JUN
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PLCs, LOGICALLY
TESLA’S LEGACY
HOW TO INTERFACE
Machine builders, users and integrators raise their voices in our20th annual Readers’ Choice Awards
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FEATURES
cover story
Power to the readersMachine builders, users and
integrators raise their voices in our
20th annual Readers’ Choice Awards
Mike Bacidore, editor in chief
26
product roundup
Human-machine interfaces expand horizonsManage and control what you see
36CONTROL DESIGN, (ISSN: 1094-3366) is published 12 times a year by Putman Media, 1501 E. Woodfield Rd., Suite 400N, Schaumburg, Illinois 60173. (Phone 630/467-1300; Fax 630/467-1124.) Periodical postage paid at Schaumburg, IL, and at additional mailing offices. Address all correspondence to Editorial and Executive Offices, same address. Printed in the United States. ©Putman Media 2020. All rights reserved. The contents of this publication should not be reproduced in whole or part without consent of the copyright owner. POSTMASTER: Please send change of address to Putman Media, PO Box 1888, Cedar Rapids IA 52406-1888; SUBSCRIPTIONS: To change or cancel a subscription, email [email protected] or call 1-800-553-8878 ext. 5020. To non-qualified subscribers in the United States and its possessions, subscriptions are $96.00 per year. Single copies are $15. International subscriptions are accepted at $200 (Airmail only.) Putman Media also publishes CHEMICAL PROCESSING, CONTROL, FOOD PROCESSING, PHARMA MANUFACTURING, PLANT SERVICES, SMART INDUSTRY and THE JOURNAL. CONTROL DESIGN assumes no responsibility for validity of claims in items reported. Canada Post International Publications Mail Product Sales Agreement No. 40028661. Canadian Mail Distributor information: World Distribution Services, Inc., Station A, PO Box 54, Windsor, Ontario, Canada N9A 6J5. Printed in the United States.
table of contentsVolume 24, No. 6
ControlDesign.com / June 2020 / 5
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9 editor’s page
Does CIP motion need TSN?Mike Bacidore, editor in chief
11 embedded intelligence
Where’s the logic in the PLC?Jeremy Pollard, CET
12 technology trends
What’s driving your application?Rick Rice, contributing editor
16 indiscrete
Festo, MassRobotics partner to develop next generation of robotics
41 real answers
What should be included in a FAT?
49 product showcase
50 automation basics
How to tell if distributed I/O is a good fitDave Perkon, technical editor
COLUMNS
Advantech Automation Corp. ......................................37
AutomationDirect................................................................2
Ballu� ...................................................................................39
Banner Engineering Corp. .............................................33
Beckho� Automation .........................................4, 24,25
Bihl+Wiedemann ..............................................................47
Digi-Key Corporation .......................................................52
Dinkle Corporation ...........................................................23
Emerson Automation Solutions .................................51
Emerson Rosemount ......................................................19
Endress + Hauser ................................................................6
HMS Networks...................................................................45
KEB America .......................................................................13
Meltric Corporation ..........................................................34
Murr Elektronik .....................................................................7
Newark .................................................................................10
Novotechnik .......................................................................22
Pepperl+Fuchs ..................................................................35
Phoenix Contact ...............................................................31
Saginaw Control & Engineering .................................43
SEW-Eurodrive ......................................................................3
SICK .......................................................................................14
SMC Corporation of America ........................................17
Telemecanique Sensors ................................................15
Vega Americas ..................................................................21
Wago Corporation ............................................................29
Wieland Electric ................................................................44
Yaskawa America ................................................................8
ad index
ControlDesign.com / June 2020 / 7
table of contentsVolume 24, No. 6
CD2006_05_07_TOC.indd 7 5/26/20 10:41 AM
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ControlDesign.com / June 2020 / 9
WHAT IS THE impact of time-sensitive networking (TSN) on a common-industrial-protocol
(CIP) motion system?
“CIP motion can be modi�ed to support the TSN network,” explained Paul Brooks, man-
ager, technology business development, at Rockwell Automation, who spoke at ODVA’s
20th annual meeting of members in Palm Harbor, Florida. “We set out to establish the
viability, bene�t and legacy of TSN in CIP motion.”
In terms of viability, CIP motion can be adapted to support TSN networks without
structural changes to either timing models or communication patterns. A bene�t is there
are foreseeable applications where motion control will not be reliable without use of a
TSN network. And, in well-engineered networks, performance of CIP motion without TSN
matches or exceeds that with TSN.
“There’s a signi�cant installed
base of CIP motion, which is work-
ing,” said Brooks. “There’s no reason
for that installed base to migrate
to TSN because they don’t have the
problems that TSN corrects.”
Four test cases were looked at:
• overloaded system without TSN
• well-engineered system with TSN
• well-engineered system without TSN: “This was the baseline against which we tested
other use cases, characteristic of every CIP motion running today,” explained Brooks.
• overloaded system with TSN: “When we turned on TSN, it stopped being broken,”
said Brooks.
All test cases use an IEEE 801.1AS clock. TSN requires the use of this clock. “In the test
con�guration we did not make the �rmware changes in the endpoints,” explained Brooks.
“In a TSN, the network clock, not the controller, is isochronous. In a CIP motion system,
the controller is the isochronous.”
For example, in a CIP motion system, the drive synchronizes to the controller. This is
true in TSN, but the controller synchs to the network, explained Brooks. “TSN is a sched-
uled Ethernet network,” he said. “In a CIP system that is not overloaded, TSN offers no
bene�ts, based on the testbed results.”
CIP motion does not need TSN, but there are other applications that do need TSN—for
example, video streaming for inspection, which might run on the same network as CIP
motion, explained Brooks.
“This is why it’s important to implement TSN, whether the application needs it or not,”
said Brooks.
Does CIP motion need TSN?editorial teameditor in chief
Mike [email protected]
digital managing editor
Christopher [email protected]
contributing editor
Rick [email protected]
contributing editor
Dave [email protected]
editorial assistant
Lori [email protected]
columnist
Jeremy [email protected]
design/productionsenior production manager
Anetta Gauthier
senior art director
Derek Chamberlain
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ControlDesign.com / June 2020 / 11
Jeremy [email protected]
embedded intelligence
WAY BACK WHEN, I declared that PC-based control would take
up over 40% of the market from the standard �rmware-based
PLC. The operating systems were varied, from Windows to Vx-
Works real-time OS. Various OS kernels were developed to pro-
vide a more real-time response to occurrences in the �eld due
to the interrupt-based systems, typically, the IBM PC platform.
A problem arose, however, since basic hardware con�gurations
were used. These included things such as a CD drive and more
interrupt-driven resources that were placed on the system.
We take so much for granted in a
PLC environment because our inter-
face to it is a slick programming envi-
ronment—an integrated development
environment (IDE)—which provides
all the commands and instructions
needed to create, download and
monitor the process software.
With PC-based control it was no different. You would never
really know the difference by looking at the screen where you
would create and monitor your application software.
Windows CE was a common platform for embedded OS-based
systems. The IBM PC board design and chipsets were copied
into different form factors, such as PC104, VME bus and PCI.
This allowed the control software to reside in an embedded
system and allowed for better control methodologies.
One of the very �rst PC-based control systems was a product
called FloPro which was developed by Ron Lavallee in the mid-
1980s. It was based on �owcharts, which constitutes a decision-
by-decision method of creating a process �ow.
However his �rst go-round was a post processor that took
�owchart symbols and converted them to ladder logic using
code that was generated on an HP-85, which is another story.
In fact he demonstrated his development to Gould Modicon,
which made overtures about buying the technology but moved
away from it for some unknown reason.
FloPro moved over to the IBM platform, and, with the ad-
dition of a communication card to connect to Allen-Bradley
remote IO system, FloPro made it into the development world at
General Motors, and a new paradigm was born.
Sequential function chart (SFC) was alternative-state-based
control software that was used in PLC �rmware. It is now avail-
able in many hardware formats, and has replaced �owcharting
as a control software state-based system.
Mike Klein started a �owcharting company called Steeple-
chase, which had early success in the world of computer-based
control. It was Windows-based and provided a much better
interface than FloPro by all accounts. Steeplechase formed alli-
ances with various companies and in fact spawned additional
�owcharting companies such as Think & Do.
Another company that was formed because of FloPro was
FlexIS process control. It was a post processor that took SFC
programming of the control
algorithms and converted that to
Allen-Bradley’s PLC-5 subroutines
in ladder logic. It was really slick
and very well done, but there was
some pushback from the industry
regarding these graphical languages
because the development minds re-
ally didn’t think in the way that was needed. Their minds were
geared for ladder-logic development, and most of the develop-
ment occurred one rung at a time.
It is all well and good to have a novel idea and a new way of
creating a controlled process program, but you have to have the
resources to create, as well maintain, the end result.
IEC 61131 has been around for almost 30 years and is now just
becoming accepted as a control software platform. Beckhoff
Automation uses a PC-based hardware platform and runs IEC
61131 control software on the machine, which also includes the
HMI. This emulates the original perceived bene�t of the original
reason for PC-based control.
Control software has morphed over the past 40 years, but
interestingly enough most processes are still PLC-based and
mainly created with ladder-logic implementations.
Almost every survey done in the past 10 years has ladder
logic being the leader in how processes are controlled.
The PLC is far from dead, but PC-based control is nowhere
near the potential it could have risen to. It’s interesting that
Rockwell Automation’s new ControlLogix platform has the op-
portunity to run Windows-based software.
Where’s the logic in the PLC?
IEC 61131 has been around for almost 30 years, and compliance with it is now becoming accepted.
JEREMY POLLARD, CET, has been writing about technology and
software issues for many years. Pollard has been involved in control
system programming and training for more than 25 years.
CD2006_11_EmbedIntel.indd 11 5/26/20 10:47 AM
12 / June 2020 / ControlDesign.com
technology trends
Rick Ricecontributing editor
WITHOUT NIKOLA TESLA, the concept of producing motion by
varying the frequency of multi-phase, alternating current
wouldn’t even exist.
Tesla was born in what is now Croatia in 1856. One of �ve
children, the young Nikola was inspired to do great things by
his mother, who invented small household appliances in her
spare time. His father, a priest and writer, wanted his son to
follow in his footsteps, but the priesthood was not to be Tesla’s
future for his desires were clearly on the sciences. After studies
in Germany, Austria and the Czech
Republic, Tesla moved to Budapest,
Hungary, where he worked for a time
at the telephone exchange while he
dabbled with ideas for an induction
motor. After trying for several years to
garner interest in his concepts, Tesla
decided to move to the United States.
Arriving in 1884 with few possessions and a letter of intro-
duction, Nikola gained employment with the famous inventor,
Thomas Edison. The two men worked side by side on various
inventions that were revolutionizing the American electric
industry. After several months together, the two parted ways.
Some would say that Edison was more about marketing and
gaining �nancial success, while Tesla was �rmly embedded
in the science of electricity, and the two personalities simply
couldn’t �nd common ground for a continued relationship.
In 1885, Tesla formed the Tesla Electric Light Company with
the support of investors who challenged him with improving
arc lighting. Having done so, he was forced out of the company
and had to resort to manual labor to support himself for a time.
Two years later, he received funding for a new Tesla Electric
Company, and his �rst invention was the development of the
alternating current (ac) electric system. His development of ac
power soon caught the attention of George Westinghouse, who
was interested in long-distance power distribution. Their col-
laboration gained popular interest in direct competition with
Tesla’s former boss, Thomas Edison, and his dc-based power
system. Despite Edison’s best efforts, and a well-publicized
smear campaign, ac-based systems quickly became the pre-
eminent power system in the world. Westinghouse purchased
Tesla’s patents in 1888 in exchange for $60,000 and stock in
Westinghouse Corporation.
