Hands-ON Education A look at Siemens’ new high school mentoring program
control SYSTEMS 10 reasons why you should choose PC-based control
Machine Safety A problem solving guide that shows what power supplies have to do with light curtains
j a n u a r y / f e b r u a r y 2 015
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The built-in simulator creates a virtual PLC so you can test your logic without the hardware present. The Windows application runs on your PC and uses the same code as the CPU firmware for the most accurate simulation. Test part of your logic or whole programs quickly and conveniently. • Simulates discrete and analog I/O with access to timers, counters, control bits, etc. • Simulate PID - use the Simulator coupled with the Trend View for outstanding visibility into your PID processes
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2015-01-15 2014-12-17 11:50 9:44 AM
17 9:44 AM
I N S I D E
COLUMNS 8 Automation Software
Jeremy Pollard uses Megaflex to prove the benefit of Windows
9 Industry Watch
Paul Hogendoorn says changes are needed in our society, and we are the start of the solution
10 Machine Safety
Tina Hull discusses how a power supply can affect a light curtain
Condition-based Autonomous
maintenance automation
Wireless
networking
26 Distorted Realities
Dick Morley explains the black swan concept — the impact of the highly improbable
NEW PRODUCTS 22 Machine Safety 22 Power Supplies 23 Motion Control 24 Machine Tools 24 Connectivity 24 Test & Measurement 25 Wire & Cable
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Ethernet
2015 3D printing
Mobile devices
Smaller, cheaper sensors
Narrow
Analytics
Big Data
Internet of Things
Pervasive
sensing
Industrial apps
Social collaboration
12 Lean Insights
Dr. Timothy Hill tells us to keep calm and go to the gemba
Industrial
Edge computing
20 Education news
Cloud SCADA
Security
In brief Deal makers Movers and shakers
systems
4 FROM THE EDITOR 5 AUTOMATION UPFRONT
FEATURES
Safety
DEPARTMENTS
Virtualization
W H A T ’ S
14
Top 5 in 2015
Is your plant floor ready for these top trends and technologies?
18
Education A look at Siemens’ new high school mentoring program By Alyssa Dalton
21
control SYSTEMS 10 reasons to choose PC-based control By Joe Ottenhof
www.AutomationMag.com • January/February 2015 3 2015-01-13 9:45 AM
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F R O M
T H E
E D I T O R www.automationmag.com
The continuous student
H
appy New Year! It’s a real pleasure to introduce myself to you as the new editor of Manufacturing AUTOMATION. I come to the publication from the Electrical Business Magazine Group, a sister magazine group at Annex Business Media where I spent four years as the associate editor covering Canada’s electrical and energy markets. As a magazine editor, I see my role as two-fold: part student, part storyteller. I, along with the rest of the Manufacturing AUTOMATION team, want to share with you the news and trends we believe will make your job easier and your plant run more efficiently. It is my belief that through learning of each other’s triumphs and failures, an industry can strengthen and thrive. Though I graduated school many years ago, I learned quickly in my career that I will never escape being a student. Everyday I am reminded of how much there is to learn about a given industry, by way of emerging technology, the launch of a breakthrough product, or just from stumbling across a company I’ve never heard of. Though I graduated Regardless of how many years I’ve spent covering an industry, I can never reach a school many years ago, point where I “know enough” of a topic, or I learned quickly in my believe I have learnt everything. After all, an industry will never be stagnant (I hope!), so career that I will never how could I be? These words have never been truer as I escape being a student. journey into the evolving world of industrial automation. This is where I need you, dear reader, to help. You are the expert, entrenched in the everyday happenings of this dynamic industry. Reach out and tell me what I should know about. Do you have a suggestion on what the magazine should cover? Perhaps you are looking to learn more about a particular trend or technology. Better yet, invite me to your workplace and share your latest successes with me, so I can see your company in action. Let me help tell your story. I encourage you to get in touch with me. After all, this is your magazine too, and you should have a hand in helping to shape its content. I hope to meet you in the coming year, but in the meantime, keep in touch. •
Vol. 30, No.1
Canada’s leading publication providing industrial automation news and technology information aimed at the discrete and process industries. Alyssa Dalton Editor adalton@annexweb.com
Svetlana Avrutin Art Director savrutin@annexweb.com
Paul Grossinger Editorial Director pgrossinger@annexweb.com
Kathryn Nyenhuis Account Co-ordinator knyenhuis@annexweb.com
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Lisa Thomson Circulation Co-ordinator 866-790-6070 ext. 201 Fax: 877-624-1940 lthomson@annexweb.com
Dick Morley Dr. Timothy Hill Paul Hogendoorn Jeremy Pollard Columnists
Mike Fredericks President mfredericks@annexweb.com
Editorial Advisory Board Al Diggins, President and General Manager, Excellence in Manufacturing Consortium, and Chairman and CEO, Canadian Manufacturing Network Piero Cherubini, Dean, Faculty of Skilled Trades and Apprenticeship, Mohawk College of Applied Arts and Technology David Green, Technology and Business-to-Business Consultant Sherman Lang, Industrial Technology Advisor, Industrial Research Assistance Program, National Research Council of Canada David McPhail, President and CEO, Memex Automation Don McCrudden, Vice-President, Business Development, Festo Nigel Southway, Business Productivity Consultant and Author on Lean Thinking Bill Valedis, Vice-President, Precision Training, Products and Services Inc.
Manufacturing AUTOMATION is published seven times a year by Annex Publishing & Printing Inc. 222 Edward Street, Aurora, Ontario L4G 1W6 Tel: (905) 727–0077 Fax: (905) 727–0017 PM # 40065710
The contents of Manufacturing Automation are copyright ©2015 by Annex Publishing & Printing Inc. and may not be reproduced in whole or part without written consent. Annex Publishing & Printing Inc. disclaims any warranty as to the accuracy, completeness or currency of the contents of this publication and disclaims all liability in respect of the results of any action taken or not taken in reliance upon information in this publication. Send address changes and return undeliverable Address Blocks to: Manufacturing AUTOMATION, P.O. Box 530, Simcoe ON N3Y 4N5. Return postage guaranteed.
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January/February 2015 • Manufacturing AUTOMATION
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A U T O M A T I O N
U P F R O N T
Company fined $70K after trainee worker gets caught in machinery
S
amuel, Son & Co., Ltd., in Burlington, Ont., has been fined $70,000 after a worker suffered fractures, other injuries and a partial finger amputation after being caught in machinery. The incident occurred on June 7, 2013, when the worker was participating in peer-to-peer job advancement training with a senior operator who was also a lead hand. The task involved running four strands of plastic strapping repeatedly back and forth the full distance of the production line to allow the hot, freshly extruded plastic strapping to cool by air. The trainee worker was instructed to shut down the machine and, while reaching for a side stop control panel near exposed rollers, one hand and forearm became entangled in plastic strapping, noted the Ministry of Labour (MOL), adding that as the worker tried to use the other hand, it also became caught. The MOL investigation found that the lead hand witnessed the event and stopped the machine, while co-workers used a hack saw to cut through the accumulation of strapping material and extricated the worker. The worker suffered bruising, sprains and bone fractures, as well as the amputation of the tip of one finger. The company — also known as Go Packaging — pleaded guilty in court to failing to appoint a competent person as supervisor when it appointed the lead hand as the supervisor. A competent person is defined as a person who is qualified because of knowledge, training and experience to organize the work and its performance; is familiar with the Occupational Health and Safety Act and the regulations that apply to the work; and has knowledge of any potential or actual danger to health or safety in the workplace. According to the MOL, the employer had not made the lead hand familiar with the Occupational Health and Safety Act or the Industrial Establishments Regulation, which applied at the workplace, and thus the lead hand was not a competent person as defined by law. In addition to the fine, the court imposed a 25-per-cent victim fine surcharge as required by the Provincial Offences Act. The surcharge is credited to a special provincial government fund to assist victims of crime.
In brief • Two Canadian wood product companies, Norbord and Ainsworth Lumber, will merge their businesses through a $759-million deal to create a global producer of oriented strand board, a type of wood panel used in residential and industrial construction. • Belden is set to acquire Tripwire in a $710-million acquisition, which it says will help deliver the next generation of cybersecurity solutions that can be deployed across industrial, enterprise and broadcast markets. • Maple Leaf Foods closed its Panet Road, Winnipeg, Man.-based plant on Dec. 31, 2014, making it the sixth closure of the year in the food giant’s multi-year reorganization of its operations.
With files from the Associated Press and the Canadian Press
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A U T O M A T I O N
DEAL MAKERS EMC partners with BMO for industry banking program The Excellence in Manufacturing Consortium (EMC) has announced a new initiative with BMO Bank of Montreal which promises to provide a high-value manufacturing resource for the industry throughout Ontario. The parties say manufacturers are increasingly faced with “hyper competition” where global interests are often able to quote on business with significantly lower costs. This new resource, they say, will help manufacturers become more productive, reduce enterprise-wide costs and access the best financial information possible to grow their businesses into new markets and sectors. “Nobody knows the challenges affecting manufacturing better than the manufacturers themselves,” said Al Diggins, EMC president and general manager. “Gone are the days of the ‘old-fashioned banker’ who intimately knew each client, their goals and challenges. We are pleased to be working together with BMO to reconnect industry with their bankers, build trusted relationships and provide better information and competitive resources for our members to be successful.” Al Giguere, vice-president of commercial banking, BMO Bank of Montreal added, “We have developed a dedicated team of qualified account managers — across the country — who understand the manufacturing industry and are committed to ensuring our clients have the tools and resources that will help them achieve short-term and long-term success.” SNC-Lavalin finalizes $3.1B sale of AltaLink SNC-Lavalin has finalized its sale of AltaLink, an Alberta-based regulated electricity transmission company, to Berkshire Hathaway Energy (BHE) for $3.1 billion. Part of the overall sale agreement will see SNC-Lavalin and MidAmerican Transmission, a subsidiary of BHE, develop engineering, procurement and construction opportunities together within
North America, including emerging transmission investments. MidAmerican Transmission has developed about $1.6 billion of transmission projects and has experience in traditional utility and stand-alone transmission projects. “Throughout our history, AltaLink’s commitment to building, owning and operating a safe, reliable and cost-effective transmission system has powered Alberta’s economy,” said Scott Thon, president and CEO of AltaLink. “Our dedication to Alberta is absolute. We remain locally managed to ensure that we continue to provide the service Albertans expect and deserve.” One hundred per cent of AltaLink’s earnings will be reinvested back into the company’s operations throughout Canada, noted BHE. “The values of BHE align with AltaLink’s values and with those of Albertans,” said Greg Abel, chair, president and CEO of BHE. “Our core principles include a strong commitment to employees and their safety, second-to-none customer service, and open, transparent relationships with regulators and key stakeholders. We are pleased to have an opportunity to play a role in Alberta’s economy and to support the continued development of its economic engine.” AltaLink will remain locally managed and incorporated under the laws of Canada, with its headquarters, senior management team and operations located in Alberta. Cascades to sell Canadian boxboard unit to Graphic Packaging Quebec-based Cascades has reached a $44.9-million deal to sell its North American boxboard manufacturing and converting assets to Georgia-based Graphic Packaging Holding Company, affecting five operations in Quebec, Ontario and Manitoba that collectively employ 670 people. The Cascades boxboard units affected by the sale are:
An interior shot of the Cascades Jonquière boxboard mill. • East Angus, Que., a mill that manufactures recycled coated boxboard for the production of folding cartons; • Jonquière, Que., a mill that manufactures three-ply coated boxboard from virgin or recycled fibre; • Winnipeg, Man., a plant that manufactures folding cartons; • Mississauga, Ont., a plant that manufactures graphic packaging; and • Cobourg, Ont., a plant that manufactures flexographic boxboard containers. Mario Plourde, Cascades president and CEO, said the sale follows in the wake of other actions taken over the year with the view to reduce its debt load, and focus its investments in certain core packaging, tissue paper and recovery sectors. “The transaction is a continuation of our acquisition strategy to grow integrated folding carton converting volumes in key geographies and end-markets. These assets will broaden our customer base and allow us to offer our current customers a wider range of products,” said David Scheible, Graphic Packaging chair, president and CEO. Cascades’ European boxboard unit will not be affected by the sale. — With files from the Canadian Press
Movers & Shakers
Encoder solutions that just make sense.
