Digital supplement to
Technology Handbook
CONNECTED MANUFACTURING A look into the products, technologies and solutions shaping the market
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Technology Handbook | CONNECTED MANUFACTURING
Control Your Destiny with Customizable Machine Analytics TwinCAT Analytics offers standard, drag-and-drop functionality that allows engineers to optimize machine performance on their own terms.
W
hether you’re a machine builder OEM or equipment end user, TwinCAT Analytics software offers unique advantages. Engineers can use the Beckhoff solution to optimize commissioning time, machine efficiency, predictive maintenance, and fast troubleshooting. TwinCAT Analytics enables users to select from a toolbox of more than 90 algorithms to help quickly find insights within the data. It supports a wide array of options for collecting and sharing data and generates a robust dashboard with one click.
Where can you gather data from? The power of Beckhoff machine controllers and the high data throughput of EtherCAT mean you can acquire data from many sources with incredible granularity. • •
•
•
PLC: Log cyclical data at microsecond rates and scope for machine optimizations or troubleshooting. Measurement terminals: Gather even more specific data from wide-ranging sensors using EtherCAT Terminals in the ELM series, among others. Devices on other networks: The Beckhoff system architecture is designed to maximize openness, allowing simple connection of more than 30 common protocols. TwinCAT analytics can access, log, and analyze data from nearly anything related, or running in the TwinCAT runtime, or data from any device capable of exposing data via an OPC UA server.
How can you access the data? While many operations are becoming more comfortable with edge or cloud computing technologies, many others require zero connectivity to equipment on the warehouse floor. TwinCAT Analytics supports these and other paradigms: •
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Cloud or edge: Our controllers offer built-in cloud connectivity, so they can easily communicate data directly to AWS, Microsoft Azure or many other cloud platforms. We can then analyze the data in TwinCAT. Local network: Maybe you don’t want to connect to the cloud, but you have an enterprise-level system that would be ideal for communicating data. We support open standards for sending machine data to these layers.
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Local controller: If your systems operate as islands of automation with absolutely no connectivity to higher levels, our “flight recorder” solution is ideal. This can log every PLC cycle’s data, including information on motion control, fieldbus diagnostics, etc., for a user-defined amount of time in a ring buffer.
What analysis options are available? TwinCAT Analytics offers more than 90 algorithms as well as the option to incorporate custom algorithms or even AI-based functions. • •
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TwinCAT 3 Analytics Library: This standard toolbox offers function blocks with simple and complex functions. Graphical Analytics: These libraires are available to use within PLC code, or from the easy drag-and-drop graphical environment of the TwinCAT Analytics Service Tool and TwinCAT Analytics Workbench. Machine learning (ML): Optimizing machine performance becomes tricky when complex motion or decisions with 10-plus variables are involved. Beckhoff offers the ability to train ML models in TwinCAT Machine Learning and run them on the controller in real time.
How can you visualize the data? The Beckhoff solution offers several ways to visualize the data in real time and to generate reports for recordkeeping. •
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One-Click Dashboard: Our no-code dashboard allows you to drag and drop the variables that you want to see to continuously visualize machine conditions, analysis results and even Overall Equipment Effectiveness (OEE). With simple integration into TwinCAT HMI, you can display both live and historical data side by side, along with a range of new interactive functions for further customization. Reporting: TwinCAT Analytics allows you to output data, e.g. at regularly scheduled intervals or when an alarm is triggered, to a standardized PDF, JSON or HTML file format. This functionality efficiently summarizes raw or processed data into reports in an automated way (it can be automatically emailed).
Beckhoff Automation Ltd. 4 Schiedel Court, Unit 1-3, Cambridge ON N3C 0H1 Local: 226-765-7700 Email: sales@beckhoff.ca • www.beckhoff.com 2 MANUFACTURING AUTOMATION · Technology Handbook Connected Manufacturing
| EC11-12USA |
Don’t let old IoT tech cloud your judgment One controller can handle PLC, motion control, secure cloud connectivity and beyond
www.beckhoff.com/cx52x0 Don’t bog down your digital transformation with expensive standalone IoT gateway devices that only do one thing – connect. And for that matter, you can skip the standalone controllers for PLC, motion, safety and more. PC-based machine controllers, including the CX52x0 series Embedded PCs from Beckhoff, deliver all the automation and connectivity functions you can throw at them. For complex control, edge computing and IoT applications, they provide an unbeatable price-to-performance ratio with extensive PC and fieldbus interface options. Let’s find a better way to go from sensor to cloud and reach your digital transformation goals – with Beckhoff.
