Control design 10 11 2023

GENERATIVE AI ELECTRIC MOTORS WHY ETHERNET? Where I fit in? Not all robots are the same, so how you integrate them with factory machinery? 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MOVIKIT on the web www.seweurodrive.com | TS11-04USA | What matters most: Your people What protects best: TwinSAFE PC-based control TwinSAFE One control platform for all machine functions System-integrated with logic in all safety components In machine safety, going for “good enough” is never the right choice Ensuring the safety of your people, equipment and products is simply not optional TwinSAFE from Beckhoff is the universal safety solution for everything from basic monitoring to complex motion in a fully integrated automation ecosystem Directly meshing with your PLC, motion control, measurement, IoT and vision technologies, TwinSAFE helps you implement more safety functionality in more places This comprehensive platform streamlines machine design with programmable safety functionality to safeguard what you value most Integrated in all TwinSAFE components: the Safety Logic Scan to learn how to safeguard your application with TwinSAFE Volume 27, No table of contents 20 cover story Where I fit in? Not all robots are the same, so how you integrate them with factory machinery? Mike Bacidore, editor-in-chief 31 product roundup Safety by the numbers Numerous devices make machines and systems safer Control Design is published times by Endeavor Business Media, LLC 1233 Janesville Ave., Fort Atkinson, WI 53538 POSTMASTER: Send address changes to Control Design, PO Box 3257, Northbrook, IL 60065-3257 SUBSCRIPTIONS: Publisher reserves the right to reject non-qualified subscriptions Subscription prices: U.S ($120 per year); Canada/Mexico ($ 250 per year); All other countries ($ 250 per year) All subscriptions payable in U.S funds Printed in the USA Copyright 2023 Endeavor Business Media, LLC All rights reserved No part of this publication can be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopies, recordings, or any information storage or retrieval system without permission from the publisher Endeavor Business Media, LLC does not assume and hereby disclaims any liability to any person or company for any loss or damage caused by errors or omissions in the material herein, regardless of whether such errors result from negligence, accident, or any other cause whatsoever The views and opinions in the articles herein are not to be taken as official expressions of the publishers, unless so stated The publishers not warrant either expressly or by implication, the factual accuracy of the articles herein, nor they so warrant any views or opinions by the authors of said articles ControlDesign.com / October/November 2023 / TOP BRANDS QUALITY PRODUCTS EASY ONLINE ORDERING MISUMI offers electrical components from trusted brands, with local inventory and fast delivery Pushbutton Switches Stack Lights Molded Case Circuit Breakers Circle Connectors Enclosures Learn More at: MISUMI.INFO/ELECTRICAL Volume 27, No table of contents Easy and secure Remote Access to your machines COLUMNS editor’s page 16 component considerations AI will change manufacturing Enhancing controlsystem security Mike Bacidore, editor in chief Shawn Cox, contributing editor 11 embedded intelligence 33 real answers From barcodes to RFID and beyond Exploring operatorinterface options Jeremy Pollard, CET 12 technology trends Innovations in electric-motor technology 42 automation basics Why Ethernet is the backbone of protocols Joey Stubbs, contributing editor Rick Rice, contributing editor ad index AutomationDirect Beckhoff Automation .4 Contemporary Controls 29 Misumi Mitsubishi Electric Automation 18, 19 Murr Elektronik 27 Digi-Key Electronics .10, 44 Novotechnik 26 Cosy+ syy+ Pepperl+Fuchs 23 New generation of industrial Remote Access Gateway SEW-Eurodrive .3 • Firewall friendly solution SMC Corporation of America .17 • Proven solution with 45+ Million VPN connections Dinkle Corporation 25 Endress+Hauser HMS Industrial Networks Icotek 30 • Free VPN service KEB America 15 VEGA Americas 13 www.ewon.biz ControlDesign.com / October/November 2023 / Process improvement is like climbing With a strong partner, you can overcome any obstacle Just as athletes rely on their teammates, we know that partnering with our customers brings the same level of support and dependability in the area of manufacturing productivity Together, we can overcome challenges and achieve a shared goal, optimizing processes with regards to economic efficiency, safety, and environmental protection Let’s improve together Do you want to learn more? www.us.endress.com editor’s page Endeavor Business Media, LLC 30 Burton Hills Blvd, Ste 185, Nashville, TN 37215 800-547-7377 ceo Chris Ferrell president Mike Bacidore editor in chief mbacidore@endeavorb2b.com June Griffin cfo Mark Zadell coo Patrick Rains cro Reggie Lawrence chief administrative and legal officer Tracy Kane AI will change manufacturing chief Digital Officer Jacquie Niemiec evp / group publisher ARTIFICIAL INTELLIGENCE (AI) WILL have numerous applications in the manufacturing Mike Christian sector—from digital twins and quality control to production efficiency and predictive vp / group publisher Keith Larson analytics The future will surely have AI’s fingerprints all over it Generative AI, which uses algorithms to generate content, such as text, images, video, code or 3D designs, has editorial team specific applications in industrial manufacturing, such as writing programs and creating editor in chief efficient designs The development of these generative applications are primarily coming Mike Bacidore mbacidore@endeavorb2b.com managing editor Anna Townshend atownshend@endeavorb2b.com digital editor Madison Ratcliff from upstream of the factory or plant Original equipment manufacturers (OEMs), such as machine builders and system integrators, are curious about AI, but the use cases are coming from the automation suppliers A supplier can provide automation that replaces technically skilled workers or elimi- mratcliff@endeavorb2b.com nates the need to create that same technology on your own ChatGPT, a well-known contributing editor generative pre-trained transformer Rick Rice rcrice.us@gmail.com (GPT), costs $700,000 a day to run, contributing editor according to SemiAnalysis These Joey Stubbs contributing editor two factors could lead to an AI-as- Shawn Cox a-service business model, joining brianshawncox@gmail.com editorial assistant software-as-a-service, robotics-as-a- Lori Goldberg service and production-as-a-service lgoldberg@endeavorb2b.com columnist Jeremy Pollard jpollard@tsuonline.com design/production production manager Anetta Gauthier ChatGPT, a well-known generative pre-trained transformer (GPT), costs $700,000 a day to run Emerson, for example, has released an AI-based software called Revamp, which runs in the cloud, that converts DeltaV control-system and safety-system code in plant modernization projects The Advanced Robotics for Manufacturing (ARM) Institute is one of the manufacturing agauthier@endeavorb2b.com institutes linked together within Manufacturing USA It recently announced eight projects ad services manager for second-round funding with plans to award nearly $1.5 million, bringing the total con- Rita Fitzgerald rfitzgerald@endeavorb2b.com art director Derek Chamberlain subscriptions Local: 847-559-7598 • Toll free: 877-382-9187 email: ControlDesign@omeda.com circulation requests / classifieds Lori Goldberg lgoldberg@endeavorb2b.com tribution to around $3.3 million across these eight projects A project team representing Ohio State University, CapSen Robotics, Yaskawa and Robins Air Force Base designed and deployed an AI robotic system capable of producing component geometries for metal-forming in automotive manufacturing, factory machinery, power plants and military equipment USC and Siemens have collaborated on a project based on AI imitation and reinforcement learning to scoop precise amounts of granular and paste-like materials more safely, replacing humans with robots Beckhoff’s TwinCAT Chat Client for its TwinCAT XAE engineering environment makes it possible to use large language models (LLMs), such as ChatGPT from OpenAI, to develop a sales team TwinCAT project in control programming The TwinCAT Chat Client enables AI-supported Account Manager engineering to automate tasks such as the creation or addition of function-block code, and Greg Zamin gzamin@endeavorb2b.com 704/256-5433 Fax: 704/256-5434 even code optimization, documentation and restructuring Account Manager Jeff Mylin jmylin@endeavorb2b.com 847/516-5879 Fax: 630/625-1124 Account Manager Kurt Belisle kbelisle@endeavorb2b.com 815/549-1034 ControlDesign.com / October/November 2023 / cover story Software development greatly improves connectivity of ro- when they are small and more easily solvable,” he explains bots to the processes they serve and also enhances those pro- “These tools can also be used for advanced planning to ac- cesses, notes Schunk’s Royster “For example, a robot tending a count for future changes to automation.” milling machine has to interface with the machine and all the The digital twin really impacts the entire lifecycle of the peripheral components such as end-of-arm tooling, workpiece production cell, adds Rapid’s Aparicio “At the beginning of conveying systems or safety equipment,” he says “Software is the automation journey with customers, digital-twin plat- greatly simplifying these device connections and shortening forms help produce concept designs faster and with the right the time for successful deployments and redeployments Ap- level of fidelity, so reachability and cycle time studies can plication software aids the users with short cuts for organizing be quickly generated to ensure the solution meets customer common robot path routines.” expectations,” he explains “When programming robots and automation components, digital-twin technology allows you to Digital twins simulate the task you want to automate, rather than having to One of the worst things that can happen when investing build a robot and physically program it in the real world, taking in new automation is to purchase and build the equipment significant time and human labor.” only to discover you cannot perform the necessary task due In the support phase, vendors can have the digital twin in to physical interferences or cycle times being unmet, adds the lab to monitor the robots remotely, making it easier to ad- Schunk’s Royster “Digital-twin and other simulation tools are dress a bug or error in the field by reviewing playbacks of that an excellent way to work through challenges ahead of time, simulation, explains Aparicio “Digital-twin models are only just beginning to make their mark in manufacturing automation, but the opportunity is massive,” he says “Real-life data for training robots can be very expensive to The Cable Entry 360° With the new distribution box, centrally routed cables can be distributed 360° in all desired directions Interested? Get your free sample now: obtain,” notes Fraunhofer’s Kraus “Therefore, we often work with simulations, for example, for skill training in the field of assembly We also develop technologies for bin picking, where the robot can pick up and sort different objects from a box (Figure 9) A real-life training would be very time-consuming, which is why we use a physics simulation to prepare the robot.” Digital-twin technologies are accelerating success for a IP54 number of Beckhoff customers “Robotics is no exception,” says Prellwitz “As we prepare for the full ATRO product launch, we are continuing to add functionality, including in this area Already the TwinCAT robotics functions generate a digital twin automatically after scanning the adapted structure and creating the control application.” During programming, you can also pull in the CAD file of the machine or fixture where the ATRO unit will be installed and simulate motion profiles, explains Prellwitz “You can then build an orbit around sensitive equipment, such as expensive sensors or other robots, to ensure the system will not enter that area or cause any damage,” he says “We also have incorporated the same web-based live-view technology that’s built into our XTS and XPlanar technologies So you can connect to the ATRO system to analyze what the robot is doing, how well its performing and what the EtherCAT diagnostics show to assess potential optimizations.” icotek@MiA23 product roundup Safety by the numbers Numerous devices make machines and systems safer SC10 series safety controller/relay hybrid Banner Engineering’s SC10 series safety control- Banner SLC4 series Banner Engineering’s SLC4 Series are Type ler is designed to replace the functionality of safety light curtains specifically designed to safe- two or more safety relay modules and features guard smaller points of operation and access on an intuitive user interface and advanced diag- compact machines They measure just 160 mm in nostic capabilities The SC10 series safety con- length and have a low-profile design that fits eas- troller is designed to work for crowded machine ily in small spaces SLC4 safety light curtains have control cabinets and smaller machines an end-to-end sensing design that eliminates DigiKey / www.digikey.com detection blind zones and maximizes the sensing capabilities of these compact safety systems They are available in models with 14 mm or 24 mm resolution to detect objects as small as a AutomationDirect Comepi safety switches finger or a hand attempting to access the doorway AutomationDirect has expanded its safety products line with RS / us.rs-online.com additional Comepi safety switches This offering includes solenoid locking tongue interlock safety switches and RFID- Wago electronic circuit breakers coded solenoid locking tongue Wago’s electronic circuit breakers are designed to focus on interlock safety switches All safety with reliable protection against overload and short switches have a 1,200 N hold- circuits They also enable