Murrelektronik has announced Bob van den Berg (photo) as its new managing director (general manager) for Canada. Boasting more than 18 years of experience in industrial automation sales, he has worked in technical sales, product management, and sales leadership. He has been with Murrelektronik Canada for the past two years. Moises Silva, who previously held the position, will assume the role of delegated member of the board (general manager) of EPH Electronics. Aurelio Banda (photo) is the new president of Beckhoff Automation’s North American operations. He will oversee all operations at the company’s Savage, Minn.based headquarters, which also houses a repair and modification centre, customer training area and the main warehouse for Beckhoff North America. He succeeds Graham Harris, who will assume a regional management role as part of a planned transition.
Model TR1 for Linear Measurement • Integrated encoder and measuring wheel • Easy installation • Operates up to 3,000 feet per minute • Adjustable, spring-loaded torsion arm
Carlo Gavazzi has promoted Michael Grant to regional industrial sales manager, Ontario. In his new role, Grant will be managing, mentoring and coaching the Ontario sales team and their sales activities in the region. The company says Grant’s “dedication and understanding” of the market makes him an integral part of building high performance sales. He previously served as an account manager for Western Ontario.
1.800.366.5412 sales@encoder.com www.encoder.com
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Photo courtesy Cascades
U P F R O N T
Linda Hasenfratz, CEO of Linamar, has been named the winner of Canada’s EY Entrepreneur Of The Year 2014 award. According to EY, she was chosen as the overall award winner for her inspiring work transforming and leading Linamar, an automotive manufacturing business. She joined her family’s business in 1990 as a machine operator on the shop floor, where she learned the business from the inside out and built a growth strategy to “propel Linamar to new heights” after taking the helm as CEO in 2002.
January/February 2015 • Manufacturing AUTOMATION
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A U T O M A T I O N
U P F R O N T
Pratt & Whitney injects $1B into jet engine R&D
New Micromill process boasts better aluminum for cars and trucks
ightweight metals player Alcoa says its new Micromill aluminum technology will give lightweight metal LWhile a better chance to replace steel in car doors and fenders. still in the testing phase, Alcoa said the process dramatically changes the microstructure of the metal, producing aluminum alloy with 40 per cent greater formability and 30 per cent greater strength than the aluminum used today, while being lighter than steel. Automakers can also expect to see reduced system and energy costs by streamlining the number of aluminum alloys used in the manufacturing process. Suitable for producing rolled products for automotive, industrial and packaging markets, Micromill “represents a major breakthrough in aluminum materials,” said chair and CEO Klaus Kleinfeld, as it will support the “creation of lighter, more fuel efficient, safer and more stylish vehicles for the future.” •
ratt & Whitney Canada P (P&WC) announced plans to invest more than $1 billion, includ-
ing $300 million from the Government of Canada, over the next four and a half years in R&D to develop new aircraft engines. The government’s contribution comes in the form of a $300-million loan through its Strategic Aerospace and Defence Initiative (SADI) program. Launched in 2007, the program is meant to help provide loans to support research and development in the aerospace and defence sectors. With the investment, P&WC can pursue its “long-standing legacy of innovation and sustain its engineering and manufacturing Centres of Excellence in Alberta, Ontario, Quebec and Nova Scotia,” said John Saabas, president of P&WC. “Our latest R&D programs include cutting-edge materials such as composites and advanced alloys to improve engine weight, a highefficiency compressor technology to enhance engine performance and reduce fuel consumption, and further improvements to our combustion systems to reduce engine emissions.” “This investment,” he noted, “will ensure that we remain technologyready to support our customers in the years ahead.” The investment will support more than 6,000 jobs across Canada, added James Moore, minister of industry. The aerospace company is also investing $275 million over five years for technology and upgrades to its facilities, including the creation of a world-class Centre of Excellence for intelligent manufacturing in Longueuil, Que. According to the company, the centre will feature three new production lines dedicated to manufacturing key components for the new-generation family of PurePower engines. It is expected to be fully operational in 2015.
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John Saabas
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Swivel Head
www.AutomationMag.com • January/February 2015 26.02.14 15:21 7 2014-05-26 2:13 PM
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A utomation
S oftware
Using Megaflex to prove the benefit of Windows By Jeremy Pollard
T
his is the final regular software review column I will be submitting to Manufacturing AUTOMATION. Thank you to you, the readers, who have provided feedback and thank you’s for bringing perhaps somewhat obscure software products to your desk. Thank you to Manufacturing AUTOMATION for giving me the privilege to be part of an outstanding technology and business-based magazine. I will miss it. Now on with the show. In my previous column, I introduced you to Electra E7 from Radica Software. It is truly object-based and runs on Microsoft’s Visio to allow small shops with small and medium-sized projects generate professional looking drawings. Visio uses stencils, and Electra provides a full stable of electrical, hydraulic, and pneumatic symbols — perfect for the small machine builder. To prove the benefit of Windows, I selected the stencil for Safety Instrumented Systems from Megaflex, part of the Instrumentation Symbols Pro product. These are symbols that are ISA compliant and have their own database where you can define line items such as manufacturer, product number(s), tag IDs and the like for your P&ID drawings. This means your drawing can have Visio, Electra or third party symbols to give your project complete electrical support. Note that the reports generated by Electra would not include any reference to the non-Electra symbols except for the page information as such. I decided to play with the symbols and create some ad hoc drawings. First up — pneumatics. I took a diagram from a pneumatic training course to work from. I used five symbols and while the orientation may not be perfect, remember I am a software guy!! Picking the symbols and placing them on the Visio grid allowed me to visualize the final layout quite well. I added text to the title block, as well as the valve body, and all that was left to do was join the lines. Right clicking on the valve body allowed me to flip orientation which also “righted” the text associated with the valve. Simple rotation left the text upside down. Onto the electric side of things. Creating a single-phase (single line) drawing is very easy since it is just like using Visio. Pick and place the symbols you need, add text where needed and you’re done. A three-phase drawing is similar, and since a reversing contactor in anyone’s books is the same, there is no vendor requirement to be like Rockwell or Siemens. Panel layouts, however, need this distinction for dimensioning. When trying to create a back plate layout using some of the symbols, I would suggest not worrying about scale. I created a simple MCR circuit using JIC symbols in less than three minutes. Due to bad eyes, I had to make it larger, which is easily accomplished by lassoing the objects and dragging them by the lower corner(s) — normal windows stuff. With AutoCAD Electrical, there is a spreadsheet interface you can use to auto-import information and create PLC input and output (I/O) drawings. With Electra, there is no such beast. The power lines, devices and connections to the I/O have to be manually entered. While not a
Here is a screenshot of my Electra E7 pneumatic test drawing, which incorporates five symbols on the Visio grid.
big deal for a small project, it is still a bit time-consuming for a project with multiples of I/O cards. One question raised to the company was concerning the connections that different PLC vendors have for their I/O modules. The response, though a bit cryptic for someone slightly unfamiliar with the true essence of the software, was helpful. Initially I talked about Electra using symbols, components and groups. To create a Rockwell Flex I/O wiring component, the provided PLC I/O module symbol needs to be redeveloped to the specifications you need and want, and then saved as a customized PLC symbol to be used wherever you need it. While I had a bit of trouble with this feature, I used the built-in PLC I/O block to generate a simple I/O drawing. Once I had created a few pages of drawings, it was time to generate the reports which the project will always use, such as a bill of material. Based on the reports, it is very important to include as much information as you can about the devices you are using. Page-to-page power lines are linked so that page references indicate the source of the power. I also created a terminal block layout from the drawings I made. It became clear to me after spending a number of hours playing around that this product requires more time than you would think since it is Visio-based. Radica Software has extended Visio and created a full-featured product that will need your time and attention to master. Having said that, it can be easily used to generate professional drawings for projects with few to many pages. • Jeremy Pollard (jpollard@tsuonline.com) has been in the industrial automation industry for more than 25 years. He has worked as a systems integrator, consultant and educator.
