Automation & Drives
AUTOMATION & DRIVES
VOL 05 | DEC-JAN 2013/14 | ` 100 www.AandD24.in
Automation & Drives
A U T O M AT I O N & D R I V E S
AUTOMATION SYSTEM REQUIREMENTS
An end user’s perspective DEC-JAN 2013/14 I VOLUME 05
Also available in China, Taiwan, Singapore, Malaysia, Thailand & Hong Kong
Efficient Manufacturing
FOCUS Food & beverage industry
P. 30, 34, 38
ROUND-TABLE A step toward enhancing competitiveness
P. 26
A&D - Interview WWW.AandD24.IN
President & CEO, Fieldbus Foundation
In association with
(p.24)
Advt
Richard J Timoney
0,01
HLM Linear Module mm repeat accuracy
SRU-mini
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Miniature Gripper
gripping force 25 % higher
Your automated handling system. It’s time to make use of your machine’s full potential.
The real kW sens offer appl the u com
www.in.schunk.com/machine-potential Jens Lehmann, Brand Ambassador of SCHUNK, the family-owned company
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To g e t h e r, we c a n e n h a n ce yo u r m a c h i n e performance and productivity through versatile and reliable motor control
The AC10 Micro Drive from Parker Hannifin is meant for OEMs and process industry users who are looking for a real value-for-money product with a high performance to price ratio. Available in the power range of 0.2 kW to 15 kW in both 230V 1- & 3-phase and 400V 3-phase versions, it is probably the only micro drive on market offering sensor-less vector control, and a choice of VVVF control curve, in a compact and user-friendly package. AC10 offers efficient, reliable, and precise control of AC Induction motor in wide range of Industrial and Commercial applications.Designed to operate in harsh and humid environments, the AC10 also saves initial cost and effort to the users with its wide array of built-in features that comes in handy to the operators during installation and commissioning. Centrifuge, Mixer, Conveyor, Wire-drawing machines, Textile, and packaging machines, or, Pump
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An effective partnership NTPC, a leading public sector company of India, is emerging as a diversified power major with presence in the entire value chain of the power generation business. Although the company has 16% of the total national capacity, it contributes 25.6% of total power generation due to its focus on high efficiency. Automation technology has been playing a significant role in NTPC’s core business operations in terms of renovation and modernisation of power plants for power plant life extension, performance optimisation and improvement of availability and efficiency. The Cover Story in this issue talks on the end-user perspective on deployment of automation systems at NTPC. It’s an interesting read where the author from NTPC shares her experience while implementing various automation technologies in different plants, and advises on the enduser expectations and the value proposition necessary for success, by way of an effective partnership with automation service providers. The Round-table this time features a report on the Panel Discussion by A&D India on the strategies to synchronise investments in automation with the changing economic cycles and the adoption of latest automation innovations to reach the desired competitiveness levels. All the panelists collectively agreed with the fact that automation solutions today should be smarter, faster & costeffective which can fulfil the exact needs of end users for reducing costs and improving quality and competitiveness, in short, just-enough automation. Check out the Round-table feature to know more. We would like to take this opportunity to wish all of our readers a very happy & successful 2014!
INNOVATIVE SENSORS FOR MEASUREMENT AND CONTROL Displacement, distance, position, dimension, temperature and colour Widest variety of physical principles 45 years of experience in sensor solutions All from one source: Advice and technical support Conception and design Production and service
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
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 India | Dec-Jan 2013/14
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 Chennai 3 Phone +91 44 24981786 | www.ipsindia.in
CONTENTS
Market
Management
10
NEWS
24
16
“INTELLIGENT SYSTEM IS THE FUTURE”
Focus
Food & beverage industry
ADAPTING TO THE CHANGING NEEDS OF PROCESS AUTOMATION
Interview with Richard J Timoney, President & CEO, Fieldbus Foundation
Interview with Darren Chen, Country Manager, Advantech India 70
TO BE FUTURE READY
A post event report on Autom@tion Tech 2013 organised by AIA
30
An article discussing right automation solutions for hygienic manufacturing needs of the food and beverage industry
Round-Table 26
A STEP TOWARD ENHANCING
34
FOUNDATION FOR BUSINESS INNOVATION
A post event report on GIL India organised by Frost & Sullivan 74
BUSINESS MEETS TECHNOLOGY
Event preview of ELECRAMA 2014 to be held in Bengaluru
MACHINE SAFETY
A read into the various needs of the food industry including suitability of the devices for high & low temperatures
COMPETITIVENESS 72
FRESH ON THE TABLE
Industry experts in discussion on how to align investment in automation with changing economic cycles 38
AUTOMATED DOCUMENT MANAGEMENT
This article highlights the shift from traditional in-house storage methods to automated document management solution and cloud-based storage system
CONTENTS
Advt
Technology
Cover Story 18
AN END USER’S PERSPECTIVE
CONTROL & REGULATION 54
An article on NTPC’s views on new age automation system adoption
A fully integrated universe
The article delves into the need for close integration of all systems and information in the process industry
MACHINE VISION 42
Inspection of hygienic tissue products
SOFTWARE & ENGINEERING 58
A feature on Web Inspection System that provides the ability to identify & categorise quality related defects with a high degree of reliability 46
High resolution imaging to cut costs
A change in design software
An application story on the benefits achieved in the quality of project documentation by PARI with the use of EPLAN software MANUFACTURING IT 62
An application system on the use of R-TECH’s visual inspection system by Peugeot SA
New Products 77
78
Achieving optimum efficiency
The feature discusses the benefits that can be achieved through the use of Ruby on Rails framework 79
INDUSTRIAL COMPUTERS & PERIPHERIES 50
Industrial PCs on the factory floor
FIELDBUS & NETWORKS 66
Open source solution
The article talking on the advantages of open source solutions like POWERLINK for modern automation requirements
The article identifies the top 5 challenges on the shopfloor and points to consider while selecting industrial PCs and associated components
Ultrafast automation technology; Connector technology; Low cost cables; AC variable frequency drives Touch screen based HMI; Standardisation and automation software tool; CANopen devices; Steel wire braided flexible cable Remote I/O modules; Multiphysics simulation platform; Flexible corrugated conduits; Air blow gun
Columns
TECH-TALK 76
Crucial elements of functional safety
An insight into safety performance and best practices for manufacturing safety programs
07 Editorial 08 Contents 80 Highlights - Next issue 80 Company index
Advt
MARKET | NEWS
ProSoft Technology announces its new President & CEO ProSoft Technology has announced the appointment of Thomas Crone as the President and CEO of the company. “Our search for ProSoft’s next CEO began this past spring,” said Gary Joke, Chairman of the Board of Director, ProSoft Technology. “With the help and guidance of an executive search team from Korn/FerryvInternational, we were looking for a candidate with experience and expertise in leading global businesses, industrial automation technology, global sales and marketing and general business management. Most importantly, we were looking for someone who would be a strong fit within the ProSoft culture. Tom fit all of our criteria”, he added. Tom Thomas Crone is comes with a vast array of experiences that will help appointed as the new take ProSoft Technology to the next level. Most recently President & CEO of he served in the role of Executive Vice President and ProSoft Technology CMO, Valin Corporation, a provider of process control and automation solutions. At Valin, he was responsible for a US-based global distribution business with five divisions, 15 operations, and 250 employees. His leadership helped guide the company through organic sales growth and multiple acquisitions. > MORE@CLICK ADI03346 | www.AandD24.in
Siemens has inaugurated its state-of-the art ‘Advanced Motor Test Centre’ at Kalwa Works in Mumbai. One of the most advanced test centres of its kind globally, the fully automated test centre houses 8 test benches capable of testing motors in the wide range of 120 W to 3000 kW. “The Indian electrical equipment Industry has witnessed a host of changes in recent years including adoption of new standards for efficiency for industrial motors. This also has given rise to new testing methods for efficiency calculation as well. “At Siemens, we have been a constant partner to the Indian manufacturing Industry by Siemens has inaugurated its stateoffering the widest range of industrial of-the art ‘Advanced Motor Test motors that conform to the new efficiency Centre’ at Kalwa Works in Mumbai standards. In fact, we are the only one to have the complete range of motors conforming to the latest efficiency norms. We are now moving a step ahead to unveil our world class test centre for motors at our facility in Kalwa, Thane,” said Wolfgang Weissler, CEO, Drive Technologies, Industry sector, Siemens Ltd. > MORE@CLICK ADI03347 | www.AandD24.in
SPS Automation India announced
Schmersal India starts factory at Pune
Messe Frankfurt Trade Fairs India together with Mesago Messe Frankfurt introduces Europe’s leading automation exhibition SPS IPC Drives to the Indian market. The organisers feel it is the perfect time to harness business opportunities across all verticals of the automation industry in India and believe the launch of ‘SPS Automation India - Driving manufacturing processes of the future’ will be the ideal platform to aid this development. The trade fair, like the mother event SPS IPC Drives (Nuremberg), will represent a leading platform for innovations in the field of industrial automation and host a vast range of displays of products, systems and services. SPS Automation India will be held from February 5 to 7, 2015 at Mahatma Mandir Convention and Exhibition Centre in Ahmedabad, Gujarat. “The solution to India’s pursuit of being a worldclass industrial competitor is automation, and we are confident that SPS Automation India will present the sector players the perfect platform to showcase technologies while allowing the Indian market,” said Raj Manek, MD, Messe Frankfurt Trade Fairs, India.
Schmersal Group has started the production in its Indian factory at Ranjangaon near Pune, Maharashtra. The plant has been built with unique precast technology in a plot area of 20,000 sq m. The first phase built-up is around 9,000 sqm and the products which will be produced in the first phase are safety position switches (both metal and plastic versions), safety door switches and safety pull cord, emergency trip wire switches. The plant has been built with During production Schmersal India ensured the following parameters. unique precast technology in a plot area of 20,000 sq m It took care of 100% testing of safety switches; starting the actual production only after completion of successful trials & testing and focus on continuous improvement for operational excellence. “Today, we have a dense network of own sales staff, engineers and distributors and we see rising demand year by year. Now a volume has been reached that justifies an own production,”said Sagar Bhosale, MD, Schmersal India Operations.
> MORE@CLICK ADI03348 | www.AandD24.in
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Siemens inaugurates advanced motor test centre
> MORE@CLICK ADI03349 | www.AandD24.in
A&D India | Dec-Jan 2013/14
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MARKET | NEWS
HARTING pushes technological change
Omron welcomes its new Managing Director
The HARTING Technology Group has released its performance in the Omron Industrial Automation has announced the appointment of Sameer financial year 2012/2013. “We have realised Gandhi as its new Managing Director for India. As the new MD, Gandhi will new record revenues”, said Philip Harting, be responsible for Omron Industrial Automation’s Senior VP, Connectivity & Networks, HARTING strategic growth and expansion in India, during the press conference at the sps/ipc/ bringing global best practices and technologies drives 2013 trade fair in Nuremberg. By to critical Indian industries. Gandhi brings an September 2013, more than 3,800 employees experience of over 23 years across multiple worldwide worked for HARTING. The company disciplines and vertical industries. He joins has created 200 new jobs within a year. The OMRON from ABB, India, where he served as VP, company is well positioned in the market for Strategic Account Management, focusing on the future and aims to deliver genuine added strengthening relationships with key customers Philip Harting, Senior value for customers, which is one of its declared in India across various ABB business verticals. Vice President, Sameer Gandhi is corporate objectives. It anticipates strong Prior to this, he held various diverse Connectivity & Networks growth opportunities in the rapidly expanding the new Managing responsibilities including sales, operations and - Integration, HARTING Director for Omron Asian markets, particularly in China. “We are P&L serving several industry verticals including Technology Group expanding our production capacities in China minerals and cement, pulp & paper and robotics. Industrial Automation India which will bring us even closer to key customers “Omron is well-known for its products and in future”, said Harting. Another major growth application strength in the industrial automation driver is HARTING’s extensive range of solutions for “integrated industry. segment globally. I would like to replicate the same in India and grow the This concept is playing a pivotal role in technological change in industry business as I see a lot of market potential and we’ve a very strong team and is therefore the key focus of HARTING’s exhibition. OMRON,” said Gandhi. > MORE@CLICK ADI03350 | www.AandD24.in
> MORE@CLICK ADI03351 | www.AandD24.in
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AUTOMATICA, MAINTAIN & Intersolar Europe 2014 The trade fairs AUTOMATICA & MAINTAIN, and the guest event Intersolar trade fair for industrial robotics and professional service robotics under Europe will take place parallelly at one roof. the New Munich Trade Fair Centre The automation industry is working from June 3 to 6, 2014. Dr Reinhard intensively on its own energy Pfeiffer, MD, MesseMünchen says, transition. Assembly systems, “We have decided to hold processes, robots and components AUTOMATICA parallel to Intersolar are being tweaked consistently to be Europe, international trade fair for more energy efficient. The show will Solar Technology. The solar energy also provide trade fair visitors with a industry is anticipating increasingly wide range of energy efficiency and on automated solutions in sustainability topics with the presence international competition. The of leading manufacturers and the combination of the two leading VDMA sustainability initiative – Blue The show will also provide trade fair visitors with a wide range of energy Competence. trade fairs in their segments is AUTOMATICA also efficiency and sustainability topics presents pioneering for production specialists. innovations to the The range of exhibitors will be international automation industry supplemented ideally by MAINTAIN - trade fair for Industrial Maintenance.” based on changes of production technologies in the automobile industry. Innovations and trends from industrial maintenance, automation, The special exhibition “Automated Composite Production” and the “Industrial mechatronics and solar energy industry will be presented under the motto Composites Production Conference” in the East Press Centre from June 5 to “One Stop – Three Shows.” 6 will examine state-of-the-art technology for increasing process speed AUTOMATICA 2014 will present a separate exhibition area for service and reducing production costs. > MORE@CLICK ADI03352 | www.AandD24.in robotics for the first time. As a result, it is positioning itself as the leading
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A&D India | Dec-Jan 2013/14
Hilsche
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05.12.2013 16:58:34
MARKET | NEWS
Agilent Technologies inaugurates CrossLab Agilent Technologies has launched the Agilent CrossLab laboratory at its Manesar campus. This initiate will further strengthen the company’s CrossLab Enterprise Services, a synchronised laboratory solution by Agilent Technologies, a service model for all instruments regardless of the brand. The laboratory is an investment done by Agilent Technologies to further strengthen the CrossLab services initiative started in India three years back for providing comprehensive service support to analytical instruments from various manufacturers which are used in pharma, biotech, food, environmental industries across India. This laboratory will help increase the capability of Agilent service The laboratory will help increasing engineering team with hands-on training the capability of its engineering on analytical instruments from various team with hands on training on manufacturers. “We are extremely proud analytical instruments of our CrossLab Laboratory which offers industry’s best facilities to our customers. The CrossLab will enable simplification product selections and purchase for our customer,” said Dr Siva Kumar Pasupathi, Country Head — Life Sciences and Chemical Analysis Unit, Agilent Technologies. > MORE@CLICK ADI03353 | www.AandD24.in
Cummins announces its power generation product line Cummins India has unveiled a series of generator sets that are compliant with the new environmental norms (CPCB II), to be implemented by the Central Pollution Control Board in India. Working ahead of the lowered emissions implementation dates, the company is at the forefront of releasing fuel-efficient and smartly-designed auxiliary power solutions. Recognising the importance of adhering to cleaner standards and the necessity of upgrading the emission norms for the betterment of the environment, the company has already commenced The series of generator sets production of the new series of generator are compliant with the new sets at its plant in Pirangut, Maharashtra. environmental norms (CPCB II), The new series of generator sets are to be implemented by the Central equipped with after-treatment systems Pollution Control Board in India that feature the most advanced exhaust emission-reduction technologies, exceeding the mandated emission standards and offering improved energy efficiencies. In addition, technological innovation has eliminated the need for diesel particulate filters by deploying a high-pressure fuel injection system that significantly optimises fuel efficiency. > MORE@CLICK ADI03354 | www.AandD24.in
Danfoss introduces VLT® Automation Drive FC 360
Emerson launches new Trellis™ platform express edition
Danfoss has unveiled its new VLT® Automation Drive FC 360. The VLT® Automation Drive FC 360 is a dedicated industry drive that provides precise and efficient motor control in a wide range of industrial applications. Due to the fact that all Danfoss frequency converters follow the standard design and operating principle, existing owners and users of VLT® drives will feel instantly at home when operating the VLT® Automation Drive FC 360. Featuring a basic yet comprehensive The VLT® Automation Drive feature set, the drive provides precise FC 360 can control electrical and energy efficient motor control. motors from 0.37-75kW Available in five frame sizes, the VLT® Automation Drive FC 360 can control electrical motors from 0.37-75kW. Designed to work in harsh and humid environments, the drive provides reliable operation in industries such as textile, pharma & chemical, plastic & rubber, metal work, material handling, food & beverage, and building materials. The drive enables precise and efficient motor control of a wide range of industrial applications such as extruders, winders, conveyors and drawing benches.
