Control Engineering Europe - April 2022

Control, Instrumentation and Automation in the Process and Manufacturing Industries April 2022 www.controlengeurope.com Implementing small and energy-efficient field sensors with IO-Link transceivers from Analog Devices Ensuring security for Out of the box vision Secure remote access industrial devices solutions via public 5G network

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CONTENTS Editor Keeping the production environment secure Suzanne Gill [email protected] In almost every production environment today there will already have been an element of convergence of information Sales Manager technology (IT) and operational technology (OT) and this Colin Campbell trend is set to continue. Of course, this means that the OT [email protected] environment needs to prepare itself for increased cybersecurity threats and so in this issue we tackle some of the key questions Production that need to be consider to ensure that plants remain Nick Jacobs protected (pg 12). [email protected] Also in this issue we look at the potential for 5G networks in industrial applications Dan Jago Group Publisher where remote access to distant equipment is required (pg 20) and we find out how true 3D data can result in fewer false positives/negatives (pg 18). David May Production Manager Suzanne Gill G and C Media Studio Design Editor – Control Engineering Europe [email protected] INDUSTRY REPORTS SUSTAINABLE ENGINEERING SOLUTIONS 4 Improving device and process visibility with FDI 22 Selecting the right network is a key step in enhancing sustainability EDITOR’S CHOICE IIoT 6 A new era in level sensing; Rapid cleaning solution for drain valves 24 Find out how IIoT technology innovations are helping transform the global supply chain COVER STORY PLCs 8 Implementing small and energy-efficient field sensors with IO-Link 26 PLCs remain an essential element in modern automation CYBERSECURITY PG 8 PG 12 12 Ensuring security for industrial devices when IT PG 22 and OT communication networks converge MACHINE VISION 16 Out of the box vision solutions; Making light work of inspection and quality control 18 Moving machine vision into the third-dimension 5G FOR INDUSTRY 20 We look at the potential for 5G in industrial applications where remote access to distant equipment is required Control Engineering Europe is a controlled circulation Control Engineering (USA) Qualified applicants in Europe 3 journal published eight times per year by IML Group Mark Hoske, must complete the registration form at plc under license from CFE Media LLC. Copyright in the Circulation http://imlrenewals.managemyaccountonline.net to receive Control Engineering Europe contents of Control Engineering Europe is the Tel: +44 (0)1732 359990 property of the publisher. Email: [email protected] free of charge. ISSN 1741-4237 Completed print or on line registration forms will Paid subscriptions for non-qualifying IML Group plc be considered for free supply of printed issues, applicants are available for £113 (U.K.), Blair House, High Street, Tonbridge, web site access and on line services. Kent TN9 1BQ UK £145 (Europe), www.controlengeurope.com £204 (rest of world); Tel: +44 (0) 1732 359990 Fax: +44 (0) 1732 770049 single copies £19. Control Engineering Europe April 2022

INDUSTRY REPORTS Global manufacturing growth figures explained New research from Interact Analysis shows that the Covid-19 projected. In fact, in a way, these numbers are understated pandemic has had a marked effect on the manufacturing because China contributes to 69% of production within the industry. While many machinery sectors are enjoying double- region and did not shrink in 2020. If China was removed, then digit growth, other areas continue to suffer due to supply the growth for the rest of the region would be 9.6% and chain issues and chip shortages. 11.5% in manufacturing and machinery respectively. Output growth of 8.3% in 2021 was recorded as A combination of supply chain disruption and the shipping manufacturing recovers from the pandemic. And, while this crisis has caused chaos for manufacturing. The ubiquitous is dwarfed by the 16% manufacturing output growth seen in just-in-time model has struggled to cope with the problems 2010 after the financial crash, it is not so unexpected – because in many cases, while container prices are at 8-9 times the pre- the financial crash saw manufacturing shrink by 8.3% in 2009. pandemic cost on popular shipping routes. In contrast, 2021 saw a decline of only 3.2%. Commenting on these figures, Adrian Lloyd, CEO at Interact The picture in the machinery sector is more volatile for two Analysis, said: “Although we are likely to see a stabilisation reasons. First, the machinery market is 1/20th the size of the of growth for many sectors in 2022, this does not necessarily overall manufacturing market, so small changes in production indicate a slowdown. A renewed production downturn is value have a big impact. Second, machinery investment is both expected in 2023/24 and the boom-bust semiconductor crisis niche and capital intensive. Some sectors, such as agricultural, is likely to have a major impact on this. We also cannot ignore semiconductor & electronics, and textile machinery are the role that the Russian invasion of Ukraine is likely to have performing strongly. Other sectors, such as aerospace, are on the market. Being the largest natural gas producer globally, having a much harder time. its effect on the worldwide manufacturing economy is likely to be colossal. From a regional perspective, Europe was by far the worst affected by the pandemic, with a 2020 manufacturing slump “Finally, a word on reshoring. This is a much-discussed trend of 7.9% and a 12% slump in machinery growth. Conversely, and has been touted as a possible solution to supply chain the USA performed much better due to a lack of federal problems. It is not. Beyond certain strategic sectors such as lockdowns and a large stimulus. semiconductors, the case for reshoring is weak and, usually, makes no economic sense. This will continue to be the case. We In 2022, the Americas (of which the US accounts for 72% may see some manufacturing shift from China to another hub of manufacturing output) will see manufacturing growth of location, such as Southeast Asia or India. But we are unlikely to 4.6%. Asia, excluding India, has handled the pandemic best see the large-scale return of manufacturing to Europe or the from a manufacturing perspective. In 2022, manufacturing United States.” growth of 7% and machinery growth of 6.5% growth are Appetite for Engineering 2022 date announced The Appetite for learning about the latest technology The event organisers Engineering team developments and successful are now seeking suitable recently revealed implementation of technology in case study presentations that the date for this food and beverage plants. from engineers working year’s Appetite for in the food and Engineering event beverage sector which will be 13th October demonstrate the benefits at the Manufacturing of automation and Technology Centre in technology adoptions Coventry. – either to increase productivity, reduce This annual event is waste or to achieve more the UK’s leading food sustainable production. and beverage sector engineering If you have a story to tell about your forum which provides this key sector automation journey please contact with an opportunity to network with [email protected]. peers and industry experts, while 4 April 2022 www.controlengeurope.com Control Engineering Europe

INDUSTRY REPORTS Improving device and process visibility with FDI Emerson has announced that its device management software “Today’s intelligent field devices offer a broad range of is the first host software to be fully registered by FieldComm data and functionality that plant personnel can use to Group to support the Field Device Integration (FDI) standard. optimise operations, but without a common standard, This is a further step in Emerson’s efforts to reduce the time collecting that data can be complex and cumbersome,” said and effort spent by end-user manufacturers Ted Masters, chief installing and configuring executive officer of field devices to achieve FieldComm Group. “By their transformation completing the process to goals. fully register AMS Device Manager’s FDI support, FDI registration will Emerson is providing its reduce the need for plants customers with the tools to support two different to more easily implement technologies to integrate a wider range of devices and maintain field devices. for holistic plant health.” Full FDI registration is important to avoid having The newest release of a patchwork of systems AMS Device Manager will and devices that only make it easier, more support individual secure, and more cost elements of FDI but still effective to access device require extensive data. FDI integration integration effort. Because technology eliminates manufacturers can pick the need for plants to and choose individual FDI support the two most features to support, some device management applications will common technologies for likely not contain every feature a plant requires. installing and configuring devices: Electronic Device Description Language (EDDL) and Field Device Tool/Device Emerson has worked with FieldComm Group for nearly two Type Manager (FDT/DTM). Instead, all FDI devices support a years to enable its AMS Device Manager to pass the group’s single installation package, so organisations will no longer rigorous testing process for registration, which requires all have to double up on time, training, and effort when features to be supported by the software. installing field devices. When managing real pressure is your job… MIPC® helps practitioner-level engineers to be where they're needed and on top of the latest industry developments and good practice in primary containment of hazardous substances. Using a blend of live, online classes, one-to-one sessions with expert tutors, and MIPC® e-learning, enhanced by a mentor’s support and guidance, EEMUA’s Mechanical shortlisted for Integrity Practitioner Certificate course delivers in-depth training to engineers the Best E-learning/ where they work – to give professionals the flexibility to learn on-site or on-call. Online Education A short Induction to suit your schedule from July 2022 adapts Initiative coursework to your site/s needs. Learning starts in September 2022. memcom membership Registration open now. excellence awards 2020 For more information please contact EEMUA [email protected] +44 (0)20 7488 0801 www.eemua.org

