Industrial Software Now More Important Than Hardware?

SafeMove2

SafeMove2

[Industrial] “Software’s Where It’s At.” The blog title was intriguing. It was implied that  industrial software was increasingly more important than hardware. Then I began to look at my accumulating queue of news. There is a bunch. Here is a sampling. It appears that more innovation time and investment is going into software than hardware. What do you think? Software is now where it’s at?

 

Cloud and Analytics

GE and Microsoft announced a partnership that will make GE’s Predix platform for the Industrial Internet available on the Microsoft Azure cloud for industrial businesses. The move marks the first step in a broad strategic collaboration between the two companies. This continues a trend I’ve noticed recently of a newly resurgent Microsoft adding clients to Azure cloud.

“Connecting industrial machines to the internet through the cloud is a huge step toward simplifying business processes and reimagining how work gets done,” said Jeff Immelt, CEO of GE. “GE is helping its customers extract value from the vast quantities of data coming out of those machines and is building an ecosystem of industry-leading partners like Microsoft that will allow the Industrial Internet to thrive on a global scale.”

Bringing Predix to Azure, according to GE, means industrial customers will now have access to additional capabilities such as natural language technology, artificial intelligence, advanced data visualization and enterprise application integration.

Microsoft predicts Azure will support the growth of the entire industrial IoT ecosystem by offering Predix customers access to “the largest cloud footprint available today”, along with data sovereignty, hybrid capabilities, and advanced developer and data services. In addition, GE and Microsoft plan to integrate Predix with Azure IoT Suite and Cortana Intelligence Suite along with Microsoft business applications, such as Office 365, Dynamics 365 and Power BI, in order to connect industrial data with business processes and analytics.

“Every industry and every company around the world is being transformed by digital technology,” said Satya Nadella, CEO, Microsoft. “Working with companies like GE, we can reach a new set of customers to help them accelerate their transformation across every line of business — from the factory floor to smart buildings.”

Software’s Where It’s At

This is the blog that brought my thinking to a focus. ARC analyst Mark Sen Gupta wrote about a recent CEO appointment. Honeywell recently announced that Dave Cote is retiring after 14 years at the helm and will be succeeded by Darius Adamczyk.

In the announcement Mr. Cote states, “Scanning & Mobility and Honeywell Process Solutions are software-based businesses with advanced offerings that blend physical and digital capabilities, and they serve as benchmarks for where the rest of Honeywell is heading. Darius’ deep expertise in software will open new growth paths for all of our businesses, which are blending Honeywell’s advanced software programming capabilities with leading-edge physical products and unparalleled domain expertise in a wide variety of industries.”  This is a very interesting statement because it recognizes a crucial shift in automation.

Says Sen Gupta, “When we think of automation we normally think of hardware: DCS, PLC, sensors.  However, most of the innovation in the industry is happening in software. This aspect of automation innovation has not escaped the attention of ExxonMobil and has led to culmination of it’s open automation initiative.  IIoT, cloud, analytics, edge computing have far more to do with what is provided from a software aspect than from a hardware aspect.  This is not to say that hardware has no value.  In fact if you were to check the balance sheets, you would find that the large automation companies earn more revenue on what we consider hardware, and something has to host the software.”

Digital Twin

Fellow ARC analyst, Dick Slansky recently wrote on how manufacturing and production systems will undergo significant changes. He foresees the eventual realization of the “lights-out” factory with adoption of all the new digital technologies.

“This is a case of leading PLM solutions providers offering advanced analytics solutions applied to the manufacturing processes and to operational optimization. The common objective is to use predictive and prescriptive analytics to improve the overall performance of production operations.”

He continues, “One of the most sought after but elusive goals of product design engineering is to validate that you have achieved all the design criteria in the as-built product. That is, closing the loop between the as-built to the as-designed, and validating that the physical product will meet all design criteria before the product is manufactured. This is where the concept of the digital twin in now being applied to product design criteria, and the goal of ‘closed-loop PLM’.”

