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Technology Handbook
CONNECTED MANUFACTURING A look into the products, technologies and solutions shaping the market
Technology Handbook | CONNECTED MANUFACTURING
P
Let your engineering data take your business further
rogressive companies are realizing there are great opportunities in leveraging their engineering data – making it work for their business beyond the confines of a single engineering silo. Data-sharing among engineering disciplines and with other departments can improve a company’s bottom line and competitiveness. It can shorten order fulfillment timelines, often dramatically, and help optimize workflows, prevent bottlenecks, capture efficiencies and implement best practices from creating the initial customer quote through every phase of production and commissioning. Project data created by one discipline should be considered a versatile tool: storable, re-usable, also sharable in real time with other engineering and enterprise software. It promises to be a must in managing the increased complexities of creating and managing Smart Factory environments. With a database-centric CAE like EPLAN Electric P8, electrical design data like component and circuit macros, even complex and scalable macros, can be shared by engineers working on the same project, even working in different locations. Furthermore, all EPLAN Platform CAE products like Electric P8, EPLAN Pro Panel and EPLAN Fluid can share data in real time, promoting inter-disciplinary collaboration that not only saves time but can produce a better-thought-out product. EPLAN users can import component datasets right into their projects from the EPLAN Data Portal, avoiding the need to create those manually. The portal is a unique tool, providing free, unbiased access to
over 760,000 vendor-validated device data sets from 205 manufacturers. This is high quality, reliable data in a standardized format, the use of which minimizes the risk of errors in creating engineering documentation. There’s more. EPLAN and Rockwell Automation offer bi-directional synchronization between Electric P8 and Studio 5000 Logix® through Studio 5000 Architect™ so existing EPLAN data can be used to automate the generation of controls software, an enormous time saver. Integrating EPLAN with SAP, based on the SAP Engineering Control Center, allows for functions such as enhanced prod-
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uct modelling utilizing verified EPLAN data (e.g. connector lists, schematics for fluid power and electrical engineering, bills of material, EPLAN evaluations, and more). Similarly, data can be exchanged bi-directionally between EPLAN and the TIA Portal Engineering Framework from Siemens for faster, error-free design of automated systems. EPLAN also can integrate with popular PLM/PDM systems like Teamcenter and PTC Windchill. Now, two new EPLAN products are expanding the horizon for integrated engineering through data-sharing and data transparency. With Syngineer, engineers using Electric P8 and popular MCAD and controls software
2 MANUFACTURING AUTOMATION · Technology Handbook Connected Manufacturing
products can integrate their efforts via this Cloud-based platform, working collaboratively instead of consecutively, a faster and more efficient way of managing workflows with a greatly reduced risk of time-eating misunderstandings or oversights. EPLAN Cogineer’s principal function is the automatic generation of electrical and fluid schematics using existing EPLAN data. Automatic schematic generation can save dozens, even hundreds of hours of engineering time on large projects, but works effectively for smaller ones, too. It reduces error risk and allows companies to start schematics generation much later in a project timeline, when the design is final or close to it. Cogineer produces full project documentation at the press of a button. That’s the promise of datasharing – doing more, faster, with greater accuracy and transparency and less effort.
Discover the power of the EPLAN Data Portal: Watch the video here:
NEW! EPLAN Cogineer, for automatic Schematics generation Watch the video here:
NEW! EPLAN Syngineer. Work mechatronically, collaboratively Watch the video here:
1 (847) 240-4667 Info@eplanusa.com www.eplanusa.com
It’s About Time Time to Save Time is money. Time saved in engineering can lower costs or be used to generate more revenue. Switching to EPLAN Electric P8 from CAD software typically reduces project time by 40% or more right out of the box – as much as 80% when using the feature-rich EPLAN portfolio to its fullest.
Time to Automate EPLAN automates time-consuming data creation and verification functions CAD users must perform manually, and often repetitively, like device tagging, error checking, performing cross-referencing and generating wiring, parts and connection lists. EPLAN automatically incorporates ready-to-use, vendor-certified datasets that can be imported from a selection of over 700,000 components via the EPLAN Data Portal.
