by Gary Mintchell | Jun 14, 2019 | Industrial Computers, Internet of Things, Manufacturing IT, Technology
A mere 2.5-hour drive south on I-75 June 13 brought me to the Schneider Electric plant in Lexington, KY that manufactures load centers and other electrical devices. Schneider Electric marketing people invited me down for tours and festivities marking the unveiling of this brownfield manifestation of Smart Factory using the latest of IIoT, AR, digitalization, and other smart manufacturing principles.
Highlights:
• Schneider Electric Lexington facility is a showcase for sharing IIoT integration strategies with End Users, Machine Builders and Partners
• Lexington plant strategically integrates connected EcoStruxure solutions to enhance efficiency and provide end-to-end operational visibility throughout supply chain operations
• Smart Factory has tracked quantifiable benefits from IIoT implementation, including a 20% reduction in mean time to repair and a 90% paperwork elimination
If this plant is to demonstrate “in real time how its EcoStruxure architecture and related suite of offerings can help increase operational efficiency and reduce costs for its customers”, I asked the natural question—“What is EcoStruxure?”
I’ve heard the term for many years, but being a little slow on the uptake, I’ve never really understood what is meant. So, they set me up with an interview with Vice President Domenic Alcaro. Refreshingly, EcoStruxure is neither a platform or a product. Alcaro told me, “EcoStruxure is a phenomenal way to explain our value structure.” The foundation block consists of connected products (connectivity being a key word). The intermediary block is what they call Edge Control. However, whereas many people look at Edge and think hardware, Schneider Electric considers it basically software. Think the InduSoft HMI product, if you will. Atop the model then are apps and analytics.
Back to the plant:
In operation for more than 60 years and employing nearly 500 people, the Lexington factory is truly a showcase of modern integrated digital experience. Among the benefits realized include empowering operators to gain visibility into operations maintenance, driving a 20% reduction in mean time to repair on critical equipment, and process digitization eliminating paper work by 90%.
“We understand the value of IIoT and the positive business impact that innovation and digitization can have on our operations – particularly in our global supply chain. As a living example of how our EcoStruxure solutions deliver benefits to our customers, we are gaining those same benefits in our operation and sharing that knowledge,” said Mourad Tamoud, Executive Vice President, Global Supply Chain, Schneider Electric. “With our latest Smart Factory showcase, we are able to demonstrate this value in real-time, show the solutions at work and share the tangible benefits that we ourselves are seeing from our own IIoT investment as we accelerate our Tailored Sustainable Connected 4.0 digital transformation.”
As part of the Smart Factory program, Schneider Electric exemplifies brownfield implementation for customers who may be facing the same challenges with their existing production facilities. The team is able to offer strategies and talk through the challenges they faced to help customers exploring IIoT connected technologies overcome those same hurdles toward their modernization goals. By sharing their experience in leveraging EcoStruxure solutions, visiting customers can better understand the value of the brownfield modernization and the resulting operational efficiencies.
In this production environment, these solutions have demonstrated operational and quantifiable value since their implementation:
• EcoStruxure Augmented Operator Advisor – Delivered a 20% reduction in mean time to repair on critical equipment where it has been implemented.
• EcoStruxure Resource Advisor and Power Monitoring Expert – Delivered 3.5% YOY energy savings in the Lexington facility in addition to $6.6 Million in regional savings since 2012; sophisticated reporting capabilities and increased transparency also drive operational performance.
• AVEVA Indusoft Web Studio – Delivered powerful Edge digitization of paper processes to eliminate paper work by 90% and cloud connectivity has enabled digital dashboarding of a critical process.
• RFID OsiSense – Eliminated 128 daily fork truck miles and eliminated $500,000 in Work in Progress (WIP) inventory with a 33% first year ROI.
• AVEVA Insight Data – Unlocked and shared silos of data in a mobile manner reducing downtime in critical processes by 5% with ROI of less than 6 months.
• Magelis GTU/GTUX HMI – Provided agile operator management of the process and vivid visual of the process onsite and via mobile devices.
Among the tidbits of information I picked up on the tour include:
Extensive use of Ethernet and IP networking. Interesting in that the very first conversations I had with a Modicon VP 20 years ago concerned how Ethernet was the network of the future. In 1999 that was revolutionary thinking. Today—it’s the backbone. Hat tip to Mark Fondl.