Emerson has launched the Trellis™ platform express edition that offers the benefits of data centre infrastructure management (DCIM) in a streamlined and simplified delivery model. The Trellis platform gives customers a holistic, real-time view of the data centre across facilities and IT resources, providing the information needed to improve overall operational efficiency and to plan for the future. The edition offers the same capabilities in a turnkey package, making it an easy, efficient and cost-effective way for customers to get started with the Trellis platform. It also offers a flexible, scalable foundation to build on as business needs change. The key advantages include a simplified ordering process and bundled packaging of functionality, making it quick and easy to deploy. Furthermore, it scales and flexes as data centre needs grow. For small and medium sized businesses the edition addresses the need to quickly and easily order and deploy a DCIM solution that is right-sized for their organisation. For large enterprise data centres considering a DCIM solution, it’s designed to address their immediate needs while reducing complexity and time to implement.
> MORE@CLICK ADI03355 | www.AandD24.in
> MORE@CLICK ADI03356 | www.AandD24.in
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A&D India | Dec-Jan 2013/14
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MARKET | INTERVIEW
‘Intelligent system is the future’ Detailing on the basic elements of an intelligent system – Internet of Things and cloud computing, Darren Chen, Country Manager, Advantech India, in this conversation with Sumedha Mahorey, speaks on the current market challenges and the opportunities in the embedded systems market. Which are the latest technology trends shaping up in the embedded systems market? In the embedded systems market, intelligence planning is one of the major trends. It works on many intelligent systems, is interconnected, responds to any situation, and can be connected to the cloud. Intelligent systems will be prevalently used in the next 20 years. The basic elements for an intelligent system are the Internet of Things and cloud computing. Which are the current demand trends emerging in the embedded systems market? Embedded system applications can be used in varied industries including telecommunications, defence, and in any other industrious market. This trend towards adoption of technology is already happening in different parts of the world. Considering demand in the global market, certain examples where intelligent systems are being used include bus transportation system where digital signage give details on the buses’ location, time to arrive at the stop, the passenger count, waiting time, among other features. How are embedded systems changing the automation industry? Previously, the data was present only on the devices, now they are connected to each other. For example, in the case of automation, in the earlier production scenario, we needed to look at the boards for details on operations. Now, all operations are connected with sensors. The manager gets all the information updated in real-time. Key embedded trends adopted by the automation industry? For the automation industry, embedded systems are being used in warehousing and process automation. In the warehouse, Tablet PC helps in locating products that are 5G tagged while in process automation, all the processes have now been
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computerised and all the information can be accessed at one single location. What are the challenges for embedded systems in the automation industry? Currently, companies are not ready to invest. They are looking at cost effective, more convenient options instead of opting for research and development of a new product. How is the embedded market shaping up amidst the sluggish growth? The current market situation opens up another opportunity for us. As the economy returns on track, customer will be more open to look for different solutions which are more efficient. This will help them save cost on maintenance and development. In the long-term, we also plan to provide total cost of ownership. What are your plans for the Indian market in 2014? We have localised and set up a company in August 2012, called Advantech India, headquartered in Bengaluru. With this, we now have the technical support centre with designing service and local repairing centre. Recently, we have also started an assembly line in Bengaluru. We also plan to start 24X7 support services this year. What is on top of your priorities for 2014? My priority is market coverage. We have many products suitable for the Indian market. To reach out to the market, we had organised the Advantech Design Forum recently. We will also have hands-on workshop for our customers. Thus, we wish to create more avenues for the customers, bringing in more business for Advantech India. ☐ > MORE@CLICK ADI03357 | www.AandD24.in
A&D India | Dec-Jan 2013/14
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C O V E R S TO R Y | T E C H N O L O G Y
Automation system requirements
AN END USERâ&#x20AC;&#x2122;S PERSPECTIVE Automation systems play a vital role in the core business operations of any industry. NTPC Ltd, a leading power major of India, has seen a variety of such systems, both from European & American vendors. It has an installed capacity of 42,454 MW out of which 4170 MW was added in the year 2012-2013. This has led to a unique experience of executing as many as 8-9 DCS systems. The end user perspective gained through such experiences is encapsulated in this article.
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Arundhati Bhattacharya General Manager (PE-C&I) & CTF (Muzzafarpur TF) NTPC Ltd
A&D India | Dec-Jan 2013/14
T E C H N O L O G Y | C O V E R S TO R Y
Figure 1: The cost per cent of automation system in the overall project cost is very less, whereas the impact on the everyday operations, safety, availability, optimisation or data analysis, preventive maintenance is very high
Irrespective of the industry, automation professionals have to face a typical challenge as depicted in Figure 1. The cost per cent of automation system in the overall project cost is very less, whereas the impact on the everyday operations, safety, availability, optimisation or data analysis, preventive maintenance is very high; a situation similar to the role of brain in human body. And here too, like the brain & all parts of the human body have to work in synchronism, the automation system, the instrumentation and the final control elements in the process have to function in tandem with each other for successful performance. Similar to human intellect, automation systems also have evolved over the years and the process is still continuing. These systems have graduated from a mere logic solver to a full fledged business support tool, encompassing all functionalities. A careful examination of the pyramid above reveals that these system functions can be broadly classified into three main subsystems - control system, Human Machine Interface (HMI) and the MIS (Management Information System). The MIS or strategy functions like process optimisation or Enterprise Resource Planning (ERP) can only be made possible if the first two sub-systems (i.e. control system & HMI) are properly engineered and put into successful operation. Hence, these aspects are considered important and hence discussed first.
Control system Perhaps the most fundamental automation system function is process safety (protections & interlocks). It is important here to mention that the electronics on which the process safety
A&D India | Dec-Jan 2013/14
Automation system pyramid: Automation systems have graduated from a mere logic solver to a full fledged business support tool encompassing all functionalities
function is implemented, is designed & engineered in such a way that under no circumstances, its failure causes safety function to be jeopardised. The concept of SIL (Safety Integrity Level) has to be carefully studied & adapted to the process as a whole in order to ensure that the above intent is met. In other words, the failure mode should be predictable and systems designed accordingly. The next layer up in the automation system pyramid is availability of the automation system or in other words fault tolerance. Simply defined, is the response of the system to different types of faults or failures; i.e. whether the system functions are available on a C&I equipment fault or failure. Redundancy of various components of the system is the time old method to build up fault tolerance. As we say, the chain is as strong as the weakest link and proper redundancy with judicious engineering should take care of this aspect. An RTD wire getting open or loose should not cause an equipment trip. At the same time, in the endeavor to avoid spurious trips, it is required that sanctity of required tripping alerts / protections as per OEM be held in place and never overlooked. As it is said, system should work when it is most expected. Nowadays, products are available which are inherently fault tolerant and use of such products should be explored to improve the automation system availability. Going up the ladder, the next area is modulating or closed loop controls. Besides reducing steady state deviation & cycling, closed loop controls must sustain performance under all process conditions, a need which can be fulfilled by employing advanced controls like the model predictive control. But these controls need to be customised and tuned to each individual
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C O V E R S TO R Y | T E C H N O L O G Y
With a capacity of nearly 20000 MW under construction & nearly thirty years of experience in operating power plants, NTPC had spearheaded the power business in India
site and for this purpose, a formal system of determining tuning parameters based on plant design data must be in place before dispatch of the system. Only fine tuning should be done at site. This is one area where knowledge holds the key. DCS vendors must develop a pool of specialised persons for this important area. Only then the potential of advanced controls can be fully utilised and automation engineers can get the last penny out of the process. This necessitates continuous evaluation of control system performance, especially when the equipment characteristics are no longer the same as it was during initial commissioning. Many third party software and even some DCS software accomplish this task.
HMI Having discussed control equipment capabilities, we come to HMI; the system through which the external world gets an access to the proprietary control system for achieving the desired result. HMI software and the system network should be optimised in such a way that there is no perceptible delay in operations including drive operations as it gives more leverage to the operator for quick decisions. ‘Dashboard navigation’ and ‘mission critical response times’ are the buzzwords. In addition to basic plant operations, other important features of HMI are alarm annunciation for proactive timely operator interventions and trip analysis for necessary corrections in plant operation/maintenance strategy. However, in most of the plants, alarm annunciation needs improvement. Attempts should be made to reach the ISA standard limit i.e. twelve alarms per hour per operator so as to give room for action by the operator. Features like trend alarm can also help in achieving this through early alerts.
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Trip analysis tools like Sequence Of Events (SOE) have become very important for pin-pointing the cause of trip. Here, as an end user, we require that all analysis tools in the DCS are integrated and a single window is provided for analysis. It is necessary to institutionalise the lessons learnt from trips. Going by this concept, software for replaying the operation scenario before a trip, gives useful insights into what should have the operator done to avoid the trip. Such software, coined ‘Power Replay’, replays the plant mimics/operations with options like rewind or backtrack, slider, etc.
Process optimisation In today’s regime, operating cost has a direct bearing on the profitability of the company. Further, we have to reduce carbon footprint as much as possible. Hence, process optimisation assumes great significance in today’s business operations and can be a game changer. It is seen that practically, if we leave these advisories to be implemented by operator, it is not possible at all stations & at all times. Hence, APC which is basically optimisation acting directly on the control system is perceived to be more beneficial. This requires huge efforts on the part of the APC supplier during commissioning in order to instill confidence among site personnel. There are three factors affecting the success of such systems, skilled manpower at the automation vendor end, guidance and co-operation of plant equipment supplier and support of site management. The automation supplier should be ready to walk that extra mile to make such systems fully beneficial to the end user. “We have to move from a contract closing paradigm to contract benchmarking paradigm.” Further, special instrumentation like the acoustic pyrometer
A&D India | Dec-Jan 2013/14
C O V E R S TO R Y | T E C H N O L O G Y
Cyber security should be taken as a social responsibility by the automation suppliers & not just as a mere contractual obligation
add value to performance optimisation as the results will be more accurate & realistic. Hence, if we consider environmental impact important, then the C&I community should strive to make instruments work at site. “Advances in control system are reaching saturation; the future challenge is tailor made instrumentation, especially boiler instrumentation”
End user concerns Having covered many points out of the end user wish list, some of the generic issues confronting the industry are discussed below. Open architecture – A boon or bane: Open architecture has definitely helped the automation industry, but the take is that the benefits have not reached the end user. Open architecture has facilitated use of commercial off-the-shelf products and has also made data transfer to enterprise systems and third party systems possible. But this hasn’t reached the stage of inter operability. By interoperability, we mean that HMI of vendor X could function with control system of vendor Y. From an end user standpoint, this is very beneficial since the life cycles of the two are different. One option is to connect HMIs of two different DCS through open protocols and operate drives of DCS X from the HMI of DCS Y. This will at least present a uniform HMI interface to the operator who is quite oblivious of the underlying dynamics. System diagnostics: A problem well defined is half solved. System diagnostics should address this definition. The expectation from end user is that irrespective of whether a component is DCS vendor’s own product or third party,
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diagnostics should be provided for all components. Third party devices should be integrated in DCS keeping in view this aspect. For this, third party products/components should be certified by the DCS vendor’s principals. Cyber security issues: As mentioned, open architecture facilitated use of commercial off-the-shelf products. This however, has in turn resulted in cyber threats to DCS. The increased connectivity of DCS with corporate network has further aggravated the situation. Today, cyber security is one of the most important concerns confronting the industry. There are three important aspects to cyber security for DCS, first, technology which involves mainly the system architecture, then the people aspect, which are the security procedures to be followed and third, the enforcement i.e. audits. Hence, technology alone cannot enforce security. There is a strong human aspect to it, which is why it is required that security be inculcated in the company culture of the supplier in the forms of policies & procedures and built right in the product design. International standards aim to address this aspect. “Technology alone cannot enforce security. There is a strong human aspect to it” As an end user, it is expected that like quality & reliability, security also should be guaranteed by the suppliers. In fact, vendor’s support for software may cease, but security related support for installations controlling critical infrastructure has to continue till the end user does not change the system especially in a scenario where vulnerabilities are being discovered even after ten years of software launch. Hidden malware pose even greater danger. Like type test, DCS should be tested extensively and certified free of all malwares. This is the kind of security assurance, an end user expects today.
A&D India | Dec-Jan 2013/14
T E C H N O L O G Y | C O V E R S TO R Y
Technology alone cannot enforce security. There is a strong human aspect to it
“Cyber security should be taken as a social responsibility by the automation suppliers & not just as a mere contractual obligation”
Obsolescence All vendors have to keep pace with new technology and as with all vendors, new technology is introduced after vigorous testing, which takes time. To this we add the time to introduce this technology in the customer specifications. So by the time, this new technology gets commissioned, it is already obsolete, especially in the HMI area which mainly uses IT products. It is an inevitable phenomenon, but nevertheless needs to be addressed. What is expected from vendors is a clear & transparent policy of support, an upfront declaration of product lifecycle and backward compatibility of new products. “We have to cope with obsolescence and not fight it”
Practices adopted At the end, some of the steps taken by NTPC Ltd in the automation systems engineering are described below. Uniform hardware for controls throughout the plant has many advantages - better inventory, better maintenance, optimised training and above all manpower optimisation. Moreover, this concept makes it possible to operate any plant area from the DCS of any other area subject to the configured authorisation in the system. In view of these benefits, this concept of having same distributed control system (DCS) for the offsite systems was introduced in NTPC in 2005 and is yielding the intended results. Uniformity of engineering and application between offsite areas & the main plant was made possible with this concept and was
A&D India | Dec-Jan 2013/14
facilitated through inhouse software for preparing interconnection schedules / cable schedules and also logic diagrams. In order to make alarming more conspicuous, three band alarm area on large video screens was conceived to maintain the look & feel of hardwired annunciation systems. This is implemented in the DCS of many suppliers, either as a standard or add-on. In 2008, secured network architecture was adopted for DCS and incorporated in the DCS system architecture of all projects engineered thereafter. Provision of security audits during FAT before system dispatch has also been incorporated. DCS system testing has been streamlined for optimising the resources both at vendor’s end and at customer end. It has three phases, the first phase, major design feature test (MDFT) which is basically a prototype testing of any new DCS, done before commencement of engineering, in order to test compliance of the product to customer specifications and early adaptation to customer needs or initiation of new development. The second phase, application testing involves testing of logics, control loops, mimics using simulation in laptops at the customer’s premises and finally the actual FAT at the vendor’s works, by which time the only aspect not checked is the total integration of the system.
Conclusion Technology should have value proposition in the business operations of the end user. The main equipment suppliers, automation vendors, consultants have to work closely with the end user to create a ‘win-win situation’ benefiting the society at large. ☐ > MORE@CLICK ADI03358 | www.AandD24.in
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MANAGEMENT | INTERVIEW
Adapting to the changing needs of process automation Richard J Timoney, President & CEO, Fieldbus Foundation, considers FOUNDATION fieldbus as a strategy to be more than just a communication protocol, and sees India ahead of the rest of the world in adopting digital fieldbus technology in process manufacturing. Excerpts from his interview with Shekhar Jitkarâ&#x20AC;Ś Brief us on the recent developments in Fieldbus Foundation. As we approach our 20th anniversary in 2014, the Fieldbus Foundation continues to embrace change and adapt to the changing needs of process automation end users. This past year has been a very busy one for the Foundation as we continue advancing our core technologies into application areas such as FOUNDATION for Safety Instrumented Functions (SIF) and for Remote Operations Management (ROM). Our new usability initiative is intended to make the digital fieldbus automation experience easier than conventional analog control systems in every conceivable way, from device setup to instrument replacement and daily maintenance practices. A key driver for this effort is the foundationâ&#x20AC;&#x2122;s new usability team, which is focused on making fieldbus devices easier to specify, set up, configure and maintain. Like other major industry initiatives focused on ease of use and human-centered design, the objective here is to allow users to focus more on utilising all-digital fieldbus technology in a way that aligns with their strategic objectives.
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Please elaborate on the recent announcement of merging of Fieldbus Foundation and HART Communication Foundation. Nothing embodies our ability to adapt and change than our merger talks with the HART Communication Foundation (HCF). In September 2013, we signed a memorandum of understanding with HCF to explore the possibilities of a merger that we believe will significantly benefit both the foundations, our device developers, and end users. In addition to leveraging the complementary benefits of the technologies, improved economies of scale would be realised through merging training and education; testing and registration; marketing through participation at trade shows, conferences, and events; online presence; and social media strategies. The new organisation would have a number of goals, including collaboration on new and existing technologies, a fully integrated marketing strategy to advance the extensive use of digital devices, improved products and services, and increased market share of digital field devices. At the same
A&D India | Dec-Jan 2013/14
INTERVEIW | MANAGEMENT
“End users in India are willing to make the commitment to truly utilise the diagnostic information that comes from digital field devices and create truly advanced maintenance strategies” Richard J Timoney
time, however, we must be careful to preserve our existing technologies. Both the FOUNDATION fieldbus and HART specifications would continue to exist separately and evolve. Each protocol would retain and maintain its own brand name, trademarks, patents and copyrights.
