Electricity + Control May 2019

FEATURES: · Analytical instrumentation

· Control systems + automation · Drives, motors + switchgear · Energy management + environmental engineering · Sensors, switches + transducers

COMMENT

ON THE COVER

FEATURES: · Analytical instrumentation

· Control systems+ automation · Drives,motors+ switchgear · Energymanagement+ environmental engineering · Sensors, switches+ transducers

The emerging new order in industry

W hat a world we live in! So much that is happening seems like the stuff of a good book – or perhaps even a night- mare! But then one does tend to wake up… possibly screaming mind you … And – this is the world we live in, made that much more exciting by our presence in it! Beneath all the noise, remarkable things continue to happen – like the con- tinued rollout of better and more efficient ways for doing things. I can recall when Eskom first began driving energy efficiency very hard – and that was at a time when it had overcapac- ity. Many folk thought it quite funny that the utility would want to sell less energy. The point made then, of course, was the more efficient we became (and let’s be honest, our industry was not then particularly efficient, thriving as it did on cheap energy … ), the less we would need to plan and build new generation, transmission and distribution capacity. However, until people felt the impact in their pockets, energy efficiency was really not taken very seriously. I suspect the impact has now been felt good and solid – although quite probably as much as a consequence of the load shedding as of the increasing cost of energy. This brings to the fore the importance of understanding efficiency, not only in a technical sense, but also in the sense of how one manages and runs any oper- ation – and how operational processes are monitored, measured, automated and

controlled. Each component of efficiency contributes to the better performance and increased profitability of the organisation. We live in a world that is data rich in many, but not all, industries. In this regard, while there are many issues that need to be considered, what is evident is that the more able we are to gather data and con- vert it into useful information, the more able we are to actually improve pretty much every aspect of our operations. Connectedness and remote capability are key attributes of the emerging new order in industry – allowing safer and smarter decisions and actions to be tak- en. There can be no doubt that the more we understand every moment of the plant operation, the more we can manage it. The question then is: ‘what is your or- ganisation doing in this regard?’

energy + information in industry

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The Leuze DDLS 500 optical data transceiver, available from Countapulse Controls , offers instantaneous data transmission. (Read more on page 19).

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CONTENTS

Features

DRIVES, MOTORS + SWITCHGEAR 4 The advantages of motor independence in drive selection Anna Hildebrand Jensen, Danfoss

8 Understanding the terminology in IEC 61439 Johan Basson, Managing Director, JB Switchgear Solutions

10 Round UP

CONTROL SYSTEMS + AUTOMATION + SYSTEMS ENGINEERING 12 Some highlights from Hannover Messe 2019

15 Round UP

SENSORS, SWITCHES + TRANSDUCERS 20 Moving towards Industry 4.0 Countapulse Controls

23 Round UP

4

ENERGY MANAGEMENT + ENVIRONMENTAL ENGINEERING 26 Efficient energy management in industry Leigh Darroll, E+C

20

29 Round UP

ANALYTICAL INSTRUMENTATION 34 Monitoring water quality in industrial processes Endress+Hauser

36 Round UP

Regulars

1 Comment 19 Cover article 39 Cyber security 40 Write @ the back

34

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The advantages of motor independence in drive selection

Anna Hildebrand Jensen, Danfoss

Motor efficiency is a key concern across industry. Plant operators and original equip- ment manufacturers (OEMs) routinely specify electric motor installations according to European or other regional efficiency ratings.

Take Note!

1. To achieve optimal econ- omy in motors and drives it is important to take account of more than IE and IES energy-efficiency ratings. 2. Universally compatible drives offer full adapt- ability to new motor tech- nology as well as other advantages. 1 2

I n Europe, the IE classification gives an indica- tion of the energy efficiency of the motor and the motor controller (also known as ac drive, variable speed drive, or frequency converter) respectively, and the IES rating defines the effi- ciency of the entire system of motor and motor controller combined. The practice of specifying IE and IES is so convenient and effective for buyers and suppliers – and not least, for legislators – that it is well on the way to going global in various forms. More than just IE However, for optimal economy it is important to be aware that the energy- and cost-efficiency of sys- tems require focus on more than just IE and IES classes. High motor and motor-drive system efficien- cy is always a strong argument, but there are oth- er important considerations which include logistics, availability and, importantly, return on investment. All these factors influence total cost of operation:

are related to their nominal point. Efficiency class- es do not take account of part load efficiencies.

