ARC Industry Forum – Digital Tech in Manufacturing and Production

ARC Industry Forum – Digital Tech in Manufacturing and Production

ARCbanner-300x250We are closing in on February and time to start thinking about the ARC Industry Forum in Orlando. I went to my first one in 1998 and have my airline and hotel reservations for this edition.

Given the demise of general industry trade shows, there are precious few opportunities to see a large cross section of the automation and control industry. This is one.

I have 2 or 3 appointments set. If you are there, ping me. Maybe we can do a “meet up” in the lounge before everyone splits for dinner or something.  Or stop me to chat during the week. ARC has once again planned an afternoon of press conferences for its sponsors. I’ll arrive in time to listen if you are presenting.

The 20th Annual ARC Industry Forum has the theme, “Industry in Transition: Navigating the New Age of Innovation”.

The conference is February 8-11, 2016 at the Renaissance Sea World in Orlando, Florida.

ARC says, “New information technologies such as Industrial Internet of Things (IIoT), Smart Manufacturing, Industrie 4.0, Digitization, and Connected Enterprise are ushering in a new age of innovation. These concepts are clearly moving past the hype, where real solutions are emerging backed by strong business cases. Expect to see innovations in smarter products, new service and operating models, new production techniques, and new approaches to design and sourcing. Join us to learn how this industrial transformation will unfold and what other companies are doing today to embrace innovation and improve their business performance.”

Questions they expect to address:

  • How will inexpensive, easy-to-install sensors change existing products and plants?
  • Will cyber security concerns impede disruptive innovation?
  • What kind of intelligence will machines have and what value will this bring?
  • What role will Wi-Fi and LTE play?
  • How do Big Data and predictive and prescriptive analytics enable operational change?
  • What is the opportunity in aftermarket services?
  • What software capabilities are needed to achieve transformational change?
  • Which industries are already changing?
  • What steps can organizations take to foster innovative thinking?

Forum’s Keynote Presentations

Michael Carroll, Vice President, Innovation & Operations Excellence, Georgia-Pacific

Michael joined Georgia-Pacific in 2010 to focus his technological and entrepreneurial talents on innovation and leadership. Prior to that he and a partner formed McTech Group, a company focused on innovative products for the building products and construction industry. In addition to his Executive Vice President responsibilities, Michael formed a Joint Venture designed to sell consumer “DIY” products to big box retailers like Wal-Mart, Home Depot, and Lowe’s. Previous positions include Director of Operations at Riverwood International, CEO of North and South American Operations at Shepherd, and Principal Change Agent at Mead Paper.

Sandy Vasser, Facilities I&E Manager, ExxonMobil Development

Sandy has been with Exxon or ExxonMobil for over 35 years and has been involved in a number of Upstream projects covering offshore facilities, onshore facilities, and cogeneration facilities. He currently manages a team of about 120 electrical and I&C professionals responsible for the design, installation, and commissioning of electrical generation and distribution systems, process control systems, and safety instrumented systems for all major ExxonMobil Upstream capital projects. This team is also responsible for developing, promoting and implementing strategies, practices, processes, and tools for successfully executing project automation and electrical activities.

Rob High, Vice President and Chief Technology Officer, Watson Solutions, IBM Software Group

Rob has overall responsibility to drive Watson Solutions technical strategy and thought leadership. He works collaboratively with the Watson engineering, research, and development teams across IBM. Prior to joining Watson Solutions, Rob was Chief Architect for the SOA Foundation and member of the IBM Academy of Technology. He championed an open industry architectural definition of the principles of business and IT alignment enabled by SOA and business process optimization, as well as ensuring IBM’s software and services portfolio is architecturally grounded to enable for efficient SOA-based solutions. Rob has 37 years of programming experience and has worked with distributed, object-oriented, component-based transaction monitors for the last 26 years.

Automation Products Announced by Rockwell Automation

Studio 5000 View Designer ScreenshotIn advance of this week’s Automation Fair at Chicago’s McCormick Place, Rockwell Automation has announced a couple of new product extensions–SoftwareStudio 5000 development environment and ControlLogix  5580.