“As IIoT, the digital thread and digital twin evolve within the overall ecosystems of product and process, the methodologies, including analytics, for both product development and production processes will  converge. The intent and goal of the digital enterprise is to maintain a continuous and real-time digital thread that connects the lifecycle from concept through design, test, and build, to supply chain and products in field.”

ABB Robotics

There has been little radical innovation within industrial robots for some time. Improvements, yes; Innovation, not so much.

But ABB has been working on the software side. It just announced SafeMove2, the latest generation of its safety certified robot monitoring software.

SafeMove2 includes a host of cutting-edge safety functions, including safe speed limits, safe standstill monitoring, safe axis ranges and position and orientation supervision.  The new generation functionality encourages the development of innovative robot applications by integrating safety features directly into the robot controller.

“To be efficient, robots must be able to move at speeds suited to the given application. At high speeds this can present a potential hazard for people working in the immediate vicinity. Historically, fences or cages have been used to separate man from machine in an effort to keep them out of harm’s way,” says Dr. Hui Zhang, Head of Product Management, ABB Robotics. “SafeMove2 allows robots and operators to work more closely together by restricting robot motion to precisely what is needed for a specific application.”

SafeMove2 allows for the creation of more efficient and flexible production scenarios, and provides tools that speed the commissioning workflow for faster setup and validation. It also integrates safety fieldbus connectivity into ABB’s IRC5 robot controller family as well as the IRC5 Single, Compact and Paint controllers.

Enabling The Industrial Internet of Things From The Plant Floor

Enabling The Industrial Internet of Things From The Plant Floor

Enabling Industrial Internet of Things (IIoT), Reliability, Scalability, and pursuing Real ROI encompass the current mantra of Fluke. Maybe you only know that company for its multimeters or infrared cameras. Well, there is much more behind the curtain.

The company has focused product development on mobile solutions, wireless communications, and data. This quarter’s product releases reflect all of that.

Infrared

F-ti450_03a_cThe new Fluke Ti450 Infrared Camera takes focus to a new level of clarity with MultiSharp Focus. An out-of-focus thermal image can give you data that may lead to misdiagnosis — potentially costing you thousands — with no way to correct it once it has been captured, short of taking new images. This new infrared camera solves this problem by delivering images automatically focused throughout the field of view.

“We are excited to announce this new technology, because it makes a real difference in situations where you have objects at multiple distances that you want in focus. Places like substations, motors driving a long production line, or electrical panels with components at varying depths,” notes Chris Rayburn, thermography business director.

MultiSharp Focus is a new technology that rapidly takes multiple images and combines them to produce one in-focus image. The advanced focusing system enables users to capture an automated, focused image of multiple targets at once, delivering the image clarity needed by professional thermographers and maintenance managers to produce top-quality results and avoid costly rework.

Waveforms

F-125b_01a_c Waveform to Industrial Internet of ThingsToday’s industrial machinery is more reliable and efficient, but can also be more difficult to troubleshoot because of the complexities of its advanced systems. The new Fluke ScopeMeter 120B Series Industrial Handheld Oscilloscope features Connect-and-View technology that recognizes signal patterns and automatically sets up the scope’s triggering, amplitude, and time base eliminating the typical trial-and-error setup process. Once the waveform is captured, the new IntellaSet intelligent measurement detection automatically selects key measurements based on the acquired waveform type and displays the most relevant measurement values (for example, Vrms and Hz for a line voltage signal, or Vpeak-peak and Hz for a square wave), helping technicians easily identify and characterize potential signal faults.

The 120B Series also features Event Capture function that captures and identifies elusive intermittent events and lists all those events that exceed a predetermined threshold. This lets technicians identify key events quickly, rather than combing through large data sets, reading by reading.