Flexible logistics Flexibility means the ability to accommodate changing customer specifications and new tech- nological trends, over the lifetime of the applica- tion. The best ac drives are compatible with all state-of-the-art motor technologies. Research ex- perts monitor upcoming trends and include new motor algorithms in software updates of the drive whenever the potential is good. Quick changeover When the supplier cannot supply a replacement motor as planned and there are bottlenecks in de- livery, a change to an alternative supplier or alter- native motor technology is often the best solution. That is when the ability of the drive to adapt to a different motor technology can be priceless. The best of these universally compatible drives offer full adaptability to a new motor technology even without the need for special firmware. Freedom from supplier dependency Limiting supplier dependency offers other advan- tages too, beyond overcoming delivery delays. In the lifetime of an application, no maintenance

- Flexible logistics - Quick changeover

- Freedom from supplier dependency - Adaptability in difficult locations.

Furthermore, it is important to realise that the effi- ciency classes of the motors and motor controllers

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crew wants to be limited in finding replacement motors due to special or non-standard motor di- mensions. Instead, the safe approach is to specify motors with standard IEC or NEMA dimensions from the outset. It will then always be possible to find alternative motors which physically fit the in- stallation. New technologies pack more power into the same motor frame size. This means that the high-efficiency motor keeps the normative dimen- sions but is often one frame size smaller. Similarly, to win the greatest benefits in mainte- nance management, it is important to have spec- ified from the outset that the ac drive connected to the motor has the compatibility to adapt to any standard motor technology. This factor is key for straightforward motor interchange. Adaptability for difficult locations A fast and easy motor retrofit, even in difficult en- vironments and awkward, inaccessible installation areas, also places particular demands on the ac drive specification. Ideally, the drive should be suitable for every installation environment. It should comply to high temperature operability without derating, and su- perior ingress protection at the level of IP55/UL Type 12 or IP66/UL Type 4X, allowing for it to be mounted without a cabinet. Another useful quality is that the drive can be mounted decentrally in the area close to the motor. When decentral mounting is not possible, the best ac drives can be mounted with as much as 150 m motor cable length and still deliver full electromagnetic compatibility. This fa- cilitates flexible installation when, for various loca- tional reasons, the drive cannot be installed close to the motor. Due to the flexibility in motor technology, the most adaptable of the drives available support far more than just increased motor efficiency. They also open the door to using motor technologies that come in smaller motor frame sizes, when this is acceptable in an exchange situation, and this opens up possibilities for solving awkward instal- lation challenges. The energy efficiency discussion in the new millennium has pushed the development of new motor technologies and the reinvention of exist- ing, older technologies. Because industry now has

variable speed drives at its disposal, the older tech- nologies can be optimised for energy efficiency.

Motor- independent drives offer the simplicity of having one drive type installed in the entire plant, with the advantage of automatic motor adaptation to deliver optimal performance of any motor.

Advantages and drawbacks Each motor type has its advantages and draw- backs. Optimisation of the induction machine to improve its energy efficiency (that is, to improve its IE rating) can result in an increase in physical di- mensions. As outlined above, in retrofit situations, its size and weight can become problematic. When comparatively assessing the advantages of different motor technologies, the following fac- tors should be taken into account. - IE class is not a characteristic of a particular technology. - Technologies differ in the way that they behave under part loads. A motor using one particular technology is not intrinsically more efficient than a motor based on another technology. It depends on the application. - Different motor technologies influence the in- rush currents. Sometimes new circuit breakers are required when changing motor type and not using variable speed drives. - Designers need to consider the cos phi/power factor of the selected motor technology when dimensioning the drive. This may result in hav- ing to over-dimension the drive. Despite the higher initial cost, the return on investment may still be attractive due to the lower energy consumption. Technologies like synchronous reluctance motors (SynRM) require a different sizing of the drive. For SynRM, the lower cos phi/power factor often results in the need to oversize the drive Best fit Which applications and motor control strategies are best suited to which motor technologies? Almost every motor technology can run with the correct voltage/frequency ratio applied. How- ever, this basic control has its limitations and ad- vanced control is a superior means of harvesting the optimal motor efficiency under varying load situations and fast load changes. For induction machines where sizing depends on current (amps), an automatic energy optimisation (AEO) control strategy is best to get

