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336 Volts of Green Engineering

MEASURE IT FIX IT

Developing a commercially viable fuel cell vehicle has been a significant challenge because
of the considerable expense of designing and testing each new concept. With NI LabVIEW
graphical programming and NI CompactRIO hardware, Ford quickly prototyped fuel cell control
unit iterations, resulting in the worlds first fuel cell plug-in hybrid.

MEASURE IT
Acquire

Acquire and
measure data
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Analyze

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processing

FIX IT
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Prototype

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Ford is just one of many customers using the NI graphical system design platform to improve the world around
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>>

Download the Ford technical case study at ni.com/336

800 258 7018

2009 National Instruments. All rights reserved. CompactRIO, LabVIEW, National Instruments, NI, and ni.com are trademarks of National Instruments.
Other product and company names listed are trademarks or trade names of their respective companies. 2009 0834

0834 Green Engineering Ford.indd 1

CD1004_FPA.indd 4

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3/22/10 12:12 PM

nS

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PUBLICATIONS
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20 Cover Story
Green Identity

iet
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tio

features

l ic
f Business Pub

l ic
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An Important First Step Toward Sustainable Manufacturing Is

Better Machine Efficiency and Conservation

Jim Montague, executive editor

Volume 14, No. 4

27 Machine Control
A Look at IEC 61508
The Standard Drives Functional Safety of Machinery in the U.S.
and Europe

Matthias Haynl, TV Rheinland

20

contents

ica
Amer

APRIL 2010

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U.S. TRADE
PUBLICATIONS

32 Product Roundup
Lets Get Mechanical
Components Are Still Easy-to-Install and Operator-Friendly

Columns

7 ControlDesign.com

19 Embedded Intelligence

Technology Goes Green

SCADA, HMI Boundaries

Blur

9 Editors Page
Term Limits

13

11 Machine Builder Mojo

Machine Information in
Your Hand

15 Live Wire

31 TechFlash
IP Opens New Doors for I/O

42 OEM Insight
Dont Fear Accuracy and
Precision

Unnecessary Redundancy?
Hot Buttons

39
CONTROL DESIGN, (ISSN: 1094-3366) is published 12 times a year by
Putman Media, 555 West Pierce Rd., Suite 301, Itasca, Illinois 60143.
(Phone 630/467-1300; Fax 630/467-1124.) Periodical postage paid at
Itasca, IL, and at additional mailing offices. Address all correspondence to
Editorial and Executive Offices, same address. Printed in the United States.
Putman Media 2010. All rights reserved. The contents of this publication
may not be reproduced in whole or part without consent of the copyright
owner. POSTMASTER: Send address changes to Control Design, Post Office
Box 3430, Northbrook, Illinois 60065-3430. SUBSCRIPTIONS: To apply
for a free subscription, fill in the form at www.ControlDesign.com/subscribemag. To non-qualified subscribers in the United States and its possessions,
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and Mexico accepted at $99.00 per year for surface and $199.00 for airmail. Putman Media also publishes CHEMICAL PROCESSING, CONTROL,
FOOD PROCESSING, industrial networking, PHARMACEUTICAL
MANUFACTURING and PLANT SERVICES. 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.

CD1004_05_TOC.indd 5

13 OEM Spotlight

35 Real Answers

Once Upon a Packer

Builder

Can OTS OS Do Embedded

Control?

16 InDiscrete

40 Product Showcase

National Engineers Week

Hits the Books
Control Design Exclusive

39 Beckhoffs Embedded PC Delivers Power

April 2010 Control Design

3/22/10 3:04 PM

CD1004_FPA.indd 6

3/22/10 12:12 PM

New White Papers

Machine Vision Academy

Are you interested in image
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Recycle. Save energy. Go

You should back up your claim

green. Buy a hybrid. These and

with specific performance and

other things are what people

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constantly talk about today. By

Contributor Loren Shaum

browsing the Internet, I find

wrote a story on sustainable

many articles that suggest how

machines, as well. His report

each of us can do our part for

established that the industry

the environment. Going green

still uses older machines, not

takes time and effort and can

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ers and system integrators

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users migrate to new greener

No matter what, I believe going

technology. Shaum studied

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this issue. Read his article, The

Special to the Web

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Focus On: Retaining

Automation KnowHow
Control Design interviews
Haumiller and Concep Machine
to get a closer look at how
companies are retaining
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articles featuring what some

Market Intelligence
Report: Motion Control
Parts 1 & 2 Learn what
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CD1004_07_WebTOC.indd 7

You can also log on to our

members are doing to make

Machine Builder Forum and

their plants, machines and

weigh in with your opinion.

products as green as possible.

There, we ask how important

Log on to www.ControlDe-

sustainable manufacturing

sign.com/greenisnotenough to

is to your customers. So far,

read Senior Technical Editor

sustainable manufacturing is

Dan Heberts story, Green

a convenient phrase to collect

Your Way. In this article,

all the energy- and material-

Hebert learns what different

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manufacturing. Green initia-

Technology, Dynatorch, GL&V

tives for machine builders have

Paper Group and Partner Pak do

been put in place, but what else

to become green.

is being practiced by machine

Building green machines

builders? Can recyclable mate-

isnt just about producing

rials replace certain machine

machines that can save energy.

components, reclaimable at the

Customers today want equip-

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replace wire and cable with

lutants, can be repurposed to

wireless alternatives? Is there a

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waste and scrap, cuts cycle and

Visit www.ControlDesign.

idle time and uses automation

com/sustain and tell us if you

to replace materials.

believe green manufacturing is

Hebert says that as a

[email protected]

controldesign.com 

ablemachine to find out more.

Did you know you can

receive Control Design
electronically? Subscribe
to the digital issue of Control
Design and youll be able to
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well send you an email each
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digital.html.

of our Machine Builder Nation

ControlDesign.com/sustain-

managing editor, digital media

View these videos at www.

ControlDesign.com/multimedia.

ControlDesign.com has

green is the answer to our future,

Katherine Bonfante

To download PDF papers, go

to www.ControlDesign.com/
whitepapers.

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April 2010 Control Design

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Term Limits
555 W. Pierce Rd., Suite 301
Itasca, Illinois 60143
630/467-1300
Fax: 630/467-1124
Editorial team
editor in chief

Joseph Feeley
[email protected]

that seems better described as an

machine builders have a growing

attempt at smart manufacturing

need to include energy-efficiency

or responsible manufacturing.

and material-conservation initiatives in their designs.

Customers demand it more

This is an altogether really good

thing. I just dont like finding that
sustainability has been co-opted

often now, and for a variety of

to be another commercialized

reasons beyond the lifecycle cost-

buzzword that means different

saving aspects.

things to different people.

If you dont find these issues

Joe Feeley

executive editor

Theres little argument that

Sustainability in simplest

becoming an important part of

terms is a zero-sum game. It

managing editor

your customers machine require-

means producing power from

mike bacidore
[email protected]

ments, I wouldnt count on it stay-

renewable or inexhaustible fuel,

ing that way. This is a rising tide

products from renewable precur-

that will floatand in some cases

sors or recyclable materials. It

sinkall boats.

probably implies not screwing up

senior technical editor

Lori Goldberg
[email protected]

the topics more coverage. April

the surroundings in the process.

The trouble with using the

includes another cover story (p20)

term sustainable correctly is

in which Jim Montague identifies

that its largely unachievable.

columnist

more machine builders who are

At least today thats the case. So

Jeremy Pollard
[email protected]

knee-deep in the process with their

weve seen its meaning change

customers. Youll also find Jim in

to better suit initiatives that

our most recent Focus On video

industry is willing to try.

Design/Production
art director

Derek Chamberlain

(www.ControlDesign.com/green-

Subscriptions

manufacturing) that previews his

customer service

888/644-1803

cover story.

circulation
audited December 2009

column (p7) at a review of our

Air & Gas Compressors

738
Engineering & Systems
Integration Services
8,959
Engines & Turbines
1,526
Food Products Machinery
1,542
Industrial Fans, Blowers,
& Air Purification Equipment
596
Industrial Heating, Refrigeration,
& Air Conditioning Equipment
1,322
560
Industrial Process Furnaces & Ovens
Machine Tools
5,561
Materials Handling, Conveyors
& Conveying Equipment
1,594
Metalworking Machinery
3,555
Mining Machinery & Equipment
481
Oil & Gas Field Machinery & Equipment 1,249
Packaging Machinery
808
Paper Industries Machinery
456
Printing Trades Machinery & Equipment 563
Pumps & Pumping Equipment
924
Rolling Mill Machinery & Equipment
151
Semiconductor
Manufacturing Machinery
1,082
Textile Machinery
222
Woodworking Machinery
244
Other Industries & Special Industrial
7,886
Machinery & Equipment NEC
TOTAL
40,019

Katherine Bonfante aims her

coverage of these subjects in the
recent past and where to find it at
ControlDesign.com.
When we discuss issues that

 he trouble with using

T
the term sustainable
correctly is that its
largely unachievable.
I only make the point so that
we can better understand each
other when a retailer talks about

include terms such as green

sustainable manufacturing with

and sustainable, were trying to

the consumer products manu-

keep the terminology consistent.

facturer that, in turn, talks to

Sustainable, in particular, is the

machine builder that, in turn,

it word right now.

talks to suppliers.

Sustainability in manufactur-

[email protected]

editorial assistant

Weve certainly been giving

Dan Hebert
[email protected]

editor in chief

Katherine Bonfante
[email protected]

Jim Montague
[email protected]

managing editor, digital media

editors page

controldesign.com

Maybe we can more uniformly

ing seems to be this overly deep

recognize the value in having

bucket that contains just about

goals to relentlessly, albeit slowly,

everything. Many companies

approach a genuinely sustainable

include machine safety, environ-

manufacturing universe by doing

mental responsibility and employ-

all these good things. And then

ee well-being. Many also include

lets keep score that way.

initiatives and programs such as

lean manufacturing, Six Sigma,
and quality management.
So, we end up with something
April 2010 Control Design

CD1004_09_Edit.indd 9

3/22/10 3:07 PM

Hazardous Locations Product Testing and Certification

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CD1004_FPA.indd 10

3/22/10 12:13 PM

RL-384

Machine Information in Your Hand

more Ethernet protocols in their plants, and its

less human-machine interface (HMI) units more

incumbent on the machine builder to ascertain

frequently, its important that you understand

which type of protocol is needed and to provide

how best to make your machines fit their overall

the machine with same.

wireless infrastructures. Increasingly, compatibil-

Although many companies use handheld HMIs

ity with existing and planned wireless machine

for machine monitoring, few are using them to

monitoring systems will be a required feature.

replace the primary machine-mounted HMI. The

For example, Mohawk Fine Papers (www.mo-

handheld HMIs are instead used to extend reach,

hawkpaper.com) in Cohoes, N.Y., uses Transparas

usually via one-way communication of machine

Visual KPI to monitor and control its paper ma-

status. Any problems requiring adjustments to

chinery and other plant components.

the machine control system typically still will be

Key performance indicators (KPIs) are delivered to handheld HMIs, in this case Blackberry

made at the machine.