“The addition of these applications [to SoftwareStudio 5000] significantly enhances our integrated development environment,” said Mike Brimmer, product manager, Rockwell Automation. “The expanded environment simplifies the design process and reduces the need for multiple tools, providing a more seamless system development experience.”

The Studio 5000 environment now includes the following:

  • The new Studio 5000 Architect application is the central point within the Studio 5000 environment where users can view the overall automation system; configure devices such as controllers, HMIs and EOIs; and manage the communications between the devices. The Studio 5000 Architect application also exchanges data with other Studio 5000 applications and third-party electrical design tools to simplify the development experience.
  • The Studio 5000 Logix Designer application is the design and maintenance software for the Allen-Bradley Logix5000 family of controllers and is used to configure discrete, process, batch, motion, safety and drive control. It simplifies the design process by providing an application-centric view of code; enhanced work flows for more efficient re-use of content; and collaborative tools that make it easier for multiple people to work together.
  • The new Studio 5000 View Designer application is the design and maintenance software for Allen-Bradley PanelView 5500 graphic terminals. The Studio 5000 View Designer application provides an intuitive, modern design environment that helps users more easily build contemporary systems. It enhances integration between the control system and operator interface to improve programming efficiency and runtime performance.
  • The new Studio 5000 Application Code Manager speeds system development by helping users build libraries of re-usable code that can be managed and deployed across their entire enterprise. Creating projects with Application Code Manager helps improve design consistency, reduce engineering costs, and achieve faster time-to-market and commissioning.

In addition, Rockwell Automation has updated the Studio 5000 environment with enhanced security and localized batch control. New security features include more user-authentication and access-control options, and a new privilege escalation capability. These features help improve productivity and system uptime by granting users the right level of access at the right time. Localized batch control allows controller-based batch sequencing and eventing to simplify system architecture for single-unit control and process skids.

11-12-15 ControlLogix 5580 imageThe new ControlLogix 5580 controller provides up to 45 percent more application capacity and includes an embedded 1-gigabyte Ethernet port to support high-performance communications, I/O and applications with up to 256 axes of motion.

“With this new controller, users can meet future capacity and throughput needs as they design smart machines and work toward building a Connected Enterprise,” said Dennis Wylie, global product manager, Rockwell Automation. “The new port and additional capacity cuts the amount of control and communications hardware required, reducing system complexity, costs and required panel space.”

In addition, the product selection process is easier with the ControlLogix 5580 controller because users can now select the appropriate model using the total number of Ethernet nodes required. A single ControlLogix 5580 controller can support up to 300 Ethernet nodes.

The controller also supports enhanced security as part of a defense-in-depth approach to help protect facilities, assets and intellectual property. The controller incorporates advanced security technologies and software features, such as digitally signed and encrypted firmware, change detection and audit logging.

Robots and Humans Collaborating for Manufacturing Success

Robots and Humans Collaborating for Manufacturing Success

Rethink Robotics SawyerMy grandson was asking about why can’t we build a better light bulb and design better batteries. He’s eight. If he keeps asking the big questions, he’ll have a good future.

I told him that there would always be problems to solve, that’s why we would need engineers and scientists. He asked, what kind of questions. I told him about the need to develop robots that could work with people. This technology will become increasingly useful to help an aging population cope with physical limitations. It will also help production when we (shortly) face a declining workforce.

I like to point to the work of Rethink Robotics. It recently announced that its Sawyer robot, the company’s second smart, collaborative robot designed for a wide range of factory environments, is available for purchase and is being deployed by manufacturers across the globe. Announced in March, Sawyer is a single-arm, high-performance robot created to handle machine tending, circuit board testing and other precise tasks that have been difficult to automate with existing robots.

Weighing only 19 kilograms (42 pounds), Sawyer features a 4kg (8.8 lbs.) payload, with seven degrees of freedom and a 1260mm reach that can maneuver into the tight spaces and varied alignments of work cells designed for humans. Its high resolution force sensing, embedded at each joint, enables Rethink Robotics’ compliant motion control, which allows the robot to “feel” its way into fixtures or machines, even when parts or positions vary. This characteristic enables a repeatability that is unique to the robotics industry, and allows Sawyer to work effectively in semi-structured environments on tasks requiring 0.1mm of tolerance.

