TAKE FLIGHT, BUT STAY GROUNDED › assets › digital_edition › 2019 › June… · Machine Tools 2,110 Materials Handling, Conveyors & Conveying Equipment 1,507 ... both online

JUN

E 2

01

9

FUTURE FACTORY FLOOR

HUMANS ANDCOBOTS

I/O ANDPROTOCOLS

2019 Readers’ Choice Awards winners integrate new trending technologies with traditional functions

TAKE FLIGHT, BUT STAY GROUNDED

CD1906_01_Cover2.indd 1 5/28/19 8:12 AM

the #1 value in automationOrder Today, Ships Today!

* See our Web site for details and restrictions. © Copyright 2019 AutomationDirect, Cumming, GA USA. All rights reserved. 1-800-633-0405

AC Drives for LE$$Quality Drives at AutomationDirect Prices.

• 1/4 to 1.5 hp, 115V(single-phase input)

• 1/4 to 3 hp, 230V(single-phase input)

• 1/4 to 5 hp, 230V(three-phase input)

The WEG CFW300 variable frequency drive is a high performance VFD for three-phase induction motors. The CFW300 series features acompact size and is ideal for applications on machines or equipmentthat require precise control with easy setup and operation. The CFW300 includes a built-in keypad and SoftPLC with free WEGProgramming Suite (WPS) software for custom tailored control schemes.

A variety of plug-in option modules for additional I/O andcommunications protocols can be added to extend capabilities.A remote keypad and fl ash memory module are also available.

WEG Compact Size High Performance AC DrivesStarting at $138.00 (CFW300A01P6S2NB20) • V/Hz or sensorless vector control modes

• PLC (built in)• PID control (built in)• 5 digital I/O (built in)• 4 digital & analog I/O option modules

(supporting additional digital, relay,analog, temperature and encoder signals)

• Side-by-side mounting(no heat dissipation space required)

• Optional Remote keypad• Optional RS-232 module (Modbus RTU)• Optional RS-485 module (Modbus RTU)• Optional USB module (for PC communications)• Fire mode• DIN rail or surface mount• Flash memory module for project transfer• One year replacement warranty• UL/CE listed

Research, price, buy at:

www.automationdirect.com/cfw300

Also AvailableAlso AvailableDC Drives

and MotorsAC Drives

up to 300 hpVFD Rated

Motors

WEG Compact Size High Performance AC Drives

Quality Drives at AutomationDirect Prices.

WEG CFW300STARTING AT

$138.00(CFW300A01P6S2NB20)

1906-ControlDesign-WEGDrives-MAG.indd 1 5/13/2019 11:57:04 AM

CD1906_FPA.indd 2 5/28/19 8:53 AM

Tired of working nights and weekends on motion control projects? It’s time to contact an automation specialist at SEW-EURODRIVE for help.

Using the latest innovation, we provide a complete package from start to finish, including expertise, project planning, software, components, commissioning, and worldwide support.

Go home and relax . . . we got this!

seweurodrive.com / 864-439-7537

Working late again?

contact an automation specialist at SEW-EURODRIVE for help.

Using the latest innovation, we provide a complete packageincluding expertise, project planning, software, components, commissioning, and worldwide support.

Go home and relax . . . we got this!

CD1906_FPA.indd 3 5/28/19 8:53 AM

CD1906_FPA.indd 4 5/28/19 8:53 AM

FEATURES

cover story

Take fl ight, but stay grounded2019 Readers’ Choice Awards winners integrate new

trending technologies with traditional functions

Mike Bacidore, editor in chief

18product roundup

What’s going on?Human-machine interfaces let you see

what’s happening30

product showcase 46CONTROL DESIGN, (ISSN: 1094-3366) is published 12 times a year by Putman Media, 1501 E. Woodfi eld Rd., Suite 400N, Schaumburg, Illinois 60173. (Phone

630/467-1300; Fax 630/467-1124.) Periodical postage paid at Schaumburg, IL, and at additional

mailing offi ces. Address all correspondence to Edito-rial and Executive Offi ces, same address. Printed in the United States. ©Putman Media 2019. All rights

reserved. The contents of this publication should not be reproduced in whole or part without consent of the copyright owner. POSTMASTER: Please send change

of address to Putman Media, PO Box 1888, Cedar Rapids IA 52406-1888; SUBSCRIPTIONS: To change or cancel a subscription, email [email protected] or call 1-800-553-8878 ext. 5020. To non-qualifi ed subscribers in the United States and its possessions, subscriptions are $96.00 per year. Single copies are

$15. International subscriptions are accepted at $200 (Airmail only.) Putman Media also publishes CHEMI-

CAL PROCESSING, CONTROL, FOOD PROCESSING, PHARMA MANUFACTURING, PLANT SERVICES,

SMART INDUSTRY and THE JOURNAL. CONTROL DE-SIGN assumes no responsibility for validity of claims in items reported. Canada Post International Publications Mail Product Sales Agreement No. 40028661. Cana-

dian Mail Distributor information: World Distribution Services, Inc., Station A, PO Box 54, Windsor, Ontario,

Canada N9A 6J5. Printed in the United States.

table of contentsVolume 23, No. 6

ControlDesign.com / June 2019 / 5

CD1906_05_07_TOC.indd 5 5/28/19 1:56 PM

© Allied Electronics & Automation, 2019

1.800.433.5700 alliedelec.comFill your cabinet at

We stock 99% of the components you need for inside and outside the

cabinet. Shop, build, and deliver – quickly and effi ciently.

Build a Better Control Cabinet

We stock 99% of the components you need for inside and outside the

cabinet. Shop, build, and deliver – quickly and effi ciently.

Build a Better Control Cabinet

APR19 Schneider-Control Cabinet Ad (CD).indd 1 3/15/19 3:10 PMCD1906_FPA.indd 6 5/28/19 8:53 AM

Your Problems

With 164 different modules that connect to create a Cube67+ system, Murrelektronikcan turn your problems into solutions. Cube67+ allows for absolute flexibility in system design while our One Cable Technology for bus & power saves time & money during installation.

770-497-9292 | murrinc.com

Our Solutions

Digital Input Digital Input/Output

Safety Output Analog Input or Output

Valve Connection Module IO-Link Master

M12 or M8 ConnectionsFreely Configurable Ports | LED Diagnostics

9 editor’s page

The future is happeningMike Bacidore, editor in chief

11 live wire

How to work in ChinaDave Perkon, technical editor

13 embedded intelligence

Software enables adaptability and flexibilityJeremy Pollard, CET

14 technology trends

Elbow to elbow, into the futureRick Rice, contributing editor

36 real answers

How does I/O dictate network protocol?Mike Bacidore, editor in chief

50 automation basics

How to document a PLC programDave Perkon, technical editor

COLUMNS

Advantech Automation ..................................................23

Allied Automation ...............................................................6

Altech Corporation ...........................................................27

AshCroft ...............................................................................38

Automation24 ...................................................................51

AutomationDirect................................................................2

B&R Industrial Automation .............................................8

Ballu� ...................................................................................24

Beckho� Automation ........................................................4

Bimba ....................................................................................15

Contemporary Controls Systems................................33

Digi-Key................................................................................52

Dinkle Corporation ...........................................................35

Endress+Hauser ...............................................................10

HMS Networks...................................................................37

icotek North America ......................................................45

KEB America .......................................................................31

Measurement Computing .............................................29

Murr Elektronik .....................................................................7

Newark .................................................................................12

Novotechnik .......................................................................44

Pepperl+Fuchs ..................................................................22

Posital-Fraba ......................................................................41

Rollon Corp .........................................................................43

SEW-Eurodrive ......................................................................3

SMC Corporation of America ........................................16

Telemecanique Sensors ................................................17

Wago Corporation ............................................................21

Wieland Electric ................................................................39

Yaskawa America .............................................................25

ad index


table of contentsVolume 23, No. 6

CD1906_05_07_TOC.indd 7 5/28/19 8:15 AM

www.br-automation.com/ACOPOStrak

ACOPOStrakUltimate Production Effectiveness

High-speed diverters Track design flexibility Purely magnetic holding

Enabling the adaptive machine. Like no other transport system.

Track design flexibilityTrack design flexibilityTrack design flexibilityTrack design flexibilityTrack design flexibilityTrack design flexibilityTrack design flexibilityTrack design flexibilityTrack design flexibilityTrack design flexibility

OEEROI

TTM

CD1906_FPA.indd 8 5/28/19 8:53 AM


“WHAT’S HAPPENING IN our private lives will happen in 5-10 years in industry,” explained

Heiko Schwindt, VP automation & electri�cation solutions, Bosch Rexroth. “Something is

coming. Arti�cial intelligence will play a big role. I don’t have a crystal ball. I don’t see the

future in 10-15 years, but we have a vision of the Factory of the Future (FotF). It’s a frame-

work of what we want to achieve at Bosch Rexroth.”

From its U.S. headquarters in Hoffman Estates. Illinois, Bosch Rexroth hosted a tour of

its FotF, which is open to customers, as well, by appointment.

“Our customers, machine builders, want more customization,” said Schwindt. “They

want to increase productivity; the want smaller batch sizes and massive technology

change. We are investing in higher connectivity, modernizing the factory for �exibility, in-

telligent systems, integrated safety and transparency. Most machines already have the data

inside, but they’re not connected. It

really depends on the value to the

customer. Connecting is not free.”

The Factory of the Future

includes three primary areas,

explained Rodney Rusk, Industry

4.0 leader at Bosch Rexroth. “It will

have distributed intelligence down

to the device level,” he said. “Intel-

ligent space will allow us the ability to move the factory �oor to accommodate what we

need to build. Today, we have set assembly lines with a set product. Mobile devices are

important. And virtual products are the digital-twin tools that will allow you to design

your system or the ability to reevaluate how you want to do your line. We’ll see more

and more of the merger between the physical and virtual.”

Intelligence can be distributed via embedded, edge and cloud computing. “It’s total

connectivity enabling fast plug-and-work functionality and a self-optimizing environ-

ment,” said Rusk. “Connectivity is the digital exchange of information—an AI exchange or

distributed learning exchange.”

A few other takeaways from the Factory of the Future:

• Ball screws and roller rails and mechanical products will soon have sensors embedded,

predicted Bipin Sen, regional sales manager.

• Out-of-the-cabinet devices will make it easier for modular machine �exibility, explained

Dave Cameron, director of sales, electric drives and controls.

• Safety is monitoring. Having all communications on one cable means all systems know

what each other is doing. The advantage of safety is increased production, said Joaquin

Ocampo, product manager.

The future is happeningeditorial teameditor in chief

Mike [email protected]

technical editor

Dave [email protected]

digital managing editor

Christopher [email protected]

contributing editor

Rick [email protected]

contributing editor

Tom [email protected]

editorial assistant

Lori [email protected]

columnist

Jeremy [email protected]

design/productionsenior production manager

Anetta Gauthier

senior art director

Derek Chamberlain

subscriptionscustomer service

800-553-8878

circulation Air & Gas Compressors 553

Engineering & Systems

Integration Services 11,547

Engines & Turbines 1,025

Food Products Machinery 1,569

Industrial Fans, Blowers

& Air Purification Equipment 526

Industrial Heating, Refrigeration

& Air Conditioning Equipment 1,139

Industrial Process Furnaces & Ovens 472

Machine Tools 2,110

Materials Handling, Conveyors

& Conveying Equipment 1,507

Metalworking Machinery 2,600

Mining Machinery & Equipment 510

Oil & Gas Field Machinery & Equipment 1,187

Packaging Machinery 906

Paper Industries Machinery 312

Printing Trades Machinery & Equipment 441

Pumps & Pumping Equipment 891

Rolling Mill Machinery & Equipment 157

Semiconductor Manufacturing

Machinery 817

Textile Machinery 172

Woodworking Machinery 274

Other Industries & Special Industrial

Machinery & Equipment NEC 11,305

TOTAL 40,020

1501 E. Woodfield Rd., Suite 400N Schaumburg, Illinois 60173

630/467-1300 Fax: 630/467-1124

In Memory of Julie Cappelletti-Lange, Vice President 1984-2012

Mike Bacidoreeditor in [email protected]

editor’s page

Intelligence can be distributed via embedded, edge and cloud

computing.

CD1906_09_Edit.indd 9 5/28/19 8:16 AM

Integrating a complete shopping experience into our website underlines our goal to help streamline your procurement processes and to improve your buying experience - both online and offline.

Introducing new possibilities on Endress.com

Set up your account and start shopping today!www.us.endress.com/e-commerce

DIGITAL+PERSONALNew possibilities, new experiences

Complete e-commerce functionality now on Endress.com

CD1906_FPA.indd 10 5/28/19 8:53 AM

U.S. MANUFACTURERS, DESIGNERS and OEMs should add some

well-thought-out � ow controls, gate valves and off switches

when transferring information from the United States to China

for manufacturing purposes, at least until our government � g-

ures out a way to add more fairness to the relationship.

My warning to U.S. manufacturers wanting to work with

China is: Be cautious. They will steal stuff from you and

make it themselves.

Fortunately, there are some good examples of how OEMs

are working with China; and assem-

bly is required.