activation of high-capacity loads ing force and require the sole- without the need to increase the nominal current setting All noid to be energized to unlock models have 0.5 to 12 A current ratings that offer the flexibility the switch The RFID-coded needed for setting the nominal models are uniquely coded for additional tamper resistance The current to suit individual applica- new Comepi safety switches come with a one-year warranty tions With a maximum width of AutomationDirect / www.automationdirect.com/ 45 mm (1.772 inches), these ECBs are designed to channel density Wago / www.wago.com Industrial framing for robotics and machine safety Industrial framing and support systems are essential to the structural integrity, efficiency and effective operation Pepperl+Fuchs USi-safety ultrasonic sensors of automated robotics and machines They also provide The USi-safety ultrasonic sensor system from Pepperl+Fuchs a safe and secure environment for employees working is designed so that machines and vehicles can be reliably pro- with or nearby various automated machine tected using state-of-the-art ultrasonic technology and all of systems Durable aluminum the advantages this brings A miniature sensor unit detached machine bases and frames are from the control interface allows the USi-safety to be used ideal for light-, medium- and heavy-duty machine applica- even in confined installation situations The design of the converter allows the sensor to tions Custom framing can be cover an elliptical, three-dimensional created using anodized and sound field with opening angles of ± 17° powder-coated finishes and is available in various colors Motion Ai / ai.motion.com and ± 5°, providing an improved level of safety Pepperl+Fuchs / www.pepperl-fuchs.com ControlDesign.com / October/November 2023 / 31 product roundup IDEC HT4P Safety Commander Siemens Simatic ET200 Series The HT4P Safety Commander is an ergonomic device designed A wide variety of I/O systems are to enable users to securely hold and protect a human-machine available for standard and fail-safe interface (HMI) tablet The HT4P can hold tablets ranging from automation Siemens Failsafe I/O series 10 inches all the way up to a 13 inches using adjustable grippers is designed to include uniform safety It can use an onboard wired LAN combined with a USB-PD connection, with a USB/ functionality for all Simatic devices, one system for standard and safety automation, compact RS-232C/RS-422 converter option also design to reduce space required, seamless system that is easy available External shielded cables to use, external safety solutions are not required and uniform with connectors are available for the operating capability of the TIA Portal enables intuitive safety HT4P in lengths of m, 10 m, 15 m and 20 m The HT4P has three onboard function engineering Siemens FA / www.siemens.com mounting positions, and a guard is available to protect against inadvertent operation of the e-stop button Rockwell Automation GuardLink 2.0 with EtherNet/IP GuardLink 2.0 is designed to offer advanced diagnostics by way IDEC / lp.idec.com of the Allen-Bradley 432ES GuardLink EtherNet/IP On-Machine Interface or a combination of the Dual GuardLink Relay and Pilz PNOZsigma safety relays EtherNet/IP Interface GuardLink 2.0 protocol also enables safety- The PNOZsigma series of safety relays from Pilz offers two- rated control device status reporting and automatic diagnostic hand, e-stop, safety gates, light barrier, time, safe speed, safe reporting to an HMI using CIP Safety over EtherNet/IP The 432ES brake control and safe voltage monitoring Units are equipped GuardLink EtherNet/IP interface is designed to connect up to with normally open safety contacts, auxiliary contacts and LED 96 safety devices via three independent safety channels The indicators for supply voltage, two-channel input interface can cascade power to additional interfaces and can status, switch status, safety contacts and keep track of timing and frequency of events to improve feedback and reset circuits Safety relays maintenance and create process efficiencies The may be used with e-stop pushbuttons, 432ES supports linear, star and Device Level safety gates and light beam devices Ring topologies while meeting the highest Designed to take up less space, they safety ratings up to SIL 3, Cat PLe range in size from 12.5 mm to 22.5 mm Rockwell Automation / www.rockwellautomation.com Galco / www.galco.com Mitsubishi MELServo-J5 EtherCAT-compatible amplifiers KEB Safety PLC Mitsubishi Electric Automation’s MELServo-J5 EtherCAT com- KEB’s Safety PLC is a Fail Safe over EtherCAT (FSoE) master patible Servo amplifiers are designed to easily integrate safety that is designed to be used in tandem with the machine PLC devices into a single network FSoE is a TÜV-certified technology to execute and monitor the safety functions of the machinery developed according to IEC 61508, standardized internationally The Safety PLC connects with other FSoE slave modules like in IEC 61784-3 and can be implemented with an approved Ether- Safe I/O and Servo Drives with CAT Master module In the event a machine breaks down or mal- Safe Motion functionality Each functions, Fail Safe is designed to revert the FSoE slave device has four safe servo to safe working conditions inputs, two safe outputs and by utilizing safety subfunctions four OSSD outputs One FSoE (STO/SS1/SS2/SOS/SBC/SLS/ master can control up to SSM/SDI/SLI/SLT) 65,535 slave devices KEB America / www.kebamerica.com 32 / October/November 2023 / ControlDesign.com Mitsubishi Electric Automation / us.mitsubishielectric.com real answers Exploring operator-interface options A CONTROL DESIGN reader writes: I’ve worked in industrial machine building since before the introduction of the Internet, when machine operator controls were a switch or a pushbutton Now, our human-machine interfaces (HMIs) control whole systems, visualize how we interact with the machines and collect data for further analysis Our company has adopted rapidly to new HMI technology, as long as it remains cabinet-mounted We’ve yet to try any new options for operator interfaces, such as wireless devices, cable-connect HMI pads or HMIs on a swivel arm We still have remote access via our cabinet-mounted HMIs, but what might some of these newer options offer that we’re missing out on? What other options are available? How we weigh them against traditional HMI? Answers Installation flexibility moves HMIs outside of the cabinet There are all sorts of variants of cabinet- or Figure 2: For hazardous areas, an HMI workstation may be easier to install than a control cabinet panel-mounted HMIs, from lower-powered operator interface panels to high-power panel PCs running Windows operating systems But in general the core functionality of a cabinet-mounted HMI and an HMI with an alternative mounting op- Often control cabinets have limited wall or enclosure door space to mount an HMI, but if the HMI is a free-standing, separately mounted unit, this display size restriction may very well