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VOL 07 | JUN-JUL 2014 | ` 100

www.AandD24.in

Driving profitability, speed & visibility

A U TO M AT I O N & D R I V E S

EqUIpMENT lIfEcyclE MANAgEMENT

fOcUS pharmaceuticals & packaging P. 36, 42, 48, 54

ROUND-TABlE cyber security in industrial automation P. 30A&D - InterviewUlrich TurckManaging Director, Hans Turck GmbH (p.28)

Coverpage_Jun-Jul_cover.indd 1 6/19/2014 3:21:26 PM

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©2012 National Instruments. All rights reserved. LabVIEW, National Instruments, NI, and ni.com are trademarks of National Instruments. Other product and company names listed are trademarks or trade names of their respective companies. 07926

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Rapid change in the economic conditions is driving the way products are being made and even the products themselves. Products and processes are increasingly getting complex. Moreover, while product variations expand, product life cycles contract. So, the challenge is to get consistently better products to market faster, while lowering manufacturing costs and maintaining profit margins. Also important is access to new technology know-hows such as leading edge automation solutions for the simplest to the most complex industrial applications and applicable information technology expertise. To do this, most manufacturers are restructuring, refocusing and restrategising their operations and staying flexible. But this is not enough; to stay competitive, manufacturers must seize every opportunity to increase productivity and throughput, reduce costs, improve product quality and reliability, while managing change on an almost daily basis.

The Cover Story in this issue deals with some of the areas that can quantify improvement initiatives for reducing operational costs, boosting efficiency and bottomline, with the help of appropriate strategies and advanced technology solutions.

The online world is under constant threat with hundreds of new worms and viruses attacking the computer systems. Even industrial automation and control systems are not immune to cyber attacks. The Round-table feature discusses the challenges in protecting the systems and development requirements of an aggregated security solution to defend against cyber security threats and vulnerabilities that affect industrial automation systems.

Happy reading!

Shekhar JitkarPublisher & Chief [email protected]

Quantifying improvement initiatives

3a& d i n d i a | J u n - J u l 2014

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Anup WadhwaDirector – AIA (Automation Industry Association)

P V SivaramMD – B&R AutomationMember – AIA

Anant MaheshwariManaging Director Honeywell Automation India

Ganapathiraman GVice President & GM (South and South-East Asia)ARC Advisory Group

Ravi AgarwalDirector, Pepperl+Fuchs (Factory Automation)

Raj Singh RatheeManaging DirectorKuka Robotics India

Jasbir SinghVice President – Electrical & InstrumentEssar Project Management Consultants

Dr KLS SharmaAdvisor Automation Education & Training

Mandar PhadkeCEO, Abhisam SoftwareFormer Head – Process ControlLanxess India Pvt Ltd

Arcot RajabahadurAutomation Consultant

Thampy MathewChairman, Fieldbus Foundation IndiaRegional Sales Director, Pepperl+Fuchs (Process Automation)

overseas Partner:

China, taiwan, Hong Kong & South-east asia

editorial_Jun-Jul14.indd 3 6/18/2014 8:41:42 PM

CO N T E N T S

Market Management

Cover Story20 equipment lifecycle mAnAGement

This feature addresses the demands of global equipment manufacturers to identify targeted areas in their business that need improvement

28 “pRODuct DeVelOpment StRAteGieS

neeD tO Be mORe plAtfORm-fOcuSeD”

Interview with Ulrich Turck, Managing Director, Hans Turck GmbH

30 ROunD-tABle

Cyber security in industrial automationThe article addresses the security challenges in industrial automation systems and approaches towards the integrated solutions

Pharma & Packaging 36 numeRicAl SimulAtiOnS fOR

cOntinuOuS mAnufActuRinG Of ActiVe

pHARmA inGReDientS

The article talks about multi-physics numerical simulation evolving as a popular technology in the pharmaceutical industry

42 BliSteR pAcK pRODuctiOn SyStem

The article highlights the latest pharmaceutical packaging processes used in blister system

48 OptimAl Slip RinG SOlutiOn

The article discusses latest solutions developed to suffice packaging challenges in the food processing industry

54 Open, ADAptABle & mODulAR SAfety

SOlutiOn

A case study focussing on safety-driven packaging solutions developed by Pilz for Oystar Group

Focus

10 neWS

16 “tecH-AiDeD efficiency impROVementS”

Interview with Babu T K, Founder & CEO, Elmeasure India

18 “pRice iS tHe mAin cHAllenGe in inDiA”

Interview with Gaurav Gupta, Managing Director, Hummel Connector Systems

eVent RepORt

78 From production automation to professional service roboticsPost event report on AUTOMATICA 2014

80 Reimagining what’s possiblePost event report on Solid Edge University 2014 held at Atlanta, USA

content page_Jun-Jul.indd 6 6/18/2014 9:49:00 PM

CONTENTS

f ielDBuS & netWORKS

58 Top 10 Fieldbus myths bustedA feature detailing on the ten myths concerning Foundation Fieldbus technology

64 Getting connectedAn application story on how Nagel Precision connected their honing machines to industrial networks with the help of Anybus X-gateways

68 SpeciAl feAtuRe

Becoming smarter & efficientThe article talks on the latest technology trends in test & measurement instruments

Technology

New Products

84 Data loggers for sensitive freight; Packaging automation technology; Thermocouple terminal blocks; Photoelectric sensors

85 Industrial PCs for rugged industrial applications; Prepaid energy meter; Intelligent tool holder management; Complete drive systems

86 Plant overview & plant structure software; Vision solution for intelligent bin picking; Differential pressure transmitter; Ethernet capable adaptor

87 USB converter for optical sensors; Measuring light grid; V/f drives; Brush motors

Columns

07 Editorial08 Contents88 Highlights - Next issue88 Company index

70 ReneWABle eneRGy

Automation in renewable energyThe feature deals with how automation vendors are addressing challenges in providing sustainable automation solutions to renewable energy sector

74 ROBOticS & HAnDlinG

Innovation in smart roboticsA feature on how the growing importance of robotics technology has changed the automation industry

83 tecH-tAlK

Cabling solutions for food packagingThe article discusses the latest developments in cabling technologies for food & packaging industry

Advt

Cover image courtesy: SHUTTERSTOCK

Advt

content page_Jun-Jul.indd 7 6/18/2014 9:49:14 PM

marke t | news

10 a&D I nd i a | J u n - J u l 2014

Honeywell launches LEAP project services

Honeywell Process Solutions recently launched LEAP project services to

help manufacturers in the processing industries get their plants up and

running faster at a lower cost. LEAP combines Honeywell Process Solutions

proprietary hardware and software, virtualisation and cloud engineering to

give users greater scheduling flexibility while reducing risk and total

automation costs by up to 30%. Multiple industries can benefit from an

estimated 80% reduction in costs related to

unnecessary rework. These features can also

help reduce avoidable schedule delays by up

to 90%. “Automation projects are increasingly

difficult to manage, especially as

implementations become larger and more

complex with the requirement to complete

quickly and efficiently,” said Vimal Kapur,

President, Honeywell Process Solutions. “LEAP

turns project execution workflow on its head,

simplifying what has traditionally been a long

and expensive process and enabling

measurable time and cost savings, so plants

can focus on the end goal of getting up and

running quickly.”

> MORE@CLICK ADI03471 | www.AandD24.in

Fieldbus Foundation usability initiative


Vimal Kapur, President,

Honeywell Process

Solutions, assures that

LEAP will enable a cost

saving process

Fieldbus Foundation recently conducted a press meet at the 2014 Hannover

Messe, where it announced a new initiative to further

enhance its open, non-proprietary Foundation Fieldbus

technical specifications. New features to technical

specifications will improve the usability of the

technology, by making the digital Fieldbus automation

experience easier than conventional analogue control

systems. The technical teams have been determining

how Foundation technology can best address the

stereotypical “3.00am device replacement” scenario,

where the user needs to get the process back online

as quickly and effectively as possible. Just as 4-20 mA

analogue devices are essentially process variable (PV)

interchangeable, the new initiative offers users’ direct

access to the PV in Foundation devices and reduce any potential complexities

in device replacement.

A simple device set-up that has no need for Device Description (DD) files

will allow the easy replacement of one device with an alternative device, to

ensure an efficient and fully flexible device replacement in all planned and

unplanned situations. Once complete, the PV interchangeability development

will be incorporated into an upgrade of the Foundation H1 Interoperability

Test Kit – ITK 7.

Foundation technical specifications now enable

host and device suppliers to offer backwards

compatibility to their users in order to simplify

device replacement. The incorporation of DD

templates also provides an interoperable way for

instrumentation companies to offer a variety of

application settings for devices. Suppliers can

embed the templates in their DDs from the factory

floor. This will make it quicker and easier for end

users to access a correct offline configuration. They

also gain the freedom to utilise a newer device with

an existing device configuration without the need

for new DDs. Recent updates of the Foundation specification include

additional advanced support for fieldbus device replacement and backwards

compatibility, Device Description (DD) templates, field diagnostics and

alarm/alert integration. The ability to utilise these enhanced features is

included in the Foundation’s new Host Profile C.

OMRON opens its first Automation Centre (ATC) in India

OmrON automation recently opened its first ATC in Mumbai, India. The

centre was inaugurated by the

company’s key leaders from the

industrial automation team from

Japan, Singapore and India. Spread

over 3750 sq ft, the facility hosts

more than 10 experts as software,

hardware and application specialists

dedicated to the ATC. “This initiative

is a part of our ‘Asia Hotspots’

strategy, one of its important tasks

being to consolidate our foothold in

India, which is indeed a highly

promising market for OMRON

Automation,” said Yutaka Miyanaga, Senior Managing Officer, Company

President—Industrial Automation Company, OMRON Corporation, Japan.

The centre aims to showcase the company’s expertise in sensing & control

technology, so that the customers are able to test their new ideas,

experience and understand how they can bring more improvements to their

current manufacturing set up and can become more competitive in their

respective fields in the industrial automation domain.


The centre aims to showcase the

company’s expertise in sensing &

control technology

Market_news_Jun-Jul14.indd 10 6/18/2014 5:40:41 PM

marke t | news

12 a&D I nd i a | J u n - J u l 2014

LabVIEW now compatible with LEGO MINDSTORMS EV3

National Instruments has recently added LabVIEW system design software

to program the LEGO MINDSTORMS EV3 robotics platform. The software is

a free download and is available for education & retail. It helps students,

engineers and hobbyists to create

programs that communicate with and

control the EV3 brick with LabVIEW. Since

the software has connectivity with

thousands of sensors, devices and

systems; users of all experience levels

can quickly design a complex and

powerful robotics project, which makes

this platform ideal for science, technology,

engineering and math (STEM) education.

The software included with EV3 products

from LEGO is also based on LabVIEW, the

same programming software used in virtually every industry to power

engineering challenges such as the Red Bull Stratos supersonic free fall

project and the CERN Large Hadron Collider. Users can connect to the

industry version of LabVIEW for additional functionality with LEGO EV3.

Students who learn the software are using the same programming tools

used by the world’s most innovative scientists and engineers.

The LabVIEW Module for LEGO

MINDSTORMS is available for

education and retail


US green building body to support LEED in India

US Green Building Council is expanding its support for Leadership in

Energy and Environmental Design (LEED) in India. “Since the buildings save

energy, water and precious resources,

they are our first line of defence in the

worldwide fight to slowdown the

impacts of climate change and

promote wellness. The multinational

architectural, engineering and

construction companies that are

leading the building boom around the

world were early adopters in the US

and they are now applying its

principles and benefits in more than

150 countries,” said Rick Fedrizzi, President, CEO & Founding Chair, USGBC.

According to a report released by the Council, India ranks third for the most

LEED-certified space globally, with nearly 12 million sq m. The system is

the most widely used rating system guiding the design, construction,

operations and maintenance of green buildings. Project teams in more than

150 countries have implemented this to create structures that cut

greenhouse gas emissions and lower utility bills for building owners through

reduced energy and water use.


Siemens 1st in PLM software ranking

Siemens has been recognised recently as the market presence leader in

the collaborative Product Definition management (cPDm) market segment

for the 13th year in a row, and in the Digital

Manufacturing market segment for the ninth year

in a row by leading product lifecycle management

(PLM) management consulting and research firm,

CIMdata Inc. Siemens’ PLM software business

unit addresses CIMdata’s cPDm category with its

Teamcenter portfolio, the world’s most widely

used digital lifecycle management software,

while its Tecnomatix portfolio is the most widely

used software in the digital manufacturing

market segment. “Our company has a consistent

track record of leadership in key areas of PLM,

including cPDm and digital manufacturing,” said

Chuck Grindstaff, President & CEO, Siemens PLM

Software. “This latest report illustrates our

commitment to maintaining leadership in these

two disciplines, which are of critical value to our

customers. In addition, our strong focus on

simulation and analysis will help our customers continue to address the

increasing complexity of tomorrow’s product innovations.”

Chuck Grindstaff,

President & CEO, Siemens

PLM Software says that

the company will maintain

leadership in cPDm and

digital manufacturing


Geometric signs contract with Volvo Cars

Geometric Limited recently announced that it has signed an application

maintenance contract with Volvo Cars, Sweden, covering major applications

from Computer Aided Design (CAD) and Product Lifecycle Management

(PLM) landscape. The company has been partnering with Volvo Cars for

their global engineering and manufacturing needs since

2010, and now has extended its application maintenance

services (AMS) engagement to include additional CAD

and PLM applications for new product development &

manufacturing engineering. It will deploy its proven

application maintenance services framework, AMS4E

based on well-defined 4E methodology, which is

designed to enable, ensure, enhance and evolve the

targeted PLM, engineering and manufacturing IT

applications to deliver value to Volvo. The company will

also leverage its extensive understanding of Volvo’s

product development IT landscape combined with its

excellent ISV relationships and experience in PLM to

support Volvo’s new product development programs.

“This contract is a testament to our commitment to

deliver the best, and Volvo’s trust in our ability to

consistently bring innovation to their CAD and PLM

applications,” said Nitin Tappe, COO, Geometric Limited.

Nitin Tappe, COO,

Geometric, said

that the contract is

a testament to the

commitment to deliver

the best, and Volvo's

trust in their ability

to consistently bring

innovation



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14 a&D I nd i a | J u n - J u l 2014

Wheelabrator holds symposium in Indore

Wheelabrator had recently organised a symposium on “Advancements in

shot blast and shot peening solutions” in Indore for various process

industries focusing on

construction, foundries and

auto industry, etc. With over

45 delegates from 18

different companies

attending this symposium,

the session was conducted

by Jagadish Kulkarni, VP –

Sales & Marketing, W&A. The

technical session included

an interactive Q&A session

with participants asking

questions on various aspects

of shot blasting process such as shot size, surface finish, shot peening and

machine maintenance. “The Indore manufacturing belt (Pithampur, Dewas

and Indore) is one of the important manufacturing hubs in Central India

with companies such as Volvo-Eicher, Caparo, Kirloskar Brothers, Gajra

Gears, Mahle engine, to have set up their manufacturing units,” said

Kulkarni.

ABB delivers green ester-filled distribution transformer

aBB’s global technological resources were recently picked by Tata Power

to develop and deliver the green ester-filled

distribution transformer. This formed a part of a

compact substation that was commissioned by

ABB India. “A transformer that catches fire

cannot be redeployed. More importantly, it puts

at risk the people in the vicinity. Ester-filled

green transformers are sustainable, environment

friendly and a safe alternative, especially for

residential areas,” said Pitamber Shivnani, Local

Division Manager - Power Products division, ABB

India. The success of the project was a result of

combined efforts of the sales and technology

teams at ABB India. In close coordination with

Tata Power and using its global expertise, the

company developed the 990 kVA 11/0.433 kV

ester filled green distribution transformer, which

was manufactured at the newly inaugurated oil-filled and dry type

distribution transformer factory at Savli, near Vadodara. The company’s

natural ester alternatives to mineral oil filled transformers have found

success across varied markets in Europe and America.

In close coordination with

Tata Power and using its

global expertise, the company

developed the 990 kVA

11/0.433 kV ester filled green

distribution transformer


The technical session included an

interactive Q&A session with participants

asking questions on shot blasting process


Industrial production grows by 3.4% in April 2014


After falling for two months, industrial production grew at a 13-month-high

rate of 3.4% in April 2014, driven mainly by

electricity generation and manufacturing. The

numbers, if sustained, could push up

economic growth, stuck below 5% for two

years now. However, economists are still not

certain about the recovery in manufacturing,

as it is driven by volatile capital goods.

According to the official data, the country’s

industrial output, as measured by the IIP, had

declined to 0.5% in March and 1.7% in

February, 2014. Industrial output grew to just

1.5% in April last year and contracted to 1.3%

the previous year. According to the economists,

slow IIP growth rate in April last year magnified

the expansion this year, in what is technically referred to as the base

effect.

Electricity generation in April this year, surged at a seven-month-high rate

of 11.9%, compared with 5.3% the previous month. Mining grew 1.2%,

after contracting 0.3% the previous month. Manufacturing, which has the

highest weight of 75.5% on IIP, grew at 2.6%, the fastest in nine months.

Had it not been for a revision in the January

data — from a 0.5% contraction to a 0.2%

rise, manufacturing output would have

declined for six months before April this year.

Its production grew 1.8% in April 2013 and

shrank 1.8% in April 2012. Sustaining

momentum in industrial production would

depend on the government’s resolve to

fast-track stalled projects, revive the

investment pipeline and lift consumption

demand by improving growth prospects,

research firm CRISIL said in an analysis.

Fourteen of the 22 industry groups on the

index posted growth in April, against 10 the

previous month. However, growth skipped consumer goods. Consumer

durables declined 7.6% in April and consumer non-durables fell 3.3%.

Overall, consumer goods declined 5.1% in April.

