to operational insights, the data generated by this technology is being used to provide improved clarity for
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buy/produce decisions and to help justify energy efficiency projects. However, energy data alone cannot drive success. The information generated by this technology must be paired with the right energy-management processes and organisational leadership capabilities. By uniting all these elements, firms can begin to develop a more holistic and effective strategy that turns energy data into actionable operational insights.
Overcome obstacles Macroeconomic trends such as global population growth and GDP expansion certainly are driving the need for cleaner, more cost-effective energy sources. These trends have prompted individual companies to target energy projects aimed at reducing consumption and improving sustainability. In addition, although financial growth is a top business objective for executives in the coming year, according to a survey from LNS research, companies are not necessarily tying sustainability and energy-management programs to this goal directly. Instead, sustainability and energy-management programs more often are tied to profitability improvements and energy usage reductions. Top sustainability objectives for 2013 include reducing the total cost of operations and reducing energy consumption. The top goal for energy management
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technology | ENERGY MANAGEMENT
•
S eek support from senior leadership: This backing is imperative for success because it often acts as a catalyst for creating an energy-focused culture and an effective Energy Intelligence software implementation. • T ake advantage of existing energy-management programs: These programs, such as ENERGY STAR, ISO 50001 and Superior Energy Performance, can serve as a helpful resource for understanding industry best practices and developing methodologies. • T ake a next-generation approach to manufacturing software: Using a common information management system for energy data can help alleviate past problems related to measuring energy data and transforming it into Connecting people, processes and technology operational insights. se role-based KPIs: Energy Intelligence software Energy Intelligence software has made it easier for companies • U standardises data sources in a way that allows everyone to achieve their sustainability and energy-management from executives and decision-makers to the shop floor to objectives by delivering data across the enterprise. The software identify specific areas for improvement and measure brings together energy and production data so it is possible to progress toward goals. view energy consumption by process or product, and even While more environmentally-conscious decisions will be allocate energy costs to the bill of materials. However, technology investment alone is not enough. Companies must expected by stakeholders over time, the operational and align and optimise key resources that include people, processes financial benefits of Energy Intelligence software warrant and technology. Instituting a few best practices in these areas enough evidence to take action now. ☐ can help ensure the technology investment reaches its full Courtesy: Rockwell Automation > MORE@CLICK ADI03453 | www.AandD24.in potential. also is reducing the total cost of operations. Executives also want to align their energy programs and operations with corporate sustainability objectives. Companies face a variety of challenges in reaching these objectives, but the top issues cited by executives both were related to technology. It includes disparate systems and data sources. Purpose-built applications often are implemented piecemeal by individual divisions or business units, so systems lack cohesion and strategic purpose. Energy metrics are not measured effectively. The proliferation of disparate systems makes it difficult to share data across the enterprise and make measurable improvements.
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sensors & encoders | TECHNOLOGY
Building designer expertise The article deals with the revolutionary leap of industrial system designs through the use of latest sensor technologies, and the expertise required to reap the benefits of this evolving technology Advancements in micro-machined inertial sensor technology are enabling revolutionary improvements in industrial system designs. Applications including industrial vehicle navigation, platform stabilisation, robotics and condition monitoring are increasingly reliant on multiple sensors to attain system objectives. However, there are barriers to overcome for obtaining these benefits, particularly in tough physical environment of many industrial applications, where temperature, vibration, limited space and other factors must be addressed. Extracting consistent data from the sensor, translating it into useful information and reacting to it within the systemâ&#x20AC;&#x2122;s timing and power budget requires expertise on the part of the designer in many technology domains.
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Bob Scannell Business Development Manager MEMS/Sensors Technology Group Analog Devices Inc
Understanding the problem Information from inertial sensors can be processed to derive different types of motion, position and directional outputs. An appropriate example of this is industrial control applications, where some form of pointing or steering of the equipment is useful. Tilt or angular sensing is often at the heart of such applications and in its simplest incarnation a mechanical bubble sensor may suffice. However, before specifying the sensor needs; the full motion dynamics, environment, life cycle and reliability expectations of the end system need to be analysed. Many systems involve more than one type of motion (rotation plus acceleration, for instance), and quite often
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TECHNOLOGY | sensors & encoders
operate on more than one axis, thus driving the need to consider combining multiple sensor types. Once the proper sensor types and technology are known, the challenge shifts to understanding and ultimately compensating for the sensor’s reaction to the environment.
Inertial sensor component: Linear rate & angular rate sensors There are several kinds of inertial sensors. MEMS (micro electro-mechanical systems) sensor technology is among the most well-established, and has brought benefits to a wide range of applications. MEMS linear rate sensors (accelerometers) has revolutionised the automotive-airbag-system industry 20 years ago. Since then, they have enabled unique features ranging from hard-disk protection on laptops to more intuitive user-motion capture in game controllers. On the other hand,
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angular-rate sensing is also available from MEMS structures based on resonator gyro. Sensing structures are electro-statically driven to resonance, produce the necessary movement to create a Coriolis effect during rotation. At the outer extremes of each sensing frame, movable fingers are placed between fixed fingers to form a capacitive pick-off structure that senses Coriolis motion.
Sensor fusion for complex motion Generally, a device’s motion is relatively complex (more than one axis), which drives the need for full inertial measurement units and integrate up to 6 degrees of freedom of inertial movement (3 linear and 3 rotational). Mostly, four or more additional degrees of freedom may be integrated, including 3 axis of magnetic sensing and 1 axis of pressure (altitude) sensing. Beyond ‘filling the gap’ for guidance when
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sensors & encoders | TECHNOLOGY
The figure shows inertial navigation system, merging multiple sensor types with the aid of Kalman filtering
GPS, optical or other interferences are present, the highest performance inertial sensors can potentially provide continual guidance, free of reliance on such external inputs. With momentum behind small, low power, multi-axis inertial sensors for consumer applications, there is an equally significant need for high accuracy. These high accuracy, environmentally robust sensor developments are driving a new surge in the adoption of MEMs inertial sensors.