be tion or no mounting at all is likely very limited This means larger displays with more screen similar So, if operation and function- area and more space for graphics and other software ality are comparable, then the key benefit of a non-cabinet-mounted solution or an HMI workstation is, in my view, the installation flexibility By installation flexibility, we mean that you are no elements are possible for operators Additionally, space may be limited in the area where the HMI is to be located A stand-alone HMI unit may take up much less space than a cabinet with a comparably sized longer limited by the size or location of the control panel-mount HMI In the case of an HMI workstation, as men- cabinet You can now mount an HMI in areas where it is tioned earlier, you can connect it to an articulating or swivel not feasible or practical to install a control cabinet with a arm to position it out of the way when not in use In addition panel-mounted HMI (Figure 1) to the ergonomic benefits of being able to move it around for operators of different sizes Alternatively, a complete HMI workstation can often be added Figure 1: A complete HMI workstation can often be added to some sort of mobile cart or trolley, which can be wheeled in and out of the process area as needed to some sort of mobile cart or trolley, which can be wheeled in and out of the process area as needed—this is particularly popular in life-science and pharmaceutical applications (Figure 2) ControlDesign.com / October/November 2023 / 33 real answers eas classified as hazardous, an HMI work- mobile HMI option In addition, there are station may be easier to implement than tablets on the market that are also suitable Adjustable, wireless or VR options improve HMI flexibility and mobility a control cabinet Depending on the area for operation in classified hazardous areas, There are currently more options for classification, everything in the control allowing them to be used throughout the HMIs that could take a company further cabinet—power supplies, HMI, additional plant Certainly, there are some potential in terms of usability and flexibility components—must either be appropri- hurdles to overcome in terms of charging, Here are some of the newer HMI op- ately rated for the hazardous area or have security, long-term evolution (LTE) or Wi-Fi tions and how they differ from, or can an additional type of protection, such networks, but a well-thought-out design be used to complement, traditional as a purge and pressurization system, and implementation can offer a lot of ben- cabinet-mounted HMIs In each case, to keep the cabinet safe (Figure 3) Many efits to operators and engineers the optimal solution also depends on For installations that may include ar- HMI workstations are already certified for mobile devices and can provide a fully In summary, each installation is a little the intended use, safety concerns and use in hazardous areas and are equipped different and has its own set of require- with all the necessary safety elements, ments and restrictions, but limiting the reducing the design and installation ef- installation to only one type of physical • HMIs on a swivel arm fort for the plant—a ready-to-go option HMI style can also limit the productivity This option allows the HMI to be of the plant There are certainly many mounted on an adjustable swivel arm installation flexibility option a step further benefits to panel mount HMI options, but or console that can be easily moved into and implement a fully wireless option with there are just as many benefits to differ- different positions This allows operators tablets and smartphones (Figure 4) Many ent mounting options to adjust the screen to a preferred work- There is also the possibility to take this control systems have apps and software that are compatible with Android or Apple AARON SEVERA product manager, HMI and fieldbus / Pepperl+Fuchs any environmental factors ing position, for example This solution is rather simple from a technical point Figure 3: A fully wireless HMI option with tablets and smartphones use apps and software that are compatible with Android or Apple mobile devices Figure 4: HMIs on swivel arm can be easily moved into different positions, allowing operators to adjust the screen to a preferred working position (Source: EAO) 34 / October/November 2023 / ControlDesign.com real answers of view, but it already offers added value to the user and significantly improves ergonomics (Figure 5) • Wireless operating devices/handhelds Portable HMIs without cables establish a wireless connection to the machines These offer more mobility than cabinetmounted HMIs because they are not tied to the control cabinet This allows operators to move freely around the work area while controlling and monitoring the machines This provides more flexibility and can increase operator productivity (Figure 6) Depending on functional safety or regulations, portable HMIs could also be Figure 5: Handheld HMIs connect wireless to machines and offer more operator mobility (Source: EAO) cabled to the machine and still provide good user mobility • Tablet or smartphone-based HMIs The use of tablets or smartphones as HMIs are similar to wireless handhelds but offer more intuitive operation, as many users are already familiar with this technology in a private environment This can, for example, reduce training time for new operators and greatly improve adoption In addition, it is possible to use an existing, physical and proven high-tech module and only develop the necessary software or interface for the required application • Augmented reality (AR) and virtual reality (VR) based HMIs These most advanced HMIs allow operators to interact with machines and processes through AR or VR glasses This can improve operational efficiency by providing operators with additional real-time information or visualizing complex tasks When weighing these options against traditional cabinet-mounted HMIs, you Figure 6: Mobile devices running HMI apps can connect wirelessly to traditional or embedded “headless” HMIs, providing great flexibility for creating operator-interface experiences for any type of application should consider the following aspects: ControlDesign.com / October/November 2023 / 35 real answers • Usability—In my opinion, user-friendli- then to carefully train them to achieve maintaining the reliability and accessibil- ness should be a top priority, as intui- the intended potential of the new or ity of a cabinet-mounted HMI tive operation can increase motivation deployed HMI and efficiency My recommendation here: Test different options in rela- Regardless of how HMIs are accessed, DOMINIQUE BURKARD industrial & UX design manager / EAO AG tion to the intended use with users to they typically contain graphical pushbuttons, indicators, setpoints, alarms and many more objects that allow users to easily monitor and control a complex system can often be worked out at a conceptual Flexible connectivity for operator controls enhances data visualization stage of the