Time to Collaborate EPLAN data-sharing optimizes workflows and improves decision-making. Users of all EPLAN CAE solutions can share data in real time. That data can be shared company-wide; EPLAN can interface with ERP/PLM/PDM systems to keep everyone in the loop.
Time to Plan Ahead EPLAN has virtually unlimited scalability for managing the increasing electrical content in designing for the IIoT/Smart Factory environment. The bigger the assignment, the more EPLAN excels. CAD can’t do that.
Time to Switch EPLAN is the future of engineering. It’s freedom to concentrate on what matter’s most – engineering – so you or your team can quickly create high-quality designs and documentation.
For more information or for a free 30-day trial, contact us at 847-240-4667 www.eplanusa.com info@eplanusa.com
Technology Handbook | CONNECTED MANUFACTURING
HARTING making Han-Modular® the best connector choice for the Smart Factory HARTING invented the modular connector over two decades ago when it launched the Han-Modular® concept. Han-Modular® has popularized the customer-configurable, modular connector which allows users to create an application-optimized, custom connector entirely from standard, catalogue parts. The plug&play efficiency of modular connectors makes a compelling case that connector-based wiring is more cost-effective than hard-wiring electrical connections in the installation and servicing of machines and production systems. The labor savings alone more than offset the one-time cost of the connectors. Han-Modular® filled a need in the plug&play environment for all-in-one interfaces that streamline the transfer of power, signal and data to distributed switch cabinets, controllers and sensors. Today, the Han-Modular® lineup boasts over 100 different modules that can be combined in Han® housings sizes 6B to 48B, including several of HARTING’s newest modular series like Han-Yellock® and Han-Eco®. The range includes contacts and inserts for current up to 200 A, high voltage up to 5000 V and signal modules with a packing density of up to 25 contacts. The range runs from Cat. 6 Ethernet interfaces, coax and USB inserts to “smart” Han® modules for various Bus technologies and mini-switches (with 4 ports.) There are even pneumatic modules for delivering properly prepared compressed air to functions like drives. Now, HARTING is adding
innovations to make Han-Modular® the smart choice for the data-intensive Smart Factory environment. For 2017, there is a new, improved removable inner frame in which to load the modules – the spring loaded “hinged frame plus.” The spring holds the frame open for loading, then closes it tightly with a clearly audible click. This permits faster, even automated assembly of the connector. And there is a new robust metal docking frame for blind mating applications like switch cabinet drawers. Other new products for use with modular include: • a PE Module for the pluggable connection of large PE Cross-sections in a 10-35mm range. (The hinged frame has two integrated connections for the 0.5-10mm2 cross-section range). Telephone 1 (855) 659-6653
HARTING.ca 4 MANUFACTURING AUTOMATION · Technology Handbook Connected Manufacturing
• Han® HP Direct, which eliminates the need to have to use the classical bulkhead mounted housing and replaces it with two mounting flanges. Installation only requires the mounting flanges to be screwed to the cabinet wall. • Han® Gigabit & Megabit high mating cycle (HMC) modules – two shielded data modules offering customers data rates of up to Gigabit Ethernet Cat. 6A. • Smart Modules, which provide the capability for identification of machine-level components, protect your equipment against surges, and add Ethernet switch functionality. HARTING’s vision is that modular connectors, the preferred choice in conventional manufacturing, will be absolutely indispensible in the IIoT future. New modules are being developed that incorporate sensors and wireless capability to provide monitoring and diagnostic features for managing complex modularized production setups. As these and other innovations reach the market, you will be able to add or swap them into your existing connector housing, so your current HARTING investment is future proof.
Read the Modular Connector FAQ Watch the video - how modular connectors outperform hardwiring of electrical connections
Build a Connector and Calculate Cost Savings
With HARTING’s Industrial Connector Configurator and Savings Calculator App
The Connector Configurator lets users create a custom modular connector and send it to a HARTING expert for feedback.