According to economists, slow IIP growth rate in April

last year magnified the expansion of the current year


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a&D I nd i a | J u n - J u l 201416

“Companies seek tech-aided efficiency”With a clear focus on enhancing market share and creating a giant manufacturing footprint in

India, Babu T K, Founder & CEO, ElMeasure India, elaborates on his company’s R&D strengths and expansion plans in the country, during a discussion with Sumedha Mahorey

How has been your experience in terms of technology evolution in the Indian power management business? India’s energy portfolio is dominated by fossil fuels (coal, gas, and oil), which have long had availability problems. Rapid economic growth only exacerbated this. Supply continues to struggle to keep pace with demand because of productivity problems, logistics, a lack of accessible reserves and environmental concerns. Energy efficiency will become a key theme as fuel costs rise and put pressure on margins. Companies are already seeking technology-aided efficiency improvements. The analog measurement products that once ruled the market to measure electrical parameters has given way to digital energy management products which is more accurate and can be networked easily for analysis and efficient management.

Which are the demand trends shaping up in your business vertical?The flourishing realty business coupled with high energy prices has increased the demand for prepaid energy meters. We, being in the energy management field, have seized this opportunity and developed prepaid energy meters with 3-in-1 solution – electricity, gas and water.

Which innovative solutions have been developed by your company in the recent times? We have developed innovative solutions for lighting control, water and battery management using wireless technology that can be easily integrated with BMS for any type of building without disturbing the present wiring system.

We have also designed light and water management systems. LMS (Lighting Management System) is a unique solution designed and developed by us. It helps the customer to monitor and manage the lighting loads using time-based and PIR (Passive Infra-Red) based occupancy and light intensity sensors. This enables the customer to maintain better and reliable lighting system which increases the lifetime of the lighting loads.

The prepaid energy meter is being launched with GSM/GPRS, Wi-fi, Zigbee communication with a lot more innovative features. The future trend being wireless, we have planned to

launch multi-function meters with Zigbee communication and products with LCD, TFT and touch screen displays, etc.

Can you elaborate on your company’s R&D strengths? How is it likely to boost competitiveness in the long term?We have an in-house R&D facility recognised by the Department of Scientific and Industrial Research (DSIR), Government of India for both hardware and firmware development in sharp difference to many of our competitors. This has enabled us to rapidly translate our ideas and concepts into products and customised solutions. Our R&D team has developed world-class products. Our products have obtained Trade mark, CE

certification and UL or ETL (Intertek) certification.

How do you plan to increase your company’s global market share, amid the current fluctuating market scenario?We have received UL and ETL certifications for our products recently and this has helped us to market our products aggressively in Europe and American continents. We have also planned for a fifth manufacturing unit in the United States in about two years time to cater to our growing demand overseas. ElMeasure is now present in over 30 countries with Japan remaining our major

export market along with Africa, Middle East, Malaysia, etc.

What are your plans in 2014-2015 in terms of new product innovation, expansion & investment?We have acquired 3 acres of land at the Hardware Park at Devanahalli near Bengaluru International Airport. Our plan is to come up with a state-of-the-art manufacturing facility measuring close to 2 lakh sq ft. The first phase of construction will be close to about 35,000 sq ft and is expected to be completed in the next 18 months. A growth strategy has been plotted for Elmeasure for the next five years. Vertical integration, acquisitions, product development, and new horizons in product offerings are part of the plan being designed for the future. ☐


Elmeasure T K Babu_Market Interview.indd 16 6/19/2014 3:57:40 PM

Janatics _210X273 A&D India

Monday, June 16, 2014 3:58:54 PM

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a&D I nd i a | J u n - J u l 201418

“Price is the main challenge in India”Discussing the challenges and expectations from the Indian market in the upcoming years,

Gaurav Gupta, MD, Hummel Connector Systems, in this interaction with Megha Roy, highlights the measures taken to cut down delivery time for an efficient service strategy

What are the emerging technology trends in your domain? We are always trying to adapt ourselves to latest technologies and introduce new products, which are both quality & price wise, in accordance to the latest technology. Keeping this in mind, We have recently introduced the HSK-INOX-HD Gland, which has been designed and developed for applications with special requirement on hygienic standards and cleaning. The Gland is suggested for areas of application where deposits of bacteria and micro-organisms need to be avoided and fast & easy cleaning has to be guaranteed, such as food, beverage, pharmaceutical as well as chemical industries.

How is Hummel Connectors pursuing its services strategy in India? Can you elaborate on the challenges in this sector? Our company is focusing on the service strategy of supplying quality products with the least possible delivery period. We keep good stock of all fast moving items and also encourage our dealers or distributors in major industrial towns to stock items so that the customer gets the best service. Another added service is by allowing special machining on boxes for our customers as per their requirements.

However, the main challenge in the Indian industry is the price factor. Products from Indian and Chinese manufacturers are available at a much lower price. Further, the customers are not much conscious on the quality aspects of our domain products, as they believe that these items are not very crucial for their end products. As far as the quality conscious customers are concerned, major European players have already entered

the market in the last two decades. Thus, to replace them without much cost benefit is a little tedious job.

How does R&D work in your domain? On which technology themes is your company currently working in terms of new product development and innovation?

We normally work as per the R&D terms of HUMMEL AG and hence haven’t focused on new product development. However, we offer ourselves as a potential source for any new product development or innovations.

Post elections, what are your expectations in terms of market growth, boost in exim and the growth in the key demand sectors?The best thing that could have happen for India is to get a firm and stable government at the centre and this has happened. I believe that India has an exciting period of growth ahead and it’s likely that with the efforts from both government & Reserve Bank of India, the market will definitely get a boost and

recover. There is also a huge potential in sectors such as auto, infrastructure, oil & gas, and telecom. What is your agenda for the year 2014-2015?The year 2014-15 will be crucial. We have seen and somehow passed a difficult time in 2013 and now we have great hope for 2014-15. The agenda for us is to strengthen and increase our market share in India, increase our production capacity, keep our customers satisfied as well as increase not only the turnover, but the margin as well. ☐


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With economic growth gradually strengthening in 2014, this feature addresses the demands of global equipment manufacturers to identify targeted areas in their business that need improvement, and help make the necessary decisive moves that can reduce operational costs, boosting efficiency and the bottomline. Once process improvements are in place, companies will be able to focus on driving new revenue streams that can help give a competitive edge as the economy improves.

Tim Moylan President Infor Asia-Pacific

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angles — per equipment model, group, parts, item line, order line, and supplier. This type of solution can help improve order-to-invoice and order-to-cash cycles, so that less working capital is tied up in accounts receivable. Greater margin control helps you resolve customer issues faster, yielding improved service levels and customer satisfaction. Equipment companies should look for an integrated system that allows them to measure value and profitability throughout the equipment lifecycle. By predicting and planning profitability, you can control margins without having to “cushion” each business deal.

Improve pricing strategies

Managing an efficient, coherent pricing strategy is an important part of the equipment business. Because of the volatility, this requires consistent monitoring and evaluation to ensure optimal results. Pricing structures should be tailored to meet the specific needs of your company and match what economic climate dictates. In some instances, you may be able to command a premium, while at other times, a discount may help you increase customer loyalty and market share. Ineffective pricing communication is often caused by poor infrastructure or disparate systems. A fully integrated solution helps to bring all pricing data together in one, consolidated view. It helps companies evaluate data on the industry, market conditions and competitors. This allows you to segment customers accurately according to equipment type, customer perceived value of parts, purchase patterns, pricing, and sensitivity. The right technology system will offer specific discount matrices for customer and product combinations to ensure that you can maintain greater control versus a more generic discount approach. By using an automatic discount level approval process, you can greatly reduce tedious, manual work for your

Manufacturing around the globe is going through a tough time — a period marked by economic slowdown, reduced liquidity, and shrinking business activity. Many heavy equipment manufacturers and dealers have been hard hit by the recent recession and forced to restructure their organisations to survive. Others are refocusing and changing their strategies, particularly in light of the impact the economy has had on equipment sales. Yet, as per an IDC Manufacturing Insights survey, Accelerating Business Change Through Next-Generation ERP (http://www.infor.com/content/analyst/call-to-action-ime-sector/), “the industry’s business indicators significantly improved over the last couple of years, with revenues and profit margins returning to pre-crisis levels.” Recessions do not last forever.

Now is the perfect time to take a good look at your business processes and see exactly where and how you can improve. By identifying targeted areas in your business that need improvement, you can make the decisive moves necessary that can help set your company up for success as the economy turns around. This article discusses some of the areas that can reduce operational costs, boosting your efficiency and bottomline. Once process improvements are in place, you will be able to focus on driving new revenue streams that can help give you a competitive edge as the economy improves. Strengthen margin control

If margins cannot be seen clearly, then they cannot be controlled effectively. Lack of margin control is largely due to poor data or data that is difficult to find or spread across disparate systems and paper records. It quickly leads to increased costs and poor decision-making. An efficient, fully integrated system is one that supports detailed data analysis, helping equipment companies like yours see margins from all


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employees. The system quickly alerts managers to underpriced product and customer combinations so that nothing goes unnoticed. Companies like yours should look for a solution that helps to create comprehensive pricing agreements with the ability to fine-tune gross, net, and discount price.

Focus on aftermarket parts sales

Aftermarket parts sales and service account for significant revenue opportunity for your business. To be successful, you need an integrated view of your business so that you can get up-to-the-minute data on customers, equipment, parts, service history, service-level agreements, and more.

The first step is to automate and modernise your warehouse processes. To do this, you need a system that supports the managing of low- and high-value stock, with an emphasis on frequency of usage and optimal storage location. An integrated solution will also allow for auto-leveling of inventory, so that parts are distributed throughout the business in the right proportions. To deliver on service, companies like yours need an advanced parts supply chain management system that facilitates effective and timely service scheduling to correspond with parts delivery. It is therefore critical to have a solution that provides forward visibility of parts requirements through effective demand management. To improve supply chain management and parts logistics, you need to interface directly between original equipment manufacturers (OEM), dealerships, and the customer base. By sharing data about equipment orders, configuration, delivery, service, and warranties in real time, you strengthen the dealer-OEM relationship. This can help you process customer orders and warranty claims more quickly. To run efficiently, equipment companies like yours need to make sure to have a sound parts-planning process in place that allows you to schedule service in a timely manner

that coincides with parts delivery. Forward visibility and effective demand management can help fine tune procurement planning, scheduling, and supply levels for customer locations in the field, as well as service vans. An integrated solution can help you simplify your warranty and claim management processes. You should look for a system that helps with tracking parts and equipment claims from inception to closure, including claim versions and final processing through to the original equipment manufacturer. With this system in place, you can gather and analyse vital data on equipment breakdowns and feed that information back to your manufacturers. This will help manufacturers get to the root of problems, so they can make improvements. An advanced warranty and claim management system is one that will include detailed search and listing functionality, making it easy for employees to locate the right claim and update customers on the spot. Overall, this type of system helps you deliver high-quality service, while maintaining a healthy profit margin. Because these processes can be directly linked to company-wide financials and overall equipment profitability, an integrated system delivers even greater value to the customer and to the equipment dealer.

Rental and leasing

As competition grows, customers expect more from their equipment and service contracts. Effective equipment utilisation is more important now than ever before. The right technology infrastructure gives your company a complete overview of your rental operations, including a clear view of asset availability, insight into the return date for assets, and a clear view of your service needs. The right system can help you integrate all your rental operations with supply chain management, finance, and service, so that you can maintain

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complex rental agreements with your customers. For leasing, your company will need an effective business application system that offers pre-calculation for all agreements. This will allow you to manage vital information for the length of the agreement, including amortisation, interest, and residual value, after each period. Look for flexible invoicing functionality to help turn ordinary service into a value-added competitive advantage.

Finance and the equipment lifecycle

Finance is a cornerstone of all organisations. Equipment companies like yours need a solid handle on accounting, budgeting, reporting, and transaction processing. Does your existing system allow you to analyse all your financial information and link it to business processes to facilitate internal benchmarking? Are you able to obtain the cost and profit data you need quickly — by customer, fleet, equipment, or project? The right technology solution can help you with these areas, as well as pinpoint the relevant business information that fuels new growth strategies in areas such as marketing, service, and parts sales. Many equipment companies today lack an integrated view of their equipment over the full equipment lifecycle. You need to be able to see machine availability, profit, and contribution, without using spreadsheets. You need to be able to see the profitability of an equipment fleet, without adding it up manually. Your warranty, sales, travel costs, and field service should not be in isolated systems. You need more broad-range support in analysing a single piece of equipment as it ages to see exactly where and how you are making a profit. With the right technology, equipment companies like yours can track every transaction and the profitability of a piece of equipment from its initial sale until disposal. This information

allows you to offer customers advance notice of when they should repair, overhaul, or replace their equipment. Equipment lifecycle management helps to establish loyalty as customers maximise the value they receive from their equipment. It will also help you keep on top of preventative maintenance schedules, ensuring that the right parts, tools, and service engineers are available when and where needed. You need to have a trusted view into a product across its lifecycle, so you can have more control over your business, as well as gain the decision-making power to enhance your overall profitability.

Quantify your improvement initiatives

Having the right business processes and technology infrastructure is the key to help you cut costs and improve operations. But who nowadays, can afford to jump into an IT investment blind? A value assessment can serve as an ideal starting point. Companies participate in a value assessment to get a projection of the business benefits that can be gained by upgrading or implementing enterprise software. This top-down evaluation tool helps to justify and quantify IT expenditure before you commit time and resources. It helps you map out best practices for implementing these improvement projects, and defines key performance indicators that help measure your progress over a two- to three-year period. For many companies, it helps to get a new technology project started, setting the scene for organisational change. This type of evaluation exercise promotes teamwork and collaboration across all functional lines of a business. It helps clearly define in monetary terms the value that a new system has to offer. When you complete a value assessment, you walk away with a sound basis and strategy for decision-making, before you’ve finalised plans for your improvement projects.

Equipment lifecycle management helps to

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Gear up for change

With an integrated system, you will be able to track the profitability of a piece of equipment from its initial sale until disposal. You can look at key lifecycle changes and associated costs over the equipment lifetime as a whole, so you have an accurate, gross profit perspective. Total lifecycle profitability carries the potential to be many times higher than the margin on the initial sale of the equipment. Oftentimes, the initial equipment sale does not offer a high-margin. Products are being commoditised, and differentiation comes through support and total customer experience. Your customers will spend more on maintaining the equipment than on the capital purchase, and you have a corresponding sales opportunity. If you have a consolidated and reliable data source, you’ll never miss another sales and service opportunity. The design of workflow in most companies is based on assumptions about roles, organisational goals, and technology that no longer apply today. By examining your existing process engineering, you can focus on all the different functional areas of your business that make it run effectively — from warehousing and parts logistics to rental, service, and finance. Does your system allow you to get good, reliable information quickly? Can you track the simple daily flow of business, knowing what your cash flow is or inventory levels are on any given day? Can you get all the customer information you need in one place? Or, do you find yourself constantly waiting around for this kind of data? As you ask yourself these questions, you may conclude that your underlying enterprise application structure is hindering your plans for the future. Sometimes radical redesign and reorganisation is needed to streamline operations, reduce costs and improve quality of service. The fact is that information technology is a key enabler for this change.

Drive new sources of revenue

Simply cutting costs to remain active in the current economy or waiting for better times is a poor long term strategy. By hesitating to find new ways of improving profits, like strategic parts pricing or parts sales and service, you run the risk of being left behind by the competition as the economy picks up again. If this is the case, you need better visibility into your operations to achieve greater margin control, productivity, and efficiency. You should be able to focus on driving new orders, creating effective marketing campaigns, and improving customer service.

Capitalise on the opportunity

Companies that emerge as winners are those that streamline their operations so that employees get the information they need to act quickly; get stronger, fitter and more productive; deploy flexible information and business process foundations to lead improvement projects. These companies focus on improving customer service and find new sources of revenue that drive growth.

Now is the time for you to focus on efficiency and learn how to improve your business as the market recovers. Make sure you have visibility into your data through a central repository. Automate as many of your processes as possible, with decision points made where work is being performed and control is built in. By using the capabilities of an integrated enterprise resource planning system, you will have a single source of quality information — a system that is easy to learn and use, and one that can carry you into the future, serving as a flexible platform for growth and profitability. ☐

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“Product development strategies need to be more platform-focused” Sharing his views on the need for not only intelligent devices but intelligent standards as well and the focus on I/O-Link consortium, Ulrich Turck, Managing Director, Hans Turck GmbH, in this exclusive interview with Sumedha Mahorey, on the eve of the opening of its new facility in Pune, discusses the global management needs of best customer-company communication & reporting systems.

What are your strategic plans for India in terms of market positioning, expansion and manufacturing activity? We recently made the decision to move the company to a new location in Pune. This enables us to have more space in order to begin with a first assembly production. This will strengthen our market position and continue the growth that we see in India. This year we are expecting a strong two digit growth.

Where do you see your Indian operations leading to in the next 5 years among Turck’s global network?Despite the fact that we entered the Indian market relatively late, we see our market position as it is represented in most countries — among the top three of the main Turck products.

How do you look at the trends in the automation & sensor business, technology & market? Where do you see the potential coming from, geography & sector-wise?An ongoing trend is the reduction of complexity. At least, the complexity for users is decreasing and will continue to decrease in the next years. For example, consider the I/O-Link. For the automation industry and their products, complexity grows but for customers, automation is eased with this technology. Another example is our multiprotocol Ethernet technology. All our new modular and compact I/O systems communicate with Profinet I/O, Modbus TCP or Ethernet/IP without intervention of the user. These devices can be operated automatically in each of the three Ethernet systems.

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to eight switching signals. That’s quite a lot for a point-to-point 3-wire connection. Another field of innovation is RFID, especially in terms of UHF technology and data integration up to the enterprise level.

There has been an increasing trend in the sensor business toward miniaturisation, precision, safety & measuring speed. How does Turck take care of these demanding expectations?We are supporting trends when we detect them on our most important measuring device – our customer. We answer all these trends with different products – one reason for our comprehensive product portfolio. Miniaturisation was fueling the development of our 32 mm small multiprotocol Block-I/O TBEN-S, for example, which will enter the market in the 4th quarter 2014. We are glad to have the required know-how in our company group. The challenge here is not only to develop very small components and products, but even more to find a way to produce these kinds of components in a fully or partly automated process for a reasonable price.