Great use of data tracking involving RFID tags, MES software, Ethernet connectivity, and visualization that coordinates all the products and containers throughout the company-wide power-and-free conveyor system.
Oh, and a Megelis computer/HMI collecting data from sensors and passing it on uses Node-RED for programming. It’s only the second instance of Node Red I’ve seen in automation.
Finally, Schneider Electric plant management correctly combines digitalization with Lean principles enhancing their daily stand ups and feeding continuous improvement.
Impressive facility. When our politicians and east coast journalists go ripping on American manufacturing, they should be forced to take deep dives into plants like this one.
by Gary Mintchell | Jun 4, 2019 | Industrial Computers, Internet of Things, Manufacturing IT
Check out a couple of interesting computing technology trends currently. On the one hand exist a few companies that exist on a solid business of I/O with a controller who also explore bringing IT technology into the OT world. On the other hand are companies who have developed powerful computing platforms for cloud applications looking for ways to bring that to the edge.
Taiwan-based Advantech builds on a solid I/O lineup with continual experimenting (along with name changes) around computing platforms. It in fact is one of the world’s largest industrial computer suppliers.
It informed the world last week that it has transformed into an “AIoT” provider. A definition of AIoT is not provided. From the context it appears to be a merging of AI (assuming artificial intelligence) and IoT. Note: I’m on vacation so I’m not calling people for interviews right now. Just passing these thoughts along from the Atlantic beach in Virginia.
The press release says that now, Advantech is accelerating AI at the edge with NVIDIA Jetson and aiming to drive the next wave of computing and real-time AI.
Linda Tsai, president of Advantech Industrial IoT Group, said, “Advantech has been in the IoT industry for a long time, and we are fully aware of the demand from edge to cloud. NVIDIA provides an energy-efficient and high-performance AI platform. It is ideal for compute-intensive embedded applications both on the edge and cloud. By closely collaborating with NVIDIA and our software partners, we’re able to develop new AIoT solutions for smart manufacturing and smart city applications.”
Advantech has developed a complete AI product line based on NVIDIA technology from the AI edge to the cloud. On the edge, utilizing the NVIDIA Jetson platform‘s powerful performance, Advantech will provide three AI edge solutions later this year: MIC-710IVA, MIC-720AI, and MIC-730AI for smart city, transportation, and manufacturing applications. These highly integrated systems allow AI application developers to rapidly create unique AI solutions based on Jetson. Advantech “amazed the world at the 2019 NVIDIA GPU Technology Conference (GTC) show in San Jose, USA on March 22 – 26 by launching its cutting-edge AI Network Video Recording (NVR) platform incorporating Advantech’s MIC-710IVA with NVIDIA Jetson Nano.”
For the AI cloud, Advantech’s SKY-6000 series servers with NVIDIA GPUs provide high-density solutions for the big data era. With industrial design capability, Advantech can successfully resolve thermal issues from high-density GPU computing. Also, NVIDIA T4 GPU qualification can ensure Advantech GPU servers have better temperature control and thermal management. This collaboration brings a more reliable server in automated optical inspection (AOI), smart transportation, medical equipment, and smart city applications.
Regarding future cooperation, Linda Tsai added, “Advantech’s partnership with NVIDIA is taking huge steps forward in making AI a reality for manufacturing, transportation, and smart city applications. Through close collaboration in AI product development and shared worldwide marketing programs, Advantech and NVIDIA are driving innovative transformations for AI applications.”
by Gary Mintchell | Apr 9, 2019 | Automation, Industrial Computers, Security
I booked a vacation several months ago that conflicted with Hannover Messe. I missed the usually chilly and damp north of Germany in favor of the definitely chilly and damp Pacific Northwest.
Many announcements from Hannover reached me anyway, though, so I’ll be going through a few this week. First up concerns using the new CIP Security protocol from ODVA. This one from Rockwell Automation.
This release talks about Rockwell’s developing solutions toward closing a cybersecurity opening within industrial automation communication.