project using, for example, HMI technology has evolved at a rapid sively hardwired controls and indicators the design-thinking method pace, taking us far from the humble However, the most advanced capabilities beginnings of exclusively hardwired of HMIs go far beyond appearances In fact, selected are robust and reliable to controls and indicators With any rapid some of the biggest advancements in HMIs ensure smooth operation, especially technological advancement like this, it is have nothing to with the display and in an industrial environment Also, only natural to experience some possible everything to with connectivity and depending on the selected solution, hesitation from users when it comes to processing See below for a small selection operation with or without gloves is not adopting the latest features To address of specific advanced features that add a an unimportant aspect when it comes this and explore the utility of these great deal of utility to an HMI: to reliability and efficiency newer features, it is important to start determine their preferences and suitability for the work environment This • R eliability—Ensure that the options • Security—When using wireless or Internet-enabled devices, it is impor- with a quick review of what users typically expect from an HMI in a straightforward way This alone is a huge advancement from the days of exclu- • Protocol conversion—In an industrial environment, it is common to see dis- tant to consider the security aspects to The most common image that comes parate communication protocols in use minimize unauthorized access and po- to mind when talking about a typical HMI from multiple devices that are not able tential security risks In addition, items is likely a cabinet-mounted touchscreen to communicate with each other direct- such as functional safety and applicable display Cabinet-mounted HMIs are here ly—think of Modbus and distributed- regulations must also be considered to stay, as it is critical in many applica- network protocol (DNP3), for example • Cost—New HMI capabilities, especially tions for operators to have immediate lo- Some advanced HMIs have the ability to AR and VR for example, can come at a cal access to machine controls However, act as fully featured protocol convert- higher cost It is important to weigh the local-only control is a clear limitation ers and data concentrators, facilitating potential benefits against the invest- and users often want more flexibility communication between previously ment costs and decide whether the when it comes to data visualization introduction will pay off in the long Fortunately, some cabinet-mounted isolated devices •M  ultiple programming languages—Some term Here, it is important to clearly HMIs also allow users to remotely connect HMIs have the ability to execute the determine from the user’s perspective and interact with them from a tablet, International Electrotechnical Commis- whether the potential solutions are PC or even cellphone through a simple sion (IEC) programming, which includes need to have or nice to have web interface—easily accessible via web ladder logic, function block diagram, browser while on the same network as the structured text and instruction list, HMI From the web interface, the experi- directly on the unit itself In some cases, can offer additional benefits in terms ence is the same as if the user were stand- this can entirely eliminate the need for of flexibility, mobility and ease of use ing in front of the physical HMI in terms a programmable logic controller (PLC) in From my experience, it is beneficial to of both monitoring and control With the an industrial system Additionally, some start with a trial phase and test the use of a virtual private network (VPN) HMIs are able to execute higher-level options to find out which ones best fit tunnel, this can be accomplished from the requirements From my experi- anywhere in the world This type of flex- ence, it is very important to involve the ible connectivity opens up nearly limitless HMIs that have slots on them where I/O users already in the concept phase and possibilities for data visualization while modules can be connected This allows Overall, more modern HMI solutions 36 / October/November 2023 / ControlDesign.com programming languages such as C • I /O expansion modules—There are also real answers users to monitor physical inputs and and ready to configure Implementation portable-document-format (PDF) file control physical outputs directly from can be painless, or much closer to it, readers, Word or Excel displays and video the HMI, which can eliminate the need when new features are additive, optional playback, allow machine training and for dedicated remote I/O in some cases and user-friendly troubleshooting instruction to be incor- • Cloud connectors—When thinking of making HMI data accessible, consider JOE WAGNER field application engineer / Red Lion that some HMIs have built-in cloud porated right on the HMI itself Voice control, which may not be suitable for all industrial environments, HMI advances follow commercial display market allows operators to interact with the ficiently publish and subscribe to large amounts of data using a cloud broker As with any technological product, new feature can be particularly useful in and the power of message queuing features are regularly being incorporated situations where operators have limited telemetry transport (MQTT) This is into industrial HMI devices Either to take manual dexterity or need to keep their an easy and cost-effective way to add advantage of new technological capabili- hands free for other tasks Industrial-Internet-of-Things (IIoT) ties or to add features that improve the connectivity to any system and be pre- user experience, efficiency in operation area that is moving into the realm of pared for the future and screen design or both industrial HMIs The idea is to create in- connectors, allowing them to very ef- machine with voice commands This Advanced data visualization is one • Data logging—One of the more common Many of the newer features in HMI tuitive interactive screens for the opera- features to find in an HMI is local data devices take advantage of developments tor Advanced charting such as treemap, logging This allows users to record in the commercial space Things like circle packing and radar charts along data in a highly customizable way, widescreen-display HMIs take advantage with colors and sizing are used to assist and support for secure-digital (SD)/ of the development in the commercial in faster decision-making microSD cards allows them to locally display or television market Multi-touch store several gigabytes worth of data and gesture control are features found in manufacturers Most HMIs have user-log- For retrieval of these data logs, more mobile devices and are now migrating to in capability and password-screen access advanced models can act as a file- industrial HMIs based on roles Newer recommendations transfer-protocol (FTP) server, make Some specific features don’t only