With constant pervasive changes in technology & market requirements, how can organisations design/plan the change management process and product development strategies? Would you like to give any examples from your company?The first task for every company is organising a knowledge management to make all the information a company has accessible for the colleagues who need to know it. In a five man start-up, you can realise that by office grapevine but it gets rather complex in a company with more than 3,350 employees. In order to interconnect our knowledge and intelligence, Turck is currently setting up an SAP ERP system for the company worldwide. With this system in charge, we will be able to react quicker and more flexibly on every market development and our customer’s demands. Additionally, product development strategies have to become more platform-focused. A good example again is our multiprotol technology that all our new I/O devices, compact as well as modular, support. The basic technology development is being rolled out to each new product. ☐

How are emerging concepts like Industry 4.0, Big Data and Cloud enabling manufacturing efficacies? What have been Turck’s contributions on this front?For Industry 4.0, we foresee a big transformation in the automation industry. But this transformation is an evolutionary process that has already begun – an evolution that did not start yesterday and won’t end tomorrow. And along this perspective of Industry 4.0 as a slowly evolving process, we align Turck’s strategy by developing solutions for more and more automated production. We are always cautious not to lose our customers’ real problems in the process. The multiprotocol technology is one such example.It is also getting more and more important to integrate automation data in enterprise and production software to maximise efficiency. It is also relevant for RFID applications, a central technology for Industry 4.0. Currently, I don’t see cloud solutions would be accepted by our customers in the field of industrial automation. There is too much doubt about data security in these sensible fields.

How can intelligent self-controlling factories become a reality?What we need is not only intelligent devices but intelligent standards as well. With I/O-Link, we have that standard already established at least for the sensor technology. This technology enables communication from the PLC to the very last device. But further standards, for inter-machine communication for instance, have to be set up. Furthermore, security issues have to be solved. When the production network enhances all the intelligence of a company, then all the intelligence and know-how of a company is potentially endangered. And within this scenario, complexity has to be kept manageable.

Currently, your company is working on which themes of innovation? What kind of technology breakthroughs are expected from Turck in the coming years?If we look at the Industry 4.0 scenario, we are quite busy in the I/O-Link consortium. We play an active role and are pushing the technology by developing more and more products using that standard. The latest offspring of our I/O-Link portfolio is our inductive coupler which uses I/O-Link to transmit up

“It is getting more and more important to integrate automation data in enterprise and production software to maximise efficiency”Ulrich Turck

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Cyber security in industrial automation To address cyber security issues for industrial automation systems, a clear understanding of the security challenges and specific defensive counter measures is required. This feature provides a holistic approach on development requirements of an aggregated security solution to defend against cyber security threats and vulnerabilities that affect an industrial automation system, while assessing latest technologies and research in the domain.

As per a recent white paper by Frost & Sullivan, developed in partnership with Schneider Electric, over the last decade, the rise in cyber attacks on critical infrastructure has resulted in cyber security becoming a central concern amongst industrial automation and control system users and vendors. Cyber threats are primarily aimed at industrial control systems such as distributed control systems (DCS), programmable logic controllers (PLC), supervisory control and data acquisition (SCADA) systems and human machine interfaces (HMI) through loopholes which can range from unsecured remote access, to inadequate firewalls, to a lack of network segmentation. In such times, understanding how to secure factory automation, process control and SCADA networks is critical if companies wish to protect these from viruses and hackers. In this feature, industrial experts – Rajabahadur Arcot, Independent Industry Analyst/Columnist & Automation Consultant; Milind Kulkarni, Head – Business Development,

Factory Automation, Siemens Ltd and Doug Wylie, CISSP, Director – Product Security Risk Management, Rockwell Automation – share their views on the adoption of modern cyber security technologies in industrial automation systems and the challenges that lie therein.

Threats in industrial automation systems

According to Kulkarni, Internet has been extended to automation as more and more automation vendors are offering web-enabled automation devices to facilitate remote monitoring and control. Increasing use of mobile devices like PDAs, smart phones, tablets and laptops for remote connection to automation world is the natural consequence. This has resulted in the rise of cyber security threats. According to Arcot,

“Industry sectors susceptible to control system cyber attacks include the electric & water utilities, chemical and oil & gas


Sumedha Mahorey Deputy Editor [email protected]

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with another potential point of weakness. This may be control system to control system, control system to enterprise, or control system to remote access solution. As an example, wireless infrastructures that expand the reach of the system and allow for untethered assets also require attention. How company’s mobile assets are tracked, how third party connectivity is managed, and even how far is the reach of the wireless network itself are all part of what must be actively considered when establishing a risk profile for a control system that makes use of such technologies.”

Adding his thoughts on the challenges, Kulkarni asserts, “Many manufacturers today want powerful and effective remote monitoring and control solutions through the web. However, what is lacking is the usage of appropriate web-enabled automation components offering secured web access. Many manufacturers, in order to saving minor costs, use low cost and less or unsecured techniques for their remote monitoring and control solutions. This is the biggest challenge today. Besides using a properly secured web-enabled device, they need to spend on deploying adequate recommended cyber security solutions.”

Designing a cyber security solution

Considering the present as well as future threats, which key factors should be focused on while developing/designing a cyber security solution for industrial automation? Addressing this, Wylie says, “Protecting industrial control systems relies on understanding and being aware of risks and threats. It also relies on having the right types and levels of security controls in place to mitigate risk. Security solutions need to be tailored to the needs of multiple customer types including machine builders, system integrators, design engineers, operators, service technicians, and in some cases remote management and support services. It’s also important to consider how any protections might affect each type of customer during the system life cycle. For instance, it’s likely that only a limited set of security controls will be used during a system design and installation.” When the system moves to its operational phase, ideally additional security controls will be enabled. During system maintenance, some of those controls may need to be temporarily disabled, but of course should be closely tracked to make sure they are turned back on once the system is

sectors. Symantec ‘Security Response’ report version 1 released in January 2014 says: the energy sector has become a major focus for targeted attacks and is now among the top five most targeted sectors worldwide.” The recent ‘A SANS Analyst Survey,’ released in April 2014 confirms that control system cyber attacks, particularly against energy-generation systems, are on the increase and becoming more targeted against specific systems.

“The architecture of control systems, such as DCS, PLC, and SCADA may comprise of innumerable nodes such as field devices, I/O cards, communication buses & networks, controllers, and operator interfaces. Most of them have software codes to compute, process, communicate and network data and information; almost all of them are cyber vulnerable,” identifies Arcot. Typically, field devices are accessible through dedicated lines, handheld devices or other communication protocols including wireless. A cyber attacker, by gaining unauthorised access to the field devices, can cause their malfunctioning by changing their characteristics and/or behaviour and thereby, manipulate the entire plant operation and control. Additionally, the control system architecture has numerous servers, engineering stations, HMI terminals, and such others. By gaining access to them, a cyber attacker can manipulate operator and controller actions. Similarly, by gaining access to communication buses and networks, an attacker could gain complete control over the network and manipulate the flow of information and command signals.

Given these threats, how should companies identify their vulnerabilities? Wylie explains, “The objectives that govern what needs to be protected in an industrial control system often depend on the criticality of the particular system; what is specifically considered to be at risk (i.e. people, assets or information); what known threats there are to the system; regulatory requirements; specific standards and other requirements that must necessarily be followed.”

Additionally, an asset owner’s particular risk tolerance also influences what is considered an acceptable level of risk for a system. In most cases, the objectives for safety, system availability and operational integrity of the system command the highest priority. In other cases, intellectual property, data confidentiality and tamper-protections are similarly critical. Wylie asserts, “It’s very typical that the point at which one system connects to another will introduce complexity along

“Manufacturers, with cyber security experts, must make adequate investments to have web-enabled automation on the plant floor integrated with cyber security system”Milind Kulkarni, Head – Business Development, Factory Automation, Siemens Ltd


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returned to its operational mode. Wylie avers, “If special considerations are not given to the fact that different security controls will be used at different times in the lifecycle of the system, it’s likely over time, many controls will be turned off and remain off for the life span of the system. Considering all of these factors can be complex and at times, overwhelming. So, it is sometimes helpful to seek out advice, training and to also get help from outside reputable sources.”

According to Kulkarni, “The moment a company has infrastructure and devices that are web-enabled in the plant, it has to have a common plant network that is essentially Ethernet-based. Using encrypted communications on the same for industrial data exchanges is inevitable. Hence, a manufacturer has the responsibility of using strong encryption technology based platforms like PROFINET while also choosing proper industrial grade secured web enabled devices. Additionally, this also needs to be complimented by appropriate cyber security solution. For example, remote access techniques using VPN (Virtual Private Network), two factor authentication, etc. In two factor authentication, the user is authenticated via a user ID and password (normally PKI based for more positive conformance). The user has a domain account and a hardware authentication token. This method provides high degree of certainty that the user really is who they claim to be.”

Need for modern cyber security support

As a company deploys new age automation, it must also consider its needs for modern cyber security support. As per Wylie, new approaches to network architectures that enable remote access into systems, increases in computing power through virtualisation, enhance the ability for systems to share data and even exponentially scale via cloud services are becoming more commonplace in industrial control systems. Along with the adoption of these solutions come new risks to the data and to the operational integrity of a control system and other systems to which it interconnects. Many questions arise: Where is my data? Who owns my data if I can’t see it? What happens if my control system loses communication with my cloud provider? Should I create my own private cloud? Is my remote connection secure?

“Considering the cloud, all the best practices and risk management approaches used to secure industrial control systems and business enterprises likely cannot reach third

party’s cloud infrastructure. The benefits these new technologies are highly compelling, yet they also should raise concerns that should be addressed by greater communication with service providers so risks are clearly understood. Here again, it can help to involve reputable, competent people with experience that can help make sure control system objectives are met along with the security objectives,” avers Wylie. Speaking on cloud technology, Kulkarni points out, “Today, hardly any industrial manufacturer prefers to have real-time plant data stored on cloud. This is because of the fear of possible security breaches in addition to the cost. The security issue as such is well-mitigated these days by the IT champions who are strong advocates of cloud technology.” Adding his views, Arcot suggests, “In my opinion, end users should not look only at the economic benefits of using cloud-based solutions. I do not see how an end user can ensure security of cloud servers. True, there may be legal options available, but they will not serve the purpose in case of control system applications.”

Technology developments

Manufacturing and process control systems are continuing to see more intelligent network appliances both inside and at the edges of these systems. Many of these new products include a growing set of capabilities designed specifically to enhance protection, increase visibility to data, and to give greater control over the information that moves within, enters or exits the system. Wylie affirms, “Industrial products that control operations and perform action in the system are often linked by network infrastructure appliances that come in contact with most every bit of data on a wire. They too are also becoming smarter and more data & network aware. For instance, some managed switches, routers, firewalls, as well as programmable automation controllers and industrial control products have a growing set of capabilities to help make them resilient to attacks while also affording customers the ability to choose added security features to help protect the device from unauthorised changes.”

Some also have security capabilities operating in the background that perform greater levels of integrity checks on data & firmware and enhance communications to build added trust with other products within a system. He adds, “Over time, such capabilities will continue to become more standard and

“Cyber security should not be viewed as an option, nor should it be left as an item open to be addressed at some point in the future” Doug Wylie, CISSP, Director – Product Security Risk Management, Rockwell Automation


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mainstream because they help address customer concerns and also help reduce risks to the safe and reliable operation of the systems used in manufacturing and process control.”

On the research frontier, which technology influencers are affecting the development roadmap of such cyber security solutions for industrial automation technologies? Answering this, Kulkarni explains, “Mobile technology and access to plant via the same is actually affecting the roadmaps of cyber security solutions. Many users today want to use web-enabled devices for the much known benefits but are not prepared to invest for the required security elements. The low priced web access solution for remote monitoring and control through laptops, tablets, smart phones, etc are excellent and handy means for remote monitoring and control. However, deploying adequate security solutions to compliment this powerful tool and ensuring proper authenticated remote access anytime is essential.”

As per Wylie, “Products such as industrial managed switches, routers and next-generation firewalls are continuing to gain new capabilities tailored toward industry and certain applications. With emerging needs and application demands, the intelligence of these products continues to expand allowing them to better understand the data passing through a system and the context of the application so they can make decisions in real-time about how to handle and route data.” Other industrial control products such as programmable controllers and connected intelligent sensors and actuators are gaining enhancements to help them better protect themselves from a variety of adverse conditions they may experience when used in a control system and also build trust relationships amongst their peer devices.

Tapping collaboration benefits

When it comes to the global manufacturing sector, how should software companies and industrial automation solution providers (ASPs) collaborate to ensure complete protection against evolving threats? Kulkarni avers, “Most critical is building the knowledge bridge between ASPs and software companies. ASPs have knowledge of implementing web functionality within their solutions but very poor knowledge about cyber security standards and implementation of cyber security framework.” Here, software companies can play an

important role and work along with ASPs by firstly, creating awareness about the need for a cyber security frame work and sharing knowledge about how the same can be used together with web enabled automation platforms for completely secured applications over web. Secondly, they can develop plug-on type strong and cost effective but scalable (not low priced) cyber security systems and solutions and bundle cyber security solutions with automation solutions while making offers.

Adding his thoughts on such collaboration, Wylie comments, “Open standards and technologies have facilitated a connected world that now often includes direct linkage between manufacturing and business operations. As industry evolves, more attention is being given to precisely how connections are made, how data is being exchanged and how the underlying technology is being developed, tested and maintained. Building assurance in the data exchange amongst products is of growing importance as is making sure that systems are more resilient and robust. With suppliers becoming more sensitised to security risks and threats, and also more reliant on each other as interconnectivity leads to large complex systems, the importance of data security and operational integrity continues to rise.”

Elaborating on the thought, Arcot says, “Overcoming control system cyber-security challenges would call for automation suppliers to assess afresh the industrial-control system architecture and all its subsystems and components in the context of their vulnerabilities to cyber-attacks. It is essential for automation vendors to collaborate with other stakeholders including standards organisations to reevaluate the readiness to meet the challenge head-on and quickly develop and offer appropriate solutions with the help of collaborative partners that are inherently cyber secure.”

Recommendations for adoption of cyber security

Protecting the industrial control systems from hackers calls for a comprehensive approach and begins with CEOs accepting cyber threats as a reality. Arcot avers, “Protecting the enterprise begins with implementing straight forward proper work related systems, such as access control and ensuring adherence to cyber security standards. Eternal vigilance, the readiness and ability of the enterprise to identify, recover, and nullify the effects of the cyber-attack are key to achieve fair degree of

“Cyber security goes beyond deploying specific technologies; it is a part of the overall governance processes and risk management across the enterprise”Rajabahadur Arcot, Independent Industry Analyst/Columnist & Automation Consultant


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protection. Apart from these, the ability and preparedness to initiate counter measures to recover quickly from the attack are also critical. The most important thing is to be aware of the threats, take serious note of the same, and plan & implement counter measures. Cyber security goes beyond deploying specific technologies; it is a part of the overall governance processes and risk management across the enterprise.”

It is essential for the industrial company to create an in-house industrial control-system cyber security team. It has to begin with the clear understanding that ensuring ICS cyber security is not the same as ensuring data security. The industrial control-system cyber security challenges are different and it is necessary for the team to consist of experts in automation, information and communication technologies, and process technologies. Making a beginning in creating the in-house industrial control-system cyber security team that is charged with the responsibility to carry out security audit, vulnerability assessment, and penetration testing, evolve solutions, and implement them.

As per Kulkarni, manufacturers, together with experts from cyber security systems must make adequate investments to have proper web-enabled automation on the plant floor integrated with cyber security system. It should have the required degree of security based on web functionalities required in the automation solution. On the other hand, Wylie believes that cyber security should not be viewed as an option, nor should it be left as an item open to be addressed at some point in the future. Unmitigated risk is still risk to a control system and to any system. Security that is proactively and thoughtfully designed into a system will remain superior to bolt-on security solutions. Giving ample consideration to security during system design, installation, operation and maintenance of control systems needs to be natural and treated in a similar manner to considerations for safety and operational integrity. Combining all of these elements together and building a security program that also includes training, awareness, discipline, planning, management and testing are necessary today, and will continue to be necessary in the future. Although determining where to start with protecting industrial control systems can seem like a daunting task, by following a methodical approach to understand risk, mitigate risk and manage that risk, it is possible to bring such risk to an acceptable level. ☐

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Sabine GoodwinSenior EngineerTechnical MarketingCD-adapco

Dr Kristian DebusDirectorLife SciencesCD-adapco

Numerical simulations for continuous manufacturing of active pharma ingredients Traditional manufacturing processes, which are batch processes, are no longer sustainable and there is no question that continuous manufacturing is the clear path forward towards leaner processes. Multi-physics numerical simulation is emerging as a game-changing technology to help continuous manufacturing for Active Pharmaceutical Ingredients (APIs) become a reality through virtual prototyping, optimisation and modeling of the complete system.


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been improving their productivity by successfully integrating continuous manufacturing into their plants. It is clear that regulatory hurdles and conservative thinking by the pharmaceutical industry can no longer be used as an excuse to avoid taking pharmaceutical manufacturing into the 21st century.

Before continuous manufacturing can become main-stream, potentially suitable candidate processes must be identified and designed, and risks must be analysed and mitigated. This will help manage regulatory compliance and make a business case for implementation. Multi-physics Computational Fluid Dynamics (CFD), a numerical method for predicting the coupled behaviour of fluid, gas and particulate flows including heat and mass transport, offers a solution for the enhanced understanding and design of these novel processes.

Virtual prototyping

Traditional manufacturing processes are based on the “design-build-test” principle in which the effects of design changes are quantified by experimental tests on physical prototypes. There are currently very few suppliers who are developing integrated systems for continuous manufacturing and, as a result, physical prototyping is anticipated to be very costly. Numerical simulations enable the engineer to build a virtual laboratory, providing insight into the performance of a

The pharmaceutical industry is encountering a decline in productivity, and outdated “tried-and-true” batch processes are at the root of the problem. The batch-based systems currently in place are inefficient due to segmented steps involving multiple facilities and requiring start-and-stop of the batch, site-to-site transfer and warehouse storage. Performed through sampling and in post-production, quality assessment of the product is also cumbersome, causing long lead times and waste.

Continuous manufacturing, a non-stop end-to-end manufacturing process, could modernise the industry and solve its productivity crisis. At a recent MIT conference, Josef Jimenez, CEO of Novartis, stated that changing production from batch to continuous will transform the way medicines are made around the world and could cut the time from development to market-entry in half. Implementation of these processes will result in smaller production plants, lower inventory costs, reduction in carbon footprint and higher quality products.