“As the world’s leading company focused on combining industrial automation with digital technology, we’re uniquely positioned to help close security gaps in connected operations,” said Megan Samford, director of product security, Rockwell Automation. “Our new offerings with built-in security deliver the industry’s best available protection of control-level traffic. This can give users confidence that the integrity of their systems and their device-to-device communications are protected from day one.”
The Allen-Bradley ControlLogix EtherNet/IP communication module is among the first industrial devices to use the CIP Security protocol from ODVA. The protocol helps make sure only authorized devices are connected in industrial operations. It also helps prevent tampering or interference with communications between those devices. CIP Security is the first industrial automation protocol to support transport layer security (TLS), the most proven security standard available.
Also, the newly enhanced Allen-Bradley ControlLogix 5580 controller is the world’s first controller to be certified compliant with today’s most robust control system security standard, IEC 62443-4-2. The standard defines the technical security requirements for industrial automation and control system components. This certification builds on the 2018 certification of the Rockwell Automation Security Development Lifecycle (SDL) to the IEC 62443-4-1 standard.
by Gary Mintchell | Feb 12, 2019 | Automation, Industrial Computers, Internet of Things
Programmers of machine control in the US still stick with the old Ladder Diagram editor, so Opto 22 adds it to its groov EPIC controller. This is sort of the outlier of the things I learned at last weeks’s ARC Industry Forum in Orlando. Most of my interviews were either cyber security or HMI/SCADA it seems. I had wall-to-wall meetings and then travel. So, I’m just catching up on thoughts.
Somewhere around 25-30 years ago I could program (not proficiently, but turn out work anyway) in BASIC, C, C++, Java, Pascal. Then I ran into Ladder Logic. Why would anyone do this, I exclaimed! In the US all this time later, it’s Ladder or nothing in much of the country. Maybe the millennials can move this forward???
Recognizing this fact of life, the prototypical flow chart programming company, Opto 22 has added a free software upgrade with standard IEC 61131-3 programming methods.
Opto says, “Adding these new programming options to the existing flowchart and custom user-written options in groov EPIC gives control engineers the ability to program using a variety of languages they already know, while taking advantage of the EPIC’s extended capabilities for automation and industrial internet of things (IIoT) applications. All IEC 61131-3 standard languages are supported by groov EPIC, including Function Block Diagram (FBD), Structured Text (ST), Sequential Function Charts (SFC), and Ladder Diagram (LD).”
Engineers can mix and match several software tools to build control and IIoT solutions on one unified platform. Plus companies can continue to leverage existing employee knowledge in IEC 61131-3 programming methods, including decades-old ladder logic.
The PC-based CODESYS® Development System V3 is used to create and compile IEC 61131-3 programs for download to a pre-installed CODESYS Runtime running on groov EPIC. The CODESYS Development System is available at no charge from the CODESYS Store. The CODESYS Runtime on groov EPIC is enabled by a free software license available from Opto 22.
“As the world’s leading manufacturer of independent IEC 61131-3 software,” stated Markus Bachmann, President of the U.S. subsidiary of the CODESYS Group, “we are excited that CODESYS has been chosen to boost Opto 22’s groov EPIC to the next level in industrial automation products, integrating state-of-the-art industrial control with new IIoT and Industry 4.0 applications.”
In addition to IEC 61131-3, groov EPIC can also be programmed using Opto 22’s native PAC Control. Field-proven, flowchart-based PAC Control with optional scripting offers 400+ plain English commands for analog process and digital sequential control, complex math, conditional branching, string handling, and other complex functions.
Other programming options include using software languages supported on the Linux operating system through secure shell. This access—along with toolchains and interpreters for Java, C/C++, Python, JavaScript/Node.js and more—allows developers to create custom applications. In addition, groov EPIC includes Node-RED as another programming option. Node-RED uses a flow-based development environment optimized for edge data processing and communications.
Integrated HMI
groov EPIC integrates the easy-to-use HMI software groov View with its control programs. Once an IEC-61131-3, PAC Control, or custom software application is developed, the control program’s tags and I/O are available for building a groov View HMI. Data from other systems and equipment on premises, at remote locations, and in the cloud can also be included in the HMI. The drag-drop-tag HMI construction is quick, security is built in, and trending and user notifications are included.