Integrated signal conditioning and sensor processing In the industrial market, applications such as vibration analysis, platform leveling and general motion control need highly integrated and reliable solutions. It is also important to provide sufficient control, calibration and programming features to make the device truly self-contained. Since the industrial sensing market is incredibly diverse, it requires a wide range of performance, integration and interfaces accommodated through integration of embedded tunable features such as digital filtering, sample-rate control, condition monitoring, power-management options and application-specific auxiliary I/O functions. A linear acceleration specification of 0.1 degree/second/g, for instance, adds 0.1 degree of error to the bias stability spec of 0.003 degree/second, in the simple environment of rotation through +/-90 degrees (1g).
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Thus, optimising sensor performance and minimising development time requires intimate knowledge of both sensor sensitivities and application environment. The calibration plan can be tailored to address the most influential elements, and thus minimise test time and compensation algorithm overhead.
Harnessing acceleration to provide vibration analysis To facilitate sensor deployment in remote and rugged environments, embedded wireless connectivity can simplify the deployment of the sensor network at a significantly reduced cost. The ability to detect and understand motion has the potential to add value to nearly any conceived application. It helps to harness the motion that a system experiences and translate that information into improved performance; enhanced safety or reliability or other added-value features. These features or performance upgrades are often implemented on existing systems. The small size and low power aspects of MEMS inertial sensor components is attractive given that the end-systemâ&#x20AC;&#x2122;s power and size envelope are already fixed, or must be minimised. However, in some cases, designers of these systems are not motion dynamics experts, and thus the availability of fully integrated and calibrated sensors can be essential in choosing to proceed with these system upgrades. â&#x2DC;? > MORE@CLICK ADI03454 | www.AandD24.in
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EVENT | PREVIEW
Platform for automated processes Addressing solutions to new challenges, effectively investing in the latest technologies and providing a roadmap to the future-oriented solutions, Automatica 2014 will be held from June 3 to 6, 2014 in Munich, Germany. A preview… Auotmatica 2014 will be held from June 3 to 6, 2014, in Munich, Germany. The event is organised by Messe München GmbH and VDMA Robotics + Automation with the aim to present the entire value-added chain in robotics and automation. It is the leading platform for innovations in automation and production processes, and has the world’s largest range of robotics, assembly and machine-vision solutions. Companies from all branches of industry will attend the event to find future-oriented solutions and manufacture higher-quality products more efficiently. It is the perfect place to gather information about the latest developments, find solutions to new challenges, make contacts and effectively invest in technologies of the future. The exhibition sectors will include assembly and handling technology; control-system technology; robotics; professional service robotics; security technology; machine vision; supply technology; positioning systems; software and drive technology.
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Robots for metalworking The two topics to be demonstrated during the event will include automation of machine tools and special robots for metalworking. “Robots are taking on increasingly complex work content all the way to complete machining, often equipped with automatic gripper replacement systems. In addition, solutions are increasingly in demand, in which robots not only automate machining centres, but also handle linking of production systems and consequently provide even more autonomy,” said Manfred Hübschmann, Managing Director, Stäubli Robotics. Kuka will present Waterproof models of the recently started KR Agilus series during the event. “Stable stainless steel covers, special surface treatments and numerous gaskets enable unrestricted use of our small precision robot in machine tools,” said Andreas Schuhbauer, Key Technology Manager, Kuka Roboter GmbH.
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PREVIEW | EVENT
Automatica 2014 will present innovations to the international automation industry that are based on changes of production technologies in the automobile industry
The development departments at ABB, Fanuc, Epson, Yaskawa and other robot manufacturers are also working on this topic, so that additional pioneering innovations can be expected at Automatica.
Solutions for the food industry The food industry is one of the biggest growth markets of the automation sector. Regardless of whether manufacturing of food, primary or secondary packaging, automation is the trend. At Automatica, exhibitors will present the latest developments and pioneering solutions for efficient and controlled, safe production methods for food. A look at the numerously implemented projects shows how far automation has progressed in the food sector. Robots milk cows, slice cheese, sort bakery goods, pack lettuce, palletise beverages – to put it short, there is hardly any process that can be imagined without them. Regardless of whether bakery goods, pasta, confectionery, meat, fish, dairy products, frozen food, fruit and vegetables, whether filling, dosing, cutting, labeling or during picking, packing and palletising, automated solutions ensure output and savings. The innovative force and dynamics of the industry are surprising in this respect. The comparison of state-of-the-art systems, which have already been in operation for several years, with that of current high-performance lines, as they can be seen at Automatica, make it clear: significant improvements have been achieved in all relevant criteria such as cycle times, availability and energy efficiency thanks to development work. Delta robot kinematics and ultrafast pickers score with more than 200 picks per minute. Modern production lines achieve output that was considered inconceivable only a few years ago.
Focus on automobile production Lightweight construction is on the agenda in automobile production, but the struggle to reduce every kilogram of weight possible presents challenges to production strategies. New production processes and technologies are required if light construction concepts are to be viable with respect to costs. The event will present innovations to the international automation industry that are based on changes of production technologies in the automobile industry. Automation in the production of lightweight components is a pivotal topic at Automatica 2014, above all in the area of composites. The special exhibition “Automated Composite Production” and the “Industrial Composites Production Conference” in the East Press Centre from June 5-6 will examine state-of-the-art technology for increasing process speed and reducing production costs.