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DRIVES, MOTORS + SWITCHGEAR

higher energy savings. For AEO, motor voltage automatically adapts to load, which reduces loss at part load. For permanent magnet and high-efficiency synchronous reluctance motors, maximum torque per amp control (MTPA control) is the most commonly applied strategy. This control extracts the highest possible torque from the motor current. In fact, these motors cannot operate at all without a drive to provide motor control. Bundling It is important to maintain focus on total cost of operation, including lifetime costs of maintenance, regular exchange and production downtime. Bundling – purchasing all equipment from one supplier – can be convenient in certain contexts. Compatibility is ensured and spare parts stock min- imised. Often there is a single point of purchase in bundling, which is also convenient. However, there may still be multiple contact points within the organisation when it comes to support: one to support the drive, one to support the motor, yet another to support other equipment in the chain. Certain commercial benefits are also available through bundling. From a legal point of view, it is valuable to establish clear lines of responsibility

for delivery, function, guarantee and support. Pur- chasing an entire system from one supplier pro- vides those clear lines. Retrofit Bundling can nonetheless be difficult in retrofit sit- uations. Imagine, for example, the scenario where a European machine built up with a proprietary motor-drive bundle is sold into an installation in a remote region, where it forms part of a critical pro- cess, and one day, it unexpectedly breaks down. In a remote location, proprietary motor technol- ogies are not readily available. So the savings in purchase price of the bundle, and more, can be quickly negated by downtime. If the application were equipped with a motor-independent drive, the circumstances in an emergency breakdown would be different: it would be extremely useful to be able to retrofit whatever local motor may be available. Retrofit facilitated by a motor-independent drive also provides the potential for achieving greater output from the system, as the original motors are usually oversized. There is an opportunity to find the ideal modern motor for the application. Im- provements in productivity output are achievable without redesign, including improvements in oper- ating efficiency and gear ratio. Universally compatible drives Motor-independent drives offer the simplicity of having one drive type installed in the entire plant. One drive serving all motor types offers some fun- damental advantages, including lower volume of spare parts stock, training of staff in only one sys- tem and straightforward maintenance. A further benefit of using motor-independent drives is that efficiency improvements can be made with no need to stray from a long-term, trusted motor vendor. A host of reasons unrelated to efficiency can be significant factors in a sup- plier/customer relationship. These may include, among many other such factors, availability and delivery time, strong history of reliability, or one motor type being entrenched in all the customers’ plant drawings. The decision on the best motor for the job is for the user to make.

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Independent components Using automatic motor adaptation, motor- independent drives can deliver optimal perfor- mance of any motor just as well as the typical bundled motor and drive package. The motor-inde- pendent solution offers efficiency on par or some- times better than the bundle, due to its ability to cater for the diverse issues beyond IE class. Motor-independent drives developers have high stakes attached to running all motor tech- nologies and will adapt to every new tech- nology that arises. Due to the motor adapta- tion being software-based, it is possible to upgrade installed drives to compatibility with new motor technologies possibly not even in- vented at the time of the drive installation. Mo- tor independence is therefore inherently valu- able in retrofit where flexibility to choose the best motor for the task is an important consideration. As noted, motor-independent drives suppliers continually test new motor technologies in order to develop new algorithms for compatibility. Then they test to validate the optimised efficiency. So when choosing the right motor technology for the task, all the relevant data required for deci- sion making is readily available from the motor- independent drives supplier. Using motor-independent drives also opens other opportunities in that independently opti- mised components can be adapted to a variety of applications, whereas a bundled package is often optimised for a particular use case. The machine builder, with the required expertise, then has the opportunity to design the highest-performance drive/motor system for a specific niche application. Cost of labour Commercial considerations of course influence the choice in optimising performance by purchas- ing each component individually. Individual speci- fication and purchase of components is a labour- intensive process. It may therefore be more eco- nomical to choose a bundle, outsource respons- ibility and sacrifice some of the performance, or it may be more economical to choose motor and drive individually and achieve top-tuned perfor- mance.

In summary The advantages of a bundled motor-drive pack- age are that there is a single point of purchase, everything matches as it should, and lines of com- mercial responsibility are clean-cut and well-de- fined. However, in the long term it can become costly and limiting, especially in breakdown and retrofit situations. The alternative, a motor-independent drive combined with a selected motor, also has its ad- vantages. Financially, it offers the advantage of future-proofing – as the options remain open to use new generations of motor technologies over a long plant life. And to fine-tune performance to the optimum for a specific application, selecting in- dividual components is usually the best approach. The choice of motor-drive bundle or motor- independent drive combined with a selected mo- tor depends on the circumstances, on the required efficiency and performance, as well as on softer factors such as long-term relationships and trust. □

About the author Anna Hildebrand Jensen is an engineer from the University of Queensland, Australia, 1989. She has worked in the mining, construction and renewables industries in research and development, production and marketing roles. She has been with Danfoss as a technical writer since 2010.