I’m sure I’m correct about this

“China is stealing” thing. There are

many examples, and I’ll point out a

few. However, since I’m biased for

the home team, I won’t talk too much

about the negative; that’s too easy.

On the positive side, I found a good example of how Wazer,

a recent OEM startup and builder of the � rst desktop waterjet,

worked with China to bring a product to market. Nisan Lerea, co-

founder and CEO at Wazer in Brooklyn, New York (www.wazer.

com) has a great story to tell (www.controldesign.com/wazer).

However, before I get to that, several engineers, vendors and

former Chinese nationals I talked to recently urged caution and

have quite the stories to tell, as well. Some cannot discuss it

due to nondisclosure agreements with U.S. companies, but what

they tell me off the record hammers home a strong and justi-

� ed distrust. Others tell the story of signi� cant loss or spying

related to China’s theft of IP. Some are even concerned about

the safety of members of their families, with high political posi-

tions in China, if their opinions and related facts about China

got out. Whether it’s IP, design drawings, hardware, software or

actual equipment provided to China, remember, what’s theirs is

theirs and what’s yours is theirs, often. That’s all about that.

So, what are some ways to work with China? “It’s best for the

United States and China to be partners,” says Lerea from Wazer.

“We have a very positive relationship with China and did most

of our product development and design for manufacturing there.”

It’s all about the bottom line. “The only way to make a $7,500

waterjet is to work with China,” says Lerea. “We knew that our

product was going to rely on off-the-shelf components from

other industries, whether it was hydraulics or pneumatics or

electromechanical systems, such as valves, � ttings, motors and

pumps, and it was tremendous value to us.”

It started when an American global venture capital � rm called

SOSV, a venture-capital � rm, invested in Wazer about three

years ago. SOSV runs a vertical accelerator program that brings

startups from all over the world to one of its locations in south-

ern China to introduce the companies to the manufacturing

ecosystem that exists there.

“We joined the program to accelerate our product develop-

ment and have access to its market

expertise and infrastructure, such

as maker spaces, in China,” says

Lerea. “Our engineering team was

there for 18 months, and I was there

for six months. Our supply chain

is based there. By living in China,

our engineers were able to com-

municate directly with the vendors. We could step foot in the

factories and work with the vendors to verify our designs.”

In terms of the dynamic of the partnership between the Unit-

ed States and China, what we have seen for the basic manufac-

turing processes is it’s all there, and it’s not coming back to the

United States, continues Lerea. “Extrusion, injection molding,

compressing molding, CNC, sheet metal cutting, bending and

powder coating, all of that exists within a two-hour radius—

hundreds of factories of each process,” he says.

The partnership was successful. “From that we were able to

create a sophisticated manufacturing tool that was affordable

and can be used in a more advanced manufacturing setting

in the United States,” says Lerea. “That to me is a very helpful

dynamic and partnership. Components well made in China can

create an end product that can push advanced manufacturing

in the United States forward.”

If you are building a manufacturing plant in China, the de-

sign and technology is basically given to China. “Wazer doesn’t

have a plant—a contact manufacturer—in China,” says Lerea.

“It is its own contract manufacturer, based in the United States,

but it has direct relations with its sub-suppliers in China.”

You’ll need to live in China and visit often with your sub-

suppliers. And, since there is very little English spoken there,

a Chinese national will need to be on the team that’s bilingual.

But be careful what you say.

How to work in China

live wire

You’ll need to live in China and visit often with your sub-suppliers.


Dave Perkontechnical [email protected]

CD1906_11_LiveWire.indd 11 5/28/19 8:17 AM

from Suppliers You Know and Trust

Discover Over a Million Engineering Products

900+ new products each week

Custom services such as kitting, panel meters,enclosures, and many more!

Market-leading online community of over 600,000 engineers

1.800.463.9275newark.com

CD1906_FPA.indd 12 5/28/19 8:54 AM


Jeremy [email protected]

embedded intelligence

AUTOMATION SOFTWARE COMES in different clothing and per-

forms different tasks. It could be a programming integrated de-

velopment environment (IDE) such as RSLogix 5000 or Codesys

3.x, or a SCADA application created in Inductive Automation’s

Ignition. It all comes in different �avors and colors.

Arti�cial intelligence (AI) is the new kid on the block and is

coming on very strong in certain sandboxes.

Machine learning applications are not new, but the methods

used are. Is AI ready for prime time? It’s sure getting there.

Sharmeer Mirza, who is a senior

research engineer at PepsiCo, recently

gave a talk on how they are using AI

and machine learning to create a bet-

ter potato chip. It is based on sensing

the texture of the chip without harm-

ing the little fellow.

The premise is to bounce a laser of

the chip, and correlate the returning sound(s) to texture creat-

ing a quality check for the product.

If this sounds like adaptive process control (APC), I would say

you are right. But using end product statistics along with APC to

create a better chip may be considered novel.

Machine learning extends into various industries such as bi-

ology, blood systems, neural networks and the like. Most would

argue that to be AI you have to use an algorithm, but in this

early stage in AI machine learning the jury may still be out.

Adaptive learning may be the automation software that leap

frogs us into true AI applications.

Also we need to remember that the control engineering disci-

pline has yet to catch up to the AI learning curve.

My good friend Dick Morley, father of the PLC, told me many

times that point-of-sale manufacturing will come to a Home

Depot near you. There are already many instances of mobile

manufacturing, such as pizzas and kitchen cabinets.

But what about a machine that can create a single unit of

Product X and then a single unit of Product Y? That’s adaptabil-

ity and �exibility.

CNC machines of current day with an automatic tool changer

isn’t AI but is adaptive based on its g-code and m-code. A 3D

printer can also be considered an adaptive machine, but then

most printers are.

Single-use devices such as a rotary phone, as we know, are

dead in the water. Can multi-function be described as adaptive?

B&R Automation, along with Control Design, wrote a white

paper on adaptive systems instead of having dedicated machine

designs. Hmm, one might say!

Automation software wears many hats as suggested. So

what member of the software community allows for a batch-

of-one mentality?

John Kowal, B&R director of business development, suggests

that each product can be individually manufactured as ordered,

like McDonald’s. You order your

product; it gets made and deliv-

ered. No �nished goods inventory

control required. In this day and age

of trends and fads, investment in

manufacturing can be made know-

ing that the new-age production

machines will be re-purposed after

the fad wanes in popularity.

Kowal makes an interesting observation, something he calls,

“digital native.” This is where a majority of youth have grown

up with the digital age of mobility, access and information ev-

erywhere. They expect things and, along with the McDonald’s

mentality, want it now; manufacturing must adapt to keep the

masses connected to the buying process.

IIoT is not legacy, but it will have to integrate with legacy

somewhere. This will take both hardware and automation soft-

ware, perhaps yet to be developed, but it will come.

Inductive Automation’s Ignition is a prime example of how

�exible an HMI/SCADA system can be, as well as supporting the

new paradigm. The way it integrates new technology and not

have things such as MQTT as a bolt-on lends itself to the tasks

at hand such as cloud data easily.

It comes down to standards. There are many bodies that are

developing certain standards, and there will be many compa-

nies who will engage these standards in order to gain market

share and to do the right things.

Make no mistake, it will be the software that will drive the

integration and sense of community in our future world.

Software enables adaptability and flexibility

IIoT is not legacy, but it will have to integrate with legacy somewhere.

JEREMY POLLARD, CET, has been writing about technology and

software issues for many years. Pollard has been involved in control

system programming and training for more than 25 years.

CD1906_13_EmbedIntel.indd 13 5/28/19 8:18 AM

14 / June 2019 / ControlDesign.com

technology trends

Rick Ricecontributing editor

[email protected]

I RECENTLY HAD AN OPPORTUNITY to attend ProFood Tech, Au-

tomate and ProMat trade shows at McCormick Place in Chicago

with a colleague.

As my colleague and I walked through the exhibits, the use of

collaborative robots was the overwhelming theme of operation.

This trend makes perfect sense when faced with the prospect

of a long drought in � nding suitable candidates to perform the

repetitive tasks of assembly and packaging goods. If you can’t

� nd people, then � nd small, people-sized replacements. The

biggest drawback to using robots in

the workplace in close proximity to

actual people is the people them-

selves. The robot doesn’t care about

the objects within the workspace, but

the people sure do.

Traditional robot applications

involved erecting a secure physical

barrier around the robot to ensure that no harm would come to

people who happen to wander into range. These earlier applica-

tions would identify the extreme range of motion of the robot

and then build a wall around the possible path to keep automa-

tion and people from coming together by accident.

As technology got more sophisticated, the work envelope be-

gan to shrink with the use of devices that would limit the reach

of the robot in particular directions. Today, a robot application

eliminates the physical barrier altogether by relying on prox-

imity-sensing devices to avoid, slow down or stop completely in

the presence of a person or other object.

The technology of presence sensing has improved dra-

matically in just a few years. Early versions involved physical

contact devices, such as a safety mat that relies on pressure

exerted by a weight applied to two conductive plates separated

from each other by nonconducting layers.

When compressed, the conducting layers will contact, trigger-

ing an output. Another example of a presence-sensing device is a

two-hand operator station.

Both of the above examples have loopholes, however. They

are both looking for the presence of a person in a particular

position. They don’t cover the scenario where someone is in a

position that is unexpected.

To extend this line of thinking, two other types of safety

devices came into play.

The � rst was a light curtain. The concept is simple enough.

Situate a series of send/receive light beams across an opening

and completely surround any other means of entry into the

danger zone. Any one beam broken would immediately disable

the machine beyond the beam.

The second approach broadens the scope of the protected

area by the use of an area or safety zone scanner.

Earlier scanners were two-dimensional and looked out from the

base in a � xed path that pulses back and forth across the width

of the covered area. Scanners have

expanded to the point of being three-

dimensional and, in some cases,

can see pretty much any direction

around a central point, both up and

down, much like a radar would.

At this point, the conventional

thinking of a de� ned safety area

with devices used to monitor any entry/egress points can be

thrown out the window. The demand for the use of a collabora-

tive robot changes the perspective from “keep the people out”

to “I know they are there, so let’s avoid them.”

The Automate 2017 show put it this way:

• Past—Separate the human from the robot.

• Present—Improved human access to the robot.

• Future—Close human/robot interaction.

In 2019, the future is here, and the expectation is that robots

and humans will be close enough to physically touch each other.

The challenge for technology developers was to come up with

ways to alter the behavior limits of the robot depending on the

degree of proximity to the human counterpart. Area scanners

are used to downgrade the movement of the robot as the hu-

man gets closer to the operating envelope, but there comes a

point where declining zones from 100% safe down to 0% safe

will still bring everything to a halt.

This type of interaction is called near-term, and the method

of sensing to still allow activity within close con� nes is much

like two humans working in the same space. The “skin” of the

robot becomes the sensing device.

Popular means of sensing the skin of the robot aren’t that much

different than our own human sensitivities. Robots are designed

using tactile (touch), capacitive, proximity, force, torque and ultra-

sonic sensors, as well as pads with compression sensors.

Elbow to elbow, into the future

If you can’t � nd people, then � nd small, people-sized replacements.

U ltr ason ic X X sof twar e allows e asy se t u p an d cu stomiz ation . R e liab ly d e te cts small ob j e ctsan d cu r v e d su r f ace s. F or mob ilee q u ipme n t an d mate r ial h an d lin g .www.tesensors.com/XXSonic

Made in the

USA

Simply easy!

Does your ultrasonic sensorstop working at the mostinopportune moments?Regardless of the application, machine builders know that faulty or insufficient detection usually means downtime and loss of revenue. The new line of Ultrasonic Sensors from Telemecanique Sensors sets a new benchmark for Ultrasonic sensing technology; in regard to their reliability, their immunity to electromagnetic interference, and their reduction of cross talk when multiple sensors are used.

An Ultrasonic Sensor from Telemecanique Sensors may be the only thing to keep you - and your business - from “hitting a wall”...

Who should you trust for your ultrasonic sensor solutions?

CD201905-Telemecanique.indd 1 4/22/2019 10:14:49 AMCD1906_14_17_TechTrends.indd 14 5/28/19 8:19 AM

More NFPA Actuator OptionsThan Ever BeforeMore NFPA Actuator OptionsThan Ever Before

The NFPA Actuatorfamily is GROWING

Bimba’s new PA Series is the perfect complement to our NFPA actuator line.It offers set bore sizes and rod diameters for a simple, straightforward counterpoint to the highly con� gurable TA Series. Standard designs and features provide the versatility your pneumatic applications need, at a price that can’t be beat.

Find out morewww.bimba.com

Specifi cation NEW! PA Series TA Series

Bore Range 1.50 – 4.00” 1.50 – 12.00”

Rod DiametersOne diameter per bore size

Multiple diameters per bore size

Mounting Options 12 20*

Flush Mount Option Standard Optional

Confi gurability Basic High

Cushioning Auto-Cushion Standard Adjustable & Fixed Optional

Seals Original Ecology Seal Bumper Piston SealOptional

Temperature Rating +25 – 175°F -20 – 200°F

Steel Body Option N/A Available

Market Price $ $$*with TAS steel body option

TAS Series

FM Series

TD Series

TA Series

PA Series

Introducing the new PA Series

BIM-13642 Bimba Resizes 2019_Control Design_New PA_060119.indd 1 5/15/19 1:08 PMCD1906_FPA.indd 15 5/28/19 8:54 AM

WirelessSerial Communications

SMC Corporation of Americawww.smcusa.com/wireless 800-762-7621

www. smcusa . com

Effective communication range up to a radius of 33 Ft.