EDITOR’S CHOICE A new era in level sensing keeps things simple With its latest product offering sensor required for both liquids and bulk new radar-chip technology, with VEGAPULS 6X, VEGA is offering a solids applications. expanded application possibilities single level radar sensor that is able to and simpler operation. measure in virtually every conceivable The new sensor is said to offer the application. best that is technically feasible today – a The radar features SIL certification, self-diagnosis system that immediately and cybersecurity issues have also Traditionally, the search for a detects damage or interference and been taken into account with suitable level sensor begins by thinking which ensures significantly high compliance with security standard IEC about which solution would work availability and safety. It also has 62443-4-2. best for an application. Choosing a radar-based level instrument has It’s true value lies in making it always been a laborious task, matching easier for users to select a device to process details to myriad radar monitor industrial processes. There is frequencies, part numbers and options no longer any need to worry about on offer. the technology, frequency or instrument version. Even setup and commissioning VEGAPULS 6X has transformed this has been reduced to a minimum, process with just one device for all and requiring now just a few clicks and basic a new selection and ordering method application parameters. In many cases, that is customer-application focused. It all application-specific settings can be enables complete, correct configuration made in VEGAPULS 6X before it leaves and even pre-calibration of the specific the factory. Bringing smarter drive capabilities to more applications Rockwell Automation is expanding conveyor applications, and more automatically compensates for the PowerFlex AC variable frequency advanced motor control processes changes. This helps users to quickly drive portfolio to support a broader that require high-performance commission the drive and maintain range of motor control applications features typically found in specialised it for the life of the drive without a to offer more flexibility, performance drive solutions. tuning expert. It also helps reduce and intelligence in the next mechanical wear and improve uptime. generation drive through TotalFORCE This addition brings a simplified technology. and consistent user experience The PowerFlex 755TS drive is to motor control applications in available with an option for enhanced The new PowerFlex 755TS three ways – it offers flexible, corrosive gas protection (XT) that drive is the first six-pulse drive to high-performance control, helps improve uptime and extend the incorporate TotalFORCE technology. operational intelligence and ease of drive’s operating life in corrosive gas Previously only available in PowerFlex commissioning and optimisation. environments. The drive is also CIP 755T drives with active front-end Security capable. When implemented, technology, TotalFORCE can now be Using a suite of features referred this helps fortify a control system by used in a wider range of applications, to as Adaptive Control, the drive providing data authenticity, integrity including traditional fan, pump, and monitors machine characteristics and confidentiality. that can change over time and Measuring the quality of liquid processes in real-time Collo’s new online measuring automatically and results in an eight- industries and many other bioprocesses, technology is said to be able to detect dimensional multiparameter, real-time to ensure that the delicate almost any change in liquid properties analysis that makes it possible to adjust microbiological process is progressing as straight from the process in real-time. the process immediately when there is a intended. quality issue. The technology enables continuous process monitoring and is universally Collo’s liquid fingerprint technology suitable for all fluids, from thin to thick. gives the manufacturing industry an opportunity to ensure that a liquid The technology is based on RF signals process behaves consistently from batch that can penetrate any liquid with to batch. As an example, it can monitor machine learning and edge computing fermentation processes widely used in analysis. It is a simple-to-use solution food, cosmetics, and pharmaceutical that adapts to any liquid process 6 April 2022 www.controlengeurope.com Control Engineering Europe

EDITOR’S CHOICE Rapid cleaning solution for drain valves Drain valves comprise up to 20% of The pulse seat clean makes control timer-controlled cleaning. The ThinkTop all valves in a typical processing plant. and validation of valve cleaning cycles also verifies that valve cleaning has been Cleaning can be costly, difficult and easy. The valve position is controlled completed. time-consuming due to long cleaning by the ThinkTop not the PLC. Besides cycles and the risk of pressure shocks. reducing the volume of CIP liquid used, Intended for use with single-seat valves programming the sensor to open and or butterfly valves used as drain valves, The new Alfa Laval ThinkTop pulse close the seat quickly ensures faster, more pulse seat clean is a standard feature seat clean addresses these issues, quickly rigorous cleaning and hygiene than of ThinkTop V50 and V70 sensing and and effectively making drain valves control units with one solenoid valve. spotless while delivering savings of up to 95% in Cleaning-in-Place (CIP) liquid. The new pulse seat clean feature is said to cut drain valve CIP liquid consumption by up to 95%. Short bursts, or pulses, drive the valve cleaning process, activating the valve when shear forces peak. Each position-based pulse takes less than a second, preventing pressure shocks in the system. The pulse creates high turbulent flow as the liquid passes through the narrow gap between the valve house and valve seat, effectively removing all residuals for spotless drain valves. Redundant PLCs for Electronics for maximum availability your hydraulics With its redundancy function, Universally applicable the RFC 4072R PLCnext Control device from Phoenix Personal consulting Contact is suited to use in high-availability applications. All information under www.w-e-st.de The PLC supports Profinet S2 redundancy without Our portfolio the need for additional Power Amplifiers applicative programming Positioning controls work. The user benefits Pressure controls from easy commissioning Synchronization controls based on the PLCnext Engineer engineering Pump controls environment. Assigning a Network connection system IP address enables automatic communication with the process-managing controller of the redundancy system, which offers up advantages during handling and when switching between connected visualisation systems. With the implemented OPC UA pub/sub functionality, high-performance and structured controller-to-controller communication can also be realised between different redundancy systems. Control Engineering Europe April 2022 7