Energy efficiency & sustainability The automation industry is working intensively on its own energy transition. Assembly systems, processes, robots and components are being tweaked consistently to be more energy efficient. Automatica is presenting pioneering technologies and the most recent developments for especially economical and sustainable production. The complexity of the topic shows how important knowledge about the latest components, processes and technologies is for sustainable production. Automatica provides trade fair visitors with a wide range of energy efficiency topics with the presence of leading manufacturers as well as the VDMA sustainability initiative Blue Competence. ☐ Courtesy: VDMA > MORE@CLICK ADI03455 | www.AandD24.in
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EVENT | report
Convention of global innovations Hannover Messe 2014, the mega trade fair on industrial technology, was held recently at Hannover, Germany. With multiple new innovations and product launches, visitors explored the future of industry and invested in the latest factory & energy technologies displayed during the show by over 5,000 exhibitors in 16 halls. A report from the fairgrounds… Hannover Messe 2014, the world’s leading trade fair on industrial technology was held on April 7-11, 2014, at Hannover, Germany. This year’s edition had a strong emphasis on industrial automation & IT; energy & environment technologies; industrial subcontracting, production engineering & services; and research & development. The trade fair attracted nearly 1,80,000 visitors from over 100 nations. Another standout feature involved the high percentage of industry professionals, top buyers & decision-makers among the attendees. “The industrial trade show addressed the key issue of the future of industry by presenting solutions needed for tomorrow’s intelligent factories,” commented Dr Jochen Köckler, Member of the Managing Board, Deutsche Messe.
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Sumedha Mahorey Deputy Editor sumedha.mahorey@publish-industry.net
Highlights Staged under the keynote theme of “Integrated Industry – NEXT STEPS”, the trade fair focused on intelligent, selforganising factories and the transformation of energy systems. Dr Dietmar Harting, Chairman, Hannover Messe Exhibitor Committee, stated, “Hannover Messe is where digitised, integrated industry is putting down roots, before growing into a mighty tree. This is the starting point for driving industrial advancement in countries around the world.” “The many and varied exhibits of Industry 4.0 plant and machinery made the coming industrial revolution a tangible reality for those in attendance,” said Köckler. A large number
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report | EVENT
“This year, we had more than 500 exhibitors from China; 250 from Italy, Turkey and Netherlands, followed by the US, France and Poland”
Marc Siemering, Senior Vice President, Deutsche Messe
of demo installations gave visitors a first-hand view of products “We will be organising CeBIT in moving through the various stages of production without any India this year. Another show, human intervention until individual processing at the very ‘Plugged In’ will be held end. Data security was another core issue at the fair. “Forum simultaneously” debates on process and data security issues attracted several Dr Andreas Gruchow, Member of the Board, Deutsche Messe thousand visitors, and industrial businesses will definitely be cooperating more closely with international cyber security providers, to prepare factories for the extensive integration that lies ahead,” noted Köckler. The focus of attention in the “energy halls” was on the transformation of energy systems. “The central theme of CeBIT in Future growth in the use of renewable forms of energy, India will be – New perspectives in decentralised energy supply systems and intelligent distribution the IT business” systems were high on the agenda. Exhibitors presented Mehul Shah, MD, Hannover Milano Fairs India technologies and solutions for the ongoing energy transition, with displays lending firm shape to the energy systems of the The awards presented during Hannover Messe included future. Highlighting on the country-wise participation, Marc Siemering, Senior Vice President, Deutsche Messe, said, “This Hermes & Robotics Award. SAG GmbH won the Hermes year, we had more than 500 exhibitors from China; 250 from Award for its iNES product, an intelligent distribution grid Italy, Turkey & Netherlands, followed by participation from management system that can be used to convert conventional the US, France and Poland. We have also seen increase in local grids in stages into smart grids. While the 2014 Robotics participation from some parts of Europe like Spain as the Award for excellence in applied robotics was won by Austrian economy is moving towards the positive. This has not only firm KEBA AG for its new way of positioning and programming mobile robots. The “KeTop T10 directMove” developed by the positively affected exhibitors’ turnout but also the visitors.” company is a new breed of handheld robot controller for positioning, guiding and programming mobile robots. Events Many conferences and forums were held during the trade Initiatives in India fair to highlight on the networking of automation and IT, While highlighting the launch of a new show in India, process automation, energy and resource efficiency, robotics and system integration, along with clever systems solutions for Dr Andreas Gruchow, Member of the Board, Deutsche Messe assembly and handling. The topics also included progress in AG, averred, “We will be organising CeBIT in India this year. materials research and lightweight construction to transform Another show, ‘Plugged In’ will be held simultaneously at the machine-building in far-reaching ways. These forums helped same venue.” Providing details of the new show, Mehul Shah, learn about the solutions already on the market in the industrial MD, Hannover Milano Fairs India, highlighted, “We are supply, production technologies, services, among other areas. organising CeBIT on November 12-14, at BIEC, Bengaluru. In Many forums were also held to discuss research, development a B2B format, the central theme of the show will be “New perspectives in the IT business”. We will be focusing on the and technology transfer in an international context. publish-industry Verlag, in official cooperation with ZVEI four forces in terms of trends in the IT business. The sectoral invited owners, managers and representatives from top focus will be on social, mobility, Big Data and the cloud and management and senior management of leading companies & the exhibitors will be clustered into eight different sectors. organisations at the VIP Talk on the RED COUCH. Chief Considering that CeBITin India is also the only CeBIT in Asia, editors of the PI expert media and Kilian Muller as Publisher there is a lot of business technology buyer interest from Asia and Editor spoke live with these experts on subjects that move Pacific, Japan and GCC which will add an Asian flavour to CeBIT in India.” the industry.