The regulatory agencies are also starting to lay the groundwork for continuous manufacturing with several initiatives and regulatory frameworks such as the Process Analytical Technology (PAT) and Quality by Design (QbD). Each of these encourages the development of new manufacturing technologies by building quality into the process and using a science-based quantified risk approach.

Both the chemical and food processing industries have

Ultra-lean manufacturing, from start of chemical synthesis to final pharmaceutical

dosage form (courtesy of Novartis-MIT Center for Continuous Manufacturing)


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product before tests are carried out. This means that the uncertainty resulting from major process and equipment changes can be evaluated up front, leading to a significant risk reduction and cost savings.

Multi-physics CFD and state-of-the-art visualisation tools also offer a wealth of detailed information, not always readily available from laboratory or experimental tests. This not only results in an increased level of insight into the details of what is going on inside the processes, it also enables innovation. For example, multi-physics CFD can help explore new reactions and molecules for drugs manufactured with a continuous process.

Design exploration and optimisation

In recent years, the phenomenal increase in computing power and the maturing of robust simulation tools have paved the way for using numerical design optimisation in production environments. Parameter studies and optimisation will be vitally important for designing and tuning of the new (often smaller) equipment required for continuous manufacturing while ensuring that the operation can efficiently handle fast reactions and remains flexible. In addition, the CFD-generated responses - obtained through design of experiments over a range of operating conditions and equipment design parameters - can be combined with statistical models to identify risk and implement robust real-time process control. This will ultimately result in reduced variability and consistent, repeatable processes.

Optimate (a module in STAR-CCM+ using Red Cedar

Technology’s HEEDS software) is an example of a tool that enables intelligent design exploration to easily consider “what if ” scenarios and identify the critical manufacturing points that define quality. For example, feeding devices for continuous manufacturing influence all downstream operations and design exploration of parameters such as feed rate will help identify their impact on final blend uniformity.

Simulating the system

Solving complex real-world problems demands an accurate, easy-to-use, multi-disciplinary approach to simulating complete systems. CFD-focused multi-physics engineering simulation tools such as STAR-CCM+ can accurately deliver full spectrum engineering results and the pharmaceutical industry should fully leverage these tools in support of the development of continuous manufacturing processes.

Up until now, integration of numerical simulations in a production environment has required a great deal of specialised knowledge, but this is no longer a showstopper. Automation and ease-of-use are enabling the deployment of CFD for complex multi-physics applications. For example, STAR-CCM+ offers state-of-the–art meshing, seamless integration with CAD and easy modeling of complex moving parts, all in a single integrated environment. The net result is more time for an engineer to analyse data instead of preparing and setting up the simulations, resulting in engineering success.

Seeing the “big picture” for continuous manufacturing will require a multi-physics approach to solving problems. Be it

Figure 2: DEM simulation for tablet coating with STAR-CCM+ showing pill coating

thickness in a fluidised bed

Figure 1: DEM simulation with STAR-CCM+ showing tablet velocity magnitude as they

tumble in a coating pan


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mixing, coating or drying, multi-phase flows lie at the core of the pharmaceutical processing industry. Capabilities such as Discrete Element Modeling (DEM), a numerical method for computing the interaction of a large number of small particles, and Eulerian Multiphase Modeling (EMP), a numerical method for simulating several phases in a system, will be invaluable for implementing continuous manufacturing of APIs. Two case studies are presented to demonstrate these capabilities.

Case Study 1: Direct Element Modeling (DEM) for pill coating

DEM simulates the motion of a large number of interacting particles and tracks them in a numerically efficient manner, modeling contact forces and energy transfer due to collision and heat transfer between particles. DEM will be particularly important in the design and optimisation of continuous coating processes to help identify the important factors for equipment design (e.g. number of spray guns) and to determine optimal equipment operation conditions (e.g. inlet temperature).

Figures 1 and 2 show STAR-CCM+ generated solutions for two types of equipment currently used for real-world tablet coating: coating pan (rotating drum) and fluidised bed. In these simulations, DEM is used to analyse the random movement of the particles as layers of coating are applied. Parameters such as particle velocities, residence time and coating thickness are tracked to assess and improve tablet coating uniformity. In addition to tablet coating, DEM can also be used to simulate other steps in manufacturing such as filling, filtering and conveyer processes.

Case study 2: Eulerian Multiphase (EMP) Modeling for mixing

EMP modeling provides an effective means for studying the interacting streams and randomly dispersed phases in multiphase flows. The EMP model in STAR-CCM+ includes an extensive range of sub-models including break-up and coalescence models for bubbles and droplets and a granular flow model for particles. Figure 3 demonstrates an EMP simulation of a gas-liquid mixer with three rotating impellers. Shown are the effects of increasing gas injection rates on gas. The ability to predict gas hold-up, a parameter that governs mass transfer across the phases and consequently rates of reaction, is a key enabler in the design of such reactors. This approach adds valuable scientific insight into the decision-making criteria to develop practical solutions for mixing and other processes in continuous manufacturing.

Conclusion

In today’s competitive climate, manufacturing must become leaner with a focus on building quality into the process. Continuous manufacturing for the pharmaceutical industry will change the way drugs are made and multi-physics CFD simulations offer a cost-effective way to perform rapid prototyping for design of new equipment and processes. In particular, design optimisation tools and powerful multiphase models such as DEM and EMP will play an important role, and the pharmaceutical industry should fully leverage these state-to-the-art technologies for the design and implementation of continuous manufacturing processes. ☐

Figure 3: Mixer model showing the effects of increasing gas injection rate using STAR-CCM+


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Bernd Webel Sales Director, Romaco [email protected]

Blister Pack ProDuction sYstemTo further enhance the production of blister packs, Aenova Group and Romaco Group have initiated development cooperation to explore end-to-end solutions for packaging tablets, capsules and oblongs. This feature demonstrates the latest pharmaceutical packaging processes focused on ensuring ease in blister system usage, shortening changeover and cleaning times, implemented by these companies.

Given that the global pharmaceutical markets are undergoing a period of change, it is expected that in the next few years, many patents for so-called blockbuster drugs will expire and, as a result, current studies are predicting an annual growth of 9% in the generics production. The variety of products available and the pressure on prices will also increase. In the light of these changes, many pharmaceutical companies


are increasingly outsourcing their manufacturing and packaging processes. In addition, specialist pharmaceutical service providers are taking responsibility for the entire production process, right through to the delivery of the medicines. This means that these service companies must always be able to respond flexibly to the requirements of the markets and accommodate fluctuations in demand.

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Competitive prices and strict adherence to delivery deadlines are essential components of the service too.

Delivering on schedule is a core competence

“In addition to quality standards, we are primarily judged on whether we can deliver our products on time”, explains Georg Reiser, Head, Packaging Competence Centre, Aenova Holding GmbH, Bad Aibling. “The pharmaceutical markets are highly competitive. As the leading European manufacturer of solid dosage forms, including soft and hard gelatin capsules, tablets and dragées, we have to supply the highest quality products at the best possible price in order to maintain our market position.” The Aenova Group is a full-service provider which has its headquarters in Pähl, Bavaria and seven sites in Germany, Switzerland, France, Romania and the USA where it develops, produces and packages pharmaceutical and healthcare products on behalf of multinational clients. Aenova supplies its products to all five continents, but its primary markets are based in Central and Eastern Europe as well as North America.

The machinery is crucial

Orders in the packaging sector varies in particular range in size from large to very small. In addition, it is important for service providers to be updated with the packaging designs and formats as required in different countries. Around 600 million blisters are filled every year at Aenova’s three

packaging sites. “This is why we need machinery that we can fully rely on and that is tailor-made to meet our needs”, says Reiser. Aenova has been using blister packaging machines from Romaco Noack for many years now. It currently has nine individual machines and two production lines supplied by the engineering company, which is based in Karlsruhe, in operation at its site in Bad Aibling in Bavaria. A Noack 960 blister system with rotary sealing and a maximum output of 600 blisters per minute is the most recent addition. It was installed in August 2012. The system includes the Promatic PC 4250 continuous motion cartoner and offers an end-to-end solution for packaging tablets, capsules and oblongs. The new technology is the result of the most recent development cooperation between Aenova and Romaco Noack.

Development cooperation generates new impetus

The cooperation between the two companies focuses on ensuring that the blister system was easy to use. It also shortens the changeover and cleaning times. While the aim was to enable one employee to change the product and packaging within a very short period, a systematic approach was taken to achieve this objective, by using a blister line model from the same family as the prototype. The Noack 930, which in principle is identical, has been in operation at Aenova since the summer of 2011. All the processes in this line were tested step-by-step under real production conditions and their potential for development was evaluated. The results of the

The Noack 960 blister system presents the latest development cooperation between Aenova and Romaco


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tests were incorporated into the design of the new blister system. “We were particularly impressed by Romaco’s single-minded approach for developing and improving its blister packaging systems”, adds Reiser. “The new Noack 960 is highly reliable and meets all the technical requirements that we specified during the planning process.”

Dual QuickFeed system

The weekly production volume of the new blister line is between 15 and 20 batches. It can be used, among other things, for packaging multi-phase products, where there is a difference between the morning and the evening dose, for example. These products are generally supplied in combined blisters. For this purpose, the company has equipped the new system with two feed units, which allow the blisters to be filled with two different products. During product changes, the patented QuickFeed technology makes it possible to remove the entire feed unit without tools in a matter of seconds. An air glide system enables the entire feed unit to be transferred to a special transport truck and then moved to a specially equipped assembly room, where the format parts are removed, all the components are cleaned and the new tools are fitted. During the changeover and cleaning period, production can continue with the second QuickFeed unit. “It is very important to us that our internal logistics enable us to fully exploit the potential of the QuickFeed technology”, explains Reiser. “We are focusing on implementing a modern lean management

system and Romaco Noack’s systems are helping us to make full use of our capacity.”

Continuous process control

A further important requirement for efficient primary and secondary packaging processes is reproducible process parameters. All the production data is entered and accessed via the user-friendly operating terminal of the blister system. Processes that have been saved can be repeated at any time and current batch data can be checked quickly. A total of 17 servo drives control the process of packaging the products into blisters and cartons. For example, the QuickAdjust station control systems are responsible for the coding, perforating and die-cutting processes. The servo drives automatically compensate for variations in foil characteristics. Also, a servo-controlled robotic transfer station moves the blisters to the cartoner. A lifting and turning unit removes the packages from the die-cutting station and a vacuum conveyor is used to transfer them to the stacking station where they are placed directly into the bucket chain of the cartoner. The high level of automation results in reliable processes and excellent product quality. “We have been impressed by the outstanding efficiency of the entire Noack 960 blister system, together with the reduction in downtime and the very good price/ performance ratio”, concludes Reiser. ☐

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Prashant Raghatwan Product Manager - Transmission, Counting & Process Technology Kuebler Automation India [email protected]

OPtimal sliP ring sOlutiOnProduct packaging is much more than ensuring hygienic food production. Besides preservation being a pivotal parameter for a resourceful packaging, increase in maintenance optimisation, ensuring high speed for packaging machines and proper cleaning during the production process are the other issues to be taken care of

One of the most important processes, mainly in the food industry, is the wrapping of the products in a suitable packaging. The packaging not only ensures hygienic food


protection against dirt and spoilage for a longer period of time, but also helps in preserving the shape, colour and the taste of the products. Furthermore, optimal packaging

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Compact & low maintenance slip ring

and SRI085, this is true both for the material of the drive unit and for all interface components such as connections and seals.

For efficient cleaning

Microbiologically, perfect products are a vital aspect for every food manufacturer. For easy and safe cleaning, the materials of the machine elements must resist aggressive detergents and disinfectants, and any reaction of materials must be excluded. They must be corrosion-resistant, mechanically robust and their surface must be completely insensitive. Both the slip ring models from Kuebler feature a fully encapsulated housing with a two-chamber system and are, therefore, safely protected against contact and are particularly easy to clean meeting the hygiene and cleaning safety requirements in aggressive environments. Thanks to the corrosion-resistant oval housing with IP64 protection level that safely protects the machine against abrasion dust. Its smooth surfaces, without undercuts are easy to maintain and simple to clean thus, facilitating regular cleaning of the machines with aggressive detergents and disinfectants required by the regulation on the hygiene of foodstuffs. This is important since the protection of the processed food requires no machine element to produce any substance that might be harmful to health or have a negative influence on the taste or smell during the production process.

contributes to the reduction of the additives used in the food, for instance additives used for its preservation. In addition, printed film packaging provides the consumer with important information about product features, nutritional content and ingredients of the packaged food. This packaging also allows a sales-promoting presentation of the products at the point of sale.

High hygienic requirements

There are many advantages of this packaging but it can be implemented only if the packaging, in addition to meeting the product requirements, also complies with the extremely strict standards and hygiene rules of the regulation on the hygiene of food products. These rules not only apply to the finished product, but also caters to the entire manufacturing process, including packaging machines, their components and all the materials used during the production process. In terms of packaging machines, slip rings are in charge of the rotary transmission of energy, signals and data between stationary and rotating platforms. Kuebler expanded its transmission technology products portfolio decisively, especially for use in this highly regulated sector. These slip rings used in packaging machines, operating in the food processing area resist reliably the harsh conditions of the working environment of food packaging machines and ensure reliably smooth functioning and long service life. For the new Kuebler slip rings SR060E

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Durably low-maintenance

A trend in mechanical engineering is the increasing maintenance optimisation with the goal of building plants requiring particularly little maintenance or even no maintenance at all. The contact materials used in the Kuebler slip rings, with contacts out of gold, silver, bronze and precious metal supports this trend: the slip ring requires minimum maintenance with an interval of 100 million revolutions, simply consisting of vacuum-cleaning the dust. Even in case of continuous operation, which is generally the case today with this kind of machines, this value is practically negligible. The slip ring SRI085 relies on contactless signal transmission to the moving machine parts; it operates totally without mechanical wear.

For the benefit of the customer

Today, packaging machines operate at high speeds. With their high rotary speeds of 500 or 800 revolutions per minute, the slip rings are best suited for use in packaging machines.

This fast pace results in increasingly short contact times for the films, for example heat-sealing in blister packaging machines. The load current capacity of up to 25 amperes allows very short heating times and thus an optimal temperature regulation – even for shortest contact times. And, as regards flexibility and easy installation, these slip rings have the best arguments for their use: flat plugs, fastening screws and anodised aluminium parts minimise the installation time for the customer. ☐


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Tel: +91 (20) 64 51 57 54 | Email: [email protected] - Focus- Kuebler Automation.indd 52 6/19/2014 3:05:22 PM

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Open, adaptable & modular safety solution Just as products come in packaging of all shapes and sizes, operators expect reliability, high cycle speeds and, in particular, flexibility from their packaging machines. Today’s packaging machines have a high degree of automation, so there is a need for intelligent, modular safety concepts that seek to maintain economic viability and deliver a competitive edge. This feature highlights the use of Pilz’s open, flexible and decentralised safety system by Oystar Group, a leading supplier of packaging machines.


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Today’s demands on packaging machines are equally diverse, as products come in packaging of all shapes and sizes. Although packaging primarily protects the content, product presentation frequently boosts the incentive to buy and so is constantly adjusted to meet point-of-sale requirements. Even when the packaging tasks are changed frequently, operators expect reliability, high cycle speeds and in particular, flexibility from their packaging machines. Today’s machines have a high degree of automation. These days, there is an average of 18,000 products on a supermarket’s shelves. In terms of marketing, packaging is a powerful, sophisticated instrument, which is largely responsible for the product’s success. The forms of packaging that product and packaging designers are coming up with, are ever more refined and the task of creative engineers is to develop automated and productive packaging solutions to suit. Even the motto is “fast, efficient and economical”. Measures must be taken to counteract the risks to which machine operators or other people are exposed in areas where processes are semi-automated or fully automated. It’s almost taken for granted that high-performance safety technology will not obstruct the production process and will work discretely in the background, so that the operators don’t even have to consider their physical safety.

Increased demands on safety and performance

Safety has been high on the list of priorities at the Oystar Group for many years. The company, whose origin dates back to 1893, is based in Stutensee near Karlsruhe, Germany and is one of the world’s leading suppliers of packaging machines, including related technologies and a broad range of services. It supplies stand-alone machines through to turnkey packaging lines via ten international production sites. These products include carton erectors, tray and case erectors, all-round packaging machines, high-performance packers, multifunctional packaging lines, palleting solutions as well as conveyor technology. The majority of packaging systems are used in the key industries of dairy, food, pharmaceuticals and cosmetics.

Oystar A+F, specialists for final packaging solutions, is equipped throughout with an open, flexible and decentralised safety system from Pilz, which has extensive diagnostics

functions. Thus, doors that have to be opened regularly or temporarily are fitted with safety gate systems designed for applications up to PL e of EN ISO 13849-1 and in many cases also have guard locking devices for process protection tasks. Earlier, these tasks would have involved costly and labour-intensive cabling work to install mechanical safety switches along with guard locking devices, and signals would have been evaluated centrally via safety relays. Precise alignment between the switch and actuator was difficult because mounting tolerances were low and the diagnostics were not always reliable. This resulted in damaged switches and attempts to manipulate the safeguards.

Open and decentralised safety concept

For a short while, Oystar A+F considered integrating safety technology into control systems of the various suppliers. This idea was soon shelved, however, on account of the high level of complexity of the software tools for various systems and the complicated software validation process this involved.

“Our primary aim was to define an open and decentralised safety concept that could be adapted to all control systems, that could not only be designed in accordance with protection type IP67, but could also be implemented with clear separation of responsibilities between safety and standard”, says Manfred Schuster, Head of Electrical Design at Oystar A+F. Since the company was familiar with Pilz’s range of products and services following years of cooperation, it opted for the configurable control system PNOZmulti Mini in combination with decentralised periphery, the input modules PDP67.

As a central safety component, the configurable control system PNOZmulti Mini has every safety-related function in its sights: Installed in the main control cabinet, the PNOZmulti Mini base unit with 20 digital inputs and 4 digital semiconductor outputs monitors the emergency stop button, reset button and mode selector switch, as well as take control of the servo amplifier all the way to a safe operational stop.