Future implementations might feature highspeed two-way access. This would allow your

chines, but instead primarily through OSIsofts

customers not only to monitor their machines

PI data historian. Other data are delivered to

remotely, but also to change control parameters

the Blackberry devices through Microsoft SQL

to adjust machine operation. These types of

Server for data extraction, transformation and

adjustments probably will be made by operators

loading, and through Microsoft Sharepoint as

in close proximity to the machine, paving the

an information portal.

way to systems that completely eliminate on-

managers, supervisors, engineers and even the

chief operating officer. Handheld HMIs played an
important role in Mohawks overall 2009 improvement in machine output, customer satisfaction
and energy consumption.

 ne handheld HMI could be used to

O
monitor and adjust many different
machines.
In these types of systems, your machine
would be provided with no local HMI. Instead,

real-time access to machine, production and

a handheld wireless HMI would be used to pro-

order status, explains Ben Whitaker, manager of

vide full monitoring of your machine along with

enterprise process reengineering at Mohawk. This

adjustment of machine operating parameters.

allows more responsiveness to customer require-

The advantages of such a system to manufac-

ments and manufacturing issues. In the mainte-

turers are numerous.

nance area, supervisors and senior engineers have

First, one handheld HMI could be used to

access to energy consumption for better response

monitor and adjust many different machines. In

to machine performance issues.

typical plant operations, an operator goes from

Machine OEMs supplying Mohawk and companies using similar systems need to make their
machine control system accessible to the data

one machine to the next to observe operating

conditions and make adjustments.
Second, an operator could access a machine

repositories accessed by handheld HMIs. This

from a safe distance, often outside a hazard-

means that links must be provided to software

ous area. This not only could improve safety,

such as data historians and often to various

but also save time as personal entrance into a

Microsoft products as well.

hazardous area is often a time-consuming task

These links are most commonly Ethernetbased, meaning that your machine should have
an Ethernet port at either the controller or the

requiring special protective personnel equipment (PPE) and lots of paperwork.

Third, linking the handheld HMI to the ma-

HMI level. This takes care of the hardware

chine and to the central control room could allow

connection, but doesnt address the software

an operator to make machine adjustments with

protocol issue. Most manufacturers use one or

the entire process in mind.

controldesign.com 

CD1004_11_Mojo.indd 11

[email protected]

Supervisors and senior managers now have

machine HMIs.

senior technical editor

their Blackberry devices including technicians,

Everyone in the plant has access to the data via

Dan Hebert, PE

devices. Data isnt accessed directly from ma-

machine builder mojo

AS Your customers use handheld wire-

April 2010 Control Design

11

3/22/10 10:13 AM

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Signal Conditioners Temperature

Controllers

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universal software platform and integrated conversion of over 200 protocols. Enable Ethernet communications
on serial devices, data acquisition, web serving, data logging and remote management via mobile devices.
Connect dissimilar devices and access orphaned data that can be used to make your process run more
efficiently. Red Lion controls awaken your technology, create transparency and span the gaps in your process
environment. Call for free catalog at (717) 767-6511 or visit www.redlion.net

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Data Acquisition

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RL-384A Corporate Ad_ControlDesign.indd 1

CD1004_FPA.indd 12

2/24/10 9:58 AM
3/22/10 4:06 PM

Once Upon a Packer Builder

OEM SPOTLIGHT

Field Service Engineers and OI Keep Customers Happy Ever After

CASE AND TRAY packers for
the food, beverage, chemical
and personal-care industries are
the primary machines designed
and built by Standard-Knapp
(www.standard-knapp.com), an
employee-owned company located in Portland, Conn. Its prodSTANDARD-KNAPP

uct line also includes uncasers,

multi-packer or bundlers, slitter/
sealers and product laners.
There are unique differences in each of the industries
we serve, says Mario Mazzotta,
customer relations and marketing manager. The food and
beverage industries constantly

FINE TOUCH
Jeff Reilly (right), controls engineer, fine-tunes the control program settings,
as Skip Miller, machine assembler, works on the 989 PakMore continuous
motion case packer with integrated 189 slitter/sealer.

increase the demand for faster

Thirteen engineers10 me-

a large inventory of parts and

handling and more efficiencies.

chanical and three electrical

typically ship part orders the

The chemical and personal care

comprise Standard-Knapps

same day theyre ordered.

industries develop many new

technical staff.

equipment, gentler product

bottle designs that are very at-

Networking on its ma-

Technology plays a major role

in after-sales support, specifi-

tractive but difficult to handle

chines is both hardwired and

cally with maintenance issues.

in a standard case packer.

digital, says Reilly. But were

Our new, graphically driven op-

The 125-year-old company

currently not using wireless

erator-interface (OI) system has

employs around 60 people, and

networking, due to cost and

a very detailed preventive main-

its machines are sold primar-

noise issues associated with

tenance schedule that visually

ily in North America, Central

wireless.

alerts maintenance personnel of

America and Asia. Machines also

All of Standard-Knapps

upcoming servicing, explains

are supported by manufacturing

machines include safety relays.

Mazzotta. Maintenance simply

licenses in Europe and in Japan.

We use safety relays to comply

can navigate to the correct

with NFPA requirements, ex-

screen on the HMI and plan for

Standard-Knapps machines

plains Reilly. New safe-off fea-

upcoming service without stop-

includes a PLC, touchscreen

tures in A-B drives and servos

ping the machine or waiting for

HMI and servos, explains

allow Category 3 safety rating

component failure.

Jeff Reilly, controls engineer.

without the wiring, external

At Standard-Knapp, inno-

Our controls are primarily

contactors and panel space.

vation is driven by customer

Control automation on

PLC-based with no embedded

Standard-Knapp employs field

demand and cost, explains

control, he says. We use PLCs

service engineers (FSEs) in a

Reilly. We believe advances

because of cost, in addition to

variety of locations throughout

in networking will have the

the benefit of having one con-

the U.S. These FSEs also per-

greatest impact on our machine

nection to upload, download

form all of our machine training

design, he says. With ad-

and edit. ControlLogix permits

at the customers facility,

vances in networking, the main

editing with just one software

says Mazzotta. The training is

difference or benefit will be the

package for ac drives, servo

divided between classroom and

use of less wiring for controls

drives and PLCs.

hands-on sessions. We stock

and communications.

controldesign.com

CD1004_13_Spotlight.indd 13

April 2010 Control Design

13

3/22/10 10:14 AM

m1500 transmitter shown ConneCted

to a meriam laminar flow unit

perfeCt for hundreds of appliCations

lab data acquisition
test and monitoring applications
barometric pressure reference
production skids

pneumatic / hydraulic go, no go testing

pressure leak testing
process control applications
plant instrumentation

oem applications
laminar flow systems
wet/wet differential monitoring and control
Head type flow metering

re
owe d b

Calibrators CommuniCators transmitters flow produCts manometers gauges

EPI

output & CommuniCation options for any appliCation

usb: power up and communicate through usb type b female

connector

rs-232: db9 female or terminal block connector for point-to-point

communication

rs-485: db9 female or terminal block connector for multi-point

(up to 254 addresses), half duplex communication

Analog: scalable 4-20mA (2-wire) or 0-5VDC (4-wire), field

selectable
digital communications via meriam digital protocol or modbus rtu protocol (pending)
Convenient field set up and re-calibration using supplied PC software or protocol commands
Compact size perfect for din rail or panel mounting; 4.625 l x 2.125 w x 1.25 h, 10 to 16 ounces
pressure ranges from 10 h20 (pending) to 3000 psi full scale
0.025% of f.s. traceable to nist including all affects of linearity, repeatability, hysteresis and
temperature over operating range of -20 to +50 C (-4 to +122 f).
14 pressure updates per second or dampen to suit application
differential (dry/dry or wet/wet), gauge, compound and absolute pressure versions for process
media compatible with 316ss
power with 8-36 VdC or power over usb with the usb option

T h e Tr u s t e d L e a d e r i n M e a s u r e m e n t & C a l i b r a t i o n S o l u t i o n s
[email protected]

CD1004_FPA.indd 14

800.817.7849

w w w. M e r i a M . C o M

3/22/10 4:03 PM

RL-384

Unnecessary Redundancy?
dual-homing at the edge of a network, which al-

be one of them yourself. The redundant is talker

lows that device to be connected to two separate

can turn a simple sentence into a complicated

points in the network, says House.

web of syntax.
The problem is, is that we need to clarify our
What you need to know is, is that there are
more potential pitfalls lying in wait.
While the redundant is talkers duplication is

maintenance might require minimal or no redundant systems, says Thomas Ferrara, director
of engineering, Atlantic Industrial Technologies
(www.aitzone.com), a designer and manufacturer of hydraulic and pneumatic systems in

be critical. The trick is knowing when redundancy

Shirley, N.Y. The ripple effect of this type of

is necessary and beneficial and when it needlessly

subsystem is containable, and therefore the

complicates the design and increases the cost.

expense of implementing redundant systems

Redundant safety and power systems are often a

is debatable, he says. There exists a middle

given. But what about control and I/O?

ground. A system without redundancy can use

unnecessary, redundant machine subsystems can

Mike Bacidore

objectives.