The Savings Calculator shows how using a connector can save money over time as compared to hardwiring the system.
Stop Hardwiring and Start Connecting Say goodbye to hardwiring and simplify with HARTING connectors. Reduce the number of wiring errors, save time and headache. Download the app and white paper to learn how connectors outperform hardwiring. HARTING, first established in 1945, delivers unrivaled reliability, efficiency, innovation and performance in connectors. With HARTING you have a partner who ensures you dependable connections that stand the test of time. Get a complete plug-and-play solution - Inquire to HARTING about its Customized Solutions business to build your assemblies. Learn more at: HARTING-usa.com/customized-solutions/
DOWNLOAD THE APP: www.harting-usa.com/hartingapplications/ DOWNLOAD THE WHITE PAPER: www.harting-u.com/category/ industrial-connectivity/
Smart Switches with the Most Compact Size and Intuitive Configuration The SDS-3008 smart switch is a new product line within Moxa’s industrial Ethernet switch family. The smart switches offer an intuitive one-page dashboard, which allows users to activate pre-configured IA protocols in one click, simplifying HMI/SCADA integration. Moreover, this is the world’s thinnest switch. With the compact size and flexible mounting design, the smart switch allows the highest installation flexibility. According to the “2016 Global Industry 4.0 Survey” conducted by PWC, the digitization of existing product portfolios, and introducing a new digital product portfolio, are two key measures that companies are planning to take in the coming years to improve production efficiency. "When a network upgrade is required, the most common concern for engineers deploying managed switches is their complexity during the whole system life cycle," noted Jack Lin, Product Manager of Moxa’s Industrial Ethernet Infrastructure Division. "That’s why we developed the smart switch. It supports the most required management functions, and has a 3-2-1 design for ease of use: 3 pre-configured protocols, 2 installation methods, and a one page switch dashboard. We believe the smart switch is an ideal solution for the manufacturing industry, especially machine builders who are on their way towards the IIoT and industry 4.0.” • Three protocols in one device Smart switches support EtherNet/IP, PROFINET, and Modbus/TCP industrial protocols, and the configuration can be done in one click via the smart UI.
• Two centimetres wide with DIN-rail and rack-mounting options Smart switches are designed for flexible installation. The compact size allows them to fit in almost any control cabinet, and they support both DIN-rail and rackmount installation. The three-way DIN-rail kit allows users to install the switches horizontally or vertically. With the optional 1U rack accessory, users can combine four smart switch units on a 19” cabinet. • One-page dashboard Smart switches come with a newly designed smart UI, which features a graphical function menu and one-page dashboard, making it easier for users to clearly visualize the status and operate the switch. For machine builders and automation engineers, being able to monitor their Ethernet switches from a SCADA/HMI gives them a great overall view of their control systems, and the ability to react in time to minimize system downtime. In addition, the most common concern related to deploying managed switches is operational complexity, including both setup and subsequent management. Moxa’s super-slim SDS3008 smart switch is designed to meet these challenges. With its simplified protocol configuration, flexible mounting design, easy-to-use interface, and slim form factor, the SDS-3008 smart switch is the perfect fit for control cabinets in any smart manufacturing application.
Manufacturers Automation Inc. 1-800-387-6268 • www.manuauto.com 6 MANUFACTURING AUTOMATION · Technology Handbook Connected Manufacturing
Best Fit for Your Control Cabinets . A new type of switch that is smarter and simpler to set up
Common Challenges for Ethernet Switch Deployment
Cost Issue For applications that require only basic monitoring and control functions, it’s not economical for engineers to choose expensive managed switches, which often support too many unneeded functions.
Space Limitations Engineers work with different types of control cabinets, and each one has space or installation limitations.
Enabling Connectivity of the Industrial IoT Reliable Networks, Sincere Service continues to be Moxa’s promise to drive the connectivity of the Industrial IoT. With over 25 years of industry experience, Moxa provides a complete solution architecture to help you tap into the potential of the Industrial
Complex Configuration IT-oriented user interfaces, which are often very complicated and come with a steep learning curve for IA engineers, make it harder to update configurations and handle basic troubleshooting tasks.