Communication is possible

up to a radius of 33ft

CD1906_FPA.indd 16 5/28/19 8:54 AM

technology trends

This idea of “force � eld” sensing has dramatically changed

the deployment of robots and our conception of what humans

can do with robots as a means to produce.

One of the more intriguing developments has been the force

sensor. Force-sensing resistors are polymer-thick � lms that reduce

in resistance with the more force applied to the active surface.

The robot reacts to the reduced resistance in much the same

fashion that a person would react to you if you were working in

very close proximity to each other and one of you made acciden-

tal contact. Instinctively, we would pull back from the contact.

The collaborative robot works in much the same manner.

Once the sensation (presence sensor) has ceased to be trig-

gered, the robot will resume activity at a slow pace until the

normal work path can be ascertained.

Another interesting use of technology is in torque sensors.

When applied to a robot, the torque used to carry out its normal

work path is monitored for any torque that is contrary to the

known operating parameters.

The contrary impulse could come from accidental contact

with the human in the operating area and could be as blunt as a

direct opposition to the travel path but might come as an ever-

so-slight brushing against the robot appendage (axis) while on

its way to the destination.

Capacitive sensing comes in the use of microscopic level

“paint” skins on the robot itself. The skin of the robot is a

capacitor, and touch by any object to the skin will result in a

change in the charge of the skin.

By monitoring this ambient capacitance, the robot controller

can respond to a change in that status quo and slow down or

stop, according to the programmed algorithm.

The technology is advancing at a rapid rate. Elbow to elbow,

forward into the battle we must go.

RICK RICE is a controls engineer at Crest Foods (www.crestfoods.com),

a dry-foods manufacturing and packaging company in Ashton, Illinois.

U ltr ason ic X X sof twar e allows e asy se t u p an d cu stomiz ation . R e liab ly d e te cts small ob j e ctsan d cu r v e d su r f ace s. F or mob ilee q u ipme n t an d mate r ial h an d lin g .www.tesensors.com/XXSonic

U ltr ason ic X X sof twar e allows e asy se t u p an d cu stomiz ationR e liab ly d e te cts small ob j e ctsan d cu r v e d su r f ace s. e q u ipme n t an d mate r ial h an d lin g .www.tesensors.com/XXSonic

U ltr ason ic X X sof twar e allows e asy se t u p an d cu stomiz ationR e liab ly d e te cts small ob j e ctsan d cu r v e d su r f ace s. e q u ipme n t an d mate r ial h an d lin g .www.tesensors.com/XXSonic

Made in the

USA

Simply easy!

Does your ultrasonic sensorstop working at the mostinopportune moments?Regardless of the application, machine builders know that faulty or insufficient detection usually means downtime and loss of revenue. The new line of Ultrasonic Sensors from Telemecanique Sensors sets a new benchmark for Ultrasonic sensing technology; in regard to their reliability, their immunity to electromagnetic interference, and their reduction of cross talk when multiple sensors are used.

An Ultrasonic Sensor from Telemecanique Sensors may be the only thing to keep you - and your business - from “hitting a wall”...

Who should you trust for your ultrasonic sensor solutions?

CD201905-Telemecanique.indd 1 4/22/2019 10:14:49 AMCD1906_14_17_TechTrends.indd 17 5/28/19 8:19 AM

2019 Readers’ Choice Awards winners integrate new trending technologies with traditional functions

AUTOMATION AND CONTROLS rarely see so much innovation converg-

ing at once. Yet, the industry still manages to stay grounded and

true to its core functions of sensing, communicating, actuating and

controlling. Each year, the Control Design Readers’ Choice Awards

capture the mindsets of machine builders, system integrators and

end users by letting them tell us which solutions they prefer.

Industry trends affect what those components do, but, like gravity,

the choices of controls engineers remain grounded in what works for

them. Currently trending are:

• industrial IoT, both wired and wireless, including private 5G

• robotics and cobotics with increased mobility, lowered costs,

integrated vision and easier implementation

• bifurcation of automation/information architecture between the

edge and the cloud

• innovation shifting from hardware to software

• data analytics, machine learning and arti� cial intelligence at

every level

• digital twinning of asset lifecycle using simulation, virtualization

and augmented reality/virtual reality

• hardware with IP67/69K ratings leaving cabinets behind.

Creativity and innovation have taken � ight, and yet our 2019 Read-

ers’ Choice Awards winners vary only slightly from previous years.

Take � ight, but stick close to the proven path.

by Mike Bacidore, chief editor


cover story

MethodologyThe 2019 Control Design Readers’ Choice Awards winners were selected by readers like you. More than 13,000 individuals who identify themselves as having buying infl uence or authority were invited to access our confi dential ballot. All of the voting is unaided, meaning that no list of supplier choices is provided for guidance or assistance in the ballot. It is created entirely by the participants, who may vote for fi rst, second and third preferences in each category. The results are grouped by Control, Hardware, Motion, Networking, Safety, Sensing and Software categories. The results do not knowingly include votes from any suppliers in the fi nal tally.

CD1906_18_29_CoverStory.indd 18 5/28/19 8:33 AM



CONTROL

CNC Controller1. Fanuc

2. Siemens

Loop Controller1. Honeywell

2. Siemens

3. Rockwell Automation

4. Yokogawa

Motion Controller1. Rockwell Automation

2. Siemens

3. Schneider Electric

4. Yaskawa

5. Fanuc

Programmable Automation Controller (PAC)


2. Siemens

3. AutomationDirect


Programmable Logic Controller (PLC)


2. Siemens

3. AutomationDirect

4. Omron


Embedded Computer System1. Rockwell Automation

2. Advantech

3. Siemens

4. Beckhoff Automation

Industrial-Grade Computer1. Advantech


3. Dell

4. Siemens

5. Phoenix Contact


HARDWARE

Circuit Protection1. Schneider Electric

2, Eaton


4. ABB

5. Siemens

Industrial Electrical Connector/Cordset

1. Turck

2. Phoenix Contact


4. Murrelektronik

Industrial Enclosure1. nVent

2. Rittal

3. Saginaw Control & Engineering

4. Hammond Manufacturing

Industrial Enclosure Thermal Product

1. nVent

2. Rittal

Operator Interface1. Rockwell Automation


3. Siemens

4. Red Lion

5. AutomationDirect

Panel Meter1. Red Lion

2. Simpson Electric

2. Precision Digital

4. Omega Engineering

Power Supply1. Rockwell Automation

2. Phoenix Contact

3. Emerson

4. Puls

5. Siemens

Relay1. Rockwell Automation

2. Phoenix Contact

3. IDEC

4. Omron


Stack Light Tower1. Rockwell Automation

2. Banner Engineering

3. Patlite

4. Werma

Terminal Block1. Phoenix Contact


3. Weidmuller

4. Wago

5. AutomationDirect


cover story


NO NODES...LIKE OUR NODES.

The WAGO-I/O-SYSTEMThe System that Started the Modular I/O Revolution• Fieldbus independent – supports 16+ protocols• 500+ digital, analog and special function I/O modules• Compact – up to 16 DI or DO in just one 12 mm wide module• XTR Series for eXTReme temperature, shock and vibration• Add-on instruction library for RSLogix 5000® software

www.wago.us/IOsystem

RSLogix 5000® is a registered trademark of Rockwell Automation – no endorsement or affiliation implied.

No Nodes - Control - Print.indd 1 4/17/18 9:28 AMCD1906_FPA.indd 21 5/28/19 8:54 AM

Wire & Cabling1. Belden

2. Southwire

3. Lapp

4. Alpha

MOTION

Gear Reducer1. SEW-Eurodrive

2. Stober

3. Wittenstein

4. ABB

Hydraulic System Controls/Components

1. Bosch Rexroth

2. Parker

3. Eaton

Industrial Electric Motor1. ABB

2. Regal-Beloit

3. Siemens

4. SEW-Eurodrive

Industrial Electric Motor Drive1. Rockwell Automation

2. ABB

3. Siemens

4. Yaskawa

Linear Motion Actuator/Slide/Guide

1. Tolomatic

1. Festo


4. SMC

5. Parker

Servo Motor


2. Yaskawa

3. Bosch Rexroth

4. Siemens

Stepper Motor

1. Oriental Motor


2. AMCI

Motor Starter



3. Siemens

4. ABB

cover story

Maximizing safety.Improving signal performance.Advancing technology.

K-System and SC-System Interface Technology

K-System Isolated Intrinsic Safety Barriers� Simple maintenance and integrated line fault detection� Easy to use: four modules satisfy 90% of all applications� 20 mm and 12.5 mm wide modules

SC-System Signal Conditioners� Conversion, standardization, and splitting of signals� High-quality galvanic isolation to protect

measurement and control circuits� 6 mm wide modules with comprehensive portfolio

for all signal types

2019


www.advantech.com

Advantech 4G LTE Cellular Router For All IoT ApplicationsFor All IoT ApplicationsICR-3241, ICR-3241W

VPN

ICR-3241, ICR-3241W

Supports 4G LTE

ICR-3241, ICR-3241W

Supports 4G LTE

ICR-3241, ICR-3241WICR-3241, ICR-3241WICR-3241, ICR-3241W

Supports 4G LTE Dual SIM Card Slots

ICR-3241, ICR-3241W

Dual SIM Card SlotsDual SIM Card SlotsDual SIM Card Slots Multiple CarriersMultiple CarriersMultiple Carriers Wide TempWide TempWide Temp IntelligentControl Modes

Multiple CarriersMultiple Carriers Wide TempWide TempWide TempWide Temp IntelligentIntelligentIntelligentControl ModesControl ModesControl ModesControl ModesControl ModesControl Modes

4G LTE Cat.4 VPN Gateway for Industrial IoT applications

Carriers support: Verizon, AT&T, T-Mobile, FirstNET (Public Safety)

Powerful CPU with 1.3 GB storage to host customer SW applications

2 X SIM with cover, Dual SIM + eSIM

2 X Ethernet 10/100, 1x RS232, 1x RS485 and I/O

Optional Wi-Fi 802.11ac using MU-MIMO technology - ICR-3241W

Optional GNSS receiver - ICR-3241W

Sleep mode & power ignition & backup real time clock

Operational temperature range from -40 °C to +75 °C (-38 °F to +167 °F)

Supports WebAccess/DMP software platform and WebAccess/VPN VPN portal solution

C

M

Y

CM

MY

CY

CMY

K

ICR-3241_print.pdf 1 5/17/19 1:49 PM

CD1906_FPA.indd 23 5/28/19 8:54 AM

Pneumatic Cylinder/Actuator1. SMC

2. Festo

3. Bimba

4. Parker

Pneumatic Systems Controls/Components

1. SMC

2. Festo

3. Emerson

4. Parker

Robots1. Fanuc

2. ABB

3. Yaskawa

4. Kuka Robotics

NETWORKING

Data Acquisition System1. National Instruments



Data Recorder1. Yokogawa


3. Honeywell

Wired Network Components1. Cisco


3. Phoenix Contact

4. Red Lion

Wireless Network Components1. Cisco

2. Phoenix Contact

3. Siemens

Network Protocol Converters/Bridges/Adapters

1. Cisco

2. HMS Industrial Networks


Network Router/Switch1. Cisco


3. Phoenix Contact

4. Red Lion

MachineMonitoring_7x4-78_EN.indd 1 5/23/2019 6:48:25 AM

cover story


For more info: http://go.yaskawa-america.com/yai1289Yaskawa America, Inc. Drives & Motion Division 1-800-YASKAWA yaskawa.com

Let’s Get ConnectedIntroducing the GA800 Variable Frequency Drive

Need your variable speed drive to have an easy and problem-free connection to your favorite Ethernet or Fieldbus network? Yaskawa takes your desire for control and data seriously.

Our new GA800 is no exception. It provides data-rich connectivity with all major industrial networks. The Industrial “Internet of Things” is here. Let Yaskawa help satisfy your appetite for it.

Your days are complicated enough. Let us help simplify them.Call Yaskawa today at 1-800-927-5292.

SUSTAINABLEFLEXIBLE

EASY

CD1906_FPA.indd 25 5/28/19 8:54 AM

Input/Output System1. Rockwell Automation

2. Phoenix Contact

3. Siemens

4. Wago

5. Turck

Machine-Mount Input/Output1. Rockwell Automation

2. Turck

3. Balluff

4. Wago

Remote Machine Access1. HMS Industrial Networks

2. Phoenix Contact

3. TeamViewer

SAFETY

Industrial Enclosure Purge System1. Pepperl+Fuchs

2. nVent

3. Rittal

Intrinsic Safety Components 1. Pepperl+Fuchs


3. Phoenix Contact

Machine Safety Components1. Rockwell Automation

2. Omron


Programmable Safety Controller1. Rockwell Automation

2. Pilz

3. Siemens


Safety Network Components1. Rockwell Automation

2. Omron

3. Siemens

Safety Relay1. Rockwell Automation

2. Pilz

3. Phoenix Contact

4. Omron

The In�uential Women in Manufacturing program recognizes women who are effecting change in the manufacturing and industrial production space.