Some systems that operate intermittently

and have inherent standby time for repair and

LIVE WIRE

Youve heard them speak. You might even

would use a majority voting scheme to circum-

ville, Tenn., believes redundancy of electronics

vent relay or signal failure. These systems can

in plants is extremely overdone. The only ben-

also implement a quick repair cycle procedure

efit usually gained from a redundant controller

to substitute for a true redundant system.

setup is the ability for online upgrades, but this

The need for redundancy comes down to the

is typically outweighed by cost and complexity,

application, explains Tyler Croft, product market-

he says. In 20 years, the only controller failures

that have occurred in facilities I have worked in
were on redundant systems. In fact, redundant
systems have caused me more heartburn than
simplex systems have.
Choy-Hsien Lin, development engineer,

The only benefit usually gained from a

redundant controller setup is the ability
for online upgrades, but this is typically
outweighed by cost and complexity.

process control, Stora Enso Publication Paper,

ing manager, GE Intelligent Platforms (www.ge-ip.

Hylte Mill, (www.storaenso.com), Hyltebruk,

com). There are applications that cannot shut

Sweden, agrees. If a failure doesnt impact the

down, in which case redundant controllers are

bottlenecks of the process, redundancy should

essential, so routine maintenance can be done on

be avoided to reduce the complexity and remove

one controller while the other is controlling the

the additional point of failure, he says.

process. If you cant lose the controller and the

When the organization can live with an inter-

program, then you need to have redundant CPUs.

ruption in the system for the time it takes to fix it,

If they want to ensure that they do not lose I/O,

redundancy is optional, explains Lee House, CTO

then they should have redundant I/O.

and vice president of engineering, GarrettCom

But Helge Hornis, Ph.D, manager, intelligent

(www.garrettcom.com). The availability of re-

systems, Pepperl+Fuchs (www.pepperl-fuchs.

placement equipment can be a factor in determin-

com) adds some words of caution when deal-

ing the need for redundancy, he says. However,

ing with redundant inputs. Its common to use

redundancy is often more cost-effective than

sensors with inverted outputs, he says. As far

dealing with the headache and cost of downtime.

as the logic is concerned, one only works with

Redundancy can involve a variety of technolo-

one output. The second output allows the PLC

gies including rapid-recovery options for a switch

to check that the sensor is still OK. His white

using a ring topology or mesh network that allows

paper on redundancy (www.ControlDesign.

data to continue to flow without interruption in

com/redundancy) explains I/O considerations in

the event that a network switch goes down; and

much greater detail.

controldesign.com 

CD1004_15_LiveWire.indd 15

[email protected]

poor mans redundancy. These redundant relays

coats and colorants headquartered in Collier-

inexpensive, redundant relays, which provide a

(www.aoc-resins.com), a supplier of resins, gel

managing editor

Dan Cox, director of engineering at AOC Resins

April 2010 Control Design

15

3/22/10 10:15 AM

INDISCRETE

National Engineers Week Hits the Books

ENGINEERS FROM Phoenix Contact in Pennsylvania
and Michigan shared their
enthusiasm for science with
local students during National
Engineers Week, Feb. 14-20, an
annual event that promotes
engineering careers to young
people and honors engineers
PHOENIX CONTACT

contributions to society.
Engineers from Phoenix
Contacts U.S. headquarters,
just outside Harrisburg, Pa.,
worked with students at the
nearby Middletown Area
Middle School. Each day, a team
of engineers taught sixth-grade

CHARGE OF THE BUBBLES

A Middletown Area sixth-grader in Pennsylvania shoots bubbles at a Van de
Graaff generator that repels them.

science class, incorporating

Phoenix Contacts auto-

engineers in Harrisburg have

hands-on activities into the

mation sales and software

had a lot of fun working with

lesson. Students learned about

development office in Ann

local students, said Jack Nehlig,

static electricity with a demon-

Arbor, Mich., also visited a local

president of Phoenix Contact

stration of a Van de Graaff gen-

school. The Ann Arbor team

USA (www.phoenixcontact.com).

erator, built an electric motor,

worked with the seventh- and

These hands-on demonstra-

raced cookie tins to see how

eighth-grade classes at Ann

tions not only show how math

the distribution of mass around

Arbor Open School. Students

and science can be fun, but also

an axis affects the speed of an

learned about the history of

how engineering impacts all of

object and built a catapult to

manufacturing and began work

our lives on a daily basis.

demonstrate momentum and

on the mini-factory project, a

trajectory. This was the third

desktop model of a production

activities, Phoenix Contact

year that the company worked

line that includes a conveyor

honored its practicing engi-

with the school for Engineers

and some simple robots.

neers with lunches in both

a combination of theory and

Week (www.eweek.org).

CD1004_16_18_Indiscrete.indd 16

Middletown and Ann Arbor.

NOTEWORTHY

MERGERS, ALLIANCES & ACQUISITION

American Sensor
Technologies (www.
astsensors.com) expanded
its CE approval for pressure
sensors, transducers,
transmitters and switches.

Sixnet (www.sixnet.com) acquired

JBM Electronics, a networking
connectivity solutions provider in
St. Louis.

IEEE launched an upgrade

to the IEEE Xplore digital
library at www.ieee.org/
newieeexplore.

16

Over the past few years, our

In addition to the school

Control Design April 2010

Cisco (www.cisco.com) joined

the Connected with Kepware
(www.kepware.com) program
to deliver OPC-based network
monitoring and management
drivers for use with its products.

Maxon Precision Motors (www.

maxonmotorusa.com) and
National Instruments (www.
ni.com) collaborated to highlight
mutual areas of interest in the
field of robotics.
Mori Seiki (www.moriseiki.co.jp)
acquired the measuring systems
business of Sony Manufacturing
Systems, a subsidiary of Sony.

controldesign.com

3/22/10 11:49 AM

Survival of the fitteSt

ol

our industrial Display Products

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flat panel monitors. Our visualization systems are
available from component general-purpose monitors to
fully integrated Class I, Division 1 systems with purge.
Manufactured with industrial-rated components, a full
family of high-performance display panel monitors is
available with 10 to 20 inch diagonal active viewing
areas and touchscreen options.
Our expert knowledge, seamless integration products,
hazardous area protection expertise, and global support
are unsurpassed. When you need safe, reliable, and
timely visualization solutions, choose Pepperl+Fuchs.
Find high-quality industrial flat panel monitors at:
www.pepperl-fuchs.com
Pepperl+Fuchs, Inc.
Twinsburg, Ohio
330.486.0002
www.pepperl-fuchs.com

CD1004_FPA.indd 17

3/24/10 11:31 AM

INDISCRETE

MHIA: 6%+
Growth in
New Orders
for 2010
Material handling equipment
orders contracted 37% in 2009
but are forecasted to grow more
than 6% in 2010, according to
Material Handling Industry of
America (MHIA).
Industrial production activ-

UCLA STUDENTS WIN SCHOLARSHIPS

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Science were selected to receive $2,500 Live EDGE scholarships to help further
their educations in electrical and electronics engineering. Of the 12 Live EDGE
scholarships awarded to engineering students worldwide, UCLA had the most
winners. The UCLA students, Abde Ali Kagalwalla and Meng Ai, who are
both first-year graduate students in electrical engineering, and Armin Axel
Brugger, a junior majoring in electrical engineering, each received $2,500. The
scholarships are part of Premier Farnells Live EDGE Challenge.

ity is increasing even though

factory operating rates remain
very low by historical comparison, said Hal Vandiver, MHIAs
executive vice president of
business development.
Demand created as the
economy shifts from recession into recovery modefilling supply chain pipelines,

OEM Pressure Instrumentation

re-establishing inventories and

responding to pent-up demandis the principal impetus
for improvement over the next
few quarters in manufacturing,
warehousing and distribution,
says Vandiver.
In addition, material handling equipment shipments
contracted 34% in 2009 but are
forecasted to grow 1-2% in 2010.
Domestic demandshipments
plus imports less exportscontracted 35% in 2009 but will
grow 1-2% in 2010. Exports and
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CD1004_16_18_Indiscrete.indd 18

about the same rate.

The Material Handling Equipment Manufacturing (MHEM)
forecast of material handling
equipment manufacturing
is released each quarter by
MHIA and looks 12-18 months
forward to anticipate changes
in the material handling and
logistics marketplace.
controldesign.com

[email protected]

3/22/10 11:50 AM

SCADA, HMI Boundaries Blur

The availability of vital operating information
in real time, data historians, KPIs and data-min-

different, but then theyre not.

ing extensions make the modern-day differences

I thought back to 1984 when I was at Rockwell

between SCADA and HMI systems very blurry.

Automation creating some project screens for a

Machine control interfaces are connected to

client sales presentation on an A-B Advisor em-

the controlling PLCs and PACs, and are connected

bedded graphics system.

to the plant-wide information highway, just as

This device was a CPM-based SCADA system

SCADA systems are. One of the more innovative

that created screen displays using object-like

products that blur the lines is embedded touch-

symbols and used small CRT display units for in-

screen terminals from Invensys/Wonderware.

terfacing. A keyboard was the main interface for

Wonderware is SCADA, but it also is HMI. Its the

the operator with custom inserts for key defini-

same development system with multiple targets.

tion. Plug-in cards were used for everything.

InduSoft is another.

The development system was intensea lot of

Many new technologies are a hit with users

and OEMs alike. A recent poll reported that most

hoop-jumping. There also was a T30 operator/

companies will use the controller vendors HMI

HMI terminal, which had a development system

offering, if available. Once upon a time there were

embedded in the unit. I dont think a touchscreen

many third-party HMI developers. They got pur-

was available in the first few product iterations,

chased by the big boys, so there are very few left.

but there were keypads on the unit faces so the

developer could assign key presses to functions.
The screen components were not complex, but

but was called an HMI.

The only portion of the SCADA component that
wasnt available was the data acquisition part

 here isnt a device on the planet that

T
cant be connected and monitored by
any HMI/SCADA system.

since there was no way to offload the data the terminal acquired, except through a serial port, but

by any HMI/SCADA system. Coupled with that,

that normally had a printer attached. As I remem-

proprietary networks are all but gone. Ethernet

ber it, the Advisor system wasnt much better.

wins that battle, wired or not. So all protocols,

Weve traversed so much technology since

then. In 25 years, we have jumped orders of magnitude forward. Most kids dont know what CPM
is, let alone an 8-in. floppy drive.
Whats different, and what hasnt changed?

still somewhat proprietary, propagate over a connectivity standard. Who knew?