Tesla was a scientist �rst and, to his own detriment, found
many of his greatest inventions patented by other people, but
it is his invention of the rotating magnetic �eld that made the
electric motor even possible. Pioneering work in the �eld of
multiphasic, alternating current has left an indelible mark on
the world we know today. Persistent campaigns by writers and
publishers of the day resulted in Nikola Tesla and his accom-
plishments fading into a sentence of mediocrity until recent
years when his achievements have been revealed to a new
group of admirers. The infamous
Tesla coil and the concept of wire-
less power distribution are once
more subjects of much interest and
inspiration to a new generation.
It is the foundation of three-
phase alternating current that
forms the base function of a
variable-frequency, or variable-speed, drive. By varying the
voltage and frequency, the speed and torque of an ac motor
can be varied in a direct, predictable relationship. Since the
original patent �led by Tesla in 1888 for the worlds �rst three-
phase induction motor, many have tried to accurately control
the speed of an induction motor. The cost of doing so was
expensive and, for a long time, restricted to heavy industry. In
the early 1980s, power electronics had advanced to the stage
where an economical means of controlling an induction motor
was possible. The variable-frequency drive (VFD) has changed
in form and function over the years since it was �rst invented.
In addition to the development and re�nement of semi-con-
ductor technology, drive topology and ever-improving control
and simulation techniques have �nely honed the algorithms
that provide control to induction motors.
The VFD consists of three main sections—a recti�er bridge
convertor, a direct current (dc) link and an inverter. The recti�er
bridge converts the incoming voltage to dc. The dc link uses a
capacitor to smooth out the converted voltage, and the invertor
changes that dc power into a quasi-sinusoidal ac voltage. These
voltage-source inverters (VSIs) are the most common form of
VFD in use today. Most drives are ac-ac, meaning they convert
ac line voltage into ac inverter voltage output, but some drives
are dc-ac, where dc incoming voltage is converted to ac inverter
output. Some drives can also convert single-phase input voltage
What’s driving your application?
Voltage-source inverters (VSIs) are the most common form of VFD in
use today.
CD2006_12_15_TechTrends.indd 12 5/26/20 10:48 AM
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technology trends
to three-phase inverter voltage output.
A few drive platforms of note include V/Hz, vector control
and direct torque control. V/Hz method is best suitable for
variable torque applications where the ac motor characteristics
dictate that the amplitude of the inverter output be adjusted to
match the load torque in a linear relationship between voltage
and frequency. The vector control method represents the stator
currents of a three-phase induction motor as two vector compo-
nents, the magnetic �ux and torque of the motor. The algorithm
then calculates the corresponding current component using the
�ux and torque components. These drives were designed for
use with high-performance applications where smooth control
is desired over the whole spectrum of operation. The objective
is full torque at zero speed and fast acceleration and decelera-
tion. Direct torque control (DTC) calculates the �ux and torque
of the motor using the voltage and current values. DTC is an
early development of VFDs.
Various control components have been added to VFD tech-
nology over the years to enhance the three basic subsystems.
Condition the incoming voltage, enhance or assist the dc link
and post-condition the inverter output. The incoming voltage
can be conditioned further using EMC �lter or line reactor.
The dc link can be assisted through the use of a brake resistor
to shunt excess energy that is back-fed into the drive when a
motor is rapidly decelerated. This action is to resist the mo-
tor turning into a generator during this deceleration. Finally,
�lters can be applied to the inverter output in the form of dV/
dt or sine wave �lter or an output reactor.
Some of the greatest advancements in the use of variable
frequency drives are the methods of programming and means
by which to trigger functions. Earlier VFDs were very manual
in nature. The drive was programming via an operator inter-
face, such as a keypad. The user would go through a series of
parameters to tell the drive how to respond to the commands
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and what settings to use for the components of the control
algorithm. Digital signals would then be used to tell the drive
to start or stop, accelerate or decelerate. Other digital signals
could be used to determine speed and direction.
The next major advancement was the use of network protocols
to provide both a means to con�gure and control a VFD. Early
versions would exchange a pre-determined block of information
to and from the drive. These would usually include status and
feedback registers from the drive and command and frequency
registries to the drive. As network topology has improved, the
use of more and more command and status registers has opened
up the ability of using the software (PLC program) to not only
control the drive and receive feedback but actually con�gure the
parameters in the drive, as well. Using a basic entry keypad to
con�gure parameters would take minutes or hours to complete
in the past. The use of software running on a laptop and a net-
work cable has reduced this to mere seconds in many cases.
The package containing the drive continues to get smaller.
A 460-Vac, 5-hp drive, for example, used to be mounted
externally to a control cabinet due the enormous size of
the drive and the large heat dissipated by the drive during
operation. The drive would have a footprint of about 12-by-10
inches and weigh about 30 lb. A modern version of that same
drive occupies a space of about 5.5 by 4 inches and weighs no
more than 1 lb.
One interesting trend is the use of a variable frequency drive
on a motion-capable logic controller. These VFDs can use en-
coder feedback to create closed-loop control and operate using
motion commands, just like a servo drive. As time goes on, the
gap between open-loop VFD control and closed-loop stepper/
servo control gets smaller and smaller.
Automation is all about perspective. Signi�cant technology
enhancements have happened, but the objects we’re controlling
are those same items invented by the wizards of the past.
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CD202006-Telemecanique.indd 1 5/15/2020 1:40:26 PMCD2006_12_15_TechTrends.indd 15 5/26/20 10:48 AM
FESTO AND MASSROBOTICS have entered into a strategic
partnership that aims to further global market growth and
innovation initiatives dedicated to the development of the next
generation of robotics.
MassRobotics, the independent, nonpro�t group serving as
an innovation hub for robotics and smart connected devices,
aims to foster a collaborative space in which to inspire the next
generation of robotics and automation innovators and builders.
The organization’s escalator model allows startups to establish,
grow, offer employment and provide value for MassRobotics’
partner organizations.
According to Festo, MassRobotics creates a supportive learn-
ing environment to engage youth and future engineers and
entrepreneurs by offering STEM workshops, competitions and
technical internships. MassRobotics supports the Ventilator
Project, which aims to solve the ventilator shortage crisis with
an low-cost ventilator designed by members; the team is cur-
rently seeking FDA approval for the device.
“Combining Festo’s in-depth know-how in manufacturing
applications and automation technology with the MassRobotics
community will enable Festo to engage with robotics and auto-
mation startups,” said Alfons Riek, vice president technology
and innovation at Festo. “We will collaborate with entrepre-
neurs and academia alike in bringing innovative new automa-
tion and robotic concepts and solutions to market.”
“Festo and the MassRobotics community will explore the
evolution of automated manufacturing solutions to autonomous
ones,” said Carlos Miranda, CEO, Festo North America. “Through
technology challenge engagements, members will co-develop
and commercialize advanced products and systems.”
“MassRobotics and Festo share a vision to develop robotic
solutions dedicated to the emerging needs of the manufacturing
sector,” said Fady Saad, cofounder and vice president of strategic
partnerships, MassRobotics. “Having an automation company
with the expertise, resources, and leading-edge development
capabilities of Festo will further the mission of MassRobotics
and create excitement about our collaborative efforts.”
Festo, MassRobotics partner to develop next generation of robotics
Shake on itFady Saad (left), MassRobotics co-founder, receives the Festo delivery of a Rize 3D printer for the MassRobotics Shared Labs from Festo senior product manager Nuzha Yakoob.
16 / June 2020 / ControlDesign.com
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Processing, Control, Food Processing, Pharma Manufactur-
ing, Plant Services and Smart Industry magazines,
have announced the 2020 class of In�uential Women in
Manufacturing.
The 20 women who were selected this year are recognized
for their leadership in manufacturing. Each honoree has
helped move the needle not only for their respective organiza-
tions, but for women and manufacturing everywhere.
The honorees were selected from 88 nominations that came
in between January 1-April 10, 2020. A team of 12 judges—
comprised of seven Putman editors and �ve IWIM alumni—re-
viewed and voted on this year’s entries.
“We’re honored to welcome these 20 women into the third
annual class of In�uential Women in Manufacturing. Their
nominations—and the people who nominated them—remind
us that with determination and passion for progress, anything
is possible,” said John Cappelletti, CEO of Putman Media.
The 2020 In�uential Women in Manufacturing honorees
will be pro�led in a dedicated e-book to be released by Putman
Media this summer. They will also be recognized during an
event taking place at the end of September.
(Sou
rce:
Fes
to)
CD2006_16_23_Indiscrete.indd 16 5/26/20 11:29 AM
CD2006_FPA.indd 17 5/26/20 11:20 AM
Congratulations to the 2020 IWIM Honorees:
• Helen Kane, Engineering Manager,
Advanced Energy Industries
• Amy Grace, Applied Data Science Fellow,
Collins Aerospace
• Dafni Bika, Global Head Pharmaceutical
Technology and Development, Astrazeneca
• Haleyanne Freedman, Market Manager
and Engineering Consultant, M Holland
• JoAnna Sohovich, CEO, Chamberlain Group
• Emily Martin, Industrial Engineering Manager,
Endress+Hauser
• Jennifer Blanchette, Director of Manufacturing,
Baxter Healthcare
• JoyL Silva, General Manager, P�zer CentreOne
• Cindy Jaudon, President, IFS Americas
• Lisa Zasada, Global Reliability Engineering Director,
General Mills
• Christy Thompson, Principal Engineer,
Global Engineering, General Mills
• Mary Beth Seasholtz, Technology Leader
for the Data Services Capability, Dow
• Jesika Young, CEO, Cimtech
• Taylor Claiborne, Operations Specialist –
Perfect Execution, Emerson
• Julie Camardo, CEO, Zweigles, Inc.
• Cindy Tomei, Vice President, Membership Growth &
Engagement, Illinois Manufacturers’ Association
• Colleen Herczak, Vice President, Quality,
Grand River Aseptic Manufacturing (GRAM)
• Meghan West, President, CNC Software
• Barbara Juncosa, Department Chair, MiraCosta College
• Sascha Harrell, Director of Education and Workforce,
Purdue University Indiana Next Generation
Manufacturing Competitiveness Center
Founded in 2017, In�uential Women in Manufacturing
seeks to recognize women who are effecting change in
manufacturing and industrial production and engaging
the next generation of manufacturing leaders.
18 / June 2020 / ControlDesign.com
indiscrete
Northrop Grumman earns top diversity accoladeNORTHROP GRUMMAN HAS been ranked 15th on DiversityInc’s an-
nual list for the Top 50 Companies for Diversity, moving up two spots
from last year’s ranking. In the DiversityInc specialty lists rankings,
Northrop Grumman was ranked 2nd for people with disabilities, and
4th for both veterans and employee resource groups (ERG). The com-
pany was also recognized as a top company for LGBT employees.
“Diversity and inclusion is rooted in our culture and our values,
and we want our employees to know they can be their true selves at
work,” said Kathy Warden, chairman, CEO and president, Northrop
Grumman. “I truly believe that diversity and inclusion drive per-
formance. Great ideas come from diversity of thought, background,
perspective, culture, gender, race, age and many other factors. We
continue to make great strides in ensuring our employees feel re-
spected and know their voices matter.”
Last year, Northrop Grumman received the highest ranking
for the �fth year in a row on the Disability Equality Index (DEI),
an annual benchmarking tool for companies to self-report their
disability policies and practices. The company was also named a
“Best Place to Work for Disability Inclusion” recipient. The award
recognized the company for its exemplary policies, strategies and
initiatives that have resulted in measureable outcomes in disabil-
ity inclusiveness in the workplace.
In addition to its other initiatives, Northrop Grumman has a
number of programs to support veterans, including a Veteran
Inclusion Committee whose mission is to support veteran engage-
ment, inclusion and retention; Operation IMPACT (Injured Military
Pursuing Assisted Career Transition), an award-winning diversity
program within Northrop Grumman focused on assisting severely
wounded service members as they transition from the military to a
private-sector career.