IWIM celebrates the wide-ranging, needle-moving accomplishments of women in industry and looks to spark conversations about best practices for building the workforce that will continue to drive the manufacturing industry forward.

Visit the In�uential Woman in Manufacturing website today to:

• Nominate an woman who has effected change

• Download our E-Book featuring our inaugural class of honorees

• Watch our On-Demand workforce webinar

• View photos from our 2018 awards ceremony

See what we're all about. www.in�uentialwomeninmanufacturing.com

Meet the women who are changing the industry

1218_IWiM_1_2_H_ad.indd 1 11/19/18 10:43 AM

cover story


SENSING

Linear Position Sensor

1. MTS

2. Balluff

3. Keyence

4. Turck

5. Ifm efector

6. Heidenhain

Machine Vision System

1. Cognex

2. Keyence

3. Omron

Encoder/Resolver Measurement


2. Heidenhain

3. BEI

4. Dynapar

5. Siemens

6. Turck

Flow Measurement

1. Emerson

2. Endress+Hauser

3. Siemens

4. Ifm efector

5. Keyence

Level Measurement1. Endress+Hauser

2. Emerson

3. Vega

4. Pepperl+Fuchs

Load Cell/Weighing Measurement1. Mettler Toledo

2. Rice Lake

3. Hardy

4. Siemens

Pressure Measurement1. Emerson

2. Endress+Hauser

3. Ifm efector

4. Siemens


Temperature Measurement1. Emerson

2. Omega

3. Endress+Hauser

4. ABB

5. Omron

Vibration Measurement1. GE


3. Emerson

4. Keyence

Photoelectric Sensing1. Banner Engineering

2. Keyence


4. Omron

5. Sick

6. Ifm efector

Proximity Switch1. Turck

2. Ifm efector

3. Pepperl+Fuchs


Ultrasonic Sensor1. Turck

2. Pepperl+Fuchs


4. Siemens

RFID/Barcode Reader1. Cognex

2. Keyence

3. Turck

4. Sick

SOFTWARE

Data Acquisition Software1. National Instruments



4. Inductive Automation

ECAD Software1. Autodesk

2. Dassault Systems

3. Eplan

cover story

For additional information, please contact Foster Printing Service, the official reprint provider for Control Design.

PMS 370 C

C: 60M: 0Y: 100K: 28

Call 866.879.9144 or [email protected]

REPRINTS ARE IDEAL FOR:n New Product Announcements n Sales Aid For Your Field Force

n PR Materials & Media Kits n Direct Mail Enclosures n Conferences &

Speaking Engagements n Recruitment & Training Packages n Customer &

Prospect Communications/Presentations n Trade Shows/Promotional Events

CUSTOM REPRINTS

Use reprints to maximize your marketing initiatives and strengthen your brand’s value.Custom reprint products of articles and features from Control Design create powerful marketing tools that serve as instantly credible endorsements.


Integrated Development Platform Software


2. Siemens

HMI Software1. Rockwell Automation


3. Siemens

4. AutomationDirect

Motion Control Software1. Rockwell Automation

2. Siemens


PC-Based Machine Control Software



3. Siemens

4. National Instruments

PLC Programming Software1. Rockwell Automation

2. Siemens


4. AutomationDirect

Network Management Software1. Rockwell Automation

2. Cisco

EDG

E

ED

GE

www.mccdaq.com

Edge Computing allows users to take measurements, analyze, and store data close to the source. With WebDAQ, web-based data loggers, and support for Python™ and low-cost Linux® controllers, creating high-quality measurement nodes on the “edge” is easier and more affordable than ever.

EDG

E

ED

GE

Take Measurements on the Edge with MCC

©2019 Measurement Computing Corporation, 10 Commerce Way, Norton, MA 02766 • [email protected]

WebDAQ Data LoggersLog and access vibration and temperature data from anywhere.

DAQ HATs for Raspberry Pi®

Bring high-quality measurements to the popular low-cost computer.

Wait ’til next yearIn 2020, we’ll mark the 20th anniversary of the Readers’ Choice Awards. Over these two decades, the categories have changed slightly, but the intent has remained the same: identifying the automation and controls you use to build machine. Suggest new categories by emailing [email protected].


Entry-level touch panelsThe CP6x00 line of entry-

level control panels and

panel PCs includes three

cabinet-mounted thin-

�lm-transistor (TFT) touch

displays and a resolution

of 1024 x 600 WSVGA. The

10.1-in-diagonal screen offers 16.7 million available colors. The

CP6600 panel PC has 1 GHz ARM Cortex A8 CPU and 1 GB DDR3

RAM. The CP6700 panel PC is equipped with an Intel Atom

processor (up to 1.91 GHz, four cores) and 2 GB DDR3L RAM

(optionally extended up to 8 GB). The CP6900 control panel with

DVI/USB extended technology operates at a distance as far as

50 m from the industrial or embedded PC.

Beckhoff Automation / 877-twincat / www.beckho�automation.com

Touch panel with built-in �rewall and VPNThe Touch Panel 600 line includes three versions to provide

the right technology

for an application. The

engine has a Cortex A9

multicore processor.

Onboard security in-

cludes a built-in �rewall

and VPN to help users

address cyberattacks. All panels are equipped with a Linux

operating system and support HTML5 technology.

Wago / www.wago.us

Augmented reality software for instant diagnosisEcoStruxure Augmented

Operator Advisor is an

augmented reality software

that superimposes real-time

data and virtual objects

onto cabinets or machines,

giving operators and techni-

cians immediate access to

relevant information. This

allows operators to open the electrical cabinet doors virtually,

with no need to shut down operations; speeds up operation and

maintenance by helping technicians to �nd information faster,

with immediate access in the �eld to real-time data, user man-

uals, instructions and diagrams; and reduces human errors by

locating the correct equipment and providing operators with

step-by-step guidance to complete maintenance procedures.

Schneider Electric / www.schneider-electric.com

Industrial panel PCsThe C2 panel PCs offer IP65 metal housing and easy replace-

ment of mass storage unit via a built-in service door. All

panels have an activated Windows 10 IoT Enterprise operating

system installed. All models are optionally available with iX

Runtime installed. The panel PCs are available in base ver-

sions and in high-performance pro versions. The base version

is suitable in low- and medium-sized applications and in 10,

15, 18 and 21 in. The pro version is for medium- and high-

end applications and is available in 15, 18 and 21 in. They are

Industry 4.0-ready with GB Ethernet.

Beijer Electronics / www.beijergroup.com

Compact and fanless panel PC The TPC-1551T(B) A) industrial panel PC has compact and fan-

less universal design and features a true-�at touchscreen with

IP66-rated front panel and wide operating temperature range

(-20 ~ 60 °C/-4 ~ 140 °F). It is equipped with an Intel

Atom E3845 quad-core processor. In ad-

dition to the system’s two serial ports,

four USB, and two GbE Intel I210 LANs

for enhanced communication, it include

an iDoor socket, HDD/SDD bay and mP-

CIE port with mSATA support.

Advantech / www.advantech.com

What’s going on?Human-machine interfaces let you see what’s happening and control it


product roundup CONTACT US [email protected]

CD1906_30_35_Roundup.indd 30 5/28/19 8:37 AM

(952) 224-1400 | [email protected] | kebblog.com/IoT

.ORG

CLOUD CONNECTIVITY AND IoT EDGE GATEWAYThe C6 Edge Router from KEB America allows users to harness the power of IoT for analytics, insights, and automation with the ability to connect to new and legacy PLC controls and support for over 40 communication drivers.

CD1906_FPA.indd 31 5/28/19 8:54 AM

High-resolution HMI built for easy readingThe Simatic HMI TP1000F mobile offers a high-resolution,10-

in display for easy reading in any ambient condition. The HMI

touch panel is designed for viewing visualizations usually

associated with 19-in industrial PC screens. The HMI offers as

many as 16 million colors and a 1280 x 800 pixel resolution. An

integrated touchscreen pen is

included. Operating on WinCC

Runtime for the TIA portal,

additional features include F

functionality, a 1.2-m fall height

and USB �ash drive ports.

Siemens / www.siemens.com

Factory �oor and outdoor environment HMIsThese industrial HMIs enable easy connection, monitoring

and process control across a range of industries. The CR1000

and CR3000 HMIs are suitable

for the factory �oor, while the

Graphite HMIs withstand ex-

treme outdoor environments.

They combine versatile plug-in

modules with protocol conver-

sion, data logging and Web-

based monitoring and control.

Red Lion / 717-767-6511 / www.redlion.net

Dynamic HMI with animationThe mapp View Paper widget makes it easier to visualize

complex manufacturing processes with dynamic HMI content.

The widget allows users

to animate SVG images

with runtime data. Users

can drag and drop the new

widget onto the desired

page in an HMI application

and con�gure it there. At

runtime, animation of the

SVG image can be con-

trolled directly from the application program. Rotations, transi-

tions and movements all can be animated from a single SVG

image, saving the time otherwise needed to create sequences

of multiple images.

B&R Industrial Automation / www.br-automation.com

HMI for extreme conditionsThe SP5000X eXtreme HMI series can be used in extreme and

hazardous conditions, including

outdoor applications. It is available

in a 7-, 12- or 15-in-wide sunlight-

readable display made with an

aluminum die-cast, stainless steel

bezel. It has an operating range

of -30 to 70 °C, a high-brightness

liquid-crystal panel displaying

screens at 1000 nits and a UL 50E Type 4X outdoor use rating.

Pro-face America / www.profaceamerica.com

Industry 4.0-ready PLC + HMI + I/OThe UniStream 7-in Built-in all-in-one controller provides the

needed communication capabilities for Industry 4.0, complete

control functionality and the ability to support UniStream

remote I/O modules over Ethernet. Both the Built-in and Built-

in Pro series support MQTT, SNMP, VNC, FTP, SMS, email and

communications via GSM/GPRS

modem. The Pro version also offers

a built-in Webserver, audio jack and

video support as well as SQL. Remote

I/O is supported by all members of

the UniStream family, both modular

and Built-in. The line comprises an

Ethernet-based Remote I/O adapter

and a range of remote I/O modules,

each offering a different con�guration of analog and digital I/O.

Unitronics / www.unitronics.com

Integrated HMI with IEC 61131-3 capabilitiesThe groov EPIC integrates the HMI software groov View with its

control programs. After an IEC 61131-3, PAC Control or custom

software application has been developed, the control program’s

tags and I/O are available for building a groov View HMI. Data

from other systems and equipment on premises, at remote loca-

tions and in the cloud can be

included. The drag-drop-tag

HMI construction has built-in

security and includes trending

and user noti�cations. Users can

view this HMI to see data and

control processes on the indus-


product roundup


trial-grade color touchscreen display on the front of the processor

or on an external HDMI monitor, Web browser or mobile device.

Opto 22 / 951-695-3000 / www.opto22.com

Panel to streamline installationThe C6 S14 panel with coordinated motion control capabilities

allows machine builders to set up visualization, control and

remote maintenance tools with one product. It includes IPC

technology for camming and coordinated motion backed by an

ARM Cortex-A9 1GHz processor. The optimized processor allows

for synchronous control and short cycle times. An integrated

micro-UPS stores parameters in the event of power loss. The

panel contains two Ethernet interfaces,

a con� gurable RS-232/422/485 serial

interface with MPI support and two USB

interfaces, and an isolated CAN interface

for CANopen operations is available.

KEB America / www.kebamerica.com

Remote-monitor HMI system � rmwareRM Shell 5 � rmware for VisuNet remote-monitor HMI systems is

based on Microsoft Windows 10 IoT Enterprise LTSB and allows

easy integration of a remote network architecture. The updated

� rmware supports an application

manager for installing third-party

application software and offers

additional security and Windows

update features. It comes pre-

loaded on all Pepperl+Fuchs thin

client-based products and pro-

vides a touch-screen interface and

plug-and-play start-up capabilities.

Security features include a Micro-

soft Universal Write Filter, built-in

� rewall, USB lockdown and optional restricted Web browser. The

� rmware comes standard with Windows Defender for virus pro-

tection but allows installation of third-party antivirus software.

Pepperl+Fuchs / 330-486-0002 / www.pepperl-fuchs.com

Learn more at www.ccontrols.com/controllers

The Advantages of a BAScontrol Open Controller

• An open communications network in IP Ethernet

• An open industry supported building automation protocol in BACnet

• An open control language that is license-free in Sedona

• Free application editor, project backup, and PC emulator

BAScontrol


Historian with bidirectional synchronizationVTScada Historian supports applications that log hundreds

of thousands of I/O. Advanced synchronization allows every

redundant SCADA server to be an up-to-the-second backup of

all process histories. The historian is part of every application

and allows any server to assume poll-

ing and logging as needed according to

a distributed server list. This reduces

computer hardware (no dedicated I/O

server) and increases levels of data

redundancy. The integrated design

means that new servers can be added

in seconds. Each server can host mul-

tiple historians, allowing for �exible data backup scenarios.