The installed base of process automation systems that are approaching or have approached the end of their useful life is about $65 billion according to ARC Advisory Group. Most of the project activity in developed regions such as North America and Western Europe revolves around control system migration and modernisation.
What are the initiatives taken by Fieldbus Foundation to keep pace with industry requirements and protect users’ Do you have any expansion plans for India? What kind of investments in its technology? activities/events have been planned for the Indian market in At the Fieldbus Foundation, it has always been our strategy the next year? to be more than just a communication protocol. We see India has one of the largest installed bases of FOUNDATION FOUNDATION technology as an automation infrastructure fieldbus on a country-by-country basis. Reliance refinery in capable not only of control in the field but also safety Jamnagar, for example, is our largest installation in the world, requirements, advanced predictive maintenance strategies, with over 30 thousand fieldbus devices, many thousands of and, most recently, as a solution for managing devices across segments, all done with nearly flawless project execution different networks and in remote applications. in cooperation with major engineering and construction FOUNDATION for ROM was designed to enable fieldbus partners like Bechtel. Many other industries in India have connectivity to remote I/O and the leading industrial wireless FOUNDATION fieldbus installed as well, including metals, protocols, and is the first successful integration of ISA100.11a, power, chemicals, pharmaceuticals, and more. This is one of WirelessHART, wired HART, and wired H1 protocols into a the primary reasons the Fieldbus Foundation held our General single standard environment without sacrificing the diagnostic Assembly in India in 2011. capabilities of existing wireless devices. We are also happy to announce that Reliance will be a key site for our series of live demonstrations of FOUNDATION What type of projects are appropriate for FOUNDATION for ROM technology. Just this year, we had the privilege of technology? demonstrating FOUNDATION for ROM technology at the Today, we estimate that FOUNDATION fieldbus has an installed Automation 2013 show in Mumbai, along with a full day seminar base of systems and devices of over $6 billion. According to ARC on ROM technology. We were also very fortunate to win the Advisory Group, shipments of fieldbus products and systems Technology Advancement Award at the show for our ROM are continuing to grow at double-digit rates. Our technology booth! We look forward to hosting the live demonstration at is installed in critical process control applications across a full Jamnagar refinery in 2015. ☐ range of industries from refining and petrochemical to oil and gas, chemical, power generation, life sciences, and even nuclear > MORE@CLICK ADI03359 | www.AandD24.in power applications.
A&D India | Dec-Jan 2013/14
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M A N A G E M E N T | R O U N D - TA B L E
A step toward enhancing competitiveness Analysing the latest trends emerging in the automation industry, this discussion features the strategies to synchronise investment in automation with the current economic cycles and the adoption of latest automation innovations to reach the desired competitive levels With the National Manufacturing Policy (NMP) of the 12th Five Year Plan accentuating the importance of manufacturing as the key to India’s global economic success, the industry is taking concerted efforts to make the end users realise the advantages of automation solutions in order to be competitive in today’s global economy. However, mass scale adoption has remained sluggish due to multiple factors, such as a slow investment scenario and cost of ownership. Addressing these issues, Frost & Sullivan had recently organised a summit on “Enhancing Manufacturing Competitiveness: New Age Solutions Driving Change on Discrete Automation” in Mumbai. As part of the summit, a panel discussion was held by A&D
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Shekhar Jitkar Chief Editor shekhar.jitkar@publish-industry.net
India to analyse emerging technologies and investment scenario in the sector. The eminent panel for the discussion included Vijay Paranjape, past President - AIA and former Director & Member – Management Board, Siemens; Manish Shah, Senior Manager – Sales & Marketing, Sarla Technologies; Haradhan Bhattacharya, General Manager – Manufacturing & MR, Mitsubishi Electric and Rajesh Ponnuru, Plant Head, ITCPune.
Emerging trends in automation There is an uncertainty in the economic climate not just in
A&D India | Dec-Jan 2013/14
M A N A G E M E N T | R O U N D - TA B L E
“Very soon mobile applications will be there in the automation industry. An app for cement industry or fertiliser industry is definitely going to be introduced to enhance implementation” Vijay Paranjape, past President - AIA and former Director & Member – Management Board, Siemens
India but also globally. With this, multiple elements that define the manufacturing context have changed. All the strategies and planning for investments are changing to suit the economic conditions. The automation phenomenon too, has undergone a massive change. Discussing these trends, Paranjape elaborates, “There was always a fear etched in the minds of the users regarding their purchases. Over a period of time, this particular fear has gone away with the ease of usability of the products. This has gone a long way in increasing the penetration in automation in SMEs. In my opinion, this should continue for the simple reason that the penetration of automation increases simplicity and the ease of usage of automation. Sharing his views on the demand drivers for automation, Ponnuru asserts, “The dialogue has changed in terms of market needs. One of the most important changes from the consumers end over the years has been the speed at which we have to keep transforming toward a better quality. The complexity of the business has gone up. The answer to this is automation. But automation is being used in different ways. In automation, we are thinking of certain parameters like how to integrate sales, distribution, manage the complexity and integrate flow to the suppliers & planning processes on the shop floor. From the consumer point of view, the discussion has moved from what is required internally to boost production and manage complexity without any errors. There should be flexibility to change or adapt to the floor or the technology to adapt to the changes of the product. For example, in FMCG, many changes happen in the discrete side and not in the process side. While making a shampoo or formulating a soap, what matters the most is how packaging is done.” Shah further adds that industry is maturing toward basic automation. “People are looking at how to enable more intelligent automation. In the recent time, they want to invest in integrated systems. The customer expectations are increasing as they are mostly going global in terms of change, flexibility
A&D India | Dec-Jan 2013/14
“Automation implementation doesn’t affect humanware. Every system has some limitations at some point of time. One of the aspects that should be kept in mind is ensuring process knowledge which should be maintained and upgraded” Rajesh Ponnuru, Plant Head, ITC-Pune
toward software & hardware changes, and communicate from one system to other. They want application systems to be more user-friendly and flexible. Automation vendors and solution providers are working toward this direction. Over a period of time, many standards have evolved. Automation vendors and IT solution providers are collaborating and evolving. We have OPC standards where customers are getting aware and vendors are working to provide effective solutions to their respective customers.” “Manufacturing is the key engine for economic growth. It is measured by the cost value. Nowadays, cost has become a very important factor in the manufacturing industry. In this cost monitoring and cost-effective product manufacturing automation plays a very important role. At the same time, predictive maintenance has eventually become more important. Before the line stop, there is an indication where the process requires prevention. Process automation is thus, very important factor to reduce costs”, says Bhattacharya.
Just-enough-automation Manufacturers are looking for smarter, faster & costeffective automation solutions which fulfil their exact needs for reducing costs, and improving quality and competitiveness. This is leading to the trend called “just-enough-automation”.
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R O U N D - TA B L E | M A N A G E M E N T
“Cost has become an important factor in manufacturing. In this cost monitoring and cost-effective product manufacturing, automation plays a very important role” Haradhan Bhattacharya, General Manager – Manufacturing & MR, Mitsubishi Electric
Addressing the overall investment scenario in automation adaptation, Paranjape asserts that one of the key demands imposed on the automation solution providers is whatever supplied should be fully used and which is easily expandable and upgradable. Just-enough-automation concept serves this purpose and has been catching up all over the world. Another trend shaping up includes various applications for smartphones. “Very soon such applications will be available in the automation industry. Whether it will be third party app or an application developed by the automation solution providers is the matter of detail, but an app for cement industry or fertiliser industry is definitely going to be introduced for the simple reason to enhance implementation” notes Paranjape.
Cost of automation
“Indian companies are willing to adopt the latest technologies. They are keen to gather more knowledge and solutions on technologies that are emerging overseas”
Manish Shah, Senior Manager – Sales & Marketing, Sarla Technologies
humanware. Every system has some limitations at some point of time. One of the aspects that should be kept in mind is ensuring process knowledge which should be maintained and upgraded. While designing the automation system or maintenance system, human interface should be ensured. Secondly, the human psyche during automation implementation is taken for granted — it will take care of everything. But in reality there are a lot of challenges. Even during automation execution human touch should be ensured for better assurance.”
Automation has the potential to be more objective, more repeatable, more accurate and quicker to respond. But even then, the most obvious driver fuelling automation remains the cost and availability of labour, especially in countries like India. If we consider a pure cost analysis, any manufacturing plant India’s stance to adopt better technologies needs to weigh the cost to acquire, train and retain labour Discussing on better infrastructure and training for against the cost of purchasing and maintaining automation systems. In industrialised nations, where labour is scarce and automation implementation in India, Shah believes that Indian expensive, this analysis is increasingly favouring automation companies are willing to adopt the latest technologies. They as the preferred solution, but in case of developing countries are keen to gather more knowledge and solutions on such as India it may not be a similar case. With the speed and technologies that are emerging overseas. There are a lot of efficiency of communications today, via the Internet and social system integrators and technologies available that can enable media, the value of maintaining high product quality has old systems or old PLCs to connect to the landscape. One of increased. At the same time, the value of automation is rising, the key things is that customers are defining their demands. but the cost of automation is falling. Thus, the equation is Willingness is there to pay more for a better quality. Addressing rapidly shifting in favour of automation. Manufacturers are the sudden surge in demand in the industry, Paranjape asserts, realising this and are developing new technologies, starting “Currently, there are ideal capacities in the industry. Naturally, with those that offer the greatest value and the fastest payback the initial upsurge in demand will be met by utilising the for their customers. Companies have been looking to expand existing capacity. This will provide the necessary time for the horizontally, by making products for different types of user industry to think of expansion of needs. This is wherein manufacturing, and vertically, by targeting different levels of automation suppliers will have to be on guard. The time manufacturing operations. This is leading to mergers, available will be a few months which should be utilised to the acquisitions as well as partnership activities. Asserting this, fullest”. ☐ > MORE@CLICK ADI03360 | www.AandD24.in Ponnuru affirms, “Automation implementation doesn’t affect
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A&D India | Dec-Jan 2013/14
FOOD & BEVERAGE | FOCUS
Fresh on the table Consumers are looking for reliable quality when they buy their groceries. Hygienic manufacturing, filling and packaging in the food industry ensures such first-class products. An important factor in hygienic value-creation chains is customer-specific solutions, which can be developed with the help of right automation solution
The key phrases in automated food production are costefficient solutions together with high hygiene standards. However, the decisive factors also include variety in products, taste and packaging, which has consequences for the set-up times and modularity of production facilities. The examples described in this article show how automation technology can make food production safer and more efficient. It is advantageous for a single-sourcing policy if the automation supplier can provide both process and factory automation.
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From process automation... The production process itself involves many different activities â&#x20AC;&#x201D; mixing and stirring, sterilisation, pasteurisation, homogenisation, filtration, dosing, weighing, filling and storage. Automation ensures the reliability of these processes. DFPI with integrated guides and displacement encoders open and close ball valves and butterfly valves. In order to control the many pneumatic semi-rotary actuators and linear drives
A&D India | Dec-Jan 2013/14
FOCUS | FOOD & BEVERAGE
installed in many breweries, central stainless steel control cabinets are used in the fermentation cellars with CPX valve terminals and service units for compressed air preparation, together with appropriate sensors.
nonetheless, corrosion-proof design is mandatory, since water splashes, cleaning agents or dripping food may otherwise damage drives and valve terminals, proximity sensors and fittings. If the installation concept calls for decentralised valve terminals, splash-proof clean design valve terminals CDVI and individual valves CDSV can be installed close to the drives ...to factory automation which are to be controlled and require no protective control In the splash zone of food processing operations, the cabinet. automation technology does not come into contact with foodâ&#x20AC;&#x201D; The clean design cylinders CDC are modular and
A&D India | Dec-Jan 2013/14
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FOOD & BEVERAGE | Focus
Solutions for the food and beverage industry include options from continuous processes to packaging
constructed without sharp edges or corners, ensuring that dirt residues or germs can be completely removed during cleaning. For the handling of workpieces, guided cylinders DGRF are now used, which are available with the option of dry-running seals. The cylinder lubrication and seals have FDA certification. The associated proximity sensors are resistant to cleaning agents, heat and mould.
The star with the gentle curves The star performer in the food zone is the stainless steel cylinder CRDSNU. Thanks to its soft, round shaped which is A lot on their plates Around 50% of consumers find that they have little time for cooking. No wonder then that sales of convenience food are constantly rising. The trend towards culinary simplicity is accompanied by a desire for fresh products. The answer to these two demands is today called “home meal replacement”. HMR is well on the way to conquer the market in Europe and many other industrialised countries. This term refers to simple, fresh food and snacks which the customer can either eat immediately or prepare at home. They are described in a variety of ways from “ready to cook” through to “ready to heat” and “ready to eat”. Home meal replacement represents a new challenge for the automation of food packaging. Attractive products need attractive packaging, while traditional requirements such as a simple protective function are also important. What is more, consumers’ environmental awareness has been increasing for years. Trays made of polyactide plastics, or PLA, are fully biodegradable, including their seal foil, and are the perfect answer to modern trends. The same applies to microwavable cardboard packaging. This is also easy to print and gives manufacturers new scope for individual product design.
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easy to maintain. Its self-adjusting end-position cushioning PPS saves users a lot of time during set-up. The CRDSNU also proves its worth in a machine for sorting salmon. Saline sea water and fish substances mean that the round cylinder is put to a hard test. What is more, it is cleaned daily with chemical additives. A standard round cylinder would give up the ghost in this application after just a few weeks. The CRDSNU, however, is in its element in this humid and aggressive environment.
Signed, sealed, delivered To ensure that drives do not fail in harsh environments, users can choose seals from the Festo modular seal system. This includes FDA-compliant standard seals suitable for food use with normal cleaning, seals for unlubricated operation and seals for applications with intensive cleaning. FKM seals are available for high temperatures up to 120°C and for acid environments, while there are hard scrapers for low temperatures down to -40° C and for applications involving sugar crystals.
End-of-line packaging Festo can provide a variety of handling solutions with a choice of drives to meet individual customers’ requirements with regard to packaging, labelling, testing and monitoring in the non-food zone at the end of the value-creation chain. Its handling experts can select from more than 30,000 products and use appropriate servopneumatic, electric or pneumatic drives for the customer application in question, together with the associated control and valve-terminal technology, sensor technology or vision systems. These are fully assembled, tested and delivered directly to the machine as ready-to-install system solutions – complete
A&D India | Dec-Jan 2013/14
Anzeige
Focus | FOOD & BEVERAGE
with all design data, circuit diagrams as well as a comprehensive functional and fixed-price guarantee. Users receive not only hardware in the form of a connection-ready module or subsystem but a complete value-creation package. Complete solutions menless work for customers’ personnel, reduce system design costs, simplify the procurement process and reduce process costs. “Fit and forget is the objective for our customers,” explains Alexander Wagner, Head of Festo Industry Segment Management for the food industry. It is rare that two handling systems are the same. The spectrum ranges from simple pick & place systems through to linear gantries, cantilever gantries, 3D gantries, the rodkinematics robotic system Tripod, high-speed gantries and individual application-specific gripper systems. “Our customers describe their handling task, we deliver a plug and work solution directly to the installation cell – there is no need for complex commissioning,” continues Wagner.
Putting an end to waste Less machine downtime, detection and elimination of leaks in compressed air systems are crucial. That is why services such as total productive maintenance, condition monitoring and energy saving services are becoming key factors in food processing. Many companies have declared war on waste and high energy prices. Food safety and energy efficiency are not mutually exclusive. On the contrary, just as food remains fresh longer through the use of hygienic automation technology, the plants in which they are produced always stay modern, reflecting state-of-the-art technology. ☐ Courtesy: Festo > MORE@CLICK ADI03361 | www.AandD24.in
Anzeige India_Allgemein_210x134_1.QXD_Anzeige India_Allgemein_210x134 11.09.12 11:25 Seite 1
Your requirement is our drive HANNING pumps, motors and drives perfectly meet the growing demand within India for customer-specific designs, software or interfaces. Our drive systems are specially developed for winding applications, textile or plastic industry as well as for elevator applications. Regardless of the nature of your requirement, our components increase your machine performance and decrease the energy consumption of your entire system. HANNING MOTORS INDIA Pvt. Ltd. · E-115/A GIDC Manjusar Savli · Vadodara 391 775 · Gujarat · India · Tel +91 2667 264820 Fax +91 2667 264819 · info@hanning-hmi.com · www.hanning-hmi.com A&D India | Dec-Jan 2013/14
Our engineering knowledge combined with local presence and German expertise ensure the perfect product. 33
FOOD & BEVERAGE | FOCUS
Machine safety
Image courtesy: Shutterstock
The article deals with the requirements of the food industry which includes application, hygiene, sealing to prevent penetration of liquids & dust, and the suitability of the devices for particularly high or low temperatures.