CX5230: Intel Atom® x5-E3930, 1.3 GHz, 2 cores
CX5240: Intel Atom® x5-E3940, 1.6 GHz, 4 cores
Technology Handbook Connected Manufacturing · MANUFACTURING AUTOMATION 3
Technology Handbook | CONNECTED MANUFACTURING
Cube 67+: 20years young and still leading the way in Decentralized Control System Solutions
C
ube 67+: The Best modular IO solution for the last 20 years! At the launch in 2003, it won machine designers and engineers over with its single cable technology providing both power and communication to the IO blocks. Star and Line topologies allowed design flexibility and installation of the control layout. Its ability to operate on multiple protocols, including Ethernet IP, Profinet, Ethercat, Profibus, and DeviceNet allowed machine builders to have one design for their machine, regardless of their customer’s PLC! The mechanical teams who previously spent countless hours and engineering time designing mounting solutions for IO blocks were able to save massive amounts of time. The ability to connect 512 IO in any configuration of inputs/outputs-digital/analog (including RTD and Thermocouple) allowed the ultimate flexibility for both designers and programmers. The addition of 2A outputs allowed customers to connect hydraulic valves and other high-current loads. Customers came to appreciate our embedded webserver, a wide range of IO blocks, and extensive diagnostics that enabled easy commissioning and troubleshooting. Especially crucial for the end customer and installation technician is our point-level short-circuit protection that does not shut down the entire block or, worse, the system. If you are using a competitor’s system that does this, call us! The large LEDs on all modules provide easy to read status of the system without the requirement for special tools or software. The embedded webserver provides detailed diagnostic information that allows you to view and set up your configuration. Faults and errors in the system are easily found and corrected, reducing downtime. Over the years, we added multiple features to keep Cube 67+ relevant to your needs. Need to add a module? No problem with our placeholder and free mapping functions that allow you to physically place the IO block anywhere on the machine and determine its position on your IO table. Want to easily record errors, uptime and publish this information to your MRP (Manufacturing Resource Planning) system? The Diagnostic Gateway provides the architecture layout, detailed fault analysis, time stamping and suggested repairs with time stamping for all activities. Need to publish this information to the cloud? Embedded OPC UA server
with detailed messaging capabilities makes this easy! Does your machine come with optional configurations? For example, on a recent customer visit to a packing machine customer, they were talking to us about his machine consisting of up to 4 separate sections. He originally thought that meant purchasing 4 systems. With our Machine Option Management (M.O.M.) function, they were able to add or subtract sections of his machine on a single system with one IP address! Saving valuable CPU memory and allowing the purchase of a less expensive PLC. The addition of IO Link Class A-B modules allows you to easily integrate your IO link devices, digital and analog hubs into our system. IODD on board makes integration and commissioning easy. A couple of clicks on your computer screen and that’s it – you’re up and running. Customers have also used IO link to extend the length of coverage from 60 to 100m. It also increases IO availability up to 2048 from 1024! Does your current supplier allow that! With Networking blocks and cables spend on your machine, representing up to 78% of the electrical cost, wouldn’t it make sense to have a 2nd opinion? Reach out to your local Murr Connectivity Expert for a free no-obligation assessment.