Safety gate system PSENslock ensures higher productivity

The safety gate system PSENslock from Pilz monitors the


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machine access points via PNOZmulti Mini. Secure safety gate monitoring is combined with a non-contact magnetic interlock with either 500 N or 1000 N. Thanks to the flexible connection options, PSENslock can be used for safety gate monitoring up to PL e, both individually and in series, and guarantees maximum manipulation protection. The safety gate system passes the signals to the decentralised PDP modules / PNOZmulti Mini. Gates, which do not require guard locking are fitted with the coded safety switch PSENcode. The connection is also made directly on-site via the decentralised PDP67 modules.

When plant and machinery are interlinked and when machines are assembled as modular systems, PNOZmulti Mini systems are simply linked to each other, thereby guaranteeing that signals are exchanged safely. “By swapping the mechanical switches for the safety gate system PSENslock from Pilz, our customers can increase the productivity and reliability of their machines considerably”, explains Schuster.

The software tool PNOZmulti Configurator makes light work of the configuration of the whole system. The clearly structured, intuitive user interface speeds up the commissioning process. All the configuration and function elements are available either as icons or in selection menus. All inputs and outputs are free to select and can be linked using logic elements via a simple drag and drop function. Pre-defined, approved function blocks and menus make it easy for users. Safety functions require in-depth specialist knowledge, particularly during configuration and implementation, so the fact that certified safety blocks are already stored within the software tool helps tremendously in gaining approval for the machine.

The Safety Calculator PAScal from Pilz enables functional safety to be verified and documented simply and with ease. The calculation software calculates and verifies the key safety parameters such as Performance Level (PL) and Safety Integrity Level (SIL) for plant and machinery safety functions.

The software can use a graphic editor to model safety functions and define not only their structure but also the usage pattern of the individual components. Given the extensive library functions, it is possible for users to import machine data in the standard library formats or to create and manage their own libraries. The result is compared with the safety parameters required for the safety functions and is displayed in graphic form.

A competent partner for every occasion

The close collaboration between Oystar and Pilz resulted in a system standard for safety, which can be adapted to cater to individual needs and requirements of various installations and machine types. Not only did Pilz supply the machines and systems, but the company was also responsible for the design, product selection, commissioning, after-sales service and support. “For us, it was an advantage that even during the commissioning phase we were able to call on Pilz’s technical support at any time, and that support was always straight-forward”, affirms Schuster.

With their distributed structure, the products in the PNOZmulti range developed by Pilz are ideally suited to systems requiring a standardised solution, from the stand-alone machine right through to modular networks. The large number of different communication interfaces makes the configurable control system a safety standard that can be applied all over the world because it can be used independently of any specific operating control system. “We were looking for a new, universal safety solution that could be clearly structured. And we found it, with the PNOZmulti Mini and the decentralised PDP67 modules”, summarises Schuster. ☐

Courtesy: Pilz

Safety Calculator PAScal from Pilz enables functional safety to be verified and documented simply and with ease


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F ie ld bus & N e twork s | t e ch n ol og y

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The first commercial Foundation Fieldbus applications were installed in 1997. Since then, over a million devices have been sold into a billion dollar market of products, applications and services. Man-years of project expertise and best practices have also been accumulated. Today, there are very few greenfield projects that do not incorporate some Foundation technology, and there are an ever increasing number of control system modernisation and migration projects that are also benefiting from the technology. The process industries are well-known for being conservative, however, and many of the old issues encountered during the initial adoption phases continue to persist as myths today. Many other myths have no basis in fact at all and it is unclear how they got started in the first place.

The good news is that these myths and customer objections can actually be turned into opportunities for the value-minded salesperson. Busting these myths and uncovering the real story

to the end user is a good way to point out the business value proposition that Foundation can bring to the end user. We have presented some of the most common myths here and provided you with the facts that bust these myths once and for all.

Myth no.1

Fieldbus implementation is too difficult: With proper training and the right partner, Foundation technology actually reduces the risk in the engineering and operational phase of the project, which also increases the net present value of the capital investment. Implementing Foundation technology does require different thinking and training. It is different, but not difficult. The accumulated knowledge governing Foundation Fieldbus engineering, for example, has been combined into a single set of free downloadable guides from the Fieldbus

toP 10 Fieldbus MYtHs bustedMany myths and misconceptions continue to persist surrounding FOUNDATION™ technology. In this feature, we bust 10 persistent myths and misconceptions surrounding a technology that is proven in the field, reliable, and open.

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Foundation. The AG-181 System Engineering Guidelines can be downloaded from the Foundation web site or by visiting the end user eesources section at www.fieldbus.org. The guide is a comprehensive resource that contains best practices for the engineering, design, and installation of Foundation Fieldbus systems.

Myth no.2

There is no cost benefit to Foundation Fieldbus: When best practices for project engineering are followed, the installed cost of a Foundation fieldbus based system can easily be much less than a conventional system in several key areas. Instrumentation commissioning and checkout times are greatly reduced. What used to take a field technician hours to accomplish, now takes minutes. Up to 75 per cent of all startup delays directly relate to instrumentation and controls. Foundation technology has the power to make commissioning easier and to reduce overall commissioning times by as much as 85 per cent. This results in faster plant startup and faster time to production. If you are a first time implementer or if Foundation technology is being deployed at your site for the first time, it makes sense to invest in some training – for your instrument technicians, operators, and other people who can benefit from the technology.

Numerous end users have avoided unplanned shutdown due to the diagnostics and function block capabilities of Foundation fieldbus. Many end users view maintenance as one of their key costs that can be cut. End users have estimated that more than half of maintenance activities result in no action. Foundation technology with its predictive diagnostics can help users develop a proactive maintenance strategy that avoids unnecessary trips to the field for routine scheduled maintenance.

Myth no.3

Why should I invest in Fieldbus when there is wireless

technology? Wireless technology has many advantages, but fieldbus and wireless technology are not mutually exclusive. Wireless in control applications is a long way off, and no end user is going to totally replace their control system infrastructure to support only wireless devices. The Fieldbus Foundation has made it our policy to co-exist with industrial wireless technologies for process automation. Through our Wireless and Remote I/O project (WIO), the Foundation has generated specifications for gateways to incorporate either ISA 100.11a or WirelessHART data into FOUNDATION systems. Combining the wealth of diagnostic data in wireless devices with the capability to manage that data and turn it into useful information in a Foundation fieldbus system is a powerful solution.

Myth no.4

There aren’t enough systems integrators with good project implementation experience: With thousands of systems installed, there is a substantial body of knowledge that has been established around successful implementation of Foundation Fieldbus project, and the list of both suppliers and systems integrators with experience in fieldbus implementation is substantial. Representatives from leading engineering firms are on the Foundation End User Advisory Council and were instrumental in the creation of the System Engineering Guidelines.

Myth no.5

Control in the field poses risks and compromises system availability: Control in the field is one of the key enablers for achieving high availability control and a stepping-stone toward single loop integrity. If there is a malfunction in the HMI and a loss of visibility into the process, controllers, or any other component in the system and the control loop, including intelligent field devices, actuators and positioners, and the network, remain unaffected. In cases where control resides in

Foundation fieldbus can save

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the DCS, field level control can add another level of redundancy. Many end users have already managed to avoid unplanned downtime when field level control took over after a failure in the system. Field level control means not only increased availability and reliability, but also increased flexibility. Controllers are free to handle higher level control functions such as advanced control and optimisation.

Myth no.6

I can get most of the field diagnostics I need from other technologies: Some network technologies offer diagnostic information, either digitally or through 4-20 mA technology. Digital networks can handle more diagnostic data than their analog counterparts, but they real value goes beyond diagnostic data. It’s what you do with all that data to turn it into useful information to help you run your business. Only Foundation Technology has the ability to take large amounts of data from field devices, digital valve positioners, and other instruments in your plant and turn it into useful information. Problem resolution hinges on the ability of systems to put data into the appropriate context. The data from Foundation devices is constantly being updated. Instead of having to poll devices for data, the data is pushed to the applications and the people that need it when they need it. Data is prioritised, to avoid alarm flooding. The data is time stamped and you can archive it and retrieve it. Foundation technology also has peer to peer communication capability, allowing devices to communicate with each other, which significantly expands the diagnostic capability of the overall system.

Myth no.7

There are interoperability issues with fieldbus devices: One of the founding principles of the Fieldbus Foundation is the support of interoperability – the ability to operate multiple devices from multiple manufacturers in the same system without loss of functionality. The H1 Interoperability Test Kit

(H1 ITK) tests the functionality of a device and its conformity with Foundation fieldbus function block and transducer block specifications. An excellent tool for troubleshooting and debugging devices, the test kit includes all hardware and software required to ensure a manufacturer’s complete device interoperability as specified by the foundation’s official registration testing procedure. The H1 ITK has now been updated to support powerful field diagnostics capabilities, which standardise how all fieldbus devices communicate their diagnostic data to the host system and asset management system–regardless of the vendor. The Foundation also offers an extensive Host Registration Program. The Fieldbus Foundation’s Host Profile Registration Process requires that the host profile under test must support a clear set of required features. Under the registration process, fieldbus hosts successfully completing the test requirements are authorised to bear the official Foundation product registration symbol. Hosts may include configuration tools, recording devices, alarm display panels, Human-Machines Interfaces (HMIs), or systems with a combination of functionality.

Myth no.8

Fieldbus is only good for new projects and not for modernisation or migration projects: Fieldbus technology is surprisingly well-suited for modernisation and migration projects, not just for large grassroots applications. Foundation Fieldbus is compatible with much of the existing wiring found in today’s plants. According to ARC Advisory Group, control system migration is the biggest issue facing end users today, and the installed base of process automation systems reaching the end of their useful life is around $65 billion. Over the years, many systems have been upgraded in a phased manner, usually at the application level. Today, we see more and more of the I/O, wiring, and control infrastructure that needs to be replaced. More than anything, users are looking to avoid a function replacement in their migration strategy – replacing their old system with a new system that has exactly the same functionality

Control in the field

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and architecture. As more end users replace their legacy hardware and applications, they are realising the value of FOUNDATION Technology to get more diagnostic data from their devices, reduce unplanned downtime, and cut down on the amount of wiring, I/O, and associated labour and infrastructure required in a conventional 4-20 mA system.

Myth no.9

Foundation Fieldbus for process safety systems will not work: TÜV granted Protocol Type Approval for the Fieldbus Foundation Safety Instrumented Functions (FFSIF) specifications in 2006. The specifications outlined by the Fieldbus Foundation comply with the IEC 61508 standard for functional safety of electrical/electronic/programmable electronic safety-related systems requirements up to, and including Safety Integrity Level 3 (SIL 3). With the release of the FFSIF specification, suppliers are developing products and systems that will be able to incorporate fieldbus diagnostics, partial stroke testing, and network monitoring and management capabilities to process safety systems. Many major end users such as Aramco and Shell have beta systems running FFSIF logic solvers and devices running today, and have openly stated that they would like to deploy this technology on all of their upcoming major projects.

No changes were made to the fundamental H1 protocol for implementation in safety instrumented systems, but additional device diagnostic functions and fault detection capabilities were required. In addition to the device diagnostics, the primary advantage to using FF-SIF as the network for safety applications is the network diagnostics that are possible. Traditional analog-based networks lack the ability to detect noise, corruption, and faults in the network. More importantly, the data handling capability of Foundation technology means that you can commission your safety system faster. Users modernising their legacy safety instrumented systems must also replace the entire system, from the devices to the logic solver, to be compliant with safety standards such as ISA 84

and IEC 61508 and 61511. FF-SIF offers reduced time to startup, easier regulatory approval, and reduced installed costs for process safety systems.

Myth no.10

Fieldbus is just for refining and chemical industry, not for batch applications or the regulated industries: Today, 10 of the top 20 food and beverage companies and 24 of the 25 top pharmaceutical companies are using Foundation technology. Foundation technology makes it easier for regulated industries to achieve compliance. Pharmaceutical manufacturers are increasingly designing their plants for fast track construction by connecting multiple pieces of OEM skid mounted equipment together. Foundation technology makes it easy to integrate different skids from different OEM suppliers quickly under a single network and automation infrastructure. The reduced footprint of Foundation technology also lends itself well to the limited space requirements of many skid mounted systems. Dealing with changes in scope that include adding new field devices after initial segments were installed is less painful because it is not necessary to install a home run cable for the device to the control cabinet.

Turning myths into opportunities

The myths and misconceptions presented here can be used quite effectively to demonstrate the business value, return on investment, and improved operational performance that Foundation technology provides. In today’s digital age, there is no reason not to include an evaluation of Foundation technology for your automation requirements, whether it is a modernisation project or a grassroots facility. The Fieldbus Foundation has numerous resources to help suppliers and end users implement successful projects, develop quality products. ☐

Courtesy: Fieldbus Foundation ([email protected])

Business case for adoption

of Foundation Fieldbus safety

instrumented functions


close to you!

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Nagel Precision Inc in Ann Arbor, Michigan, is the US subsidiary of German Nagel Maschinen- u Werkzeugfabrik GmbH. They create machines for honing, super finishing, and deep hole drilling which are used to manufacture engine blocks, transmissions, pinion gears, valves and other metal artefacts which require a very smooth surface. The machines are installed in manufacturing plants around the world by companies such as GM, Chrysler, KIA, Hyundai, and Ford.

The network dilemma

Nagel Precision’s machinery is built on an EtherNet/IP-based control system with an Allen Bradley PLC, often with the Rockwell Kinetix 6000 multi-axis servo drives as the pivotal core. However, since the honing machines are exported to factories all over the world, Nagel was faced with the problem of how to communicate with other networks, especially

Getting connectedAn application story on how Nagel Precision connected their honing machines to industrial networks with the help of Anybus X-gateways

Fieldbus & Networking - HMS.indd 64 6/17/2014 7:17:47 PM

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PROFINET which is frequently used in car manufacturing plants. “We first started out with third party network cards,” says Jim Saule, Director — Information Technology, Nagel Precision Inc. “However, these were a bit cumbersome since they required a lot of configuration and were also quite expensive. It was also sometimes hard to find the correct card. That’s when I started investigating into the Anybus X-gateway from HMS. I liked the fact that one could support several different networks with the same configuration – something which would save us a lot of work.”

Cost cut

About two years ago, the first Anybus X-gateways were installed in Nagel Precision’s systems. The solution was delivered by HMS’s distributor in Michigan – McNaughton McKay Inc. The possibility to focus on the core business instead of network connectivity has been an important decision parameter for choosing Anybus – the fact that the gateways are half the price of the third-party cards. “We don’t want to understand every type of controller out there,” says Saule. “We would rather focus on perfecting our honing machines. Anybus X-gateways has allowed us to do just that. Furthermore, the third party network cards cost us about 1200-1500 dollars each, now we are down to around half that cost for a gateway.”

How it works

If the honing machine is to be installed in a factory that runs EtherNet/IP, it can be connected directly and communicated on the network. But if the factory runs another network (for example PROFINET), an Anybus X-gateway is required. The gateway works as a translator between EtherNet/IP and the factory system and ‘translates’ parameters such as positioning data, status of the drives, start/stop commands etc. The communication stream is transparent on both sides of the gateway making the honing machine a separate node on the factory floor, fully able to communicate with the plant-wide network. “We have been using the Anybus X-gateway for more than two years now and it has been flawless,” says Saule. “I have been designing these types of systems for more than 20 years and really appreciate the fact that we can support several different networks with the Anybus X-gateway. This enables us focus on our core business – building honing machinery – rather than working with compliance for different networks. I would definitely recommend any machine builder to look into Anybus, the variety is great and there are substantial savings to be made”. ☐

Courtesy: HMS Industrial Networks


The Anybus X-gateway allows Nagel’s Allen Bradley PLC to

communicate with any other industrial network

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Today, the Indian industry is witnessing a key trend of increased quality-consciousness, lean processes and inclination towards energy savings. The realisation that energy saved can be turned into profit is growing with time. Also, increased awareness to reduce environmental impact, for example, through controlled industrial emissions, is expected to have an impact on the test equipment market.

Energy savings & PAT scheme

Bureau of Energy Efficiency (BEE), under the Ministry of Power, India recently introduced Perform Achieve Trade (PAT) scheme with an aim to reduce energy consumption in industries across India. BEE has notified every industry falling under this scheme about their energy efficiency targets. To implement this scheme, every industry has to appoint an energy audit cell to keep a track on its progress towards energy efficiency targets.

Compliance to industry standards & norms

Several industries are now achieving compliance to their industry-specific norms. This in-turn calls for the need of more accurate, precise and robust test & measuring technology. In other developed countries, several industry norms are already in place and industries comply with the same. However, in India, it is just the beginning.

Multi-functional measuring instruments

With the advent of smarter technology, with little or no scope for human intervention, measuring instruments are now error-free, easy to operate, convenient to use and most importantly, multi-functional. One single instrument can measure multiple parameters, and can also make analysis easy, thus simplifying a technician’s or an engineer’s job. For example, the multi-functional instrument testo 480. With this instrument and its

Kalidas BhangareManaging DirectorTesto [email protected]

BecoMIng sMarTer & effIcIenT With the advent of smarter measuring technologies, measuring instruments are now error-free, easy to operate and most importantly multi-functional. This article deals with latest technology trends and innovations in testing & measuring instruments.

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Kalidas BhangareManaging DirectorTesto [email protected]

digital probes, the user can record parameters such as flow, temperature, humidity, pressure, illuminance, radiated heat, degree of turbulence, CO2 and Lux.

Digitisation of refrigeration manifolds

It’s time to switch over into the age of efficiency – from analog to digital refrigeration manifolds. The HVAC system’s efficiency can be improved not only with skilled technicians but also with accurate measuring instruments. Digital 550 can measure multiple parameters with a single instrument. Analog readout increases chances of errors, is time consuming and difficult in handling. While digital testo 550 is fast & accurate and is easy to handle, its large illuminated digital display minimises errors. There are different gauges for different refrigerants. But testo 550 - single manifold has 39 different refrigerants stored. Analog output requires to be processed in the form of charts & calculations in order to derive conclusions. But a digital 550 facilitates fast conclusions derived from all information on the display itself. Thus, it’s the digital age driving more efficiency by reducing errors and saving time & efforts.