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A&D India | Dec-Jan 2013/14
FOCUS | FOOD & BEVERAGE
Not a single person, who is constructing safety appliances for machinery & plants, and selecting the required components to that effect, will deny that machinery safety is an extremely complex issue. There are many standards based on the machinery directive, which accurately define, amongst other things, the selection procedure for these components. There are also many different possibilities as well to protect each and every hazardous point.
Image courtesy: Shutterstock
Special requirements of hygiene The selection criterion for safety guards used on and in machines of the food industry are even more comprehensive. In addition to the generally applicable machinery safety regulations, the requirements placed on hygiene often have to be taken into account. Though this field of activity is not as complex as the machinery safety, it also requires special attention. First, it must be determined, in which of the four hygiene areas the safety switchgear to be selected will be used. In the dry area, only protection against soiling is required. In the splash zone, there is a risk of contamination or crosscontamination, considering that the staff touches both foodstuffs and machine. The wet area is exposed to a high risk of bacterial contamination; therefore, regular low-pressure cleaning operations with chemicals or hot cleaning activities are an integral part of the prescribed hygienic measures. The contamination risk is even higher in the aggressive area, where a frequent hot-steam cleaning or high-pressure cleaning with aggressive cleaning agents takes place. This means that the switchgear used should be capable of withstanding water jets with a pressure of at least 80 bar and a temperature of 80째C.
Hygienic design and efficient sealing It is evident that conventional safety switchgear cannot be used under these circumstances. In addition to that, the hygienic requirements lead to the creation of two totally different properties. First, the switchgear must be able to resist
A&D India | Dec-Jan 2013/14
the frequent cleaning activities, which are not evident for electrical or electromechanical components and which moreover places high requirements. In this way, the use of conventional electro-mechanical safety switches & solenoid interlocks for instance is excluded, in the wet and aggressive area.
Switchgear programme for the food industry For this reason, foodstuff machinery construction was the first industry, which used safety sensors instead of the conventional electromechanical safety switches. These non-contact safety switchgear provide trouble-free cleaning because of the smooth surfaces of the sensor & actuator, and in addition to that, they can be installed in concealed mounting, e.g. behind plastic covers. The current innovations in this industry specific field of machinery safety include the BNS 40S magnetic safety switch. These switches have been developed for high-end applications, i.e. in this case for use in wet areas in the immediate vicinity of the product. Their stainless steel enclosure is resistant to corrosion and to cleaning liquids. Due to their slim design with fine-polished surface, they can be smoothly integrated in the typical surrounding construction of foodstuff machines. As the BNS 40S is IP 69 K, it can be considered as high-pressure cleaner-resistant. The high switching distance enables a concealed mounting behind non-ferromagnetic covers. During the design, a great attention was paid to avoid dirt pockets and the compatibility of the device with commonly used cleaning agents it has been tested in accordance with ECOLAB.
Safety sensor with CSS technology This safety sensor with cylindrical design uses the CSS (Coded Safety Sensor) technology developed and patented by Schmersal for the bi-directional communication between the sensor and the actuator. This operating principle features, amongst others, the advantage that up to 31 sensors can be
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FOOD & BEVERAGE | FOCUS
The CSS 30 S is completely encapsulated in a stainless steel enclosure and has protection class IP 69K
wired in series and evaluated through a single safetymonitoring module. Even in this series-wiring format, safety circuits with Performance Level e to EN 13849-1 (SIL 3, control category 4) can be set up. In addition to that, the sensors are capable of detecting misalignments of the guard door and emitting an alarm at an early stage. In this way, undesired machine stops can be avoided in the plants of the foodstuff production. The CSS 30 S is completely encapsulated in a stainless steel enclosure and has protection class IP 69K. The CSS sensor technology was modified so as to function even through stainless steel covers. As an alternative, the CSS 300, a lower-cost variant with thermo- plastic enclosure, is available.
Integrated RFID technology Another safety sensor, which has become increasingly popular in the foodstuff machine construction industry as well as in the packaging industry, is the RSS 36 which is available in a version with integrated AS-i Safety Interface. In addition to the CSS technology, this safety sensor also features a RFID chip. This provides for the use of different coding variants, thus enhancing the protection against tampering. Other features of the RSS 36 are the universal mounting possibilities, the high switching distance and the protection class IP 69 K. Because of its robust design, this sensor can also be used as an end stop on small doors and flaps. The optionally integrated, fully thermoplastic-encapsulated magnetic latching eliminates the need for additional hygiene-compliant latching stops. Because of these features, the RSS 36 has quickly become popular in many fields of application - also for the protection of hazardous points on foodstuff machinery. Under extreme circumstances however, the use of a safety sensor with stainless steel enclosure is a more appropriate solution.
Solenoid interlock Though the new AZM 300 solenoid interlock, which
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Schmersal has recently launched in the market, was not especially developed for the foodstuff and packaging industries, the component is expected to open up many applications in these fields in the future. The elements contributing to this success are the new and flexible interlocking system in the form of a rotary Maltese cross and the numerous mounting possibilities. The codification through the RFID sensor technology is another standard feature of the RSS 36, just like the adjustable latching force. Moreover, the device has been designed in accordance with the hygienic design principles and because of the protection class IP 69 K, the AZM 300 is also suitable for use in hygiene-sensitive areas.
State-of-the-art technologies The series of safety switchgear demonstrate that foodstuff machinery construction places very special additional requirements on machine safety components and systems and that these requirements can be smoothly fulfilled, provided that the builder chooses components that have been designed in accordance with the hygienic design principles. For other application profiles of the foodstuff machinery construction e.g. for applications with very low temperatures and for filling stations for raw materials in powder form, which have to meet explosion protection requirements - there are other safety switchgear featuring state-of-the-art technologies, providing for a high level of safety and productivity. Just as important as the industry portfolio is the consultancy of the customers of the foodstuff machinery construction by experts with adequate practical know-how. In this respect, the sales department is supported by an industry management, which can rely on adequate expertise in the foodstuff industry and its related packaging technology. â&#x2DC;? Courtesy: Schmersal > MORE@CLICK ADI03362 | www.AandD24.in
A&D India | Dec-Jan 2013/14
Image courtesy: Siemens
FOOD & BEVERAGE | FOCUS
AUTOMATED DOCUMENT MANAGEMENT The article deals with the shift from traditional in-house storage methods of filing cabinets and endless paper files, toward an automated document management solution and cloud-based storage system to increase productivity, food safety, and quality in the food and beverage industry.
Jennifer Brusco Editorial Content Manager TraceGains jennifer.brusco@tracegains.com
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A&D India | Dec-Jan 2013/14
FOCUS | FOOD & BEVERAGE
Image courtesy: Siemens
Todayâ&#x20AC;&#x2122;s food and beverage industry is ruled by documents and regulations from the global, state, and federal levels. There is a growing shift from the traditional in-house storage methods of filing cabinets and endless paper files, toward an automated document management solution and cloud-based storage system to increase productivity, food safety, and quality. Although there are several management systems currently available, not all are equal. Some systems house documents; few make those documents easily searchable or usable. Other systems look at only a single element of the documents, and require manual entry of data points to make the information useful. Still other systems enable companies to identify issues, neglect to make that information actionable or alert the staff to issues on a real-time basis.
Effective automation system elements The most effective and reliable automation systems incorporate alerts and actions to the most critical business needs. These systems allow companies to increase their business intelligence capabilities and insights. Following are some critical elements of an automated system. Real-time decision making: Operating food and beverage business in todayâ&#x20AC;&#x2122;s mobile environment requires immediate access to alerts, notifications, and important quality and safety information. When an ingredient comes into receiving out of specification (based on the companyâ&#x20AC;&#x2122;s pre-determined specifications) an alert must be automatically generated and sent to the appropriate staff. Only with the automation methodology, can personnel effectively manage the situation at the point of error, versus reacting to a recall or issue on the plant floor. Easy storage, archiving, indexing, and retrieval: It is not
A&D India | Dec-Jan 2013/14
enough to just store documents anymore. Systems must be able to index, and allow for easy retrieval of information when and where that information is needed. During an FDA Audit, the inspector may request specific documentation, such as certifications or proof of organic or gluten-free claim. Previously, quality assurance management would have shuffled through paper records; with an automated system in place, they are able to search for and retrieve the needed documentation quickly and painlessly. Only in food and beverage is the rigor of producing these documents mandated. Supplier scorecarding and automatic review of Certificates of Analysis (CoA) attributes against business rules: With each ingredient shipment, a company may receive 10 to 50 certificates of analysis (CoA). Unfortunately, attributes are not located in the same place on each CoA, making it difficult to scan and identify out-of-spec issues on an ingredient at the time of delivery. Add inevitable human error into the mix, and one can predict that out-of-spec ingredients make it to the plant floor (and sometimes into finished products.). An automated solution minimises human error and the risk associated. Additionally, an effective food and beverage automation solution will record supplier performance on an on-going basis, allowing the company to make better business decisions when selecting a supplier for a new product or adjusting sources for current products. 365 audit readiness: Audits are not always planned; sometimes companies must react to impromptu inspections. This requires that all documentation be up-to-date and regulatory compliance (whether local, state, federal, or global) is met. Not only must all certificates and documents be current and accurate, they also must be easy to find. FSMA, GFSI, and other regulatory compliance
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FOOD & BEVERAGE | FOCUS
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requirements: Industry and regulatory initiatives such as the Global Food Safety Initiative (GFSI) and the Food Safety Modernisation Act (FSMA) require additional renewed focus on good supplier management and documentation systems. Prior legal advice to the industry recommended writing nothing down. All that has changed; these new initiatives and regulations mandate documentation and proof of everything. The new mantra is “If it isn’t documented, it didn’t happen.”
Case studies Berner Food and Beverage, Inc, a leading private-label and store-brand supplier of quality food and beverage products, experienced strain when moving from SQF 2000 Level 2 to Level 3. Berner faced significantly more stringent compliance requirements for the quality and food safety practices of its suppliers, including detailed proof of compliance for ingredients and packaging. They also wanted greater transparency all the way to its suppliers’ docks and to reduce just-in-time inventory through continuous and immediate visibility into potential supply chain disruptions due to supplier quality, compliance, or late/short shipment problems. To address these needs, Berner selected the TraceGains platform which consists of supplier management, supplier compliance, and supplier impact modules; companies like Berner need this technology to help continuously verify whether a supplier, as well as every one of its shipments, is in compliance with all the company’s business rules and ingredient specifications. When suppliers are out of compliance or nearing a violation, the system automatically initiates supplier corrective action requests (SCARs), sends e-notifications to both internal and
40
supplier personnel, and can automatically suspend or put on probation suppliers and any of their shipments. This automation solution also measures the financial impact of non-compliances and monetises the potential damage done by a supplier in areas such as manufacturing efficiency, finished goods quality, and product safety. This system provides a comprehensive purchase order acknowledgment tracking function, with alerts for supplier late or short shipments that may cause supply chain disruptions. Ottens Flavors, a world-wide flavor supplier, also works with numerous stringent external verification bodies. Between the more than 600 suppliers around the world that Ottens managed and increased regulatory pressures, Ottens needed a solution to better manage their business. It was no longer enough to show that each supplier was compliant with auditor expectations. Ottens now had to be able to prove which specific plant had provided which materials, and that this plant itself had been audited and judged compliant with industry norms and best practices.
Proactive v/s reactive management Progressive, forward-thinking, lean food and beverage executives and quality professionals choose to be proactive in their quality assurance and safety practices. Food and beverage companies which used the ‘react quickly’ strategy to handle disruptions in the supply chain are no longer in business. Company communication and reaction to situations remains a vital function; proactive strategies to manage these issues, before they become an active crisis management, have become more paramount. The shift toward automation in comprehensive document management ensures the tools are
A&D India | Dec-Jan 2013/14
FOCUS | FOOD & BEVERAGE
available to make the shift from reactive to proactive. Illes’ Seasonings & Flavors, a third-generation family business that produces liquid and dry food products sold to food manufacturers and national restaurant chains, made this shift. David Schauf, VP – Quality (and Technical Adviser to R&D) and his team at Illes Seasonings, needed to improve a manual process that could not easily scale as business velocity and record-keeping requirements increased. The updated and improved vendor management control program now receives and stores supplier-provided information electronically in the new automation solution. Any non-conformances are immediately flagged and alerted against those rules and requirements, enabling Illes’ staff to refocus on problem resolution instead of problem detection. While rapid growth continues, additional staffing was not required. An errorprone process was rendered largely “error-proof ”.
A&D India | Dec-Jan 2013/14
Always audit ready One of the biggest drains on productivity at a food and beverage company comes from preparing for and managing audits. Now more than ever, companies must have documented proof of compliance from every angle. And with new regulations coming out regularly, the pressures can be great. Food manufacturers must ensure that all suppliers are within compliance and that all documentation and certifications are current and up to spec. Only when companies have access to these data are they truly always ‘Audit Ready’. This creates peace of mind, security and improved business performance and quality. ☐ > MORE@CLICK ADI03363 | www.AandD24.in
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MACHINE VISION | TECHNOLOGY
Inspection of hygienic tissue products The article focuses on the Web Inspection System that provides the ability to identify & categorise quality relevant defects with a high degree of reliability. The demand for higher quality in tissue products is on the rise. Because of increased competition, there is a need for both increased production speeds and simultaneously for a reduction in sheet breaks. At the Ortmann production facility of SCA Hygiene Products GmbH located in Austria, experts quickly realised that the ability to meet these customer demands would require the use of a fully-automated inspection system. This realisation prompted the decision to invest in a Web Inspection System (WIS) from ISRA VISION - a system that provides the ability to identify and categorise quality relevant defects with a high degree of reliability. In addition, a Web Break Monitoring system (WBM) offered by the same
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manufacturer documents web breaks on the processing line itself. This allows problems in production and processing to become transparent, making it possible to react immediately and therefore, to significantly increase production efficiency. SCA Hygiene Products GmbHâ&#x20AC;&#x2122;s corporate vision aims to improve the quality of life. The WIS and WBM play a critical role in assuring highest quality products and above average production efficiency.
Identifying every defect at highest resolutions The WIS monitors the quality of the webs of tissue produced
A&D India | Dec-Jan 2013/14
MACHINE VISION | TECHNOLOGY
An example of partitioning an image across multiple threads
on the PM4 paper machine. The machine produces the thin distribution, making it possible to choose and treat the tambour raw paper at a width of 7 m. At the end of the machine, it is accordingly. The defects are also documented in the defect then divided in half lengthwise, and as a result 2 rolls are statistics and in the lot report. created with a width of 3.5 m each. The tambour rolls are then Preventing web breaks in the processing line wound onto the reel. “We made the decision to invest in a WIS from ISRA The ability to closely link the inspection system with the VISION for our hygienic tissue manufacturing”, explains Reinhard Höld, Production Manager – Processing Department, WBM increases the benefits even more. Three or four tambours SCA Ortmann. “This allows us to increase the production are unreeled in parallel in the downstream processing line, speed of our PM4 paper machine, while maintaining the same where they are perforated, in part printed and then processed level of quality or even improving it.” The WIS is able to into two, three or four-ply products. In the final step, completely identify almost every relevant defect at highest resolution even packaged end products then roll off the processing line. during tissue production on the 7 m wide web at highest Installed at the line’s most critical processing steps are the production speeds. The state-of-the-art web inspection system WBM cameras, which focus in particular on the unwinders. makes it possible to reliably detect even the smallest of typical The WBM cameras, seven in total and some of which are highdefects, such as holes, folds and spots, at a resolution down to speed units, supply detailed and exactly synchronised images just a few hundred µm with the transmission process. Because one after the other that allow for a highly efficient cause it identifies defects immediately, steps can be taken to intervene analysis and the ability to draw conclusions about how defects in the process itself, thereby reducing the number of defective develop in the system. The entire process chain is monitored and each & every cause of defects is reliably identified. Any materials being produced. remaining breaks are analysed precisely and the potential Seamlessly detecting, categorising & causes immediately remedied, if possible.
recording defects
Conclusion
The inspection system consists of highest quality standard Modern inspection systems give the customer the ability to components that have been tried and tested. In addition to high power infrared LED technology and the advanced robust increase value and in effect sustainability by optimising software algorithms installed on cutting edge computer processes. “We were able to increase the efficiency of the technology, the product also features robust camera technology. machine by 5%” concludes Höld. The WIS and the WBM The technology can be easily integrated into a paper machine‘s greatly improve the effective capacities of the entire production tightest production environment, and supplies reliable results facility by not only increasing the quality of products, but also despite dust and heat. Because of the way it is constructed, the the manufacturing efficiency. They ensure that the Ortmann system is highly customisable to match the needs of the production site, a facility that has been producing paper since 1917, will remain a successful operation for many years to customer. The WIS measures, analyses and categorises all defective come. ☐ areas automatically and seamlessly. This data is recorded in Courtesy: ISRA VISION the tambour report so that processing has the most accurate > MORE@CLICK ADI03364 | www.AandD24.in information in advance with regard to quality and defect
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A&D India | Dec-Jan 2013/14
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04.09.13 09:42
MACHINE VISION | TECHNOLOGY
A
HIGH RESOLUTION IMAGING TO CUT COSTS An application story on the use of R-TECH’s visual inspection system by PSA (Peugeot SA), a French automobile manufacturer, to inspect the car door panels of its Peugot 508 sedan
C The door panels for PSA’s Peugeot 508 are manufactured on semi-automated lines. Three operators working on four different lines assemble components that are then welded together. The front and rear doors of each Peugeot 508 have 24 different options. Door handles, inserts, power-window buttons, speaker foam, cloth, plastic-coated fabrics and leather are fitted and protected with plastic film. The only things not yet assembled are the sill lights and wiring. The doors are then inspected by a vision system, particularly since their components are fitted by hand. Cost and quality considerations make this system a must. Not only must it check the placement of door components, it must also have sufficient resolution to be able to spot differences in the door covers – like the slightest difference between plastic-coated fabrics, (artificial leather) and natural leather – and distinguish between different colours and stitching.