Fluke Connect

The Industrial Internet of Things is all about connections and data. As part of Fluke Connect— a system of wireless test tools that communicate via the Fluke Connect app, or Fluke Connect Assets software, a cloud-based solution that gathers measurements to provide a comprehensive view of critical equipment status — the 120B Series can automatically record waveform data to the Fluke Connect app on smartphones or tablets ensuring accuracy and eliminating manual recording of data. Those measurements are then wirelessly uploaded to the cloud and can be combined with measurement data from multiple Fluke Connect test tools to create and share reports from the job site via email and collaborate in real time with other colleagues, increasing productivity in the field. Storing then comparing and contrasting waveforms of specific asset test points over time enables maintenance engineers to better identify and troubleshoot conditions that can lead to failures.

Work Orders

6007307a-en-fca-work-order-list to the Industrial Internet of ThingsFluke introduces Work Orders, the latest enhancement to the Fluke Connect Assets, an asset management software solution that works with the Fluke Connect system of wireless test tools. Using this new Fluke Connect Assets feature maintenance managers can:

  • View complete work order history coupled with measurement data related to a specific plant asset
  • Create work orders from anywhere
  • Confidently assign the job to the appropriate technician and balance the task with other work orders in the system.

Technicians are provided with actual measurement data right in the work order allowing them to better understand the problem and work instructions.

The Fluke Connect system allows entire maintenance teams to capture and wirelessly share data via their smartphones.  Using the AutoRecord feature measurements are transferred directly from Fluke Connect wireless test tools – eliminating transcription errors – and can be uploaded to FlukeCloud storage. Measurements can be assigned to a specific asset for sharing and analysis. Technicians can collaborate with their colleagues to discuss problems while sharing data and images in real time with ShareLive video calls, which speeds problem solving, decision-making and approvals.

Clamp Meters

F-125b_10a_cOften the most frustrating task for electricians and maintenance technicians is to troubleshoot intermittent faults because they rarely occur at convenient times. The new Fluke Connect-enabled 370 FC Series Clamp Meters log measurements to pinpoint intermittent faults precisely without the need for the technician to be present. Those measurements are then wirelessly transmitted to the Fluke Connect app on smartphones or tablets and automatically uploaded to the cloud, keeping technicians outside the arc flash zone and away from dangerous moving machinery, improving safety.

The CAT IV 600 V, CAT III 1000 V safety-rated clamp meters offer advanced troubleshooting performance to capture a wide range of measurements with a single tool, including:

  • Proprietary in-rush measurement technology to filter out noise and capture motor starting current exactly as the circuit protection sees it;
  • Integrated variable frequency drive low pass filter (376 FC and 375 FC models only) for accurate motor drive measurements;
  • True-rms voltage and current for accurate measurements on non-linear signals;
  • 500 mV dc measurement range to interface with other accessories (376 FC and 375 FC models only);
  • Expanded measurement range to 2500 A ac with the iFlex flexible current probes, which provide access to large conductors in tight spaces.

As part of Fluke Connect— the industry’s largest system of software and more than 30 wireless test tools — technicians can wirelessly transmit measurement data from the 370 FC Series clamp meters and other test tools to their smartphones for secure storage on the Fluke Cloud and team access from the field. With the Fluke Connect smartphone app, technicians can combine measurement data from multiple Fluke Connect test tools to create and share reports from the job site via email and collaborate in real time with other colleagues with ShareLive video calls, increasing productivity in the field.

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.

CyberSecurity Blog Looks at IIoT Challenges

Belden’s “The State of Security” blog has published “5 Key Challenges for the Internet of Things (IIoT)” featuring thoughts from a variety of experts and observers. They included a couple of paragraphs from me. Check it out.

Key Challenge #1: Settling on Device Capabilities

Key Challenge #2: Supply Chain Concerns

Key Challenge #3: Security

Key Challenge #4: Bridging the Gaps that Divide Us

Key Challenge #5: Safety

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.

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