Smarter technology

Easy accessibility and easy availability of USB connectivity is a prime advantage boosting the USB-based technology in test & measurement industry. Almost all devices around, be it a mobile or a desktop are equipped with USB connection. Moreover, with one multi-port USB, multiple devices can be connected simultaneously. There is no loss of signal, whatsoever, while transmitting the data through USB.

At the same time, the awareness regarding wireless technology and its demand is increasing rapidly. Users of wireless test equipment enjoy the freedom from wiring and cabling mess, low maintenance and reduced manpower. Also, its installation is simpler than imagined – in shortest possible time and in lower costs too. With very low downtime, wireless technology in totality, provides far more returns on the money as against the wired technology. Testo’s wireless data monitoring system called Saveris for temperature & humidity measurement

has gained wider acceptance with time for automated and uninterrupted measurement and data monitoring.

Newer applications of measurement technology

Measurement technology is penetrating deeper into varied industries. Today, data loggers and wireless monitoring system

– Saveris are used in many pharma plants & cleanrooms for climate monitoring.

High energy plants such as cement, steel and power find Testo flue gas analysers as an inevitable solution for emission monitoring and complying to pollution control board norms. Any maintenance department – be it electrical or mechanical finds extensive applications of thermal imagers for predictive & preventive maintenance. The company ensures that the HVAC contractors or facility managers are equipped with the best-in-class measurement technology with all rounder multi-parameter measuring instruments, refrigeration manifolds, leak detectors and so on. It has instruments such as testo 635-2 which comes with a U-value probe that helps evaluate energy efficiency of buildings by measuring heat losses of walls & windows.

U-value measurement otherwise is a tough task as it requires three temperature values to be measured concurrently and U-value is then required to be calculated. But testo instrument automatically displays U-value as a result of three measured values via its three wires.

Key drivers of test & measurement industry

Simpler & reliable technology, easy to operate, convenient to use, robust, error-free and minimum human intervention are some of the key technology trends customers can look out for in future. Availability of software and other aids make analysis part of measurement simpler and error-free too. There is no doubt that every new product that gets introduced in the market has some remarkable features to look out for. The test & measurement technology just gets incredibly smarter with advanced technologies. ☐

Switch to digital

refrigeration manifold


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There is no denying that India is expected to face an energy crisis in future, if it continues its huge dependence on fossil fuels, such as coal and natural gas. India is one of the largest energy consumers across the world and its burgeoning population demand for energy is expected to increase rapidly. Energy security is a key requirement if India expects to grow consistently at over 7% per annum. A viable solution lies in harnessing the available renewable energy sources, which will decrease dependence on fossil fuels. This gains significant importance on the back of recent issues with coal linkages and

natural gas supplies to power plants. Focusing on renewable energy has twin benefits. Firstly, it reduces the country’s dependence on non-renewable energy. Secondly, it eases imports to bridge the fiscal deficit. However, there needs to be consistent investment in developing the infrastructure to harness renewable sources of energy such as solar, wind, biomass and small hydro.

Currently, according to the government estimates, roughly 12.6% of the total installed capacity is from renewable sources. The government should incentivise projects based on renewable

Automation in renewable energyThe article highlights how automation vendors are addressing the challenges in providing sustainable and efficient automation solutions to the renewable energy sector. Utility companies are investing in automation and control solutions (ACS) to optimise generation, monitor and control operations, and energy management. There is also a great need for automation solutions on the transmission and distribution side of renewable energy generation, to cut T&D losses.

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energy to realise the actual potential of renewable energy. The target for renewable energy capacity addition under the 12th Five Year plan is 29,800 MW, which will take the share of renewable energy to roughly about 17% of the total installed capacity. A planned capacity addition under the 12th plan is approximately a third of the planned capacity additions powered by coal and gas. A lot of the momentum is also driven by the government, which is active in bringing 100% FDI in renewable energy projects and providing incentives to renewable energy generation, such as the Jawaharlal Nehru National Solar Mission for both grid-connected and off-grid solar systems. There is a higher push for renewables compared to conventional fuels, as renewable energy generation is becoming cost competitive compared to thermal power generation. Generation based incentives (GBI), renewable energy certificates (REC), and renewable purchase obligations (RPO) will also push investments in this sector.

ACS enables efficient management and effective utilisation of resources in renewable power generation. Automation vendors are offering ACS as part of a larger, integrated solution specifically designed for renewable power generation.

Automation solutions in renewable energy

Automation vendors have woken up to the challenges in providing sustainable and efficient automation solutions to the renewable energy sector. Utility companies are investing in ACS to optimise generation, monitor and control operations, and energy management. There is also a great need for automation solutions on the transmission and distribution side of renewable energy generation, to cut T&D losses.

Plant control and monitoring solutions such as Supervisory Control and Data Acquisition (SCADA), and Distributed Control Systems (DCS) coupled with Human Machine Interface (HMI) & Remote Terminal Unit (RTU) and other intelligent control solutions enable supervisory control over power generation, transmission devices and assist in plant monitoring and safety. Power and Energy Management Systems (EMS) are responsible for efficient monitoring and control of generated power from generation plants to the distribution load centres. At the distribution load centres, the DMS (Distribution Management System) takes responsibility of managing distribution from the load centres to the individual end users.

Advt


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due to various incentives such as renewable energy certificates and renewable purchase obligations for each state distribution company. The hydro power sector aims to add over 100 Gigawatt (GW) to the overall installed capacity by 2032. Other renewable sources of energy such as biomass, urban, and industrial waste power will see localised investments in India. With such a drive on renewable power generation, there will be a huge market for ACS in India. Approximately 10 to 15% of the total project cost (excluding land cost) in solar and wind segment can be attributed to ACS. In the small and large hydro projects (small and large hydro), the total spend on automation systems is around 3 to 5% of the total project cost.

Increasing reliance on ACS to manage power generation along with smart grids to ensure reliable T&D infrastructure will propel the market for automation systems. These automation systems will replace the archaic and ageing infrastructure, thereby increasing flexibility in operations with real time management and control across the spectrum of power generation.

Conclusion

India is currently facing significant pressure on its resources due to increasing urbanisation, which does not augur well for it in the long term. A sustainable solution lies in complementing power generation from renewable sources as well as trimming the demand side with a focus on energy efficiency. Sustainable cities and smart cities, which are gaining momentum in India, are based on a similar concept. Developing sustainable cities will minimise energy requirements, reduce pollution of natural resources and its environmental impact, a way to a better future in the country. ☐

Courtesy: Frost & Sullivan

Intelligent field devices such as transmitters, analysers, valves, actuators, flow meters, and other field devices coupled with networking and communication equipment such as Foundation Fieldbus can assist in real-time monitoring and control of renewable energy systems and equipment. Control systems such as the Programmable Logic Controller (PLC) and variable frequency drives will help in advanced control of Level 0 devices for efficient management as per requirement, thus reducing power usage.

Automation and energy control centres (Level 3) can help in implementing plant level controls and provide complete visibility to entire systems. These systems can support scalable and modular architecture of the underlying SCADA/EMS systems. They are intrinsically designed to enable expansion and integration of diversely located multiple sub-systems and online interactive controls. Automation solutions for each level of automation such as energy management solutions, motor and drive control solutions, control system applications, control centre applications will assist to increase flexibility in design and functionality of the underlying hardware systems.

On the T&D side, smart grids can be more effective in India as it enables real-time data management, analyses and controls power generation, transmission, and distribution. Smart grids will eventually evolve networking and communication systems from the erstwhile serial systems to an IP based system utilising routers and switches along the network.

Opportunity for ACS in the renewable sector

India has made good progress in bringing renewable technologies to the fore and offering excellent opportunities for ACS manufacturers. New installations of wind and solar energy are expected to rise significantly in the 12th plan. The renewable energy sector is anticipated to get a further boost from investors > MORE@CLICK ADI03492 | www.AandD24.in

Automation vendors are offering ACS

as part of a larger, integrated solution

specifically designed for renewable

power generation


Industry in Transition: The Information Driven Enterprise in a Connected World

P R E S E N T I N G A R C ’ S T W E L F T H I N D I A F O R U M

Space Is Limited! Call India +91-80-2554-7114 or USA +1-781-471-1000, Register on-line at www.arcweb.com/events/arc-industry-forum-india/,

or e-mail [email protected].

FEATURED TOPICS:

INFORMATION DRIVEN MANUFACTURING

AUTOMATION AND ENTERPRISE TRENDS

ADVANCED CONTROL SOLUTIONS

ENERGY MANAGEMENT STRATEGIES

THE FACTORY OF THE FUTURE

ASSET PERFORMANCE MANAGEMENT STRATEGIES

MOBILITY SOLUTIONS FOR PLANT PERSONNEL

OPERATIONAL EXCELLENCE AND CYBER SECURITY

REMOTE DEVICE CONNECTIVITY ENABLES THE INTERNET OF THINGS

CLOUD-BASED SOLUTIONS FOR IMPROVED MANUFACTURING

PERFORMANCE

WIRELESS CONTROL

VISION, EXPERIENCE, ANSWERS FOR INDUSTRY

TO REGISTER:

Globally, the investment climate is still tenuous and risk-averse and this

has impacted industrial growth. India’s economic growth has temporarily

decelerated due to the global headwinds and domestic rumblings; but industry

analysts predict that it’s just a matter of time before the growth engine is back

on track. However, for a successful transition it is imperative for industries

to adopt new information technologies, such as cloud computing, mobility,

social technologies, Internet of Things, big data/analytics, and 3D visualization.

Information driven digital enterprises leverage new technologies to achieve

agility and sustain a competitive edge.

ARC Advisory Group’s Twelfth India Forum is a much anticipated event for

industry executives and technology solution providers in the process and

discrete industries. Process industries typically comprise of chemical, oil and

gas; electric power including renewable energy; cement, metals and mining;

food and beverage; and pharmaceutical industries. Discrete industries comprise

of aerospace, automotive/auto components, capital equipment, consumer

products, defense, electronics, high technology, and medical equipment. Solution

providers are implementing path-breaking technologies in both sectors. ARC’s

Forum provides an appropriate networking platform for key decision makers

and thought leaders to share their experiences and insights on best practices,

strategies, and technologies, along with suppliers of automation systems,

enterprise solutions, and manufacturing IT solutions. The knowledge transfer

will come from case study presentations, panel discussions, workshops, and

peer-to-peer networking.

Whether you are a manufacturer or a solution provider, this forum will help you

make well-informed decisions on investing in new information driven technologies.

C

M

Y

CM

MY

CY

CMY

K

ARC 210X273.pdf 6/16/2014 3:03:28 PM

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After turning the dial to heavy duty and pushing the start button, Modi waits for the click which indicates that the interlock mechanism successfully locked the door of the washing machine. Shortly after, the water starts to flow and the machine indicates that the soak and scour phase is in progress. Now it’s time for Modi to move on to the next washing machine.

Modi is short for MoDiBot, or Mobile Diagnosis Robot, an autonomous test platform for household appliance testing, developed by engineers at Loccioni, a leading provider of test, measurement, and automation solutions from Italy. MoDiBot works in a test laboratory, allowing scientists and researchers to apply new technologies and validate the algorithms and applications of their autonomous systems to put them on the touchstone for adoption in the life-cycle test laboratories of white goods manufacturers around the world.

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Innovation in smart robotics

Without a doubt, robotics technology is an emerging priority. Today they play an important role in applications characterised with one of the 3D’s: dull, dirty, or dangerous. Here’s a look at how enabling technologies for the proliferation of robots in industrial and commercial applications have changed the paradigm of automation.

Opening new perspectives

According to Dr Cristina Cristalli, Director of the Research for Innovation Group at Loccioni, robotics is an excellent way to move & place sensors and measurement equipment, opening a new perspective for the automation of reliability testing. While she described some challenges, as well as the technologies required for the adoption of autonomous platforms for one very specific use case, she also explained that most of the robotics systems used across industries and application areas share the same core components and architectural approach. The combination of one or more robotic manipulators (arms) mounted on top of an autonomous platform is a common mechanical solution. Based on this combination, the industry and research community has developed many application specific variations over the last few decades; however, robots

Satish Mohanram Business Development ManagerNational Instruments [email protected]

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into a standard engineering discipline, allowing a broader adoption? The big innovations are in the embedded control systems, software tools, sensor technology and battery and energy efficiency technology. No matter how complex the hardware architecture might be—sense, think and act is a common paradigm to implement innovative robotic applications.

A big impact on the adoption of robotics comes through the ever increasing processor performance. Only recently available in desktop PCs, powerful multicore-processors have been adapted for embedded systems. These processors are attractive for robotics systems because lower footprint embedded systems comply with tight power, space, and weight constraints of the robotics industry. Powered by real-time operating systems, they are capable of executing many of the mission-critical tasks, close control loops, and can perform I/O operations and communicate with other devices.

Development of robotics applications

The computational components alone, however, will not

simplify the development of robotics applications. According to Dr David Barrett, well-known roboticist and professor at

are far from being ingrained in our everyday life and robotics technology has not been adopted at the same rate as information technologies or RF technology.

Paving the way

The question that arises is what are the technologies that pave the way for robots out of the laboratory? Without a doubt, a significant part of the innovation takes place in the ‘smarts’ of the robot where a common architecture includes a network of interconnected embedded systems. Some of these embedded systems perform small and dedicated tasks such as battery management, motor control, or sensor fusion and are based on lower footprint programmable logic devices (PLDs) and microprocessors. Additionally, most robotic systems contain one or more high-performance embedded systems that use the latest processor technology to execute mission critical tasks, ensure safety, leverage machine perform image processing, and run advanced control algorithms. Overall, robots are complex mechatronical systems and programming them often requires a large team of PhD-level experts.

Another question that comes to mind is which technologies are driving robotics innovation and will transform robotics


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LV robotics module


Olin College, “the robotics industry badly needs an industrial grade, hardened, richly supported software development system to build intelligent, autonomous, mobile robots that can sense, think, and act in the complex real world around them.” In other words, industry needs a software tool that abstracts the complexity of these interconnected high-performance computational devices and provides ready-to-use building blocks for the most common tasks in robotics applications such as sensor connectivity, navigation, localisation, path planning, obstacle avoidance, or vision guided motion. Over the last couple of years, industry and the research community developed these types of tools in the form of open source software packages like Willow Garages Robot Operating System (ROS) or commercial tools like NI LabVIEW Robotics. The labview robotics is a graphical system design tool that supports different models of computation for the implementation of robotics applications and makes it possible to deploy to different targets such as multicore processors, real-time processors, or FPGAs.

Besides embedded control systems and high-productivity software tools, sensors and sensor connectivity play a key role; thus, it is not surprising that the current proliferation of sensors is shaking up the robotics industry. The availability of compact Micro-electromechanical systems (MEMS) sensors that are heavily used in commercial products such as smart phones or controllers for entertainment consoles have led to a price erosion for accelerometers, gyro sensors, and even more standard sensors including light, pressure, or temperature. However, it is not solely about price. The MEMS technology also simplifies the processing of sensor information because the devices include signal conditioning and translate the sensor information into useful data that is sent back via standard protocols such as I2C. The reuse of commercial technologies sometimes goes even further. Rather than capitalising on price advantages for components used in commercial products, the robotics industry adapts the commercial product directly. USB cameras or the popular Kinect controller from Microsoft are

good examples that demonstrate this trend. Recently, this commercial product made it possible for many robotic systems to recognise and locate objects in a 3D space at a significantly lower cost than previous solutions.

Deploying robots effectively

The last key area of innovation to deploy robots to the field

is the area of energy efficiency and battery technology. Operated in a research laboratory, robotic systems usually stay connected to a power outlet. While this might work for some applications areas, there are many use cases of robotics where the autonomous operation requires independent energy sources often in the form of batteries. Implementing energy efficient operation of the robot actuators and using low power embedded control systems can help reduce energy consumption. At the same time, there has been a lot of innovation in battery technology, which is driven by the focus of the automotive industry on alternative energy sources for modern vehicles and the increasing use of mobile devices like laptops, tablets, and smart phones. The robotics industry can capitalise on the heavy investment of global players such as Toyota, GM, Apple or Samsung.

All of these technologies were essential components in the design and deployment of MoDiBot to the first life cycle test facility. Robotic technology allowed the manufacturer to perform automated testing of dozens of devices at the same time and around the clock. The same technologies that enabled Loccioni to develop their revolutionary test system will help to grow the adoption of smarter robots in industrial and commercial applications and will transform robotics technology into a commodity engineering discipline rather than simply a research exercise. Ultimately, this will make it possible for robots to leave the laboratory and settle into our everyday life. ☐


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E V E N T | r ep ort

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The 6th edition of AUTOMATICA, organised by VDMA Robotik + Automation, offered automation solutions for competitive production, energy efficiency, lightweight construction, professional service robotics and Industry 4.0, among the main topics. AUTOMATICA 2014, held on June 3-6, 2014, drew a positive balance: over 10% more visitors and 7% more exhibitors than the previous edition. Dr Reinhard Pfeiffer, Deputy Trade Fair CEO, said, “The growth rates and the high degree of satisfaction among exhibitors and visitors prove that AUTOMATICA has expanded its leading role.” Patrick Schwarzkopf, Managing Director, VDMA Robotik + Automation, added, “AUTOMATICA provides a decisive contribution to a change in production as an innovation platform. Trade visitors from the whole world learn what the future looks like at AUTOMATICA.”

Robotics and automation gaining global importance

A total of 32% of the visitors came from foreign countries, an increase of more than 15% as compared to the last edition.

“The motto of AUTOMATICA – “Optimise Your Production” – is experiencing a boom throughout the whole world,” explained Hans-Dieter Baumtrog, Chairman, Board of VDMA Robotics + Automation. “It concerns the quality, safety and sustainability of products. Integrated assembly solutions, robotics and industrial machine vision are the key to success in this context. The increasing internationalisation of AUTOMATICA is a clear indication of this development,” he added. Stefan Kapferer, Permanent State Secretary at the German Federal Ministry for Economic Affairs and Energy,

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From production automation to professional service roboticsUnder the motto “Optimise Your Production”, AUTOMATICA 2014, held recently in Munich, Germany, exhibited the relevant topics dealing with production optimisation in five trade fair halls, where experts from industry and research talked about sustainability ranging from production and lightweight construction to professional service robotics and smart factory (Industry 4.0)


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From production automation to professional service robotics

Industrial experts discussed the latest

technologies, innovation, research needs

and the challenges in the global robotics

and automation industry

said, “AUTOMATICA has once again demonstrated the outstanding position of Germany in robotics and automation.”