Applications
Connectivity Edge Connectivity
Industrial Computing
Serial I/O Video Connectivity Connectivity Connectivity
Embedded Computers
Moxa’s Solution Architecture Networking Infrastructure
Edge Connectivity • Industrial Computing • Network Infrastructure
How May We Help You?
Manufacturers Automation Inc. 1600 King Street North, St. Jacobs, ON N0B 2N0 - 1-800-387-6268 - www.manuauto.com
Devices
Device & Industrial Network Routers Management
Industrial Industrial Ethernet Wireless LAN
ADVANCED WARNINGS How the connected industry can help you predict and prevent failures BY SUNDEEP SANGHAVI
H
istory repeats itself, that’s the saying. Well, the same can be said for failure. Despite being 17 years into the 21st century, it is not uncommon to see stories of product recalls, factory failures or
other — avoidable — accidents repeated and claiming lives, year after year. Despite technological advances around the world, these incidents remain a regular part of everyday life. In 2016, this was no different. Samsung was plagued by the faulty Galaxy
8 MANUFACTURING AUTOMATION · Technology Handbook Connected Manufacturing
Note7, resulting in global recalls; airbag manufacturer Takata sparked a global scare after 11 people were killed by defective products in the United States, and Japanese air-carrier All Nippon Airways (ANA) was forced to ground its entire Dreamliner fleet due to defective engines. The list goes on. But it really doesn’t have to be this way. Technological advances have come far enough to see machines with the capabilities to predict and forewarn where and when things will go wrong.
The power of IoT allows machines to communicate quickly and easily with the appropriate people to take the right actions. machines, and finished products them- to human interface monitors (HMIs) selves equipped with AI, can learn from long before serious problems manifest previous results by applying cognitive themselves. The power of IoT allows approaches to predictive maintenance. machines to communicate quickly and Processes — such as building cars, easily with the appropriate people to planes, and even buildings — will reap take the right actions. the benefits of heightened levels of data The combination of machine analysis from machines. learning and AI means that advanced Motor industry analyst IHS Auto- machines can monitor the data from motive forecasts there will be more than those all important in-built sensors 24 150 million actively connected cars on our hours a day. It is only by properly emroads by 2020. The combined develop- ploying these vital developments that ment of car features and aftermarket businesses can reverse their fortunes devices could result in some two billion when it comes to incidents, accidents connected cars on the world’s roads just and recalls. five years later. Such a staggering number will result in quantities of data that would The possibilities are limitless make it humanly impossible to detect, And it isn’t just about machines on isolate and predict incidents. factory floors giving advance warnings Conservative estimates predict about potential danger. Predictive the average car will produce up to 30 maintenance can also help minimize terabytes of data every day. downtime on the plant floor This data is a treasure trove and increase productivity of information regarding across the board, saving the health of the vehicle, time and money for all. The amount of money a year the including how, when and The fact is that by global manufacturing where the vehicle is driven; combining telemetric data industry could save the driving style and preferand predictive maintenthrough predictive maintenance, ences it is subjected to, and ance, manufacturers can according to much more. maximize the lifetimes and McKinsey research. Only proper analysis can usefulness of the machines reveal meaningful connecthey have at their disposal. tions, trends and patterns By combining data provided that can help provide a better driver by sensors — on products, machines or experience and improve vehicle quality vehicles — with predictive techniques, and reliability. This leads to a stronger this data can be used to capture the realcompetitive position and new oppor- time status of parts and functions. This tunities for revenue. information, more easily harvested by adopting data science, machine learning, AI and IoT, can be used to improve How does it work? What seems like an incredibly compli- safety and give human overseers a “heads cated process actually is not. Machines up,” solving future problems before they with predictive maintenance capabil- even occur. | MA ities monitor results through in-built Sanghavi is the co-founder and CEO sensors and interpret this information, Sundeep of DataRPM, an industry pioneer in cognitive with the help of data science, in order data science. He’s a highly accomplished and data junkie with more than to predict when a failure will occur. entrepreneur 20 years of experience using data as the These warnings can be communicated currency to perform advanced analytics.