Uers can log redundantly to third-party historians if needed

(licensed separately).

Trihedral / www.trihedral.com

Scalable HMI with protocol conversionRed Lion CR3000 HMIs provide

protocol conversion and connec-

tivity choices along with visual

display features to deliver operator

interface devices that scale and

adapt as requirements change. The

automation HMI combines a list of

more than 300 industrial drivers

with the Crimson 3.1 development platform. It includes real-

time data logging and a built-in Web server.

Newark / www.newark.com

HMI for centralized control of multiple locationsConnecting the MonoTouch V9 with a VPN helps to provide

improved service and work ef�ciency. It allows users to gain

centralized control of multiple locations. Operational data

from several sites can be collected and monitored from a PC

accessing the cloud server.

The HMI has been integrated

into such industries as as-

sembly machines, packaging

machines, press machines and

semiconductor manufacturing

equipment.

Fuji America / americas.fujielectric.com

Graphic terminals with widescreen, touch and keypad optionsThe Allen-Bradley PanelView 5510

family of graphic terminals offer

display sizes ranging from 7 to 19 in

with widescreen, touch and keypad

options. EtherNet/IP with device-

level ring and embedded switch

technology help to support network

fault tolerance and reduce downtime.

Onscreen buttons and enhanced navigation help to increase

operator ef�ciency. Using the Rockwell Software Studio 5000

View Designer application, the HMI features Logix tag-based

alarms, a PDF viewer, a terminal emulator, VNC remote access

and real-time and historical trending.

Rockwell Automation / www.rockwellautomation.com

HMI interface and logic controller in oneThe programmable TX700 series of HMI/PLCs have available

communication interfaces ranging from Modbus RTU to OPC-

UA and support for a variety of industrial Ethernet �eldbuses.

The line uses multicore processors at an operating frequency

of 800 MHz and a Linux-based platform. This makes it possible

to implement complex control tasks and visualizations. The

device’s all-glass capacitive touch display provides intui-

tive operation with gesture control

similar to that used in smartphones.

Overall system complexity is reduced

through the single device functioning

as both the HMI interface and logic

controller. It is available in display

sizes of 5, 7, 10, 15 and 21 in.

Turck / 800-544-7769 / www.turck.us

Stop switch with IP66 certi�cationThe series 61 E-Stop Switch Compact has added IP66 certi�ca-

tion in addition to the existing IP67 and IP69K. IP66 certi�ca-

tion provides protection

against powerful water-

jets, IP67 provides protec-

tion against immersion

up to 1 m in depth, and

IP69K provides protection

against powerful high


product roundup


temperature waterjets, making the prod-

uct suitable for critical functions in haz-

ardous environments, especially space-

restricted applications. It also meets EN

ISO 13850, EN 60947-5-1, EN 60947-5-5

and EN IEC 60204 certi� cations. It has a

low back panel depth of 21.2 mm and a

27-or 40-mm-diameter lens.

EAO / 203-951-4600 / www.eao.com

IEC 61131-3-compliant HMI with CoDeSyscMT3090 with built-in CoDeSys is a high-

performance HMI in compliance with the

IEC 61131-3 PLC standard. The product is

built on an architecture in which a duo-

core CPU runs two independent operating

systems. With the multi-core proces-

sor, the HMI is able to not only provide

data visualization with an operable user

interface but also run controller logic. The

two systems run independently without

mutual interfer-

ence. The HMI

has a delicate

graphical UI and

advanced inte-

gration features

and the control-

ler system supports multiple languages

such as FBD, LD, IL, ST, SFC and CFC.

Weintek USA / 425-488-1100 / www.weintekusa.com

Compact dual Ethernet HMI or weintekWeintek’s Model MT8053iE dual-Ether-

net HMI is available

in a 4.3-in size. The

dual Ethernet port

allows the device to

be on two inde-

pendent networks,

whereby one port

connects to the

controller, and the other one connects

to the host computer or is used for

remote control (e.g., built-in EasyAccess

2.0). Separation of networks eliminates

network interference and congestion

and also helps to improve data transfer

reliability and stability.

Rohtek Automation / 425-328-8445 / www.rohtek.com



real answers CONTACT US [email protected]

A CONTROL DESIGN reader writes: We

manufacture OEM and custom ma-

chines—discrete manufacturing—and

are looking for ways to reduce integration

time and overall cost. Speci�cally, we’re

looking at I/O termination methods. We

want to move away from wire or cable

from the �eld device to the enclosure

terminal strip. We are looking to reduce

the large bundles of wire and terminat-

ing our I/O at the edge, but technology

and reliability concerns are part of the

discussion. There are many network,

protocol and hardware choices, so what

are our options, and how can we be more

ef�cient with I/O termination?

Answers

Follow protocolReducing wiring costs was the problem

industrial networks were developed to

address. Unless you have very speci�c

application requirements, for example,

such as those needed for high-speed

motion control, most Industrial Ether-

net networks will be able to handle your

machine cycle times.

There are a variety of industrial Ether-

nets from which to choose, and typically

there’s not one “best” solution. The net-

work “religion wars” are more about the

ability of integrated solution providers to

have cohesive, well-implemented product

offerings across their entire product lines

than one network protocol being “better”

than another.

So, if you have a preferred vendor,

then go with the vendor’s native net-

work protocol. But if you want to use

devices from various vendors, then use

the network that they all have in com-

mon. Preference should be given to the

network protocol supported by your PLC

controller, since the controller’s native

network is usually easier to implement

than a competitive network.

PHIL MARSHALL

CEO / Hilscher North America / www.hilscher.com

Choose for the userWhen it comes to choosing an I/O termina-

tion method, there are a few things to

consider. First, consider the size of your

machine. Small skidded machines may

not have a lot of bene�t for distributed I/O

since the wire runs are short, but you can

still optimize to reduce integration time.

Use easy-operating, tool-free levers on

your terminal blocks for �eld terminals or

use IP67 sensor and actuator connectors.

They are easy to mount and connect eight

to 10 local I/O points and then have a single

cable to route back to your control cabinet.

For systems that are physically large,

distributed I/O is very bene�cial. In

some cases users can use an HMI and

PLC all in one and use a �eldbus coupler

to monitor and control remote distrib-

uted I/O. There are lots of good options

for �eldbuses; however, Ethernet-based

devices are the trend.

There is a wide variety of protocols

including Modbus TCP/UDP, EtherNet/IP,

EtherCAT and Pro�net. A lot of times the

choice of the �eldbus is dependent on the

dominant one in the end user’s plant. It

can be easier on the maintenance staff

to work with the �eldbus they are used

to. Modbus TCP/UDP has been around for

decades and is readily available on �eld

devices like drives or �ow meters.

CHARLIE NORZ

automation product manager / Wago / www.wago.com

Next generationSometimes, simple questions need

simple answers. The simplest way of

reducing the wiring costs for your I/O

termination is to reduce the number of

wires to one single cable. AS-Interface

(ASi), the worldwide leading system at

the automation base for the ef�cient inte-

gration of sensors and actuators, makes

it possible (Figure 1).

Despite the variety of features, the

installation is very simple and fast;

modules are hooked up onto the cable

via piercing technology. Special needles

pierce a small hole through the isolation

and contact the wires without damaging

them. You can change the position of the

module just by taking it off and moving

it to another position. The topology of

your network is completely free and can

follow the shape of your machine—even

networks with 1,000 meters in length

can be realized.

For cases where an additional auxiliary

power supply is inevitable, an additional

cable—black ASi pro�le cable—can be

used to transfer the energy. Just like the

yellow ASi cable, it is contacted via pierc-

ing technology, and it can use the same

cable duct, as well.

AS-Interface is a bus system designed

for �eld devices that is capable of trans-

ferring standard and safety signals, up to

PLe/SIL 3/Cat. 4, as well as energy on one

single, two-conductor electrical cable—

the ASi cable. With it, usual cable trees

can be replaced.

ASi-5—the latest innovation stage of

AS-Interface—is able to transmit large

data volumes, up to 384 bits, within very

short cycle times, 1.27 ms, which makes it

an alternative for higher-level �eldbuses,

How does I/O dictate network protocol?

CD1906_36_45_RealAnswers.indd 36 5/28/19 8:41 AM

such as Ethernet/IP. Moreover, power and

data are transmitted over the same cable,

so that in many cases there is no need for

additional power supplies in the � eld.

The connection to the PLC is realized

over a gateway, which speaks the match-

ing protocol of your PLC. When you have

to change the PLC, you just change the

gateway, and the rest of the installation

stays the same (Figure 2).

The different ASi modules offer you

the right connection for every signal; dig-

ital I/Os, analog signals and even IO-Link

sensors can easily be made bus-capable

in the blink of an eye. The key lies in the

� at, yellow ASi cable.

DENYS SERHA

fi eld application engineer / Bihl+Wiedemann / www.

bihl-wiedemann.com

Multi-port interconnectionMachine builders/OEMs often need to

wire multiple sensors and other discrete

devices back to a control panel. One

option is Remote I/O with each input con-

verted to a digital communication signal,

but this tends to be expensive and limits

use to controllers capable of receiving

and interpreting the digital signal. A less

expensive solution is to simply take a

group of input signals and combine them

into a single cable using junction blocks

designed speci� cally for this purpose.

Multi-port interconnection junction

blocks provide a simple and effective way

to organize machine wiring for a variety

of machine control applications, such as

packaging equipment and conveying sys-

tems. These systems typically have many

www.ewon.biz

Secure Remote Access to PLC, HMI, ...

Cosy 131Industrial Remote Access Gateway

• Firewall friendly solution

• Proven solution with 13+ Million VPN connections

• Free VPN service

2015201620172018...

Piercing technologyFigure 1: The simplest way of reducing the wiring costs for your I/O termination is to reduce the number of wires to one single cable.

Network gatewayFigure 2: The connection to the PLC is realized over a gateway, which speaks the matching protocol of your PLC.


I/O points, such as sensors or solenoid-

operated valves, consolidated in one loca-

tion. These devices are usually hardwired

to a junction box or separately wired back

to the main control cabinet. Multi-port

junction blocks provide a more ef�cient

and cost-effective solution: one main con-

trol cable is run back to the main control

cabinet, so the cost associated with errors

in wiring, rewiring and I/O replacement is

greatly reduced.

JIM KREBS

engineer / AutomationDirect / www.automationdirect.com

Split systemsMachine builders are running cables

faster than ever. Split systems allow you

to run 10, 20 or even 40 or more, pre-ter-

minated cables into machines, while still

maintaining NEMA ratings, in a matter

of minutes. Machine builders are now

avoiding �eld termination entirely and

sourcing their cables pre-terminated. This

allows them to maintain manufacturer’s

warranty and very quickly and easily run

their cables into the machine through

a single hole. This reduction in labor

time, maintenance of cable warranty and

avoidance of possible errors with the �eld

termination process can save you count-

less dollars in production costs.

ANDY WOODS

chief operating o�cer / icotek North America / www.

icotek-usa.com

Don’t �ght the PLC battleWhile many industrial network proto-

cols are indeed available, there are two

device-level communication methodolo-

gies that lend themselves to reduced

wiring: AS-interface and IO-Link. Each

has its own advantages in terms of data

throughput, speed and capability, and

they are complementary technologies

that can offer different bene�ts for the

OEM. Both are PLC-independent, so

there’s no need to �ght the PLC battle.

AS-interface, a low-level industrial net-

work with more than 36 million installed

devices across the globe, is supported

by more than 350 device vendors. With

network distances of up to 500 meters and

real answers

The product you manufacture is only as good as the parts it’s made from. One bad component can bring down the system and your reputation. The Ashcroft® G2 pressure transducer is engineered for long term reliability and stands up to high shock, vibration and extreme temperatures. A wide variety of electrical and pressure connections make it an easy fit in nearly any installation. Need something special?

Our Custom Engineered Solutions experts would like to review your requirement and adapt a sensor to meet your need. To learn more about the G2 and other Ashcroft specialty pressure transducers, visit www.ashcroft.com or call 203-385-0635.

EXTRAORDINARY PERFORMANCE ON AN OEM BUDGET

ALSO OF INTEREST

GV FOR EXTREME VIBRATION G3 FOR AGGRESSIVE MEDIA

tel: 203-378-8281

email: [email protected]

www.ashcroft.com

19 April Control Design 015-5815.indd 1 3/21/19 4:17 PM


the ability to accommodate 248 inputs

and 248 outputs on a single, two-wire

cable, it’s common to realize up to 90%

fewer termination points in large net-

works. Savings of up to 75% in installation

costs alone are common.

IO-Link is a point-to-point communica-

tion methodology, originally developed as

a means of connecting sensors to control-

lers. With a 20-meter limit on the cable

length between master and device, IO-Link

is best suited for use where the control-

ler is in close proximity to the machine-

mounted sensor devices. A unique solution

inside the cabinet can reduce panel wiring

time and hardware cost. By utilizing IO-

Link on motor starters inside the control

cabinet, installation time can be reduced

by at least 50%, and overall cost reductions

of greater than 25% are common.