Northrop Grumman has 13 ERGs that provide bene�ts for both
members and the company. Across more than 270 chapters,
these groups include those supporting African Americans, Asian
Paci�c Islanders, Hispanics, Native Americans, women, people
with disabilities, veterans, LGBT employees, young professionals,
parents and families, multiple generation, virtual employees and
environmentalists.
The DiversityInc Top 50 list, issued yearly since 2001, rec-
ognizes companies for diversity and inclusion management.
These companies excel in areas such as hiring and retaining and
promoting women, minorities, people with disabilities, LGBT
individuals and veterans.
CD2006_16_23_Indiscrete.indd 18 5/26/20 11:29 AM
cutting-edge corrosion management maximizing operational output.Emerson transforms refinery throughput and safety with actionable, real-time corrosion and erosion data. Non-intrusive Rosemount™ wireless monitoring systems drive more efficient operations for an increase in production and decrease in potential shutdowns.
Download the whitepaper atEmerson.com/WeSeeCorrosion
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EECO6_P5895_WeSee_Corrosion_Control_Ad.indd 1 2/25/2020 1:45:55 PMCD2006_FPA.indd 19 5/26/20 11:20 AM
ELEMENT14 ANNOUNCED THE launch of
the “Fighting Germs” Project14 design
challenge. The challenge is engaging ele-
ment14’s problem-solving designers and
engineers to �nd innovative solutions to
�ghting germs, one of the most ef�cient
ways to slow the spread of COVID-19.
The goal of this challenge is for mem-
bers of the element14 Community to
create an affordable project that uses re-
sources and components that are readily
available so others can easily replicate
their designs. The hope is that people
around the world will be able to help
slow and prevent the spread of COVID-19
in their communities with these innova-
tive approaches.
“Everyone has the opportunity to do
their part to help slow the spread of this
disease, and that is especially true of
our amazing community of engineers,
makers and hobbyists,” said Dianne
Kibbey, global head of community and
social media for the element14 Com-
munity. “Our members came to us just
as the lock-downs started and asked us
to launch a challenge for new innova-
tions in this area. We encourage our
more than 730,000 members to put their
unique design skills to work and create
solutions to help prevent the spread of
this pandemic.”
Unlike other design challenges,
there are no speci�c requirements to
participate. element14 says solutions
could include face protection, body
temperature monitor/access controls,
contactless disinfection of frequently
touched surfaces and automated dis-
ease testing.
The grand prize winner of the “Fight-
ing Germs” design challenge will win
a $200 shopping cart to Newark, a $200
donation to their preferred COVID-19
charitable cause and a Flir thermal im-
aging camera. An additional 3 winners
will each receive $100 shopping carts
to Newark to help bring their designs
to life along with a UV sanitizing lamp.
Members can work on tackling this chal-
lenge solo or in teams, as long as they
collaborate remotely.
The “Fighting Germs” Project 14
design challenge is open now through
June 15. Winners will be announced by
June 29.
20 / June 2020 / ControlDesign.com
indiscrete
Element14 launches design challenge to help fight COVID-19
WITNESSING GROWTH IN the recent
past, smart factory projects have per-
formed well on the back of rising adop-
tion of analytics and cyber security
tools. The global smart factory market
value surpassed $95 billion in 2019, and
a new study from Future Market In-
sights (FMI) projects solid double-digit
growth for the market during forecast
period of 2020-2030.
The worldwide coronavirus (COVID-19)
pandemic triggered considerable down-
turn across industries, particularly smart
factory market, FMI reports. Deploy-
ment of smart technologies could be
bene�cial in breaking the pattern of the
virus. However, massive slowdown in the
manufacturing sector, especially in Asia,
is straining economic activities across
various industrial domains. These factors
are constantly putting pressure on smart
factory market and would adversely af-
fect the market supply chain, it adds.
For the forecast period 2020-2030, the
new report highlights the following:
• Software demand will grow at a
signi�cant CAGR throughout the
forecast period.
• Among software components, distrib-
uted control systems hold a leading
market share as they are widely used
in factories for monitoring and control-
ling various processes.
• Discrete industry remains key revenue
generator in smart factory market and
would maintain the trend through 2030.
• Business partnerships help increase
revenue, and new innovations in IT
domain are enabling smart factory
solution providers reach new potential
customers, globally.
To sustain extreme competition, FMI
reports that a majority of companies
are adopting data-driven technologies
such as big data analytics, intelligent
automation, arti�cial intelligence (AI)
and sensor technologies. Data-driven
technologies offer an opportunity in
transformation of existing manufactur-
ing paradigm to smart manufacturing.
Further, they empower companies to
craft new strategies to gain leading edge.
Smart factory market surpasses $95 billion in 2019
CD2006_16_23_Indiscrete.indd 20 5/26/20 11:29 AM
Adjustment via smartphone
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CD2006_FPA.indd 21 5/26/20 11:20 AM
ARC ADVISORY GROUP research on the
global Operator Training Simulators
(OTS) market shows that as the cur-
rent generation of experienced workers
retires from the industrial workforce,
high-� delity operator training simulator
(OTS) technology will play an increas-
ingly important role in getting the new
generation of operators and mainte-
nance technicians up to speed. As a re-
sult, the ARC market research indicates
that the overall market for OTS solu-
tions should recoup slowly with modest
growth over the forecast period despite
the global pandemic. This includes both
OTS software and services.
“A trend we’re seeing is for power
generation plants, pipeline operators,
re� neries, and petrochemical plants
to increasingly outsource the develop-
ment and maintenance of high-� delity,
unit-speci� c training simulators to their
OTS suppliers, such as Honeywell, GSE
Systems, Yokogawa, Emerson, and Yok-
ogawa,” said Rick Rys, senior consultant
at ARC Advisory and key author of ARC’s
Operator Training Simulators Global
Market Research report. “This generates
incremental revenue for the suppliers
and enables the end users to focus on
their core competencies.”
This ARC research explores current
and historical market performance and
related technology and business trends,
identi� es leading technology suppliers
and provides � ve-year global forecasts for
the Operator Training Simulators market.
Conveyorsystem market to see only 2.9% growthTHE GLOBAL CONVEYOR system market is
anticipated to witness only a growth of
2.9% according to a recent Fact.MR report.
With that growth it would create an
absolute dollar opportunity of more than
$3.1 billion. It is projected to be valued at
more than $12.9 billion by the end of the
forecast period of 2020 to 2030. According
to the data research organization, indus-
trial automation solutions among end-
users has paved way for novel conveyor
system designs to enhance productivity.
Fact.MR also says that the coronavi-
rus pandemic is distorting many supply
chains, especially for e-commerce compa-
nies. A dramatic spike in orders followed
by a reduction in manufacturing and
shipping, along with products running
out of stocks has brought on an abrupt
change in consumer buying behavior. This
is creating high demand for warehouse
space, which is expected to boost demand
for a material handling equipment such as
conveyor and storage systems.
Due to COVID-19 lockdown, the manu-
facturing industry is facing dormancy
due to complete shutdown of business
indiscrete
ARC: Retiring workforce drives operator training simulator growth
CD2006_16_23_Indiscrete.indd 22 5/26/20 11:29 AM
operations. Those companies who have
been able to restart their manufacturing
facilities are facing abruptly scaled down
production for conveyor belt material due
to a greatly affected supply chain. This
will hinder adoption of conveyor belts.
The segment is expected to lose value of
$5.0 billion by the end of forecast period.
CLPA global strategic advisor to increase reach of CC-Link IE TSNCC-LINK PARTNER ASSOCIATION (CLPA),
which promotes the widespread usage
of the CC-Link open industrial network
family, announced the creation of a
global strategic advisor role for which it
recruited Thomas J. Burke to � ll.
Burke is the past president, executive
director and founding leader of the OPC
Foundation, which is focused on deliver-
ing the best speci� cations, technology,
process and certi� cation necessary to
achieve multi-vendor, multi-platform,
secure reliable information integration
across disparate devices and applications
from the factory � oor to the enterprise.
CC-Link IE TSN combines the gigabit
bandwidth of CC-Link IE with Time-
Sensitive Networking (TSN) to meet fu-
ture automation market demands, such
as Industry 4.0. This provides � exible
integration of Operational Technology
(OT) and IT while further strengthen-
ing performance and functionality.
A comprehensive portfolio of device
development options also ensures that
any vendor can easily add this technol-
ogy to their product line-up. The aim is
to improve ef� ciency and reduce time
to market for Smart Factories utiliz-
ing the IIoT and the products they
manufacture. A year and a half after the
announcement of the CC-Link IE TSN
speci� cations, more than 100 partner
products have been released or are un-
der development.
Highly Efficient Wiring Solution
CD2006_16_23_Indiscrete.indd 23 5/26/20 11:30 AM
Machine safety technology has come a long way
from the basic safety relays of the past. Today, ma-
chine designers have more advanced safety tools at
their disposal, including highly integrated program-
mable safety solutions. The best offerings in this
category include safety solutions that can leverage
standard hardware, software and networking infra-
structure to implement high levels of safety up to SIL
3 according to IEC 61508 and ISO 13849.
In practice, this means that users can install
I/O with built-in safety logic right alongside stan-
dard I/O in the same segment, whether that’s on
a DIN rail or mounted on a machine. Other au-
tomation hardware comes with integrated safety
functionality, such as servo drives and distributed
drive systems. In terms of networking, the safety
data can be transmitted over a standard industrial
Ethernet or fieldbus using a “black channel” ap-
proach. With the proliferation of safety func-
tionality to many more hardware types, machine
builders can distribute more safety in more places
while increasing performance and reducing over-
all equipment and cabling costs.
Q: How has the ever-expanding availability and use
of programmable I/O impacted the spread of inte-
grated safety and programmable safety logic?
A: More people are using programmable safety I/O
because of its many advantages, such as the wide
range of form factors. These include standard DIN-
rail-mountable terminals in the same segment as
standard I/O and machine-mountable I/O modules,
which reduce cabling to the control panel. Integrated
safety devices have really made it easy for machine
builders to offer more safety in more places.
Because of integrated safety’s programmability
in standard automation software, you can config-
ure complicated logic inside a simple input device
to make it safer for the people who are operating
the machine. This enables machine builders to
use safety as a competitive advantage and deliver
many different safety features rather than just
hardwiring an e-stop to certify the machine accord-
ing to minimal safety requirements.
Programmable safety with safety I/O is easier to
implement and less expensive – during commis-
sioning and in the long term. It reduces the num-
ber of components and, as a result, the control
cabinet footprint. Machines are safer, and they
have less downtime because of easier restarts
from a safe stop to a running state. These are ma-
jor reasons why more machine builders are imple-
menting integrated programmable safety, rather
than the traditional approach.
Q: What are the benefits of programmable safety
over older ways of implementing machine safety,
such as safety relays?
A: Traditional safety relays are still the most common
method, but they just cut the power to stop ma-
chines. Integrated programmable safety does much
more. First, the safety is totally integrated into the
machine control system, so you have a wealth of di-
agnostic information available. That’s really important.
When a machine stops, it’s crucial to understand
why. With simple safety relays, you have to open the
control cabinet just to know which relay tripped and,
usually, trace the wiring back to the field device.
With integrated safety logic, you have access to
much more diagnostic data. EtherCAT and Twin-
SAFE, especially, provide information down to the ter-
minal level to localize where a signal tripped and why.
Another challenge with safety relays is that specific
relays only offer specific functionalities. There are
separate devices for e-stops, door switches, safety
mats and other devices. Adding another e-stop us-
ing traditional safety relays involves significant wiring
effort. Therefore, the component list gets bigger and
bigger when commissioning a safety system.
When using integrated safety, this functionality is
mostly handled in software, so the hardware side is
simpler. The safety I/O is either an input or an out-
SPONSORED CONTENT
A case for integrated safety systems
SREE SWARNA GUTTA I/O Product Manager,
Beckhoff Automation
24 / June 2020 / ControlDesign.com
CD2005_24_25_Beckhoff_QA.indd 24 5/26/20 11:01 AM
put, and what it does is up to the program. Changes require little to
no rewiring, since safety logic updates take place in software. But
the system retains the necessary redundancy using the TÜV-certi-
fied Safety over EtherCAT (FSoE) protocol.