So where are we now? Which way do things
migrate? My next few columns will reveal all.
Web-based clients, licensing issues, Visual Basic,

Well, everything and nothing. What has remained

C#/F#, scripting and server-based everything all

the same are applications these devices inter-

have their pros and cons.

face with. Im sure there are 30-year-old plywood

For instance, anyone who would use a fixed

presses with modern industrial computer inter-

HMI with embedded firmware for development, in

faces running Windows-based software that we

my opinion, is crazy. A touchscreen interface with

only dreamed about when the process was first

Embedded XP or Linux and a true development

installed using T30s and Advisor systems.

platform has to be on your radar. And Ill tell you

Whats different is methodologydevelopment

[email protected]

grayscale. It was a fully embedded SCADA system

With this development, there isnt a device on

the planet that cant be connected and monitored

effective. There were color screens, as well as

The big third-party camp these days is in OPC

servers, which is very odd.

Jeremy Pollard, CET

code generation, driver configuration and object

embedded intelligence

I will be a presenter at a SCADA conference in

Bogota, Columbia, in August. SCADA and HMI are

why next time.

software, options for development and runtime

platforms, connectivity, protocols and transmis-

jeremy Pollard has been writing about technology and

sion methods and tons of third-party support us-

software issues for many years. Publisher of The Software

ing such standards as ActiveX, .NET, Java, AJAX,

User Online, he has been involved in control system

XML and HTTP.

programming and training for more than 25 years.

controldesign.com 

CD1004_19_EmbedIntel.indd 19

April 2010 Control Design

19

3/22/10 10:17 AM

by Jim Montague, executive editor

An Important First Step Toward Sustainable Manufacturing Is

Better Machine Efficiency and Conservation
The customer is always rightand these
days that can mean going green. Consumers,

carbon footprint, and all of them are concerned about

retailers and pretty much everyone else is waking up

the cost of energy, says Greg Hyatt, Mori Seikis engi-

to the value of saving energy and reducing waste. As

neering vice president. So they ask us to make our

a result, many demand that utilities and manufactur-

machines more energy efficient, but the more interest-

ers run greener and provide tools enabling them to

ing challenge is when they have innovations in their

be more ecologically responsible themselves. In turn,

own products that require us to provide new machin-

manufacturers require machines and equipment that

ing solutions to enable their new technology.

Many of our customers are concerned about their

consume fewer resources and produce more sustainable products. So, some machine builders are rede-

Combining Tasks

signing to run greener and handle greener materials.

While making machines simpler is one way to go

However, the reality of a sustainable manufacturing

green, other builders are joining together several

environmentan environment based on renewable

devices to save energy and materials. For example,

sources of energy and raw materialsis a long way off

Hyatt reports that Mori Seiki MTLs newly released

for many industries. Basically, like so much else, the

grind-hardening process brings together formerly

concept of sustainability rolls downhill.

So, going green is a first step for manufacturers and machine builders. It is
also a way to make some green.
For example, jet fuel is very expensive, and so airlines try to conserve it
by flying planes with lighter airframes.
This is why airplane manufacturers and

separate rough machining, heat treat-

The reality of
a sustainable
manufacturing
environment is a
long, long way off for
many industries.

their parts suppliers use more carbonfiber-reinforced plastic parts. However,

ing and finish machining processes

into one center, such as its NT4250DCG
mill/turning machine that makes
heavy machine parts. Besides combining machining functions, grind
hardening uses heat from rough
machining to selectively heat-treat
machined parts in the same unit. This
allows users to avoid sending parts out

machining carbon-fiber can produce potentially

to an off-site furnace for heat-treating. Hyatt reports

unhealthy particles, and so machine tool builder Mori

this process is 85-95% less costly than traditional

Seiki USAs (www.moriseikius.com) Machining Tech-

machining and heat-treating methods.

nology Lab (MTL) recently developed and implemented

its Zerochip high-pressure vacuum process for many

More Than Efficiency

of its machining centers. The system uses hollow ma-

Is this just good old efficiency dressed up in green

chine spindles through which a specialized vacuum

clothing? No and yes. While traditional efficiency af-

sucks the dust-like chips from machining carbon-fiber,

fects a builder and its end users, green manufacturing

graphite and composite materials into a sealed con-

influences a wider circle of disciplines and require-

tainer. This allows users to safely machine the lighter,

mentseventually touching everyone. In short, green

energy-saving parts they need for green airplanes, as

manufacturing appears to embrace more technical

well as racing cars, bicycles and other future products.

areas and a larger jurisdiction than efficiency.

20

Control Design April 2010 

CD1004_20_25_CvrStory.indd 20

controldesign.com

3/23/10 12:58 PM

We see and hear about green and sustainability all the time, so we offer energy savings and simpler designs in the machines we
build, explains Craig Friesen, product manager
at packaging machine builder Thiele Technologies
(www.thieletech.com) in Minneapolis. For instance, we
can do 440 V or 220 V machines that use less current, save
power, cost less to run and help the environment. Or
we simplify the design and have a conveyor that used
to need two motors now operate with one. However,
this doesnt always involve equipment and can instead
involve greener consumables. For example, he says, a
customer might want to use a more recyclable hot adhesive, and Thiele then needs to design around it.
It can be hard to get more efficiency and energy savings out
of a machine that weve been building for 50 years, but wed rather
update a design than invent a whole new machine, and so we have
to be very creative, he adds. We work with our fabrication shop
and engineering group, look at what we usually build, perhaps a
laser cutter and brake, and then design easier-to-manufacture parts.
Its an ongoing process, and there are lots of baby steps. But sometimes, after building the same model for years, an engineering and
assembly guy suddenly says, I think if we did this differently, we
could save some assembly time.

Saving Energy
No doubt the most obvious and significant way
to go green is to conserve energy. Mark Elsass,
applications and technical services manager
for Milacrons (www.milacron.com) U.S.
mold-making operations in Batavia, Ohio,
reports, For us, green means being
more energy-efficient by using larger
and more efficient motors to translate
rotational motion to linear and using
servo-driven motors to drive the axes
on our electric machines instead of

CD1004_20_25_CvrStory.indd 21

3/23/10 12:58 PM

SO YOU WANT TO GO GREEN?

Creating more efficient machines, applications,
facilities and products requires users to adopt and
follow some better practices. Though each machine and
application is different, here are some basic practices
that can be used across a variety of production settings
and industries.
Measure and evaluate the energy, materials, water,
compressed air and other resources you and your
organization are using now and begin to develop a
plan for conserving those resources. This plan might
include powering down or turning off equipment
when its not being used and replacing simple
induction motors and drives with variable-speed
motors and drives or servo drives that can more closely
match production needs with energy used.

the ac induction motors we used

Check if your machine, application or facility could use

regeneration technology, which typically uses a shared
power source and linked drives to capture power from
decelerating components and use their energy to
accelerate other components.
Conduct a mini-audit of one of your machines or
production processes, investigate which solutions might
help it save energy or reduce materials, implement a test
or trial run and evaluate the savings it generated.
Examine all the materials that your machines consume
or process into products and seek ways to reduce waste,
perhaps by running closer to tolerances or by recycling
materials. Also, check if more sustainable alternative
materials could be used, and determine which design
changes they might require in your machines.

Likewise, to better handle sea-

(www.sew-eurodrive.com) Movigear

on previous machines. Because we

sonally fluctuating demand and

mechatronic drive units in a single-

supply machines to users to make

increasing product varieties and

line network installation (SNI) on the

molds, we work closely with mold

save energy at the same time, Ger-

container and box conveyors serving

manufacturers on what their users

man brewer and bottler C&A Veltins

its new 60,000 bottles/hr filling line

will need as they seek to be more

(www.veltins.com) decided in 2007

in its new plant in its hometown

efficient and sustainable.

to deploy 284 of SEW Eurodrives

of Meschede-Grevenstein. The line

alternates between Veltins Pilsner,
alcohol-free and beer-mixture products, and must quickly change over
between different bottle types.
Movigear optimizes the interfaces between its motor and
gears by directly combining those
gears, motor, drive, motion control
and communications in a single
gear housing, which reportedly
achieves 12-20% better efficiency
and delivers similar energy savings, according to Rich Mintz,
SEW Eurodrives strategic product
marketing manager.
To further simplify its network
infrastructure, the brewerys SNI
daisy-chained its Movigear units
together by their three-phase
power cables, but these wires also
use a PowerLAN method to carry
the applications high-frequency
communication signals, adds
Mintz. This meant that Veltins
didnt need to install about 4600
m of 24 V standard bus wiring,
and so it saved about 60% on its
cable costs, he explains.
controldesign.com

CD1004_20_25_CvrStory.indd 22

3/23/10 12:59 PM

Speed

using servo drives instead of bleeder resistors. For example, a thermoforming machine that makes yogurt
cups might have platens that press down in sequence
to form the cups rough shape and internal ribs. Each
step requires the drives to use a large spike of energy,
but where the excess energy used to go to a resistor
that dissipated it as heat, it can be put back on the
grid by being stored in capacitors and then shared on
a dc bus between multiple drives.

Conserving Materials
While saving energy is hugely beneficial, its also just
the beginning of going green. Machine builders and
SPARTANICS

end users need to think about how to reduce waste,

recycle and seek alternative materials that are easier
on their communities and the environment. Some

RECYCLING PLASTIC

veteran builders say this challenge is similar to learn-

Figure 1: Spartanics laser die cutting systems can add

components for neatly stacking leftover plastic die cut material.

ing about and adopting any new capability.

Green is just one more ripple in the whole process
and history of understanding customers and learn-

Energy in Europe

ing what their real problems are because they dont

Not surprisingly, European manufacturers and machine

always tell you, says Thomas Kleeman, CEO of Spar-

builders have dealt with higher energy costs for a lot

tanics (www.spartanics.com) in Rolling Meadows, Ill.

longer than their counterparts in North America and

For example, about 10 years ago, our European cus-

elsewhere, so they have many lessons to offer about

tomers wanted to stack the leftover material coming

green manufacturing and the goals of sustainability.

off our PVC plastic printing and die cutting machines

Every organization can look at the energy, materi-

that make credit cards, so they could ship it to their

als, water, compressed air and other resources they

recyclers more easily. As a result, we designed and built

consume, says Scott Hibbard, automation vice presi-

a machine to neatly stack all this scrap that used to go

dent at Bosch Rexroth (www.boschrexroth-us.com).

into a bin. This material still goes into a dumpster in the

This can involve plugging in a kilowatt meter and

U.S., but more end users here are looking at this kind of

turning off some lights, but it also can involve looking

recycling. These types of plastic can either be reused by

at the resources consumed by individual processes

their initial manufacturer or used down-market in milk

and changing machine programs to save energy by

jugs, traffic cones and park benches.