Sawyer offers a unique combination of features that distinguish it from other conventional and collaborative robots, including compliant motion control, embedded vision with a built-in Cognex camera and Rethink’s Robot Positioning System, a component of the proprietary and industry-leading Intera software platform. Powering both Sawyer and Rethink’s first collaborative robot, Baxter, the Intera system makes deploying the robots far easier than typical industrial robots. While traditional robots typically take an average of 200 hours to program and deploy, Sawyer can be deployed in under two hours and can easily be trained by typical factory technicians – not roboticists.

Sawyer is purpose-designed for enterprise-level deployments, with a useful life of 35,000 hours of operation. The robot is IP54-rated, making it ideal for harsh factory environments. Since its introduction, Sawyer has been field tested extensively at leading manufacturers’ sites around the world, and is currently being deployed on production lines in many of those facilities.

The process improves the efficiency of the product line while allowing GE’s employees to handle the more dexterous and cognitive work needed to complete the task.

General Electric has been testing Sawyer over the past month and will deploy their first robot in a GE Lighting plant in Hendersonville, North Carolina. A prime example of true human-robot collaboration, Sawyer will be on a production line positioning parts into a light fixture as a GE employee completes the assembly. The process improves the efficiency of the product line while allowing GE’s employees to handle the more dexterous and cognitive work needed to complete the task.

“The ability to deploy a smart, collaborative robot like Sawyer provides a significant flexibility advantage to our production team, while still meeting our world class quality, precision and speed standards,” said Kelley Brooks, global advanced manufacturing & engineering leader at GE Lighting. “Utilizing this technology is an integral part of our Brilliant Factory initiative to connect all parts of the supply chain from product design, to engineering, to the factory floor and beyond in order to deliver customized LED solutions for our customers.”

Sawyer is also set to be deployed in Steelcase Inc.’s (NYSE: SCS) Grand Rapids factory, where it will work in tandem with the company’s welding machine. Sawyer will work to pick and place parts in pairs of two, enabling a completely autonomous welding process. The robot’s small footprint, long reach and higher payload capacity make it ideal for the Steelcase team. In addition to handling changes in parts and lines seamlessly, Sawyer’s IP54 rating allows the robot to work in manufacturing environments with liquids and particle hazards present.

“Having already deployed several Baxter robots successfully, we’ve seen the value that collaborative robots bring to the factory floor,” said Edward Vander Bilt, leader of innovation at Steelcase. “These robots are the game-changers of modern manufacturing, and Rethink Robotics is leading the evolving relationship between humans and machines that allow each to do what they do best.”

Sawyer is a significant addition to the company’s smart, collaborative robot family, which also includes the groundbreaking Baxter robot that defined the category of safe, interactive, affordable automation. Sawyer is available for purchase in manufacturing environments throughout North America, Europe and Asia-Pacific.

“After announcing Sawyer in March, the worldwide demand we have seen for the robot has been overwhelming,” said Rethink Robotics President and Chief Executive Officer Scott Eckert. “Manufacturers around the globe understand that Sawyer opens the door for a wealth of new applications and opportunities to improve their business, and they are eager to get it onto their production floors.”

ODVA Elects Leaders, Learns About Smart Factory

ODVA Elects Leaders, Learns About Smart Factory

ODVA, the organization that develops and promotes networking protocols such as DeviceNet and EtherNet/IP, recently held its 17th Meeting.

ODVA’s Board of Directors for its 18th term are:

  • Rolf Birkhofer, managing director for process solutions at Endress+Hauser,
  • Thomas Bürger, vice president of engineering automation systems at Bosch Rexroth,
  • Michael Höing, executive vice-president of cross divisional functions at Weidmüller Interface,
  • Fabrice Jadot, senior vice-president for innovation and technology and CTO for the industry business of Schneider Electric,
  • Tony Shakib, vice president of business development for the Internet of Things Business Development at Cisco Systems,
  • Masaru Takeuchi, general manager of controller business and automation systems for industrial automation business at Omron, and
  • Jürgen Weinhofer, vice-president for common architecture and technology for Rockwell Automation.