Blue Competence – the sustainability initiative of VDMA

VDMA Robotik + Automation presented the sustainability initiative Blue Competence, at its booth. The focus was on sparing use of resources and sustainable production processes. The main topics of the initiative were energy saving, minimising emissions and consumption of raw materials, life cycle costs, the recycling industry and future mobility. A simulator at AUTOMATICA made the topic of energy efficiency comprehensible.

Automated production of lightweight components

Energy efficiency and sustainability also determine the increasing importance of lightweight construction solutions in very different branches of industry. A decisive factor in this context is the automated production of lightweight components

– above all in the area of composites. The special exhibition “Automated Composite Production” and the conference for “Industrial Composite Production” during the show examined state-of-the-art technology for increasing process speed and reducing production costs. Practical examples from the industry sectors – automobile construction and aerospace as well as mechanical and plant engineering were the focus of the conference, which was organised by the leading-edge cluster MAI Carbon.

ISR/ROBOTICS 2014

The largest robotics conference in Germany (8th German Conference on Robotics) in connection with the 45th International Symposium on Robotics (ISR) took place during the show this year. The conference was organised by the Fraunhofer IPA and the German Robotics Society (DGR).

Experts showed the latest in research and development concerning components and technologies as well as new markets and applications in approx 150 presentations in this event.

SPARC: € 2.8 billion for European robotics

The role of the industry is becoming very clear on a European level. Neelie Kroes, Vice President, European Commission, announced the world’s largest civil robotics promotion programme SPARC at AUTOMATICA 2014. With a total volume of € 2.8 billion, Europe’s leading position is to be expanded and consequently more than 240,000 jobs created. Kroes emphasised: “AUTOMATICA is a perfect opportunity to showcase the latest European robotics technology.”

Man & machine to work hand-in-hand

Robotics and automation are reaching a new dimension with man-machine cooperation. Robots are handling work in the place of people that is monotonous, injurious to health and requires no special job skills. This makes workplaces more productive, flexible and ergonomic. The event also showed the enormous potential for small- and medium-sized firms in numerous examples.

Professional service robotics – a fantastic start

Marketable service robotics created a lot of interest. More than 60 companies, specialised in service robotics with B2B relation, exhibited the outstanding possibilities of intelligent service robots and components from the areas of medicine and nursing, inspection and maintenance as well as logistics. The Berlin-based company, Argo Medical Technologies won the first Service Robotics Masters Start-up Award with its exoskeleton suit, which provides paraplegics with the possibility to walk again. ☐

Courtesy: VDMA Robotik + Automation> MORE@CLICK ADI03494 | www.AandD24.in

Event Report - VDMA - Jun-Jul 2014.indd 79 6/19/2014 3:49:32 PM

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A&D I nd i a | J u n - J u l 2014

Siemens PLM Software organises Solid Edge University every year to introduce lastest technologies and equip its users with the knowledge & tools to work with an ability to re-imagine what’s possible in 3D design. This year, the day 1 of SEU2014 began with an energetic presentation by Karsten Newbury, Senior VP and GM — Mainstream Engineering Software, Siemens PLM Software, on how their technologies have been efficiently and innovatively used by various leading manufacturers in the world. He presented interesting case studies on how their CAD software helped Swiss ski manufacturer Stöckli to produce customised products in large numbers. Ever since the ski makers’ combined experience has been available as a dataset in the Solid Edge CAD software, the

design of a ski variant takes only an hour instead of two days, Newbury mentioned.

Next, Newbury placed the limelight on the use of Siemens PLM software by NASA scientists to help create the Mars rover ‘Curiosity’. On the strategic initiatives, he said, “Our key focus is on empowering the user to design and better development of the synchronous technology to help products market better. This year, we will be launching apps store for Solid Edge. Eurozone stores will also go live in the coming months. We are also getting into close collaboration with GrabCAD and Kenesto this year.” Following this, Hardi Meybaum, CEO, GrabCAD announced that his company has licensed Siemens’ Parasolid® software to provide 3D model interrogation,

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Reimagining what’s possible in 3D design Siemens PLM Software hosted Solid Edge University 2014 (SEU2014) on May 12-14, 2014 at Atlanta, USA, to provide a unique opportunity to its users to enhance their productivity, and have a firsthand look at Solid Edge ST7.


Sumedha Mahorey Deputy Editor [email protected]


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Reimagining what’s possible in 3D design

inspection and visualisation within their Workbench application for cloud-based product data management.

The keynote address for Day 1 was presented by Ali Kermani, Product Designer, Brand Manager, and VP — Digital Media, Razor USA, who bagged the Toy-of-the-Year award for his innovative Crazy Cart. Kermani amazed the audience with his drifting stunts on stage & efforts put in by him & his team to develop the award winning Crazy Cart. He pointed out how his journey was simplified from ideation to reality stage with the use of Solid Edge software. This was followed by the launch of ST7, the newest version of Solid Edge 3D design solution.

Accelerating product design management

Packed with 1,300 user-requested enhancements, Solid Edge ST7 grabbed the audience attention with its remarkable attention to detail, newly-added functionalities and ease of use. Introducing ST7, Dan Staples, VP — Solid Edge Product Development, Siemens PLM Software, focused on four major pillars for its development: accelerating 3D modeling, streamlining design management, powering up with new apps and ensuring amazing user experience.

Some of the standout enhancements included creation of blank from a 3D model. Staples explained, “Rapid creation of manufacturing information for components that are manufactured using forming, stamping and deep drawn manufacturing processes is now possible using the “Create Blank” command that enables you to create a flattened blank from any 3D model. Formability of different materials is assessed and blank sizes are calculated.”

ST7 also boasts of a breakthrough duplicate components command. “This command speeds assembly design in which components are duplicated in many positions and orientations. Multiple copies of a component can be created based on designated “from” and “to” positions and orientations of existing components,” explained Staples.

Major additions also include easy and powerful photorealistic rendering of products designed using Solid Edge with a tightly integrated rendering capability that is included with Solid Edge Classic and Premium. The solution uses KeyShot®, the fastest & easiest way to create beautiful product images and processes concurrently with modeling operations. Staples elaborated, “You can render while you design. Any changes to the model are automatically updated in the rendered

image using the “Live Link” capability with no need for you to reassign materials, set up animations again or update any other settings. The resulting images are presented using KeyShot’s viewport concurrently with the modeling session.”

The enhanced Microsoft Surface Pro in ST7 offers full support for Solid Edge design tasks and expanded support for finger gestures is now included. For example, a single finger drag enables a pan operation in 2D and a rotate operation in 3D, and a two finger pinch enables a zoom-in operation.

The launch of ST7 was followed by presentations on “Technology mega-trends driving innovation in product design” by Jeremy Barnes, Partner Evangelist, Global ISV, Microsoft and “Make time-to-market your competitive edge – empowering design and manufacturing” by Nishant Saini, Director – Product Sales & Marketing, Geometric Americas. Saini also informed, “We have announced the availability of version 2014 of CAMWorks for Solid Edge software. The new version provides tighter integration to enable customers to reduce programming time to further accelerate time-to-market. The feature-based approach seems much more intuitive than the process of creating profiles and chains method. The automatic feature recognition and tool path associatively helps reduce programming time by as much as ten times.” Post the presentation, the participants indulged in technical breakout sessions on how can open engineering help in faster working, simplifying design, among others.

The keynote address for Day 2 was presented by Anthony Decarolis, CEO and Alon Razgour, Industrial Designer, Alpha Omega. They focused on the use of Solid Edge software for inventing medical devices that treat human brain. This was followed by a talk by Wes Shimanek, Workstation Segment Manager, Datacenter Group, Technical Computing Group, Intel Computing Group on “How to fast track product design?” Breakout sessions with live demos & workshops followed.

“Our Edison2 Very Light Car that won the Automotive X Prize was entirely designed in Solid Edge. The subscription model now exists in Solid Edge, which takes it one step further. For a temporary job, it helps us in adjusting the cost.”Oliver Kuttner, Founder & CEO, Edison2

“Our key focus is on empowering the user to design and the better development of synchronous technology to help products market better” Karsten Newbury, Senior VP & GM, Mainstream Engineering Software, Siemens PLM Software


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A&D I nd i a | J u n - J u l 201482

In discussion with the management

While commenting on how he anticipated the technology upgradation and the new functionalities of ST7 to be absorbed in various world markets, John Fox, VP – Marketing, Mainstream Engineering Software, Siemens PLM Software affirmed, “The audience reaction during the debut were very positive. I am really excited about the breadth of new capabilities in ST7 and the fact that there was as much Solid Edge core platform & technologies as it was about our partnerships, what we call Solid Edge apps. In particular, the announcement of our partnership with Luxion has been well-received.” With many participating channel partners, users and industrial experts, let’s understand the business strategy that goes behind the launch of new functionalities every year. Newbury asserted, “Solid Edge is a volume product. We have over 5 lakh seats now. We typically don’t have, like in the enterprise world, a handful of key customers that dictate what is developed. We really look at the broad market requirements. Most of the times, this helps in addressing the requirements of most of the markets. We do have some examples where we have special drafting standards, where we place a special team to develop the specific needs for the market. In India, some years ago, we worked with a partner who developed special add-ons around the jewelry industry. So, 80% of the development is catered to the global requirements, as we look at special high growth markets and investments, starting with language. But generally, we have found that most of the functionalities can be found across the world.”

So, how are these breakthrough functionalities added every year? Addressing the query, Staples elaborated on the strategy that goes behind new product development. He briefed, “To me, it is about balancing process and innovation. It’s very easy to have processes and not be innovative. And it is hard to be innovative and do it randomly. The hard part is to have processes and innovation together. We have a team of about 15 people who are engineers with experience working in different industries and they know what engineers want. We have our industrial designers and graphics designers, who figure out what engineers want and how it can be delivered.”

User views

One of the major users of the Solid Edge platform is Edison2, which combines sound physics with innovative

design to produce workable & sustainable transportation solutions. A&D India had the opportunity to speak to Oliver Kuttner, Founder & CEO, Edison2, during the SEU2104. When asked about his views on Solid Edge technology, Kuttner said,

“We design racing cars destined to be one of the most efficient cars in the world. Since mid-90s, we have used Solid Edge software. Our Edison2 Very Light Car that won the Automotive X Prize was entirely designed in Solid Edge.” Adding on why his company chose the Solid Edge software, Kuttner pointed out, “Our chief designer used it & we all have grown into it. It’s very efficient and easy to adapt as compared to other programs. The subscription model now exists, which takes it one step further. For a temporary job, it helps us in adjusting the cost.”

While commenting on the new capabilities of ST7, another user, Ricardo Espinosa, Design Engineer, Kimball International, said, “The new built-in image rendering capabilities in Solid Edge ST7 will provide a tremendous advantage for our business development. During meetings with customers, we will be able to respond to requests for customised products by taking their input, easily modifying the model with synchronous technology and generating realistic images for instant review.”

With a jam-packed audience, over 75 technical sessions, workshops, live demos and suggestions from the user industry during the event, SEU2014 drew to a close on May 14, 2014 with a thought invoking awards ceremony for the participants. ☐


“We have announced the availability of version 2014 of CAMWorks for Solid Edge software, the 3D CAD tool from Siemens PLM Software for mainstream manufacturing market” Nishant Saini, Director - Product Sales & Marketing, Geometric Americas

“The duplicate command speeds assembly design in which components are duplicated in many positions and orientations” Dan Staples, VP – Solid Edge Product Development, Siemens PLM Software

“The audience reaction during the debut of ST7 were very positive, John Fox, VP – Marketing, Mainstream Engineering Software, Siemens PLM Software


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Similar to the food & beverage industry, there are a few industries, which are multifaceted and demanding when it comes to their requirements with regards to their operating conditions. The strict hygiene and cleanliness requirements, which exists in the food processing industry, also apply to electrical component manufacturing. There are complex requirements for cables and accessories in the food & beverage industry and in bottling & food packaging plants. These must be resistant to a whole host of chemical, thermal and physical stresses so that they can be used in refrigerated areas and damp environments and can still fulfill their function reliably. Components and materials of the cables also play an important role in the food industry with respect to the degree of protection, corrosion resistance and hygiene.

The packaging operations in food and beverage processing plants typically contain many automated processes. Technology has a significant impact on these processes. Lapp India provides comprehensive range of standard and specialised products to one of the renowned industry leaders who revolutionised the food packaging industry through their innovation and dedication.

Solution requirements

There was a need to expand the factory, in order to meet the growing requirements of safe and hygienic food packaging. This project required bulk amount of cables for wiring the entire factory. The cables were to be used for supplying power to the machines; controlling applications of the machines; internal wiring for the factory

There are complex requirements for cables and accessories in the food & beverage

industry and in bottling & food packaging plants

CABLING SOLuTIONS fOr fOOD pACkAGINGThe article deals with the latest developments in standard and specialised cabling solutions to meet the growing requirements of safe and hygienic food packaging industry.

area; internal and external lighting applications of the factory; low loss data transmission for various man-machine interfaces and also for machines, which required automation.

There was a need for cable glands to ensure secure connection. Additionally, cable conduits were also ordered to offer physical protection to the cables from mechanical and chemical stress.

Cabling solutions

The company provides complete solutions for the new factory. For internal wiring, factory lighting and other fixed applications, it offers single core power cables that have a halogen-free compound insulated outer sheath and are composed of few strands of bare copper wires. The high purity of copper enables the company to obtain greater connectivity in the cables. Keeping in mind the application and space constraints, Lapp India provided cables that were flame retardent, offered superior chemical resistance and exhibited high electrical performance to supply power to the machines. For applications that required screening, cable which are highly flexible, durable and > MORE@CLICK ADI03496 | www.AandD24.in

ideal for internal wiring of electric and electronic equipment in switch cabinets, were supplied. These specialised cables catered to direct burial needs and to the requirements of speed control and fluid control in the machines, adjusting the speed of the servomotor and PLC based control. For seamless data transmission, the company provided highly flexible cables that offered joint free construction.

Cable accessories for enhanced protection

Lapp India supplies cable glands to protect the cables from bending, oil seepage and vibrations in the machine. Connectors ensure secure connection between cable and machine. These versatile cables provide higher conductivity as compared to other cables with the same cross-sectional area. It is superior in quality and efficiently catering to the reliability factor in terms of consistent performance. The cables adhere to highest industry standards CE/VDE/ROHS. ☐Courtesy: Lapp Cables

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Data loggers for sensitive freight

testo’s new 184 data logger offers easiest operation with

pre-configuration and easy PDF readout with no software installation.

These data loggers offer hassle-free data logging in transport. Start, stop,

& read, - these are

the three easy steps

to guard sensitive

freight during

transport. The new

transit 184 data

loggers are

plug-&-play data

loggers that operate

intuitively with just a

press of start & stop

buttons, run on pre-configuration and create a PDF report on plugging to a

computer or even on-site through NFC smartphone. The new transport

data logger family has six different variants which includes display /

without display, use & throw / multi-use loggers for temperature/humidity,

shock measurement and one especially for dry ice applications (-80°C).

The use & throw loggers – testo 184 T1/T2 can be used multiple times

within 90 days & 150 days lifetime respectively.

Testo 184 are a new series of plug-&-play data loggers

for transport that are pre-configured and do not require

docking station or any software installation

Packaging automation technology

B&R’s reACTION technology reduces response times in industrial

automation applications down to 1 µs. This new approach allows

extremely time-critical sub-processes to

be managed using standard hardware –

all within the requirements of IEC 61131

– while cutting costs by reducing the load

on the controller and optimising

performance to match high-end

packaging machines demands. Primary

packaging is the most challenging task in

the packaging industry. In these

machines, the packaging material meets

the product at the highest possible speed;

as a result, the level of precision has a

direct influence on both product quality and the usage of raw materials.

Gravimetric and volumetric filling processes in liquid filling machines, for

example, can take advantage of the technology to operate valves and

sensors with an unrivaled precision of 1 µs. Other high-speed packaging

machine functions like code stamping and bad product rejection can

combine reACTION and NetTime technologies to synchronise motion

control and distributed I/O to achieve absolute precision.

reACTION technology increases

the performance of high-speed

packaging machines

> MORE@CLICK ADI03497 | www.AandD24.in > MORE@CLICK ADI03498 | www.AandD24.in

Thermocouple terminal blocks

connectwell has introduced its

thermocouple terminal blocks

CTT2.5UK, CTT2.5UJ, CTT2.5UT &

CTT2.5UE that are used with

thermocouple wires in measurement

applications. As per DIN 43713 &

DIN 43714 the current carrying

element of the terminal block is

made of the same material as the

thermocouple wire. These special

current carrying elements ensure

that there is no loss of potential at

the connecting points. The types of

thermocouple wires that can be

connected using standard

thermocouple terminal blocks

include ‘K’ type – Chromel (Ni/Cr),

Alumel (Ni/Al); ‘J’ type – Iron (Fe), Constantan (Cu/Ni); ‘T’ type – Copper

(Cu), Constantan (Cu/Ni) and ‘E’ type – Chromel (Ni/Cr), Constantan (Cu/Ni).

These terminal blocks are an ideal choice for heaters and boiler

application with thermocouples.

These special current carrying

elements ensure that there

is no loss of potential at the

connecting points


Photoelectric sensors

leuze has introduced three

photoelectric sensors with their

intelligent fastening concept

and sensor technology that

leaves no customer’s demand

unfulfilled. With robust housing

in IP 67 for use in difficult

industrial conditions and two

complementary switching

outputs for light and dark

switching operation the sensors

are bright, with highly visible

yellow / green status displays

for operation signal and are

performance reserved. The

features include A²LS active

suppression of extraneous light

for reliable suppression of

ambient and stray light; simple

alignment through brightly visible bright Vision® light spot and large

operating temperature range from -40 °C to +60 °C.