Having access to the safety program in code benefits serial
machine production. Transferring code from one machine to an-
other machine is easy. All you need to do is wire the I/O as you
normally would.
In addition, analog safety is available in programmable systems.
Purely digital safety relays can only be on or off. Analog safety al-
lows machines to constantly check the pressure or the tempera-
ture on a module, for example, and safely turn it off before it fails.
That reduces machine downtime and helps with maintenance.
Q: What opportunities exist for technology convergence in
safety systems?
A: When we speak about integrated safety, we’re talking about
one system. On the hardware side, standard I/O and certi-
fied safety I/O integrate easily into the same segment. On the
software and programming side, Beckhoff provides TwinCAT 3
software as a universal engineering and runtime platform for all
machine automation needs. It’s all one system.
What advantages does it give? All the information is immedi-
ately accessible, including the diagnostic data. Because it’s all in
one system, you can put that diagnostic information on an HMI
alongside other machine performance stats. If something hap-
pens, operators or maintenance can easily troubleshoot it, for
example. Also, machine builders talk a lot about IoT and remote
monitoring. Uploading the safety data to the cloud, a database
or HMI is possible and easier to accomplish in one system. For
many years, TwinCAT has been driving the convergence of all of
these industrial automation technologies.
Q: Some machines used in discrete manufacturing require intrin-
sically safe I/O hardware and explosion protection. What advice
do you give to these OEMs?
A: When we talk about safety in a standard machine, people
think about e-stops and safety switches. When we talk about
intrinsic safety, people immediately think of the oil and gas indus-
try. The perception is that intrinsically safe devices only belong
in those industries, but that’s not true. Intrinsic safety is used
in other industries, such as processing sugar and flour, where
there’s significant dust, or cosmetics, alcohol and many others
with vapors that are prone to explosion.
Typically, engineers use intrinsically safe barriers with standard
I/Os, rather than intrinsically safe modules. This adds up to more
parts, bigger control panels and higher costs. It’s better to use
an intrinsically safe module that slides right next to standard I/O
or safety I/O. Intrinsically safe I/O terminals provide reliable, low-
voltage communication directly to sensors and devices in hazard-
ous areas, even in Zone 1 or Zone 0 where dust or other particles
could act as an ignition source. They simplify safety architectures
and are equally important to machine builder OEMs.
Q: What technologies or best practices are being used to ensure
the security of safety data?
A: Many people worry about whether their data is secure and
what might happen if it’s not. With EtherCAT, the functional prin-
ciples make data automatically secure. EtherCAT establishes
secure networking because it’s set up without any IP addresses,
and the EtherCAT master knows exactly what kind of data to ex-
pect from the slave devices. Through EtherCAT’s default mode of
operating, your data is already secure.
For safety data, it’s actually more protected. FSoE uses a
“black channel” approach, so standard devices can’t read the
safety data when it passes through. Only the safety terminals
recognize the data. They read and process that data, then send
commands in response. Using TwinSAFE, customers don’t have
to worry about data security, especially when using EtherCAT.
For more information about Beckhoff Automation integrated
safety, please visit www.beckhoff.com/twinsafe.
SPONSORED CONTENT
SAFETY, INCORPORATEDIntegrated safety systems, such as TwinSAFE, incorporate safety program engineering into the universal TwinCAT 3 automation platform used for PLC, motion control and more.
ControlDesign.com / June 2020 / 25
CD2005_24_25_Beckhoff_QA.indd 25 5/26/20 11:02 AM
by Mike Bacidore, editor in chief
26 / June 2020 / ControlDesign.com
cover story
CD2006_26_35_CoverStory.indd 26 5/26/20 11:32 AM
ControlDesign.com / June 2020 / 27
THIS YEAR MARKS the 20th anniver-
sary of the Control Design Readers’
Choice Awards. The past two decades
have been as liberating as they’ve been
innovative. Remote
capabilities and
software-driven
enhancements have pushed technology
forward so fast there seems to be no
limit to what can’t be automated or up-
graded. The impossible has become the
standard, and industry has shaken off
technological restrictions
without looking back.
When is the last time you even heard
someone utter the word, “bandwidth”?
The future is here, and, while many
of the technologies and products are
new, the majority of the suppliers have
gone the distance, innovating new solu-
tions or acquiring them to complement
an existing portfolio. Once again, the
readers of Control Design have delivered
on identifying their favorite component
and system suppliers.
by Mike Bacidore, editor in chief
MethodologyFor the 2020 Control Design Read-
ers’ Choice Awards, more than
15,000 individuals who identify
themselves as having buying in� u-
ence or authority were invited to ac-
cess our con� dential ballot. All of the
voting is unaided, meaning that no list
of supplier choices is provided for guid-
ance or assistance in the ballot. It is cre-
ated entirely by the participants, who may
vote for � rst, second and third preferences
in each category. The results are grouped
by Control, Hardware, Motion, Networking,
Safety, Sensing and Software categories.
The results do not knowingly include votes
from any suppliers in the � nal tally.
CD2006_26_35_CoverStory.indd 27 5/26/20 11:33 AM
CONTROL
CNC Controller1. Fanuc
2. Siemens
Loop Controller1. Rockwell Automation
2. Siemens
3. Yokogawa
Motion Controller1. Rockwell Automation
2. Siemens
3. Schneider Electric
Programmable Automation Controller (PAC)
1. Rockwell Automation
2. Siemens
3. Schneider Electric
4. Omron
Programmable Logic Controller (PLC)
1. Rockwell Automation
2. Siemens
3. AutomationDirect
4. Omron
5. Schneider Electric
Embedded Computer System
1. Rockwell Automation
2. Siemens
3. Beckhoff Automation
4. Advantech
Industrial-Grade Computer
1. Rockwell Automation
3. Beckhoff Automation
4. Siemens
5. Advantech
5. Phoenix Contact
HARDWARE
Circuit Protection
1. Eaton
2. Siemens
3. Schneider Electric
4. Rockwell Automation
5. ABB
Industrial Electrical Connector/Cordset
1. Turck
2. Murrelektronik
3. Banner Engineering
4. Rockwell Automation
5. Phoenix Contact
Industrial Enclosure
1. nVent
2. Rittal
3. Saginaw Control & Engineering
4. Hammond Manufacturing
Industrial Enclosure Thermal Product
1. nVent
2. Rittal
Operator Interface1. Rockwell Automation
2. Schneider Electric
3. Siemens
4. AutomationDirect
5. Red LIon
Panel Meter1. Red Lion
2. AutomationDirect
3. Omron
Power Supply1. Rockwell Automation
2. Emerson
3. Phoenix Contact
4. Puls
5. Siemens
Relay1. Rockwell Automation
2. Phoenix Contact
3. Schneider Electric
4. Omron
5. IDEC
6. Siemens
Stack Light Tower1. Rockwell Automation
2. Banner Engineering
3. Patlite
4. Schneider Electric
5. Siemens
6. Werma
28 / June 2020 / ControlDesign.com
cover story
CD2006_26_35_CoverStory.indd 28 5/26/20 11:33 AM
Learn more about our HMI family: www.wago.us/touchpanel
OPERATE. CONTROL. VISUALIZE.TOUCH PANEL 600: PLC + HMI ALL-IN-ONE
• High resolution graphics and glass panels• Support of all six IEC PLC programming languages• Multiple fieldbuses: Ethernet/IP, MODBUS TCP/UDP, CANopen, EtherCAT• IIoT-Ready: Sparkplug, native MQTT with built-in Firewall and VPN• Linux OS with Docker Container capabilities
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CD_Updated Touch Panel Ad.indd 1 5/22/20 2:26 PMCD2006_FPA.indd 29 5/26/20 11:21 AM
Terminal Block1. Phoenix Contact
2. Wago
3. Rockwell Automation
4. Weidmuller
5. AutomationDirect
Wire & Cabling1. Belden
2. Lapp
3. Southwire
4. Alpha
MOTION
Gear Reducer1. Altra Industrial Motion
2. SEW-Eurodrive
3. Timken
4. Wittenstein
5. ABB
Hydraulic System Controls/ Components
1. Parker
2. Eaton
3. Bosch Rexroth
4. Festo
Industrial Electric Motor1. ABB
2. Regal-Beloit
3. Siemens
4. Weg
Industrial Electric Motor Drive1. Rockwell Automation
2. ABB
3. Siemens
4. Eaton
5. Yaskawa
Linear Motion Actuator/ Slide/Guide
1. Altra Industrial Motion
2. Tolomatic
3. Festo
4. SMC
5. Rockwell Automation
Servo Motor1. Rockwell Automation
2. Siemens
3. Yaskawa
4. Bosch Rexroth
5. Altra Industrial Motion
6. Schneider Electric
Stepper Motor1. Oriental Motor
2. AutomationDirect
3. Rockwell Automation
4. Parker
Motor Starter1. Rockwell Automation
2. Siemens
3. Schneider Electric
4. Eaton
Pneumatic Cylinder/Actuator1. SMC
2. Festo
3. Bimba
4. Parker
Pneumatic Systems Controls/Components
1. SMC
2. Festo
3. Emerson
4. Parker
Robots
1. Fanuc
2. ABB
3. Kuka Robotics
4. Yaskawa
NETWORKING
Data Acquisition System
1. National Instruments
2. Rockwell Automation
3. Schneider Electric
Data Recorder
1. Yokogawa
2. Rockwell Automation
3. Omega
Wired Network Components
1. Cisco
2. Rockwell Automation
3. Red Lion
4. Moxa
5. Phoenix Contact
Wireless Network Components
1. Cisco
2. Siemens
3. Moxa
4. Phoenix Contact
Network Protocol Converters/Bridges/Adapters
1. HMS Industrial Networks
2. Rockwell Automation
3. Moxa
4. Red Lion
5. Cisco
30 / June 2020 / ControlDesign.com
cover story
CD2006_26_35_CoverStory.indd 30 5/26/20 11:33 AM
www.phoenixcontact.com/warranty
© PHOENIX CONTACT 2019
Extending a lifetime of peace of mindOur Limited Lifetime Warranty is our promise to you that the products you install in your control cabinets are built to last. Free your mind with a variety of warranted products that will last for a lifetime. All you need to do is register, and then relax. Isn’t it time you trusted Phoenix Contact to build your cabinet confidence?
IMC-001905_ADVNewLLWAd_PeaceofMindwarranty.indd 1 7/11/2019 2:08:04 PMCD2006_FPA.indd 31 5/26/20 11:21 AM
Network Router/Switch1. Cisco
2. Rockwell Automation
3. Red Lion
4. Siemens
5. Moxa
6. Phoenix Contact
Input/Output System1. Rockwell Automation
2. Phoenix Contact
3. Siemens
4. Wago
5. Turck
Machine-Mount Input/Output1. Rockwell Automation
2. Turck
3. Balluff
4. Siemens
Remote Machine Access1. HMS Industrial Networks
2. Phoenix Contact
3. Rockwell Automation
SAFETY
Industrial Enclosure Purge System1. Pepperl+Fuchs
2. nVent
3. Rittal
Intrinsic Safety Components 1. Pepperl+Fuchs
2. Banner Engineering
3. Eaton
4. Pilz
5. Rockwell Automation
6. Phoenix Contact
Machine Safety Components1. Rockwell Automation
2. Omron
3. Banner Engineering
Programmable Safety Controller1. Rockwell Automation
2. Sick
3. Siemens
4. Pilz
5. Beckhoff
Safety Network Components1. Rockwell Automation
2. Cisco
3. Siemens
Safety Relay1. Rockwell Automation
2. Banner Engineering
3. Phoenix Contact
4. Omron
5. Pilz
SENSING
Linear Position Sensor1. Balluff
2. Turck
3. Keyence
4. MTS
5. Pepperl_Fuchs
6. Heidenhain
Machine Vision System1. Cognex
2. Keyence
3. Omron
4. Banner Engineering
Encoder/Resolver Measurement1. Rockwell Automation
2. Encoder Products Co.
3. BEI
4. Dynapar
5. Heidenhain
6. Turck
Flow Measurement1. Emerson
2. Endress+Hauser
3. Ifm efector
4. Keyence
5. Siemens
Level Measurement1. Endress+Hauser
2. Emerson
3. Vega
4. Pepperl+Fuchs
5. Siemens
Load Cell/Weighing Measurement1. Mettler Toledo
2. Rice Lake
3. Hardy
4. Omega
Pressure Measurement1. Emerson
2. Endress+Hauser
3. Siemens
4. Omega
5. Keyence
Temperature Measurement1. Emerson
2. Omega
3. Endress+Hauser
4. Pyromation
5. Ifm efector
32 / June 2020 / ControlDesign.com
cover story
CD2006_26_35_CoverStory.indd 32 5/26/20 11:33 AM
Smart Sensors for Every Challenge
Built Rugged and Reliable for the Real World
Smart laser measurement sensors from Banner Engineering reliably solve the most challenging measurement and inspection applications. From clear object detection to ultra-precise measurements, our laser sensors solve complex challenges with fewer, more powerful devices.