Security is top of mind for many from the Cybersecurity and Infrastruc- the data available from a web interface include the HMI, but other parts of the ture Security Agency (CISA) are being or sync the data to a structured-query- control solution An integrated develop- incorporated into HMI designs to prevent language (SQL) database ment environment (IDE), for example, al- malware intrusions and manage risk lows the development of the HMI screens There is no doubt that HMIs will con- Let’s not forget artificial intelligence along with the rest of the control system (AI) Along with the introduction of AI tinue to advance, and new features are This drastically increases productivity into machine control systems, AI has a always just around the corner The key to for the design engineers and reduces or place in the HMI Coupled with advanced successful user adoption lies in main- eliminates the need to jump between data visualization, AI has the potential to taining essential legacy features, like HMI and control development environ- make decisions for the operator and dis- the accessibility of a cabinet-mounted ments entering the same information play the decision or narrow down choices HMI, while adding new features that The ability to develop intuitive screens for an operator, driving the intuitive goal provide clear value without disruption for the machine operator is a must Some For instance, using an HMI web interface of the best HMI products available have for tablet viewing and control should the ability to host animations where already, but weighing whether to invest typically complement a cabinet-mounted an active visual representation of the in advanced HMI features usually rests HMI rather than entirely replace it machine or parts of the machine can be on the type and purpose of the machine displayed to the operator being designed Factors such as func- Similarly, other advanced features such as protocol conversion and cloud Contextualized help and documen- of machine operation Most HMI users probably think of this tion, price and degree of manufacturing connectors are much easier to adopt tation features, the ability of the HMI integration will all play into the decision when they are already built into the HMI to host other common tools, such as to use the advanced features ControlDesign.com / October/November 2023 / 37 real answers hardened option, including touchscreens particular, wireless TSN capabilities can in any application, one of the first things The HMI is front and center when used protected by an industrial-grade hous- help HMI was one of the initial use cases visible on a machine It may make sense, if ing, illuminated e-stop and pushbutton brought up by members to Avnu Alliance a high-value machining center or integrat- keys, SD card slot and USB interface, that that motivated the development of the ed multi-line process is being designed, the works with protocols such as Profinet, Wireless TSN testing program high-end featured HMI is the best choice EtherNet IP, message passing interface for premium user feature and function that (MPI) and others These are just a few and mobility for HMI devices, reducing imparts high value to the machine examples There are many more options installation costs The TSN features can available to you ensure the time-critical data is prioritized CLARK KROMENAKER product manager—HMI, IPC, controllers, software / Omron ERIC HALVORSON partnership marketing manager II – strategic programs / Incorporating operational safety and security DigiKey Wireless capabilities enable flexibility and delivered with determinism on a shared network with other applications By adopting standards-based connectivity silicon and protocols with TSN support, And, as you stated, there are a great Deterministic and low-latency cloud infrastructure for operator control virtualization many more options available than ever Arguably, the HMI is an industrial PC run- Given the progress on TSN-capable before These options vary in price, capa- ning an industrial control application One wireless devices that we’re seeing in the bility and durability of the biggest challenges is maintaining Avnu Alliance plugfests, the capabilities and securing those platforms over time, to start deploying and testing wireless consumer-grade tablets or even smart as they are rarely upgraded or patched HMI applications exist Avnu is work- phones, one of the more attractive fea- One of the exciting developments here is ing diligently to launch the testing and tures is that operators are able to access the use of cloud infrastructure local to the certification program for wireless TSN the system utilizing apps This frees the plant to centralize and virtualize the HMI, devices, and this is an excellent time for operator to walk the facility, spot check leaving a simple terminal in the field This interested companies to engage and start for physical verification of conditions, would allow much simpler upgrading testing these new capabilities and com- update programming and check errors all and enhancing the HMI, providing more pare them with traditional HMI solutions with the ability to pull up data and draw- flexibility and security for the manufac- DAVE CALVACANTI ings at the swipe of a finger turer, not to mention the cost reduction president and principal engineer / Avnu Alliance and Intel Human-machine interface has evolved greatly since the days before the Internet If we look at remote monitoring from However, to be in compliance with customers can get additional operational benefits in addition to the flexibility enabled for the HMI application from hardware as industrial PCs tend to safety regulations, a good consumer- be more expensive than server platforms grade HMI product would need to incor- with the same performance Naturally, porate safety products like emergency the network between the machine and Tethered, wireless or headless HMI provide continuous automation visualization stops (e-stops) and operator-presence the local cloud infrastructure needs to For an industrial environment where triggers, also known as a dead man’s resilient, secure, deterministic and low- operators need constant local automation switch, along with internet security Fire- latency, but that is available What else visualization, a traditional panel-mount walls and good operational security are a could we apply that concept to? HMI, using a device able to endure the must for any wireless product Products exist on the market that PAUL DIDIER solution architect manager / Cisco satisfy the need for integrating conve- temperatures, contamination, moisture and other plant-floor conditions typically remains the most preferred option solutions that allow the user to utilize an Wireless HMI applications meet TSN devices a large-screen HMI is desired and the iPad or comparable product and pair an HMI is a use case where delivering data operator needs to be able to interact with e-stop with an operator-presence trigger with bounded latency and high reliability different