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Choice of machine vision system A number of companies offered systems with three cameras on each side. However, R-TECH, a firm based in the south eastern French town of Marignier, designed a system with a total of just two cameras and a much lower price tag. “We believed that we could deliver the necessary results with just one Keyence camera on each side,” explains Nicolas Galmiche, Director, R-TECH. “No other solution on the market can match Keyence’s performance in terms of resolution and processing speed.” R-TECH chose Keyence’s CV-5000 series vision system. With its 5 megapixel resolution (2432 × 2050 pixels - 61 ms processing time), this model is unique to the market. CV-5000 Series models are controlled by a high-speed colour image processing engine and a high-speed RISC (reduced instruction
A&D India | Dec-Jan 2013/14
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The camera and highresolution lens
set computer) CPU. Both are supplemented by two DSPs (digital been operating flawlessly since its installation in early 2010. signal processors) designed specifically for image processing. Already a leader in vision system technology, Keyence is now These four processors are used to achieve specific processing also a leader in vision system software with a completely and attain the fastest processing speed possible. Detection was revamped offering thanks to the CV-5000 series second edition. also complicated by the fact that the interior sides of the car Keyence’s software offering features processing functions that doors contain openings and an LED. R-TECH designed a stand out for their stability in varying conditions, speed, and specific lighting system that solves this problem. First, it ease of use. For example, the ShapeTRAX tool ensures stable illuminates both doors, one side at a time. The captured images detection without being influenced by ambient light or shaded are then filtered to black and white. Then the light is shut off so areas on targets. ShapeTRAX is a powerful positioning tool that that the vision system can easily detect the LED. As a result, the is easy to set up regardless of the target. The new ShapeTRAX inspection is reliable and successful each time. function is ten times faster than conventional positioning tools “The other advantage for both us and our customer is that we and ensures repeatability of 1/40th of a pixel. worked with an existing vision system. There was no custom “We are completely satisfied with how Keyence has revamped development involved and our customer has a non-proprietary its software solutions. The system is very intuitive, capable of solution,” says Galmiche. displaying completely in French, highly reliable, and the new filters are very useful.” “It’s worked out great and we are considering deploying it at Benefits PSA’s other sites,” says Galmiche. Based in the heart of the Arve The barcode on each door is scanned by a reader that sends Valley in France’s Haute-Savoie region, R-TECH offers many this information to the vision system via Ethernet so that it can turnkey solutions. It uses its industrial experience and perform the necessary checks. The information is then fed to organisational structure to create comprehensive applications the company’s central quality control system. With only around that meet the specific requirements of its customers. Its 12 seconds in which to perform the entire set of checks, time is automation and mechanical solutions are designed and of the essence. “The Keyence camera has no problem keeping manufactured in-house. R-TECH deploys its solutions in France, up with this rate,” says Galmiche. PSA’s plant uses a JIT Spain, Slovakia, Belgium and Germany. ☐ production system in which the time between electronic order Courtesy: Keyence > MORE@CLICK ADI03365 | www.AandD24.in and delivery on its lines is just 3 hours. The vision system has
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A&D India | Dec-Jan 2013/14
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I N D U S T R I A L C O M P U T E R S & P E R I P H E R I E S | A P P L I C AT I O N
INDUSTRIAL PCS ON THE FACTORY FLOOR With the gaining popularity of PC-based control systems, plant engineers are turning to industrial PCs for control, HMI and data collection applications. This article identifies the top five challenges typically encountered on the factory floor, and offers points to consider when selecting industrial PCs and associated components. Bjoern Falke Product Marketing Manager Control and Software Products Phoenix Contact
Selecting the right mass storage for an industrial environment is crucial for the long-term reliability of an industrial PC. Factors to consider are not only size but also shock and vibration as well as read & write speed and number of write cycles. Mass storage choices usually are the traditional rotating hard drive (HDD), the newer non-rotating solid-state drives (SSD) or small CompactFlash速 (CF) cards. Each of these mass storage options has advantages and disadvantages. Traditional rotating hard drives offer large storage space of hundred gigabytes (GB), fast data access and a relatively low price per GB of storage space. While rotating HDDs are perfectly suited for applications that write a large amount of data, they can be the incorrect choice for applications on moving or vibrating equipment. Non-rotating solid-state drives (SSD) are gaining popularity due to the drop in prices in the last few years. Originally developed for military and space
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exploration projects where price was no object, these memory chip-based, rugged mass storage drives are now affordable enough for industrial applications. Due to their design, SSDs are virtually immune to shock and vibration, can tolerate higher temperature swings than HDDs and are completely silent in operation. While the general features of an SSD may make them appear as the perfect fit for industrial use, they do not come without certain design limitations. One problem is that certain SSDs are not suited for write-intensive applications, such as constantly writing data to a SQL data base. Typically, the two different SSD designs include the MLC (multi-layer cell) and the SLC (single-layer cell) SSD. MLC SSDs cost less than SLC SSDs, but have fairly limited writecycle tolerance and slower data access speeds. MLCs are thus only suited for applications that do not write much data back
A&D India | Dec-Jan 2013/14
A P P L I C AT I O N | I N D U S T R I A L C O M P U T E R S & P E R I P H E R I E S
onto the SSD. SLC SSDs offer higher data access speeds, but have a price premium per GB versus MLC SSDs. Typically, SLC SSDs can tolerate more write cycles and higher temperature swings. SSD manufacturers are trying to overcome the SSD write-cycle limitations with internal design features and smart wear algorithms that store data across the entire drive, thus exercising the SSD’s memory cells in a more uniform manner. Another mass storage choice is the small CompactFlash (CF) card. These cards are typically offered as a smaller storage size option below the SSDs. CFs come in removable and fixed disk flavors, so selecting the right CF is important. While CF cards are now available with SLC technology, they are limited by the read and write speed of the IDE bus. Thus, they are slower than a SSD on a SATA bus. Due to the CF’s smaller size, they are well suited for embedded operating system use, such as Microsoft® Windows® Embedded Standard or Windows® CE.
Embedded v/s desktop operating system Embedded operating systems, have several advantages over their full-featured, bigger brothers. Embedded operating systems typically cost less, fit on a smaller (thus lower cost)
A&D India | Dec-Jan 2013/14
mass storage device and do not require a formal shutdown procedure. There are not only limitations as to features, but also legal implications. One such issue is that embedded operating systems should not be used as general purpose operating systems like those commonly found in desktop PCs. Embedded OS’s use is limited and bound by the often-overlooked Microsoft Embedded licensing agreement. Besides other limitations and restrictions, the agreement states that the system shall only be deployed for purpose-built functions. While Windows® Embedded Standard or Windows® Embedded CE 6.0 core have a lower price point and smaller footprint than Windows® XP or Windows® 7, they also have lower functionality. To get their footprint smaller, the operating systems erase features such as drivers or certain applications. This alone may make them unsuitable for more complex industrial applications. In addition, embedded operating systems require that the customer has specific knowledge plus the tools necessary (e.g. Microsoft embedded toolkit) to build the software image and deploy it.
Underestimating the security risk The world is becoming more and more interconnected.
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I N D U S T R I A L C O M P U T E R S & P E R I P H E R I E S | A P P L I C AT I O N
Easy accessible mass storage drives increase serviceability
While the connectivity can be great for fast and easy data exchange or remote machine monitoring, it can also open up the door for unauthorised outside network access, hackers, viruses or just unnecessary traffic that hinders performance. This not only poses a risk for the machines, but also for the entire plant network. While Stuxnet has gained international headlines, it is just one of several attacks on industrial equipment in recent months. One can mitigate cyber security threats with a few simple steps. It includes using a dedicated hardware firewall prevents unauthorised and unwanted traffic without siphoning off IPC resources like software firewalls do. The hardware firewall can also log traffic and access attempts, giving you an audit trail of who is trying to access what. Disabling USB access removes a very common attack vector and will help keep the IPC malware free. This is easily done right in the BIOS. Adding password protection to the settings ensures they aren’t switched back on. Using a router to separate plant network from the IT network can give insulation and isolation. With today’s private networking, there’s no need to share a subnet with the rest of the office world. Putting the plant on a separate IT network gives more protection and makes it easier to control access; all the while still reaping the benefits of being able to share information with plant management, logistics, etc. Monitoring the PC for infection is crucial. Anti-virus software is one solution, but this works best in the IT world. Newer, less-invasive solutions like CIFS Integrity monitoring don’t require database or signature updates from the internet. They use brief, scheduled scans to compare current system to a baseline and can catch malware that doesn’t show up in antivirus databases. In fact, a CIFS scan would have detected a Stuxnet-infected PC more than a year before an anti-virus program. Security isn’t something that just happens, so be proactive.
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Using multiple layers of security, provides defense-in-depth that will keep the IPCs, in particular, and plant network, in general, safe and productive.
Energy-efficient design Over the lifetime of a single PC, you can save a significant amount in energy costs by simply purchasing a more energyefficient model. While that model may cost a little more initially, it will save the money in the long run. Design features such as low-power consumption CPUs or SSDs as well as more energy-efficient external power supplies all have a positive impact on the energy bill.
Easy serviceability Fast access to connectors, mass storage and the Real-Time Clock (RTC)/BIOS buffer battery can be the crucial difference in whether a machine is down for just a matter of minutes or a matter of hours. Easily removable mass storage drives utilising pull out trays can be exchanged within minutes without removing or even disassembling the PC. This also applies to the Real-Time Clock/BIOS battery or secondary compactFlash or SD cards. In addition, external 24 V power supplies, and easy integration of uninterruptible power supplies (UPSs), increase serviceability and system uptime. Long-term availability of spare parts and CPUs from the long-term road map series give additional peace of mind. This ensures the freshly purchased IPC will not be obsolete six months later. With a repair-friendly, modular design, and any required repair can be performed quickly, limiting downtime to a minimum. ☐ > MORE@CLICK ADI03366 | www.AandD24.in
A&D India | Dec-Jan 2013/14
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2013-04-12 09:55:00
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
A fully integrated universe The article delves into the need for close integration of all systems and information in the process industry to manage complexities and ensure continuously improved competitiveness The market requirements and challenges in the process industry are fast changing. The market situation is, for example, strongly influenced by urbanisation, increase of life time and environmental concerns. In the same time, the process industry faces the challenge to continuously increase their productivity and product quality. To handle these and other challenges & requirements at the same time, a close integration of all systems and information is required to manage complexities and ensure continuously improved competitiveness.
Integrating plant planning & automation engineering During plant design and basic engineering phases, many valuable data is generated and documented in several independent systems and tools. This information later forms the basis for detail engineering and commissioning phase. If this information is handled from the beginning on a common platform, it will reduce the time for detail engineering and
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Sascha Maennl Head of Vertical Sub Segments, Process Automation South Asia, Siemens Ltd
commissioning drastically and can be used later for operation & maintenance as well. For example, during an early phase of the project, the type of an automatic control valve is specified to the vendor. This information is later part of the basis for the hardware engineering where cable sizes and protection are calculated at the end part of the control loop in a process automation system. To avoid the usage of unclear information, this information should be stored in one place as a single object and used in all project instances. If later, in an operation & maintenance phase, this valve has to be replaced with a different type, the system will automatically update all relevant documents and give the feedback on electrical protection and cable size, etc. The key to success lays in the consistent information flow from the product design right down to production on the basis of an integrated tool chain. Such a practice minimises time to market through an integrated approach throughout all planning phases. To fully utilise this saving potential, an optimum co-operation of all tools and teams is required.
A&D India | Dec-Jan 2013/14
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
Configurations and structures are exchanged between COMOS and SIMATIC PCS 7 during the first phase – in an object-oriented manner
A common platform will bring out this potential that will allow consumption by 3% to 10%. It minimises standard deviations, project phases to more and more in a parallel mode as a single optimises the transition between operation points and tool, thus ensuring the data quality and consistency. minimises manual interventions as well. This overall will make To give an example, in today’s tool landscape, the hardware your process more stable and minimises the production and software engineering are carried out in a sequential downtime. manner, to ensure that the hardware used for the software An overall information management and data consistency design is matching with that of the hardware drawings. Here, throughout the entire lifecycle of a plant is the key answer for each of them is working with their own data models and hence the requirements and challenges of today’s process industries such a scenario reduces flexibility. around the globe. Siemens provides answers to these challenges However, a common data model of hardware and software of the process industry with the integration of plant planning engineering enables parallel work as both can use different and automation engineering based of COMOS and PCS 7. To views of the same object. Taking for example, if the software give some more background regarding the advantages of an engineer needs to change the controller system with a common inherent to an integrated architecture, the company looks after data model, the controller for a DCS system will notify the the whole plant lifecycle. The company understands a holistic hardware engineer in real time and ensure a high quality of the plant management with an integrated view across all lifecycle basic planning, which leads to a cost reduction during the phases. execution and commissioning phase. Having all this information and data in place and A fully integrated architecture from field level up to the consistently linked optimised plant utilisation based on a enterprise level will reduce the interfaces, increase the structured and reality operator, training and simulation is integrated diagnostics, economise the storage of redundant possible. The result is a qualification of plant operators in a data and also provide the required modularity and scalability. safe environment without risks, coupled with preparation for Keeping all this in mind, the next step is continuous critical situations. monitoring of all key indicators of your processes like energy or water consumption, thermal losses, etc. Having all data of The way forward the complete plant life cycle concentrated into a common The outlook into the future clearly shows that more and platform, an intelligently designed process can react and indicate early if some parameters are likely to deviate from the more integration of automation engineering, plant engineering, standard range. In an example during a plant commission, the MES and PLM is happening towards a digital enterprise minimum and maximum energy consumption of a motor is platform. The company is working already since quite some documented in a system and during the life time the same is time on a way towards a digital enterprise. Software is becoming measured continually, an intelligent system can indicate well increasingly important for implementing the digital factory. in advance an upcoming maintenance of end of life time of the Without shared product and production lifecycle, we have motor. The benefit is real energy optimisation with a nearly reached the limits of further productivity increase with combination of plant asset management for intelligent and real a connection of best-in-class tools and products via data assets. It supports predictive maintenance & energy savings import and export function. A universal integration with a shared data model will open the door to overcome the declining and facilitates increased plant availability. Furthermore, based on all the information generated over IT productivity. ☐ life cycle of a project, advanced process control functionality > MORE@CLICK ADI03367 | www.AandD24.in within a DCS system can typically reduce the energy
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A&D India | Dec-Jan 2013/14
S O F T WA R E & E N G I N E E R I N G | A P P L I C AT I O N
A change in design software The feature discusses the significant benefits achieved in the quality of project documentation by PARI with the use of EPLAN software With over 850 employees and 6 facilities worldwide, Precision Automation & Robotics India Ltd (PARI), a global automation solution player, provides a complete range of automation solutions including conceptualising, designing, manufacturing, implementing and supporting of advanced factory automation systems. The company operates in three business verticals - automated manufacturing & robotic solutions, automated car parking & automated logistics.