Authorized users can view this HMI to see data and control processes on the integral, industrial-grade color touchscreen display on the front of the EPIC processor. They can also view the HMI on an external HDMI monitor, and from any web browser or mobile device.
Free Product Upgrade
To take advantage of this new programming option, current groov EPIC owners can simply install a free upgrade. As with all quarterly upgrades to groov EPIC since its introduction in February 2018, this upgrade requires only a software download. Unlike all other industrial automation products and platforms, groov EPIC is improved quarterly based on user feedback, with no need to replace existing hardware. These software upgrades provide significant performance improvements and protect user hardware investments, all at little or no cost. The groov EPIC system can change with you as your application grows or changes.
groov EPIC System
Based on Opto 22’s 45 years of experience as an automation manufacturer, the groov EPIC system merges tough industrial hardware with open protocols and standards to provide an ideal system for both automation and IIoT applications. Built to withstand conditions at the edge of networks in factories and remote locations, EPIC is approved for use by UL in hazardous locations and is ATEX compliant. EPIC can be used to collect, process, view and exchange data where it is produced, and this data can then be securely shared among databases, cloud services, PLC systems and other components. In recognition of its unique capabilities, groov EPIC won the 2019 Control Engineering Engineers’ Choice Award in the Industrial Internet of Things Connectivity category.
by Gary Mintchell | Jan 11, 2019 | Automation, Industrial Computers, Motion Control
I’m finally catching up on news from past trips. I stopped by the Beckhoff Automation booth at SPS in Nuremberg last November and chatted for about an hour over all the displays. Here is a sampling.
TwinSAFE: modular, scalable and distributed safety applications
The ability to distribute the intelligence of an entire safety application across multiple TwinSAFE Logic-capable I/O modules enables the flexible implementation of increasingly modular architectures that can be adapted to given system requirements even more effectively than before.
It is possible to adapt the TwinSAFE system even more specifically to the individual requirements of a machine concept as well as to a broader spectrum of safety applications. The new I/O components include:
– TwinSAFE EtherCAT Terminal EL1918: digital terminal with eight safe inputs
– TwinSAFE EtherCAT Terminal EL2911: safe potential supply terminal with four safe inputs and one safe output
– TwinSAFE EtherCAT Box EP1957-0022: IP 67-protected digital combi module with eight safe inputs and four safe outputs
System-integrated and inexpensive precision measurement technology for efficient machines and test benches
ELM314x economy line of the EtherCAT measurement modules supplements the established ELM3x0x line with a lower cost 1 ksps class. This simplifies the use of the system-integrated precision measurement technology, which taps significant optimisation and efficiency potentials both in production machines and in inline test benches.
The new ELM314x measurement modules are available in 2, 4, 6 and 8-channel versions. High-precision measurements with an accuracy of 100 ppm are possible – and in a wide temperature range from 10 to 40 °C at that. Each channel of the measurement modules can be set to current or voltage measurements with a sampling rate of up to 1 ksps per channel. Analog signals in the ranges from ±1.25 to ±10 V, 0 to10 V, ±20 mA or 0/4 to 20 mA can be processed.
Typical application examples include part geometry measurement on the fly, as well as fast, but highly precise weighing procedures, e.g. in bottling plants. In general, the ELM314x EtherCAT measurement modules are ideal for recording data from 10 V/20 mA sensors and forfeeding real-time information directly back into the process.
CX7000 Embedded PC
The CX7000 Embedded PC opens up the convenience and efficiency of the TwinCAT 3 software environment to compact controllers. This enhances the scalability of PC-based control technology from Beckhoff – ranging from mini-PLCs to many-core Industrial PCs. An advanced 400 MHz processor and built-in configurable I/Os mean the Embedded PC delivers an optimum price/performance ratio.
Equipped with an ARM Cortex-M7 processor (32 bit, 400 MHz), the CX7000 Embedded PC makes considerably higher processing power available in the low-cost, compact controller segment. Furthermore, all the advantages of the TwinCAT 3 software generation can be utilised, while an extremely compact design with dimensions of just 49 x 100 x 72 mm ensures optimum scalability of PC-based control for small controller applications that typically require minimum footprint.