COVER STORY sponsored article IMPLEMENTING SMALL AND ENERGY- EFFICIENT FIELD SENSORS WITH IO-LINK Suhel Dhanani discusses the role of IO-Link in the creation of Industry 4.0 sensing solutions. Historically, industrial sensors INDUSTRIAL CONTROLLER were analogue, including a sensing element and FIELDBUS some way to get the data to a controller in a unidirectional INDUSTRIAL fashion. Then came binary sensors, SENSORS which provided a digital on/off signal, and included a sensing Figure 1: IOF-iLginukrepr2ot:oIcOo-lLisinuksepdrtootcoocnonleicst uinsteeldligteontcoedngneedcetviincetsetloligtheenftaectdogryenetwork. element – inductive, capacitive, ultrasonic, photoelectric, etc – with 20V to 30V for the master andd1e8vticoes to theDfeacstiogrny innegtwIoOrk-.Link sensors a semiconductor switching element. Data, however, was still limited to 30V for the device (sensor or actuator). Industrial field sensors must be unidirectional communication from the sensor to the master, there was Analog Devices’ IO-Link handbook rugged, small, and very energy no error control, and a technician was required on the factory floor for tasks elaborates IO-Link advantages as efficient so that the heat dissipation such as manual calibration. A better solution was needed to follows: ‘IO-Link is a technology is kept to a minimum. Most IO- meet the demands of Industry 4.0. The solution is the IO-Link protocol, a that enables a traditional binary Link sensors have the following relatively new standard for industrial sensors that is showing a phenomenal or analogue sensor to become an components: growth trajectory – The IO-Link organisation estimates that over 16 intelligent sensor that no longer just • Sensing element with the associated million IO-Link enabled nodes are being used in the field to date. That gathers data but allows a user to analogue front end (AFE) number is still growing. IO-Link is a standardised technology remotely change its settings based on • A microcontroller that processes (IEC 61131-9) that regulates how sensors and actuators in industrial real-time feedback obtained on the data, and in the case of an IO-Link systems interact with a controller. IO-Link is a point-to-point health and status of other sensors on sensor, also runs the lightweight communication link with standardised connectors, cables, and protocols. The the line, as well as the manufacturing protocol stack. IO-Link system is designed to work within the industry standard 3-wire operation it needs to perform. IO-Link • An IO-Link transceiver that is the sensor and actuator infrastructure and comprises an IO-Link Master and IO- technology enables sensors to become physical layer. Link Device products. IO-Link communication is between interchangeable through a common • Power supply and in many cases one master and one device (sensor or actuator). Communication is physical interface that uses a protocol protection (TVS for surge, EFT/burst, binary (half-duplex) and is limited to a distance of 20m, using unshielded stack and an IO Device Description ESD, etc.). cables. Communication requires a 3-wire interface (L+. C/Q, and L-). The (IODD) file to enable a configurable Heat dissipation supply range in an IO-Link system is sensor port. It is truly plug-and-play ready while providing the ability to Once we understand the typical reconfigure parameters on-the-fly.’ components, we can look at how Within the factory network a hypothetical sensor power is hierarchy, the IO-Link protocol sits at budgeted. (See Figure 2) All of these the edge – which typically is where numbers are estimates. They show sensors and actuators are located. that the transceiver (output stage) (See Figure 1) Many times, the edge power consumption matters when devices communicate to a gateway budgeting the total system power that translates the IO-Link protocol to consumption of a sensor. the fieldbus of choice. Let‘s start at the left-most side, 8 April 2022 www.controlengeurope.com Control Engineering Europe

sponsored article COVER STORY which specifies an older generation of transceivers from Analog Devices, the next biggest concern for all industrial IO-Link sensor. That way it becomes MAX14827A, dissipates a remarkably sensors, and it applies as well to the clearer how advances in technology low 70mW when driving a 100mA new IO-Link sensors. Board space in the microcontroller (MCU) and the load. This is achieved by optimising the becomes increasingly at premium as output stage (i.e., the transceiver) has technology to deliver a very low 2.3Ω we migrate to a smaller form-factor. contributed to the lowering of the (typ.) RON (on-resistance). total system power over the years. Figure 3 shows that for a 12mm For sensors that use very low diameter housing, the transceiver (in a Original or first generation IO-Link operating current, say 3 to 5mA, and wafer level package – WLP – package) transceivers consumed 400mW or require a 3.3V and/or a 5V supply; the and the DC-DC can sit side by side higher. The newest low-power Analog regulated power can be sourced via on a regular PCB which has 10.5mm Devices IO-Link transceivers consume an LDO. And indeed, Analog Devices’ width. There is still room for vias and less than 100mW. Also, the MCUs have IO-Link transceivers have included an wires on the same side. If the sensor helped. A legacy MCU consumes as integrated LDO. But as the current housing is 6mm, then the PCB width is much as 180mW, but the newer low- demand increases to say 30mA, the down to 4.5mm. Then the chips have power MCU can go down to 50mW. LDO will soon become the dominant to be mounted on both sides of the source of power/heat dissipation in the PCB even with small WLP packages. A state-of-art IO-Link transceiver system. To compare at 30mA, the power coupled with a low-power MCU can consumption of an LDO can be as high To enable these sizes, the keep the total sensor power budget as 600mW. transceiver must be available in within the range of 400mW to a wafer-level package (WLP) that 500mW. LDO Power @30mA = (24-3.3) x 30mA allows for the smallest size. This size = 621mW limitation is also one of the reasons Power dissipation is directly related we have integrated a DC-DC inside to heat dissipation. The smaller the For comparison, a DC-DC buck our newest IO-Link transceiver. sensor the more stringent the power converter supplying a 30mA sensor dissipation specification. By some with a 3V output voltage will dissipate But most industrial sensors also estimates, an 8mm diameter (M8) just 90mW. Assuming the converter is must be designed to work in a enclosed cylindrical IO-Link sensor will 90% efficient (just 9mW power loss), rugged environment, which means specify a maximum power dissipation the overall power consumption is just they must incorporate protection of 400mW and a 12mm diameter (M12) 90 + 9 = 99mW. Analog Devices’ newest circuitry such as TVS diodes. This enclosed cylindrical IO-Link sensor will IO-Link transceivers have integrated a is where it is important to pay specify a maximum power dissipation of high-efficiency DC-DC regulator. attention to the Absolute Maximum 600mW. Ratings specification for the IO-Link Size of IO-Link sensor transceivers. And the technology keeps getting better. One of the new IO-Link After heat dissipation, size is the To elaborate, why does 65V Figure 2: A hypothetical IO-Link industrial sensor power budget. > p10 Control Engineering Europe Figure 3: A hypothwewtiwc.acloInOtr-oLliennkgienudroupsetr.cioaml sensor power budget April 2022 9

COVER STORY sponsored article Figure 3: Size is another big issue in the newest IO-Link sensor designs. Absolute Maximum Ratings on the to an acceptable level. This diode is Conclusion IOs reduce the size of the sensor more than 3x the size than the one subsystem? Typically, the sensor required for the Analog Devices The first-generation IO-Link transceiver needs to survive surge pulses transceiver. technology came in easy-to-use TQFN between the 4-pins: GND, C/Q, packages with integrated LDOs that DI, DO. Analog Devices’ IO-Link The size impact of a larger TVS would meet the needs of a small transceivers have a specification of diode in the overall sensor design is sensor design. As power and size 65V Absolute Maximum Ratings. If significant if the transceiver Absolute considerations mounted, the second- we take an example of a 1KV at 24V Maximum (Abs Max) ratings generation transceiver technology surge between C/Q and GND. specification is lower. Table 1 shows optimised power consumption by an estimated difference in the PCB moving to a technology that gave us Voltage between C/Q and GND = area. The assumption here is that the lower RON to further reduce power TVS clamp voltage + TVS forward sensor must be able to withstand a consumption and were made available voltage high-level surge of ±1KV/24A. in even smaller WLP packages. With the higher Absolute The next generation of IO-Link The newest generation of Maximum Ratings specification, transceivers have even improved transceivers recognise the need to the designer can use a small TVS upon this. The newer IO-Link integrate both the protection and a diode – such as SMAJ33 – whose transceivers from Analog Devices high-efficiency DC-DC buck regulator clamp voltage is 60V at 24A, and TVS now feature an integrated protection to further reduce the size and the heat forward voltage is 1V at 24A. on IO-Link line interface pins (V24, dissipation of the sensor subsystem. C/Q, DI, and GND). All pins feature Voltage between C/Q and GND = integrated ±1.2kV/500Ω surge As IO-Link technology gets 61V protection. In addition, all pins deployed in even more industrial are also reverse-voltage protected, sensors, these device specifications are This value above is within short-circuit protected and hot-plug key to implement small, ruggedised, the Absolute Maximum Ratings protected. power-efficient sensors. plus-cir specification of the Analog Devices transceiver. Even with all the integrated Suhel Dhanani is Director of Business protection features as well as the Development for the Industrial & However, if the Absolute integrated DC-DC buck regulator, these Healthcare Business Unit at Analog Maximum Ratings specification is devices are available in a tiny WLP Devices. lower – typically in the industry it package (4.1mm x 2.1mm); enabling a is around 45V – then a much larger really small IO-Link sensor design. www.analog.com TVS diode such as the SMCJ33 is required to clamp the voltage down Smallest TVS Diode IO-Link TRANSCEIVER WITH ABSOLUTE IO-Link TRANSCEIVER WITH ABSOLUTE Max Voltage MAXIMUM RATING 65V MAXIMUM RATING 45V Total PCB Area SMAJ33 SMCJ33 61V 45V 40.5mm2 144mm2 Table 1: Advantages of 65V Absolute Maximum Rating on sensor size. 10 April 2022 www.controlengeurope.com Control Engineering Europe