GLENN SYMONDS

product marketing manager / Siemens Industry, Smart

Infrastructure—Control Products / www.siemens.com

I/O architecturesFor the longest time I/O termination was

the only cost-effective way for machine

builds. Over the years, many technolo-

gies have been developed to increase the

productivity for machine builders. We

call it the evolution of I/O architectures.

The wiring and terminations are

the � rst generation of the I/O integra-

tion philosophy that relies heavily on

centralized controls architectures with

laborious and time-consuming wir-

ing. Terminating each wire is a six-step

process that includes routing, cutting,

stripping, ferruling, labeling and ter-

minating. Typically, it takes about 7-10

minutes per wire for experts. So, if you

have 100 terminations it would take up

to about 12 hours of time, equating to

about $700-$1,000 of labor cost.

All of this hard work is also accompa-

nied by absolutely no diagnostics. With

human error probability stats at about

10-15%, you are looking at additional cost

of debugging wiring errors and re-works.

All these are non-value-added activities.

The second generation of I/O architec-

tures adds passive junction boxes. These

help to shorten the cable runs from the

sensors to the junction box, but do not

reduce any terminations or offer any

diagnostics.

The third philosophy in I/O architec-

tures is distributed or remote I/O stations

using � eldbus or network architecture.

There are two choices here: (1) using

remote termination boxes or (2) using re-

mote I/O blocks with direct connections.

The � rst choice helps with distributing

your terminations closer to the sensors

but does not help reduce any termina-

tions. So, it helps with shorter cable

runs and probably provides a little more

diagnostics but adds the cost of remote

termination control panels. The second

choice, however, offers shorter cable runs,

onboard diagnostics of short circuits or

overcurrent, drastically reduces termina-

tions. Just as importantly, it considerably

reduces the need for debugging, which

reduces overall labor costs.

But the limitation here is that typically

a distributed network block can host 16

inputs or outputs or four to eight analog

points, or some mix thereof.

So, when you need the 17th input or

output, you need to add another I/O block

on the network, if you need one addi-

tional analog input or output, you need a

different block, and so on. Basically, you

are dumping the I/O slices from the cabi-

net out on the machine connected with

network nodes. So, the marginal cost of

update is very high.

The fourth or the latest generation

of I/O architecture is based on IO-Link

technology. This technology has been out

for more than a decade, and it is gaining


very fast acceptance in the market. It is also the technology

most useful for Industry 4.0 or Industrial Internet of Things.

With each IO-Link master block, you typically get up to eight

IO-Link ports, and each port can host a variety of I/O. The I/O

devices or I/O hubs are child nodes that spawn out of the IO-

Link master to capture discrete I/O, analog I/O, smart devices

such as RFID, smart sensors such as pressure, color, ultrasonic,

laser distance or even transducers and encoders.

Now, with this technology, one IO-Link master could

host up to 240 I/O points with IO-Link I/O hubs, or up to 64

channels of analog I/O or eight IO-Link smart devices or any

combination thereof.

There are more and more manufacturers introducing new

devices that would go on IO-Link. There is an in�ux of smart

devices on IO-Link, such as valve manifolds, grippers, vacuum

generators, stack lights and RFID systems. Since IO-Link is a

data communication and not signal transmission, each IO-Link

device offers considerable amounts of diagnostics. The IO-Link

devices could be con�gured to provide events in alarming situ-

ations for ease of maintenance and troubleshooting. The best

part is you could use standard sensor cables that you are using

today throughout the architecture except the IO-Link master

that sits on the network. With IP67-rated IO-Link masters, you

could use molded quick-connect cables to avoid any miswiring.

SHISHIR REGE

marketing manager / Ballu� / www.ballu�.com Get remote

I/O communication and powerThere are different platforms of I/O devices to choose from to

create custom wiring solutions that reduce the wiring effort

of connecting I/Os to the control. An I/O system can utilize

single-cable connectivity to transfer I/O communication and

power between your choice of different, con�gurable I/O mod-

ules (Figure 3). Using this system translates to reduced wiring

between modules by combining power and communication,

reduced wire length to devices, simple plug connections with

standard M12 and M8 options, easy valve integration and

reduced IP addresses across the entire network. Modules are

protocol-independent, so, once you choose the correct com-

munication protocol for the bus node, the rest of the modules

in the system remain the same no matter whether you are

working with Ethernet/IP or Pro�Net.

You will �nd a lot of technologies to look at when you start to

consider wiring methods.

AARON HENRY

VP strategic development / Murrelektronik / www.murrinc.com

Remote I/O reduces wiringRemote I/O systems provide the best option for combining

conventional I/O signals—AI, AO, DI, and DO—with modern

communication protocols such as Pro�bus DP, Pro�net and

Modbus RTU/TCP. These systems convert the standard analog

and digital signals into a single communication protocol used

by the manufacturing facility.

One bene�t that a remote I/O system brings is the ability to

reduce the wiring back to the control room. In a point-to-point

installation, huge amounts of wiring are needed to and from

the �eld device and the control room, which requires long

cable lengths, engineering design and costly installation time.

A remote I/O system is typically installed as close to the �eld

device as possible. This allows for a maximum reduction of

wiring, since the installation has a single communication cable/

bus running back to the control room, effectively reducing your

wiring costs by nearly 50%.


real answers

Con�gurationFigure 3: An I/O system can utilize single-cable connectivity to transfer I/O com-munication and power between your choice of di�erent, configurable I/O modules.


A remote I/O system’s bus commu-

nication also allows you to reduce the

number of DCS I/O cards, saving money

and also cabinet space in the control

room. In a point-to-point installation,

individual I/O cards are required for each

signal type. Depending on the instru-

ment count, this could be a substantial

quantity of I/O cards. In a bus-commu-

nication architecture, the DCS control

cards would be drastically reduced,

because only communication cards for

the speci�c bus, such as Pro�net, would

be required.

Most remote I/O systems are based

on a backplane structure, with slots for

a communication module, I/O modules

and power supplies. The high-density I/O

modules allow for the maximum number

of modules to be placed inside a single

cabinet. Many remote I/O systems can be

integrated in both general purpose and

hazardous location installations (Figure 4).

ALBINO SALAZAR

technical support supervisor / Pepperl+Fuchs / www.

pepperl-fuchs.com/usa

Network architectureIt seems to me that a network I/O system

is something you should look into. Going

to a network I/O system will allow you to

reduce �eld cabling from many individu-

al wires to as little as one network cable.

This can reduce the cost of building the

enclosure and makes it much easier to

seal the enclosure from environmental

issues, such as water and dust.

Over the years a number of network

technologies have come into general use,

and, due to advances in technology, some

have been replaced. For some very high-

speed applications, putting the I/O on a

network could have caused some latency

issues, but the recent high-speed net-

works of up to 100 GB are making these

issues rare exceptions.

The current frontrunners in industrial

networks are almost all Ethernet-based.

EtherCAT, Ethernet/IP and Pro�net as

examples are all Ethernet-based. Most,

including these three, are in the public

domain, so manufacturers of automa-

tion equipment can enable their products

with them. Each has its own features

that may make it more suitable for an

application. For example, EtherCAT is

highly regarded for motion applications.

In all cases an overlaying protocol is

added to increase determinism. Reliabil-

ity is very high with these protocols. On

the data side there are checksums and

retries to ensure data transfer.

POSITAL Takes a Fresh Look at Motor Feedback

■ Precision motor feedback for servo and stepper motors

■ Flexible encoder solutions for small drives, robots

■ Incremental, absolute, singleturn and multiturn variants

■ Fast and easy installation with factory-friendly alignment tolerances

■ Low sensitivity to dust and moisture

■ Good resistance to shock and vibration

www.posital.com

MEET OUR NEW KIT ENCODER

FAMILY!

Hazardous integrationFigure 4: Many remote I/O systems can be integrated in both general purpose and hazardous location installations.


On the hardware side, IP20 or IP67

blocks are available for most environ-

mentals. Most terminations with these

protocols are with an RJ45 connector and

jack. So it is very common and easy to

terminate or purchase pre-made cables.

In IP67 environments, typically M12 con-

nectors are used for liquid and dust tight

operation. I/O terminations are some-

times dictated by the environment.

Specialized networks are also being

used at the sensor and I/O level. One

example is IO-Link. IO-Link was designed

as an optimized protocol for sensors but

is now �nding use in more advanced

devices. Data integrity is very high. Here

again you can �nd connectivity for IP20

applications with cage clamp or screw

terminal or M12 connectors for liquid and

dust tight operation (Figure 5).

A typical modern network architec-

ture can have EtherNet/IP at the top

level for the high data transfer rates and

determinism; EtherCAT for its determin-

ism and performance with motion and

I/O; and IO-Link at the sensor level for

highest speed with smaller data packets

found in sensors.

There are more than just these net-

works out there. If you start your design

with the most modern and capable net-

works, you can ensure years of reliable

operation and the lowest total cost of

ownership.

CLARK KROMENAKER

product manager—HMI, IPC, controllers, software / Omron

Automation Americas / www.automation.omron.com

Away from parallel wiringIn today’s manufacturing world, automa-

tion has become king; and, with that,

companies are constantly looking for

ways to do it better, faster and cheaper.

Massive bundles of wire have always

been a thorn in the side of process

improvement and general organization.

Fortunately, there are many technol-

ogy options available to eliminate this

hassle, so that you can reduce your in-

tegration time and improve your future

productivity.

The two options I would suggest are:

(1) distributed modular I/O and (2) wire-

less technology, depending on how much

of a transition you are willing to make.

The �rst step is to look at your control

system and determine which protocol

you can use. Whether it is Ethernet/

IP, Pro�net or Modbus TCP, you need to

decide if you are always going to use the

same controller, or will you vary between

manufacturers. If you think you might

switch, you will want to use a brand that

supports all of the common protocols.

In terms of distributed modular I/O,

this solution lets you terminate outside of

the cabinet and at your machine, while re-

ducing the number of individual wires to

a fraction of what they were before, often

bringing you down to just a few cables.

Distributed modular I/O allows you to

terminate your I/O where you need it and

eliminates many bundles of wire. Also,

if you have a long distance to span, you


real answers

Modern architectureFigure 5: A typical modern network architecture can have EtherNet/IP at the top level for the high data transfer rates and determinism; EtherCAT for its determinism and performance with motion and I/O; and IO-Link at the sensor level for highest speed with smaller data packets found in sensors.


can use an IP67 direct machine-mount

option. While not the most cost-effec-

tive option, these options are still less

expensive than additional intermediate

cabinets. Both of these options allow you

to collect data at a single point and com-

municate over an industrial network.

Depending on how invested you are

in cutting the cord, so to speak, wireless

I/O can be an intriguing solution. While

they can be a little more of a capital

investment up front, they often pay

for themselves in terms of installation

cost savings, versatility, ease of use and

placement and reduced maintenance

costs. One of the main issues with wire-

less technology is that it must match the

durability and reliability of a traditional

cable connection. For this reason, it is

important to select a brand that offers

the correct ingress protection and area

classi�cation ratings for your needs. It

is also important to select a technol-

ogy that transmits I/O signals, as well

as serial data, and is capable of being

implemented in point-to-point connec-

tions or more complex networks. These

attributes will give you the freedom to

transmit I/O to I/O, I/O to serial or serial

to serial. Another attractive option is

industrial Bluetooth. Industrial Bluetooth

modules can replace Ethernet, or other

cables, with a reliable wireless connec-

tion. Bluetooth is particularly useful for

mobile applications, such as cobots or

robots, eliminating costly cable runs.

Implementation of one or both of

these solutions will greatly increase your

termination ef�ciency. However, with so

many options and brands available today,

it is important to select one that has the

most versatility and features that match

your current, as well as future, needs.

WILL MORRIS

product portfolio manager / Allied Electronics &

Automation / www.alliedelec.com

Distributed I/O and �eldbusThe use of distributed I/O is becoming

more prevalent with several options

when it comes to protocols.

By placing distributed I/O blocks on

the machine with a �eldbus system, you

only need to run the power and �eldbus

cable back to the PLC.

MOVE YOURROBOT

*Robot not included

Seven axes, infinite possibilities. Rollon’s Seventh Axis expands your work area and enhances your automation system—from painting to palletizing. Integrate this shuttle system with any robot up to 2,000 kg.palletizing. Integrate this shuttle system with any robot up to 2,000 kg.palletizing. Integrate this shuttle system with any robot up to 2,000 kg.

LEARN MORE AT MOVEYOURROBOT.COM

Seventh Axis


We like to use M12 connector blocks

that allow short cabling to the sensors.

If a cable is damaged, you can quickly

change it out without pulling wires back

to the PLC enclosure.

One manufacturer we like to use offers

a �eldbus block that allows changing

out the bus coupler instead of the whole

system. This makes the installation

independent of the controls and �eldbus,

allowing OEMs to adapt to an end user’s

PLC and �eldbus speci�cation.

When using a �eldbus protocol, always

look at how it integrates into your PLC.

Many manufactures have developed

electronic data sheet (EDS) �les that al-

low products to easily be identi�ed and

commissioned in your control system.

Also, pay attention to the environment

that the I/O blocks and cabling will be in-

stalled in and select the proper IP rating.