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EVENT | report
“People come to us being an Indian company with an Indian manufacturing base for alternative, cost-effective and reliable options” Sandeep Saheta, Director – Sales & Marketing, Connectwell Industries
Exhibitors’ viewpoint While elaborating on this year’s response at Hannover Messe 2014, Sandeep Saheta, Director – Sales & Marketing, Connectwell Industries, said, “This year’s Hannover Messe has been exciting enough. We consider it as a platform to showcase our products to visitors from world-over. This year has also been successful on this aspect. People come to us being an Indian company with an Indian manufacturing base for alternative, cost-effective and reliable options. We continue to see good demand from Eurozone customers. On the technology front, in connection technology, there has been a definite shift toward faster and safer connections. We are addressing these technology shifts by launching products that meet the ever changing expectations of customers globally. This year, we have launched the new CX Series spring clamp terminal blocks which is more compact and efficient with higher voltages.Also, to cater the solar industry, we now have 1,000 volt spring clamp terminal block. This is an offering that we would roll out across the globe in the coming months.” Affirming good demand at the fair, Ashish Manchanda, MD, Finder India, said, “For us, the response has been very good. Right from Day 1, we have had many footfalls and quality people who meant serious business. This is the kind of platform that makes new innovations successful. It also brings many Indian visitors to Hannover.” On the technology trends witnessed during the show, he asserted, “The technologies displayed this year are very encouraging. People are willing to spend money on innovations which is apparent from the overall dimension & variety at the show.” Highlighting the new launches and response from various sectors, Manchanda pointed out, “This year, we have launched 11 new products. Primarily, we have seen more demand in the power, O&G and building infrastructure sectors. Everybody is quite encouraged as business has been better in the first quarter of 2014.” For some, the show was not as good as for many. Vijay Kambe, Partner, KB Electronics, noted, “We are displaying programmable power supply, a cost-effective solution with equally good reliability. We have also displayed solar pump controllers and solar MPPT chargers for the European market. The response that we have got at the show is not good so far. We have found that this time the number of participants & visitors are less. Our experience with EEPC has not been very good. Next year, since India is the host country, EEPC should better get their show together.”
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“The technologies displayed this year are very encouraging. People are willing to spend money on innovations” Ashish Manchanda, MD, Finder India
“We are here to identify the technologies that can be modified & brought into use in the Indian urban infrastructure development” Capt VW Katre, Member, Executive Council, IEEMA
The association angle India’s representation at Hannover Messe has been consistent over the past years. Elaborating on Indian participation, Capt VW Katre, Member, Executive Council, IEEMA, said, “Members have come on their own at this fair, sometimes with reference from IEEMA or as part of EEPC. Most of the Indian manufacturers come here with a purpose to seek technology rather than to provide it. To the best of our knowledge, some of our members in the past have been able to formulate either a technology transfer, or a joint venture at this fair. We are here to identify the technologies that can be modified and brought into use in the Indian urban infrastructure development. Even though this is an extraordinarily vast field, we have identified technologies in the areas of smart grid, solar power, LEDs for lighting systems, more intelligent usage of power through technology deployment at this year’s Hannover Messe. We also have an ongoing dialogue with ZVEI to discuss newer thought processes, innovations and technologies.” With multiple forums, innovations and product launches, this year’s Hannover Messe turned out to be the key event for initiating the technology curve for integrated industry in the following year globally. The next Hannover Messe will be staged on April 13-17, 2015. ☐ > MORE@CLICK ADI03456 | www.AandD24.in
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EVENT | report
Building an idea factory Showcasing latest trends in automation technologies that offer concrete solutions to aspiring SME manufacturers who are looking for innovative ways to compete in the global economy, Automation Industry Association (AIA) in partnership with Wisdom Solutions and Maharatta Chamber of Commerce Industries & Agriculture, had recently organised a conference on “Leveraging technology for quantum jump in business” in Pune. A report… Automation Industry Association (AIA) had recently organised a forum on “Leveraging technology for quantum jump in business” in Pune, in partnership with by Wisdom Solutions and Maharatta Chamber of Commerce Industries & Agriculture. The purpose of the event was to inspire SMEs to view the tangible benefits and opportunities offered by new technologies to grow business opportunities.
Future of manufacturing industry Anup Wadhwa, Director, Automation Industry Association, facilitated a presentation of three case studies focused on automation by practitioners from the SME segment. In his opening remarks, he spoke about ‘Reshaping the future: transcending barriers with real time acumen’. He pointed that future manufacturing industry will be about convergence of technologies and intelligent collaboration of the entire ecosystem. He discussed how knowledge islands are
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synchronising and various processes inside and outside the plant are interconnected and interdependent from production to shipping. The entire business system is based on innovation partnership from strategy to execution which needs real-time acumen comprising of business acumen, operations acumen and process excellence. This discussion highlighted the following benefits: Efficiency and compliances: Increase throughput, reduce cost, improve accuracy and reliability and reduce human fatigue and human interference. Process improvement: Enhance productivity, improve quality and consistency, to work in areas unsafe for human operation, easy verification, validation and tracking. Business transformation and performance: Experiential transformation, provides real-time feedback to align sales and marketing and allows response capture and lead nurture; increases customer satisfaction and brand perception; and improves productivity of overall organisation.
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report | EVENT
Baxter common sense robots in the future are expected to meet with self-learning robots specifically designed to be affordable for mid-size and small manufacturers
Case study 1
Case study 3
During the conference, Pradeep Bhalwankar, MD, Twin During the conference, an interesting presentation was Engineers, shared his journey of automation enabled machines, given by Uday Mehta, MD, Sunrise Computer Systems, on how and concluded with a fascinating video of the Baxter common ‘One plus one equals eleven’. He discussed the importance of sense robots. “Twin Engineers, for many years restricted itself e-learning and how he embarked a new journey of developing to installations that were in close proximity to Pune because a strong e-learning platform. Then, after two years when the service needs were heavy. By embracing quality automation e-learning became a very common platform, he looked at a components it developed machines of superior capability that new dimension and his brainchild Maharishi Augmented were customised for auto majors in South and North India. Reality Domain (MARS) was born, integrated with mobile We also ventured in export markets as the machines they technology for learning and evaluation. MARS connects real make can be serviced easily via remote diagnostics,” he said. world to digital world by understanding the complex structure As per Bhalwankar, multi-axis movement in future will meet and working of human brain with the help of sensors. The with self-learning robots specifically designed to be affordable possible applications of MARS include trainning unskilled for mid-size and small manufacturers. New trends in workers in new skills set within the factory, in technical/ automation technologies offer concrete solutions to aspiring industrial schools, at dealer’s location or in the overseas plants SME manufacturers who are looking for innovative ways to of multinational companies. compete in the global economy.