Detect or measure any target:• Clear and reflective targets • Very dark targets, even against a dark background• Multicolored targets with many color transitions • Extremely small targets
Learn more at : bannerengineering.com/smartsensors
CD2006_FPA.indd 33 5/26/20 11:21 AM
Vibration Measurement1. GE
2. Rockwell Automation
3. Emerson
4. Keyence
Photoelectric Sensing
1. Banner Engineering
2. Keyence
3. Pepperl+Fuchs
4. Rockwell Automation
5. Omron
Proximity Switch
1. Turck
2. Pepperl+Fuchs
3. Rockwell Automation
4. Ifm efector
Ultrasonic Sensor
1. Banner Engineering
2. Pepperl+Fuchs
3. Rockwell Automation
4. Siemens
5. ifm efector
RFID/Barcode Reader
1. Cognex
2. Keyence
3. Banner Engineering
4. Siemens
5. Sick
SOFTWARE
Data Acquisition Software
1. Rockwell Automation
2. Data q
3. Kepware
4. Schneider Electric
5. National instruments
5. Inductive Automation
cover story
• UL/CSA listed for motor and branch circuit disconnect switching
• 20-200 A, .75-100 HP, up to IP69K
• Plug and play connections with integral LOTO provisions cut changeout downtime by 50%
• Motor mounted, inline, and wallbox configurations allow installation in a convenient location
©2020 MELTRIC Corporation AD2009
BEFO
RE YOU
BUY
meltric.com/sampleRestrictions apply.
MELTRIC Simplifies Motor ConnectionsMELTRIC Switch-Rated devices meet NEC requirements for ‘line of sight’ motor disconnects.
Learn more at meltric.com
UL/CSA listed for motor and branch circuit disconnect switching
configurations
34 / June 2020 / ControlDesign.com
CD2006_26_35_CoverStory.indd 34 5/26/20 11:33 AM
ECAD Software1. Autodesk
2. Dassault Systems
3. Eplan
Integrated Development Platform Software
1. Rockwell Automation
2. Siemens
3. Beckhoff Automation
HMI Software1. Rockwell Automation
2. Schneider Electric
3. Siemens
Motion Control Software1. Rockwell Automation
2. Siemens
3. Schneider Electric
4. Beckhoff Automation
PC-Based Machine Control Software
1. Rockwell Automation
2. Beckhoff Automation
PLC Programming Software1. Rockwell Automation
2. Siemens
2. Schneider Electric
Network Management Software1. Rockwell Automation
2. Cisco
� Globally certified Type Z / Ex pzc system for Div. 2 and Zone 2/22 applications � Fully automatic control and pressure compensation in a low-cost, compact housing� Touch screen display and preset purge programs for easy system setup
www.pepperl-fuchs.com/purge7500
Bebco EPS® 7500 Series Purge and Pressurization System
Trusting in experience.Relying on expertise.Revolutionizing protection.
What did we miss?Each year, we poll the readers of Control Design to determine which suppliers you’re using to provide the solutions you need, but the technology sometimes changes. We can use your help in identifying the automation and controls you are using to build machines. Suggest new categories by emailing [email protected].
CD2006_26_35_CoverStory.indd 35 5/26/20 11:34 AM
HMI panels with multitouch technologyThese 7- to 22-in HMI Uni�ed Comfort Panels offer visualization
improvements over the predecessor devices. A capacitive glass
front with multitouch technology makes them as convenient to
use as a smartphone or tablet. The sharp colors and contrast im-
prove readability and ease of use. Visualization on the devices is
based on the Simatic WinCC Uni�ed visualization system in TIA
Portal and is suitable for scalable solutions, from machine-level
applications to distributed SCADA solutions. The Simatic HMI
product portfolio also has the option to expand functions with
apps. HMI panels previously were used exclusively for visualiza-
tion software. The integration of Siemens Industrial Edge
enables users to run other programs
simultaneously alongside this
standard device functionality.
Siemens / www.siemens.com
Headless remote HMI without attached displayIntended for users who don’t require a built-in HMI display, need
a larger display or would rather use a mobile app, the C-more
EA9 series remote HMI unit provides the functionality of a touch
panel without touchscreen interface. The headless unit sup-
ports an HD 1280x720 pixel screen
resolution with an HDMI output that
supplies both video and audio out. The
EA9-RHMI has an 800-MHz CPU and
82 MB of project memory, includes
two serial ports—USB 2.0 Types A and
B—a built-in SD memory card slot and one Ethernet port. The
Ethernet 10/100 Base-T port supports program download, remote
Internet access and communications to PLCs and PCs.
AutomationDirect / 800-633-0405 / www.automationdirect.com
Modular industrial displaysRXi industrial displays are designed to work with Emerson PLCs,
PAC solutions and third-party control systems. They feature
standardized physical designs to minimize the variety of enclo-
sure cutouts required for OEM applications, making each display
easily replaceable and upgradeable in the �eld with no need to
modify existing or install new cabinets. Three display types
provide options for a variety of
applications: Panel PC includes a
high-performance and rugged in-
dustrial PC for powerful comput-
ing capabilities, Industrial Monitor
works with most industrial or
commercial PCs for plant �oor visualization, and Web Panel sup-
ports Web-hosted applications. Displays are available in sizes
ranging from 7 to 24 in.
Emerson / emerson.com
Industrial thin client for virtualized HMI systemsThe BTC12 and BTC14 thin clients feature VisuNet RM Shell
5 �rmware, the latest generation of thin client �rmware for
industrial-grade security and stability. Designed for use in harsh
industrial environments, their Intel Apollo Lake and AMD Ryzen
processors support operator workstation setups with as many
as four monitors. The BTC12
has two DisplayPort connec-
tions for dual video output,
supporting 4K (Ultra HD) resolution at 60 Hz. The BTC14 has four
DisplayPort connections for quad video applications. Both thin
clients also support D++ (allows connectivity to an HDMI moni-
tor via a passive DP-to-HDMI cable) and Multi-Stream Transport
protocol (daisy chaining multiple monitors to one display port).
Pepperl+Fuchs / www.pepperl-fuchs.com
UL Type 4X HMI seriesThe Harmony GTUX HMI series for ex-
treme conditions combines the 7-, 12- or
15-in-wide sunlight-readable display—
made with an aluminum die-cast, stain-
less steel bezel—with the HMIG3X box
unit. This combination offers operating temperatures ranging
from -30 to 70 °C, a high brightness liquid crystal panel display-
ing screens at 1,000 nits and a UL 50E Type 4X Outdoor use rat-
ing. The series is suitable for multiple applications under harsh
environmental conditions. The display also features UV protec-
tion, conformal coating and vibration and shock resistance.
Schneider Electric / www.se.com
Human-machine interfaces expand horizonsManage and control what you see
36 / June 2020 / ControlDesign.com
product roundup CONTACT US [email protected]
CD2006_36_40_Roundup.indd 36 5/26/20 10:52 AM
Compact EtherCAT Controller and Slice I/OA Scalable Control Platform Especially Made for System Integration
DIN-Rail Control IPC with EtherCAT Slice IO Expansion
AMAX-5000 is a revolutionary compact size controller, featuring high-speed processing, flexible expansion, and a high
degree of integration. This series offers an impressive array of features: AMAX-5580 embedded controller, EtherCAT I/O
module—AMAX-50xx series, and PCIe module—AMAX-54xx series. The combination of our latest AMAX-5580 IIoT
embedded controller with an EtherCAT I/O module and PCIe module provides a powerful tool for realizing smart
industrial 4.0 applications. AMAX-5000 series can integrate with third-party software, making it easier for industrial
equipment manufacturers to develop smart IIoT applications. So for example, when developing machine vision and
machine control applications, integrators can install image recognition software on AMAX-5580, connect USB 3.0 or PoE
modules and attach industrial cameras, paired with an EtherCAT I/O module to control a robotic arm. For predictive
equipment maintenance applications, acquisition and analysis software on AMAX-5580, along with an EtherCAT I/O
module, allows operators to remotely collect data, obtain equipment status, perform equipment diagnostics, and
schedule maintenance tasks.
• Intel 6th Gen Core i7/ i5/ Celeron CPU
• 2 x LAN, 4 x USB 3.0, 2 x Serial,
VGA+HDMI Dual Display
• Compact and fanless design
• BIOS/ OS optimized for CODESYS/
EtherCAT environment
DIN-Rail Control IPC
• 2 x PoE/2xGbE expansion module
• PCIe-mini card with SIM card slot
• 2 x Isolated RS-232/422/485
• 4 x USB 3.0 with full bandwidth
PCIe Expansion Module
• EtherCAT coupler module
• DI/ DO/ AI/ AO module
• RTD module/ Thermocouple
• Encoder/ counter module
EtherCAT I/O ModuleCAT I/O Me Exp MN R il C t l
www.advantech.com
CD2006_FPA.indd 37 5/26/20 11:21 AM
One-click dashboard for engineering ef�ciencyWith the TwinCAT Analytics One-Click Dashboard, all it takes
for users is a simple mouse click to generate an entire HTML5-
enabled analytics dashboard based on the PLC code that then
is loaded into a selected Analyt-
ics Runtime container. When the
process completes, users receive
a network address to access the
dashboard in a Web browser. This
ability to generate dashboards
without the need to design graph-
ics or write a single line of code saves time in engineering
processes. Based on the TwinCAT 3 HMI, this functionality
provides at least one HMI Control for every TwinCAT Analytics
algorithm, each with an up-to-date tile design that follows the
latest Web development standards.
Beckhoff Automation / 877-twincat / www.beckho�automation.com
Moisture- and water-resistant stainless steel panelThe C6 is a moisture- and water-resistant stainless steel HMI.
The IP69K-certi�ed panel uses 316L stainless steel and is
offered as a standalone HMI or
HMI+PLC combo. It offers protec-
tion in environments in which
high-pressure water or steam is
used to sanitize or clean equip-
ment. The HMI supports more than
40 different communication drivers, including EtherNet/IP, Pro-
�net and Modbus, so it can be paired with almost every PLC. It
includes a micro UPS to protect nonvolatile data and a software
tool that permits backup, restoration and transfer of programs.
Integrated remote maintenance capability comes standard and
allows monitoring and maintenance of remote installations us-
ing a secure VPN connection.
KEB America / www.kebamerica.com
Panel with onboard securityTouch Panel 600 offers high-tech screens and high-quality
visualizations as well as advanced features. The engine has a
Cortex A9 multicore processor providing fast operating speeds.