LINDSEY KIELMEYER

marketing coordinator / Martin Control Systems, Plain

City, Ohio / www.martincsi.com / member, Control System

Integrators Association (www.controlsys.org)

No cabinetOne of the trends we are seeing to reduce

overall hardware and installation costs

would be the move toward a cabinet-

free solution or an on-machine solution.

There are several bene�ts of moving

components out of the control cabinet.

First, it reduces the size and cost of

the control cabinet. Additionally, using

a network communication to control

the components outside the cabinet

reduces the number of cables routing

out of the cabinet. This reduces time

required to wire into terminal blocks

and reduces the length of cable runs to

the components.

Second, it reduces wiring errors and

time by using M-style connectors for

network communication and power.

These types of connectors are available

as cordsets (connectors at each end) and

patchcords (connector at one end, leads

on the other). They are also available

as �eld-attachable for quick assembly.

Additionally, they are keyed according

to functionality to help prevent wiring

errors. The combination of a network

communication with M-style connectors

is commonly used and helps to reduce

the concern of machine reliability.

Third, it reduces wiring runs by

mounting the components closer to the

end devices.

With this design, a machine can

be modular because a portion can be

disconnected quickly for shipping and

then put together just as quickly at the

customer site, resulting in an overall

reduction in installation costs.

As an alternative to using an on-ma-

chine solution, I/O can also be mounted

closer to input/output devices or motors,

reducing wiring runs. This distributed

I/O option offers standard and safety

modules with �eld-ready terminal blocks

and reduces the need for separate I/O

terminations. I/O adapters also allow for

various network communication options,

such as �beroptic support.

TOK KIANG LING

global product manager / Rockwell Automation /

www.rockwellautomation.com

EtherCAT solutionsExcessive wiring for standard I/O sys-

tems can certainly be time-consuming

and costly. In addition to the labor

involved in installation, point-to-point

real answers

Wear-Free Angle Measurement

RFC 4800 Series of touchless sensors use a magnet attached to your application’s rotating shaft. Now with IO-Link output option, these sensors can be easily connected with a 3-wire version. Voltage, current and other digital output options provide design flexibility. They keep measuring even during a loss of power, reporting the correct position when it is restored.

Key specifications:• Repeatability to 0.1°• Measures 0 to 360°

• Resolution to 14-bit• Linearity ≤ ±0.5% of F.S.

• 2-ch. version option• Speed output option

Novotechnik U.S., Inc. Telephone: 508-485-2244Email: [email protected]

Free touchless angle sensors primer: www.novotechnik.com/rfc48


wiring creates a greater risk of errors during commissioning,

which can take up additional machine-builder and end-user

time while troubleshooting. A more effective option for mid- to

high-volume machine builders is to implement pluggable Ether-

CAT I/O terminals or machine-mountable EtherCAT modules.

The system allows machine builders to design custom circuit

boards for the necessary I/Os and standard connectors, which

offers signi�cant advantages and ROI for series machine pro-

duction. Prefabricated cables or coded plug connectors enable

the connection of standard cables to the board in a machine

control system. The terminals are also about half the size of

their standard DIN rail-mounted I/O counterparts, and this

leads to dramatic reductions in equipment footprint, enabling

installation of I/O inside the machine to reduce the size and

number of electrical cabinets.

Designed for harsh production environments, rugged Ether-

CAT modules come with an IP67 protection rating, including

plastic and zinc die-cast models. There are also stainless steel

IP69K versions.On top of standard digital/analog inputs/outputs,

both the circuit board-pluggable and machine-mountable I/O

offer high-density 16-channel options, motion control termi-

nals that support one-cable technology for power and feedback

and even TÜV-certi�ed machine safety with I/O in yellow

housings. This range ensures practically all I/O requirements

for discrete manufacturing applications are available in the

pluggable form factor but can also connect directly to standard,

DIN rail-mountable I/O if speci�c couplers or other extensions

are needed. All of these solutions harness the proven Ether-

CAT protocol, an open industrial Ethernet solution that boasts

the ability to support up to 65,535 devices on a single network.

Built-in LED lights display EtherCAT diagnostics directly on the

hardware as they do on standard terminals. These factors make

each solution an even more compelling choice to reduce wiring

in production machines.

SREE SWARNA GUTTA

I/O application specialist / Beckho� Automation / www.beckho�.com

Enter the �eldbusThis is a great time to be evolving your machine-controls design

into a �eldbus solution. There have been tremendous improve-

ments in industrial network technology. The large automotive

manufacturers have led the way in driving common network

speci�cations and implementing quick-disconnect (QD) I/O and

power solutions. The necessity of shorter project timelines and

quicker startups and the scarcity of “friendly” electricians have

helped to increase the pace of the implementation.

Automation manufacturers have responded with plug-and-

play solutions for the two dominant �eldbuses—Ethernet/IP

and Pro�net. There are other options here, but nowhere near

the number of solutions and reliability between those two. Your

PLC manufacturer’s country of origin will dictate your decision

between the two.

On top of that, your distributor, also known as your solution

partner, should be able to help with the design choices and

target the low-hanging fruit on your machine.

An evaluation of the required �eld I/O, type, density and

whatever �exibility required will help re�ne your choices. The

solution partner will also be able to provide demo products and

working solutions; the wheel has already been designed, no

need to start from scratch. This should help to reduce any extra

burden on your controls staff; they have enough other opportu-

nities making the machine work.

TOM LANDON

automation manager / Motion Industries Electrical Specialties Group /

www.motion-ind.com

KEL-ER: Cable entry frames for routing preterminated cables with protection class up to IP66 / UL type 12/4X.

Certified protection class Very high strain relief according to EN 62444 Warranty of pre-terminated cables remains Quick assembly High cable density

www.icotek-usa.com

Split cable entry frame

Very high strain relief according to EN 62444

GET ONE 4 FREE!

[email protected]

312-643-2315

Wire Your Machine

With Pre-Terminated

Cables!UP TO

ULTYPE4X


Food-safe bearings designed for aggressive cleaningDodge food-safe mounted ball bearings are designed to with-

stand caustic, high-pressure cleaning and sanitation processes.

The bearings have an IP69 water protection rating without the

use of an end cover, making them suitable for use in the food

and beverage industry in which equipment must be cleaned

aggressively. The bear-

ings’ 100% stainless

steel insert design

is combined with a

KleenTec top coat

to offer protection

against corrosion. The

smooth housing without a grease �tting minimizes contami-

nation harbor points and is easy to clean. The bearings are

available in a variety of housing styles, including pillow block,

tapped base, �ange and take-ups.

ABB / www.abb.com

IP66 sealed polycarbonate and ABS enclosuresOptimized for use in harsh industrial environments, the 1554

�at-lid and 1555 styled-lid ranges of ABS and UV-stabilized

polycarbonate enclosures provide IP66

sealing and good mechanical protec-

tion. The light-grey RAL 7035 enclo-

sures are designed to house printed

circuit boards or DIN rail-mounted

components. IP66 sealing is achieved

through a one-piece silicone gasket in a

tongue and groove seal. The styled lids

include a recess suitable for mounting

a membrane keyboard and also are �tted with PCB mounting

bosses. Bases are �tted with internal DIN rail mounting tabs in

all but two sizes and standoffs for mounting PCBs or optional

internal panels are provided in all versions.

Hammond Manufacturing / www.hammondmfg.com

Dual Gigabit Ethernet expansion moduleThe E5 dual Gigabit Ethernet expan-

sion board provides an easy way to add

additional Ethernet ports to high-stress

embedded computer systems. The mini

PCIe board works in industrial tempera-

ture applications from -40 to 85 °C. It is

self-contained with onboard magnetic isolation. No off-board

magnetics or special cabling is needed. Customization options

include conformal coating, revision locks, custom labeling, cus-

tomized testing and screening. The board is compatible with a

variety of operating systems such as Linux and Windows.

VersaLogic / 800-824-3163 / www.versalogic.com

Shafted rotary encoders with IP69K electrical protectionJ1 shafted rotary encoders are made to

ensure total protection from extreme

temperature �uctuation, intense machine

vibration and pressure washdown. They

are available in J1939, voltage and quadra-

ture outputs, as well as others. Prototyped

on an FDM 3-D printer, the encapsulation

method creates a fully protected electron-

ics package, which makes an environmental barrier between

the encoder’s shaft and bearing package. Other features include

absolute multiturn capability and MIL-STD 202 rating for shock

and vibration. Customizable connector options are available.

Joral / 262-378-5500 / www.joralllc.com

NEMA-rated weatherproof enclosuresThe TEF14-series includes 45 enclosure con�gurations and 15

essential accessories. Features include a weatherproof NEMA

design in standard 14- x 12- x 7-in sizes; a fully gasketed raised

lid for secure protection; pad lockable

stainless steel quick-release latches;

UV-stabilized polyester-reinforced �-

berglass construction; and options such

as cooling fans, power sources, heaters,

insulated, PoE, terminal blocks, DIN rail, pre-drilled mount-

ing plates, vents and UL-listed con�guration. Con�gurations

include 120-Vac, 240-Vac, 12-Vdc, PoE-ready and nonpowered

enclosures. Custom modi�cations also are available.

Transtector Systems / www.transtector.com

Low-voltage dc drive with snap-on programmable board optionThe DCL series is a low-voltage, brushless motor control that

operates in the 12- to 48-Vdc power bandwidth, up to 30 Amps

peak (1 minute) or 15 Amps continuously. The drive’s design re-


product showcase CONTACT US [email protected]

CD1906_46_49_Showcase.indd 46 5/28/19 8:47 AM

moves many of the trim pots and

jumpers associated with typical

motor controls. The drive can be

customized for speci�c OEM ap-

plications and motors. For users

who wish to modify calibration in

the �eld, the drive uses program-

mer board CPC300-1 (sold separately) that snaps onto the unit

and provides calibration of 10 different parameters, as well as

DIP switches for setting different modes of operation.

American Control Electronics / www.americancontrolelectronics.com

Compact hollow-shaft angle sensorThe WAL 340 hollow-shaft angle sensor provides absolute, ro-

tary position. Sensor dimensions are 32 x 39 mm. A notch built

into the housing aids alignment. The

device has a measurement range of 0 to

290°. Mechanical range is a continuous

360° with no stop. It accepts an 8-mm

D-shaped shaft. Other speci�cations

include resolution of <0.3°, repeatabil-

ity of 0.3° and independent linearity

of ±1% of measurement range. As an

absolute sensor, it continues to track

angle even if power is removed, report-

ing the correct position when power is

restored. It is protected from ingress of water and dust to IP65.

Novotechnik U.S. / 508-485-2244 / www.novotechnik.com

Compact linear voice coil motorThe LVCM-032-076-02 linear voice coil motor has a stroke

length of 2.5 in. (63.5 mm) with a force-to-size ratio of 1.8 lb

(8 N) and a peak force of 5.7 lb (25.3 N) at 10% duty cycle. This

quiet, low-inertia, high-acceleration, brushless, high-speed

linear dc motor has zero cogging and features high accuracy

and repeatability when operated in a closed loop as a dc servo

motor. It features a 10-32 UNC-2B threaded mounting hole

in the center of the housing and two 6-32-UNC-2B threaded

mounting holes on the coil end. Complete plug-and-

play systems including an encoder and

servo controller also are

available.

Moticont / 888-785-1804 /

www.moticont.com

Safety controller with functionality of two safety relaysThe SC10 series safety controller monitors safety devices on

smaller machines with hazardous motion. The controller can

replace the functionality of two or more safety relay modules. It

has 10 inputs, including four that can be converted to outputs,

and features automatic terminal optimization (ATO), which

makes it possible to increase the number of avail-

able inputs from 10 up to 14 to accommodate addi-

tional input devices. Two independent 6-Amp relay

outputs with three normally open sets of contacts

enable the creation of independent safety zones

with unique outputs for different safety functions.

Banner Engineering / www.bannerengineering.com

Magnetic sensors with IO-Link, analogThese magnetic position sensors combine IO-Link, analog voltage

and analog current in one device to overcome the limitations of

discrete pneumatic cylinder switches. The sensors provide con-

tinuous linear feedback, detecting and measuring the position of

pneumatic or hydraulic cylinder rods and actuators through non-

ferrous housing walls, over the entire measurement range. They

do it all contact-free. They are suitable for Industry 4.0 as they

improve ease of automation size change and allow for condition

monitoring and predictive maintenance. The sensors calculate

the actual target position of the magnet and output it as a

position-dependent analog or IO-Link signal. They

deliver signal stability and reliability.

Balluff / www.ballu�.com

Machine learning for automationThis machine learning (ML) solution is seamlessly integrated

into TwinCAT 3 software. Building on established standards, it

offers ML applications the same advantages of system openness

familiar from PC-based control technology. In addition, this solu-

tion supports real-time ML, allowing

it to simultaneously handle tasks such

as motion control. Functions include

TwinCAT 3 Machine Learning Infer-

ence Engine for classic ML algorithms,

such as support vector machine (SVM) and principal component

analysis (PCA) and TwinCAT 3 Neural Network Inference Engine

for deep learning and neural networks, such as multilayer percep-

trons (MLPs) and convolutional neural networks (CNNs).