Officers for the 18th term are:

  • Katherine Voss, president & executive director.
  • Joakim Wiberg, chief technology officer,
  • Christopher Lynch, secretary, and
  • Jürgen Weinhofer, treasurer.

 

ODVA’s Technical Review Board (TRB) are Mr. Rudy Belliardi of Schneider Electric, Mr. Paul Didier of Cisco Systems, Dr. Jörg Hähniche of Endress+Hauser, Dr. Ludwig Leurs of Bosch Rexroth, Mr. Shinji Murayama of Omron, Mr. Eric Scott of Molex, Mr. Dave VanGompel of Rockwell Automation, and Mr. Joakim Wiberg of HMS Industrial Networks. As ODVA’s chief technology officer, Joakim Wiberg will be the TRB chairperson.

Smart Factory

In a keynote speech given by Prof. Dr.-Ing Detlef Zühlke, executive chairman of SmartFactory, he announced that the 2016 SmartFactory Demonstrator will include a proof of concept implementation of ODVA’s machine data model. The proof of concept will be supported by ODVA principal member Bosch Rexroth, which is also an executive member of SmartFactory.

ODVA’s machine data model is a result of ODVA’s initiative for the Optimization of Machine Integration (OMI) which was first announced in 2011 in cooperation with Sercos International and the OPC Foundation.

The OMI initiative is focused on techniques to optimize the integration of manufacturing machinery with the industrial ecosystem. One of the key machine integration problems that OMI seeks to solve is the streamlining and standardization of heterogeneous communication interfaces, such as CIP and Sercos, in order to enable standard reporting methods and tools across machines and thus aid in the management of machines and the monitoring of their states.

To investigate and develop standards in this area, ODVA established a Special Interest Group (SIG) for Machinery Information with participants from ODVA principal members Bosch Rexroth, Rockwell Automation, and Schneider Electric along with invited experts from OPC Foundation and Sercos International. The SIG has now completed its first phase of work to define a standard approach to machine data models which will then be mapped to the structures in CIP, OPC-UA, and Sercos. The 2016 SmartFactory production cell sponsored by Bosch Rexroth will illustrate the benefits of this approach.

“The concepts and standards being developed as a result of ODVA’s initiative for the Optimization of Machine Integration are well aligned with the goals of the SmartFactory,” said Prof. Dr.-Ing Detlef Zühlke, executive chairman of the Technology-Initiative SmartFactory KL e.V. “The concepts for ODVA’s machine data model will be a welcome addition to the SmartFactory demonstrator in 2016.”

“Certain types of data are typical to machine-to-supervisory communication. This data can be placed into logical groupings such as base machine context, conditioning monitoring, energy, safety, machine diagnostics, machine states, production recipes and product information,” stated Dr. Ludwig Leurs, co-chair of ODVA’s SIG for Machinery Information and engineering manager of Ethernet convergence for Bosch Rexroth. “The SmartFactory demonstrator will allow the SIG participants to prove out the concepts in ODVA’s machine data model before completing final specification for the model and its mapping to the protocol standards.”

“The concept of ODVA’s machine data model is groundbreaking because it applies the concept of “Things” as conceived in the Industrial Internet of Things to the machine itself,” said Katherine Voss, ODVA president and executive director. “The alignment of SmartFactory with the Industrie 4.0 initiative, and thus the Industrial Internet of Things, makes the 2016 SmartFactory demonstrator an ideal venue to illustrate the benefits of ODVA’s concept of the machine.”

ODVA’s machine data model will be integrated into the Bosch Rexroth production cell for 2016 SmartFactory demonstrator that will premiere at Hannover Fair 2016 on April 25, 2016.