Case study 2 Another highlight was the powerful presentation of smart automation of a milk plant by Vishwas Chitale, Partner, Chitale Dairy. He spoke about Business Process Automation (BPA) which focuses on running the business perspective to automate, monitor and analyse process model by executing, controlling and optimising the various processes. BPA often deals with event driven, mission critical and core processes. Processes like animal data recording, buffalo feeding, breeding and milking and how they are successfully integrated, controlled and managed by smart automation system at Chitale Dairy were showcased during the presentation.
Toward a quantum business jump
Nitin Ahir, Senior Trainer & Head Coach, Wisdom Solutions, explained technology as an initiator and how it can be used for catapulting team productivity and efficient collaboration. He discussed how the technology is currently under-utilised and the business owners are undoubtedly missing huge opportunities of growth due to this. He concluded by suggesting that we need to make up a choice about using technology if ever we need a quantum business jump in business. The conference addressed various ways of leveraging technology and reiterated its strong application in the manufacturing sector. ☐ Courtesy: Automation Industry Association > MORE@CLICK ADI03457 | www.AandD24.in
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T E C H N O L O G Y | TA L K
Rough & Tough Cables Suitable cabling solutions are necessary for tyre manufacturing factories to withstand high temperature & harsh operational conditions Tyre manufacturing industry plays an integral role in the transport sector. The Indian tyre industry has witnessed a tremendous growth for the past few years. In fact, availability of raw material (natural rubber) and ultramodern production facilities has led the country to emerge as one of the world’s most competitive tyre markets. According to Indian Tyre Industry Forecast 2015, the tyre production in India is anticipated to reach 191 million units by the end of FY 2016. Moreover, manufacturers are expected to invest huge amount into the industry over the next few years, with a major proportion of this investment directed toward the radial tyre capacity expansion. Tyre manufacturers in India are evolving greatly in terms of latest technology innovations. Lapp India has supplied superior quality cabling solutions for a leading global tyre manufacturer specialising in slow moving vehicles which is considered to be the world’s largest manufacturers of tyres for material handling and load handling vehicles.
Solution requirements The prime requirement was cabling solutions for large scale maintenance purposes in various crane and drag chain applications to transport raw materials and finished goods from one part of the factory to another; machines with parts that have to go through constant motion which will require remote controlling and trolley systems. The tyre manufacturing company required cables that can resist high temperatures of the tyre manufacturing factory and be dirt/dust resistant. Additionally, they also needed single core and multi-core heat resistant cables which
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can safely be used in harsh operational conditions.
Flexible cables for high movement applications Since the crane systems undergo constant movement, Lapp India provided cables that are flat and are highly flexible and durable, making them ideal for high movement applications. These cables maintain high standards as they are flame retardant and can withstand high temperatures. For trolley systems, the company supplied cables that are ideal for locations with space constraints. They are highly flexible and are also capable of withstanding harsh environmental and operational conditions. These cables are made up of strands of bare or tinned copper wires with rubber based core insulation. Additionally, the cables also have individual core screening consisting of tin-plated copper braiding and plastic foil wrapping. The copper braiding screens the cable against electromagnetic interference.
Heat resistant cables For these applications, Lapp India supplied silicon cables ideal for locations which have high ambient temperatures and where insulating sheath materials of conventional cables will embrittle after a short while. The cables comprise fine wires with tinned copper conductor. They have silicone based core insulation with a twisted and layered core. The cables also possess a silicone-based outer sheath. Moreover, these cables are halogen-free and flame-retardant and are resistant to oils, alcohols, vegetable and animal fats and chemical substances.
The tyre manufacturing company required cables that can resist high temperatures of the tyre manufacturing factory and be dirt/ dust resistant
The company also provided conduits to offer additional protection to cables used in the drag chain. These conduits are dimensionally stable and offer high resistance to oil, petrol, acid and grease. The conduits are air tight and impermeable along with the added features of being halogen and calcium free.
Key features The cables possess special features like weather-resistant flat rubber cables with copper screening, copper braiding screens the cable against electromagnetic interference and the flexibility simplifies installation where space is limited. The cables are made of silicone-based outer sheath halogen free and are flame retardant adhering to highest industry standards VDE/IEC. Extended temperature range of -25°C to +90°C with core insulation rubber compound and possesses insulating properties after combustion due to remaining SiO2 ash on the conductor. ☐ Courtesy: Lapp Cables > MORE@CLICK ADI03458 | www.AandD24.in
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news | technology
Automation solution for packaging B&R has developed reACTION and NetTime technology which reduces response times in industrial automation applications down to 1 µs, allowing extremely time-critical sub processes to be managed using standard hardware within IEC 61131 requirements. The performance of high-speed machine functions such as product labelling or rejection of sub-par products has also The newest solutions for the gained an enormous boost – without packaging industry will be on display added costs – through such on May 8 - 14, 2014 at interpack 2014 technologies. Packaging lines demand in Dusseldorf extreme levels of productivity and flexibility across the board - from the primary and secondary solutions straight through to the end-of-line equipment. This can be achieved through a modular design with control and drive components installed directly on the machine‘s frame - or even on rotating parts. B&R combines maximum performance, extreme flexibility and real openness with IP65-rated ACOPOS remote servo drives and ACOPOSmotor motor-integrated servo drives, and X67 series of machine-mountable I/O and safe I/O modules.