Use of EPLAN PARI switched to EPLAN in 2004 and since then has never looked back. With a large market base in India, Europe and the US, PARI felt the need for an error-free design system to help cater to the high standards of quality expected. However, the software that was being used by PARI required the work to be done manually, which held a potential risk for errors at every step. Switching to the current solution gave PARI a host of advantages including generation of various reports, at the click of button, generation of Bill of Material (BOM) automatically based on the schematics, automatic assignment of device IDs and wire numbering and easy error detection (for example, not allowing two different voltage wires to be connected). The change also helped in the provision of different standard symbol libraries, customisation when following different drawing standards, uniformity in the presentation of the wiring diagrams (the look is independent of the engineer), and in the creation of the internal component layouts of panels by using footprints from a library. “EPLAN is a well-designed user-friendly software. It has reduced the engineering time by at least 40%. The quality and data consistency over the documentation is very good,” says Atul Patil, VP – Control Systems Engineering, PARI, on the effectiveness of the change. PARI experienced a smooth transition from the existing software to the use of the present solution. Before the launch of EPLAN, all engineers at PARI were trained to work on EPLAN. The faculty especially focused on providing adequate training
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A&D India | Dec-Jan 2013/14
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S O F T WA R E & E N G I N E E R I N G | A P P L I C AT I O N
PARI operates through deploying well-engineered automation solutions through mass-customised technologies and system to achieve the global needs of its customers
to all the engineers associated with hardware design. The result was a successful setting up of standard part’s database, macros, templates, etc, making it easy for the engineers at PARI to do a better job in lesser time. Commenting on the significant amount of savings in time, Patil says, “We had not set any target in reduction of project turnaround time, when we switched over to EPLAN. Our focus then was to generate good-looking error free drawings of international level. We did not set any specific goals in this regards, but yes, it has reduced the engineering time by at least 40%.”
Execution of a typical project at PARI PARI uses EPLAN in its design phase. In a typical project, the designing starts with the creation of a platform based on customer requirement. The engineering solution is used in designing plot frames, forms, symbol libraries, schemes, database, etc. Based on this, the wiring diagram is created after which auto-ferruling, device numbering and PLC numbering is done to optimise time. PARI designs schematics in-house for the panels along with the field wiring. The production team at PARI uses terminal/wire/cable reports and the wiring schematics during the production phase of the project, to wire up the panels/boxes and the field wiring. After the design phase, the clients of PARI continue to use EPLAN schematics for maintenance purposes. For clients who wish for their schematics in software other than EPLAN, PARI further uses the engineering solution to produce an output in editable format as required by the client.
Impact on PARI’s engineering productivity Although PARI’s primary reason to change its design software was to generate impressive and error-free drawings of international level, EPLAN has in turn provided a positive impact on PARI’s overall engineering productivity. PARI reports a reduction in engineering time by a massive 40% by reducing the engineering hours for wiring diagram preparation,
checking and associated re-work. PARI is also planning to directly import the bill of material (BOM) generated via the software into their home grown ERP system – hence reducing the errors in ordering material and saving time in entering the BOM into the ERP.
PARI succeeds in eliminating errors The successful launch of the engineering solution has encouraged best practices in PARI in four different areas, namely through the provision of standardisation of recurrent content, through faster and more reliable generation of documentation, through the reduction or elimination of errors and easier error-checking and through faster integration of data corrections and customer-specified changes. At PARI, the control design engineers use EPLAN mainly for schematic generation. 1500+ macros have been created, including DIN and ANSI type macros and corresponding parts database. The product has also enabled PARI to use DIN based modularisation using the HLA+LOD concept. Engineers at PARI further use associated products like EPLAN Data Portal to pick up parts. The high quality wiring diagrams produced by PARI are also found to be far superior to their international competitors, a fact that has been widely expressed by PARI’s various clients. PARI’s satisfaction has resulted in them rating the service and support at a high 4, on a scale of 1 to 5. This stems from the fact that the product has not only made it possible to increase production even further, but has also provided a full range of services to fall back upon. Extremely satisfied with the current engineering solutions, PARI also recently purchased EPLAN Fluid to aid in other areas of design and production. Overall, PARI found EPLAN as a reliable tool, especially since it contributed towards significant improvements in areas such as project documentation, error reduction, content standardisation and document generation. ☐ Courtesy: EPLAN > MORE@CLICK ADI03368 | www.AandD24.in
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A&D India | Dec-Jan 2013/14
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The new ABB industrial drives simplify your world because they are allcompatible. The ACS880 drives are designed to tackle any motor-driven application, in any industry, whatever the power range. The drives can be flexibly connected to different automation networks, and through the use of direct torque control, they precisely control different motors such as AC induction and permanent magnet motors. Yet, despite the drivesâ&#x20AC;&#x2122; wide-ranging capability, they are remarkably easy to use and integrate. To learn about our new industrial drives and the benefits they can offer to you, visit. www.abb.com/drives
ABB India Contact Center Toll Free Number : 1800 420 0707 E-mail : contact.center@in.abb.com
M A N U FA C T U R I N G I T | T E C H N O L O G Y
ACHIEVING OPTIMUM EFFICIENCY The article details on the Ruby on Rails framework that can develop and build a solution within time constraints, and has the ability to quickly adapt to changing production processes and technologies
Gautam Rege Director Josh Software gautam@joshsoftware.com
Globalisation has enabled companies to set up manufacturing units around the world to aid in effective distribution, cost advantages, optimum resource allocation, and most importantly, increased production. The existence of manufacturing set-ups across the world has made it even more difficult to effectively administer their functioning. With reduced infrastructure costs due to cloud computing technology and penetration of highspeed broadband internet increasing every year, using web applications to monitor and oversee manufacturing operations spanning different locations can help an organisation realise its full production potential. There has been great interest in using manufacturing operations management solutions at the production level of many organisations. Organisations have looked at building web applications for their manufacturing set ups for enterprise resource planning (ERP), supply chain management, and quality control.
technologies, it is important to choose the right framework to build your applications in. A framework that can develop and build a solution within time constraints, and more importantly, a framework that has the ability to quickly adapt to changing production processes and technology. Supported by the fast growing adoption of the framework in building web solutions, Ruby on Rails designed to build an online application for manufacturing set ups and support organisations across ERP, supply chain, and quality control functions. Manufacturing companies constantly strive to get the most from their production set ups, and the Ruby on Rails framework can aid in reaching this level of optimisation. It allows organisations to get the right boost to set up online applications for large-scale ERP solutions; furthermore, this solution can be built in the Ruby on Rails framework with a quick turnaround time as compared to other web frameworks.
Choosing the right framework
Need to be agile
Due to the ever-evolving manufacturing processes and
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As ERP frameworks give an integrated view of core
A&D India | Dec-Jan 2013/14
Projek
M A N U FA C T U R I N G I T | T E C H N O L O G Y
The image indicates that 3 agents are down and 2 agents are alive streaming data from machines connected to them. The "Last Event" indicates the last data packet received and "Event Count" indicates the number of events received in the last hour
manufacturing and business processes, it is important for the ERP solution to be agile as organisations evolve or change their production process, technologies, and resources. ERP solutions built in the Ruby on Rails framework can allow for a quick adaptability to account for any changes in the production process. Being an open source and an economical option, this framework can be suited for SMEs and emerging manufacturing companies as well. A robust ERP solution can also help a company monitor their production and through the use of web solutions, put the organisation in a better position to make quick changes and fill any gaps or inefficiencies within the system and processes. Apart from enterprise resource planning, efficient management of the supply chain is the key to generate the full potential of a manufacturing set up. The supply chain needs to be monitored and controlled with care as its mismanagement can lead to a severe drop in the production potential of a manufacturing unit; furthermore, the supply chain is one of the most complex aspects to a manufacturing process due to the need of customisation of each step from procurement to inventory management to consumption. The ability of Rails to offer a quicker and cost-effective customisation and maintenance makes its selection to build a supply chain solution a necessity. A web solution for supply chain management can also support in remote monitoring of several manufacturing set-ups from a distant location. This would prove to be great advantage for companies having several units spread across different geographies. The monitoring and data notifications can be sent to any communication device for instantaneous eradication of inadequacies within the supply chain. In addition, authorisation and verification of changes in the supply chain can be now reduced to minutes due to the real-time monitoring the web solution provides. A well-oiled supply chain can lead to great manufacturing process, and Rails can help facilitate this level of proficiency. Planning resources and managing supply is important, but the quality of your product gives your business a sustained long-term value. A set of procedures, policies, and processes that ensure the quality of a manufactured product is, today,
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leading to the success of businesses globally. Along with automation, system and process quality is becoming increasingly important. Certifications such as Six Sigma and ISO are becoming pre-requisites in the business environment. However, rather than just being a paper certification, most SMEs and even larger organisations are now looking at improving their processing by going paperless. Rails applications can provide the perfect leverage to sanction such systems because of its flexibility, faster development and lower costs. Besides helping to improve the manufacturing process, an improvement in quality output will lead to an improved market share, increase in sales growth and competitive advantage. Due to the cost efficiency of building solutions in the Ruby framework, quality assurance web solutions built in Ruby framework can be availed by a variety of manufacturing companies regardless of their size.
Cost-effective solution With every manufacturing company aspiring for the highest levels of efficiency and productivity, Ruby on Rails can be a good choice to build web solutions to help businesses generate their full potential. The returns on using the Rails framework can be identified across a variety of parameters. The most apparent advantage of using the Rails framework is the time the solutions can delivered in, which in some cases, can be within a quarter of the time taken using other frameworks. Changes to the online systems are fast and easy, the maintenance of these online systems is trivial. Rails integrate with state of the art databases that are meant for scale and performance. Rails is an open-source framework (hence free) and does not require large heavy duty servers but can be hosted in the cloud or on standard commodity servers, itâ&#x20AC;&#x2122;s a huge cost and time saver. Additionally, the language framework provides a cost-effective method to build solutions around key manufacturing aspects such as resource planning, supply management, and perhaps the most important in todayâ&#x20AC;&#x2122;s competitive scenario, quality assurance. â&#x2DC;? > MORE@CLICK ADI03369 | www.AandD24.in
A&D India | Dec-Jan 2013/14
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FIELDBUSES & NETWORKS | TECHNOLOGY
Open source solution Performance without limits, flexible topologies, machine modularity, and advanced interaction of sensors & controls are the requirements of modern automation. Sufficing these are new open source developments like POWERLINK Ninad Deshpande Marketing - Open Technology B&R Industrial Automation Ninad.Deshpande@br-automation.com
What is “open source”? Is it something which has no owner? Or is it something which is unmanaged? There are many misconceptions about the term “open source”. Open basically means usage without restrictions. The software source code is not only available free of cost but also available for free redistribution. In the course of redistribution, it can also be modified and have derived works. The Open Source Initiative (OSI) is an organisation dedicated for promoting open-source software and takes the responsibility for reviewing and approving licenses as OSD-conformant. A few famous open source technologies are Firefox, Android, Apache, Linux and POWERLINK. Why open source? This is another question which needs to be answered for better understanding of the open technologies. Better quality, no vendor lock-in, security, lower costs, and last but not the least availability of source code without licenses are a few answers which can be provided. A certain example which
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can be cited on better quality is of a research conducted which shows Linux, an open source operating system having fewer bugs as compared to the proprietary software. The US White House shifted from the proprietary content management system – CMS to Drupal open source CMS in 2009 showing the class of security provided by an open source platform. The proprietary system technically seems to be very efficient in the beginning but then soon one understands the inefficient interoperability with other systems. The proprietary systems have an unclear long term policy and limiting to one vendor.
Evolving automation industry The automation industry is demanding higher speeds, accuracy and reliability and to achieve this customers go for either a new system or upgrading of the current system. PLC, HMI, sensors and drives are amongst the few of the various
A&D India | Dec-Jan 2013/14
Processes Under Control
Stationary dynamometer for cutting force measurement
Joining systems with measuring ranges up to 300 kN
Force displacement monitors for 100 % control of assembly processes
Force sensors with measuring ranges from 1 mN up to 20 MN
Torque sensors with measuring ranges from 0,01 up to 20 000 N¡m
300-704e-06.11
Rotating dynamometer for cutting force measurement
Kistlerâ&#x20AC;&#x2122;s piezoelectric dynamometers are the basis for accurate verification of simulation results and general process analysis. The dynamometers mea sure cutting forces during milling, turning, drilling
and grinding processes. This is essential for com prehensive process optimization. Kistler Instruments (India) Pvt. Ltd., Tel. +91 129 4113 555, +91 44 4213 2332, +91 20 2712 6366, Email: sales.in@kistler.com & '& ( ! "
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FIELDBUSES & NETWORKS | TECHNOLOGY
automation products which are used in the plant. The “10 Criteria”. customers do not want to be tied down by single automation POWERLINK also has a BSD license which is a family of a suppliers and are now more directed to defining standards permissive free software licenses, imposing minimal rather than defining the suppliers. The customers are more restrictions on the redistribution of covered software. This is interested in long-term availability and a stable platform. in contrast to copy left licenses, which have reciprocity shareAutomation suppliers are willing to work with systems which alike requirements. This BSD license states that everyone is have no single owner, no patents, no royalty and no copyright. allowed to use and change the code and achieve derived works There may be many automation suppliers providing various with an ability to re-publish changes under any other license. products but the backbone of th‘e system which is Performance without limits, flexible topologies, machine communication is desired by many to be open so that the modularity, and advanced interaction of sensors and controls vendor dependency can be avoided. are the requirements of modern automation and POWERLINK satisfies all these requirements seamlessly.
Trends in fieldbus
Like the automation industry, fieldbuses are also evolving with a view to provide users with fast speeds, easy diagnostics and maintenance. Wired serial technology was the starting point for communication eventually evolving into fieldbus technology which was faster than the wired technology. The recent evolutions seen in this communication technology is the shift towards the Industrial Ethernet. The Ethernet based communication technology offers better diagnostics over conventional fieldbus approaches. A simple industrial CAT5 cable is used for wiring which can be plugged in the devices, thus no skilled man power is needed for wiring. Customers have become increasingly aware about the fact that the network will be a key differentiator.
A real-time open solution for industrial Ethernet Ethernet POWERLINK, which is a real time open source solution, is used as a communication backbone in systems. POWERLINK is the world-wide leader for real time Ethernet solutions with an installation base of close to 750,000 systems and 3100 OEM trusting in POWERLINK. License for POWERLINK is recognised by the Open Source Initiative as OSD-Conformant under the Open Source Definition
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Benefits POWERLINK is the only real-time deterministic solution based on standard Ethernet and is the only open solution in the market. Here, determinism is defined as the ability of a network to send a piece of information to a specific destination and receive a response in a time frame that is predictable and repeatable. With the rapid evolution of Ethernet from 100 Mbits/s to 1 Gbits/s and further with POWERLINK, the user safeguards and future proofs his investment as POWERLINK is ready for these evolutions. Thus, any standard PC or any industrial PC having an Ethernet port can be used to run POWERLINK. POWERLINK enables the user to work with the topology which is desired by the machine and irrespective of the topology selected, delivers maximum performance. Redundancy is also another feature in the offering by POWERLINK, including ring, multi-master and media redundancy. Equipped with all these features, POWERLINK is able to achieve cycle times as low as 100 µs. It also provides for maximum performance, is based on standard Ethernet, is absolutely open and has the lowest total cost of ownership, thus satisfying all requirements for industrial automation. ☐ > MORE@CLICK ADI03370 | www.AandD24.in
A&D India | Dec-Jan 2013/14
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EVENT | REPORT
To be furure ready To serve as the bridge between manufacturing competitiveness and automation, Autom@tion Tech 2013 was recently organised by Automation Industry Association in Pune. A report… In an era where reduced budgets limit the scope for trials and error, Autom@tion Tech 2013, on the theme ‘Automation for Manufacturing Competitiveness’ was recently organised by Automation Industry Association (AIA) at Pune to serve as a timely reminder for manufacturing leaders to be future ready. In his opening address, keynote speaker K Nandakumar, President, AIA, drew an analogy from America’s School for War, saying “It’s a world of VUCA (volatility, uncertainty, complexity, ambiguity). To sustain the VUCA world, we must be conscious of how we manufacture. Feed into the global grid, shape consumer demand, reform governance and price our planet. Presenting an appropriate definition for automation, he said, “It is the industrial infrastructure that delivers ultimate customer experience making positive difference in the community.” While speaking on how to leverage automation for leadership in manufacturing, he pointed at various measures needed to enhance manufacturing value addition (MVA) and the state of Indian economy. He also asserted that the share of manufacturing sector in India’s GDP is likely to
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increase by nearly 20% by 2020, creating a major challenge to mobilise energy resources to suffice growing demands. Mentioning the growth drivers, he said, “Capital goods industry is the growth driver for India.” The capital goods sector comprises of plant & machinery, equipment/accessories required for manufacturing/production, either directly or indirectly, of goods or for rendering services, including those required for replacement, modernisation, technological upgradation & expansion. It also includes packaging machinery & equipment, refrigeration equipment, power generating sets, equipment & instruments for testing, research & development, quality & pollution control, and automation for all verticals & across consumer goods. Stressing on automation tools widely used in the industry, he said, “The five tools of automation include intelligent sensing, hardware and software control, safe and timely actuation, interactive human machine interface, and real-time communication and integration with MIS.” Identifying new technologies in automation, he noted, “Some of the latest
A&D India | Dec-Jan 2013/14
REPORT | EVENT
(From L to R) Milind Kulkarni, Head – Factory Automation, Siemens; Vishwas Chitale, Director & CTO, Chitale Dairy; Dr Rajiv Shukla, Director, Anita Automation; Mukund Muley, MD, Cotmac Electronics; Karam Vir Rehani, Founder, KVR Consulting during the panel discussion
technologies in automation include industrial wireless, compact and light weight robots, embedded intelligence in HMIs and tomachine (M2M) communications, web services & application integration, and manufacturing execution systems.” He also devised a new term ‘train the trainer,’ so that he can go back and train students, thereby enhancing manufacturing competitiveness. Padmashri Dr Vijay Bhatkar, Chairman, Board of Governors, IIT Delhi, known for his path breaking pursuits in Government, industry, R&D and academia, was the chief guest for the occasion. “In automotive, we have transformed from total backwardness. Ability to add value in manufacturing is important for manufacturing industry to thrive. Whenever we have had a challenge or have been denied anything, we have responded. The present time offers an opportunity to create intelligently designed machines to add intelligence on the matter and the energy we process. In the future, we may be able to think and control. I would like to see automation reaching the pinnacle in Pune, which is also the engineering capital of India,” he said.