Like what you see, but not your copy? Control, Instrumentation and Automation in the Process and Manufacturing Industries Control, Instrumentation and Automation in the Process and Manufacturing Industries March 2022 April 2022 www.controlengeurope.com www.controlengeurope.com fwreIomnitmehprlAgIeOynm--aeLelifonnfigtkciniDtegrenavstnmisficceaeeslllidvaesnerdsnsors FEMDDnvTiuigrUoltinntiim-afiPeledunTtrwEpnionasbseles Out ofsothluetiboonxs vision vSiaecpuurbelricem5Gotneeatwccoersks Einnsduurisntrgiasledcuerviitcyesfor Maeknignigneseursitnaginpaabyle Movitnogthineteeldliggeence Mobile rtohbeoirtsmaorvee making GET YOUR FREE MAGAZINE REGISTRATION TODAY If you or/and a colleague would like to receive free copies of Control Engineering Europe every month, you can register by scanning the QR code below Open the QR code on your phone or launch the camera on an iPhone, scan the QR code above and complete the online form or Visit https://data.imlgroup.uk/cee-reg-page/ or Phone: +44 (0) 1732 359990

CYBERSECURITY ENSURING SECURITY FOR INDUSTRIAL DEVICES Key questions about factory-floor and industrial cybersecurity, as IT and OT communication networks rapidly converge, are addressed in a whitepaper from HMS Industrial Networks. Cybersecurity is a critical issue terms of enhanced levels of production, a process that has been going on as industrial technology (IT) quality and profits. It will also provide for some time. A common way of and operational technology industrial processes with much better achieving this is to only use selected (OT) converge. General factory possibilities to enable predictive points of entry at certain places in a floor automation and many industrial maintenance and analysis. plant/factory. However, the trend and applications need to be prepared for evolution is clearly going in a direction increased cybersecurity threats. Where Cybersecurity needs attention where these will open up more. things are going and what security While some factories or installations measures will be needed are the big At the same time, however, these will continue to be tightly closed the questions. And often the magnitude advances make industrial advantages interconnectivity can of the potential threats is hard, if not communication networks and bring, and driven by Industry 4.0, the impossible, to estimate due to the manufacturing processes vulnerable to market is striving to connect industrial simple fact that the threat landscape is intrusion and attacks, and intrusions are machines to the IT level to enhance constantly evolving. happening at industrial plants at an maintenance, analysis and production increasing rate. effectiveness. Manufacturing industries today are undergoing a significant digital To improve security, IT security The result is that a fast-growing transformation as Information requirements for industrial number of industrial machines will no Technology (IT) and Operational communication standards and longer be isolated from the outside Technology (OT) communication systems development processes need to be world. Going forward, a factory needs rapidly converge, thanks to smart carefully considered to make sure that to consider opening selected entry industrial automation devices that they are protected, today and in the points on different levels. There will are designed to provide more useful future. most certainly be a transition period as information than ever before – in many this opening up occurs; what remains cases through the use of networks Five key questions about factory-floor to be seen is how fast and how costly like OPC UA and MQTT transferring and industrial cybersecurity include: it will be. data to IT domains, combined with • How widely might the factory floor • Aren’t factories closed systems, existing industrial Ethernet networks, meaning that outside access is that in their turn also evolves, adding of the future be connected to higher denied? features and TSN capabilities. The result level systems? Not necessarily, but it depends on is that a larger range of data is being Extracting information from devices, made available and collected from the machines and production lines, and factory floor, across local enterprise IT passing it on to other IT systems, is functions, on-site storage, and into the external cloud – to give companies new competitive advantages. The IT/OT convergence, encompassing aspects of Industry 4.0 and the Industrial Internet of Things (IIoT), allows new interconnected communication which helps factory OT equipment create greater value out of data shared with local IT applications or via a manufacturer’s IoT Platforms. This cross- shared data can offer many benefits in 12 April 2022 www.controlengeurope.com Control Engineering Europe

CYBERSECURITY how we define ‘closed’. If there is employee or outside contractor, someone else’s technology to solve the absolutely no connection to the bringing a non-secure USB memory actual security part? internet, then yes it has a higher stick containing a virus into a protection from external threats. factory. Upon connecting to an It is HMS’s belief that in many However, a factory owner needs to internal computer or port, the virus cases this will be possible, and even consider security on different levels. itself enables its installation. preferred. And when industrial For example, even if it is closed to the manufacturers are required by their internet, people allowed inside the The increasing complexity of customers and end users to do this, factory can make security ‘mistakes’ production machines is pushing local the use of communication solutions that need to be considered. Examples engineering teams to interact with that include built-in security features might be: their suppliers through remote access will help them do it more easily and 1. An external maintenance person solutions that, if not fully secured and efficiently. Thus, a manufacturer of managed, will create additional entry automation equipment can meet their connects their laptop to a machine points to the factory. This trend will customers’ installation requirements for diagnostic purposes. This clearly continue and accelerate. related to security, but without the connection may expose the factory • Who will have responsibility to ensure headaches and investments needed to to unnecessary risks and threats – that an installation is secure? do it by themselves. such as viruses or access to internal Everyone will eventually have to confidential documents and data consider security aspects in both It is worth pointing out that security 2. A PC being connected to an unused new and old installations, and then is not only meant to prevent someone network port on an industrial build systems in different levels by from outside the factory getting Ethernet network, where only the segmenting various parts of a factory access to the network. It can also be machine communication is allowed. to create a higher security level. There intended to protect the network, and 3. Incorrect firmware being will also be a need to accommodate the products on this network, inside downloaded to a machine. co-existence with older products/ the factory. 4. An employee making unintentional installations using older networks. In • Do I need to secure all my products, or configuration changes, through addition to the question stated in the can I only secure the ones considered tools, web or other environments headline, another interesting question to be at risk? And how do I know that do not require authentication. is: Can device manufacturers rely on which products those are? 5. Someone, either an inside This will be the key question when specifying a new factory or installation > p14 The link between functional safety and cybersecurity Functional safety is an essential criterion for complex and so should also be fully reliable in relation to OT cyber industrial plants. The aim is always to ensure that all the security, in line with standard IEC 62443. safety systems are operating properly, in line with their OT cybersecurity certification: ISASecure certification is an SIL. But what happens when a SIL device is also network official assessment scheme for certifying compliance with connected? the requirements of standard IEC 62443, ensuring resilience Functional safety certification: A device can be subjected in the face of attacks, and based on values such as security, to a third-party assessment, to certify its SIL and so show helpfulness, integrity, and confidentiality. that it meets the necessary functional safety standards, thus ensuring its compliance with the requirements of standard Cyber security certification is often required for functional IEC 61508. safety – in the case of sensors that communicate with controllers via network protocols, for example – but it is SIL certification is globally valid and is the most direct and even more important for components that form part of an authoritative way to demonstrate the complete reliability automation and control network designed to protect the of a product in terms of its functional safety for the user, system from external attacks. wherever a third-party has specific accreditation for The future of functional safety: The future of functional evaluating functional safety. safety is moving towards a merger between compliance and Reliability of network connected devices: The idea of the digitalisation of safety devices. Dual certification for an reliability can be extended to various objects vulnerable to item to meet the requirements of both IEC 61508 and IEC hacking. For example, a SIL item that involves a network 62443 ensures an even higher level of reliability, improves protocol, or certain accessory or diagnostic functions that overall safety, and certainly increases the sales potential of communicate with a field network, or an SIL item that is the product. Although this system may appear rather novel, connected via Bluetooth or Wi-Fi. it is in fact readily accessible, and can create an immediate competitive advantage for many manufacturers. These all need to be protected against malicious attacks, Control Engineering Europe www.controlengeurope.com April 2022 13