For more information go to: https://www.murr.ca/ca-en/highlights/cube67/ 4 MANUFACTURING AUTOMATION · Technology Handbook Connected Manufacturing
Technology Handbook Connected Manufacturing · MANUFACTURING AUTOMATION 5
Technology Handbook | CONNECTED MANUFACTURING
T
he WAGO IoT Box provides a preassembled and cUL-compliant control panel, equipped with the WAGO Energy Data Management software that requires no PLC programming knowledge to get started. Everything that you need to provide accurate control information is taken care of. Automatic detection of connected I/O modules, simple coupling of Modbus devices (by importing a CSV file), and clear presentation of all configured inputs are ready to be discovered from your newly defined energy data management. With many industrial systems and machines, there can be noticeable constraints in their connection infrastructure. This solution is entirely customizable by leveraging the modular WAGO 750 I/O System with capabilities for over 500 different modules. This enables precise measurement and monitoring of critical variables such as flow rates, temperatures, pressures, rotations, and fluid levels. Data visualization specialists need more flexibility where they can connect any system and machines. This provides valuable knowledge to promptly complete tasks, provide supplies in a timely manner, and ultimately be a problem solver in a wide range of specialty areas. The IoT Box seamlessly integrates with many industrial fieldbuses and IT systems, with industry-standard protocols offering comprehensive visibility across your operations. Enjoy the convenience of multicloud connectivity, allowing transmission of process and device data to different cloud platforms with two simultaneous connections. The IoT Box›s capability for air leakage detection, air compressor predictive maintenance, and motor current analysis provides valuable insights into potential issues, allowing for proactive maintenance and minimizing costly downtime. Improve operations with WAGES (Water, Air, Gas, Electricity, and Steam) for a more sustainable and competitive manufacturing environment. The uniquely designed IoT Box starts with enhancing your applications and ends with the transformation of your power needs. By consolidating data in the cloud, the WAGO IoT Box offers a comprehensive view of consumption across buildings, systems and machines, facilitating direct comparisons.
This enables improved consumption forecasting by summarizing and comparing data with historical information. The first step lies in data collection which can be acquired from various sources such as: Temperature, Power consumption, or Fieldbus-based devices (ex. Modbus meters) Now that the data has been retrieved and sent to the IoT Box it has capabilities to transform raw values to engineering units (*C,L,Ft), store data with local SQL database or export to CSV, and it will send data to a Cloud, server, or a device with MQTT or Modbus. Once the IoT Box recognizes the language from the machine or energy source, the next and final stage is getting the control data to the Backoffice user. One of the many interesting features of this stage is providing “out of specification” alarms to operators via built-in email functionality. Another advantage is the ability to calculate with built-in math functions as well as automatically take action through switching outputs based on input values. Take in the view, you’ve got the IoT Box collecting and transforming your technology. With the IoT Box split into two main sections you will notice the controller of your choice accompanied by an ethernet switch at the top. Moving down is where you’ll get to an ethernet connection, the 120VAC power supply and fusing as well as a cable gland for power plug & I/O. Unlock further industry and research development when you are ready to explore the best hardware and software for your application. At WAGO there’s an unwavering force of people seeking out the next comprehensive concept leading to optimization of existing processes and setting up new business models – while being prepared for future opportunities and challenges. Innovation for manufacturing efficiency. Customizable control panel, data management, and predictive maintenance in one solution.
Contact for further information Business Development Manager, IIoT and Linux Tyrone Visser tyrone.visser@wago.com
6 MANUFACTURING AUTOMATION · Technology Handbook Connected Manufacturing
YOUR CONTROLLER CHOICE
120VAC POWER SUPPLY AND FUSING
IoT BOX
In the fast-paced and competitive world of manufacturing, staying ahead requires continuous innovation and optimization. At WAGO, we understand the challenges faced by plant managers and operations teams in their quest for enhanced efficiency, reduced costs, and improved productivity. That’s why we have developed the WAGO IoT Box – an all-in-one solution designed to transform your industrial monitoring and optimization processes.
Technology Handbook Connected Manufacturing · MANUFACTURING AUTOMATION 7
Technology Handbook | CONNECTED MANUFACTURING
CONNECTED SOLUTIONS TO TODAY’S PROBLEMS Connected factory technologies offer comprehensive solutions to address critical challenges in manufacturing BY SUKANYA RAY GHOSH
technology is starting to take a firmer hold, whether it be within the footprint of a particular machine (for example, a pneumatic valve manifold communicating wirelessly to the PLC) or throughout the manufacturing facility as a whole (example: calling for parts using AMRs or vibration/temperature sensors communicating data into a cloud data service). IO-Link is another technology that is taking root (RA-02162023). “What these have in common is simplicity and speed of deployment. Cutting the cord and going wireless eliminates the need for time-consuming wiring, which is subject to mistakes resulting in troubleshooting,” explains Almeida.