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Understanding the terminology in IEC 61439

Johan Basson, Managing Director, JB Switchgear Solutions (Pty) Ltd

I n this tutorial we look at the topic of ‘Internal forms of separation’ in electrical switchgear and controlgear assemblies, where a variety of standard arrangements are detailed. They are la- belled Form 1, Form 2, Form 3 and Form 4. Forms 2, 3 and 4 are further broken down into Forms 2a, 2b, 3a, 3b, 4a and 4b. Each form relates to the internal separation of busbars, functional units and terminals. Internal separation is achieved by the use of barriers or partitions (including metallic or non-metallic), insu- lation of live parts, or an integral housing (such as a moulded case circuit breaker). The internal bar- riers should provide protection against contact to IPXXB and/or IP2X standards. Form 1 has no separation, while Form 4b has the greatest, with busbars, functional units and terminals all being separated – as shown in the figures below. The main reason for separating an assembly is to facilitate access to a part of the as- sembly while other parts may remain energised and in service. Although in general separation does not improve the electrical performance of the assembly it does provide: - Protection against contact with live parts be- longing to the adjacent functional units The IEC 61439 series of standards is applicable to low voltage switchgear and controlgear assemblies. Johan Basson looks at some of the terminologies and explains them so that the reader may gain better understanding of their meaning. Extracts from the standard itself are used extensively.

- Protection against the passage of solid foreign bodies from one unit of an assembly to an ad- jacent unit.

1. The different forms of internal separation for electrical switchgear and controlgear assemblies facilitate access to a part of the assembly while other parts may remain energised and in service. Take Note! 1

Forms of internal separation

Busbars, including distribution busbars

Enclosure

Internal separation

Functional unit

Terminal(s) for external conductors

Form 1 • No internal separation

Form 2 • Separation of busbars from all functional units

Form 2a: Terminals not separated from busbars

Form 2b: Terminals separated from busbars

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Form 3 • Separation of busbars from all functional units • Separation of all functional units from one another

• Separation of terminals for external conductors and external conductors from the functional units, but not from the termi- nals of other functional units.

Form 3a: Terminals not separated from busbars

Form 3b: Terminals and external conductors separated from busbars

Form 4 • Separation of busbars from all functional units • Separation of all functional units from one another

• Separation of terminals for external conductors associated with a functional unit from the terminals of any other functional unit and the busbar • Separation of external conductors from the busbars • Separation of the external conductors associated with a func- tional unit from other functional units and their terminals • External conductors need not be separated from each other.

Form 4a: Terminals in same compartment as associated functional unit

Form 4b: Terminals not in same compartment as associated functional unit

All drawings sourced from IEC 61439.

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round up DRIVES, MOTORS + SWITCHGEAR

Drive alignment laser

BMG’s extensive range of Fenner power transmission components and instruments includes the Fenner Drive Alignment Laser, designed for accurate pulley and sprocket alignment in order to reduce wear on belts and pulleys and ensure drive efficiency. Carlo Beukes, Business Unit Manager, Power Transmission at BMG, says, “The portable Fenner Drive Alignment Laser sys- tem – which is suitable for both vertical and horizontal mounted machines – is quick and easy to use and delivers accurate results. It is a compact and lightweight tool and the la- ser line allows rapid adjustment to perfect alignment. Conventional alignment meth- ods, which often require difficult, lengthy po- sitioning of components, can prolong down- time and affect efficiency. “The Fenner alignment system shows parallel and angular misalignment,” says Beu-

kes. “As a result, drive efficiency is improved and energy savings can be increased. With minimal friction and vibration, the service life of chain, sprockets, shafts and bearings is significantly extended and the costs of main- tenance, repair and downtime are reduced.” For maximum accuracy, the mounting unit is magnetised to attach firmly to sheaves or pulleys. It is also possible to attach this in- strument to non-magnetic sheaves simply using double-sided adhesive tape. BMG’s Fenner range includes synchro- nous transmission belts, pulleys and acces- sories, as well as shaft fixings, chain drives and couplings. The company also supplies Fenner shaft-mounted speed reducers (SMSRs). Enquiries: Carlo Beukes at BMG. Tel. +27 (0)11 620 7558, or email: carlob@bmgworld.net

BMG’s new Fenner Drive Alignment Laser is designed for quick and accurate pulley and sprocket alignment to improve drive efficien- cy, reduce wear and enhance energy savings.