CYBERSECURITY containing industrial network protection for the product’s control over the specific security communication. The level of security intended usage. policies within a factory. Therefore, will probably be decided based on strengthening the device to handle numerous factors. This could be the A security product, on the any situation will help provide value of the product being made, the other hand, is a product more reliable security performance value of the information and processes developed with the sole regardless of the installation inside the factory, the consequences of purpose of addressing conditions. a security breach the level of restricted specific cybersecurity access inside the factory, IT/internet functionality, e.g. a firewall, Security also depends on acceptance network connections, and type of a DPI gateway, or data diode. by users that already have a strong data on the network, to give some Naturally, those products are focus on security management. For examples. also secure products. Those example, if a factory demands that kinds of products have been its webpages shall be accessible on It is not totally clear yet how and at developed in order to differentiate the network, only products with what speed IT security in industrial themselves on the market and to make HTTPS (secure web protocol) can be communication networks will develop their customers’ jobs easier when they accepted. This, in turn, means the in the future, and what routes will need to implement specific security manufacturer/device maker needs to be taken to achieve it. However, HMS measures. support this secure functionality in is actively using its deep network • Is it the device manufacturer’s their product. plus-cir communication experience to responsibility to solve the security undertake numerous progressive steps requirements in a factory? The original HMS Industrial Networks that will ensure that its communication The quick answer is no, it is not the Whitepaper can be downloaded from solutions, and the users’ automation device maker’s sole responsibility to www.hms-networks.com/technologies/ devices and systems, will be secure as IT solve security. But, vendors wishing iot-security and OT converge further in the future. to sell devices in an international In this context, it is important to note marketplace with a wide variation the difference between the meaning of use cases, will have to meet the of a ‘secure’ product and a ‘security’ protection requirements of an product. A secure product is any installation, using security protocols type of product, e.g. an I/O block, a and functions built into the product. proximity sensor, or a PLC – that has been developed with security in mind, A secure infrastructure is based and therefore certain security methods on in-depth security, which itself is and counter measures have been built on several lines of defense – implemented to add a certain level of going down to the component level. But the device vendor will have no Practical cybersecurity measures Discussion during a recent EEMUA seminar on industrial There are many potential benefits to be gained by cybersecurity highlighted several points of concern and moving industrial control system functionality to the the corresponding actions required. cloud, but only if the correct cyber security policies and procedures have been put in place and rigorously The vast majority of Internet of Things (IoT) devices implemented for the existing physical infrastructure and devices with embedded operating systems are and users. insecure. Deficiencies such as long outdated operating systems, hard-coded passwords and outdated, insecure Companies tend to concentrate their efforts on the or otherwise vulnerable libraries have all been identified. early steps in the cyber posture improvement cycle – The issue goes beyond good coding practice on the part namely device inventory, network diagram and risk of the vendors and EEMUA believes that automation assessment and mitigations – which is good. However, vendors need to raise their game and identify the actual given the high likelihood of attack, companies also function of any code that they didn’t write themselves. need to raise the priority of putting in place effective measures for containing and managing an incident Users currently have little appreciation of the value of –many of these measures could be achieved at very logs, how to process and use them and correlate their low-cost. content against events. Handling logs is often regarded as an IT problem, but gaining maximum value requires www.eemua.org OT knowledge. 14 April 2022 www.controlengeurope.com Control Engineering Europe

SAVE THE DATE! 13th October 2022 Manufacturing Technology Centre, Coventry Appetite for Engineering provides the UK food and beverage manufacturing industry with a forum to network with peers and industry experts, while learning about engineering developments and successful implementations. For more information contact: Trevor Southerden 01732 359990 [email protected] www.appetite4eng.co.uk

MACHINE VISION OUT OF THE BOX VISION SOLUTIONS Neil Sandhu explains how integration of machine vision solutions into a wide range of applications is now a much easier task than it has traditionally been. A machine vision automation users can benefit from off-the-shelf Sensor apps project is not something solutions for common tasks, experienced to undertake lightly. Until machine builders can radically reduce Sensor manufacturers have become recently, it would have required their development time and cost. Even software and solution providers. SICK, for expert programming and specialist a few years ago, this would have been example, has developed the AppSpace knowledge. It could take months, and unthinkable. software ecosystem which aims to make significant investment. The final rewards it easy to download a ready-made ‘App’ could be great, but the journey would Hardware innovations – such as CMOS to configure a programmable 2D or 3D often be long and hard. Some projects – alongside a broadening choice of vision sensor. would inevitably stall, as the more technologies including 3D time-of-flight cautious feared ending up with a system snapshot and stereovision, have widened Through AppSpace, crucially, everyone that did not fulfil its initial expectations. the options to generate high-quality benefits from a shared experience. The image data. Vision sensors now have groundwork done for specific customer Now, in just a few years, developments processing power onboard so they can be applications has been exploited to create in both hardware and software have programmed to run applications on the more general, repeatable ‘Apps’. With opened an accessible road to rapid device, or through more localised, edge ready-made, all-in-one, application- integration. While many more end- integrations. specific solutions, there is no longer a need to ‘reinvent the wheel’. New vision sensors make light work of inspection and quality control Thanks to user- incorrectly applied friendly application adhesive; sensing software, even incorrect product inexperienced users orientation or will be able to easily positioning; and and quickly configure counting the number the new Dualis 2D of items present in the vision sensors to target area. perform complex and demanding inspection The ifm Vision and recognition tasks, Assistant application says ifm. software, which is supplied as standard In standard with the sensors, applications, set up incorporates ‘wizards’ can be completed in as which provide detailed little as two minutes, set up guidance for according to the company, and the sensor is capable of many of these applications, and also offers an advanced checking patterns, shapes, areas, dimensions, contours and mode that allows experienced users to access additional even target contrast, either as individual parameters or in functionality. combination. Dualis sensors feature integrated illumination and are available in both infrared and RGB-W versions. With the Typical applications for Dualis 2D vision sensors RGB-W versions items can be distinguished by colour, include detection of missing components in assemblies; while the built-in polarising filter also makes it possible identification of malformed threads, missing holes or 16 April 2022 www.controlengeurope.com Control Engineering Europe

MACHINE VISION Over the past 18 months, SICK has into a stand-alone, belt-picking sensor for for an Automated Mobile Robot (AMR) released Apps for a range of common both industrial and collaborative robots, to pick up a pallet or dolly are pre- vision applications, as well as for more including robot brands such as Universal processed and evaluated on the sensor, complex classifications using deep Robots. then transmitted directly to the vehicle learning. These are now even available control. on high-performance cameras, such as With SICK’s Pallet Pocket Detection the SICK Inspector P611 that can fit into SensorApp, the measured values required With new SensorApps being the palm of your hand. introduced all the time, many common inspection, robot picking, and AMR All SICK’s 2D Inspector P programmable navigation tasks can now be set up in a vision sensors come with a ready-to- fraction of the time it took previously. use Quality Inspection App, radically shortcutting set up time. Now SICK is Ending up with a successful system going even further to develop ready- will still demand careful planning and made ‘plug and play’ systems that arrive it is advisable to consult a manufacturer in a box, along with all the necessary with experience and a broad portfolio. hardware, ready to be powered up. However, now there is more opportunity than ever to reap the rewards of greater The options extend to common robot inspection accuracy, repeatability, reduced guidance tasks such as belt or bin-picking. waste and increased machine availability For static and mobile machines, there that an automated machine vision system is a simple and direct connection to the can bring. plus-cir robot controller or PLC. Systems are quick to teach and ready to use. For Neil Sandhu is UK product manager for example, SICK’s Belt Pick Toolkit App Imaging, Measurement and Ranging at software, installed on the Trispector P SICK. He is also chair of the UK Industrial programmable 3D vision camera, turns Vision Association (UKIVA). to detect highly reflective objects easily. To minimise the effect of extraneous light, the sensors incorporate a daylight filter and, in strongly fluctuating light conditions, they can be configured to take up to five images with different exposure times and automatically select the best of these for analysis. To ensure compatibility with a wide range of applications, Dualis 2D vision sensors can be supplied with standard, wide- angle or telephoto lenses, with all versions available with either Ethernet/IP or PROFINET TCP/IP interfaces. Control Engineering Europe April 2022 17