Needs of the factory floor The connected factory technologies of today are designed to achieve a number of goals on the factory floor. Increased efficiency and productivity, improved quality control, better decision making, predictive maintenance and improved safety are some of the broad objectives that manufacturers target with these technologies, shares Warren Osak, CEO of Electromate. The data collected from the technologies of today are actively used to analyze processes, and predict failing machine components or issues before it actually stops functioning. Arshdeep Singh from Black Controls shares that remote accessibility has
8 MANUFACTURING AUTOMATION · Technology Handbook Connected Manufacturing
become a big part of every modern system for customer and OEM support. Cloud/ web-based HMIs are also being used increasingly due to their low cost and flexibility to display information that is not necessarily directly related to the machine they are situated at.
Reaping rewards with right implementation Not every technology is suitable for every factory floor. To obtain the best results, it is essential to identify the specific issues that the manufacturer wishes to address. Distributed IO provides a good example, according to Almeida. “There are many options to choose from, but which one to choose depends on the particular scenario. Where pneumatics are concerned it makes sense to use IO integrated on the manifold as oftentimes the actuators and sensors are located in close proximity to the valve manifold. Those sensors are connected to the IO blocks via M8 or M12 connections, then a single network cable is run back to a switch or the valve manifold communicates wirelessly back to the PLC. This makes deployment more efficient and keeps the technology under a single platform to minimize the need to manage handshakes between differing technologies from different manufacturers,” he explains. Another example, he shares is
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I
n the increasingly data-driven and data-ruled world of today, leveraging the right pieces of data can define the level of success for every manufacturer. Connected factory technologies available today can equip manufacturers with just the right amount of information to make the key decisions for optimizing and growing their businesses. With significant advancements in the technologies themselves in recent years, the end-users are now aware of what to implement to reap more rewards. Bob van den Berg, managing director at Murrelektronik Canada shares that manufacturers are currently requesting solutions that are scalable, modular and have the ability to connect to the cloud at some point. “Many manufacturers think they need to do something with IIoT or Industry 4.0 but they haven’t really defined what that is yet. So, the ability to be able to do that at a future time is extremely important. If they need to increase or add functions to the machine, they should be able to do that,” he says. Robotics, Industry 4.0, IIOT, artificial intelligence, machine learning and cybersecurity solutions are all in high demand. The specific asks vary according to the type of factory and the processes they run. Robert Almeida, business development manager at Advanced Motion & Controls further adds that wireless
technologies that overlay over existing legacy equipment already deployed onto the factory floor. “These technologies make older equipment Industry 4.0 ready without disrupting or redesigning the existing equipment. You use the same sensors, controllers and same PLC code. This overlay technology is connected in parallel and translates the existing signals into data formatted for enhanced use. This data is now used to measure and track the health of the equipment, providing similar visibility to what you would expect from a newer piece of automation.” When making a choice, examples of successful implementation can offer better clarity regarding expectations. Bon van den Berg shares an example of a manufacturer customer that achieved success with the right technology choice. “We had a customer with a part washing machine that had 32 sections. Depending on what parts they were washing, they needed to bring certain sections of the machine in and out. We were able to show them through one connection point to a PLC, how to be able to do that. If they need to remove a module from the machine, they can resection it. If they need to reattach it, they can. We also eliminated the need for them to use analog cards and devices, converting them over to IO-link for measuring devices. That
allowed them then to simply connect and then replace these devices if they needed to as well. Overall savings for the customer was 25 percent in costs and 30 percent in installation labour.” Manufacturers often have legacy systems on their plant floors. Replacing such equipment completely is a highly expensive and time-consuming process. This consideration often deters them from adding new technologies. “While modern sensors come with advanced IoT capabilities, not everything needs to be upgraded on legacy systems to start introducing connected factories,” says Singh. “Even with older hardware (PLCs), new sensing can be added that works with the legacy PLC and also has IoT capabilities. Connected factories can also simply start by adding a remote access device like an Ewon Industrial Gateway. Having remote access setup to your system allows for many capabilities including remote troubleshooting and diagnostics of devices like PLCs, HMIs, VFDs, servos, vision systems and sensors.” He further adds that new technologies like AMRs can be integrated into older factories with legacy equipment with minimal impact. Black Controls, for example, assesses a production facility’s current state and provides a road map to implementing technologies like remote monitoring and AMRs.