Energy measurement device ElMeasure has launched Power Duos — an advanced product that measures both AC and DC power source of a hybrid power scenario. The new product offers comprehensive world-class AC/DC power and dual source energy measurement and monitoring with communication option for integration with ElMeasure’s energy management system that helps to reduce The new product day-to-day operating costs and to avoid costly offers comprehensive business interruptions. The product combines world-class AC/DC state-of-the-art technology with harmonic viewing, power and dual source data logging and performance benchmarking. energy measurement Power Duos is loaded with features and functions and monitoring with that can perform multiple tasks that generally communication option require three or more different products. The key for integration with features include true RMS measurement; ElMeasure’s energy simultaneous sampling of Volts & Amps - AC and management system DC and reverse lock option user programmable for positive energy accumulation. It can be applied in DC energy management systems; power distribution for telecommunication tower control room and industrial DC control systems.
> MORE@CLICK ADI03459 | www.AandD24.in
> MORE@CLICK ADI03460 | www.AandD24.in
Terminal blocks to fight vibration
Safety light curtains
Connectwell has recently launched three terminal blocks STH3, STH4 and STH6 that are preferred for application where the connections are subjected to severe vibration. Here, the wire is crimped to a ring or fork lug and is screwed on to the flat current bar of the terminal block. The fastening nut in the block always remains captive in the hinged plastic carrier and the carrier is lifted to insert the lugs and then snapped into position. The nut can then be fastened to complete the connection. It can be operated using a standard screwdriver too. These terminal blocks have IP20 (Finger Safe) The fastening nut in the block always protection and do not need any remains captive in the hinged plastic additional shrouding. In fact, two carrier and the carrier is lifted to insert lugs can be connected to the the lugs and then snapped into position terminal without even sacrificing the safety of the concerned block.
Contrinex’s Safetinex light curtains consist of a sender and a receiver unit which, by exchanging sequential coded infrared rays, create a protective field between them. A safety relay connected to the AOPD (active optoelectronic protective devices) sends signals to the machine controller. Correctly installed, the light curtain detects any intrusion into the danger zone, activates the relay and thus, ensures an emergency stop of the system concerned. The distance between sender and receiver, as well as the dimensions of the optics, The light curtains consist determine the size of the protective field. of a sender and a receiver Safetinex YBB light curtains are ideal for unit which, by exchanging finger and hand protection. For the sequential coded infrared access protection of larger areas, the rays, create a protective field Swiss specialists offer the YCA between them multi-beam photoelectric sensors. These curtains have a resolution “R” of 14 mm for finger protection or 30 mm for hand protection. “R” is the sum of the distance of the beams from each other (i) and the effective diameter of a beam (b): R = i + b.
> MORE@CLICK ADI03461 | www.AandD24.in
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> MORE@CLICK ADI03462 | www.AandD24.in
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technology | news
Engineering software tool EPLAN has launched a new version EEC One. Available in 17 languages, the software supports important international standards and norms for the global market. The newly integrated dictionary function also ensures direct access to the EPLAN dictionary and hence translates the entire documentation of the schematics in all possible languages. Language barriers are removed and the efficiency level of the software usage is increased too. Also, a fixed Available in 17 languages, the software value can be specified for the supports important international standards position of macros with respect and norms for the global market to the predecessor macro. The deep connection to the EPLAN Platform is also reflected in the integrated parts selection. The software directly accesses the EPLAN parts database and transfers parts and their reference data. Transmission errors can be avoided due to the automated data transfer and efficiency can be increased at the same time. The software is compatible with the current EPLAN Platform 2.3 and the predecessor version 2.2 too. > MORE@CLICK ADI03463 | www.AandD24.in
Pneumatic rotary lift
Test and evaluation kit for real-time ethernet Hilscher GmbH offers a test and evaluation kit for the six most common real-time-Ethernet systems. The kit is suitable for development, test labs, education & end users. It contains a cifX master PC card, three NXIO slave test-devices and a netANALYZER as Ethernet analysis device with Gigabit-Ethernet PC-interface. It also contains Ethernet cables, power supply and master & slave firmwares for It contains a cifX master PC card, EtherCAT, EtherNet/IP, Modbus three NXIO slave test-devices and a TCP, POWERLINK (slave only), netANALYZER as Ethernet analysis device PROFINET and Sercos. The with Gigabit-Ethernet PC-interface comprehensive documentation leads the user in a step-by-step guide through the configuration of the network using SYCON.net. It explains the measurement of important network parameters using the netANALYZER which has no influence on the network and analysis methods supported with graphic output. It also captures all process data with name resolution & always passive with zero delay. > MORE@CLICK ADI03464 | www.AandD24.in
Stripable control cable series
SCHUNK has added the pneumatic rotary lift unit DRL 20 to its program for modular high-performance assembly. It offers a particularly compact unit and allows highly dynamic and smooth pick & place operations in confined spaces of the complex assembly plants, assembling electronics, medical and consumer goods with rotating angles of 90° or 180°. Since the units are positively driven behind the movement of the vertical cylinder and the rotary drive by a cam roller, both can be switched sooner and the cycle time is considerably shortened. At a minimum loading and rotation angle of 180°, 75 cycles per minute can be achieved. To additionally increase the plant’s productivity and process reliability, its effector can be directly stopped over the individual target position. It will go DRL 20’s effector can into standby position, until the feeding or the be directly stopped deposit unit is ready. At an operating over the individual pressure of 5 bar, it achieves a torque of target position 2.26 Nm and a lifting force of 245 N.
igus recently introduced CFRIP, which has been added to all control cable series with PVC jackets and in motor cable families. With the unique CFRIP principle, chainflex cables can be stripped quickly and safely in large lengths without damaging cores. Similar to a zipper, it opens by simply pulling on the CFRIP tearing thread within the jacket to the desired length. With it, installers save up to 50% of the usual required time for With the unique CFRIP principle, stripping. Apart from that, chainflex cables can be stripped quickly specific stripping tools are no and safely in large lengths without longer required. Along with PVC damaging cores control cables chainflex CF5, tearing thread in the outer jacket and the shielded version chainflex CF6, tearing thread in the inner jacket – now the control cable families CF5, CF6, CF130 and CF140 as well as the complete multi-core motor cable families are equipped with the CFRIP thread. Around 230 chainflex cable types with integrated CFRIP tool are currently available. More cable series with integrated CFRIP are in development.