Onboard security includes a built-in �rewall and VPN to help
users address cyberattacks. All panels are equipped with the
future-ready Linux operating system and support HTML5
technology. They include three versions-—Control, Visu and
Web Panel—so users can select
the technology that suits their
applications. All of the devices
include features such as an
energy-saving standby func-
tion, integrated sensors for
automatic brightness adjustment and an easy-to-mount design
to make installation and operation simple.
Wago / www.wago.us
Industry 4.0-ready built-in all-in-one controllerThe UniStream built-in all-in-one controller brings advanced
communication capabilities for Industry 4.0, complete con-
trol functionality and the ability to
support the UniStream remote I/O
modules over Ethernet. The compact
controller is available in two series:
UniStream 7” Built-in and UniStream
7” Built-in Pro. Both series support
MQTT, SNMP, VNC, FTP, SMS, email
and communications via GSM/GPRS modem. The Pro version
also offers a built-in Webserver, audio jack and video support,
as well as SQL, a plus for system integrators and OEMs facing
Industry 4.0. The line comprises an Ethernet-based remote I/O
adapter and a range of remote I/O modules, each offering a dif-
ferent con�guration of analog and digital I/O.
Unitronics / 617-657-6596 / www.unitronics.com
HMI upgrade with no PLC code changesWith Change Your View, machine builders can upgrade to the
latest HTML5-based, high-de�nition HMI technology with-
out having to change their existing PLC code. It works with a
variety of PLC brands and is operating system-independent, so
it can run on smart phones, tablets or any Web-enabled device.
It delivers contemporary, easy-to-navigate, connected HMI
software. Easy to develop from the mapp View drag-and-drop
HMI software tool and featuring an extensive widget library,
Change Your View can accom-
modate 3-D models, HD videos,
animations and PDF �les. The
hardware includes wide aspect
ratio, high de�nition, touch and
multi-touch panels.
B&R / www.br-automation.com
38 / June 2020 / ControlDesign.com
product roundup
CD2006_36_40_Roundup.indd 38 5/26/20 10:53 AM
I/O for IIoT connectionThe groov RIO family of intelligent, distributed I/O for IIoT
and automation applications connects traditional wired
switches and sensors directly to Ethernet networks, software
applications and cloud platforms without intermediary con-
trol or communication hardware, such as PLCs, PACs or PCs.
GRV-R7-MM1001-10 is a standalone, 10-channel, multisignal,
multifunction I/O unit for signals includ-
ing thermocouples (TCs), integrated circuit
temperature devices (ICTDs), voltage inputs,
current inputs, millivolt inputs, discrete dc
inputs, self-wetting discrete inputs, discrete
dc sinking outputs and Form C mechani-
cal relays. Two channels provide special
features such as pulse counting, on- and
off-time totalization, software latching and
frequency measurement.
Opto 22 / 951-695-3000 / www.opto22.com
Excel add-in for SCADA historical dataPut SCADA historical data across an organization using
Microsoft Excel. In addition to VTScada’s standard reporting
options, version 12 allows users
to export data from VTScada’s
Enterprise Historian to Excel
spreadsheets on PCs or iOS
devices. After the add-in has
been downloaded from the
Microsoft Of� ce Store or App
Source, users choose a server,
set VTScada as the data source
and select I/O using the built-in query builder. No coding or SQL
is required. Data is imported as desired. Queries and connec-
tions are saved with Excel documents and can be emailed and
refreshed as required. To keep historical data secure, SSL/TLS
is required when using this add-in.
Trihedral / www.trihedral.com
CD2006_36_40_Roundup.indd 39 5/26/20 10:53 AM
Scalable HMI with protocol conversionRed Lion CR3000 HMIs provide proto-
col conversion and connectivity choic-
es along with visual display features
to deliver operator interface devices
that scale and adapt as requirements
change. The automation HMI combines a list of more than 300
industrial drivers with the Crimson 3.1 development platform.
It includes real-time data logging and a built-in Web server.
Newark / www.newark.com
Hazardous conditions HMIThe SP5000X extreme HMI series can be used in extreme
or hazardous conditions, including outdoor applications. It
combines the SP5000X 7- or 12-in-wide
sunlight-readable display made with
an aluminum die-cast stainless steel
bezel with the SP5B90X box unit. This
combination offers operating tem-
peratures ranging from -30 to 70 °C, a
high brightness liquid crystal panel
displaying screens at 1,000 nits and a UL 50E Type 4X outdoor
use rating. The series is suitable for multiple applications under
harsh environmental conditions (3C3).
Pro-face America / www.profaceamerica.com
HMI with VNC or VPN compatibilityThe Monitouch HMI series is designed to provide critical data
on the shop �oor with a virtual network computing (VNC)
service or remote locations with a virtual private network
(VPN) server. The VNC allows users to view and operate
HMI screen on the factory �oor via PC or
tablet devices without any license re-
quirement. Using a VPN, more methods
of communicating are available for cen-
tralized control of multiple locations
and remote maintenance.
Fuji Electric / www.americas.fujielectric.com
Arm-based industrial panel PC for IoT applicationsThe TPC-71W line of industrial panel PCs is aimed at machine
automation and Web-terminal applications. This Arm-based
machine features a 7-in true-�at display with P-CAP multitouch
control, high resolution and an NXP Arm Cortex-A9 i.MX 6 dual/
quad-core processor to deliver high-performance computing.
The system also features a serial port with a 120Ω termination
resistor that supports the CAN 2.0B protocol and offers a pro-
grammable bit rate of up to 1 Mb/sec. It
is equipped with the Google Chro-
mium embedded Web browser and
support for various operating systems,
including Android, Linux Yocto and
Linux Ubuntu with QT GUI toolkits.
Advantech / www.advantech.com
Scalable HMI productsThis intuitive and �exible HMI technology offers clear func-
tionality and a library of premade
objects for key applications.
Scalable with a va-
riety of widescreen
sizes, the Sysmac NA
series HMI facilitates
the quick implementation of dynamic user interfaces that help
to boost productivity and minimize downtime. The design
is based on real applications and customer requirements, a
future-proofed, scalable platform that will evolve with ever-
changing needs, allowing real-time reaction to events.
Omron / automation.omron.com
Machine-mounted HMIsThe machine-mounted Allen-
Bradley ArmorView Plus 7 graph-
ic terminal is fully enclosed.
The prepackaged solution can
be ordered with integrated I/O
and push buttons. Whether an
on-machine, cabinet-free HMI is being deployed to save space
on the shop �oor or to help operators work better by having line
of sight from the HMI to the machine, the terminal provides
mounting options to meet users’ needs. It can be attached in a
range of orientations to a swing arm, pedestal or �xed surface
and uses Ethernet I/O communication to minimize wiring. It
has an IP66 rating, providing ingress protection against dust
and high-volume pressurized water.
Rockwell Automation / www.rockwellautomation.com
40 / June 2020 / ControlDesign.com
product roundup
CD2006_36_40_Roundup.indd 40 5/26/20 10:53 AM
ControlDesign.com / June 2020 / 41
real answersCONTACT US [email protected]
A CONTROL DESIGN reader writes: As an automation engineer at a
large discrete part manufacturer, I need to create a factory-accep-
tance-test (FAT) plan for a $2 million high-speed, automated sys-
tem. It has multiple stations with several robots, motion control,
vision inspections and many �eldbus digital and analog I/O. The
question is what should I include in a FAT? I don’t know where to
start. Also, are there diagnostic tools or software to make perform-
ing the de�ned tests easier to complete? What do you suggest?
Answers
Built-in diagnosticsMany automation technology manufacturers include test-
ing and validation processes in their integrated development
environments. The embedded processes guide users through a
step-by-step process to validate different operations and com-
ponents to ensure that they work as expected.
TODD MASON-DARNELL
marketing manager, services & safety / Omron Automation Americas /
automation.omron.com
FAT the specsYou will want to attempt as much testing as physically and eco-
nomically possible at the location of testing. The main goal of
the FAT is to certify that what has been built is able to perform
the functions that are possible to test and is the milestone that
will determine whether to ship the system to site. If the FAT is
thorough and no changes occur other than installation, you can
isolate the factory-acceptance-tested (FATed) system as an area
that is highly unlikely to cause an issue during commission.
In essence, the problem should be how the FATed system was
electrically/mechanically connected at the plant site. The FATed
system is not always going to be a part to avoid blaming issues
during commission but should be one of the last areas to check,
unless the conditions presented lead back to it.
To start, begin with the various design documents. Func-
tional speci�cation and other design specs along with mechani-
cal and electrical drawings are what should determine the tests
to be performed. For example, electrical drawings for a panel
should be checked for each wire to be correct from the hard-
ware in the panel to the terminals where the �eld wires will
be terminated. This is often done by the shop that builds the
panel, and, depending on who the system is developed for, one
may need to witness this test or redo the testing in front of the
customer. The speci�cations will detail how hardware should
be utilized and programmed. This will need to be tested to as-
sure the speci�cations have been followed. This portion of the
test is where the physical and economic judgment of feasibility
comes in. If you are staging this in your of�ce, you will likely be
short on space, power and quite a few other things. Here you as-
sess what can be tested. Some of this testing could be handled
with simulation. Simulation can be done with software or using
potentiometers, switches, dials and meters to simulate or read
signals. If you system-assemble items and you have enough
space to only partially test, and it is physically possible, you will
want to demonstrate that in the FAT.
So, what do you gain from completing a thorough FAT?
1. Prior to going to the �eld, you likely catch a high majority of
issues in all areas of the design and may have some unfore-
seen issues as per what the end user wanted remedied.
2. Commissioning should be considerably shorter if a thorough
FAT wasn’t completed, as most problems are arise during �eld
installation.
3. Most importantly, changes and corrections that occur in the
�eld are considerably more expensive, so the savings in money
and �eld time will lead to a happier end user and �eld team.
DEAN DEGRAZIA
operations manager / Applied Control Engineering (ACE) / www.ace-net.com / Society for
Maintenance and Reliability Professionals (SMRP, www.smrp.org) member
No two FATs are the sameA FAT is a “factory debug” to assure that when the system ar-
rives on site, it should be able to be installed and get up and
running quickly and smoothly.
While there are standard tests that are routinely conducted,
there is no set checklist during a FAT; it can consist of a variety
of inspection points and tests per the request of the customer,
based on your requirements and unique equipment speci�ca-
tions. In general, the following things are covered during a FAT:
• comprehensive inspection—this is typically customized based
on the equipment and the requests of the customer, but can
include a range of conformity checks and veri�cations, such
as whether the actual equipment matches up to the drawings
and name plate data
What should be included in a FAT?
CD2006_41_48_RealAnswers.indd 41 5/26/20 10:58 AM
• contract audit—this consists of a review of the original agree-
ment to make sure all contractual obligations are met
• function test—this procedure simulates the system in opera-
tion to provide proof of functionality; these tests usually
include veri�cation of relevant documents, including user
manuals, P&IDs and any type of instructions that come with
the equipment to make sure they are accurate.
It’s important to note here that there are varying levels of a
FAT. They can be performed at a very basic level, such as setting
up the main pieces of the system with temporary wiring and
making sure everything moves as it is supposed to; or a more
complete FAT can be conducted where the manufacturer physi-
cally builds the whole system in the shop to test it fully. In the
latter example, the system is then taken apart moved to the
customer’s site and put back together again.
FATs are bene�cial not just for the buyer and end users but
for the manufacturer, as well. Both parties can be assured that
the equipment meets all the contractual speci�cations and any
issues can be addressed before arriving at the customer’s site.
Rectifying issues while the system is still in the possession of
the manufacturer helps to keep the project on track and within
budget. FATs almost always save time and money over �xing
issues in the �eld.
The safety of your employees is always a top concern, so the
quality assurance gives you the peace of mind that all compo-
nents of your system are functioning the way they should and
within the full range of operating speci�cations.
Additionally, FATs help to determine who is responsible
for the problems that are identi�ed. Sometimes the issues
are the manufacturer’s responsibility, for example, when an
instrument doesn’t work properly. Other times they are the
customer’s responsibility. For example, if a customer decides,
after seeing the physical layout, that it wants to recon�gure
the design, the manufacturer can move things around prior to
shipping it to site.