$630B
Developments in artificial intelligence (AI), machine learning, the Internet of Things (IoT) and data science mean that humans no longer need to rely on their colleagues to spot danger — technology can do it for us. It’s just a matter of adopting these processes and technologies in the first place.
The facts as they stand This may sound like a pipedream, but it’s not. According to reports from McKinsey, predictive maintenance — the term for using AI and machine learning to prevent future incidents — could save global businesses an incredible $630 billion a year by 2025. This is because manufacturing
Technology Handbook Connected Manufacturing · MANUFACTURING AUTOMATION 9
WHY MOBILE APPS ARE INCREASINGLY IMPORTANT FOR THE INDUSTRY
Ways to leverage today’s digital and mobile industrial solutions BY PAULO JORGE
T
he Industrial Internet of Things (IIoT) gathers pace by connecting people, machines, plants, logistics, products as well as processes and systems. Smartphones, tablets, sensors and smart HMI systems form the cornerstones of this new technological age in the industry. However, the real advantage and added value of digital and mobile solutions emerge from the integration of a wide range of professional applications. Paulo Jorge de Almeida,
10 MANUFACTURING AUTOMATION · Technology Handbook Connected Manufacturing
system engineer at ecom, explains why applications and software solutions – in addition to innovative hardware – are becoming increasingly important in industries with hazardous areas. They streamline not only a production step, but a whole value-added chain. Next step: Collaborative working Many industrial companies with extensive terrain or explosive areas today continue to use outdated technologies to plan, execute, manage and control
Smartphones, tablets, sensors and smart HMI systems form the cornerstones of this new technological age in the industry. their business processes. Employees are not well integrated in the flow of information and due to a lack of alternatives, certifications or purely out of habit (“we’ve always done it this way”), many tasks are still being performed with clipboard and paper. These archaic methods bring increased risk and inflexibility to the business, being error prone and inefficient. This also leads to mobile workers carrying more than they should when walking around the site, creating a potential safety issue and affecting the wellbeing of their workforce. With industry-leading, intrinsically safe 4G/LTE Android smartphones and tablets – certified up to Division 1 and Zone 1/21 – employees, experts, teams, and project groups can now use professional industry applications in hazardous areas to work and live faster and more agile, while profiting from a step change in flexibility and future-proofing. Collaborative work on mobile devices goes even further than simply calling a colleague for assistance – it enables the mobile worker to fulfill their work efficiently and safely — at any location, at any time, and with any mission or business-critical information at hand in real time. Video conferencing applications are one of the best example of how mobile wireless solutions in hazardous areas open up new ways of communication for documentation, remote diagnostics and maintenance purposes. At the point of inspection or while maintenance work is executed, the mobile worker simply streams videos directly from the hazardous area to experts or the responsible members at the control centre or any other place. This allows a remote diagnosis in real time and to initiate appropriate measures or repairs immediately without losing valuable time and the need of a specialist to visit the facility or offshore platform in person. Furthermore, with push-to-talk applications, smartphones or tablets can also be interconnected with existing radio infrastructure such as LMR,
Tetra or DMR. This makes it possible to share and receive – e.g. via group calls – real-time information on assets - thus, expensive breakdown and repair times can be significantly reduced. Make better decisions and increase productivity Competitive, productivity and profitability advantages of the IIoT can only be exploited with a high level of information density along the entire decision-making and process chain. An important element of the decisionmaking process is, for example, the mobile dashboard. Executives have data and knowledge provided live by employees responsible for the production and operation of plants, comprehensive and manageable at their fingertips, thereby enabling them to act proactively rather than reactively — to identify trends, and to make datadriven predictions. In short, executives make better decisions. As a result, employees can concentrate fully on their respective tasks on site by using digital workflows and orders. Planning apps integrated into ERP systems serve to visualize the assignments, personnel, resources, live monitoring, execution and much more. The specific procedures and measures can be individually assigned to the technicians and mechanics. The mobile worker is shown the assignment on their smartphone or tablet display. Once the job is done, he or she can record on the mobile device which process steps and tasks were completed, how much time was needed and if so, what materials were used. A suitable application automatically transmits this information to the ERP system. In the absence of an Internet connection, the data can also be read in offline and is immediately updated in the documentation when the company network is accessed again. This helps to improve workflows, enabling mobile workers to cut down on time spent on administrative tasks at the end of each day, while significantly increasing wrench-time.