For the most up-to-date news, stories and videos, check us out at
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January/February 2015 • Manufacturing AUTOMATION
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Meeting Mr. Williams By Paul Hogendoorn
L
ast November, I had the pleasure of visiting Atlanta for a tradeshow (FabTech) we were exhibiting in. It’s been a long time since I had been there, and much had changed. I was impressed with its parks and buildings, its air of confidence, and the friendliness of its people. When it comes right down to it though, great cities are made by the people that live there. I met Mr. Williams shortly after I parked my car. I had a lot on my mind — I had to get registered, find my booth, and figure out a way to tote all my stuff there, and all in less than an hour. Mr. Williams started the conversation. “Excuse me, sir. It was really cold last night and I’m hungry. I was wondering if you could help me out.” It was hard to guess his age — he could have been forty, he could have been sixty. The only thing that seemed obvious, from his appearance and his manner, was that he has lived this way for many years. Through the wise insights of some really dedicated people, I have gained a sense for some of the reasons a person might end up on the street. It’s not as easy as “drugs,” or “alcohol,” or “laziness,” or even “choices.” For many, it’s a mental or emotional health issue. For others, it is a matter of having no choice; home is not a safe place. And for others, likely Mr. Williams, it’s a transgenerational issue; their grandparents were jobless and largely homeless, their parents were born into that state, and then they were too. It’s hard to break the cycle, and safety nets alone won’t fix it. I usually keep a few loose bills in my pocket, but the moment I heard his polite petition, I knew I was caught in an awkward state; I only had Canadian money in my pocket and a couple $20 US bills in my wallet safely tucked in my inside jacket pocket. I answered as kindly as I could, “All I have is a few Canadian dollars, if you want them, you can have them.” I lied. He started walking away. But then he turned and came back, and as if he didn’t hear or understand my explanation (or perhaps he didn’t believe it), he asked again, “Please, sir, can you help me?” I knew what the answer was — yes, of course I could help him. The real question to me was would I help him, or would I lie again? At the same moment, another business traveller a couple of parking spaces away yelled out, “Hey! Quit bothering those people. Why don’t you get a job!” In that moment, I realized I can be part of the continuing broken paradigm, where the beggars beg and the rest of us don’t have the energy to really understand, or I could slow down for a moment and see him as an individual, not all that different from me. “What’s your name?” I asked, as I began the process of fishing out my wallet. “Mr. Williams,” he answered. “Mr. Williams,” I said, “I’m sorry I lied.” I gave him twenty bucks, and then continued to load marketing material and a computer screen on a dolly I brought with me. He asked to help, but I told him I had it covered. He insisted, nearly begging me to accept his help. I was worried about the screen falling off the dolly, and said I’d prefer to do it myself. I was hoping he understood, but I realized afterward that my accepting his help would’ve been a bigger blessing to him than the money I gave him. We — the manufacturers, the entrepreneurs, the business leaders and the workers — are the true wealth generators of our society. It’s not Wall Street or the government, it’s us. We also are the beginning of the solution — not the whole solution, but the start. We can’t cure society’s problems with our money, no matter how much we might make or give away. Where we need to be more generous however, is with our time, our caring and our understanding. Mr. Williams might have been asking for a few dollars, but what he really needed was to matter to someone — in that morning, me. I don’t know what needs to be done to change his life, but I think spending a bit of time with him may have changed his day a bit — and who knows what happens from there. I do know it changed my day — and who knows what happens from there. Changes are needed in our society, but I think it starts with us, at a more personal level. Thank you, Mr. Williams. I hope you are doing well. • Paul Hogendoorn (paulh@getfreepoint.com) is co-founder of FreePoint Technologies, “Measure. Analyze. Share.” (Don’t forget to share!) www.AutomationMag.com • January/February 2015 9 Hiwin_MA_Jan.indd 1
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M achine
S afet y
How can a power supply affect a light curtain? By Tina Hull
R
(pink)
(black cable)
(yellow)
Receiver
(brown)
ODDS2 (White) ODDS2 (Black)
(brown)
(blue) OV 24VDC
(red) (yellow) IMAGE 2
(gray) (pink)
Receiver
(black cable)
(black) (yellow)
(gray cable)
(brown)
Emitter OV
ODDS2 (White) ODDS2 (Black)
(brown)
(white) (red) (blue)
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Now align the light curtains. In this case, the customer even set up a webcam so we could see the blue light come on to verify it was correct. If the controller uses LED indicator lights, go ahead and connect the inputs. Watching the LEDs is an easy way to see if the beams are being broken. Remember to use a test rod or some other disposable device thick enough to break a beam when you do this, not your hand! You can also test the continuity with a multimeter. Everything up to this point was correct, but the machine would still only turn on when the beams were broken. This is when an application engineer was sent out to investigate further. When he tested the continuity between the power supply and the light curtain, it was discovered that the 24 V was connected to one power supply, while the 0 V was connected to another power supply. Most people’s first thought would be to jumper the 24 V connections between the two power supplies, but you do not want to do this. The power supplies used for safety and motion should always be separate. Safety devices and controllers need a 24 VDC SELV (Separated Extra Low Voltage) power supply. This is to maintain the integrity of the safety of the machine and to help eliminate false tripping due to inrush currents if other devices on the same supply are switched on. On the motion side, when the relay coil on the brake is actuated, it causes a negative current spike. Diodes are built into many high quality relays and controllers to reduce the spike. Refer to Image 3. While part of the remaining spike can be absorbed by a good quality
IMAGE 1
(gray)
(gray cable)
• Verify the communication connections between the emitter and receiver were made.
• Check the 0 V and 24 VDC connections. • Image 1 and Image 2 are two simplified wiring drawings for auto reset. The second one has three additional connections. These are for a test switch, reset pushbutton and auxiliary output. Only connect the ones being used. • Make sure any switch being used is rated for micro loads.
Emitter
ecently I had a customer whose machine would only run when the light curtain beams were broken. Yes, this is the opposite of how a safety light curtain is designed to operate. In fact, I was wondering how it was even possible. This is a part of a modular packaging system consisting of a delta robot with safe motion, allowing it to have a direct to the safety central processing unit (CPU). It has a vision system and conveyor. The safety measures consist of an emergency stop and two light curtains monitored by a safety PLC. The tech support team members involved are experts with the motion, controls, safety and vision system. My safety experts provided a checklist of items the customer could verify regarding the light curtain. Originally the team thought this would be quickly solved over the phone, but the fact that you are reading this means they were wrong! Why don’t I just take you through the steps, just in case you come across a similar issue? First, make sure the light curtains are properly connected. Most light curtains in Canada, the Americas and Europe are PNP, also referred to as sourcing. This provides a path to +24 VDC, which prevents a malfunction due to an earth fault, more commonly a short caused by a wire whisker touching the frame. Machines from other countries may come with NPN (sinking) light curtains. Suppliers may have different ways to indicate if the light curtain is PNP or NPN. In this example, it was listed on the label within the part number. The customer gave us a part number of F3SJ-B0225P25-D — the P indicates it is PNP. (Note: If it was N, it would be NPN.) Since most safety-related issues are caused by wiring, a wiring diagram was sent to the customer for verification. In this case, the wiring was correct. Here are some common wiring checks you can do:
24VDC (red) (yellow) Photos © Omron Automation and Safety
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My safety experts provided a checklist of items the customer could verify regarding the light curtain. Originally the team thought this would be quickly solved over the phone, but the fact scame_EurekaHD@1-20#_Layout 1 that you are reading this means they were wrong! power supply, a portion of the spike still resonates and causes noise in the I/O signal. High noise can cause unpredictable results. The signal could be On even if the input says the signal is Off. Worst yet, troubleshooting becomes difficult if it happens across multiple inputs. Also, having too many devices on a power supply reduces its ability to absorb all of the spikes. (See Image 4.) Later I found out that many hours of troubleshooting could have been saved if we just read the light curtain data sheet. It says “For a PNP output, connect the load between the output and 0 V line. Connecting the load between the output and +24 V line results in dangerous condition because the operation mode is reversed to On when light is interrupted.” The customer traced the wires and separated them so the light curtain and the rest of the safety were on one power supply. Now the light curtain was working correctly. Here is a summary of what you can do to prevent this from happening to you: • Use separate power supplies for servo brakes and I/O to avoid shorting; • Use a separate power supply rated for SELV for safety devices to avoid false tripping; • Select a good quality power supply that is properly rated for the devices; and • Read the data sheets!
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If you have issues with currently installed safety devices randomly tripping, especially at start-up, begin with checking the wiring and power supply rating. Who knows, maybe your problem is also as simple as a single wire on the wrong power supply. • Tina Hull is a product engineer for safety at Omron Automation and Safety.
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L ean
I nsights
Keep calm and go to the gemba By Dr. Timothy Hill
I
was re-reading Powered By Honda: Developing Excellence in the Global Enterprise in which the start of chapter 2 describes Teruyuki (Terry) Mauro and the lessons he learned from Soichiro Honda. Mauro said that the word “gemba” most defines the continuous improvement philosophy Mr. Honda lived and taught his associates and suppliers. Gemba is the word for “actual place” and I use it in the original Japanese because once you get your head around “going to the actual place,” you’ll learn that there’s much more to learn! Similar to Toyota’s Three Reals we can think of gemba (the real place), gembitsu (the real parts) and gengitsu (the real situation). Toyota’s Three Reals are the Real Place, the Real Problem and the Real Situation. When I’m talking to senior North American executives about gemba, they tend to nod along with what I’m saying but rarely, if ever, go to the gemba themselves. They say that they have a lot of paperwork to catch up on, meetings to go to and the like. They like to manage by reading reports, tending to paperwork and in general, never going to gemba. These managers tend to focus on short-term problems and putting out fires. The Lean manager goes to gemba and manages the processes in question by leading, coaching and facilitating progress. These managers tend to emphasize how a problem could be solved, involving those closest to production in the answer, and never letting a problem escalate to the point where they’re putting out fires all of the time. In doing so, the Lean manager gets to do coaching — guiding the suggestion on how to better describe the problems they’re facing, how to do a proper root cause analysis and how to make the problem go away forever, instead of putting BandAids on symptoms. I’ve seen instances where managers don’t go to the gemba, people are promoted so as to manage problems, and the problems just don’t ever go away. In fact, one client I had a long time ago had a recurring problem for almost 20 years. They had it as an agenda item 12
Gemba is the word for “actual place” and I use it in the original Japanese because once you get your head around “going to the actual place,” you’ll learn that there’s much more to learn! every month for each one of those 22 years! We resolved the problem, permanently, in one afternoon when everyone went to the gemba! What’s more, the managers learned an invaluable lesson — they’ve got to go to the gemba and this means that they’ve got to make time in their planners for it! If you are a manager or an executive, harness the power of going to the gemba. Use these opportunities to learn how to see, coach and facilitate improvements. In one instance, we eliminated several layers of report writing by having the senior executives come down to the gemba and listen in on the brief Lean meetings. People were posting their ideas to their Lean board, talking in a team about the suggestions and congratulating each other when the suggestion succeeded. The senior managers didn’t need a report to tell them this, they had to go to the gemba. In addition, their goodwill quotient went up, all because they were seen as being interested in peoples’ suggestions. A great deal of the enthusiasm for the Toyota Kata has to do with just this — make better coaches out of your managers. Here are some tips:
1. Make the time. Have your managers start each day with a gemba walk. Everyone will tell you that they’re busy, but are they busy doing the right thing?
2. Take the time to have your managers really understand what someone is trying to say about a problem. Is there a simpler way to describe it?
Question from the floor Question: You’ve said that checklists make for great standard work. We’ve created checklists for a lot of our tasks and they worked pretty well when they were first introduced. Then compliance with the checklists dropped. What did we do wrong? Answer: Barring such things as large-scale turnover (then it would be a training issue), the chances are that you didn’t tie peoples’ accountabilities to the doing of the standard work (i.e., the checklist). Here’s a checklist for you to follow: • Create the checklist with input from those “closest to production” (meaning those who make or use the goods or services). • Do a pilot — try out the checklist on a few sites, not everywhere all at once. Only when you’ve got the bugs ironed out will you expand! • Make sure you’ve got a reasonably small area for improvement. Aiming for too much will certainly cause “compliance fade.” • Make sure you have the goals and objectives of the checklist tied to someone’s accountabilities and be prepared to follow up on this. You’re not “holding their feet to the flames” but you are making sure that if it is someone’s job to do this, they’ll be doing it! • Once the pilot goes well and the successes are communicated to everyone, then think about expanding it. Don’t rush in to the application of the checklist without any communication! It’s best if you tie in the person or people who originally thought of the idea!