MACHINE VISION MOVING MACHINE VISION INTO THE THIRD-DIMENSION Find out how true 3D data, with algorithms specifically designed for three-dimensional measurements can result in fewer false positives/negatives. Machine vision systems have Fully-rendered 3D objects generated by hardware and algorithms intentionally traditionally inspected engineered to operate in a true 3D space. objects by reducing the three-dimensional ‘real distortion. This can also lead to scenarios Reveal hidden features world’ to two-dimensional flat images. where some points are occluded or Through careful choice of software, concealed from the camera. Today’s automation engineers can use hardware, and calibration, width sensors to quickly determine the height and length dimensioning data can Today, presenting data as 3D point of points in a scene and use that data be extracted from 2D machine vision clouds offers a solution to avoiding to create a richer description of a 2D images. perceived distortion and for capturing image. The addition of this height However, for many industrial multiple Z values for every X, Y value – representation takes data beyond 2D to applications that involves inspecting or an important consideration for convex 2.5D. 2.5D data offers more than pure assembling objects, height information parts, for example. Although system 2D data, but it only represents a portion must also be considered to succeed. designers are taking advantage of the of what humans can see. 3D machine vision is able to capture lower costs of 3D hardware to solve and process width, length, and height complex part inspection and assembly Generally speaking, systems that information from objects in order to tasks, these same solutions suffer from a visualise data in 2.5D encode height address these applications. lack of 3D algorithms and tools designed information using false colour, similar The vast majority of industrial specifically for high-density to the way a thermal image presents applications involve guiding, identifying, temperature information through gauging, or inspecting objects that 3D points clouds, often referred different coloured pixels. These maps are 3D. For these tasks, machine vision to as true 3D. Now, advanced image limit a vision system’s capabilities system designers struggle with how processing solutions are combining because they are difficult to interpret much cost and complexity to add to cost-effective 3D imaging hardware and make it challenging for operators to the system to achieve their automated with powerful 3D algorithms. This process the details of a 3D part. inspection or assembly goals. For integration results in greater accuracy example, can the key measurement and enables the location of hidden Furthermore, height maps cannot be made, or assembly be performed or occluded defects. It also makes the accommodate rotation and tilting with using only a 2D image of a 3D object? operator’s job easier by displaying the same accuracy as a full 3D point If a measurement involves an object fully-rendered 3D objects instead of cloud because 2.5D data is tied to the that has significant variation in height 2.5D images where height is conveyed viewing direction of the receiving across the part, then height information by colour. sensor and the underlying 2D grid must be considered for an accurate (e.g. conveyor surface). This leads to measurement. The next question is how much height information does the system really need? Can ‘minimal’ height information be collected – for example, pixel height as perceived from the camera’s location? This produces accurate height measurements of the first point along the optical axis (2.5D height maps), but accuracy decreases as the pixel moves farther from the axis due to perceived 18 April 2022 www.controlengeurope.com Control Engineering Europe

MACHINE VISION the possible introduction of perceived 3D interpretation distortions and the potential for lower 2.5D interpretation accuracy vision inspections due to the introduction of perspective distortion. Example of 2.5D approach compared to 3D solution: As a coffee mug is rotated, 2.5D tools will interpret the concave interior as flat, whereas true 3D tools will pick up on the curvature and A true 3D vision system instead generate a more accurate rendering of the object. provides a point cloud, which is a collection of data points from a scene Building true 3D tools circle region. As illustrated above, the that is independent from the receiver or ability for true 3D data sets to represent the underlying grid, allowing the system Despite the benefits of a true 3D multiple height values for each X,Y to fully render the object as it appears in point cloud when making automated location and apply tools designed for 3D the real world. Consider this – in a 2.5D measurements, adoption of 3D systems environments simplifies system design representation, every X,Y position on the for machine vision inspection has while infusing accuracy into the final grid will only have one Z representing been slow due to concerns about cost, results. the height. complexity, and performance when compared to 2D inspection solutions. A Recent advances in semiconductors In a 3D point cloud, all points have true 3D integrated solution can address and sensors are driving down the independent X,Y,Z values, so any X,Y these obstacles. cost of acquiring a machine vision position can have multiple Z values. image and this is enabling designers True 3D algorithms are designed to add more cameras to their machine This additional information enables for 3D geometric structures – such as vision solutions, giving them rich accurate representations of shapes cuboids, spheres, and cylinders. dimensional data to make more accurate with hidden features, such as concave measurements and improve assembly. objects. Processing data in 3D allows These geometric structures lend To handle the demands of these for information taken from different themselves to the defining subsets increasingly complex automation tasks perspectives to be fused to inspect of the 3D point cloud as regions of in a 3D world, designers need access to features, such as indentations and interest, allowing for regions of interest true 3D algorithmic tools. screw holes, while providing a realistic to be both simple and effective in 3D. depiction of an object for more intuitive Conversely, designers must account for Much like colour machine vision 15 operator analysis. the distortion and hidden features that years ago, the world is adopting 3D may occur when using a 2D algorithm machine vision because it mimics human Using a 3D point cloud also provides on a 2.5D image. This requires the perception, providing intuitive ways flexibility. 3D images can be used to region of interest to be aligned with the for people to interact with modern create 2D images from their pixel supporting surface under the object. machinery. These future 3D vision intensity values and from multiple systems will require multiple sensors perspectives. They can also be used to Consider the case of making an arc and dense true 3D point clouds to create highly accurate 2.5D false colour measurement of a convex part. A 2.5D handle more demanding assembly and images. image interpolates the data it cannot inspection tasks. plus-cir directly access. Accuracy differences Attempting to merge two different between a 2.5D tool that is interpolating This article was taken from a Cognex 2.5D images of the same object taken and estimating height values could be whitepaper entitled ‘True 3D Vision for from different perspectives is a non- completely right or wrong depending on improved accuracy, ease of use over trivial task for software. Additionally, if if it’s a convex- or concave-shaped part. traditional SE 2.5D solution’. two pixels from two separate images Similarly, applying a 2D circle tool to a are close to each other, the system may 3D data set will result in an oval, not a have to interpolate Z values due to differences in the relationship between the underlying grids. However, when using 3D data, it is easier for the software to combine the two datasets in a common global coordinate space for inspection, assembly, or post-inspection rework operations. This can be done at minimal computational cost and without introducing computational defects in the scene. In short, a true 3D point cloud is a ‘super set’ of data that allows for results in different dimensions and can be used with various tool sets. Control Engineering Europe www.controlengeurope.com April 2022 19