Speedway_CD_Apr10 o.indd 1
CD1004_20_25_CvrStory.indd 23

3/16/10 11:07:12 AM
3/23/10 1:00 PM

Spartanics builds laser and hard-tool die cutting,

screen printing and re-registration, machine vision
inspection and finishing machines, which are used to
produce everything from credit cards to automotive
dashboards and displays (Figure 1).
We also see more users who want to say they employ
materials from more sustainable sources, such as biodegradable plastics made more from corn and grasses, and
less from petroleum, adds Kleeman. However, were
finding bio-plastics have to be handled differently because theyre harder for us to cut. So, were learning how
these plastics act, and were developing some different
tools to make the die cuts. We also work with our end
users and their materials suppliers to test which new
THIELE TECHNOLOGIES

methods work best with these new bio-plastics.

Simplify the Machines

Besides just trying to save energy, green manufacturing
also can mean simplifying packaging machine designs,
so they can run more flexibly and efficiently and also
save on raw materials while making lighter, stronger
packages, adds Friesen. We build packaging machines
for consumer goods manufacturers, and they demand
green equipment, he says. This is because their cus-

STRONGER BOXES
Figure 2: Thiele Technologies SWF Bliss-Matic case former
uses PLCs to increase the machines flexibility and change
corrugated box parts more easily, which enables users to
implement new and stronger designs that use less materials.

Helping progressive process control companies

run and grow successful businesses

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Which end-user markets will remain strong?
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Introducing an online sales training program
including sales, technology and industry applications modules
Resources for the Worlds Leading Process Control Suppliers

Measurement, Control and Automation Association

905.844.6822

CD1004_20_25_CvrStory.indd 24

[email protected]

www.measure.org

3/23/10 1:00 PM

tomers are retailers who use supplier

Computing/HMI

Serial

I/O

standards such as Walmarts Green

Scorecard, which require goods
manufacturers to address environmental impacts and sustainability
issues. So, if a customer needs to

The right connection creates

incredible power.

design a greener package that uses

less material, we have to make sure

Connectivity and control. Making your interface as reliable as the

our machines can handle these

tidesand just as strong. Sealevel creates hardware and software

new designs. Once we understand

what theyre trying to accomplish,
then we can go back to them with

solutions for both digital and serial interface requirements.

We Listen. Think. And Create.

machine design modifications that

achieve what they want.

It can be hard to get more

efficiency and energy
savings out of a machine
that weve been building 
for 50 years.
Friesen says Thiele refined the

Experience exceptional computing at low

power with the SBC-R9, an application-ready
platform for your next product design.

design on its Bliss corrugated boxforming machines about a year ago,

so they have fewer parts and use
PLCs instead of relay logic, which
makes them more energy-efficient
and able to do more functions for the
same cost (Figure 2). We can control
all the Bliss functions through its
PLC, which is more flexible and easy
to program than the programmable
logic system and cams and encoders
that we used previously, he says.
This new flexibility allows us to
change box parts to stronger designs
that use less materials.
In the end, green manufacturing
and sustainability are just a couple
more design requirements that
end users can tack onto the next
request for proposal (RFP) and design
specifications. I dont see green and
sustainability backing off anytime
soon, adds Friesen. Were going
to have more regulation of energy
use and waste generation, and so
retailers will push their suppliers
to provide products to accomplish

sealevel.com > [email protected] > 864. 843. 4343

these goals.
controldesign.com 

1986-2010, Sealevel Systems, Inc. All rights reserved.

CD1004_20_25_CvrStory.indd 25

3/23/10 1:01 PM

Great things come in

small packages
Introducing the 411 Series miniature solenoid valve from ASCO. Designers used to frustrating
tradeoffs are in for a great little surprise. Because compared to competing products, these new valves
deliver up to twice as many cycles of reliable, repeatable performance in medical devices, analytical
products, and instrumentation. Yet they offer 12% to 15% lighter weight, plus better performance for the
same power critical in battery-operated portable devices. These valves also provide 12%-15% higher
flow rates, improved maximum operating pressure differential (MOPD), and full RoHS compliance.
Call ASCO to make a big difference in your design!

4
800-972-ASCO (2726)

CD1004_FPA.indd 26

www.ascovalve.com/411

e-mail: [email protected]

3/22/10 12:13 PM

MACHINE C ONTROL

A Look at IEC 61508

The Standard Drives Functional Safety of Machinery in the U.S. and Europe
by Matthias Haynl, TV Rheinland

In the past, industrial machinery safety functions

Application-Independent, Technology-Dependent

such as e-stop were hardwired, and the failure modes

IEC 61508 is the basic functional safety standard for de-

and failure data of these components, such as relays,

signers of functional-safety-related devices and system

were very well known. The applicable standards

integrators of safety-related systems. The IEC 61508

were EN954-1:1996 (Safety of MachinerySafety Re-

standard is application-independent but technology-de-

lated Parts of Control Systems) for Europe and NFPA

pendent. Its scope includes electrical, electronic and pro-

79:1997 (Electrical Safety for Industrial Machinery) for

grammable electronic (E/E/PE) safety-related systems.

the U.S. Additionally, complex components such as

The standard is written in such a way that it can be used

microcontrollers or microprocessors were not consid-

as a framework for other technologies, as well.

ered or allowed to be involved in the performance of

the safety functions.
Prior to the changes in the standards, the number of

IEC 61508 addresses the functional hazards of new

technological advances. A major feature of this standard considers the possible occurrence of dangerous

devices used to implement and perform safety func-

failure that might arise from incorrect specifications,

tions was not a factor as long as the particular devices

omissions, random or systemic hardware failure,

had the same safety category. With technology moving

software errors, common cause failures, human error

forward and complex componentsfor example, micro-

and other influences. IEC 61508 contains requirements

controllers or microprocessorsbecoming integrated

for preventing failures by avoiding the introduc-

in safety systems, the fault behavior becomes more

tion of faults and for controlling failures by ensuring

sophisticated. When the failure modes and the failure

safety even when faults are present. Additionally, the

data are not well-defined and the fault conditions cannot

standard provides new requirements for a products

be determined completely, the incorrect functioning of

overall safety lifecycle. This takes into consideration

these new technologies has to be addressed.

every phase of a product from initial concept to final

Traditional safety assessments such as for electri-

decommissioning or disposal.

cal safety are not sufficient to cover all of the safety-

The standard uses a risk-based approach to deter-

relevant aspects of todays technologies. As a result,

mine safety integrity requirements of safety-related

functional safety, which is an assessment of the com-

E/E/PE systems. The probability approach targets

ponents or systems that impact functional hazards, is

random hardware faults that could be dangerous and, if

a critical item to be addressed.

undetected, result in loss of the safety function. It spec-

IEC 61508 was introduced in 1999 as the basic

ifies four discrete safety integrity levels (SILs) of safety

standard for functional safety. It is a comprehensive

performance for a safety function. SIL 1 is the lowest

standard composed of seven parts. Parts 1-4 are nor-

level of safety integrity, and SIL 4 is the highest level.

mative, and parts 5-7 are informative.

Requirements to achieve safety integrity at the higher

levels are more meticulous than the lower levels.
One attribute of the SIL classification is the danger-

Where in the World?

Functional safety requirements are mandatory
for European machinery, but it can be a different
story for similar safety requirements in North
America. Which regulations do you follow? Join the
functional safety discussion at www.ControlDesign.
com/functionalsafety.

ous failure probability. System integrators have to

consider all devices and components implemented to
perform the safety function and ensure that the dangerous failure probability corresponds to the targeted
SIL. Hence, it is important to know how many devices
implement and perform the safety function, and the
manufacturer of safety-related devices has to determine the specific safety parameters.

controldesign.com 

CD1004_27_29_Featr2.indd 27

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27

3/22/10 2:37 PM

Another focus of IEC 61508 is the overall safety life-

related electrical, electronic and programmable

cycle, the corresponding E/E/PE system safety lifecycle

electronic control systems) is driven by IEC 61508 and

and the software safety lifecycle. The purpose of this is

makes recommendations for the design, integration and

to avoid systematic faults during design and develop-

validation of safety-related E/E/PE systems for indus-

ment, installation and commissioning, operation,

trial machines. EN 62061:2005 has the same SILs as IEC

maintenance and modification of the safety-related

61508, except SIL 4 is as relevant to the risk reduction

equipment and systems. Systematic faults can occur

requirements normally associated with machinery. The

in either hardware or software designs. Measures and

main focus of EN 62061:2005 is the safety function

techniques to avoid and control them are specified by

from specification to validation. The standard requires

IEC 61508-2 and IEC 61508-3. To address the functional

a complete functional safety assessment in reference to

safety requirements in reference to the overall safety,

IEC 61508 for complex systems or subsystems.

E/E/PE system safety and software safety lifecycle

IEC61508-1 requires an effective management of
functional safety (MFS). The MFS
covers responsibilities, procedures
and activities with respect to the
overall safety, E/E/PE system safety
and software safety lifecycle.

Functional Safety in Europe

IEC 61508, or EN 61508, is not a harmonized European standard. That

It is also important to note that the applicationdependent standard EN 62061:2005 also specifies

The standard provides new

requirements for a products
overall safety lifecycle. This
takes into consideration
every phase of a product
from initial concept to final
decommissioning or disposal.

means it cannot be used exclusively

increased severity levels for EMC

testing. The standard makes references to general electrical safety
requirements for machinery, for
example, to EN 60204-1 for protection against electric shock.
The harmonized European standard EN ISO 13849-1:2008 (Safety of
machinerySafety-related parts
of control systems) combines the

as proof of CE conformity. To comply with the machin-

complex probability method from IEC 61508 and the

ery directives requirements, the harmonized stan-

deterministic category approach from EN 954-1 on the

dards EN 62061:2005 and EN ISO 13849-1:2008 are the

basis of the risk assessment. The safety classifications of

most relevant from the functional safety point of view.