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From the bookshelf Real Numbers: Management Accounting in a Lean Organization, by Jean E. Cunningham and Orest J. Flume I bought this book thinking that I could find a source on how to operationalize Lean cost savings and ideally describe those savings in dollar terms. To my surprise, this book wasn’t about that. It was about how to bring the finance and accounting departments into the era of Lean. The authors’ contention is that most executives are not getting an accurate picture of their company’s performance. They point to current management accounting practices and how they tend to produce financial statements that are unnecessarily complex and confusing. As a result, most companies are run by executives who do not fully understand their own financial information. I have seen this first-hand. The authors describe how to apply Lean to the financial function, and the management accounting model they illustrate points the way to the true profit potential of Lean. Besides, this book is worth it to hear Flume’s description of how they applied these lessons to Wiremold! Accountant-types will benefit from the many ways they can provide a higher level of service identified here. Lean leaders will be better prepared to communicate with finance personnel. Those looking to better understand “the numbers” will have a new understanding of them, the actual impact of traditional accounting methods rooted in our businesses, and the obstructions we’ve rooted in internal policy and culture, which are often treated as external or externalities. Some of what is covered includes: • How accounting can provide significantly more value to the business, and vastly improve how they support decision making; • Open book management, which firms can leverage to promote trust and a sense of personal ownership in the business; and • The reasons some people will struggle in the process to provide more relevant info, and what the CFO needs to understand to move past this. I’ll let you know about my ongoing search to operationally define Lean savings. Who knows? Maybe I’ll write another book!
Do they really understand the problem or are they just reacting to whatever has presented itself first? 3. Do the managers encourage people to really see the current condition, the future condition and how to transition from one to the other?
So, whether you hear about gemba from Toyota, Honda or anyone else, remember that it’s the very best way
to get your head around a problem. Why don’t you simply go and see? • Dr.Timothy Hill (drtim@kyoseicanada.ca) is an industrial and organizational psychologist and certified Lean Six Sigma Master Black Belt with global expertise in human resources/human capital.
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4. Are the managers really helping people with their problem solving? Many, many times, the correct root cause is not the first root cause that they identify!
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S tor y
Cloud SCADA
Security
C o v er
Condition-based Autonomous
Wireless
networking
Industrial
Ethernet
2015 2015 3D printing
in
Mobile devices
Smaller, cheaper sensors
Narrow
O
ur January/February issue staple is back — Manufacturing AUTOMATION has compiled the top trends and technologies Canadian manufacturers should watch out for in the upcoming year, as predicted by a handful of industry experts. While last year’s responses centred on additive manufacturing (3D printing) and the Internet of Things, this year’s experts offer a more diverse mix of predictions. Most noted are sensors, smart and connected networks, and mobile technology as major trends of the year. As Kevin Prouty of Aberdeen Group told us (the second expert listed), he believes 2015 is about “consolidating the gains in automation and information systems, and pushing the boundaries in other areas.” That said, is your business ready to take on the New Year?
Jim Pinto is an international speaker, technology futurist, automation consultant and writer. 1. Internet of Things (IoT): The Industrial Inter-
net will transform the next decade. Some estimate 50 billion devices will be IoT-connected by 2020. Intelligent sensors and networks will take measurement and control to the next level. Processes will self-govern with intelligent devices that can measure performance and take corrective action to avoid unscheduled breakdowns. This will dramatically improve productivity 14
Internet of Things
systems
Big Data
Key trends and technologies your plant floor could see this year
Safety
Analytics
Pervasive
sensing
Edge computing
Virtualization
Top 5
maintenance automation
Industrial apps
Social collaboration and efficiencies in the production process and throughout the supply chain. IoT is starting to spread rapidly in factories and industrial plants. Growth will be bottom-up, not top-down.
Technology maturity still prevents some manufacturers from running mission-critical applications in the cloud.
2. Smaller, cheaper sensors: Every manufac-
ago, it would have been unthinkable that modern manufacturing could be done without factories, machine tools and economies of scale. 3D printing is reshaping product development and manufacturing. Today, manufacturing is possible without tooling, large assembly lines or multiple supply chains. The idea of do-it-yourself manufacturing is really coming to the forefront.
turing business today is looking at new sensor technologies to streamline processes and improve quality control. System developers and manufacturers are looking for smaller, cheaper sensors. Many sensors are still too physically large and expensive, which limits widespread use in IoT. Wearable sensors will monitor employees in hazardous environments and, in the case of an emergency, will track the location of each employee in the factory.
3. Cloud computing: More manufacturers will
invest in leading-edge cloud computing technology because it reduces capital expenditures and IT labour costs. Cloud computing technology transfers the responsibility for running on-premises hardware and software to cloud computing providers to handle ongoing work such as software upgrades and hardware maintenance. The benefits typically include quicker deployment and operational flexibility. The cloud helps to optimize operations by enabling collaboration among remote mobile workers and suppliers, allowing fast and secure access for data-driven decisions. Significant gains in efficiency, cost and capability can be achieved as more products become intelligent and cloud-connected.
4. 3D printing in manufacturing: Just a decade
5. Mobile devices in automation: Today, the
omnipresent smartphone has more power than a super-computer of just a couple decades ago. The use of WiFi-connected tablets, smartphones and mobile devices is generating strong growth in industrial manufacturing. Handheld devices can be used to report the status of every fixed device in the factory, giving personnel mobile access to real-time, actionable information. This reduces costs, improves operating efficiency, boosts productivity, and increases throughput with existing people and resources. Diagnostics and service functions can be accessible via mobile phones, with cheap two-way audio and video visibility to aid troubleshooting and service procedures. More and more employers are allowing BYOD (bring your own device), as manufacturing employees are increasingly working beyond the “four walls” of the factory.
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2. Condition-based maintenance: Traditional
calendar-based or reactive maintenance approaches are not only costly in themselves, they can also result in even more costly production interruptions. In contrast, today’s condition-based maintenance avoids unnecessary maintenance and enables critical maintenance to be performed based on actual need. Software-based predictive capabilities can also provide early warning of impending failures. The emerging Industrial Internet of Things (IIoT) holds promise to bring predictive and condition-based maintenance to the next level.
3. 3D printing: While still in its early stages, 3D
printing or “additive manufacturing” is emerging as a game-changer for manufacturers. Already widely used for rapid-prototyping for product design, increasingly, ARC is seeing this technology being implemented to manufacture actual parts and products, particularly those that do not lend themselves well to conventional detractive manufacturing approaches.
Kevin Prouty oversees all research operations at Aberdeen Group, and is responsible for creating and delivering research deliverables to educate end user organizations to action regarding their use of technology to address business challenges. 1. Security: Years ago, as an automation engineer, I wondered why anyone would ever worry about PLC or DCS security. I thought to myself, “who would waste their time hacking into those plant systems?” Boy was I wrong. What we’ve come to find out is that there is no silver bullet for system security on the plant floor. An Aberdeen report on industrial network security shows companies are aware of the threat and striving to reach the same level of security as their IT brethren.
2. Safety systems: 2015 will be the year safety
systems stop being the sorry stepchild of the automation world. Aberdeen research shows almost half of high-performing companies have integrated their safety systems with their plant automation systems. This single platform approach to automation is a key safety and operational efficiency foundation.
3. Wireless networking: 2015 is again a water-
shed year for industrial networking. It will be the year wireless and wired are treated as equal partners. Factory automation people still look askance at wireless as a backbone, but our research shows over half of high-performing manufacturers will look to wireless as their primary communication technology in 2015.
4. Industrial Ethernet: Industrial Ethernet has
continued to grow up. It is not the science fiction all-encompassing web we envisioned 30 years ago, but its ubiquity is a sign of its growth. In 2015, it will be in almost every plant. But even as we enter the second half of this decade, there is work to do. Our report on Industrial Ethernet shows only 33 per cent of manufactures still use it to enable complete interoperability across their enterprise. 16
5. Self-manufacturing machines & products:
I am not going to get into the Internet of Things, a phrase I would love to never hear again in 2015. However, one interesting aspect of the drive for more software and technology in manufactured products is the wealth of information now available from those products. I have stumbled upon innovative companies that are turning on the embedded technology early and are allowing a machine to collect its own manufacturing information. This is leading to an upsurge in preshipping testing and diagnostics. Manufacturing systems are now being configured to collect and analyze all of this self-collected data, which is being integrated into self-collected field data. In the end, a machine can warn an operator when something is wrong in its own manufacturing. SkyNet is just around the corner. So there you have it. No flying cars, but a steady pace of leveraging technology and information for a better manufacturing tomorrow, today.
Paul Miller, senior editor and content director at ARC Advisory Group, has been a “student of the automation industry” for almost 30 years. Prior to ARC, Paul was a contributing editor to several automation publications and, before that, he served as media relations director for a global industrial automation supplier. 1. Intelligent, configurable I/O: With many
of today’s owner-operators focused on reducing automation project costs and duration, intelligent, configurable I/O has emerged as an important technology to do so. Unlike conventional DCS I/O which must be defined at an early stage in the project and does not easily accommodate the inevitable late-stage project changes, the latest generation of intelligent I/O can be characterized and configured via software. This increases flexibility and allows late-stage changes to be made without adding significant cost or project delays.
4. Smart sensors: While smart sensors have been gradually supplanting conventional sensors for many years in industrial operations, they are now reshaping the automation landscape. Today’s microprocessor-based smart field devices with on-board processing capabilities and full bidirectional communications can typically generate 20 to 50 times more readings beyond the primary value (PV) to increase confidence in the measurements. The vast amount of data (big data) available from the thousands of smart sensors distributed across an industrial plant can be used to support predictive maintenance and process optimization. 5. Virtualization: Virtualization is the separation of an IT resource from specific physical hardware. Virtualization can be applied to any IT resource, including servers, storage, desktops and networks. While virtualization has become a highly mature IT technology, it also plays an increasingly important role in industrial automation, particularly wherever server hardware is used. Virtualization reduces the costs and resources required to purchase, implement, and support server hardware and software. Virtualization is also finding its way into selected (non-control-related) embedded devices within automation systems.
Naveen Kumar, Frost & Sullivan senior industry analyst, holds five years of consulting experience in the industrial automation space. He helps companies achieve growth, innovation and leadership with his expertise in corporate strategy and competitive intelligence. 1. Pervasive sensing: In response to new oper-
ational mandates in a variety of rugged environments, asset management and optimization will come centre stage once automation integration ends. However, development has been hindered by high cost and implementation difficulties. In this situation, pervasive sensing technology has the potential to enable easy access to process and asset data not captured with traditional systems. These robust wireless sensors do not require complex installation, intensive maintenance or calibration once installed. According to Emerson, pervasive sensing is expected to more than double the existing $16 billion measurement market over the next 10 years by helping production facilities enhance site safety, reliability
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and energy efficiency. From GE’s perspective, pervasive connectivity is poised to transform the expectations of industrial machines.