Discussions at the conference Sanjay Kachare, Head-Operations, Kimberly Clark, shared how automation strategies impact all aspects of manufacturing, because complexity of operations continues to increase. To make the transition to sustainable manufacturing, Kachare said, “the increasing need for energy efficiency, emissions monitoring, regulatory tracking, process changes, packaging changes, asset upgrades, and new controls and metering places greater demands on design and engineering teams to collaborate in bringing new functionality and enhanced visibility to manufacturing operations.” Vishwas Chitale, Director and CTO, Chitale Dairy, while presenting on the topic – financial analysis of automation investments, emphasised that holistic use of automation across
A&D India | Dec-Jan 2013/14
the entire business process is warranted. He shared how his business is managed with dynamic business intelligence dashboards that provide drill down capability to view and analyse cost and production information coming in from realtime data collectors. He also shared his vision to connect the business with the cloud. Nidamaluri Nagesh, recipient of the prestigious Boss Kettering Award for Innovation on Collaborative Robots and currently, Senior GM, Mahindra Vehicles, dealt with automation game changers, connected manufacturing and disruptive technology. Quoting a Gartner report, Nagesh emphasised, “Manufacturers need a fully connected enterprise to compete in today’s global economy. They need to connect their manufacturing operations and business systems while sharing performance data with machine builders and tier suppliers to improve processes, increase production and reduce risk. Discussing game changers in automation, he noted, “The evolution of automation will embed technologies in such a way that they are transparent to the user and allow untrained users to not only operate but also become capable of performing selfguided maintenance tasks. Leading the way is the convergence of functionalities on a single HMI dashboard, as part of an integrated control capability based on international standards. This convergence is led by Moore’s Law and enabled by a host of new technologies, ranging from three dimensional immersive animations to networked safety, to energy and condition monitoring technologies, to mainstream consumer and IT platforms.” At Autom@tion 2013, global technology leaders like Microsoft, Rockwell Automation and Siemens also pitched in with the previews of future automation technologies. To sum up, Autom@tion Tech displayed how automation is a hidden value amplifier and how manufacturing businesses can unlock profit potential with real-time decision power. ☐ > MORE@CLICK ADI03371 | www.AandD24.in
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EVENT | REPORT
Foundation for business innovation GIL India-2013 hosted by Frost & Sullivan in Mumbai, paved the way for an interface with delegates on ‘disrupt, collapse, and transform - Are you ready? A report…. Frost & Sullivan recently conducted its global event in Mumbai on October 8, 2013. Titled under “Discovering the next big thing, leveraging mega trend opportunities to grow and innovate - today, tomorrow & beyond,” it brought together a global network of today’s best thinkers, visionaries and thought leaders learning how to leverage innovation as a resource to address global challenges.
Highlights The Blue Sky Innovation workshop touched upon the current business scenario and concluded that while it is important for companies to focus on the cash cows of the present, the rapidly changing market could mean that the current business is heading toward a dead end. It also highlighted the importance to make sure the companies are aware and in tune with the greater market changes and are looking to develop new offerings that keep up,
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and potentially, disrupt, collapse and recreate new and current market spaces. “Blue Sky innovation complements traditional innovation in driving business performance. Collaborations can lead to increased pipeline of ideas, more robust ideas with quicker and more directed development, and a reduction in costs. Innovation requires synergised interaction between all the key players in the broader innovation environment. The key components, separately and in combination, provide the foundation for successful innovation. Organisations move beyond an ad-hoc approach when they develop the capabilities and synergies that support sustainable innovation. But the larger question is - how should you be incorporating Blue Sky thinking into your business?”, said Mark Simoncelli, Global Director, Growth Implementation Solutions, Frost & Sullivan. The innovation diagnostic proposed by Frost & Sullivan is the first step towards developing the roadmap to optimal
A&D India | Dec-Jan 2013/14
REPORT | EVENT
Dr Amit Piathankar, Managing Director, Emerson Process Management, India, Sunjay Dabir, Sr Director – India Engineering, Diebold India Pvt Ltd and Dr Aloknath De, Chief Technology Officer & Sr VP, Digital Media and Communication, Samsung India during the panel discussion
innovation. The diagnostic tool evaluates an organisation’s innovation readiness through a parametric understanding of its strategic, operational, and resource capabilities. “The innovation management system reaches across the organisation. Over and above in the innovation process, there are several other functions of the organisation that impact innovation. All these components need to interact in a synergised way within the organisation. But the challenge is – ‘What are you going to be changing to make yourself more innovative as an individual, more innovative as a company and to help make you more innovative as a country,” added Simoncelli.
Emerging trends The presentation focused on the impact of the emerging AWARD TITLE Competitive Strategy Leadership Award - 2012 Competitive Strategy Leadership Award - Indian Calibration and Repair Services Market - 2012-13 Customer Service Leadership Award - Indian Calibration and Repair Services Market - 2012-13 Customer Value Leadership Excellence - Indian Dimensional Metrology Market - 2012-13 New Product Innovation Leadership Award - Secured Cloud Backup Platform for Enterprises, India - 2013 Indian LSP Brand of the Year - 2013 International LSP Brand of the Year - 2013
A&D India | Dec-Jan 2013/14
COMPANY Eris Lifesciences Private Limited Tektronix India Pvt. Ltd. Agilent Technologies India Pvt. Ltd. Carl Zeiss India Pvt. Ltd.
Vaultize Gati-KWE Limited DHL Express (India) Pvt. Ltd.
mega trends in the countries specially India and revealed that urbanisation will continue to drive India’s infrastructure development which will lead to the formation of four mega regions by 2025, each with a population of over 15 million. Mega cities are likely to contribute 70 % of India’s GDP in 2030 and 8 mega corridors will surface by 2021 and 70 satellite towns by 2020. It also highlighted the genY, working age population, working women and the Indian middle class will continue to be the most influential segments, triggering new social, technological, and economic needs. The compound impact of mega trends is expected to bring a paradigm shift toward smart lifestyles, smart governance, connected society & new business models. Mega trends further indicated that in India, three out of 10 two-wheelers will be an electric vehicle; cities will become smart and sustainable; multipurpose super-appliances will become increasingly popular; renewable energy sources will become a formalised part of the grid and one out of every 10 retail transactions will be an online transaction Frost & Sullivan estimated that in India, there will be a 60-million-tonnes shortfall of food grains, 30 million-tonnes shortfall of pulses and cereals, 35 million-tonnes shortfall of fruits and vegetables, 30% ground water depletion, 92% utilisation of available water. These statistics re-enforce the need to pay heed to these imminent conditions and draw out a plan to save the resources before they are completely depleted. ☐ Courtesy: Frost & Sullivan > MORE@CLICK ADI03372 | www.AandD24.in
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EVENT | PREVIEW
Business meets technology With about 1,000 exhibitors, and more than 1,25,000 visitors from India and over 130 countries, ELECRAMA-2104 will demonstrate latest technologies, reliable and robust products in the electrical T&D industry from January 8 to 12, 2013, at BIEC, Bengaluru. A preview… ELECRAMA-2014 will be opening its door to the electrical transmission and distribution equipment industry with the objective of promoting the ‘Made-in-India’ brand to a global audience on January 8, 2013, at Bengaluru. Supported by the Ministry of Power, Ministry of Heavy Industries & Public Enterprises and Ministry of Commerce & Industry, Government of India, State Government of Karnataka, BESCOM and KPTCL, this edition of ELECRAMA has a unique theme of ‘Go Global.’ The five-day fair will majorly showcase products and technologies through the entire voltage spectrum, from 220 V to 1200 kV, conforming to global standards and specifications. Global CEOs including Gregoire Poux-Guillaume, President, Alstom Grid; Jean Pascal Tricoire, Chairman & CEO, Schneider Electric SA; Tony Gatt, President, Energy Division, TE Connectivity are the Global Brand Ambassadors of ELECRAMA-2014. R N Nayak, CMD, Powergrid Corporation of India is the Indian Brand Ambassador of ELECRAMA-2014.
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Event highlights ELECRAMA-2014 will play host to a number of technical and commercial interactions through its finely planned portfolio of concurrent events. CEO Summit: ELECRAMA-2014 will host interesting high power dialogues that will involve captains of the industry for the sector. The CEO Summit has been organised on January 8, 2013. These discussions will touch upon macro-economic factors impacting the industry from a global perspective. It will also introduce the various investment opportunities available in Karnataka and the country. International T&D Conclave: ELECRAMA-2014 will also host the International T&D Conclave on January 9. A half-day conclave structured for experience sharing between the global power transmission & distribution utilities and industry stakeholders. The session will focus on the business contours
A&D India | Dec-Jan 2013/14
PREVIEW | EVENT
“ELECRAMA-2014 is IEEMA’s endeavour to promote the ‘Made in India’ brand and enhance Indian exports of electrical equipment. We are targeting 5% share of global trade in electrical equipment in the next 10 years from the current 1%, so that we reach US$ 25 billion export mark” Sanjeev Sardana, Chairman, ELECRAMA-2014
and opportunities in the global T&D sector like practices, well as sharing case studies and experiences. policies, finance, trade, skill development and government TRAFOTECH 2014: ELECRAMA-2014 will play host to regulations. Heads of power utilities from Nigeria, Kenya, Saudi TRAFOTECH, an international conference that provides stateArabia, Libya and Zambia, in addition to the Director of of the-art information on transformer engineering and Sustainable Energy, The World Bank, Washington, would be technology. This event will be held on January 10 and 11, 2013. addressing the conclave on investment opportunities in the The conference will provide transformer designers, power sector in their respective countries. manufacturers, users and consultants a common platform to CIGRE Tutorials: On January 9, CIGRE Tutorials sessions review the latest advances and futuristic trends, share operational on high voltage equipment, overhead lines, substations, HVDC experiences and discuss the requirements of transformers for and power electronics, and distribution systems and dispersed smart grid systems. generation, would be held by renowned global experts. Engineer Infinite 2014: Engineer Infinite 2014 will include ChangeXchange 2014 – 2nd Reverse Buyer-Seller Meet recent trends in the subjects related to electrical energy sector, (RBSM): IEEMA is organising ChangeXchange 2014 – 2nd IT and computer science branches along with the traditional Reverse Buyer-Seller Meet (RBSM) concurrently with ‘electro technology’ branches. It aims to channelise the creative ELECRAMA-2014 with support from the Department of potential of the Indian youth for the benefit of the electrical Commerce, Ministry of Commerce & Industry, Government of energy sector in India. The number of online registrations for India, under the Market Access Initiative (MAI) Scheme. this edition is almost three times and project entries are more ChangeXchange 2014 will be the biggest meeting place of foreign than double. The project proposals cover 13 technology areas. buyers who plan to source electrical products and equipment There is a widespread participation from all over the country from India. It has special hosted packages for buyers from with more than 8,000 registrations and over 1,500 entries. countries of Africa, ASEAN, CIS, Latin American and SAARC, Innovation Day: Innovation Day on January 10, 2013, will along with Iran. Around 450 buyers from these regions would be a half-day session with international and Indian technical be taking part in the RBSM. The RBSM will open new vistas for community engaged in serious discussions on a topic that will Indian industry in the global market, offering components, enlighten, inspire and elevate the participants. The theme for finished products, product re-design and re-engineering discussion is ‘ElectriCITY and Digital Societies’, dealing with expertise that match or exceed global standards. changing role of electricity in the new age digitised society, Conductor Seminar: New generation conductors or High smart grids, mass transport, rural empowerment with ICT, Performance Conductors (HPC) have been developed to uprate intelligent and automated infrastructure. India’s Best Young transmission & distribution corridors. In order to understand in talent will be recognised and rewarded by world renowned detail about the types of high performance conductors, their experts. There will also be announcements of key futuristic benefits, how they are strung, what are the hardware used, etc., initiatives of IEEMA in collaboration with global technical an experience sharing seminar on ‘Conductors’ is being bodies/organisations of highest repute and respect. ☐ organised on January 10, 2013. Eminent speakers from India > MORE@CLICK ADI03373 | www.AandD24.in and abroad will be presenting different aspects of this topic, as
A&D India | Dec-Jan 2013/14
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T E C H N O L O G Y | TA L K
CRUCIAL ELEMENTS OF FUNCTIONAL SAFETY The article highlights safety programs and examines the larger trends of the best performers, providing valuable insights into what can be accomplished when safety is implemented holistically, with consideration to a manufacturer’s larger operations The Aberdeen Group, in three separate surveys, has showed that manufacturing executives use four key performance indicators to measure safety performance. It includes overall equipment effectiveness (OEE); repeat accident rate; injury frequency rate and unscheduled asset downtime. The survey found that best-inclass manufacturers, defined as the top 20% of aggregate performance scorers, achieve 5 to 7 % higher OEE, 2 to 4% less unscheduled downtime and less than half the injury rate of average performers. Best-in-class manufacturers share a common set of best practices that can be grouped into three core elements of any safety program. It consists of culture (behavioural); compliance (procedural) and capital (technical).
Culture A safety culture is generally indicative of the broader company culture. Safety culture represents worker and company behaviour. A major food manufacturer recently worked with Bright Side Inc, an Ohio-based behavioral strategy firm that works with dozens of organisations on building safety into the culture. One of the manufacturer’s plants had received a corporate certification for superior discipline, and best work processes and practices. However, after a safety assessment, it was revealed that workers weren’t actually reporting all safety incidents because they were concerned it could jeopardise the plant’s hard-earned certification. To address this, Bright Side and the manufacturer addressed three strategic employee behaviors. It includes transparency; shared leadership and accountability and business, self-
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rationalisation. One of the biggest hurdles to overcome in achieving a strong safety culture is creating a shared and common appreciation for safety among all parties – from top floor to shop floor.
Compliance A significant challenge for manufacturers is determining how to bridge the disconnect between engineering and EH&S. Both groups need to collaborate and work toward a common goal, but may not have a solid understanding of the other’s job or function. Communicating, holding meetings and understanding how each person’s job affects the other’s will allow these teams to work toward a shared goal rather than the personal outcomes of each group.