Get more for less As technology investments can be quite expensive, manufacturers expect to maximize ROI on every solution they implement. Osak suggests the following tips that will help them achieve that goal. Streamline operations: By improving processes, reducing waste and increasing efficiency, manufacturers can produce more with fewer resources. Invest in technology: Implementing technology such as automation, artificial intelligence and machine learning can help manufacturers increase productivity, reduce errors and improve quality. Utilize data analytics: Collecting and analyzing data on operations, customer behaviour and market trends can help manufacturers make informed decisions about production and reduce waste. Collaborate with suppliers: Building strong relationships with suppliers and working together to reduce waste and improve supply chain efficiencies can help manufacturers get more for less. | MA
Technology Handbook Connected Manufacturing · MANUFACTURING AUTOMATION 9
Technology Handbook | CONNECTED MANUFACTURING
ARTIFICIAL INTELLIGENCE OF THINGS (AIOT) IS HERE. IS CANADA READY?
T
he widely quoted phrase “the network is the computer”, coined in 1984 by Sun Microsystems VP John Gage, signified a trend that saw the transport of data become an essential pillar of information technology (IT). Today, computing devices that do not connect to the internet are virtually extinct. In manufacturing and other fields, a similar fusion is taking place between cloud-based artificial intelligence (AI) technology and installations of Internet of Things (IoT) devices. The trend will see the operational technology (OT) that is used in industrial automation being enabled with the same computing power that is now being used to analyze medical images, predict disruptions in global supply chains and identify vulnerabilities in a corporate financial plan. “AIoT is the fusion of two disruptive technologies, IoT and AI,” says René Breyel, AIoT strategic advisor at Montreal-based consulting firm Claridion. “IoT provides access to the state of any object or device in the physical world, and AI gives us the analysis of that data in order to understand and act on it.” Connecting sensors to computing systems is nothing new – supervisory control and data acquisition (SCADA)– based monitoring systems date back to the 1960s. “We’ve had connectivity for oil rigs in the ocean for fifteen or twenty years,” says Breyel. “But those were multi-million-dollar solutions that were
adopted because these rigs were really critical. Today, with the pricing drop of electronics and wireless connectivity, and with computing capacity and AI we get in the cloud, those amazing technologies are becoming widely available to every industry.” Breyel sees three key areas where manufacturing will benefit from AIoT. “One key area is performance,” he says. “Because we get better information about machines and processes and their level of performance in real time, we are able to process them more efficiently to make smarter decisions and produce more.” The second benefit is better quality. “This is basically the same idea,” says Breyel. “You get more and richer data about what you produce, so you can control quality more effectively.” Last but not least, AIoT can monitor the location of employees, forklifts, robots or machine tools to identify and mitigate safety risks. “Again, with more and better information, enriched by intelligent analytics, it becomes easier to understand and manage risk,” says Breyel.
Europe leads the charge European companies, typically ahead of North America in industrial automation, are taking the lead in developing AIoT applications, and the most advanced use cases for the technology are in European countries.
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Bosch operates a fully AIoT enabled semiconductor plant in Dresden, Germany. The IoT network monitors sensors, systems and products throughout the manufacturing processes, collecting the equivalent of 500 pages of text per second. AI-powered algorithms analyze the data in real time to predict trends and mitigate problems. One of the advantages of this new capability is that the scope of data management can cover an entire manufacturing process from end to end. Waggeryd Cell Pulp Mill in southern Sweden, with production capacity of 175,000 tonnes per year, worked with Asea Brown Boveri (ABB) to deploy 156 smart sensors that monitor the entire power chain. This allows AI-enabled software to predict plant-wide trends based on power consumption, speed, vibration and temperatures. To respond to this growing trend, Breyel joined with a few colleagues to found AIoT Canada, a not-for-profit cluster dedicated to educating Canadian business and government leaders about AIoT. “It’s a story we started five years ago,” says Breyel. “We saw that we really needed an organization of people that are really involved with this to push the idea forward in Canada.” At the outset, the organization turned to Europe for advice. “Bosch in Germany is a global leader in Industry 4.0 solutions and IoT connectivity,” says
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AIoT promises to bring the power of AI to the operational technology that runs our factories. BY JACOB STOLLER
Breyel. “Four years ago, we brought them to Montreal to provide IoT training. They presented a digital innovation model but came to the conclusion that we didn’t have the maturity to push this kind of training at this level in North America at that time. For me, this was a wake-up call.”