EN ISO 13849-1:2008 are performance levels (PLs), where

The harmonized European standard EN 62061:2005

PL a is the lowest level and PL e the highest. The simpli-

(Safety of machineryFunctional safety of safety-

fied procedure under EN ISO 13849-1:2008 considers

the relevant parameters and architectures to provide a

IEC 61508:
THE BASIC STANDARD
FOR FUNCTIONAL SAFETY
Functional safety assessments of the components
or systems address the correct performance of the
assigned safety functions as required for the necessary
level of risk reduction. In 1999, the new standard
IEC 61508 (Functional safety of electrical/electronic/
programmable electronic safety-related systems) was
issued. IEC 61508 consists of the following parts:
Part 1: General requirements
Part 2: Requirements for E/E/PE safety-related systems
Part 3: Software requirements
Part 4: Definitions and abbreviations
Part 5: Examples of methods for the determination of
safety integrity levels
Part 6: Guidelines on the application of IEC 61508-2
and IEC 61508-3
Part 7: Overview of techniques and measures

practical assessment solution for machinery safety. The

simplified procedures could be used only for the designated architectures described in the standard.
The requirements of EN ISO 13849-1:2008 and EN
62061:2005 are to some extent identical and complementary. The scope or introduction to the standards
determines which of the two is most applicable.

Functional Safety Requirements in the U.S.

In the U.S., the mandatory requirements for certification and validation of safety systems designed for machinery safety are specified under the Code of Federal
Regulations (CFR), available from OSHA. The 29 CFR
1910, Subpart O, specifies the minimum requirements
for machinery and machine guardingfor example,
29 CFR 1910.217 for presence-sensing devices, or 29
CFR 1910.212 for machine guarding.
Requirements can be found in 29 CFR 1910.217 for
safe conditions in the event of any single failure. In

28

Control Design April 2010

CD1004_27_29_Featr2.indd 28

controldesign.com

3/22/10 2:37 PM

MACHINE C ONTROL

STANDARDS IN RELATIONSHIP
Overall, there are similarities to the EU and U.S. approaches with regard to the safety loop and the risk-based approach.
The following table shows the advantages and weaknesses of the standards.
Standard
IEC 61508

IEC 62061
EN 62061

Pros

Cons

Assessment of the complete safety lifecycle

Non-harmonized European standard

Covers hardware and software for simple and complex systems

Complex and sophisticated for safety of machinery, especially

for the machine builder

Partly simplified approach as under IEC 61508

(e.g., QM requirements)

References to IEC 61508 can lead to a difficult understanding

Covers configuration, parameterization

and embedded software aspects
Complex systems and components are covered up to SIL3
Harmonized European standard

ISO 13849
EN ISO 13849

Simpler approach as under IEC 61508 (e.g., QM

requirements, calculation of safety-related parameters)

Restrictions apply for complex electronics regarding the PL

Covers configuration and parameterization

and embedded software aspects

Not applicable for complex programmable systems

Continues with the EN 954-1 requirements

Results of the safety parameters are very conservative

Covers non-electrical, electromechanical

and complex electronics
Harmonized European standard

29 CFR 1910, Subpart O

Simpler approach as under IEC 61508

(e.g., QM requirements)

Probability approach is not covered

Regulates the requirements for all kinds of machinery

and the related equipment

Not suitable for complex electronics (e.g., safety-related PLC)

OSHA-recognized third-party validation required

Does not specify specific standards

addition, the term control reliability is specified and

Future Developments and Directions

drives requirements regarding the design, validation

Machine components and safety functions will become

and certification of safety-related systems. Of note is a

more complex and sophisticated. Intelligent and distrib-

requirement that an OSHA-recognized third-party vali-

uted control will manage functions such as an intelli-

dation organization shall be used to validate whether:

gent safety area around hazardous areas or objects. New

The design of components, subsystems, software

communication media such as wireless technology will

and assemblies meets OSHA performance require-

be in the safety loop to reduce wiring and provide more

ments and are ready for the intended use

mobility and flexibility. The use of safety communica-

The performance of combined subsystems meets

OSHAs operational requirements.

tion buses is de facto a standard today.

Functional safety requirements are mandatory for

Typical analysis methods like failure mode and ef-

machinery safety in Europe. Yet it also is wise to consid-

fect analysis (FMEA), as well as the general approach to

er these requirements for machinery in North America.

perform a risk evaluation and a hazard analysis, are ref-

It is likely that updates to related standards are going to

erenced. The probability approachfor example, under

cover new approaches and technological advancements

EN ISO 13849-1:2008 or EN 62061:2005is not considered

to address overall functional safety hazards.

or required under the OSHA requirements at this point

in time; however the deterministic approach regarding

MATTHIAS HAYNL has been manager of functional safety

the system architecture and behavior are similar to the

with TV Rheinlands Functional Safety Division since 2003. He

EN 954-1:1996 requirements. Application-dependent

has experience in the testing and assessment of safety-related

standards for the U.S. would be ANSI B11.19:2003 (Per-

systems of power plants, nuclear power plants, processing

formance criteria for Safeguarding) or NFPA 79:2007

machinery and industrial machinery. He can be reached at

(Electrical Standard for Industrial Machinery).

[email protected].

controldesign.com

CD1004_27_29_Featr2.indd 29

April 2010 Control Design

29

3/22/10 2:37 PM

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IP Opens New Doors for I/O

Machine-mount I/O has been widely accepted
in European markets for several years now, says

spite its upside, adoption has been relatively slow.

Aaron Henry, marketing manager, Murrelek-

However, recent changes in terminal nodes, wire

tronik (www.murrinc.com). Builders in the U.S.

schemes and IP protection have made machine-

are beginning to understand the benefits of dis-

mount I/O more attractive.

tributed I/O systems, he says. IP67 is an added

John Harmon, networking and connectivity

level of protection for most machine builders,

field-wired installations. Molded cordsets, cap-

ness of machine-mount I/O. Initial node costs

tured gaskets and less upfront preparation also

are about half of what they were just 10 years

allow machine builders to inventory fewer parts,

ago, he says. And today we have higher-

have less pre-assembly time and reduce the

performance I/O networks, more network cable

number of installation errors.

knowledge at the floor level.

Machine-mount I/O has the ability to concen-

IP67-rated and higher-rated control components

have made machine-mount I/O viable, explains
Tracy Lenz, senior product supportWago-I/O-

trate multiple sensor inputs or actuator outputs

System and advanced electronics (www.wago.

on one IP67 interface, says Stephen Arnold, senior

com). While IP67-grade designs make them

automation product marketing specialist, Sch-

physically robust, electromagnetic compatibility

neider Electric (www.us.schneider-electric.com).

(EMC) issues play a role in reliability, says Lenz.

These IP67 blocks connect to the control system

Machine-mounting options and layout are what

with common, open-architecture fieldbus net-

make or break IP67-grade I/O. Does the design

works such as CANopen, eliminating the expense

provide more than one mounting option?

and support issues surrounding proprietary

network solutions, he explains. These I/O blocks
also communicate on Ethernet networks such
as Modbus TCP/IP and EtherNet/IP. When these
networks are used on an I/O block, the application
benefits from the speed and bandwidth available
on the network but keeps the price of sensors and

Today we have higher-performance I/O

networks, more network cable options
and an overall acceptance and deeper
knowledge at the floor level.
In reality, machine-mount I/O can be many

actuators low since the network doesnt need to

different things, explains Karie Daudt, senior

be embedded in each I/O device.

product manager, Turck (www.turck.com). For

The IP67 protection rating is comparable

example, an IP20 I/O node in a small enclosure

to NEMA 6 and 6P, meaning the devices are

is technically machine-mount I/O, says Daudt.

resistant to harsh environments, moisture and

The difference is that the points themselves

dust, says Kurt Wadowick, I/O systems special-

still are physically landed on the I/O rather than

ist, Beckhoff Automation (www.beckhoff.com).

terminal blocks. In this solution, you still hard-

Today, line, tree or star topologies are possible

wire the points themselves.

with machine-mounted boxes.

The general concept is to locate the control

Decentralized I/O systems are commonly

available in the market but require a vast array of

component as near to the actuators and sen-

wires, says Susanne Walker, product manager

sors as possible, explains Bruce Centofanti, sales

advanced connectivity, Weidmller (www.weid-

manager, fieldbus I/O and control technology, B&R

muller.com). Cable-based solutions, especially

Industrial Automation (www.br-automation.com).

for bus communication, can be problematic or

This can reduce or shorten wiring runs to devices

even impossible in applications with moving sys-

and results in cleaner design and construction

tem parts such as drag chains or slip rings, she

cost savings, he says. Some manufacturers offer

explains. Flexing stress can cause cable breakage

an IP67 I/O that delivers faster update rates to the

and compromise the integrity of the equipment

master PAC, PLC or distributed control system.

and the entire manufacturing line.

controldesign.com 

CD1004_31_Techflash.indd 31

[email protected]

options and an overall acceptance and deeper

who struggle to reach IP65 with most current

believes the reduced costs drive the attractive-

Mike Bacidore

product manager, Balluff (www.balluff.com),

techflash

Machine-mount I/O replaces parallel wiring

by extending the network into the machine. De-

April 2010 Control Design

31

3/22/10 10:22 AM

[email protected]

PRODUCT ROUNDUP

Lets Get Mechanical

Components Are Still Easy-to-Install and Operator-Friendly
even as alternatives have

force outputs can meet most

choose your accuracy

been developed, mechanical

application requirements,

eLine ball rail and cam roller

components remain as much

ranging from a few ounces to

linear guide systems are avail-

a part of the motion profile as

several tons using force-multi-

able in sizes 15, 20, and 25 with

speed and accuracy.

plying air cylinders.

single-piece rail lengths to 4 m.