2. Edge computing: As availability
of pervasive sensors and pervasive connectivity evolves, edge computing will likely place computing applications, data and services at the logical extremes of a network. This technology enables analytics and knowledge generation at the source of the data itself. With the emergence of cloud-based industrial automation platforms, edge computing technologies can help improve performance, achieve greater uptime and lower total cost of ownership (TCO). In this case, only select data makes it into the central data stores of Level 4 for further processing in the cloud. This will tremendously improve data processing capabilities and create significant value without complex data transportation and management.
3. Cloud SCADA: When data gen-
erated from various sources can be aggregated in the cloud and combined with third party inputs, there lie significant opportunities to utilize data in unprecedented ways. One option is to directly connect SCADA applications to a control network with upstream processing occurring in the cloud. Another is to allow SCADA applications to be hosted entirely in the cloud and pass instructions back to the control device inside a corporate network. With improvements in industrial control systems (ICS) security, cloud SCADA may penetrate quickly owing to its ability to significantly reduce costs, achieve greater reliability and enhance functionality.
4. Industrial apps: With the emer-
gence of pervasive sensors and connected networks, the next key area will be industrial apps similar to those in the consumer world. Development of industrial software will become cheaper and more responsive to customer needs with the adoption of the “mass innovation” model using a global community of third party developers. Developers can create “industrial apps” that use consumer-grade technologies and provide easier access to data sources. For end-users needing more specific applications to suit their manufacturing processes but do not want to spend more for unused features, a generic platform with options to choose different features could revolutionize the industry.
5. Autonomous automation: Autonomous automation consists of software agents to help adapt computer
controlled industrial machinery and processes. This functionality self-manages unfavourable conditions and self-optimizes according to evolving requirements. Each machine module in the production line has advanced algorithms represented by the software agent, self-manages the process, and works in coordination with other modules. This approach will distribute intelligence by allowing machines to learn over time and increase their ability to respond to situations autonomously. This technology applies to several closed loop automated systems to work in tandem and optimize human intervention.
Matthew Littlefield founded LNS Research in 2011 and is now president and principal analyst, overseeing LNS’ coverage of the industrial value chain. A recognized industry expert and sought after public speaker, Matthew spent five years at the Aberdeen Group leading the Global Manufacturing Research practice prior to founding LNS, and five years working with several global manufacturers in both engineering and shop floor management roles. 1. IIoT platform category emergence: In today’s marketplace, no
IIoT platform vendor can claim a one-stop shop in the industrial space, nor is it even agreed upon what would need to be delivered by a onestop shop. In 2015, a consensus will emerge as to what should be provided by such an IIoT platform; likely this will be around four core capabilities, including: application development, connectivity, analytics, and cloud. In today’s marketplace, most vendors can offer two, some may be able to claim three. As new innovation, acquisitions and partnerships emerge, leaders and laggards will also emerge. There will also be movement in how existing automation and software vendors leverage these platforms to develop new solutions in quality, EHS, MOM and APM.
Examples of these narrow analytics could include: production planning and scheduling, reliability, quality vision, employee health and safety.
3. Social collaboration: We are
all accustomed to social networking tools such as Facebook, Twitter, LinkedIn and more. However, even though a machine can have a Twitter feed, it doesn’t mean it should. In 2015, enterprise-focused collaboration solutions will make their way to the plant floor. This will enable benefits of social collaboration tools, like: the capture of tribal knowledge, collaboration across sites, extending the reach of limited expertise, and search. However, it will do it in a way that will keep information and automation professionals happy regarding security and control.
4. Smart connected assets: Advances in networking and connectivity technologies, especially with the increasing number of partnerships between traditional
IT/telecom and industrial automation vendors, will enable OEMs and asset owners to offer new services and business models. In industries like machine building, industrial equipment manufacturing, oil field services and more, there will be a dramatic increase in offerings of remote monitoring and reliability as a service.
5. Smart connected operations: As Internet-enabled technologies and analytical capabilities push to the edge of the manufacturing network, new modes of manufacturing will be enabled. This will include the creation of cyber-physical and self-organizing systems that will move away from central orchestration to distributed orchestration. Machines, materials, assets and people will communicate independently and make local decisions based on connectivity to the larger supply and demand chains that will increase flexibility and allow new modes of manufacturing like mass-customization. •
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2. Big data, narrow analytics:
Manufacturers today are awash in data, but as it has been said before, still lag in intelligence. The challenge previously has been accessing credible and up-to-date data, as well as having an accurate model of the manufacturing environment. Today, big data analytical solutions are generally very broad with vanilla statistical tools. In 2015, many new analytics vendors will emerge to use big data analytics to solve very narrow industrial analytics problems, addressing the gap that many manufacturers have limited data science expertise.
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E d u cation
T tal-perspective e
High school students tour the Siemens Canada wind turbine facility in Tillsonburg, Ont.
Siemens Canada donated $15,000 to the Halton Learning Foundation (HLF) last September to help support advanced manufacturing and robotics programs at Garth Webb Secondary School. L to R: Robert Hardt, Siemens Canada president/CEO; Larry O’Malley, Garth Webb principal; Maria Ferraro, Siemens Canada CFO; Karmel Sakran, HLF chair; Kelly Amos, Halton District School Board chair; and Lesley Mansfield, HLF executive director.
By Alyssa Dalton
“W
ith how the worldwide manufacturing industry is changing, you see more and more technology from the IT world coming into manufacturing: the Internet of Things, new tools and new processes,” says Robert Hardt, president and CEO of Siemens Canada. “Young people will face a totally different set of requirements in the near future. We need to make sure, as companies and as a society, that both secondary and post-secondary schools start to adapt to these systems.” In an effort to help prepare students for this new direction, Siemens Canada and Halton Learning Foundation (HLF) — a charity that aims to enrich educational opportunities and eliminate economic barriers to learning for Halton District School Board students — have partnered for
• ROBOTICS • ELECTRONICS • ELECTROMECHANICAL • PROGRAMMABLE LOGIC CONTROLLERS
an educational program that allows Siemens employees to come into high school classes to motivate, guide and mentor the students. Oakville, Ont.-based Garth Webb Secondary School was selected for the partnership because of its advanced manufacturing and robotics programs, which feature a hands-on lab where students can learn about different types of technology, and how it works together in the practical field. The classroom speakers lead classes of various grades — including robotics, careers, civics and law — and provide valuable insights into the working world, and the changing technologies that are shaping the future. The idea is that students will get to learn exactly what it means to be an engineer, a project manager or law professional in the manufacturing world. With a focus on what technology and science means to them, the speakers also share their own career path experiences and help answer questions on what career a particular post-secondary course can lead to. “I think technology should be seen as an integral part of the school. It’s something everyone should be taking, as opposed to being hidden in the back of the school for only a certain percentage of students,” says Paul White, technology and business department leader at Garth Webb. Along with the mentoring aspect, Siemens Canada donated $15,000 to HLF in September to help students who require additional financial assistance, as well as support the school’s advanced manufacturing and robotics programs.
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The students can visit the company’s manufacturing facilities to learn first-hand about a typical workday. The first trip was a guided tour of the Tillsonburg, Ont., wind turbine manufacturing facility, where students got to see employees cut materials and work with the blades directly on the production line. “We got phenomenon feedback,” says Hardt. “We have some young engineers at our office and because of the similar generations with them and the students, they could easily strike up conversation. The students were able to see how our engineers transitioned from school life to work life. It was quite positive to see.” He notes that by showing the skills needed in a manufacturing environment, students can see how classroom learning translates to realworld application. “Students can gain the total perspective they aren’t able to from a book or a lecture. I think you really must bring young people to the ‘real action,’” he says. One of the questions educators are always asked by students is When am I ever going to use this?, laughs Larry O’Malley, principal of the school. He says he has been pushing for innovative technology programming at the school since it opened its doors September 2012. It was great seeing
January/February 2015 • Manufacturing AUTOMATION
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e education
A look at Siemens’ new high school mentoring program
Volunteer speakers visit Garth Webb Secondary School to share their education and career paths with students, and conduct hands-on activities that use critical thinking skills.
how the students’ eyes were opened when they saw their curriculum being used in a real working environment, he says. Similarly, eight Garth Webb students visited the company’s Canadian head office on November 5 for Take Our Kids To Work Day to see how engineers work in an office environment, “which is quite a bit different from the manufacturing side,” says Hardt.
photos courtesy Siemens Canada
Providing Innovation 2014 AHR EXPO
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It’s time to educate
As evidenced by many published reports, it’s no secret that the skilled trades need new blood, so why aren’t more young people applying? White believes university-bound pressure from parents is a strong factor. “I read a study that surveyed a number of parents and while a majority of them agreed that skilled trades jobs are in demand and well-paying jobs, most say those jobs are fine for someone else’s kids... but not their own.” According to White, greater understanding of advanced manufacturing will challenge negative stereotypes and encourage young people and their families to explore these career choices. Two misconceptions of the industry that could act as turns-offs, he says, is the belief that the work environment is dirty, dark and greasy, and that jobs are leaving North America. “But that’s not the case with advancing manufacturing here,” he says. For O’Malley, manufacturing-based classes are beneficial to all students, not just those who plan to pursue it as a career, as students can teach critical thinking skills, such as the ability to collaborate and problem solve. “Those critical thinking skills will help them no matter what pathway they choose.” He says he has seen a “dramatic shift” over the last five to six years in attitudes that place higher value on university education. He believes partnerships like this, in addition to the increase of joint university-college programs, can help spread awareness of the various post-secondary options. “Schools need vibrant and energetic tech programs for kids who enjoy learning in a hands-on, practical way,” says O’Malley. “It’s important all students be able to take the courses they want to take, and that all pathways for post-secondary destinations are being honoured.” As a result of the success with Garth Webb, Siemens Canada says it plans to extend the program model to other high schools across the country. •
Manufacturing Automation’s 16th Annual Automation Education and Training Guide — a directory of automation-specific education and training courses offered at colleges and universities across Canada — is available in the education portal at www.AutomationMag.com.