It’s not just about technology One of the big challenges is that AIoT involves connecting factory devices to the internet – something that was off limits in the past, for security and intellectual property concerns. “There has traditionally been a gap between IT and operational technology (OT), the large industrial platforms that were implemented by companies like Siemens, Omron or ABB,” says Breyel. “These are used to manage all the different components in the factory. They have their own networks, their own protocols, their own security stack, and their own databases. But now we are coming up with solutions where IoT sensors are being connected to an IP wireless network going into the cloud.
So now we want to bring those two networks together and implement IoT and AI stuff on top of that. This becomes quite challenging.” One of the problems is that OT networks are completely new territory for IT people. “IT people are not used to managing OT systems because they were never allowed to interact with those operational and very sensitive infrastructures,” says Breyel. “The problem for them is that this factory equipment is in production 24/7, so as soon as you touch anything, it is risky and complicated. So, companies will need a strategy to deal with that.” In general, it is the people issues that will be most challenging. “The technology is there, and people in manufacturing understand their processes and see the value in this, which is why AIoT is moving forward so quickly,” says Breyel. “The difficult and risky part is that the right people don’t have access to the training and education required to learn how to bring these two silos together. That will take a new degree of digital literacy across the organization, and a digital transformation plan.”
Canada faces some particular challenges. One is that Canadian telcos favour cellular technologies and do not deploy LPWAN (Low Power, Wide Area Network), which is well suited to IoT networks and more widely available in Europe. Another is that relative to other countries, Canada has a large number of SME manufacturers that lack the resources to engage in a major technology transformation. AIoT Canada is building a community that will help mediate these issues. In spite of the challenges, AIoT Canada is seeing enormous interest from Canadian companies. The speed with which AIoT is developing gives industrial leaders little choice about getting on board with the technology. “The integration of these disruptive technologies within our factories is no longer an option,” says Breyel. “Industrial leaders must absolutely take them into account and integrate them into their strategic plan for their digital transformation.” | MA Jacob Stoller is a journalist and author who writes about Lean, information technology and finance.
Technology Handbook Connected Manufacturing · MANUFACTURING AUTOMATION 11
TAKING THE REINS: Women in leadership roles inspiring change. p. 12 IS CANADA READY FOR AIOT?: AIoT promises to bring the power of AI to operational technology. p. 12
CASE STUDY:
Automated welding system increases speed of production using EtherCAT and PC-based control. p. 14
CONNECTED SOLUTIONS How the latest technologies are solving critical problems in manufacturing. p. 14
CASE STUDY: Honda’s retooling strategy for future-proof facilities. p. 16
TECHNOLOGY: Top five trends in motion control for 2023 p. 14
CASE STUDY:
Improving performance specs on custom machines with vendor support. p. 16
CYBERSECURITY: Building secure connected factories of the future p. 18
CATCHING UP WITH INDUSTRY 4.0: Canadian manufacturers lag in technology adoption p. 8
THE BIG PICTURE: An overview of Canada’s participation at Hannover Messe 2023. p. 22
FAR-SIGHTED VISION: Artificial intelligence will allow machine vision implementaion in a growing capacity. p. 16
THE BIG PICTURE Notes from the field: Trends in artificial intelligence shaping the industry today p. 24
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Systematix offers solid support to client Leggett & Platt Lakeshore throughout its automation journeys and beyond. p.10
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COBOTS
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A heavy equipment maker adds cobots to its high-mix low-volume manufacturing environment. p.10
Automation technologies and solutions to consider this year p.8
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technology. p. 12 power of AI to operational AIoT promises to bring the IS CANADA READY FOR AIOT?:
control. p. 14 of production using EtherCAT and PC-based Automated welding system increases speed
CASE STUDY:
Messe 2023. p. 22 participation at Hannover An overview of Canada’s THE BIG PICTURE:
in technology adoption p. 8 Canadian manufacturers lag INDUSTRY 4.0: CATCHING UP WITH
implementaion in a growing capacity. p. 16 Artificial intelligence will allow machine vision
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the industry today p. 24 artificial intelligence shaping Notes from the field: Trends in THE BIG PICTURE
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