All inspections and testing are done at the vendor’s location,
usually on the shop �oor so that when/if issues arise, they are
in an area that is convenient for modi�cations to be made to the
equipment. Since the purpose of a FAT is to qualify the equip-
ment prior to shipment, it should never be conducted at the
customer’s facility.
The manufacturer and customer can choose whomever
they would like from their companies to be present during the
factory acceptance test. It’s a good idea to have any/all of the
following on location:
• project managers
• operators
• plant engineers
• maintenance personnel.
The more valuable input that is received from both parties,
the more successful the test will be, which will help to facilitate
a fast-track startup.
As we’ve mentioned, it’s hard to outline exactly what a fac-
tory acceptance test consists of because each one is unique to
the equipment it involves and the specialized requirements of
the customer. While keeping in mind that no two are alike, here
is an example to give you a better idea of the inspection points
and tests that are used to validate the equipment. This example
is for an automated reactor system:
• scope—the tests to be performed by the manufacturer to
establish acceptability of the equipment and the conformance
with the applicable drawings and speci�cations
• applicable standards and speci�cations—a list of any relevant
safety guidelines published by National Electrical Manufacturers
Association (NEMA) or National Electric Code (NEC), for example
• reference documents—a complete set of all relevant docu-
ments to be available during the execution of the FAT and
marked up as required; these drawings are usually located in
an appendix at the back of the protocol
• testing equipment—a list of the equipment and instrumentation,
such as vacuum gauge or tachometer, used during this test
• system skid has its own list:
a. Verify all lines and components are present and installed
as per the plan. Check that components are new, anchored
suf�ciently to frame and built in accordance with the
speci�cations outlined in the applicable list.
b. Verify equipment is fabricated as per drawings and manu-
facturing quality meets expectations.
c. Verify pressure, temperature and material information on
42 / June 2020 / ControlDesign.com
real answers
The manufacturer and customer can choose whomever they would like from their companies to be present during the factory acceptance test. It’s a good idea to have any/all of the following on location:
project managers
operators
plant engineers
maintenance personnel
CD2006_41_48_RealAnswers.indd 42 5/26/20 10:56 AM
the National Board nameplate to be
consistent with speci�cations.
d. Verify motor manufacturer, model
and serial number. Also con�rm
motor classi�cation meets speci�ed
class and division standards.
e. Verify lines hold pressure when fully
assembled; record pressure at start
and stop. This test is generally con-
ducted for 60 minutes to ensure the
system meets the acceptance criteria.
f. Verify lines hold vacuum when fully
assembled; record pressure at start
and stop. This test is also conducted
for 60 minutes to ensure the system
meets the acceptance criteria.
g. Verify that system documentation is
complete.
Each test should yield an acceptable
result with no issues. Corrective steps will
be taken if a test fails and any retesting
will be performed if required. Some tests
may require additional testing or clari�ca-
tion of the testing methods. Under these
conditions, additional comments will
be documented in the deviation section
of the FAT. Deviations are redlined to be
captured in �nal as-built drawings.
A list of remaining follow-up items
should be put together to note any
modi�cations/adjustments or addi-
tional tests that need to be made prior
to delivery. Make sure to verify panel
component checks, auto mode controls
(agitator), manual mode controls (reactor
on-off valves, modulating valves), analog
displays, sequences (system purge, pres-
sure/vacuum control, system leak test,
charge liquids, re�ux/solvent strip, exo-
thermic additions interlocks) and reactor
light operations.
By systematically carrying out all
items on the checklist, all FAT partici-
pants from both sides can gain the assur-
ance needed to feel prepared and ready
for start-up.
There are numerous advantages to
having a FAT, for both parties involved.
The seller can ensure that the system is
operational and the project is optimized
to stay on track to be delivered on time.
The buyer can qualify the equipment
against the contractual agreement as per
the order speci�cations.
It is important to note that it is not
uncommon for there to be minor glitches
the �rst time new systems are powered
up. The bene�t of conducting a FAT is
that the manufacturer can take care of
typical �rst-run issues.
There are numerous additional bene�ts:
• Customers can “touch and feel” the
equipment while it is in operational
mode before it ships.
• The manufacturer can provide some
initial hands-on training to the cus-
tomer, giving operating personnel more
con�dence when running the machinery
for the �rst time in real-world settings.
• Key project people from both sides
are together, making it an ideal time
to review the bill of materials, discuss
required and recommended spare parts
(for start-up and �rst year of operation)
and review maintenance procedures
and equipment limitations.
• The thorough FAT documentation can
be used as a template for the Installa-
tion Quali�cation portion of the vali-
dated process/installation.
• Based on the results of the FAT, both
parties can create a punch list of addi-
tional items that need to be addressed
prior to shipment.
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CD2006_41_48_RealAnswers.indd 43 5/26/20 10:57 AM
Times can vary depending on the
complexity of the system and the cor-
responding FAT, but they are typically
scheduled 2-4 weeks prior to the ship
date to help maintain on-time delivery.
The duration of the FAT can be anywhere
from one day up to a couple of weeks.
There is no extra cost for the cus-
tomer to have a FAT performed on the
system as it is generally included in
the scope of the project. That being
said, the expense that is factored into
the project for FAT is dependent on
the customer’s requirements. It is very
important for you to communicate early
in the project exactly what your testing
needs are so the criteria can be outlined
and agreed upon by both parties. This
helps to set your expectations to the
manufacturer, and the manufacturer
will be sure to include the relevant tests
in your checklist.
While FATs can be costly for the
manufacturer with respect to the time
and labor involved in performing them,
it’s more time and cost effective to do a
FAT and do it right to mitigate any issues
prior to delivery.
A FAT gives manufacturers and you,
the customer, an opportunity to do
a trial run and see the equipment in
operation before it is installed in your
facility. This makes any modi� cations
and adjustments much easier to make
and ensures the equipment will run
with full operational ef� ciency. It is
proven that when verifying, inspecting,
and testing is performed prior to ship-
ment, it greatly reduces start-up issues
once the equipment arrives at your site.
With a thorough factory acceptance test
performed, you can be con� dent in the
system you are receiving and be ready to
put it into production.
DANIEL WEISS
senior product manager / Newark / www.newark.com
FAT—from start to � nishThe factory acceptance test (FAT) is
a document, whether maintained in
electronic format or printed on paper,
designed to enumerate performance re-
quirements and record the achievement
of those requirements. Completion of
the FAT provides the system integrator
clearance to deliver the control system
to the customer site—thus, delivery
from the factory to the customer. This
document explains the need for the FAT
and its minimal requirements for con-
tractual obligation.
Automation system integrators, PLC/
PAC programmers, robotics designers,
process engineers and custom coders all
face a challenge when creating. The pro-
grammer writes code with the purpose
of ful� lling a need. Those needs may
have been scratched on a napkin; they
may have been delivered in a 300-page
governmental boilerplate speci� cation;
or most likely they’re conveyed some-
where in between. The programmer’s
task is to create action out of need; the
code ful� lls a requirement that marries
sensors, actuators, databases, images
and reports. Eventually, the program-
mer will step back and admire the work,
only to wonder if it has fully satis� ed the
speci� cations. Not only does it need to
answer the question, “Is this what you
wanted?” It must also provide proof to
the same one who handed the speci� ca-
tion in the � rst place. Perhaps ful� lling
the speci� cation also means signi� cant
ful� llment of contractual obligation,
leading to remuneration.
The above scenarios have played out
time after time in varying degrees ever
since the advent of the electrical switch.
So what is the manner in which one proves
contractual satisfaction? This is where the
factory acceptance test � gures prominent-
ly in the integrator’s deliverables.
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What is the factory acceptance test,
and what is it not? The FAT should be
a document serving as a platform of
proof for moving from the programmer’s
shop—the factory—to the end user’s
site. In its simplest form, the FAT should
be a document that is a near-perfect
recount of the speci�cation given the
programmer. While this may seem overly
simplistic, this is how the programmer
conveys their understanding of what was
expected. If there is any misunderstand-
ing between programmer and customer,
it will come out in the words of the FAT.
It should also be noted that sometimes
the manufacturing systems are so large
they can and must be broken down into
subsystems. If there is a way to subdivide
a manufacturing line to smaller stand-
alone portions, then this could warrant
the generation of a FAT for each portion.
Robotics stations, standalone skids, sub-
assemblies from other manufacturers:
All can be described and tested in their
own FATs. The decision to subdivide FATs
is at the discretion of the system integra-
tor, in agreement with the customer.
The FAT is not the �rst document of
proof. It should never be the �rst docu-
ment. Instead, the FAT is usually second-
to-last in a long line of deliverables.
To put it in perspective, many system
integrators will employ a near facsimile
of the following list of deliverables:
1. functional requirement speci�ca-
tion—system integrator expresses
the understanding of the system
desired by the customer, expressed in
general terms
2. scope of work—system integrator
expresses their understanding of who
does what during the execution of
the contract
3. proposal—system integrator then
produces a price associated with
ful�lling that functional requirement
speci�cation, within the guidelines of
the scope of work
4. detailed design speci�cation—system
integrator then creates documentation
to support the work required, including
equipment drawings, such as architec-
tural drawings, schematics, enclo-
sures, pipe schedules, I/O lists, HMI
screen prints and report formats, and
guiding the customer and subcontrac-
tors toward complete installation
5. factory acceptance test—test of the
programmed system prior to delivery
6. site acceptance test—FAT performed
after delivery, at the end user’s location.
Granted, there are deviations from
this, based on the industry supported.
Pharmaceuticals, food and chemical
industries all follow different testing
standards, per the U.S. Code of Federal
Regulations (CFR), but the underlying
framework still exists.
An important factor of each of the doc-
uments above is that they are described
as deliverables. The system integrator
creates them, while the customer should
see them and should have the ability to
in�uence them—yes, even the proposal.
Often the system integrator will insist on
customer signature on each document
before moving on to the next. A customer
signature means the customer is in
agreement, and the system integrator is
free to move forward.
Signatures generally imply the docu-
ment is printed on paper and signed
on paper. Other electronic means are
becoming the norm, as well, as long as all
parties have access.
What should be seen in a FAT? If the
system integrator is following the above
generic path of documents, the FAT will
include many sections and subsections
for examination. Their FAT will most
likely “carry along” the details provided
in the previous speci�cations. Below are
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CD2006_41_48_RealAnswers.indd 45 5/26/20 10:57 AM
some typical headings for FAT inclusion.
Within each heading are questions the
system integrator should try to explain.
Automatic operations: What is the sys-
tem’s expected behavior? Is it a continu-
ous system or a batching system? What
are the major components? This could be
paragraphs of information spelling out
the behavior of the system.
• I/O Testing—If there is processor I/O,
those points should be listed. This
could also include inspection of the
enclosure(s), wiring practices and qual-
ity of workmanship. This section only
exists if the I/O is to be terminated to
the �eld devices as part of the factory
assembly. If the system can only be
wired at the site, this section is omit-
ted. If additional diagnostic tools are
needed, this should also be noted.
• Normal sequence of operations—If the
system is a batching operation or if it
does behave in a regulated series of
steps, those steps would be included in
this section. Normal robotics actions
would also be listed in this section.
• Interlocks—Often the operation of
the system means de�ning conditions
in which equipment should not run,
or perhaps withdraw to a safe state.
Interlocks are de�ned to protect the
equipment from self-destruction (think
overtravel, physical barriers, pre-exist-
ing conditions). List all interlocks for all
equipment that can be energized.
• Safety—This is a topic that addresses
personnel safety. If there is the pres-
ence of moving equipment (robotics,
gears, belts) or exposure to released
energy (steam, stored electricity,
potential energy), safety equipment is
necessary. This section would address
those testing requirements. Not all sys-
tems would have the safety measures
in place, dependent on the extent of
system testing.