5G FOR INDUSTRY SECURE REMOTE ACCESS VIA PUBLIC 5G NETWORK Sander Rotmensen looks at the potential for 5G in industrial applications where remote access to distant equipment is required. Since the 1970s, mobile wireless network is indeed the right answer. However, the full implementation networks have enjoyed With 5G, a new mobile of these three main scenarios is not gains in performance with possible simultaneously within the each new generation. Now communications standard was same network. A network can only the 5th generation of the mobile developed for the first time which took be designed and configured in such a communications standard (5G) is into consideration industrial use cases way to fully support one scenario. For being introduced. Its main benefits are – and it is already being deployed. 5G example, it can offer either the highest higher bandwidth, greater reliability, brings three main scenarios – enhanced possible data rate or the lowest lower latency, and lower power Mobile Broadband (eMBB), Ultra- possible latency. Both at the same time consumption. Reliable Low-Latency Communications are not possible. (URLLC), and massive Machine-Type This new technology seems Communications (mMTC). These Implementation approaches predestined for use in industrial scenarios serve different application applications where the requirements areas – eMBB is bandwidth-oriented This is where the necessity of different for wireless networks are different and URLLC supports the requirements implementation approaches for 5G from the ones for public, commercial of industrial IoT applications such networks comes into play. A public 5G mobile phone networks. as low latency with best possible network is typically set up to provide reliability. mMTC is used for high bandwidths for video telephony, Industrial private 5G networks are the applications which require low power video streaming, and other data- key to success here, but for applications consumption and contain a large intensive applications. High bandwidth requiring remote access to distant number of connected devices. is a key argument advertised by mobile machinery or equipment, a public 5G providers who are already introducing 5G in a number of countries around the world. However, for the majority of applications in a factory, bandwidth plays a minor role. The emphasis here is mainly on reliability and ultra- short latencies when it comes to communications. Therefore, private networks are an integral part of the 5G standard. They enable companies to establish their own local 5G networks and adapt them to their mission- critical applications. For this purpose, the German Federal Network Agency (Bundesnetzagentur) has reserved part of the frequency spectrum for use in private, local 5G networks. This spectrum can be obtained for the setup of local campus networks for a reasonable fee. In addition to requiring local wireless connectivity, the industry is also increasingly demanding remote access to distant machinery and equipment, 20 April 2022 www.controlengeurope.com Control Engineering Europe

5G FOR INDUSTRY Remote maintenance of standard production machines at different end customers with SINEMA Remote Connect. for example for remote maintenance. With the wireless technologies of security. The user can choose whether In those applications, communication 5G, significantly more bandwidth, with the system is to be hosted locally or on usually takes place over great higher reliability, is made available at the Internet and which machines or distances. Public mobile networks the edges of the radio cells and the which section of the plant are accessible enable access to distant participants, average data rate for users within a to service technicians. even in other countries. Moreover, radio cell also increases. service technicians can connect to the In addition, a central user machinery to be serviced via mobile Data-intensive applications management solution with optional communications while en-route. Active Directory connection – a suite By increasing coverage and bandwidth, of directory-based identity-related Public 5G networks are an important 5G networks make it possible to run services – facilitates the management pillar for remote access and remote data-intensive applications even at of rights. In combination with the maintenance solutions. The advantage the edges of radio cells, which would high bandwidths, the stability of of 5G lies in the flexibility of the have been difficult to do with previous 5G networks, and the simplicity of technology, which is an integral part mobile wireless networks – for example, rendezvous server solutions, a reliable of the standard. Very high bandwidths the reliable and stable transmission of and stable remote access via mobile can be made available to users in large amounts of data for firmware communications can be realised even in urban areas through small radio cells updates which reduces the need distant areas. and high frequencies. In rural areas, for on-site service calls. To make the radio cells have to cover a larger area connection of the remote stations No matter where the journey which is why lower frequencies are easier, so-called rendezvous servers are goes – it is only a matter of time used and the available bandwidth is used. Siemens management platform until 5G will establish itself in the divided among more users. Particularly for VPN connections – SINEMA Remote industry. Its flexibility, with its different at the edges of radio cells, massive Connect – provides just such a solution. implementation approaches – private losses in bandwidth and stability It enables convenient and secure access and/or public – makes this standard the of the communication connection to remote machinery or equipment most versatile mobile communications can be expected using Long-Term – even if they are integrated into solution for the industry. Solutions Evolution (LTE) or Universal Mobile other networks. The server application previously not feasible are now within Telecommunications System (UMTS). enables an easy management of VPN reach, and applications no one dared to However, it is precisely in these remote tunnel connections between control think about may be realised in the near locations where a stable broadband center, service technicians, and remotely future. plus-cir transmission is required for remote installed machinery or equipment. The maintenance or video streams, e.g., of rendezvous server solution offers the Sander Rotmensen is head of water stations. user a high degree of flexibility and Industrial Wireless Communication Products for Siemens Digital Industries. Control Engineering Europe www.controlengeurope.com April 2022 21

SUSTAINABLE ENGINEERING SOLUTIONS DRIVING UP SUSTAINABILITY WITH YOUR COMMUNICATIONS NETWORK Tom Burke explains why selecting the right network technology is a key step in enhancing sustainability in manufacturing. Sustainability is a key aspect to consider during the development and upgrade of manufacturing facilities. It is important, therefore, that machine builders pay close attention to the network technology used when providing automation systems to enhance energy and resource efficiency as it will determine the advantages that can be unlocked. By employing a solution that supports transparent, convergent communications, ambitious green targets can be met. Future-looking industrial communication networks incorporate enabling technologies that are designed to support digital manufacturing strategies, helping companies optimise and intensify their processes. In addition factory where all application levels are eliminate inefficiencies and increase to driving up profitability, they can interconnected. Consequently, a facility’s productivity. Thanks to automated also greatly contribute to reducing the Bill of Materials (BoM) is reduced, which feedback and feedforward mechanisms, environmental impact of shop floor ultimately leads to decreased material the operating conditions can be operations. usage. Fewer parts and less materials, adjusted on-the-fly in line with the A key example of such a technology in turn, lower the infrastructure-related results obtained. This makes it possible is CC-Link IE TSN, which uses Time- environmental impact of the factory to reduce cycle times, energy and Sensitive Networking (TSN) to transition and its products. resource utilisation, all aspects which are towards convergent architectures for Convergence enabling network crucial to minimising the environmental data sharing. technologies also have a role to play. impact of manufacturing activities. Reducing bill of materials CC-Link IE TSN, for example, can CC-Link IE TSN can help machine help manufacturers gain a unique builders incorporate the latest Perhaps the most obvious result of understanding of their shop floor technologies into their projects, employing a convergent architecture operations. Automation specialists enhancing their offering to customers for industrial communications is should therefore create setups that can and competitiveness in the marketplace. simplification, as all nodes are part generate large volumes of highly visible This network technology can, for of a single network, rather than and accessible data while also making it example, support the creation of multiple dedicated systems. In effect, available for processing by information highly accurate digital twins and CC-Link IE TSN merges data sharing technology (IT) and operational cyber-physical systems (CPS) to optimise for operational technology (OT), such technology (OT) based systems. By process efficiency as well as productivity. as control and safety communications, doing this, they can deliver solutions Ultimately, businesses can effectively with higher enterprise-level information that help end users obtain holistic increase the sustainability of their technology (IT) structures. overviews and accurate predictions – for operations in a highly profitable, By creating automation solutions that example, end product quality forecasts. futureproof manner. plus-cir utilise this simplified setup, machine By shedding light on the running builders can decrease the number processes, it is possible for customers Tom Burke is global strategic advisor of components required to create a to gain actionable insights on how to at CLPA. 22 April 2022 www.controlengeurope.com Control Engineering Europe