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www.AutomationMag.com • January/February 2015 19 Lafert_PEM_Aug.indd 1
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N ews
Photos © Luke Gillett, Niagara College Canada
Niagara College to open advanced manufacturing innovation centre
Ontario says it is investing $4.2 million to help build the Niagara College Advanced Manufacturing Innovation Centre, a permanent, high-tech facility that will provide hands-on applied learning and innovative business solutions. With more than 15,000 square feet of lab space, the centre boasts state-of-the-art equipment and research facilities for Ontario-based manufacturers, along with access to the expertise and business services of faculty and students. These services will help reduce production costs and minimize production time, and bring the talent and skills of the college’s students together with local industry, noted the government. “The centre’s community will boost the regional economy by developing commercialization solutions, innovating products and processes, and expanding into new markets,” added Dr. Dan Patterson, president of Niagara College. Niagara College Research and Innovation, the college’s research division, provides real-world solutions for business, industry and the community through applied research and knowledge transfer activities, including projects with Niagara-based Kwik Mix and St. Catharines-based W.S. Tyler. “Our government is focused on ensuring that economic recovery is felt in every part of the province, and the Advanced Manufacturing Innovation Centre is sure to make a strong impact here in Niagara. Investing in knowledge transfer at Niagara College will train tomorrow’s business leaders, and generate a positive climate for local businesses to create jobs and attract investment,” said Jim Bradley, deputy government house leader and MPP for St. Catharines. The centre aims to be completed and operational by late 2015/early 2016.
Educators want better tools to teach skilled trades: CAF
A report by the Canadian Apprenticeship Forum (CAF-FCA) suggests that with 91 per cent of educators convinced skilled tradespeople will always be in demand, there is a strong case for connecting students to hands-on activities and accurate employment data. In a survey of 715 teachers across Canada, 93 per cent say they are encouraging students to consider careers in the skilled trades. On the other hand, only 13 per cent of parents and 18 per cent of youth agree, highlighting gaps among the three groups when it comes to awareness of career pathways after high school. Educators are the most positive in their perceptions of tradespeople, finds the report. It notes that educators believe there is room for more field trips and hands-on opportunities, better-equipped trades classrooms and more integration of skilled trades content in high school curricula. “This tells us educators are thirsty to pass along insights to their students, particularly when it comes to connecting class work to employment opportunities,” said Sarah Watts-Rynard, executive director of CAF-FCA. 20
Four organizations team up to address “critical” CNC machinist shortage
Four manufacturing organizations say they have banded together for a new “by industry, for industry” learning program to actively hire and train unemployed/underemployed youth to help address a “critical” shortage of CNC machinists. With an immediate need for 270 CNC machinists now and 700 in the next two years, they say, the Canadian Manufacturers and Exporters (CME), Canadian Tooling & Machining Association (CTMA), Ontario Aerospace Council (OAC), and Organization of Canadian Nuclear Industries (OCI) have developed the Ontario Manufacturing Learning Consortium (OMLC) and the CNC Machinist (Level 1) Selection and Learning Program. According to Rod Jones, program co-director at OMLC, there are few CNC machining post-secondary programs in the province and “young people coming out of these programs don’t fully meet industry needs, so a different kind of solution was required.” “This earn-while-you-learn hands-on program provides Ontario youth with the opportunity to learn a trade focused on innovation and technology, while starting a career in the manufacturing sector,” explained Ian Howcroft, CME Ontario vice president. Youth who qualify and are hired by a company will start with three weeks of classroom learning, followed by 23 weeks of shop floor learning with production CNC machines. Employers can interview pre-qualified candidates, then select and hire those who fit their company. “The companies have been very enthusiastic about the quality of the people we’ve brought to them and several have expressed interest in hiring other youth from future rounds,” said Peter Drews, who acts as the OMLC mentor and coach for the youth and companies. Initially launched in the Greater Toronto Area (GTA), there are plans to expand the CNC Machinist Learning Program to other manufacturing areas in Ontario in 2015.
Saskatoon welcomes Manufacturing Centre of Excellence
Larry Rosia (left), president and CEO of Saskatchewan Polytechnic and Derek Lothian, vice-president Saskatchewan of Canadian Manufacturers & Exporters (CME).
Photo courtesy CME
E d u cation
A Memorandum of Understanding (MoU) was signed between the Canadian Manufacturers & Exporters (CME) and Saskatchewan Polytechnic to formally establish the Centre of Excellence at the school’s Saskatoon campus. The centre will focus on productivity improvement, innovation, and workforce development for the provincial manufacturing sector. “Manufacturing has been a key component to Saskatchewan’s unprecedented economic growth,” said economy minister Bill Boyd, adding that the centre will provide manufacturers with the resources, services and leadership necessary to compete and win in both domestic and global markets. “Manufacturers in this province are already recognized around the world as world-class,” said Tom Kishchuk, chair of the Saskatchewan Manufacturing Council, and president and CEO of Mitsubishi Hitachi Power Systems Canada. “But as markets evolve, so do the demands of business; it is imperative that manufacturers have timely access to the supports, training and best practices they need to continue creating jobs, stimulating investment, and driving economic growth.” The ministry of the economy has committed $1.5 million over three years to the centre and is working with CME to develop the programming. Other organizations providing support to the centre include Athabasca University and the National Research Council of Canada Industrial Research Assistance Program. •
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control
s y stem S
10 reasons to choose PC-based control By Joe Ottenhof
PC
-based control systems for industrial applications have been around in various forms for as long as PCs themselves. In fact, PCs have been relied upon for machine control just about as long as PLCs have. In certain circles, however, there continues to be a misunderstanding about the reliability and capability of an Industrial PC (IPC) for “real” machine control applications. When we speak of PC-based controls, we are talking about an industrial control system that utilizes a PC designed as a control platform. While functionally the same as an office PC, the IPC is specifically designed to be rugged enough for demanding plant environments. IPCs are tested to be a reliable computing platform with operating specifications to withstand plant environmental factors such as temperature, vibration and shock — far exceeding the commercial PC. Components used are qualified, standardized and available in the long-term, with product lifecycles that can go toe to toe with any PLC and win. The PC-based control platform offers a wide range of reliability and capability advantages, among other benefits. Here are 10 reasons that make this case:
1.
PC control leverages mainstream hardware computing technology
The IPC uses the same basic technology used in the millions of PCs produced everyday around the world. The latest technology gets implemented in the IPC without the need to prorate development costs over many years and millions of devices. No matter which PLC one may use, that supplier can never match the sheer volume of product produced by a single PC supplier. The net result is that the PC control platform is always modern and always reflective of state-of-the-art computing power. The PC is a mainstream societal technology, yet the PLC is quite the stranger to most of society.
2.
PC control leverages mainstream software computing technology
Many IPCs use Microsoft operating systems for non-real-time control tasks. This means that the IPC can be used for multiple applications. Not only will the IPC perform as the real-time control platform, it can also be used as the HMI platform simultaneously. It also provides the connection to the enterprise network using standard Ethernet (NIC) connectivity. Other non-Microsoft operating systems, such as Linux, can also be used.
3.
IPCs are lower in cost
IPC manufacturers take advantage of their economy of scale to produce lower cost products. The PLC manufacturer creates a proprietary electronics platform, the cost of which is prorated over thousands of units rather than millions of units... the unfortunate by-product then is that the PLC platform ages quickly from a technology perspective. An outdated IPC can be replaced anytime, likely with a lower cost model that reflects the powerful dynamic in the PC world of “increased power at ever lower costs.”
4.
IPCs are more powerful
Many IPCs today use multi-core, 64-bit architectures with several gigabytes of RAM and have virtually unlimited mass storage, providing a tremendously capable computing platform. The PLC is designed for a single task and is equipped with just enough processing power to perform that task. Compare this with the typical PC computing capability and there really is no comparison.
5.
IPCs are future-proof
The PC is the ultimate “de facto” standard. There is no end in sight, either to the form factor (ATX, 3½ inch, PC104) or the concept. Combining with Windows operating systems and IEC 61131-3 programming software creates a computing and control platform that will “always be there.” Compare this with the traditional PLC product family with a three to five year general availability and again, no comparison.
6.
PC control protects Intellectual Property (IP)
A PC control solution is implemented in software, abstracted from hardware. The customer’s investment is maintained in a truly “open” architecture that can be moved from one IPC brand to another with rarely anything more than a software recompile. Compare this with a PLC solution which is usually a function of software developed on proprietary hardware. The software cannot be separated from the hardware, so there is no abstraction between the two. Unavailability or lack of support on a PLC platform usually means a complete redevelopment of the software application, starting from scratch.
7.
PCs are more maintainable
The IPC control solution uses technology known to the masses. The Windows environment is familiar and comfortable to more people and ultimately to more of today’s maintenance personnel whether they admit it or not. IPC users can utilize more internal resources than would be available to support a PLC platform.
8.
PC control provides simpler control architecture
The power of the IPC combined with a high speed, real-time control network, such as EtherCAT, means the control architecture can be compressed into a single layer. There is no need for gateways, switches, protocol converters or data links. All control devices are on one Ethernet-based CAT5e network.
9.
PC control provides better diagnostics
The power of Microsoft is perhaps most evident in the number of third party applications available for the operating system. A PC-based control platform easily exports control information for offline processing by third party applications and tools, resulting in powerful diagnostic and analytical tools that can provide improved performance, maintainability and reliability. By comparison, the PLC has few resources available for advanced diagnostics. A maintenance person often takes extreme action such as “forcing a contact” to resolve machine operational issues rather than being directed to the “root cause” by advanced diagnostics.
10.