With multi-functional I/O channels directly integrated, the CX7000 assures excellent value for money:
- 8 digital inputs, 24 V DC, 3 ms filter, type 3
- 4 digital outputs, 24 V DC, 0.5 A, 1-wire technology
These integrated multi-functional I/Os can be configured for other operating modes via TwinCAT 3, enabling the option to use fast counting or processing of analog values:
- counter mode: 1 x 100 kHz digital counter input, 1 x digital input as up/down counter, 2 x digital counter outputs
- incremental encoder mode: 2 x digital inputs for 100 kHz encoder signal, 2 x digital encoder outputs
- analog signal mode: 2 x digital inputs configured as analog inputs 0…10 V, 12 bit
- PWM signal mode: 2 x digital outputs configured for PWM signal
EtherCAT G
The technology expansion EtherCAT G takes the high EtherCAT performance to the next level by delivering the Gigabit Ethernet speeds needed to support highly data-intensive applications. The latest technology expansion is not only compatible with the globally established 100 Mbit/s EtherCAT standard, but also provides the same familiar ease of use. In addition, the new branch controller model for EtherCAT G enables efficient operation of multiple network segments in parallel.
EtherCAT G supports standard Ethernet transmission rates of 1 Gbit/s; its EtherCAT G10 counterpart, already introduced as a proof-of-concept technology study, is even faster with data rates of 10 Gbit/s. The sharp increase in transmission rates beyond the standard 100 Mbit/s provided by EtherCAT significantly increases the possible data throughput. With propagation delay times through devices as a limiting factor on the one hand, but boosted by the newly introduced branch model on the other, EtherCAT G can deliver a two-to-sevenfold performance increase, depending on the application.
Hans Beckhoff, the company’s Managing Director comments: “EtherCAT G and G10 raise performance to entirely new levels that will enable our customers to build the best, highest-performing machinery in the world! EtherCAT G and G10 are not meant to replace the highly successful EtherCAT standard based on 100 Mbit/s Ethernet. The new performance levels are intended as system-compatible expansions.”
XPlanar: Flying Motion
Beckhoff is opening up new avenues in machine design with XPlanar. This is made possible by planar movers that float freely above arbitrarily arranged planar tiles and enable extremely flexible, precise and highly dynamic positioning. For machine builders this results in maximum flexibility and simplification in the design of machines and plants.
The XPlanar system combines the individual arrangement of planar tiles with the multi-dimensional positioning capability of the planar movers floating above them. The movers can be moved jerk-freeand contact-free in two dimensions at up to 4 m/s with 2 g acceleration and 50 µm positioning repeatability – and noiselessly and without abrasion.
The planar motor system is highly scalable to suit individual needs and considerably simplifies the design of machines and plants. Due to the maximum flexibility in mover positioning and the very high dynamics it is possible, for example, to divide product flows very simply and individually, so that previously necessary robots or inflexible mechanical devices can be efficiently replaced. The contact-free mover travel also eliminates wear, emissions and the carryover of contaminations.
The collision-free and synchronised movement of several movers with automatic path optimisation are further features provided by the TwinCAT automation software. The movement of several movers together in a group, for example, allows the maximum payload to be increased.
by Gary Mintchell | Nov 9, 2018 | Automation, Industrial Computers, Internet of Things
Advantech has been appearing on a variety of lists of prominent Internet of Things suppliers. The Taiwanese computer company with a US office in Cincinnati, OH and intellectual leadership, supplies intelligent I/O, a variety of computing devices, and HMI devices.
Several years ago I was privileged to be invited to Suzhou, China to attend Advantech’s user conference. It was an impressive event. This year they called it the “first IoT Co-Creation Summit.”
More than five thousand Advantech clients and partners from around the world attended the summit. Here Advantech introduced its newest IoT platform structure WISE-PaaS 3.0 and 32 IoT solution ready packages (SRPs) co-created with software and industry partners.
The event in itself will aid in the software/hardware integration for various industries, connect and build a complete industrial IoT ecosystem and value chain, and allow Advantech and partners to officially step into the next IoT stage.
Advantech Chairman KC Liu stated that in view of IoT application characteristic’s diversity and fragmented market, Advantech has assisted industries in integrating and connecting existing hardware and software and regards creating a complete industry value chain as its primary task in IoT industry development.