points in the machine with both to ensure compliance with regulatory is extremely important This is where hands and the HMI without walking back safety Some customers may want a more time-sensitive networking (TSN), and in and forth from the machine to the HMI nience with safety and security, such as 38 / October/November 2023 / ControlDesign.com HMIs on a swing arm are useful when real answers Of course, the HMI needs to be installed in an enclosure rated for the area, or a Video Electronics Standards Association (VESA)mountable, totally enclosed HMI would be needed, which can drive up costs If the environment allows it, and a smaller screen size is acceptable, the wireless or tethered—cable—options give the operator the ability to move around the environment while operating, although they may not have both hands free These devices can be easily damaged in the wrong environment There are HMIs that support remote access via apps For applications where only mobile HMI is needed, a headless HMI is a unique device, which can be mounted internal to a control panel and support remote connectivity (Figure 7) Many users find this headless HMI to be an ideal way to add mobile HMI to their applications in a cost-effective and protected way The mobile device connects via a wireless network to the headless HMI, and operators use the app on the mobile device of their choice to access HMI screens This way only the mobile HMI is exposed The headless HMI can also drive Figure 7: A wide range of extensions can be added to ruggedized, industrial HMIs to suit the needs of an application (Source: EMAG and Beckhoff) an external display, fulfilling the previous installations discussed by connecting an industrial monitor that is panel-mounted lution on mid-range control applications ture (OPC UA) and support for a variety or VESA-mounted to a swing arm and modular-type machines These of industrial Ethernet fieldbuses, making types of devices will control, display, them ideal for modern automation sys- trend and communicate to upper-level tems in a wide range of industries BOBBY THORNTON product engineer for HMI and Click PLCs / AutomationDirect systems, if needed They could poten- ROBERTO SOLIS Visualization capabilities enhance HMIs tially act as your edge controller for IIoT The HMI world has definitely taken device variants rated up to IP67, where advantage of smaller and more power- a cabinet is no longer needed An HMI Mobile technology is spreading intelligence across the machine ful semiconductors like in consumer is no longer a simple display and could It sounds like you’re ahead of the curve electronics Having more powerful become the cornerstone of the control HMI design is often one of the last things microcontrollers, opens the opportunity system with the appropriate hardware that machine builders and their end to have HMI devices that not only act as for the application Available commu- customers focus on But it significantly local display and control for the opera- nication interfaces range from Modbus impacts people’s ability to operate ma- tor, but also as full-blown PLCs with remote terminal unit (RTU) to open plat- chines effectively and their opinions of visualization This is a cost-effective so- form communications unified architec- the system overall Moving forward, you senior product manager, fieldbus technology / Turck applications On top of that, there are ControlDesign.com / October/November 2023 / 39 real answers should watch for several upgrades in solid aluminum and hygienic stainless hurdles in training, considering the terms of hardware capabilities, software steel, as well as flexibility for custom- ongoing labor shortage functionality and machine-design trends ization (Figure 8) And the concerns about PC-based control We enjoy helping engineers design Multi-touch functionality in the hardware is critical here, but the HMI are really perceived risks Many of our the perfect control panel for their ma- software needs to be up to current customers have been successfully using chines That might mean adjusting color programming standards to make things PC control in the field for decades—spe- schemes and adding logos to fit corpo- like pinch to zoom or swiping through cific to HMI, most of these customers have rate-branding guidelines Or it could be screens a reality (Figure 9) And it makes been able to eliminate the stand-alone PC adding a full range of e-stops, pushbut- it possible to access or operate the ma- used for the HMI, so there’s an immediate ton extensions, keyed access or radio-fre- chine from different devices via a web hardware reduction and better synchroni- quency-identification (RFID) readers for interface, scaling this interface to fit zation of all HMI and control components managing credentials, jog buttons and Gone are the days when old-school screens with single touch and plastic handwheels for CNC applications Still, you could make the most incred- From a software perspective, people want HMIs to be truly customizable, flexible and adaptable A fully integrated HMI bezels reigned supreme Sure, they’re ible panel out there, but the functional- package should be built from the ground still around But the last decade has seen ity has to match the application I don’t up based on standardized web-based major advances, and the legacy options’ know many people who like clicking technologies (Figure 10) A modern web lack of personalization and functionality through 500 commands to set a param- application is every bit as capable as the make them feel like an afterthought eter In fact, most customers and equip- native platform apps of yesteryear, with ment end users tell us their operator the added benefit of compatibility across built into the cabinet, HMI hardware interface must be as simple as using a any device with a browser So with a should be ruggedized with options for smartphone Otherwise, they face major secure login, you can access the machine Whether it’s on a pole, swivel arm or from a smartphone, tablet, wireless pendant or other mobile technology This translates to an HMI package that unlocks all the potential of contemporary web development The list of advantages is long, but it includes responsive design—one codebase for all devices— unlimited graphical and styling customization, a powerful scripting environment and open-source software integration So, if you’re already doing this, why does it matter if your HMI hardware is built into a cabinet or remote? Well, the machine design is headed toward cabinetfree concepts This is increasingly made possible by IP67-rated control solutions like industrial PCs, drives and I/O modules that can mount directly on machines Maybe it’s just spreading intelligence across the machine to make cabinets smaller Either way, your HMI will likely Figure 8: Along with options for mounting and customization, multi-touch functionality delivers an intuitive user experience that simplifies operator training (Source Beckhoff) need to move A pole mount is great if that panel can be stationary