Advanced mechanical

Installation, operation and

motion control components

maintenance are more easily

working in unison with todays

accomplished with mechanical

electronic controls offer this

motion components, too, says

performance at a cost-effective

Bob Jeter, applications engi-

price point, which maximizes

neer, Amacoil (www.amacoil.

customer value, says David

com). Mechanical components

Hein, vice president of engi-

require little to no training and

neering, Nexen Group (www.

are easy to install and oper-

Users choose between accuracy

nexengroup.com).

ate, he explains. Electronics

classes N and E, with or without

can be complex and require ex-

preload. Family of eLine prod-

ager, Thomson (www.thomson-

pert technical support, while

ucts includes both styles of run-

linear.com), illustrates how the

setup for mechanical devices

ner blocks, end seals and front

technology remains the best

is generally intuitive and they

lube units on standardized rails.

choice in certain applications.

are easy to fix, thereby reduc-

Bosch Rexroth; 800/322-6724;

One example is electrome-

ing downtime.

www.boschrexroth-us.com

John Pieri, product line man-

chanical wrap spring and friction clutches and brakes, which

SERVO GEAR UNITS

are widely used as an alterna-

Low backlash planetary and

BALL SCREW ALTERNATIVE

tive to leading-edge servo tech-

helical-bevel servo gear units

PDP alternative to ball screws is

nology, says Pieri. Clutches

have input speeds to 6000 rpm

made of two ground WMH pin-

and brakes offer flexible or cus-

with 15 integer ratios from 3 to

ions connected through a pre-

tom mounting, simple installa-

100 and circumferential back-

tion, high accuracy, low power

lash as low as 1 arc/min. PSC,

draw and high torque per unit

PSF and BSF gear units span

size, all at an inexpensive cost

ranges of 253000 Nm of torque

compared to servo technology.

in 18 different models with

Servo technology is overkill for

most motion applications, in
that the complexity and cost
far exceed the requirement.

load system to reduce rack-and-

George Edwards, chief engi-

pinion mesh backlash. When

neer, Fabco-Air (www.fabco-air.

mounted at the output flange of

com), agrees that simplicity

SRP, a high-tech planetary gear-

and cost are major attributes

head, PDP offers four different

of mechanical motion. Most

input adapters to accept most

teeth, eight reduction ratios,

follow fairly simple paths, he

any servo motor or be mounted

angle-drive versions, two-output

explains. Pneumatic actuators

directly on SEWs dynamic

pinion diameters for each size,

can provide these motions for

synchronous DS, CM and CMP

and an input interface in-line

low initial cost and follow with

servo motors.

flange or with a 90 angle.

easy, low-cost maintenance

SEW Eurodrive; 888/sew-3876;

Andantex USA; 800/713 6170;

and service as well. Pneumatic

www.seweurodrive.com

www.andantex.com

32

CD1004_32_34_Roundup.indd 32

modules with straight or helical

machine element motions

Control Design April 2010 

controldesign.com

3/22/10 10:23 AM

LINEAR ACTUATORS

size; available stroke lengths

Eclipse spring-engaged, servo

MDrive linear actuators with

range 18 in.

motor brakes have a split hub,

integrated step motor and

AutomationDirect; 770/889-2858;

zero backlash clamp collar for

driver technology come in

www.automationdirect.com

attachment to the servo motor

three motor sizes and non-

shaft in a variety of input and

captive and external shaft

styles, with options including

CAGED TECHNOLOGY

programmable controller and

SBK ball screw has a recircula-

motion control technology.

tion structure where balls are

These products have an input

picked up in the tangential

direction and the lead-angle
direction by end caps. It has
Caged Technology with a synthetic resin cage and patented
curvature that cradles each ball

PRODUCT ROUNDUP

SERVO BRAKES

output flange/shaft combinations. Torque ranges 2125 Nm,

with low inertia, high tensional
rigidity with no system wind-

voltage range from +12 to +75

up, integral flanges that adapt

Vdc, nominal load limits of up

to any servo motor and mount-

to 200 lb and full (256 x 200) mi-

ing style and NEMA 23, 34 and

crostepping with an operating

42 frame sizes.

range of 40 to 85 C.

and separates it from the next

Nexen Group; 651/484-5900;

Intelligent Motion Systems;

one. SBK is available with screw

www.nexengroup.com

860/295-6102; www.imshome.com

shaft outer diameters ranging

1532 mm and nut diameters
ranging 3858 mm.

HAve Travel

air power

THK America; 847/310-1111;

Pro Series ballscrew-driven

Nitra pneumatic line of stain-

www.thk.com/us

linear stages in 68 standard

less steel, round body, non-re-

models have travels of 501500

pairable cylinders feature type

mm. The tabletop can be outfit-

304 stainless steel bodies with

WORM GEAR REDUCERS

ted with an optional brush

double rolled-in construction

Ultra Kleen right-angle, worm

with high-strength aluminum

gear reducers are available in

alloy porting ends. Single

quill and three-piece coupled

and double acting models are

available with nose, pivot and
double-end mounting options.
Some models are available with
magnetic pistons for position
assembly and models are avail-

indication. Bore sizes range

able with a 5 mm/rev, 20 mm/

/16 2 in.; depending on bore

rev, or 25 mm/rev ballscrew

input and with solid or hollow

with a matched brushless

output. Made of stainless steel

rotary servo motor to provide

for washdown protection, the

maximum travel speeds to 1400

units are available in ratios of 17,

mm/s with 6 m accuracy, 1

21, 23, 26 and 30 with center dis-

m bidirectional repeatability

tances 1.75-3 in., and a factory-

and up to 0.5 m resolution.

filled H1 food-grade lubricant.

Aerotech; 412/967-6854;

Baldor; 479/414-4711;

www.aerotech.com

www.baldor.com

controldesign.com 

CD1004_32_34_Roundup.indd 33

April 2010 Control Design

33

3/22/10 10:24 AM

PRODUCT ROUNDUP

BE DYNAMIC
Electric actuator EGC is de-

MORE, MORE, MORE

signed for high dynamic speeds

Find more mechanical motion components from companies

and high rigidity. This modular

actuator can be used as an

such as Amacoil, Portescap, Ross Controls and Wittenstein

at www.ControlDesign.com/roundupsarchive.

INDUSTRIAL-GRADE POSITIONER
HD-N industrial-grade positioner offers bending moment
of inertia for rigidity and
individual component adapted

minimal deflection, lubrication

to third-party motors or as a

for life and maintenance-free

complete system provided by

one source. The unit is available in toothed belt and ball

noise or vibration control has

screw designs, as well as differ-

a self-lubricating, polyacetal

ent screw pitches.

nut that is radially preloaded

Festo; 631/404-3173;

on a 303 stainless steel screw.

www.festo.com/us

The assembly offers torque

consistency and repeatabil-

bearings and ball screws. Posi-

ity when traversing in either

tioners can come with custom

ANTI-BACKLASH

direction through its unique

motor mounts.

ZBX Series anti-backlash

load transfer capability.

Parker Electromechanical

linear actuator assembly for

HaydonKerk; 800/243-2715;

Automation Div.; 800/245-6903;

vertical applications requiring

www.haydonkerk.com

www.parkermotion.com/hd

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CD1004_32_34_Roundup.indd 34

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Control Design April 2010

controldesign.com

3/22/10 11:44 AM

Can OTS OS Do Embedded Control?

controller with a mature homegrown operating

available I/O and peripherals, and ability to leverage

system (OS). Were looking to upgrade, and were

new technology such as multi-core processors and

wondering whats the best choice for an industrial

FPGAs. The startup time alone required to bring

strength OS. There are lots of options at various

up your own board and validate that the RTOS is

prices, and were a bit confused about the best

working correctly can be reduced drastically with

way to go. Were used to supporting our own OS,

an offering that supports commercial-off-the-shelf

so our level of technical expertise is pretty high.

(COTS) hardware, rather than custom-assembled

Does anyone have machine control experience

boards. These savings are on top of the reduced risk

with an off-the-shelf (OTS) OS for embedded con-

and additional time savings gained with vendor-

trol that theyd like to share?

tested, industry-vetted I/O drivers that allow the

from February 10 Control Design

ANSWERS

user to easily expand the systems hardware components and interfaces to the real world when projects
experience feature creep. Any system can be
expanded; however, some platforms require register

Tested and Reliable

The right off-the-shelf OS should be selected on

level development to get support for specific I/O.

[email protected]

Hardware and driver support affects time to

market, flexibility to scale to the right controller,

real answers

Our semiconductor processing machinery is controlled by our proprietary embedded

Kurt Williams, LabView product manager

technical details such as determinism, driver

National Instruments, www.ni.com

availability, hardware support, performance and

footprint, as well as the business impact of the

Real-Time Performance

system, cost, time to market and scalability. Several

We have embedded controllers running vxWorks,

real-time operating systems will do the job; the

Linux and Windows XP Embedded with various

difference will be in the details of the development

real-time extensions. These were selected to

tools and the ecosystem surrounding the platform.

provide a range of real-time performance at dif-

Initially, the control systems current requirements and possible future requirements

ferent price points, while all have mature, robust

development tools.

should be clearly defined and compared with

the potential RTOS platforms. Many soft RTOSs
are marketed for embedded designs, but fail to
provide hard real-time performance for critical
processes or machine control. The requirements
around the level of determinism required should
be well understood. Also, consider the level of
real-time safe communication mechanisms for
inter-process and intra-process communication
included with the platform, along with the availability of application-specific functions and algorithms necessary to complete the project. While
testing and validation is always necessary for a
reliable system, vendor or community-provided
code bases will save time, rather than spend it to

JuneS PROBLEM
WE USE A micro PLC to control our metal-cutting
machines with good results. When customers
see that we use a PLC, they want to specify
brand, causing us multiple headaches in design,
programming and after-sales support. Theres very
little variability in the operating parameters from
machine to machine, so were actually thinking of
switching to a preprogrammed relay that would
be set up and delivered by the vendor ready to go
with its own part number. If a machine needed
something a little different, we would order it
preprogrammed accordingly. Are we mortgaging
future versatility for fewer headaches right now?

design and implement new reusable functions for

communication, analysis and control. Because no
application is written perfectly the first time, the
platforms debugging tools for viewing threads
and tasks, identifying priority inversions and
resource contentions and tracking down errors

SEND US YOUR COMMENTS, SUGGESTIONS OR

SOLUTIONS FOR THIS PROBLEM. Well include it
in the June 10 issue and post it on ControlDesign.
com. Email us at [email protected]. Please
include your company, location and title.

should also be evaluated.

controldesign.com 

CD1004_35_37_RealAnswrs.indd 35

April 2010 Control Design

35

3/22/10 11:53 AM

real answers

Most machine controllers use COTS devices for

nents and integration tools. Our eVM embedded

vision, motion and process control, and other spe-

virtualization platform enables you to combine

cialized tasks. Suppliers provide an API and/or IDE

the old and new worlds, while saving costs and

and tools that typically run on Windows and spe-

improving reliability at the same time.

cific embedded operating systems. Identify the top

Kim Hartman, vice president, sales and marketing,

candidates for each requirement and determine

TenAsys, www.tenasys.com

which OS will provide integrated API and tools.