• Contingencies—When something in
the process goes awry, there needs to
be a way to walk back the system to a
safe state.
• Manual operations—The system may
provide for operator manual overrides.
Such would be explained in this section.
Graphical user interface (GUI) operations:
This is a section dedicated to the depic-
tion of the system for the user. This could
be something as simple as a single LED, a
cloud-based status report or an HMI page,
all the way up to FDA-regulated SCADA
screens.
• Screen standards—What are the ex-
pected colors, fonts, behaviors of the
GUI reports?
• Pushbuttons/function keys—If there
are keystrokes that provide common
functions throughout the pages, what
are they?
• Screen descriptions—If the system
contains multiple screens/pages, they
should be listed, each page given its
own subsection with details about what
is depicted.
• Other functions—Is there user manage-
ment? Are passwords required to limit
access? Does an annunciator panel
make noise? Will vision inspections
need further de�nition? What are the
go/no-go requirements?
• Reports—Perhaps the system generates
periodic reports, or even user de�ned
reports. What �elds are provided in
those reports?
Every single item that can be listed
above can be tested. Keep in mind, if it
can be disputed by the customer, it is
worthy of testing. To extend this even
further, if it is worthy of testing, it should
have its own check box. That check box
becomes the moment-by-moment target
of achievement as the programmer walks
through the FAT.
Every scenario can be played out dif-
ferently. Some sections and subsections
can be quite elaborate while some won’t
even exist.
A copy of the FAT should be transmit-
ted to the customer for review, ensuring
all are working toward the same goal.
The system integrator will usually
execute the FAT prior to inviting the cus-
tomer to visit and witness. This way, the
system integrator can work out the kinks
before the customer arrives.
On the day(s) of FAT execution, all par-
ties should agree on one copy being used
for signatures. In general, if the document
has been agreed upon prior, project com-
munications have been open and honest
prior, and the programmer has already
executed the FAT prior, the day of FAT wit-
ness testing should be quite smooth.
Successful completion of the FAT
should be evidenced in the signatures
provided by both the system integrator
and the customer. If there are discrepan-
cies, changes or simple oversights, they
should be addressed accordingly:
• Quick �xes should be addressed on the
spot, streamlining the execution.
• Discrepancies or changes may require
further work, thus necessitating a
future date visit. If this is the case, ap-
pendices of changes should accompany
the FAT document.
The need for testing can often require
simulation. This could include simu-
46 / June 2020 / ControlDesign.com
real answers
If it can be disputed by the customer, it is worthy of testing. To extend this even further, if it is worthy of testing, it should have its own check box.
CD2006_41_48_RealAnswers.indd 46 5/26/20 10:57 AM
lated I/O (large switchboards with toggle
switches, analog simulators, safety
mats, light curtains), interconnection
with other systems (�eldbus connec-
tions, interposing relays), polling drivers
(Modbus RTU/TCP, BACnet for building
automation, OPC servers/clients or oth-
ers) or simply simulation efforts (forced
I/O points or GUI inputs). If there are sig-
nals that must be checked, appropriate
instrumentation should also be applied
(serial breakout boxes, oscilloscopes,
Wireshark captures, voltmeters). The
need for diagnostic tools should be ad-
dressed in the FAT as a portion of the I/O
testing, commonly where they’re applied.
Successful completion of the FAT
means the system can be delivered. If the
system is then to be wired in the �eld,
the next step would be the site accep-
tance test (SAT), with real conditions and
real-life equipment. A smooth FAT can
lead to an equally smooth SAT.
Well-written speci�cations are crucial.
This fact stands true for both sides of
the contract. If the customer provides an
incomplete or nebulous speci�cation, or
if the system integrator produces equally
poor documentation, the GIGO (garbage in,
garbage out) principle will promise both
parties contentious phone calls and tense
meetings. The production of good docu-
ments can be just as indispensable as the
actual code writing. In light of this, if either
party feels there is room for ambiguity,
then the moment for discussion is now.
DANIEL A. BOONE
senior solutions engineer, engineering services /
Phoenix Contact USA / www.phoenixcontact.com
Envision all scenariosMost of the time the FAT is performed
to see if a machine meets the original
speci�cation. The speci�cation must be
well-written, and the machine must be
thoroughly designed for all production sce-
narios. Any design changes required after
the FAT can create extra costs and have
the potential to ruin the project budget.
To make a good factory acceptance
test, you must consider all possible
machine functions. I would avoid using
extra software to evaluate the machine
for the FAT. Instead, design a FAT that
encompasses all possible production
scenarios and use the software already
available in the HMI or PLC.
I would start by breaking down all
machine functions separately and
verifying that all parts of the process
are working correctly. Then I would run
product. However, just producing product
is not good enough for a FAT because the
machine must be able to handle all raw
materials given to it, even if the material
is out of speci�cation. The FAT should
test samples of raw material that meet
the design speci�cations and samples
that are outside of the tolerance range.
A properly designed machine will reject
irregular materials and accept those that
meet the speci�cation. Vision systems,
smart sensors and mechanical test �x-
tures support this.
Redundancy must also be considered.
Is there a way to shut down one part of
the machine while the rest keeps run-
ning? Is there a way to substitute a hu-
man into the process while a part of the
machine is being repaired? In short, all
conceivable scenarios must be taken into
account to verify that the machine will
meet the requirements of the factory.
TIM CICERCHI
technical services manager, factory automation division /
Pepperl+Fuchs / us.pepperl-fuchs.com
Step by stepThe focus on the process of running a FAT
is as important as testing to speci�ca-
tions. Some key elements in order of oc-
currence in a FAT process are as follows.
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Clear operational speci�cations to be
de�ned up front and agreed upon:
• expectations to vendor to be clari�ed
before FAT
• con�rm standardization of features and
speci�cations to other systems on-site.
Break system out to major sections:
• test each system individually
• con�rm data availability, communications
and access from each part of the system.
Functional operation to be validated:
• clear test plan that is communicated to
vendor up front
• acceptance criteria for the testing to be
performed
• de�ne needs of the actual FAT execution,
such as tools, labor, test products to use
• testing performed to be representative of
actual production usage, using actual prod-
ucts and throughput requirements.
Utilize a sign-off checklist:
• complete as-built electrical and mechanical
drawings
• proof of certi�cation, such as UL and NEMA,
• user manuals
• controller programs, if included contractually
• operations and maintenance guides.
The usage of diagnostics tools would
be based on speci�c requirements of the
system. Some of these tools may already be
in the production environment. Some of the
tools may be provided by the vendor. This
would have to be de�ned when the validation
plan is de�ned prior to FAT, to set the right
expectations from the vendor.
CHRIS THOMAS
senior application design engineer / Schneider Electric /
www.se.com/us
Use best practicesBest practices for FAT should typically be
categorized into multiple sections such as:
• hardware
• software
• HMI/SCADA
• �eld device communication test
• cybersecurity.
Each of these parts should then be divided
in visual and functional tests. It should be
reviewed and approved by stakeholders
involved in the test. The FAT plan should
clearly detail test description, which can be
broken down into multiple tests, and each
test should have acceptance criteria so there
is no ambiguity on what quali�es for a suc-
cessful test.
In addition to testing different areas such
as hardware or software, it is essential to
perform integrated FAT with all components
connected. If the test involves integration
with drives or servos or other critical com-
ponents, it is recommended to have at least
one sample of each type available for FAT
to ensure that communication with these
critical components will function as required
when installed on a machine.
Most suppliers of control systems or PLCs
also offer simulator, which is a good tool for
application software and HMI tests without
hardware. Some automation vendors offer
simulator on a cloud platform, which can
also enable remote software FAT with a
customer, vendor or other parties involved
helping to reduce travel needs.
SWAPNIL V. ADKAR
senior market development manager, global OEMs /
Honeywell Process Solutions / www.honeywellprocess.com
48 / June 2020 / ControlDesign.com
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Fax: 630/467-1124Best practices for FAT should typically be categorized into multiple sections such as hardware, software, HMI/SCADA, �eld device communication test and cybersecurity.
CD2006_41_48_RealAnswers.indd 48 5/26/20 10:57 AM
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THE DISCRETE AND analog signals and related input and out-
put (I/O) wires running all over an automated machine have
become a part of the past. They, have given way to distributed
machine I/O which sends the signals over a communication
cable typically using an industrial Ethernet protocol. This
distributed machine I/O has seen signi� cant technological
development over the past decade—it’s well beyond simple I/O
signals. It should be considered on all but the smallest ma-
chines for all sensor and control needs.
There are history and advantages
that led to the development of distrib-
uted I/O and its expanding popular-
ity. As a result, there are a variety of
devices and communication options
available and many ways to apply
distributed machine I/O technology.
Distributed machine I/O is popular
today for the same reason the distributed control system (DCS)
was developed decades ago for use in process plants. Without
distributed I/O, discrete wires and analog signal cables would
need to run hundreds if not thousands of feet for just one signal,
and there could be thousands of signal lines. Moving the I/O
to distributed locations and replacing those wires and cables
with just a communication cable and power conductors saved a
signi� cant amount of time and material costs, and don’t forget
the conduit installation. Sure, there are costs related to commu-
nication modules or the appropriate controller at each end of the
communication link, but the advantages outweigh them.
That communication wire connecting the distributed I/O
carries more than just the signal level of the input or output. It
carries data, and, when designing a machine with distributed
I/O, development time should be spent using that data. It starts
with including fault messages if the network connection is lost.
Fortunately, that is rare with industrial hardware, but it does
happen, just as a broken wire or loose terminal does.
As the use of distributed machine I/O grew over the past
decade, some resisted its use as they thought physical wires for
each signal was more reliable; that is not the case. Industrial
Ethernet communication and protocols, such as EtherNet/IP
and Pro� net, are reliable, fast and full of data.
The data � ows both ways, as well. The communication link
can be used to con� gure the device or change setpoints, de-
pending on the type of distributed I/O. It can also read signi� -
cant amounts of status and diagnostic data.
This is especially true when it comes to variable frequency
drives and servo ampli� ers, which can be considered distributed
I/O whether it’s mounded in the control panel or mounded on the
machine next to the motor. It’s real I/O when it comes to reset, en-
able, home, run, stop and reverse signals, but it can also be used to
change speed, acceleration and the motion pro� les of the motor.
Again, the many status and diagnostic bits, actual speed,
current and similar variables should
be monitored in a control program.
Time is well spent when program-
ming these drives and ampli� ers to
monitor, use and control these dis-
tributed devices. A carefully written
control program can be reused in a
variety of motion control applica-
tions where the programmer simply places a position, speed,
acceleration and deceleration into the appropriate variables
and triggers a move command. Simple monitoring of a motion
complete bit signals the end of the move.
Cameras can also be thought of as a distributed machine I/O
device. Although it provides advanced image acquisition and
analysis functionality, it also looks a lot like discrete and analog
I/O when viewing its status and results data. And it should be
programmed as such.
Of course, the biggest use of distributed machine I/O is in the
multi-point I/O systems, sensor blocks and � eld I/O that move
the discrete connections out to four- or eight-point modules
placed strategically around the machine. Distributed I/O racks
are also commonly used on a wide variety of machines. Even
if the I/O point is only 8 ft from the control cabinet, distributed
I/O is a valid solution.
Pneumatic valve manifolds should also be a part of distrib-
uted machine I/O. Not only does the communication signal con-
trol the valves, the same manifold can include input and output
connections. With the data capabilities enabled with distrib-
uted I/O, some of the pneumatic systems can control pressure
and � ow and monitor the same, as well as provide additional
diagnostic and troubleshooting information. It is another area
where time should be spent to program in the use for more
capable machine control and display of this information.
How to tell if distributed I/O is a good fi t
50 / June 2020 / ControlDesign.com
Dave Perkoncontributing editor
automation basics
Even if the I/O point is only 8 ft from the control cabinet, distributed I/O
is a valid solution.
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