Optimising OEMs’ costs for engineering machines

and through the life cycle of the machine. For simplified installa- tion, book and compact form factors reduce the machine footprint and allow efficient space usage, whether the machine is mounted in a frame or installed in an electrical cabinet. Fewer additional devices are needed to manage the machine safely and repeated sequential movements are managed internally within the drive. Printed circuit boards are class 3C3 coated, in accordance with IEC 61721-3-3, to protect against corrosion in harsh environments. The drives maintain a thermal state allowing uninterrupted oper- ation with ambient temperatures up to 60 °C. Integrated safety features include a safe stop and speed control as well as a guard door locking device. The system is suitable for applications in materials handling, packaging, the textile industry, mechanical actuators and hoisting. Magnet supports the Altivar ATV320 range with a technical ad- visory and installation service throughout Southern Africa. Enquiries: Magnet.Tel. +27 (0)31 274 1998, or email samantha@magnetgroup.co.za

Magnet supplies a range of Schneider energy management and automation systems which includes the Altivar ATV320 variable speed drives (VSDs). This system, developed to improve a ma- chine’s performance in diverse applications, also supports the op- timisation of design and engineering costs for original equipment manufacturers. “Schneider’s range of variable speed drives – with simple plug- and-play commissioning – meets simple and advanced application requirements for three phase synchronous and asynchronous mo- tors from 0,18 to 15 kW,” says Brian Howarth, Managing Director of the Magnet Group. “The Altivar ATV320 drive, which combines safety, reliability and simplicity, is used for building more effective machines, with greater reliability, at optimised costs.The drives provide for contin- uous machine operation, even in harsh environments with elevat- ed ambient temperature levels, dust, electrical interruptions and mechanical disturbances. “Schneider drives also maximise machine operating time be- cause production changes, maintenance, safety diagnostics, net- work configuration and system integration can be accomplished quickly,” says Howarth. Altivar ATV320 drives meet various machine throughput re- quirements, including open loop motor control, with dynamic accuracy for start/stop applications and torque-sensitive opera- tions, even at low speed. Closed loop motor control is offered for applications requiring velocity-sensitive operation or precise positioning. The drive system offers advanced connectivity with automation architecture via all common fieldbuses, in real time, with fast task cycle times. The Altivar range is designed for easy integration with various machine layouts. It reduces total machine costs during installation

Altivar ATV320 variable speed drives are designed to improve machine performance and allow for optimising OEM engineering costs.

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Driving the conveyors in new Mpumalanga coal mine

A greenfield coal mine in the Mpumalanga coalfields region has standardised on drives from SEW-EURODRIVE for its entire con- veyor-belt system. This entailed a 27-unit order that was assem- bled at the original equipment manufacturer’s Nelspruit facility and transported directly to site early this year. The order consisted of a complete drive package in the form of a simple ‘bolt-on’ solution for the conveyor-belt system. This included the drives, gearboxes, base plates, guards and, in one instance, an ancillary cooler. The project was facilitated by the Projects Department of SEW-EURODRIVE, under the direction of Project Sales Represent- atives Brett Weinmann and Bruce Farthing. This specialist in-house