> MORE@CLICK ADI03465 | www.AandD24.in
> MORE@CLICK ADI03466 | www.AandD24.in
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A & D I n d i a | A p r- M a y 2 0 1 4
news | technology
Light-weight laser profile scanner
Measuring light grid
Micro-Epsilon has introduced a compact, light-weight laser profile scanner scanCONTROL 2600/2900 with integrated controller enclosed in a 380 g aluminium housing. While the small sensor provides a large range of features, up to 4,000 profiles per second can be transferred to a PC for further processing. It also offers a measuring rate up to 640 points per profile. The measuring range starts at a distance of 53 mm from the sensor and can be extended up to 390 The scanCONTROL mm, depending on the sensor model. 2600/2900 offers a Gigabit ethernet interface and measuring rate up to 640 multi-purpose interface for RS422 points per profile connections are available for the scanner. The digital inputs can be used for synchronising and triggering. An additional output unit can be used to provide more output signals. It is particularly well suited for applications that require a low sensor weight, for example, in automotive production or when sensors are mounted to robot arms.
Pepperl+Fuchs has recently launched the new LGM Series measuring light grid where the values are digitally transmitted at extremely fast cycle times, even with beam crossover activated, using IO-Link, enabling convenient commissioning and maintenance from the control level. Parameterisation and configuration are completed via a PC. The light grids have an ultra-low profile to fit into tight spaces. Innovative, tool-free mounting accessories make installation, alignment and replacement fast and easy. The IP67 aluminium housing withstands harsh environmental conditions even at cold-storage temperatures. It is available with various resolutions and field heights up The LGM light grids to 3200 mm, permitting large measuring have an ultra-low ranges. Unlike complex products with profile to fit into single-beam output that evaluate each beam tight spaces measuring light grids provide measured values in millimeters without time-consuming calculations and set new standards with their compact design, functionality and unique price/performance ratio.
> MORE@CLICK ADI03467 | www.AandD24.in
> MORE@CLICK ADI03468 | www.AandD24.in
Managed switches for Ethernet network Phoenix Contact has launched new managed switches of 3000 Series which support comprehensive IT–compatible functions range and are reliable and maintenance-friendly and ideal for inexpensive & reliable ethernet networks. The comprehensive features of the switch include easy to fit in industrial harsh environment such as narrow design, DIN rail mountable and extended temp range up to 75 degrees. The redundant power supply features The redundant power supply features increase the maximum availability increase the maximum availability of of the switches and LEDs. They the switches and LEDs also possess extended ring redundancy in critical infrastructure applications. It has the latest security functions such as 802.11 x radius authentication; Mac based port security and encrypted management access with HTTPS. To increase network performance, comprehensive filtering and prioritising functions can also be configured through static and dynamic VLAN, flow control, storm control and traffic shaping along with quality over Service (QoS) with four priority queues. > MORE@CLICK ADI03469 | www.AandD24.in
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Statement about ownership & other particulars about A&D, as required to be published in the first issue every year after the last day of February 1. Place of Publication: 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001 2. Periodicity of Publication: Bi-monthly 3. Printer’s Name: Kala Jyothi Process Pvt Ltd Address: S.No. 185, Kondapur, R R District, AP 500 133 4. Publisher’s Name: Shekhar Jitkar Nationality: Indian Address: 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001 5. Editor’s Name: Shekhar Jitkar Nationality: Indian Address: 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001 6. N ames & addresses of individuals who own A&D and partners or shareholders holding more than 1% of total capital of publish-industry India Pvt Ltd, 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001 Details of the shareholders of publish-industry India Pvt Ltd who are holding more than 1% of the paid up equity share capital of the company as on 24-04-2014: a) publish-industry Verlag GmbH, NymphenburgerStrasse 86, 80636 Munich, Germany b) Kilian Mueller, NymphenburgerStrasse 86, 80636 Munich, Germany I, Shekhar Jitkar, hereby declare that all the particulars given above are true to the best of my knowledge and belief.
Dated: 24th April 2014 Sd/SHEKHAR JITKAR Signature of the Publisher
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h i g h l i g h t s | c o m pa n y i n d e x | I m p r i n t
Highlights - (Jun/Jul 2014) impRINT
Automation & Drives
Publisher / Chief Editor Efficient Manufacturing
Shekhar Jitkar shekhar.jitkar@publish-industry.net Deputy Editor Sumedha Mahorey sumedha.mahorey@publish-industry.net Sub-editor & Correspondent Srimoyee Lahiri srimoyee.lahiri@publish-industry.net
»»Pharmaceuticals & Packaging The pharmaceutical industry has poured millions of dollars into new technologies over the past two decades, but this has had little impact on the high drop-out rate and cost of drug development. The next issue addresses latest developments in automation for this industry vertical, steps toward miniaturisation, and robotics-based strategies. Most companies acknowledge packaging and packaging operations as significant components of their supply chains. The next issue will focus on the latest innovations in automation technologies for this sector, RFID, and will present application stories from the world of packaging industry.
»»Fieldbuses & Networks In the recent years, there has been an increase in focus on application of Fieldbus & Networks technology. One of the problems that have impeded the rapid adoption of fieldbus technology has been the lack of standardisation. Several competing alliances were created that all strived to develop an open fieldbus that would establish itself as standard. The result is that today there exist a plethora of standards for open fieldbuses. In the next issue, we take a look at some of the standards and recent developments in this sector.