The Technology Initiative SmartFactory KL e.V. was founded in 2005 as a non-profit association to establish a network of industrial and research partners which initiate and implement together research and development projects ranging from base technologies to the development of marketable products.

Today SmartFactory is a manufacturer-independent demonstration and research platform and unique in Europe.

ODVA Elects Leaders, Learns About Smart Factory

Connected World Powered by the Cloud

The famous Internet of Things would be just so many useless streams of bits without a place to store them before analysis can be done. Therefore, the importance of the Cloud. Microsoft has jumped in big time with its Azure Cloud.

Early last month, Microsoft held AzureCon and announced new solutions spanning containers, security, infrastructure and the Internet of Things (IoT) that enable organizations of all sizes to transform their business in today’s mobile-first, cloud-first world.

“We live in a connected world, and the intelligent cloud is powering it all,” said Scott Guthrie, executive vice president of Microsoft’s Cloud + Enterprise Division. “As data and devices continue to proliferate, there is vast opportunity for businesses to tap into their data to make their applications more intelligent. Through our offerings across applications, data and IoT, and cloud infrastructure, we are enabling companies to innovate more easily and rapidly, using the tools and platforms they know and love.”

Innovation through choice and simplicity

Applications are at the heart of business growth and transformation, and containerization is an increasingly popular way to maximize application value. Furthering its commitment to container technology and extending customer choice, Microsoft announced a new Azure Container Service that will combine the openness of Apache Mesos and Docker with the hyper-scale of Azure for container orchestration and management. With the service, organizations using Azure will now be able to easily deploy and configure Mesos to cluster and schedule Dockerized applications across multiple virtual hosts. Unlike many other container services in market today, this offering is based on open source to enable customer choice across the ecosystem and will support Windows Server containers in the future. The service will be available for preview by the end of the year.

Internet of Things and big data

The intelligent cloud is powered by data. Microsoft announced that its Azure IoT Suite is now available for customers to purchase. The Azure IoT Suite integrates with a company’s existing processes, devices and systems to build and scale IoT projects across their business using preconfigured solutions. In addition, Microsoft announced the new Microsoft Azure Certified for IoT program, an ecosystem of partners whose offerings have been tested and certified so businesses can take their next IoT project from testing to production, more quickly. Current partners include BeagleBone, Freescale Intel Corporation, Raspberry Pi, Resin.io, Seeed Technology Inc., and Texas Instruments Inc.

Microsoft also announced the expansion of Azure Data Lake. This includes Azure Data Lake Analytics, Azure Data Lake Store, a new programming language U-SQL, and Azure HDInsight general availability on Linux.

Intelligent infrastructure

Security is often cited as a top concern when moving to the cloud. Microsoft announced Azure Security Center, a new integrated experience that gives customers visibility and control of the security of their Azure resources without impeding agility, and helps customers stay ahead of threats even as they evolve.

This service integrates with security solutions from companies such as Barracuda, Checkpoint, Cisco Systems Inc., CloudFlare, F5 Networks, Imperva, Incapsula and Trend Micro Inc. In addition to enabling integrated security, monitoring and policy management, Azure Security Center also provides recommendations. By analyzing information gathered from customers’ deployments and comparing with global threat intelligence aggregated by Microsoft, the service introduces ability to detect threats while taking the guesswork out of cloud security. Azure Security Center will be broadly available for Azure customers by the end of the year.

Finally, continuing investments to deliver industry-leading compute capacity, Microsoft is announcing the N-series, a new family of Azure Virtual Machines (VMs) powered by NVIDIA GPUs. GPUs have long been used for compute and graphics-intensive workloads. Microsoft is the first hyper-scale provider to announce VMs featuring NVIDIA Grid 2.0 technology and the industry-leading Tesla Accelerated Computing Platform for professional graphics applications, deep learning, high-performance computing and more. A preview will be available in a few months.

Microsoft announced the Azure Compute Pre-Purchase Plan, a new pricing program designed for customers with steady state, predictable workloads on Azure. With this new offer, customers who pre-purchase Azure compute for one year can realize cost savings of up to 63 percent. This plan will be available globally starting Dec. 1.

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