PC control converts hardware “boxes” to software applications
If you think about what is in a special “box” that performs an auxiliary function within the control system (for motion control, measurement, safety or something else), you will see that it consists of some sensor electronics, a processor, some memory and usually special software or firmware. The PC control platform has all the necessary computing technology to accomplish the required functions of that box already. In PC-based control, the sensor or other field device simply gets connected to standard I/O. The special application can be implemented in powerful software, either in real-time using IEC 6 1131-3 programming tools or in standard computing languages, such as C and C++. In conclusion, a PC-based control system provides a powerful, flexible, maintainable and very cost-effective alternative to a traditional PLCbased system. There are many thousands of PC-based control applications around the world — and here in Canada — that provide many of the benefits described in this article. Granted, there is still resistance to change from those who still swear by PLC-based platforms in the name of stability or reliability, or a friendly relationship with a distributor. Change may require additional work to migrate over to a more modern and powerful system, but no business has ridden the “we’ve always done it this way” mantra to long-term success in today’s globally competitive industrial marketplace. • Joe Ottenhof is general manager of Beckhoff Automation Canada Ltd. He has over 30 years of experience in industrial automation and controls. Ottenhof is an Engineering Technology graduate of St. Lawrence College, Kingston, Ont., where he studied Instrumentation and Process Control. www.AutomationMag.com • January/February 2015 21
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P R O D U C T S MACHIN E
S AF ET Y
DIN rail mounted universal safety relay
Wieland Electric has developed a compact DIN rail mounted universal safety relay for monitoring a range of machine safety functions, including emergency stops, elevator access control, and heating/burner installations. The SNO4083 series accepts inputs from single and dual channel emergency stop sensors with dry contacts (NO+NO or NO+NC) and PNP outputs from active sensors. It is available in 24 VDC or 115/230 VAC versions with either screwclamp or spring-clamp pluggable terminations. The relay’s output features three NO and one NC auxiliary contacts. Synchronous time monitoring function (1.5 seconds and 0.5 seconds) ensures that faulty sensors or improper adjustment is detected, adds the company. www.wieland-safety.com
Expandable safety controller
The XS26-2 expandable safety controller from Banner Engineering has the capability to add up to eight expansion I/O modules. Designed
POWE R
to adapt to diverse automation requirements, the base controller models have 26 input terminals, four terminals for two redundant safety PNP outputs and a USB connection for loading configurations. According to the company, the unit’s complementary PC graphical user interface configuration software is uncluttered and easy to navigate for configuring and documenting safety functions and assessing the status of connected input or output devices. www.bannerengineering.com
SIL 2 compatibility for horn and strobe families
SIL (Safety Integrity Level) 2 compatibility has been added to E2S Warning Signals’ horn and strobe families. Initially available for the BEx explosion proof 117 dB(A) horns and 5, 10 and 15 Joule strobes, the explosion-proof GNEx GRP family will be the next one to be upgraded, says the company. Users no longer have to inspect and test each individual warning device, it adds, saying SIL 2 technology will read the sound output of the horn and the light emitted by the strobe to check if it is working properly. The technology promises spurious signals are not picked up by the sensors to
EtherNet IP adapter safety function for 3xi-B CNCs
Fanuc says it has introduced CIP safety functionality with the EtherNet/ IP adapter safety function for its 3xi-B CNCs that enables safety communication with Rockwell Automation controller (Logix PAC) systems. Designed specifically to communicate between safety controller and CNC with safety signals for automotive transfer lines, the functionality boasts integrated safety signal communication, lower maintenance, improved productivity and transparent data access across the connected manufacturing enterprise. According to the company, it communicates digital input/output signals across Ethernet with high
reliability to further simplify the hardware and connections needed. Using built–in redundancy, a special processor monitors safety-related parameters and guarantees the integrity and safety of the system by tracking the actual position and speed of the servomotors, spindle motors and I/O interfaces, it adds. www.fanucamerica.com
Safety light curtains
The latest generation of Type 4 light curtains and perimeter guarding grids from Schmersal boast new features and additional safety. The multifunctional SLC445 and SLG445 claim to be costeffective, easy to assemble, simple to integrate into existing structures, and do not require an external switchgear to control functionality. Promising the highest protection for the user, the products have been developed in three product ranges to cover different requirements. All functions available with the SLC440 model are available in the SLC445 and SLG445 models, including: fixed blanking; floating blanking fixed blanking with movable edge; double reset; contractor control (EDM); automatic mode; restart mode; and beam coding. According to the company, the light curtains are best used in applications that require the highest level of productivity and flexibility at the man-machine interface. www.schmersal.com
S UPP L I E S
Definite purpose contactors up to 90A
for HVAC or lighting applications, but can also be used for other applications where economical switching is preferred. www.gavazzionline.com
Power supply line offers up to 150V output power
Carlo Gavazzi has launched its new generation of GDP series definite purpose contactors available in one pole, one pole with shunt, or two pole configurations with maximum ratings of 25, 32 or 40A. The units are also offered in three pole configurations with maximum amperage ratings of 25, 32, 40, 50, 60, 75 or 90. Lug terminals are standard on all three pole models. UL recognized and RoHS compliant, the series is designed 22
ensure a reliable monitoring at all times, says E2S. To comply with SIL 2 requirements, this is only done during an automatic test of the system and any faults are reported back when the system returns to its normal monitoring state. Communication with the system control panel can be configured in two ways: either a contact is closed or a series resistor is brought into the monitoring circuit in the event of a fault. www.e2swarningsignals.com
The B&K Precision 9200 multirange programmable DC power supply line includes four 200-600W models that promise to deliver power in any combination of the rated voltage and current up to the maximum output power of the supply. With voltage and current ranges up to 150V and 25A, the devices are suitable for electronics
manufacturing, R&D, service and repair, and education. According to B&K, the multi-range design helps save bench space and cost by eliminating the need for multiple power supplies on the bench or buying more power than necessary. On the front panel, the unit features a 1 mV/0.1 mA display, output On/ Off control, and a user interface with numerical keypad, cursor keys and rotary control knob to adjust voltage and current settings. Other features include a built-in digital voltmeter (DVM), output timer function, and overvoltage (OVP), overpower (OPP), and overtemperature (OTP) protection modes. www.bkprecision.com
Extended output for power supply series
TDK Corporation has introduced 800W models to TDK-Lambda’s Z+ series of programmable DC
power supplies. The series is now available with output voltages of 0-10, 0-20, 0-36, 0-60, 0-160, 0-320 and 0-650 VDC with output powers of 200800W to address industrial and laboratory applications. With a five-year warranty, the TDKLambda Z+ 800W high voltage models have the same features and compact dimensions (2U high and 2.76-in. wide) as existing models and achieve efficiencies of up to 89 per cent. They can operate in either constant current or constant voltage modes and accept a universal 85-265 VAC input. Safety certifications include UL/EN/IEC61010-1 and the series is designed to meet UL/ EN60950-1. www.us.tdk-lambda.com/lp
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P R O D U C T S
MOTION
CO N TR O L
Aluminum worm gearboxes
AutomationDirect has expanded its mechanical power transmission product line to include aluminum worm gearboxes in five frame sizes, with gear ratios from 10:1 to 100:1. Constructed of aluminum alloy housings, the worm gearboxes are designed with a C-flange input and hardened hollow-bore output shafts. The gearboxes are available in 30-75 mm box sizes and feature double-lipped embedded oil seals to help minimize leakage, while epoxy paint helps protect against corrosion. Designed to change drive direction by 90 degrees, the gearboxes are mountable in any direction except motor pointing up; the maintenance-free reducer requires no vent plug or breather, says the company. The gearboxes are suited for use with electric motors for reducing output speed, increasing torque, changing drive direction, or running two loads from one motor in applications such as conveyors, packaging machines and rotary tables. www.automationdirect.com
Cabinet-free drive control
deviation via the cabinet, which reduces machine assembly wiring by 90 per cent, says the company. With the decentralized modules, machine manufacturers can also connect up to 20 units in a cable harness up to 200 m long. www.boschrexroth-us.com
Three-phase AC motor drive
absolute rotary encoders into multiturn absolute rotary encoders. When a permanent magnetic field near the Wiegand sensor is rotated, it generates a change in the direction of the magnetic field in the core of the Wiegand sensor, and in turn, creates an induction voltage in the coil around the sensor which eliminates the need for an internal battery. The units boast accuracies of 1-0.1 degree. www.pepperl-fuchs.us
Digital versions of M/V family motor controllers
ABB is expanding its motion control offering with a range of threephase AC motor drives promising remarkable system building flexibility for high-power and continuous machinery and motion control applications, including centralized control to intelligent stand-alone motion solutions. The integrated features of the MotiFlex e180 range means that the drive platform can be used without additional hardware in applications with different control systems architectures, communications and motor feedback schemes, says the company. In total, nine new drives offer a choice of continuous power outputs up to 90A, and peak outputs up to a maximum of 120A. The drives can be softwareconfigured for EtherCAT, Modbus TCP, Ethernet/IP or Powerlink based systems with further options in development. www.abbmotion.com
The M/V family of motor controllers from Advanced Motion Controls has added two digital drives, models DVC250A060 and DVC200A100. DVC250A060 outputs 150A continuous and 250A peak for up to 10 seconds at voltages from 20-54 VDC,
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Magnetic absolute rotary encoders Bosch Rexroth says its IndraDrive Mi series enables machine manufacturers to integrate all electric drive components directly into the machine, resulting in cabinet-free, module machines with a minimized footprint. The company says it is moving the complete drive technology from the cabinet to the machine with decentralized supply and mains modules. The mains module includes a mains filter, mains regulator and mains protection in one device, while the power supply, control electronics, brake resistor and brake transistors are located in the supply module. The machines and modules are connected to the power supply directly without
Pepperl+Fuchs describes its ENA58IL and ENA36IL magnetic absolute rotary encoders as nextgeneration encoders that combine precision and high-speed resolution in a compact design. Promising to maximize process reliability, efficiency and service life, the models are based on a magnetic detection principle and use a twoaxis Hall sensor. This measures changes in the magnetic field allowing the angular measurement to be generated by the encoder electronics. Meanwhile, a Wiegand sensor turns these single-turn
while DVC200A100 outputs 125A continuous and 200A peak for up to 10 seconds at voltages from 20-80 VDC. Maintaining the same dimensions as their analog predecessors, the motor controllers are four-quadrant servo drives designed for specific applications that include mobile robots, AGV’s, UGV’s, material handling and transport vehicles in industrial environments. Both models operate over CANopen and are configured using AMC’s DriveWare 7 software. www.a-m-c.com
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www.AutomationMag.com • January/February 2015 23 MA_EmployerofChoiceAward_ad .indd 1
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P R O D U C T S MACHIN E
TO O L S
Wire stripper features self-adjusting blade
Weidmuller says its stripax ULtimate wire stripper is a highprecision tool designed to strip wires that have tough, halogen-free insulation. Promising to simplify and reduce wire preparation time, stripax ULtimate features a selfadjusting blade that automatically adapts to the wire size. An additional adjustment can be made by turning a screw beneath the strip blades, for large gauge or wire with very hard insulation. It also features a three-stage partial stripping function to retain a portion of stripped insulation on the tip of the conductors, which the company
TE ST
&
says helps prevent the wire strands from fanning out, simplifying the process of ferrule placement. www.weidmuller.com
wide variety of gears and splines, the company says. www.sandvik.coromant.com
Gear milling technology
Ansell’s “Oil is a Chemical” campaign hopes to raise awareness of manufacturing industries about the health challenges that can result from prolonged exposure to oil. According to the company, oil and lubricants are a contributing factor in the development of occupational skin disease (allergies and dermatitis) when absorbed through the skin. Aiming to provide dexterous oil-resistant gloves, the company has introduced its next generation HyFlex general-purpose knit gloves with an oil-repellent impermeable outer layer. Workers “no longer need to compromise on protection in order to wear the right glove for oily tasks,” it says. The line also incorporates Ansell Grip Technology boasting exceptional grip on slippery, oily surfaces. www.ansell.com