Data capture redefined Professional data capture applications in combination with the right intrinsically safe mobile devices provide several advantages for businesses operating in hazardous areas. The most obvious advantage is the cost effectiveness, as no additional hardware for scanning assets is needed. Using specialized software packages also helps to prevent unwanted outages. Since the app is designed to integrate with other applications and backend systems, its use has a direct impact on work process effectiveness and visibility, reacting faster to anomalies, streamlining decision-making and ultimately reducing costs. Besides, as many engineering managers will know only too well, descriptions of equipment and assets can vary widely depending on the engineer reporting the problem. These variations often cause confusion and waste time since identical assets and equipment cannot be differentiated when being transferred to backend systems. By scanning and entering data directly into input fields of various applications and minimizing the use of freehand text, mobile workers begin to record more consistent data. This enables easier manual or even automated analysis and reduces the risk of human error. Thus, incorrect input and poorly transcribed records can be avoided entirely. Mobile communication of the future Mobile apps have not only changed our daily life, but also our way of working. From minor applications, such as a barcode scanner, to major integrated software solutions developed specifically for individual customers, all these applications provide greater efficiency and productivity, not only in industries with hazardous areas. Ex-certified smartphones, tablets and peripherals form the technological basis for networked applications, which will be the decisive factor for corporate success in the upcoming years. | MA Paulo Jorge de Almeida is a specialist in application engineering consulting. ecom is a global provider of integrated solutions and mobile computing and communication devices for use in potentially hazardous areas as found in the chemical, petrochemical, pharmaceutical, oil and gas, mining, power generation, and food and beverage industries.
Technology Handbook Connected Manufacturing · MANUFACTURING AUTOMATION 11
DON’T MISS OUT on your next issue of
IT’S FAST, IT’S EASY AND IT’S FREE! DICK MORLEY: A glimpse into the many facets of the esteemed “Father of the PLC.” p.18
spOtlight: highlights from our fireside chat with nathalie pilon, aBB canada managing director. p.15
Defence-in-Depth Best practices to help industrial operators deploy the internet of things securely and reliably. p.22
TRAINING: How you can millennials and SPOT THE DIFFERENCE: attract simultaneously boost your How to choose the right lighting for machine vision business. p.17
applications. p.26
ETHERNET GAINS: Acadian Seaplants capacity grows by 40 per cent with new processing facility. p.20
LIGHTING RETROFITS: LEAN MANUFACTURING: Industy bakery welcomes Defining culture as an environment favourable to continuous improvement. p.10
INDUSTRIAL NETWORKS: Selecting components that make the grade. p.24
Machine safety: how you can prepare for the upcoming Ontario machine safety blitz. p.21
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MOTORS AND DRIVES: An overview of the most popular rotary motion technologies. p.24
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from 3D printers to industrial sensors and the internet of things (iot) — key trends and technologies that will impact your plant floor this year. p.16
HANNOVER WRAP-UP: Couldn’t attend this year‘s Hannover Messe? Catch up on standout moments from the action-packed fair. p.26 OCTOBER 2016
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AUTOMATION SOFTWARE: Four big-picture benefits of PLM for small manufacturers. p.24
Sodecia uses PC control, EtherCAT and programmable safety to accelerate robot cell performance for automotive assembly. p.22
in 2016
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MACHINE SAFETY: Integrated safety technology boosts motion system functionality. p.15
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INTERNET OF THINGS: Manufacturers who embrace IoT are leading the digital transformation. p.23
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