Advantech is introducing new features for its WISE-PaaS 3.0 and sharing a number of IoT solution ready packages (SRPs), based on WISE-PaaS, developed with numerous co-creation partners. The company is also outlining future co-creation strategies and schedules for the upcoming year.
Allan Yang, Chief Technology Officer at Advantech said, “While IoT is currently flourishing and many companies have invested in connectivity and data collection equipment, we are still in the early stages of generating value from IoT data. Since WISE-PaaS launched in 2014, Advantech has continued its integration and improved connectivity with open source communities. Our IoT software modules are developed to create operational cloud platform services oriented around the commercial value generated by data acquisition. Data-driven innovation has thus become the main target for our WISE-PaaS evolution.
WISE-PaaS 3.0 offers four main function modules:
- WISE-PaaS/SaaS Composer: a cloud configuration tool with visible workflow. WISE-PaaS/SaaS Composer supports customized component plotting for simple and intuitive 3D modeling application and interaction. It updates views at millisecond rates and, together with WISE-PaaS/Dashboard, presents critical management data in a visually intuitive display to help extract valuable data and improve operational efficiency.
- WISE-PaaS/AFS (AI Framework Service): an artificial intelligence training model and deployment service framework. The WISE-PaaS/AFS provides a simple drag and drop interface that allows developers to quickly input industrial data. When combined with AI algorithms, the service builds an effective inference engine with automatic deployment to edge computing platforms. AFS offers model accuracy management, model retraining, and automated redeployment. It simultaneously controls multiple AI models in the application field; offering automated model accuracy improvements and life-cycle management services.
- WISE-PaaS/APM (Asset Performance Management): an equipment network connection remote maintenance service framework. WISE-PaaS/APM connects to a wide array of on-site industrial equipment controls and communication protocols. It supports the latest edge computing open standard, EdgeX Foundry, and includes built-in equipment management and workflow integration templates. Jointly with the AFS, APM accelerates Machine to Intelligence (M2I) application development.
- Microservice development framework: WISE-PaaS contains a micro service development framework to help developers rapidly create program design frameworks while reducing development requisites. Micro service functions, such as service finding, load balancing, service administration, and configuration center, all offer built-in flexible support mechanisms.
Advantech recently established a water treatment system, jointly developed with GSD (China) Co., Ltd., and a CNC equipment remote operation service, jointly developed with Yeong Chin Machinery Industries Co. Ltd. Both partnerships demonstrate how industrial digital transformations, led by Advantech and its partners through the co-creation model, offer innovative win-win IoT solutions.
Advantech’s IIoT iAutomation Group has launched a broad selection of rackmount GPU Servers from 1U to 4U. The SKY-6000 GPU server series are powered by Intel Xeon scalable processors and each of these highly scalable GPU-optimized servers support up to five NVIDIA Tesla P4 GPUs. IPMI management functions and smart fan control ensure better temperature control and thermal management environments. Every GPU pair includes one high-speed PCIe slot for highly parallel applications like artificial intelligence (AI), deep learning, self-driving cars, smart city applications, health care, high performance computing, virtual reality, and much more.
AI Deep Learning GPU Solution
With support for up to five pcs of half-length half-height (HHHL) GPU cards or one full-height full-length (FHFL) double deck card, plus one full-height half-length (FHHL) GPU card, the SKY-6100 series are designed for NVidia Tesla P4 HHHL GPU cards, making it the best choice for deep learning applications.
IPMI Server Management
With IPMI 2.0 support, the SKY-6000 series allows users to monitor, manage, and control servers remotely and receive alerts if any sensors detect device or component faults. In addition, event logs record important information about the server which can be controlled remotely using the IPMI KVM.
Smart Fan Control
The optimized thermal design separates the CPU and GPU fan zones, making sure the GPU card is not preheated or thermally affected by any other heat source. Also, with the smart fan control mechanism, fan speeds are controlled based on different CPU and GPU workloads and ambient temperature. This feature lowers the acoustic noise of GPUs that have heavy loading but not CPUs. Advantech’s SKY-6000 server series are available for order now.