The IDE needs to support your preferred pro-

Interfaces and Safety

gramming language and should have debugging

Look beyond current requirements. Although

tools to reduce development time. We should be fo-

deterministic real-time response and low OS

cused on improving process, not building and sup-

overhead are important, so is how the RTOS ad-

porting development tools. Consider the third-party

dresses growing software complexity, demand for

APIs and whether you plan to run the HMI directly

better user interfaces and expectations for safety

on the machine controller or via an external panel.

and security certification.

Regarding maturity, reliability and portabil-

At some point, your design could need to mi-

ity, choose an OS that supports a broad range of

grate to a multicore processoreither its the only

processors and base hardware platforms. Make

viable choice or user demand for advanced fea-

a decision that considers future advances in CPU

tures increases software complexity, generating

technology and provides a clear roadmap to lever-

the need for greater processing capacity. Either

age current investment on future designs.

way, an RTOS with proven multicore support can

Josh Jensen, product manager,

Kollmorgen, www.kollmorgen.com

provide an invaluable migration path.

Multicore chips come in a variety of configurations, including a single general-purpose processor

Embedded Virtualization

with a DSP, multiple general-purpose processors

It is not always necessary to purchase a new OS.

and multiple DSP accelerators and stand-alone

A complex motion system can be constructed

dual- or quad-core general-purpose processors. If

by combining your existing software with new

your system requires pure computing capacity, you

devices and new application code.

probably need the third option, in which case the

The combination of these elements and the abil-

RTOS should support parallel processing through

ity to handle multiple operating environments at

symmetric multiprocessing (SMP). The RTOS

the same time is possible through virtualization,

vendor should also provide system-tracing tools

but not the type often used in office and server

that can analyze the highly complex system-level

environments that sometimes fails in time-critical

interactions that characterize multi-core designs

applications. Embedded virtualization technology

to focus on areas that yield the greatest gains in

maximizes the predictability of the response of

parallelism and performance.

the application code in order to support a multi-

The complexity of your software design probably

OS environment to hardware-generated signals. It

is growing. However, this complexity cannot be

does so by isolating hardware between virtual en-

passed along to your end users; the system must re-

vironments so as not to detract from the systems

main easy to use. This is particularly true now that

ability to respond quickly.

consumer devices like iPhones have dramatically

Your existing embedded OS runs in parallel with Windows on a standard PC-compatible

platform enabling faster migration from out-

raised user expectations about attractive, easy-touse human-machine interfaces (HMIs).

It is difficult to create appealing HMIs without

dated hardware to modern embedded platforms.

support from the RTOS. It should support hard-

In addition to preserving your legacy system, the

ware-accelerated 2D/3D-graphic APIs and high-

technology provides the deterministic response

level user interface design tools. Also, to create

necessary for time-critical events by partitioning

a sophisticated user interface, developers must

and allocating hardware devices ensuring that

often combine multiple graphics technologies

time-critical I/O resources arent virtualized.

such as Adobe Flash, native 2D/3D graphics ap-

The solution sounds complicated, but its sold

plications, HTML content and video on the same

out-of-the-box with all of the necessary compo-

display. Thus, the RTOS must provide facilities

36

CD1004_35_37_RealAnswrs.indd 36

Control Design April 2010 

controldesign.com

3/22/10 11:53 AM

ment, it can be important to keep your options

Look for standard interfaces to ensure portability.

open. An RTOS that can be upgraded to a certifi-

Many off-the-shelf RTOSs support time

partitioning, which allows developers to place
programs into virtual compartments and to al-

able version without API changes is a real benefit.

Kerry Johnson, senior product manager,
QNX Software Systems, www.qnx.com

locate a guaranteed amount of CPU time to each

compartment. Such guarantees simplify the job

Heres a Product

of integrating software subsystems from multiple

In the past, machine builders had to venture

development teams or vendors. They can also

outside their core competencies to design custom

contain runaway threads and denial-of-service

operating systems because PC operating systems

attacks, enabling higher availability, and allow a

were not designed to be real-time and not stable

developer to debug a live system without starving

enough for machine control.

critical processes of CPU time.

As systems grow more connected and complex,

Our Simatic WinAC RTX is a programmable logic

controller designed to run on open platform PC

so do concerns for safety and security. IEC 61508

systems. It offers the I/O logic control of a PLC with

defines a number of safety integrity levels, such as

integration to standard PC platform interfaces and

SIL 3, that define measures to prevent systematic

high-level languages.

failures (bugs) from being designed into a system.

Its real-time and deterministic capabilities are

Likewise, The Common Criteria for Information

met by operating in an extremely stable Ardence

Technology Security Evaluation defines a set of se-

RTX real-time OS extension. With its Open De-

curity requirements that can be applied to embed-

velopers Kit, migrating high-level programs and

ded devices. A certifiable RTOS can greatly reduce

intellectual designs is possible.

the effort required to achieve such certifications.

Even if certification isnt an immediate require-

real answers

to layer these multiple technologies seamlessly.

Eric Kaczor, product manager, discrete automation,

Siemens Industry, www.industry.siemens.com

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CD1004_40_41_Showcase.indd 40

Control Design April 2010 

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controldesign.com 

CD1004_40_41_Showcase.indd 41

April 2010 Control Design

866-879-9144 ext. 168

41

3/23/10 10:01 AM

Ned Lecky [email protected]

oem insight

Dont Fear Accuracy and Precision

Accuracy. Precision. GR&R. Two words

and the lines are sort of worn off here and there.

and an acronym that strike fear into the hearts

Maybe there is dirt or grit in the gauge. Our mea-

of many a manufacturing engineer or control

surement technician does his best, but it should

system designer. The terms and principles are ex-

be no surprise that if we measure the block over

tremely well-understood by most QA and process

and over again, the readings will vary consider-

control specialists, but what about the rest of us

ablyin this case, over a range of more than 0.1

mortals trying to wade through statistics without

in. Clearly, a much less precise gauge.

getting bogged down in too many details? To

Loss of precision can come from gauge inade-

start with, we have some object that we wish to

quacies or from operator training. Differentiating

measure. We could be measuring weight, length,

between the two is important and commonly is

color, shapethe type doesnt matter. The mea-

accomplished using analysis of variance gauge re-

surement device we needa scale or a ruler or a

peatability & reproducibility (ANOVA GR&R), often

colorimeteris called a gauge.

just called GR&R. A precise statistical technique

The accuracy of a measurement is the degree

(ANOVA) is used to analyze multiple measure-

to which it is close to the actual, true measure-

ments made by multiple operators using the same

ment. The true measurement is taken, if you will,

gauge. This not only determines the precision of

by some sort of perfect measurement system or a

the gauge, but it also analyzes how the precision

measurement system that is calibrated and tested

and accuracy vary from operator to operator. Each

to some extremely trustworthy degree. The ac-

gauge most likely has some tricks to its use and

curacy of our on-the-floor measurement would be

requires a certain amount of training, patience

the difference between that perfect measurement

and practice to use well. The GR&R study provides

and the one we get. If we have a block measured

a way to determine not only how good the gauge

 he GR&R provides a hugely

T
important data point for
interpreting measurements
coming from the factory floor.

is, but how consistent each operator is in using

the gauge and what each operators skill level is.
GR&Rs are quite easy to do, contrary to factory
myth. Just five or 10 measurements with three
operators or so is usually enough to give great
insight into the quality of the gauge and the

and certified to really be exactly 1 in. and our

consistency of operator training. A more detailed

in-process gauge reads 1.053 in., this one single

study with 20 measurements using, say, 10 opera-

measurement is accurate to within 0.053 in.

tors, is often as complicated as one needs to get to

That makes sense. Precision could be a little

differentiate between accuracy, repeatability and

harder to grasp. Precision is a measure of how

operator training. The GR&R provides a hugely

easy it is to repeat a measurement taken with a

important data point for interpreting measure-

gauge. In fact, repeatability is another name for

ments coming from the factory floor.

precision. What if I measure the block with the

In todays automated measurement world, are

same gauge three more times and get: 1.051, 1.052

GR&Rs obsolete? Absolutely not. In my industry,

and 1.054? Well, this is a relatively precise gauge.

machine vision, we always use GR&R studies to

Our measurements only vary over a range of

evaluate our calibration (accuracy), the quality

0.004 in., and I might be tempted to say that the

of our image acquisition and analysis algorithms

precision of the gauge is something like 0.002 in.

(which affect precision) and the ability to run the

In practice, we would use statistical methods to

same parts through different inspection stations

analyze all of these readings and use a statistical

and get the same measurements. Automated

tool such as standard deviation to determine that,

GR&Rs are quite easy to design and perform.

say, 90% of our readings would range over some

particular window.
What if my three measurements were: 1.041,

in control systems and machine vision. As owner of Lecky

1.101, 0.987. We see gauges like this in real fac-

Integration (www.lecky.com), he consults for OEMs,

tories all the time. Maybe its an old micrometer

system integrators and machine vision providers.

42

CD1004_42_Insight.indd 42

Ned Lecky is an ME and EE with 25 years of experience

Control Design April 2010 

controldesign.com

3/22/10 10:32 AM

Even with all of my experience in

the industry, AutomationXchange
provided opportunities for me to find
solutions to advance my machines
that I was not aware of before.
Dr. Thomas Pool
Manager of Electrical Engineering
KLIKLOK-WOODMAN

SM

SOLUTION PROVIDER PROFILE

Among the industry-leading solution providers featured
at AutomationXchange 2010 is Siemens Industry, which
helps customers in the global industrial manufacturing and machine building sectors succeed by providing
complete electrical, engineering and automation solutions. With a product and services portfolio that spans the
entire automation space from PLCs to motion controllers
and drives to safety, Siemens Industry provides totally
integrated software, hardware and services solutions for
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AUGUST 8-11, 2010 PARK CITY, UTAH

For more information on attending AutomationXchange,
contact Andy Wuebben, Executive Director, at 952.224.7640

CT-CD_AUTO_AD2.indd
5
CD1004_FPA.indd
43

3/23/109:48
9:43
3/23/10
AMAM

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