»»Test & Measurement Wireless is changing the face of test & measurement equipment at a pace never seen before. Due to the increasing need for greater accuracy and higher definition measurement, the tools involved in the test and measurement industry are constantly developing to accommodate technological advancements in the industries they cater to. The upcoming issue gives an insight into the recent advancements made in this field and looks at how beneficial the systems can be to various industries
Features Writer Megha Roy megha.roy@publish-industry.net Advertising Sales Sagar Tamhane (Regional Head - North & East) Contact: +91 9820692293 sagar.tamhane@publish-industry.net Dhiraj Bhalerao (Regional Head - West & South) Contact: +91 9820211816 dhiraj.bhalerao@publish-industry.net Prabhugouda Patil Bengaluru Contact: +91 9980432663 prabhu.patil@publish-industry.net Advertising Sales (Germany) Caroline Häfner (+49 - 89 - 500 383 - 53) Doreen Haugk (+49 - 89 - 500 383 - 27) sales@publish-industry.net Overseas Partner Ringier Trade Media Ltd China, Taiwan & South-East Asia Tel: +852 2369 - 8788 mchhay@ringier.com.hk Design & Layout Sovan Lal Tudu (Senior Designer) sovan.tudu@publish-industry.net
company Index Name . . . . . . . . . . . . . . . . . . . . . . . . . . Page ABB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Allegion India . . . . . . . . . . . . . . . . . . . . . . . 18 Analog Devices . . . . . . . . . . . . . . . . . . . . . . 64 Ansys Inc . . . . . . . . . . . . . . . . . . . . . . . 12, 14 ARC Group . . . . . . . . . . . . . . . . . . . . . . . . . 20 Automation Industry Association (AIA) . . . . 36, 74 Avadhoot Automation . . . . . . . . . . . . . . . . . . 36 Avasarala Technologies . . . . . . . . . . . . . . . . . 36 B&R Industrial Automation . . . . . Cover, 6,7, 77 Baumer . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Bharat Bijlee . . . . . . . . . . . . . . . . . . . . . . . . 29 Chanto Air Hydrantics Co Ltd . . . . . . . . . . . . . 15 Connectwell Industries . . . . . . . . . . . . . . . 9, 77 Contrinex Automation . . . . . . . . . . . . . . . 1, 77 CST Sensors . . . . . . . . . . . . . . . . . . . . . . . . 27 Delta India Electronics . . . . . . . . . . . . . . . . . 31 Deutsche Messe . . . . . . . . . . . . . . . . . . . . . 70 EIMeasure . . . . . . . . . . . . . . . . . . . . . . . . . 77 Emerson Network Power . . . . . . . . . . . . . . . 10 Emerson Process Management . . . . . . . . . . . 42 Eplan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
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Name . . . . . . . . . . . . . . . . . . . . . . . . . . Page Faro Business Technologies . . . . . . . . . . . . . 23 Festo Controls . . . . . . . . . . . . . . . . . . . . . . . 41 Galil Motion Control . . . . . . . .Back Inside Cover HGS Automation . . . . . . . . . . . . . . . . . . . . . . 8 Hilscher India . . . . . . . . . . . . . . . . . . . . 19, 78 HMS Industrial Networks . . . . . . . . . . . . . . . . 57 Honeywell . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Hummel Connector Systems . . . . . . . Back Cover ICP Das . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 IFM Electronic India . . . . . . . . . . . . . . . . . . . 47 Igus India Pvt Ltd . . . . . . . . . . . . . . . . . . . 2, 78 IIITB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Kollmorgen . . . . . . . . . . . . . . . . . . . . . . . . . 12 Kubler Automation . . . . . . . . . . . . . . . . . . . . 61 Lapp Cables . . . . . . . . . . . . . . . . . . . . . 12, 76 MathWorks . . . . . . . . . . . . . . . . . . . . . . . . . 10 MentorWise Advisors . . . . . . . . . . . . . . . . . . 36 Messe Frankfurt . . . . . . . . . . . . . . . . . . . . . 67 Micro-Epsilon . . . . . . . . . . . . . . . . . . . . . 5, 79 Mifa Systems . . . . . . . . . . . . . . . . . . . . . . . 63 National Instruments . . . . . . . . . . . . . . 4, 16, 56
Name . . . . . . . . . . . . . . . . . . . . . . . . . . Page Okuma . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Omron Automation . . . . . . . . . . . . . . . . . . . . . 3 P+F FA Division . . . . . . . . . . . . . . 8,12, 45,79 P+F PA Division . . . . . . . . . . . . . . . . . 17, 36 Parker Hannifin . . . . . . . . . . . . . . . . . . . . . . 53 Phoenix Contact . . . . . . . . . . . . . . . . . . 55, 79 Pilz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Red Lion . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Reliance Industries . . . . . . . . . . . . . . . . . . . . 24 Renu Electronics . . . . . . . . . . . . . . . . . . . . . 39 Rockwell Automation . . . . . . . . . . . . . . . . . . 62 Schneider Electric . . . . . . . . . . . . . . . . . . . . . 8 Schunk Intec India . . . . . . Front Inside Cover, 78 Sesame Motor Corp . . . . . . . . . . . . . . . . . . . 65 Siemens PLM . . . . . . . . . . . . . . . . . . . . . . . . 8 Siemens . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 TÜV SÜD Chemie Service . . . . . . . . . . . . . . . 48 VDMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Vega India Level & Pressure Measurement . . . 11
Editorial & Business Office publish-industry India Pvt Ltd 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001, Maharashtra, India Ph: + 91 - 20 - 6451 5752 Board of Directors Kilian Müller (CEO - Worldwide) Hanno Hardt (Head - Marketing & Business Development) Frank Wiegand (COO - Worldwide) Shekhar Jitkar (Publisher / Chief Editor) Subscription Annual Subscription Price: Rs 600 includes shipping and VAT. AandD.india@publish-industry.net Ph: +91-20-6451 5754 Printing Kala Jyothi Process Pvt Ltd, S.No: 185, Kondapur, R R District, AP 500 133, INDIA Copyright/Reprinting The publishing company holds all publishing and usage rights. The reprinting, duplication and online publication of editorial contributions is only allowed with express written permission from the publishing company. The publishing company and editorial staff are not liable for any unsolicited manuscripts, photos and illustrations which have been submitted. Internet http://www.aandd24.in
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