However, we’ve seen many swivel arms that help to 40 / October/November 2023 / ControlDesign.com real answers deliver an operator interface that’s physically connected to the machine but can move with the operator as they start or examine different processes It all starts with thinking about the HMI early in the design process—not to say you couldn’t add a more fitting panel later But an industrial control panel that’s optimized for branding, operation and machine design can provide the perfect touch ERIC REINER IPC product manager / Beckhoff Automation On-machine equipment offers improved operator ergonomics and line of sight When it comes to HMI, on-machine options are especially attractive Mounting them on swing arms and attaching Figure 9: HMI software should be based on web design principles to offer a consistently better experience no matter the hardware being used (Source: Beckhoff) optional side handles can help increase operator comfort with improved ergonomics and give operators line of sight to critical process areas You can also combine on-machine terminals and PCs with hardwired buttons and selector switches since both include options for embedded pilot devices, as well as a hard-wired emergency-stop button If your facility already has HMI hardware and software, rest assured that you can add on-machine devices while maintaining consistency with your installed base On-machine industrial PCs can also run application software, which offers cloudbased collaborative HMI development On-machine monitors which could be paired with an enclosure-mounted box PC or thin client are on the horizon It’s an exciting time to be involved in industrial machine building with on-machine equipment offering you new opportunities for saving space, time and money Figure 10: A fully integrated HMI package should be built from the ground up based on standardized web-based technologies AL LETOURNEAU senior commercial portfolio manager, visualization & computing platforms / Rockwell Automation ControlDesign.com / October/November 2023 / 41 live wire Joey Stubbs joey.stubbs@gmail.com Why Ethernet is the backbone of protocols IF YOU HAVE been paying any attention to the offerings of high- the International Organization of Standardization (ISO) Open speed fieldbuses at all in the past 10 years, you may have no- System Interconnection (OSI) model ticed that most, if not all, of the mainstream offerings are based So, why is this change such a big deal? Well, whether we like on Ethernet technology But why is this, and why was Ethernet to acknowledge it or not, the automation industry is not that chosen in the first place, and what are some of the advantages big, especially compared to the much larger IT community and of adopting Ethernet as the basis for so many different commu- consumer electronics markets nication protocols? Therefore, cabling, connectors, network cards and other in- In the 1990s, fieldbuses were still a relatively new and game-changing concept Instead of bundles of individual frastructure devices become less expensive because there are many suppliers making them, not just one or two Competi- home-run wiring that ran from tion drives costs down field-device terminal strips or to local I/O racks, a fieldbus allowed device signals to be terminated to I/O located remotely in the field near the input/output (I/O) devices them- Another result of using IEEE A fieldbus allowed device signals to be terminated to I/O located remotely in the field selves, which were then intercon- 802.3 as the basis for communication is the aforementioned diagnostic tools, which were prohibitively expensive with proprietary protocols, become much more af- nected with a digital fieldbus, which fordable or even free with Ethernet communicated inputs to the programmable logic controller variants Frame capture and decoding software utilities from (PLC) or other type of controller, and was sent the output data a variety of companies makes examining and troubleshooting Wiring runs were much shorter, thus saving money on cable, industrial Ethernet protocols very easy, even examining the conduit and the associated labor costs timing and jitter of frames, command and response of bits to In this “fieldbus war,” there were dozens of different proprietary, or near-proprietary, fieldbuses offered by many different automation companies Many were for simple I/O, some dedi- individual I/O channels on the network and even detecting lost, corrupt or destroyed frames Another advantage of utilizing a commodity technology cated to motion, others specifically for process control Some such as Ethernet comes from who drives the innovations were based on serial communication, others on optical or coax and improvements of the underlying standard For the first cable There was not a huge incentive to be open, nor to even few decades of industrial fieldbus existence, those duties support third-party devices The closed nature of most proto- and associated expense fell to the companies developing cols was viewed as a way of keeping customers from migrating their own fieldbuses to a competitor’s control system Some of the main drawbacks for fieldbus users during this With Ethernet, the larger consumer and IT community steers enhancements and developments to the communication stan- time resulted from the closed nature of the fieldbus systems dard Now, those same innovations that help us stream movies, Dedicated and very expensive fieldbus master cards, pro- synchronize sound to video playback and play games online prietary cabling and connectors and extremely specialized also help us make advances in industrial communication in diagnostic and troubleshooting tools could only be used for factories and other industries In this case, the innovations for that particular protocol consumer products help improve our industrial networking Around the year 2000, several automation companies and fieldbus consortiums independently began development of Ethernet-based fieldbus protocols based on the most widely Joey Stubbs is a former Navy nuclear technician, holds a BSEE used communication standard in the world—Institute of Elec- from the University of South Carolina, was a development trical and Electronics Engineers (IEEE) 802.3, Ethernet physical engineer in the fiber optics industry and is the former head layer, media access control (MAC) and other select layers of of the EtherCAT Technology group in North America 42 / October/November 2023 / ControlDesign.com Sensing • Control • Motion • Connectivity • Safety • Displays • Design Get your subscription to Control Design the print magazine for machine builders FREE TO QUALIFIED INDIVIDUALS IN THE UNITED STATES NETWORK S TOPOLOGIE ING: PLC PROGRAMM THEN NOW AND RS FLEXIBLE MOTO S AND DRIVE For focused controls automation coverage l-networking Has industria become so technology that it user-friendly ate and oper ll, insta can ? maintain itself Written with discrete manufacturing in mind W ho’s atching wthe henhouse? 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