The photoelectric sensors have

two complementary switching

outputs for light and dark switching

operation


Tech_news_Jun-Jul-2014.indd 84 6/18/2014 9:26:33 PM

n e w s | technology

85A& D I n d i a | J u n - J u n 2014

Complete drive systems

igus has recently developed drylin SLW Protect and drylin SLWT-1080

that provides an effective protection mechanism and safeguards the lead

screw and lead screw nut against

impact from falling components and

debris. This enhances its

maintenance-free characteristics, a

feature also shared by the drylin

SLWT-1080. The new linear unit is

equipped with a twin lead screw,

which allows separate control of

the carriages. Various lead screw

pitches can be combined,

therefore providing maximum

design and operating flexibility.

The drylin E stepper motors also

create new design possibilities. The compact design of the laterally

mounted motor flange allows the motor to be mounted adjacent to the

system, therefore reducing the overall system footprint. The new xiros

ball bearings made from FDA compliant xirodur F180 material, combined

with aluminium guide rollers that provide wider options for packaging

system solutions, included within this are the cost-effective flanged ball

bearings made from xirodur B180.

Industrial PCs for rugged industrial applications

The Designline 1000 series Industrial PCs from Phoenix contact are

designed for rugged industrial applications. The PC is IP65 protected with

completely closed housing.

Thanks to an easy installation

system, the Designline 1000

series IPCs can be installed

directly to the machine. The

configurable and energy-

efficient concept is the right

solution for future operation

and monitoring in industrial

applications. The PC has slim

profile of thickness 60 mm

that requires lesser space and

improves aesthetics. The

device can be used in difficult

climatic conditions with high operating temperature range between -20°

to +55°. Excellent sliding properties and a scratch-resistant surface mean

that the series can be used universally. In addition, the devices are easy

to clean and can be operated with gloves. It is equipped with multi-touch

user interfaces.

Intelligent tool holder management

SchUnK’s data matrix code allows an intelligent tool holder management.

Regardless of whether it is done manually by smart phone, or fully

automated with a machine tool scanner, every tool holder can be reliably

identified with the help of a code and together with the corresponding data

base system, these can be

exactly assigned. Within the

framework of intelligent

manufacturing processes, it is

possible to generate a precise

history together with the data

from the superior cloud, with

sites of operation, used tools,

service life, and machining

parameters. According to the

individual systematic

arrangement of documents, the

data matrix code can be

individually defined. In contrast

to the glued on RFID tags, which

require the re-balancing of the tool holders, and under unfavourable

conditions these tags might get lost. The data matrix code is permanent

and has no influence on the balancing quality.

The PC has slim profile of thickness 60 mm

that requires lesser space and improves

aesthetics

With a data matrix code the tool holders

can be clearly identified and assigned

Prepaid energy meter

elMeasure has developed a unique 3-in-1

contactless prepaid energy meter in process

parameters such as water, gas etc that can be

integrated and its consumption can be

monitored along with electrical parameters. The

design is completely micro-controller based,

thus, providing an effective and reliable solution

to the service providers. The service provider

needs to install the meter and further activities

involve the consumer. It is sufficient for the

service provider to have one manpower to

recharge the card as per the consumer’s

request. Its main features include compact wall

mounting design; dual source measurement (EB

& DG); 3-in-1 m with option to integrate process

parameters; pre-paid metering system using

contactless smart cards with an accuracy class 1.0. The application areas

include shopping malls / multiplexes, residential townships / apartments,

commercial buildings and employee quarters. The advantages include

advanced RF card technology, tamper proof construction and reduced cost

of manpower for billing / collection.

The advantages of this

prepaid energy meter

include advanced RF card

technology, by reducing

cost of manpower for

billing / collection



Long service life knife edge rollers

provide accurate and lubricant-free

deflection of conveyor belts



t e ch n o lo gy | n e w s

86 A&D I nd i a | J u n - J u n 2014

Plant overview & plant structure software

ePlAn has integrated the new Eplan Platform 2.3 with innovative

functions to increase

project quality & data

consistency and reduce

configuration costs. Users

can benefit from very easy

entry into this new planning

method based on the Eplan

Platform. The central

dialogue in the software is

the new preplanning

navigator. In this dialogue,

the defined segments for

preplanning are displayed

and administered within the

project. The use of preplanning macros and copying & moving existing

segments by drag and drop makes it quick and easy to create and edit

machine/ plant structures. Alternatively, the CAE software has the option

of working directly in the graphical editor for preplanning. The data

defined at the pre-planning stage can be output in report form and used,

for example, for parts lists or for calculating prices and labour

Plant overview (P&ID) and plant structure

(navigator) for transparent and integrated

pre-planning

Vision solution for intelligent bin picking

With its advanced 3D Robot Vision Technology SHAPESCAN3D, ISRA

VISIon has developed a

solution for intelligent bin

picking. The system is

available as a new,

improved variant and

facilitates the safe

recognition and picking

of the most complex

part geometries and

works considerably

faster. The technology offers a nearly unlimited variety of identifiable parts,

including those with complex shapes. Users reach highest flexibility on

the factory floor, saving valuable space because additional mechanisms

for the separation of parts are no longer required. Its key feature is the

efficient processing of 3D point clouds. These are created from a scan of

the bin contents by structured laser line lighting and a camera stereo

setup. The company’s 3D recognition processes, analyse the point clouds

and extract objects from them. After that, the system detects their spatial

position – allowing an accurate grip by the robot. Detection method and

hardware are perfectly matched to one another.

Ethernet capable adaptor

hilscher has expanded its series of NL 50-MP Ethernet capable SIMATIC®

MPI/DP/PPI adaptors by the DIN rail

mountable device NT 50-MPI. Sixteen

simultaneous Ethernet connections

and the access to maximum 32 PLCs

in parallel are supported. As a 100%

replacement for an original Siemens

S7 Ethernet-CP the device allows

programming, remote maintenance

and the connection of visualisations

such as WinCC over Ethernet. The

device allows the Ethernet coupling of

ethernet portless S7-PLCs over their

MPI or PROFIBUS interface. To

configure a PLC to PLC connection

NetPro in STEP®7 is used as usual.

Also routing across multiple and networked PLCs is possible. The

protocols RFC1006, DHCP and NTP time distribution to a PLC are part of

the comprehensive scope of services supported. The device is configured

either in STEP7® with an embedded driver or via a web browser. The

driver is Windows 7® and STEP®7 64Bit compatible and supports Siemens

TIA Portal already.

The technology offers an unlimited variety of

identifiable parts, including those with complex shapes

The device allows the Ethernet

coupling of ethernet portless

S7-PLCs over their MPI or

PROFIBUS interface




Differential pressure transmitter

Keller Ag’s PRD-33 X series is a differential pressure transmitter that

features a double sensor for measuring the

differential and line pressure independently,

highly accurate measurements and has a

high overload resistance. Combining these

benefits, it opens up new possibilities such

as measuring the levels in liquefied gas

tanks safely, accurately and at a

reasonable price. The PRD-33 X has two

independent sensors that measures the

line pressure and the differential pressure.

The transmitter achieves its particularly

high accuracy level up to ±0.05% FS due to

its calibration over the entire pressure and

temperature range. The mathematical model

calculated in this way corrects all repeatable

errors. The high level of accuracy is therefore

guaranteed as an error band within the

overall compensated range. The floating assembly of the sensor unit

provides the ideal protection from external forces during installation. The

PRD-33 X is perfectly suitable for use with (liquid) oxygen, argon,

nitrogen, helium and carbon dioxide.

The PRD-33 X is

perfectly suitable

for use with (liquid)

oxygen, argon,

nitrogen, helium and

carbon dioxide



n e w s | technology

87A& D I n d i a | J u n - J u n 2014

USB converter for optical sensors

Micro-epsilon has recently launched 4x RS422/USB converter that

converts digital signals from up to 4 optical sensors into a USB data

packet. The converter is suitable for laser triangulation and confocal-

chromatic displacement

sensors from the

company. Unlike other

commercially available

USB hubs, the new

converter ensures

synchronous data

acquisition for a defined

temporal allocation of

the four RS422 inputs.

This is particularly

important for small

system solutions with

multiple sensors, for

example, in thickness measurements. The new converter has 4 trigger

inputs and a trigger output for connecting additional converters. The

connected sensors and the converter can be programmed through

software.

Unlike other commercially available

USB hubs, the new converter ensures

synchronous data acquisition for a defined

temporal allocation of the four RS422 inputs

Measuring light grid

The new LGM series measuring light grid from

Pepperl+Fuchs receives direct measured values in

millimeters, such as the object height, lowest or

highest object position, sum, average, etc. The

values are digitally transmitted at extremely fast

cycle times, even with beam crossover activated,

using I/O-link, which enables convenient

commissioning and maintenance from the control

level. These light grids have an ultra-low profile to

fit into tight spaces. Innovative, tool-free mounting

accessories make installation, alignment, and

replacement fast and easy. The IP67 aluminium

housing withstands harsh environmental conditions

even at cold-storage temperatures. The LGM is

available with various resolutions and field

heights up to 3200 mm, permitting large

measuring ranges. These measuring light grids

provide measured values in millimeters without

time-consuming calculations and set new

standards with their compact design,

functionality, and unique price/performance ratio.

The new LGM Series

measuring light grids

provide the measured

values directly in

millimeters


V/f drives

hitachi has recently introduced a wide, rugged range of AC drives up to

400 KW ratings. These are available as simple v/f drives and also

sensorless and flux vector drives.

Simple v/f drives (L300 and X200)

are suitable for fan, pump,

compressor applications and are

available upto 132 KW. These drives

also incorporate a special algorithm

to ensure higher energy savings in

fan/pump applications. The series

can maintain 150% torque at 0 Hz.

These drives can be used for

position control applications with

the addition of a feedback option

card. The SJ700 series has an inbuilt

braking circuit upto 22 KW and a built

in EMC filter up to 55 KW. The latest

WJ200 drives has many class leading

features such as 200% starting torque.

It has special algorithms to improve low speed regulation and can be

used for simple positioning applications with encoder feedback without

the use of any add on card.

These drives can be

used for position control

applications with the

addition of a feedback

option card


Brush motors

crouzet Motors’ DCmind brush motors are particularly well suited to

applications in medical, biopharmaceutical, laboratory, industrial

machinery and high performance

office equipment & systems.

These can be used in a variety of

other high performance

applications such as pumps and

valves, railway and railcars, as

well as military and aeronautics.

These brush motors have a

noise level of only 35 dB, about

the sound of a whispered

conversation and 20 dB less

than the current motor standard

range. These brush motors are 80% efficient with a minimum service life

of 5,000 hours when used in normal power loads. The new product range

includes 15, 25 and 55 watt motors with a 42 mm diameter, and 55 and

104 watt motors with a 63 mm diameter. These motors support 12, 24

and 48 volt power supplies and are available with several accessories

and adaptations, including rear brake, optical or Hall effect encoders (1 or

2 channels), connectors and wires, voltage, speed & power, shaft

dimensions and material.

These brush motors are 80% efficient

with a minimum service life of 5,000

hours when used in normal power loads



88 A&D I nd i a | J u n - J u l 2014

Highlights - (Aug/Sep 2014)

h Igh l Igh t s | compA ny InDex | Impr Int

company IndexName . . . . . . . . . . . . . . . . . . . . . . . . . Page

Ajay Kumar Garg Engineering College . . . . . . 41

ARC Group . . . . . . . . . . . . . . . . . . . . . . . . 73

ABB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

B&R Industrial Automation . . . . . .Cover, 8, 9, 84

Bharat Bijlee . . . . . . . . . . . . . . . . . . . . . . . 23

Connectwell Industries . . . . . . . . . . . . . . 11, 84

Contrinex Automation . . . . . . . . . . . . . . . . . 15

CST Sensors . . . . . . . . . . . . . . . . . . . . 25, 87

CD-Adapco . . . . . . . . . . . . . . . . . . . . . . . . 36

Delta India Electronics . . . . . . . . . . . . . . . . . . 3

Dynalog India . . . . . . . . . . . . . . . . . . . . . . . 53

ElMeasure India . . . . . . . . . . . . . . . 16, 43, 85

Edison2 . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Eplan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Electronic Relays (India) . . . . . . . . . . . . . . . . 65

Festo Controls . . . . . . . . . . . . . . . . . . . . . . . 4

Frost & Sullivan . . . . . . . . . . . . . . . . . . . . . 70

Fieldbus Foundation . . . . . . . . . . . . . . . 10, 58

Galil Motion Control . . . . . . . . .Back Inside Cover

Name . . . . . . . . . . . . . . . . . . . . . . . . . Page

Geometric . . . . . . . . . . . . . . . . . . . . . . 12, 80

GrabCAD . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Hans Turck GmbH . . . . . . . . . . . . . . . . . . . 28

Hitachi . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Hilscher India . . . . . . . . . . . . . . . . . . . . 19, 86

Honeywell Process Solutions . . . . . . . . . . . . 10

HMS Industrial Networks . . . . . . . . . . . . 33, 64

Hummel Connector Systems . . . Back Cover, 18

ICP Das . . . . . . . . . . . . . . . . . . . . . . . . . . 57

IED Communications . . . . . . . . . . . . . . . . . . 67

Infor Asia Pacific . . . . . . . . . . . . . . . . . . . . . 20

IFM Electronic India . . . . . . . . . . . . . . . . . . . 63

igus India . . . . . . . . . . . . . . . . . . . . . . . . 2, 85

ISRA VISION . . . . . . . . . . . . . . . . . . . . . . . 86

Janatics . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Keller AG . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Kubler Automation . . . . . . . . . . . . . . . . 48, 61

Leuze Electronic . . . . . . . . . . . . . . . . . . 27, 84

Messe Frankfurt . . . . . . . . . . . . . . . . . . . . . 45

Name . . . . . . . . . . . . . . . . . . . . . . . . . Page

Micro-Epsilon . . . . . . . . . . . . . . . . . . . . . 7, 87

Mifa Systems . . . . . . . . . . . . . . . . . . . . . . . 71

National Instruments . . . . . . . . . . . . . 6, 12, 74

Omron Automation . . . . . . . . . . . . . . . . . 1, 10

Pepperl + Fuchs . . . . . . . . . . . . . . . . . . . . 87

Phoenix Contact . . . . . . . . . . . . . . . 39, 51, 85

Pilz . . . . . . . . . . . . . . . . . . . . . . . . . . . 49, 54

Romaco . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Renu Electronics . . . . . . . . . . . . . . . . . . . . . 47

Rockwell Automation . . . . . . . . . . . . . . . . 5, 30

Schunk Intec India . . . . . . Front Inside Cover, 85

Sesame Motor Corp . . . . . . . . . . . . . . . . . . 75

Siemens . . . . . . . . . . . . . . . . . . . . . . . 12, 30

Siemens PLM Software . . . . . . . . . . . . . . . . 80

Strategi Automation . . . . . . . . . . . . . . . . . . . 35

Testo India . . . . . . . . . . . . . . . . . . . . . 68, 84

Vega India Level & Pressure Measurement . . . 13

VDMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Wheelabrator . . . . . . . . . . . . . . . . . . . . . . . 14

Wireless Automation »Wireless continues to be one of the fastest growing segments in the automation market for two reasons. First, it is much less costly to have devices communicate on a wireless network rather than going through the process of installing conduit. The other is the available access to very difficult locations and hazardous areas in the plant. The coming issue of a&d India takes a look at these applications, for which, maintenance and diagnostic tasks can be accomplished more quickly, effectively and safely using a wireless connection.

Control & Regulation »Future automation trends in control technology suggest that total solutions in which tasks are distributed according to free capacity are growing in importance, while the individual components are becoming irrelevant to the customer. advances in control and regulation technology bring in enhanced productivity and efficiencies. Keeping up with the latest developments and innovations on this front, the next edition will highlight on the applications of this technology for multiple sectors.

Semiconductor & Electronics »With demand rising in the semiconductor industry for low-cost, high-volume, flexible manufacturing, there is a need of leading-edge automation and information technology solutions that help customers meet their business and technical goals. The next issue of a&d India features the latest solutions & technologies in semiconductors and electronics to be competitive and reduce risk with lower costs.

ImpRInT

Publisher / Chief Editor Shekhar Jitkar [email protected]

Deputy Editor Sumedha mahorey [email protected]

Sub-editor & Correspondent

Srimoyee Lahiri [email protected]

Features Writer megha Roy [email protected]

Advertising Sales Sagar Tamhane (Regional Head - north & east) contact: +91 9820692293 [email protected]

dhiraj Bhalerao (Regional Head - West & South) contact: +91 9820211816 [email protected]

prabhugouda patil Bengaluru contact: +91 9980432663 [email protected]

Advertising Sales (Germany) caroline Häfner (+49 - 89 - 500 383 - 53) doreen Haugk (+49 - 89 - 500 383 - 27) [email protected]

Overseas Partner Ringier Trade media Ltd china, Taiwan & South-east asia Tel: +852 2369 - 8788 [email protected]

Design & Layout Sovan Lal Tudu (Senior designer) [email protected]

Editorial & Business Office publish-industry India pvt Ltd 302, Sarosh Bhavan, dr ambedkar Road, camp, pune 411 001, maharashtra, India ph: + 91 - 20 - 6451 5752

Board of Directors Kilian müller (ceo - Worldwide) Hanno Hardt (Head - marketing & Business development) Frank Wiegand (coo - Worldwide) Shekhar Jitkar (publisher / chief editor)

Subscription annual Subscription price: Rs 600 includes shipping and VaT. [email protected] ph: +91-20-6451 5754

Printing Kala Jyothi process pvt Ltd, S.no: 185, Kondapur, R R district, ap 500 133, IndIa

Copyright/Reprinting The publishing company holds all publishing and usage rights. The reprinting, duplication and online publication of editorial contributions is only allowed with express written permission from the publishing company. The publishing company and editorial staff are not liable for any unsolicited manuscripts, photos and illustrations which have been submitted.

Internet http://www.aandd24.in

Highlights_ Jun-Jul_2014.indd 88 6/19/2014 4:12:53 PM

GALIL MOTION CONTROLALL THE RIGHT MOVES FOR ULTIMATE PRECISION

Our cost effective standard

or custom motion controllers

can handle virtually any application.

Select any number of axes and I/O.

Choose internal servo or stepper drives

for one small package, or connect to

external drives. Our products are easy-to-

program, can be up and running in minutes,

and are backed by unparalleled technical support.

galil.com1.800.377.6329

a&d jun jul 2014

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