Beckhoff Automation / 877-twincat / www.beckho�automation.com



Compact step motors with high torque for space-limited applicationsThese compact, lightweight step motors are available in NEMA

sizes 8, 11 and 14 for applications with limited space. They offer

high torque up to 22 oz-in at low speed. Even while sized small-

er, the motors operate with high step accuracy and resolution

as well as low vibration and noise. The line includes NEMA

size 8 in two lengths (1.24 and 1.85 in) and holding torque up to

4.53 oz-in, NEMA size 11 in two lengths (1.22 and 2.05 in) and

holding torque up to 14.16 oz-in and NEMA size

14 in two lengths (1.02 and 1.57 in) and holding

torques up to 25.53 oz-in.

Applied Motion Products / 800-525-

1609 / www.applied-motion.com

M12 �eld termination connectors and In-line adaptersThese M12 �eld termination connectors and in-line adapters

handle harsh-environment connectivity applications. The M12

interconnects were designed for factory automation, industrial

control, test equipment, I/O connectivity, sensors and actua-

tors or any connectivity application in which a screw-down

interface is necessary. The M12FT8A series �eld termination

connectors feature M12 eight-pin, A-code

connectors and are available in male,

female, straight and right-angle options.

The TC-M128AM-2M128AF-S is a shielded

M12, eight-pin, A-code male to dual female

M12, eight-pin, A-code, female T coupler that

is IP67-rated. The M128AMFS is a male to female, eight-pin, A-

code, panel-mount adapter that also is IP67-rated and features

straight-through wiring.

L-com / www.l-com.com

Compact I/O block for con�guration and monitoring via IO-LinkThe FEN20-4IOL industrial Ethernet I/O module uses IO-Link to

improve device con�guration, monitoring and replacement in

industrial applications. The compact block offers four IO-Link

channels. It is suitable for limited-space and

small I/O applications. In addition to the

device functioning as an IO-Link master,

each of the IO-Link (C/Q) pins can be

con�gured as digital input or output. The

I/O also is a �eld logic controller (FLC). As

an FLC, the module can carry out control tasks at the �eld level.

This enables users to implement simpler applications without

the need for an additional PLC.

Turck / www.turck.us

Vented miniature linear position sensorsThe vented versions of the M-375 miniature LVDT linear posi-

tion sensors are specially designed for reliability and accuracy

under a combination of high pressure, extreme temperatures,

shock and vibration conditions. Offering a lightweight, low

mass core and a compact 3/8-in diameter, these miniature

ac-operated position sensors are suitable for high-response

dynamic measurement

required in hydraulic and

material testing systems in

which space is at a pre-

mium. With vented holes

in the housing, pressure is

equalized inside and outside the sensors for reliable operation

in temperature extremes of -65 to 400 °F (-54 to 204 °C) and

operating pressures of 30,000 psi.

NewTek Sensor Solutions / www.newteksensors.com

Brushless motor with integral driveThe EnduraMax 75i series is a 75-mm-diameter brushless dc

motor with an all-digital integrated drive. The compact, high-

power-density motor is capable of controlling torque, speed and

position in a range of industrial applications. The line offers

three standard stack lengths with continuous rated power up

to 370 W, continuous rated torque up to 1.3 Nm (190 oz-in) and

rated speed of up to 5,150 rpm. The 12-, 24- or

48-Vdc winding voltage choices make it

suitable for battery-powered appli-

cations. Command inputs may be

±10 Vdc, 4-20 mA or via an optional

CANopen or Modbus port.

Allied Motion Technologies / www.alliedmotion.com

Class II and Class 2 power supplyThe DRL100-24-1/C2 is certi�ed as a Class 2 power supply in

accordance with NEC (per UL 1310) and as a limited power

source (per UL 60950 clause 2.5 requirements). The unit also

has a Class II construction with double insulation for operation


product showcase


without an earth ground connection. This 88 W-rated 24-V

model is housed in a rugged plastic enclosure, with overall

dimensions of 72 x 91 x 55.6 mm. The input range is 85 to 264

Vac, withstanding surges of up to 300 Vac for 5 seconds. The

input to output isolation is 3,000 Vac.

TDK-Lambda Americas / 800-lambda-4 / www.us.tdk-lambda.com

Resistive touch panelsThis series of customizable, �ush-surface, resistive touch panels have less than half the input

force of conventional resistive panels, nearly identical to that of projected capacitive panels.

The FID-1300 (four-wire) and FID-1520 (�ve-wire) series touch panels support a minimum input

force of 0.02 N (0.45 typical) while maintaining user input and

smooth sliding and �icking operations. A variety of implements

can be used to activate touch input, including bare skin, gloved

�ngers, wet �ngers, pens or stylus pens. The FID-1300 is avail-

able with two-point input, enlarge/shrink and rotation opera-

tions using a dual-touch control board.

Fujitsu Components America / www.fujitsu.com

LTE Cat-M1 router with built-in redundant powerThis Verizon-certi�ed LTE Cat-M1 router, the ICR-3211B, is a WWAN solution for applications that

don’t require high speeds usually associated with 4G LTE. LTE Cat-M1 devices provide similar

speeds to 2G (375kbps up/down), better building penetration for urban or bunkered installations

and lower power for battery-powered applications. It has a built-in supercapacitor for sending

“last gasp” messages if the primary power supply is interrupted. Other features include an open

Linux platform with development support for Python, Node-RED, C/C++,

Ethernet and RS-232/485 interfaces for �exible connected device

support, dual SIM cards and internal eSIM, a rugged metal enclo-

sure and an operating temperature range of -40 to 75 °C.

Advantech / 888-576-9668 / www.advantech.com

Side screen operator touch panelsThe Sinumerik CNC Blackline touch panels are available with a side

screen enhancement. This development enables users to customize the

CNC panel, laying out the operator panel in real time, using a drag-and-

drop technology. Screens can be customized to view documents, camera

projections, Web server access information, access protection data for IT

security protocols and even user administration. The side screen achieves

features and functionality such as the ongoing checking of machine tool

status, quicker and easier navigation, elimination of mechanical keys and

keyboards additions. The side screen can be opened or closed on either the left or right side of

the master operator panel.

Siemens / www.siemens.com

publishing teamgroup publisher & vp, content

Keith Larson [email protected]

vp, sales & publishing director

sales teamnortheastern and mid-atlantic regional manager

Dave Fisher [email protected]

508/543-5172 Fax: 508/543-3061

24 Cannon Forge Dr.

Foxboro, Massachusetts 02035

midwestern and southern regional manager

Greg Zamin [email protected]

704/256-5433 Fax: 704/256-5434

1501 E. Woodfield Rd., Suite 400N

Schaumburg, Illinois 60173

western and mountain regional manager

Jeff Mylin [email protected]

847/516-5879 Fax: 630/625-1124

digital sales specialist

Jeanne Freedland

[email protected]

805/773-4299 Fax: 805/773-0451

classified manager

Lori Goldberg [email protected]

630/467-1300 Fax: 630/467-1124

executive staffpresident & ceo

John M. Cappelletti

cfo

Rick Kasper

vp, creative services, production

Steve Herner

reprintsFoster Reprints • www.fosterprinting.com

Jill Kaletha

[email protected]

866-879-9144 ext. 194

The only magazine exclusively

dedicated to the original equipment manufactur-

ing (OEM) market for

instrumentation and controls—the

largest market for industrial controls.

1501 E. Woodfield Rd., Suite 400N

Schaumburg, Illinois 60173

630/467-1300

Fax: 630/467-1124



SO, YOU HAVE A PLC, and you need to program it to run an au-

tomated machine. If you want to be a programming hack, just

sit down and start writing the ladder logic and debug it. While

you may understand your methods, others won’t, at least not

quickly. So, if you want to do it like the big integrators do, there

are some things to focus on to ensure ef� cient development of

PLC-based control systems.

There is more to it than just writing the PLC program. The

architecture of the program must � rst be de� ned, and, once

written, it will need to be debugged,

tested and accepted, often by dif-

ferent individuals. Outside of the

program itself, this documentation

includes a machine controls pro-

gramming speci� cation.

When spearheading the control

software design effort, there should

be a strong emphasis on creating software that is documented,

organized, structured and reusable. This emphasis helps to

ensure ef� cient development of PLC-based control systems.

One of the key points is to write it down. Documenting the

program before it is written, as a programming speci� cation,

not only helps program development, the documentation can

then be edited into an acceptance testing document. It also

helps the understanding of the control system over the 10-plus

years it will be in operation for the other guy’s bene� t.

Beyond documenting the machine operation modes, ma-

chine cycle control and the machine sequences themselves, it

is important to document the hardware and software (� rm-

ware and version) used to create the program, as well, that

information is especially important � ve years from now, so

make sure it is updated, as-built.

Inside the program, there is much documentation, as well.

Many controllers are now capable of storing and displaying the

rung and device descriptions. The days of lost documentation

are past. However, there are ways to make the program more

readable, and that should be documented both outside and in-

side a program, as well.

While there are many parts to a PLC program that needs to

be written, if the auto cycle sequence—the part that repeats ev-

ery machine cycle—isn’t clearly written, it’s likely an example

of how to confuse the next guy who looks at it.

There is much more to writing a best-case example of a PLC

program, and that includes de� ning how to create self-docu-

menting memory, programs and functions. In the past, the PLC

memory was � xed. The manufacturer controlled variable nam-

ing and often limited the number of variables. Inputs (I), Outputs

(O), Bits (B), Integers (I), Floating point (F) and String (S) variable

names all started with an identifying letter, for example I:0/1,

O:1/0, B3:0/15. The type of variable is indicated in the name, but

not the function. In this case, a description is added to de� ne the

variable function, such as “System

air pressure ok.”

With most newer PLCs and PACs,

tag-based variable naming is used.

The contacts, coils, timers and coun-

ters can be self-de� ning, and how it

is done should be documented to be

consistent.

And careful variable naming will help with the auto complete

function that groups variables together when selecting them

from a drop-down list during program development.

For example, in a system with three stations, the variable

name local to each station can start with S100, S200 and S300.

These pre� xes can make it easy to copy and paste programs

and then search and replace the pre� x, as needed. It’s a form

of reusable code. Another example is a robot that has multiple

pick-and-place motions that set a “busy” local bit when each

motion is in cycle. It may be helpful to have the word, “busy,” in

the � rst part of the variable name. In this case, the auto-com-

plete feature displays all the busy bits together, (for example,

b_BusyR1PickNest1, b_BusyR1PickNest2, b_BusyR1PlaceTest1,

b_BusyR1MoveToClear). In this case the b_ indicates the vari-

able type is a bit. Some choose not to use these variable type

identi� ers, and it’s documented.

Alternatively, the pre� x vlb_ could be used to indicate vari-

able local bit and vpb_ to indicate a variable program (global)

bit. The point is variable naming should be de� ned so others

can understand the naming convention used. And, no matter

the naming convention, if the variable tag name is not self-

de� ning, add a descriptor, such as “Robot 1 is busy picking from

nest 1,” and there are many other examples. These self-de� ning

names or descriptors or both, are for the next guy. Be a courte-

ous programmer and document things.

How to document a PLC program


Dave Perkontechnical editor

[email protected]

automation basics

These self-de� ning names or descriptors or both are

for the next guy.

CD1906_50_AutoBasics.indd 50 5/28/19 8:48 AM

YOU DESERVE reliable timer relays with targeted signal control

automation24 .com/timer-relays

� Alternative solution to controllers in simple applications

� Multiple time functions and ranges

� Reliable digital output functionality

� Timer functions can be easilly adjusted via push buttons or rotary knobs

Need technical support? We are happy to advise you personally!

L I V EC H AT

L I V EC H AT

L I V EC H AT

YOU DESERVE fast delivery – all products in stock in our US warehouseAutomation24 – your online supplier for automation technology

Same-dayshipping

Exceptionalpricing

Best service with tech support

Continuously growingbrand selection

800-250-6772 (toll-free) or 610-981-2900 [email protected] www.automation24.com

$ 4 2. 6 6 MSRP: $47.40

-10 %Digital multifunction timer relay 600DT-CUItem no. 102080

Timer relaysfrom Selec

W

ARRANTY

W

A

W

A

W

RRANTY

W

ARRANTY

2 YEAR

2 2 2 2 2 2 2 2 2 2 2 YEARYEARYEARYEARYEARYEARYEARYEARYEARYEARYEARYEARYEARYEARYEARYEARYEARYEARYEARYEARYEARYEARYEARYEARYEARYEARYEARYEARYEARYEARYEARYEARYEARYEARYEARYEARYEAR

$ 3 5 . 4 6 MSRP: $39.40

-10 %Cyclic timer relay 55XC-P8-CUItem no. 400295

$35.82 MSRP: $39.80

-10 %On delay/Interval timer relay 800XU-CUItem no. 400296

CD1906_FPA.indd 51 5/28/19 8:55 AM

190218_AutoM_CTRL_US.indd 1 2/14/19 2:57 PMCD1906_FPA.indd 52 5/28/19 8:55 AM

Documents

TAKE FLIGHT, BUT STAY GROUNDED › assets › digital_edition › 2019 › June… · Machine Tools 2,110 Materials Handling, Conveyors & Conveying Equipment 1,507 ... both online