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IIoT TECHNOLOGY RUGGEDISING THE SUPPLY CHAIN WITH IIoT TECHNOLOGY Eric Wendt discusses how IIoT technology innovations are helping transform the global supply chain. T he supply chain has been shortcomings in the supply chain manufacturing industry and the supply continually evolving over the – mainly, a lack of robustness. The chain as a whole cannot be understated years with the rise of advanced process had become so centralised that – it enables new functionalities technologies like sensors and when an event affected even just one and more intelligent, predictive, Artificial Intelligence (AI), with the manufacturer, it had a broad impact and proactive processes that lead to goal of keeping the supply chain lean. around the world. When demand enhanced efficiencies. Lessening the amount of inventory in came back rapidly, the supply chain was the pipeline meant using components not robust or diverse enough to bring Improved asset tracking and raw materials in the most efficient sufficient raw material into factories, and cost-effective ways, but when the and many of them shut down entirely. IIoT is bringing sensor usage to a new COVID-19 pandemic hit, it caused global The labour shortage only added to level, primarily when it comes to asset supply chain disruptions the like of the disruption – with closures or staff tracking for assessing where assets which we have never seen before. shortages causing delays in steps along are in the supply chain at any given the entire supply chain. time. For example, if a container has An initial dramatic drop in end an asset tracker, a customer can see if product demand sent a shock through Technology such as smart sensors that container is still on a ship or if it the system, and later on in the pandemic and AI can help create a more robust has arrived at a port. But, only knowing we experienced the exact opposite system and fix many of the cracks in the the location of one particular asset is issue amidst a surge of demand for supply chain revealed by the pandemic. not sufficient when it takes, say, 20 products and a delivery and inventory The impact the Industrial Internet of components before actually starting to storage shortage. This revealed major Things (IIoT) has already had on the produce a product. 24 April 2022 www.controlengeurope.com Control Engineering Europe

IIoT TECHNOLOGY Since manufacturers are often components needed for production. achieve real-time improvements. managing multiple products, An AI system can use data from the components and raw materials, IoT sensors while pulling in third-party What’s ahead? sensors allow a unified view of all of data like weather information and port the data coming from each of these information to predict delays and when The intersection of real-time data and AI different containers. Aggregating all all of the necessary components will technologies, including the application of this data so it is more meaningful arrive. Edge computing – processing that of new sensors, has created numerous to both the business, and often the data collected by sensors closer to the new avenues for insight into the supply consumer who is tracking their order source rather than communicating it chain, and will continue to fuel the from home, is also crucial. back to the cloud – also greatly increases future of how manufacturing works. data efficiency. Beyond location tracking, many The IIoT has offered so much new different sensors are used for a Because there are so many data points functionality and much of it is becoming variety of products to provide more from the sensors and outside parties, relatively inexpensive to implement data throughout the supply chain AI can usually do this analysis quicker – such as low-cost processors. From a and improve asset tracking – from and more accurately than a human, cost perspective, it is easier now than it environmental sensors that track and this intelligent, automated system has ever been to integrate sensors into temperature, humidity and pressure, to allows workers to spend less time on the different types of products to monitor positioning sensors like accelerometers mundane, manual tasks. Instead, they data that was not financially feasible and gyroscope sensors that track a are freed up to do more creative, skilled in the past. For example, vision sensors, product’s position and orientation. With work like managing the system and their which are essentially cameras, are this kind of data, you can pinpoint the internal customers and providing human advancing rapidly and AI can analyse all time and place a product may have been judgment calls when necessary. of the data coming out of each pixel in damaged on route. the camera with improved software. It is important to note that this data Asset trackers and sensors are management system is not taking the All of the devices in our lives – from becoming less expensive, so there is place of workers. Rather, it is feeding cars to health trackers to industrial more widespread usage. With that more meaningful information to automation – have become smarter and increase in the number of sensors, data the individual managing the system. more connected with the use of sensors management becomes more important. Ultimately, data management using used in conjunction with AI, machine AI brings new value through increased learning and edge computing. As more Data management using AI efficiency and accuracy across the board. and more data is collected from sensors, systems will become more complex and If an operations manager needs to Digi-Key’s role in this supply chain the use of AI and machine learning determine whether a factory can run transformation is largely on supplying will be critical to performing higher- production at a certain time, they need hardware, but as a company, we are also level analyses of all of the information to know if all the necessary components focused on software functionality – both being gathered. These innovations will will be at the factory in time. In the past, internally and with customers. Digi- continue to give us a more holistic view this has been something of a guessing Key’s biggest advances recently have and control of the supply chain, and game with little visibility into accurate, come from better tracking, pricing and hopefully help prevent disruptions in the real-time information needed to plan purchasing tools, and with these systems global supply chain like those we have production runs. in place we can quickly and easily experienced in the last few years. plus-cir exchange and analyse data throughout The good news is that due to IIoT the warehouse and beyond. This new Eric Wendt is director of automation it is now possible to utilise AI to easily software and data will increase operator and electrical products for Digi-Key aggregate and analyse all of the asset productivity, reduce quality defects and Electronics. tracking data available for the different Control Engineering Europe www.controlengeurope.com April 2022 25

PLCs PLCS REMAIN ESSENTIAL IN MODERN AUTOMATION Programmable logic controllers (PLCs) often fill an essential role in automation by communicating, monitoring and controlling automated processes and will continue to do so in the IIoT era, says Aaron Block. Since programmable logic Image courtesy Inductive Automation. while maintaining open data flow. controllers (PLCs) ushered Sidestepping network connectivity issues in Industry 3.0 over 50 years interoperability. Modern PLCs are an that might result in massive loss of data, ago, they have remained one integral part of these IIoT networks, MQTT’s store-and-forward capability of the cornerstones of automation. with many of the recent advancements collects data on the PLC itself for up to PLCs are industrial computers used centering around the onboard seven days and when the network is to control various electro-mechanical implementation of IIoT-enabling reconnected, backlogs the information processes in manufacturing facilities technologies, giving the device a to a server. and automation environments. PLCs more active role in the overall system often fill an essential role in supervisory architecture. Contrary to the outdated Do more with your PLCs control and data acquisition (SCADA) notion that PLCs are only useful for systems, acting as the physical interface basic I/O, newer models possess diverse While critical, PLCs are only one part between devices on the plant floor and communication capabilities, including of a successful data management human-machine interfaces (HMIs), as cloud connectivity and edge computing, architecture. To fully unlock a system’s well as communicating, monitoring and making them powerful tools whether on capabilities, you need to connect controlling automated processes. the plant floor or in a remote location. PLCs with best-of-breed solutions. Implementing a robust automation From food and beverage production PLCs power the edge software like Ignition by Inductive to water utilities to manufacturing, PLCs Automation not only collects and logs are integral components in virtually Particularly in industries such as oil data from virtually any PLC, but it also every area of modern automation. Using and gas, gathering edge-of-network provides tools for performing advanced real-time programming, PLCs are able to data can be prohibitively difficult analytics to help your organisation capture input data from machinery on due to harsh environments or lack of make more informed, data-driven the plant floor and apply user-created infrastructure. Edge computing strives decisions. plus-cir program logic in response, producing to overcome these difficulties by moving output data or commands to run a PLC polling closer to the source, reducing Aaron Block is marketing content writer variety of applications alongside tools latency while increasing reliability. at inductive Automation. like structured query language (SQL) databases. Edge-of-network PLCs often employ This article has previously appeared on IIoT-ready communication protocols www.controleng.com IIoT without PLCs? like message queuing telemetry transport (MQTT), which uses a publish- As organisations continue to digitally subscribe model to save bandwidth transform by implementing Industry 4.0 technology, the methods for leveraging PLCs have likewise progressed. In modern SCADA systems, data is the focal point, but the traditional poll-response method for collecting data from PLCs is not always sufficient. In more complex or dispersed systems, PLCs are still a cornerstone, but they can support wildly different architectures. Industrial Internet of Things (IIoT) technologies have afforded organisations newfound levels of 26 April 2022 www.controlengeurope.com Control Engineering Europe

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