Capital It’s important for manufacturers to have a solid understanding of their safety technologies and techniques. Companies can do this by determining which of the following categories they best fit into. r Incomplete or improper: Safety is an afterthought if it is considered at all. Workers are expected to keep themselves safe. If safety technologies are used, they are likely to be misused, defeated, or non-safety technologies are used in place of safety technologies. r Basic: Efforts are made to ensure the plant is compliant with safety regulations. In place of standard control devices, basic safety technologies & techniques are used, including safety relays and lock-out/
Companies that approach safety holistically across culture, compliance and capital can improve productivity, gain efficiencies and experience improved employee morale
tag-out procedures. Optimised: Supplemental safety technologies and techniques are used to optimise safety. In particular, manufacturers use alternatives to lock-out/tag-out tasks when they are deemed to be cumbersome, costly or time consuming. The benefits of optimising safety extend far beyond fewer injuries or fines. Companies that approach safety holistically across culture, compliance and capital can improve productivity, gain efficiencies and experience improved employee morale, while protecting their brand reputation. ☐
r
Courtesy: Rockwell Automation > MORE@CLICK ADI03374 | www.AandD24.in
A&D India | Dec-Jan 2013/14
NEWS | TECHNOLOGY
Ultrafast automation technology B&R has recently developed the reACTION technology which offers to reduce cycle times in industrial automation down to 1 µs. This new approach allows extremely time-critical sub-processes to be managed using standard hardware – all within the requirements of IEC 61131– while cutting costs by reducing the load on the controller and optimising performance to match demands. The result is an immense increase in performance without added costs. The fastest response times achieved in the field, from receiving the input signal to sending the output signal, have seldom been under 100 µs – until now. With reACTION technology, programs The reACTION technology offers created in the function block editor to reduce cycle times in industrial are executed directly on I/O modules automation down to 1 µs from the X20 and X67 series, eliminating internal data transmission and allowing response times to be reduced to as low as 1 µs. B&R takes advantage of the automation studio for development environment’s ability to allocate software modules to distributed hardware and utilise the surplus capacity of logic components in the modules. > MORE@CLICK ADI03375 | www.AandD24.in
Low cost cables
The PROFIBUS connector, netLink Proxy from Hilscher converts PROFIBUS slave into a PROFINET device without added installation expenditures. When plugged netLink Proxy directly onto the Profibus device, a PROFIBUS scan function detects the connected slave and automatically determines its configuration. Together with the slave GSD file, the configuration is converted The PROFIBUS connector, netLink into a standardised GSDML file, which Proxy converts PROFIBUS slave into is imported into the PROFINET controller then a PROFINET device without added configuration tool, the plug is ready for installation expenditures PROFINET and can be connected directly to Profinet Controller via RJ45 socket provided on netLink Proxy. It transparently maps the DP unit data. The transformation of acyclic DVP1 services read/write/alarm is supported as well. It guarantees a fast entry into the PROFINET world to the traditional PROFIBUS device manufacturers. netLINK PROXY integrates a PROFIBUSDP slave into any superordinate PROFINET network. As connector the device is plugged directly onto the PROFIBUS-DP interface of the DP-Slave and connects to the PROFINET network via the RJ45 socket. > MORE@CLICK ADI03376 | www.AandD24.in
AC variable frequency drives
igus has recently developed chainflex M, a range that covers all types of cables from control, motor, servo and measuring system cables to data and bus cables and guarantees reliable low-cost cables. chainflex M stands for a service life guaranteed for one million double strokes. This means, the specialist for moving cables is the first supplier on the market to link low-priced cables with a guaranteed service life in the energy chain. igus can make this reliability promise because their cables and systems are subjected to permanent simulated-reality tests. All cable families in the chainflex M range – whether these are motor, servo or measuring system cables – cost 20-30% less than the chainflex M, a range of reliable ranges on offer so far. This development low-cost cables covers all cable includes the optimisation of materials types, for one million double and adaptation of the twisting and strokes in energy chains. shielding methods particularly where mechanical engineering systems are designed for one million parts or cycles and work under normal environmental conditions. For example, it is not always necessary to use products that have undergone cost-intensive approval procedures. > MORE@CLICK ADI03377 | www.AandD24.in
A&D India | Dec-Jan 2013/14
Connector technology
Parker Hannifin India has launched its new series of AC variable frequency drive, the AC10 Micro Drive. AC10 is a simple, reliable and extremely versatile drive providing solution to every-day motor control applications requiring speed or torque control and are available in the power range of 0.2 kW to 15 kW. The typical applications for AC10 include conveyors, centrifuges, fans, mixers, packaging machines and textile machines to name a few. Offering extremely compact AC10 is a simple, reliable and dimensions and features associated with extremely versatile drive providing higher specification drives, AC10 solution to every-day motor provides an optimised solution for OEM control applications machine builders and process industry users, seeking a simple cost-effective drive without any compromise in performance. The many functional benefits such as auto-tuning sensorless vector mode, built-in PLC functionality, multiple V/f, etc are available as standard which makes the device beyond simple V/Hz motor control. It is built in PID controller and is quick and easy set-up for process control and no external controller needed. It features user selectable V/f curve that serves optimised control and extra energy savings. > MORE@CLICK ADI03378 | www.AandD24.in
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TECHNOLOGY | NEWS
Touch screen based HMI
Standardisation and automation software tool
FlexiPanels© HMI series from Renu Electronics offer multiple models for monitoring, controlling and connectivity. It offers advanced features of both the operator Interface and the PLC. While maintaining low cost, offers single programming environment for both of HMI & PLC with reduced programming time. This multi-function unit lowers overall system cost, panel space & wiring, it has on-board support for digital & analog I/Os. High speed pulse outputs control speed and motion up to two axis. Analog Inputs are universal type (RTD, Thermocouple, mA, Volts). The series is the latest offering from the company with known FlexiPanels© HMI series offer performance, high reliability and has advanced features of both the ‘CE’ & ‘UL’ listings. It finds its operator Interface and the PLC applications in various industries like packaging, machine tools, food, pharma, and textile. Its features include 3” monochrome touch screen with multicolour backlight; HMI with integrated I/Os; digital inputs – bidirectional; digital outputs - OC / relays; high speed counters and timers; support for quadrature inputs and PWM output and universal analog inputs.
Eplan Platform has launched version 2.3 that focuses on standardisation and automation, and opens up new opportunities for users when it comes to standard-compliant design and handling safety values. Simple macro editing and extended search functions for system settings guarantee highly productive engineering for users. Another practical benefit: central administration of phased-out The Eplan Platform 2.3 allows project devices and associated test runs to structures and designations to be give transparency and safety to implemented on a user-friendly basis in existing projects.The latest version compliance with this current standard 2.3 of the Eplan Platform is characterised by standardised and largely automated engineering across a consistent database. There is comprehensive support for new standard-compliant designations based on EN 81346 and the safety values focused VDMA 66413 exchange format. The central administration of phased-out items and a new search function for system settings are additional new features of the CAE software to allow interdisciplinary cooperation and configuration.
> MORE@CLICK ADI03379 | www.AandD24.in
> MORE@CLICK ADI03380 | www.AandD24.in
CANopen devices
Steel wire braided flexible cable
The CM CANopen module from HMS Industrial Networks enables users of the SIMATIC S7-1200 PLC to integrate CANopen devices into their automation systems. The CM CANopen is an extension module for the SIMATIC S7-1200, enabling the PLC to communicate with devices on a CANopen network. It plugs into the S7-1200 and works as a translator between nodes on a CANopen network and the S7-1200. The module fits mechanically into the standard S7-1200 system rack and can be configured to The CM CANopen is an extension module be both master and slave. No for the SIMATIC S7-1200, enabling the programming is needed to PLC to communicate with devices on a configure the communication CANopen network between CANopen and the PLC – users set up how they want the data to flow in the accompanying CM CANopen. It is possible to plug in three CM CANopen modules per PLC, and 16 CANopen slave nodes can be connected to each module (each module supports 256 bytes input and 256 bytes output). There is also support for transparent CAN 2.0A for custom protocol handling.
Lapp has developed steel braided cables that have the additional benefits owing to the galvanised steel wire braid and transparent PVC outer sheath. It retains flexibility and ease of installation and offers a high degree of mechanical protection and notch resistance often extending the service life of an installation. The flexible, transparent PVC outer sheath provides oil, abrasion and chemical resistance. It facilitates better electrical performance The steel braided cables retain due to 4 KV test voltage. These flexibility & ease of installation and cables have a wide range of offers a high degree of mechanical applications like the cable tray protection and notch resistance application and can be used under adverse operating conditions or when exposed to high mechanical strain. Steel braided cables are utilised in plant engineering, industrial machinery, heating and air-conditioning systems, for fixed installation and occasional flexing at free. The PVC sheath of the cable ensures flame retardance and protection against certain acids. Apart from the above the steel wire braided cables can also be manufactured with special features like UV resistance & anti rodent properties.
> MORE@CLICK ADI03381 | www.AandD24.in
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> MORE@CLICK ADI03382 | www.AandD24.in
A&D India | Dec-Jan 2013/14
NEWS | TECHNOLOGY
Remote I/O modules
Multiphysics simulation platform
Pepperl+Fuchs completes its wide range of I/O modules with the half-size, eight-channel digital input modules and offers the most compact remote I/O solution for process automation. The slim modules save valuable space in switch cabinets, thereby reducing the cost per channel. The new housings of the digital high-density input modules are half as wide as those of the previous version, but this is partly due to the compact plug construction. The two plug-in connectors found on the front of the housing each have eight contacts. In addition, the redesigned housing features status The new modules require LEDs for each of the eight available around 40% less installation channels, enabling quick diagnostics and space in a complete remote accelerating both commissioning and I/O system including com unit maintenance. The new modules require coupler and power supply around 40% less installation space in a complete remote I/O system including com unit coupler and power supply, depending on the signal mix. The innovative, slim modules can be installed in spaces where larger switch cabinets cannot fit.
COMSOL has released the Multiphysics速 4.4, the latest version of its powerful platform for the modeling and simulation of electrical, mechanical, fluid, and chemical applications. A ribbon design has been introduced to the COMSOL Desktop速 environment, when run on Windows速 platforms, to provide easier navigation and an enhanced user experience. By grouping commands and displaying them as needed, the ribbon makes it easier to find and use the tools. Commands are grouped and ordered according to the main modeling tasks, which Multiphysics simulation of a heating are grouped under dedicated tabs circuit using the new COMSOL Desktop速 for definitions, geometry, physics, environment with a ribbon design, located mesh, study, and results. It brings at the top of the screen several additional workflow improvements such as a one-click select feature that enables faster selections in the graphics window. A noteworthy feature is a new auto-complete search function that allows uses to quickly find the post-processing variables.
> MORE@CLICK ADI03383 | www.AandD24.in
Flexible corrugated conduits Controlwell has recently developed flexible corrugated conduits that are made up of high quality materials and have extremely small bending radius. The second units offer good impact resistance and come with added benefits like being UV resistant, halogen-free, acid-proof and flame retardant in nature.These conduits have an extremely small bending radius and offer high impact resistance. When combined with Controlwell conduit glands these offer IP67 protection to cables housed there-in. The materials range include polyamide6, The flexible corrugated conduits are polyethylene, polypropylene, made up of high quality materials and galvanised and steel & PVC have extremely small bending radius coated galvanised steel.The temperature varies from 6 to 40oC to +105oCcontinuous, +150oC short term for Polyamide; 40oC to +135oC continuous, +150oC shortterm for Polypropylene; 15oC to +60oC continuous for polyethylene and Polyamide6 alcohol, benzol, greases, mineral oil, diesel fuel, seawater and petrol. > MORE@CLICK ADI03385 | www.AandD24.in
A&D India | Dec-Jan 2013/14
> MORE@CLICK ADI03384 | www.AandD24.in
Air blow gun Janatics has recently developed air blow gun with different types of nozzles. The blow gun with straight tube; angled tube; long straight tube provides a perfect choice and solutions to the customers based upon the application requirement. Blow guns with extended nozzle provide longer reach. Extended angled nozzles are designed for use in difficult-to-reach locations. These are made of engineering plastic and ergonomically designed, easy to handle, light weight, easy to hang, unbreakable and can be used in open environments. Designed for efficient cleaning with minimum air supply, blow guns are normally used in applications like textile mills, food processing, foundries, SPMs, and machine tools. The Air Blow Gun - Size G1/4 series offer medium, compressed air. Its applications include blowing off chips in machine tools; foundries; assembly lines; service stations; painting (part cleaning); textile mills; injection moulding machines (cooling of moulds) and pressure die casting machines. > MORE@CLICK ADI03386 | www.AandD24.in
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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 - Dec’13-Jan’14 IMPRINT
Automation & Drives
Publisher / Chief Editor ShekharManufacturing Jitkar Efficient shekhar.jitkar@publish-industry.net Deputy Editor Sumedha Mahorey sumedha.mahorey@publish-industry.net Sub-editor & Correspondent Srimoyee Lahiri srimoyee.lahiri@publish-industry.net
» Power & Energy Power plant control systems combine innovative technology and broad functionality with established operational reliability. Enhancement of power plant control systems is an ongoing process with the aim of further improving cost effectiveness, functionality and quality. The next issue will highlight some of the trends in power plant automation and energy management.
» Software & Engg Tools Software & engineering tools automate project management activities, manage all work products produced throughout the process, and assist engineers in their analysis, design, coding and testing work. The next issue will see how these tools can provide for better productivity and efficient use of time.
» Drives & Components With a consistent programming structure and common operator interface, drives ease programming and configuration, and reduce set-up time, training, and operation. Today’s drives offer a broad range of control modes, features, options, and packaging. The next issue will have articles on drives & components with details on the current developments in this area.
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COMPANY INDEX Name . . . . . . . . . . . . . . . . . . . . . . . . . Page AIA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 ABB . . . . . . . . . . . . . . . . . . . . . . . . . 61, 12 Agilent Technologies . . . . . . . . . . . . . . . . . . 14 B&R Industrial Automation . . . Cover, 8,9, 66, 77 Bharat Bijlee . . . . . . . . . . . . . . . . . . . . . . . 57 Cummins . . . . . . . . . . . . . . . . . . . . . . . . . 14 Comsol . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Connectwell Industries . . . . . . . . . . . . . . . . 11 Contrinex Automation . . . . . . . . . . . . . . . . . 43 Delta India Electronics . . . . . . . . . . . . . . . . 59 Danfoss. . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Eplan . . . . . . . . . . . . . . . . . . . . . . . . . 58, 78 Emerson . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Fieldbus Foundation . . . . . . . . . . . . . . . . . . 24 Festo Controls . . . . . . . . . . . . . . . . . . . . 2, 30 Faro Business Technologies . . . . . . . . . . . . . 55 Frost & Sullivan . . . . . . . . . . . . . . . . . . . . . 72 Galil Motion Control . . . . . . . .Back Inside Cover Harting Technology Group . . . . . . . . . . . . . . 12 HMS Industrial Networks . . . . . . . . . . . . 53, 78
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Name . . . . . . . . . . . . . . . . . . . . . . . . . Page Hanning Motors . . . . . . . . . . . . . . . . . . . . . 33 Hummel Connector Systems . . . . . . Back Cover Hilscher India . . . . . . . . . . . . . . . . . . . 13, 77 ITC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 ISRA Vision . . . . . . . . . . . . . . . . . . . . . . . . 42 Igus India Pvt Ltd . . . . . . . . . . . . . . . . . 69, 77 ICP Das . . . . . . . . . . . . . . . . . . . . . . . . . . 63 IFM electronic India . . . . . . . . . . . . . . . . . . 65 IEEMA. . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Josh Software . . . . . . . . . . . . . . . . . . . . . . 62 Janatics . . . . . . . . . . . . . . . . . . . . . . . 37, 79 Keyence . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Kistler India . . . . . . . . . . . . . . . . . . . . . . . . 67 Kubler Automation . . . . . . . . . . . . . . . . . . . 17 Katlax Enterprises . . . . . . . . . . . . . . . . . . . . 4 L&T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Lapp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Messe Frankfurt Trade Fairs India . . . . . . . . . 10 Mesago Messe Frankfurt . . . . . . . . . . . . . . . 10 Mifa Systems . . . . . . . . . . . . . . . . . . . . . . 51
Name . . . . . . . . . . . . . . . . . . . . . . . . . Page Micro-Epsilon . . . . . . . . . . . . . . . . . . . . . . . 7 Mitsubishi Electric . . . . . . . . . . . . . . . . . 3, 26 NTPC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Omron Automation . . . . . . . . . . . . . . . . . 5, 12 Prosoft Technology . . . . . . . . . . . . . . . . . . . 10 Parker Hannifin . . . . . . . . . . . . . . . . . . . 1, 77 Phoenix Contact . . . . . . . . . . . . . . . . . . . . . 50 P+F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Rockwell Automation. . . . . . . . . . . . . . . . 6, 76 Renu Electronics . . . . . . . . . . . . . . . . . 47, 78 Sarla Technologies . . . . . . . . . . . . . . . . . . . 26 Schneider . . . . . . . . . . . . . . . . . . . . . . . . . 49 Schmersal India . . . . . . . . . . . . . . . 10, 29, 34 Sesame Motor . . . . . . . . . . . . . . . . . . . . . 41 Siemens . . . . . . . . . . . . . . . . . . . . 10, 26, 54 Schunk Intec India . . . . . . Front Inside Cover, 45 TrainsGains . . . . . . . . . . . . . . . . . . . . . . . . 38 Vega India Level & Pressure Measurement . . 15
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. em.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
A&D India | Dec-Jan 2013/14