Sandvik Coromant’s InvoMilling software for the flexible manufacturing of gears and splines on universal five-axis machining centres is designed for use when machining small and mediumsized batches and when short lead times are a priority. With the CAM software InvoMilling 1.0, the CNC program is generated to produce different gear profiles with a limited range of standard-stocked precision tools. The InvoMilling software is developed by Sandvik Coromant and Euklid, a company with experience in gears and advanced CAD/CAM solutions. Combined with the dedicated InvoMilling cutters, CoroMill 161 and CoroMill 162, the software guarantees short lead times for production of a very
Oil-repellent gloves
M E A S UR E M E N T
Temperature and power measurement modules
B&R Automation is extending the X20 I/O system to include a temperature measurement module with fourwire resistance measurement, and a power measurement module with four current inputs for connecting external transformers with a 333 mV output. Up to four platinum PT100 temperature sensors that are complaint with IEC 60751 can be connected to the X20ATB312 temperature measurement module using four-wire connection technology. Wiring the compact four-channel X20 module, which has a 12.5 mm width, is done using a X20TB1F 16-pin terminal block. The X20AP3161 energy measurement module is equipped with three voltage inputs for a maximum of 3x 480 VAC and four current inputs for connecting external current transformers with 333 mV output. The module measures reactive and apparent power individually for each of the three phases and for all of them collectively. The power consumption of each phase and the total sum is also recorded. www.br-automation.com 24
COnNE CTIVITY
iPad vibration monitor
GTI Predictive Technology has designed VibeRMS LT, a single channel vibration documentation tool for the iPad. Users can view live vibration data (velocity, acceleration, displacement) and create reports at the site on the tablet. Reports include machine data, spectrum
Rockwell Automation and Cisco have released the design and implementation guide Deploying 802.11 Wireless LAN Technology within a Converged Plantwide Ethernet Architecture which aims to help users implement standard, IP-based wireless networks in a more robust, secure and scalable way. The guide highlights 802.11 wireless LAN (WLAN) solutions within a Converged Plantwide Ethernet (CPwE) architecture, including design considerations for fixed position, nomadic and mobile equipment use cases. It also includes explanations for how to configure, maintain and troubleshoot WLAN for each use case, and documentation on how the architectures were tested and validated by Cisco and Rockwell Automation. www.rockwellautomation.com http://thenetwork.cisco.com
Wireless serial device server
Wireless pressure, humidity and temperature data logger
The OM-CP-RFPRHTEMP2000A wireless data logger from Omega is designed for monitoring weather data, measuring barometric pressure, and monitoring storage or warehouse environments that contain sensitive material. Other features include configurable alarms, battery life indicator and wall or surface mounting options. Users can select the desired units in the current reading, minimum, maximum and average statistics are displayed on the LCD screen. Suitable for use as a standalone data logger, it can also be used with the OM-CP-RFC1000EXT wireless transceiver to transmit data back to a central PC. www.omega.com
Guide for deploying wireless equipment in The Connected Enterprise
data, alerts and alarms, user notes and integrated tablet photos. The accompanying software is useful for documenting: incoming and outgoing inspection of new and repaired equipment; certification of newly installed machines; and field commissioning. Meanwhile, the Build Machine function includes templates for common machine types (motors, pumps, fans) and the ability to combine machine types to create machine train templates. VibeRMS LT includes iPad Mini 2, VibeRMS software, accelerometer with magnet base, and an industrial case. www.gtipredictive.com
3-axis RF field strength meter
Anaheim Scientific has introduced the E200 three-axis RF field strength meter, the second in its series of electromagnetic meters. Designed for measuring and monitoring radio-frequency electromagnetic field strengths, the meter boasts adjustable alarm thresholds, the ability to store and recall up to 200 data sets, and rugged construction. It is well suited for both field and lab use, says the company, adding that the high frequency radiation range covers 50-3.5 GHz. anaheimscientific.com
Antaira Technologies has released the STW-61xC industrial wireless serial device server series which encompasses bridge mode and WiFi direct technology solutions. With the series, users can use a bridging mode to establish a simultaneous threeway communication path within a single unit (serial-to-wireless, serial-to-Ethernet, and Ethernetto-wireless), permitting any serial and Ethernet device to link to a wireless network to form a threeway communication, it describes. It can communicate on a 2.4 GHz bandwidth and operate on a wide voltage input range of 9~48 VDC which is IEEE 802.11b/g/n compliant with WPA, WPA2 and 802.1x. Model options include STW-611C (one port) and STW-612C (two ports of RS232/422/485 serial which can wirelessly transmit data at speeds up to 921.6Kbps). www.antaira.com
January/February 2015 • Manufacturing AUTOMATION
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P R O D U C T S
WI RE
&
CABL E
Expanded M8, M12, 7/8 in. cable assemblies
Harting says its “major” expansion of its M8, M12 and 7/8 in. overmoulded cable assembly lineup will provide customers with the convenience of onestop shopping for reliable, robust connectivity. The expansion boasts a series of M8 versions with both 3- and 4-pole configurations; a lineup of M12 A-code assemblies used in sensor, actuator and DeviceNet applications available in 4-, 5- and 8-pole versions that support 2 - 12 contacts; and M12 12-pole assemblies in several configurations. The M8 and M12 A-code assemblies are available in all common single-ended and dualended units: male/male, female/ female and male/female, with straight/straight, straight/angled and angled/angled connectors. The M12 12-pole assemblies include double-ended versions of the same connector, a male/female straight connector version, and male and female single-ended assemblies. The 7/8 in. overmoulded assemblies are available in 3-, 4- and 5-pole versions, angled or straight, singleor double-ended. www.harting-usa.com
Thermocouple wire
Watlow’s N type thermocouple wire promises superior repeatability and resistance to oxidation over K type wires at temperatures of 1,500 degrees F and up, or in applications where sulphur is present. The N type thermocouple wire meets special limits of error from 2002,000 degrees F. This nickel-based thermocouple alloy can be used in many high-temperature heattreating applications, including specialty aerospace heat treating. The wire boasts improved repeatability between 700-1,100 degrees F, says Watlow. www.watlow.com
Cord sets
Belden has released new wash-down cord sets as part of its Lumberg Automation product portfolio. The cord sets are designed to withstand extreme temperatures,
immense pressure and the chemical exposure typical in high-intensity cleaning processes. They also ensure functional reliability in all harsh industrial settings, particularly for the food and beverage, chemical and pharmaceutical industries, adds Belden. The cord sets feature goldplated crimp contacts, high shock
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and vibration resistance, and IP67, IP68 and IP69K certification for ingress protection. According to the company, the cord sets can withstand the high-shock and vibration found in industrial environments, which helps to maintain a high productivity level of equipment. www.belden.com
www.AutomationMag.com • January/February 25 15-01-192015 2:14 PM
2015-01-19 2:19 PM
R E A L I T I E S
Pay attention to the black swan By DICK MORLEY
W
e’re beginning to have a problem with the technological culture. We believe that rules are the only thing that can control the environment. For example, rules can make our economy work by predicting the sales for the next quarter... but don’t believe it. We have to believe in some of the numbers, but also in the black swan concept. The black swan is defined as the impact of the highly improbable, a concept explored in a book of the same name by Nassim Nicholas Taleb. The black swan tries to manage unpredictable events. This relationship comes from the European concept that the existence of white swans with a black swan is highly unlikely, even impossible. A black swan event is an event that is unknown and is typically big and bad. We tend to find simplistic causality as a basis for events being predictable. Taleb’s book, by the way, spent many weeks on the New York Times bestseller list. Everyone suggests you should make a will for your end-of-life procedures. Seldom are they carried out. In fiction, the twists and turns of predictability are what makes the novel a novel. We trust too much in the numbers. Modern innovation has us driving a car by looking in the rear-view mirror — it implies we can predict the future by looking at the potholes of the past. Engineering is an effort to make everything in the future by using the tools of the past. Recently I was talking to an expert in risk management and healthcare. He suggests three rules for happiness. Ask yourself, “Am I happy with the existing system?” If you are, read no further. But most of us are not happy with the existing systems.
So what do we change to, how can we accomplish that and what action should be taken? We believe that the rules of large corporations define the position of our experience. If you believe that, you are in real trouble. You could conclude that elephants can’t dance. But they do. The value of Facebook was not built on the foundation of existing rules. My favorite rule breaker is the programmable controller. It’s so stupid in programming sequences that we don’t give it a second thought. Nowadays, they’re trying to make the PLC another computer. The dragon of complexity feeds on simplicity. The danger of the bureaucrat and MBA thinking enhances and feeds the dragon. If I remember my Roman history days, the bureaucrats in the Roman Senate were deciding whether to raise an army while the enemy was charging up the steps. It is important that you do not make the best decision, but that you make a decision immediately. Not making a decision is the worst decision of all. The bureaucrat gets caught up in the rules, not the needs, and assumes government will follow the rules and prosper accordingly. We can think of several examples of rules
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CYBERSECURITY Three common cybersecurity issues in industrial control systems and how to manage them
Encoder Products Company......................................6 Excellence In Manufacturing Consortium...............17 George Brown College............................................18
2014 SOFTWARE CASE STUDY GUIDE The latest software solutions help manufacturers solve their biggest challenges
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AUTOMATION UPFRONT Inside Mohawk College’s new Additive Manufacturing Resource Centre
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the Future oF sensors harnessing technology to create smarter plant floors
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Hiwin Corporation....................................................9 Lafert North America..............................................19
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AUTOMATION TRENDS
The top technologies that will impact the plant floor in 2014
Dick Morley (morley@barn.org) is the inventor of the PLC, an author, speaker, automation industry maverick and a self-proclaimed ubergeek.
AutomationDirect..................................................IFC
For fastest service visit www.automationmag.com and click the subscription button The challenge of developing a custom guarding solution for a sterile environment
And you don’t even know what the game is. The game is accepting chance, understanding that you’re making no progress if you don’t feel bumps in the road, and listening to your spouse. Sometimes that relationship makes your teeth grind. Listen. As of this writing, Thanksgiving has come and gone, and all the turkeys were hit by the swan. We expect the holidays will put our rules to the test. Get exercise and sleep well. A new year is upon us and make sure it’s the year you want to remember. Good night, noble reader. •
Allied Electronics Inc...............................................15
it’s fast, it’s easy and it’s free! FINDING FUNDS
• You can’t win • You can’t break even • You can’t get out of the game
A d
on your next issue of
Government funding that supports HR and training
governing behaviour and failing — several that come to mind are the banning of alcohol, the war on drugs, and regulating the Internet. You can’t be an artist with a paint-by-number kit. My daughter, Pat (an artist), likes to say she can teach anyone to draw but she can’t make them an artist. The curve of obsolescence and the black swan Always remember that you-know-what happens and physics says that no organization can exist without waste disposal. The physics concept is a black box that has four arrows: input, output, waste and power. The foundation of physics, and possibly the only law that sticks, is the law of thermodynamics:
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Murrelektronik Canada.............................................3
EMPLOYEE EDUCATION Ottawa-based manufacturer launches work-supported apprenticeship program
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Our editorial advisory board discusses positive trends in the manufacturing industry, and where we go from here
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SCHUNK Intec Corp...................................................7 Siemens Canada Ltd............................................OBC TD Bank - Equipment Financing............................ IBC Techspan Industries Inc...........................................11
January/February 2015 • Manufacturing AUTOMATION
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