department focuses on providing clients with complete solutions. Weinmann explains that the long-term aim of the Projects De- partment is to establish relationships with project houses in particu- lar, which put their designs out to competitive tender. Thereafter it is the responsibility of Farthing, a qualified mechanical engineer, to develop a solution best suited for the specific application and that is presented to the client for approval. “Our team is dynamic,” says Weinmann. “We strive to offer the best solution together with best customer service and technical back-up. We don’t simply supply products, but look at the applica- tion holistically.” The order for the new mine’s conveyor-belt system had to be customised and an important part of the service was ensuring the required specifications were met and keeping to the delivery date. “We like to be on-site during this critical phase of any project, to ensure that everything is according to specification and installed correctly. For example, we double-check the oil levels and the align- ment of the units and are also present at the first cold start-up,” Weinmann notes. Critical to the success of this project was the close working re- lationship with the project house, which allowed SEW-EURODRIVE an extended lead time. “This enables us to iron out all the technical specifications in advance and benefits our sub-suppliers as well,” Farthing says. SEW-EURODRIVE has subsequently received orders for anoth- er three cross-border projects with the same client, assisting in expanding its footprint in the African mining industry. Enquiries: SEW-EURODRIVE. Visit: www.SEWEurodriveSA The WEG VSD can also be used to set sleep and wake modes in the pump operation. This facilitates significant cost savings as pumping can then be done on a demand-driven basis. Where there are multiple pumps in use at the same pump sta- tion,WEG Pump Genius software and theWEG CFW11 VSD can be used to alternate motor usage automatically in order to ensure that each motor/pump combination has equal operation time. This pre- vents one pump being subjected to excessive wear and regulates the wear across all the pumps – resulting in the lower total cost of ownership for the installation. WEG VSDs support optimisation of water usage in the agribusi- ness which in turn supports effective land use. Enquiries: ZestWEG Group Africa.Tel. +27 (0)11 723 6000 or email: marketing@zestweg.com

The 27-unit drive package for the conveyor system was assembled at the OEM’s Nelspruit facility before being transported to the installation site.

Cost savings in water collection and pumping systems

WEG Variable Speed Drives (VSDs) offer the agricultural sector a way to reduce operating costs on automated water collection systems with a reduction in motor energy consumption when the motor speed is reduced. In addition, the VSDs allow for monitoring of all functionalities of a pumping operation, including special functions that contribute to saving operating costs and will optimise, control and protect the entire irrigation system. The drives can send commands automatically to the electric motor to facilitate control of the pumping installation and enable greater effectiveness when irrigating. TheWEG CFW 700 frequency inverter or VSD provides accurate speed variation for the electric motor, ensuring it operates accord- ing to the pressure needs of the irrigation system. With the neces- sary field telemetry, it can also take different land inclinations into account. Another important benefit is the drive’s ability to detect low pressure – indicating leakage in a pipeline. With this early warning from the VSD, users do not need to install specialised leak detec- tion equipment and can take remedial action as soon as required. Where water is being pumped from a river to the dam for fur- ther irrigation, use of the WEG VSD allows optimum control of the water level. It will prevent overflow situations and dry pumping can be set up without the addition of flow sensors.

The WEG CFW 11 VSD used in the Pump Genius configuration for an agricultural installation.

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CONTROL SYSTEMS + AUTOMATION

Some highlights from Hannover Messe 2019

An alliance for the IIoT At Hannover Messe 2019, seven leading suppliers from mechanical engineering, industrial automation and software announced the foundation of the Open Industry 4.0 Alliance. Through this cooperation, the com- panies aim to overcome proprietary solutions and boost the digital transformation of industry in Europe and further afield.

F ounding members of the alliance are Beckhoff, Endress+Hauser, Hilscher, ifm, KUKA, Multivac and SAP. In principle, the alliance is open to all companies. Balluff, Gebhardt, Pepperl+Fuchs, Schmidtsche Schack, Samson and WIKA have already joined the alliance as members. All companies are mutually committed to the creation of a standardised and open ecosystem for the operation of highly automated factories and process plants with the integration of logistics and services. Matthias Altendorf, CEO of the Endress+ Hauser Group, said, “The open architecture of the Open Industry 4.0 Alliance meets all the re- quirements of the process industry. It is based on standards, ensures transparency across all busi- ness processes, and guarantees the integrity of the systems. This enables process plant operators to leverage the potential of digitalisation.” The alliance members are planning to realise a so-called Open Industry 4.0 Framework based on existing standards such as I/O Link, OPC UA and RAMI, for the entire route from objects in the workshop to services. Customers can choose from a modular system of compatible and scalable solution and service components.

The connection to the SAP software portfolio supports the integration of a company’s business processes as well as collaboration with partners across company boundaries. The open architec- ture allows for simple connection of further sys- tem landscapes. More information about the Open Indus- try 4.0 Alliance will soon be published at www.openindustry4.com.

1. This new alliance is creating an open eco- system to enable the digital transformation of industrial plants. Take Note! 1

The Open Industry 4.0 Alliance aims to create a standardised and open ecosystem for the digitalisation of industrial production facilities.

For more information contact Endress+Hauser, email: info@za.endress.com or visit: www.endress.com/en

TwinCAT Scope software Beckhoff used the platform of Hannover Messe to introduce a number of new products to the market, including its TwinCAT Scope software.

I n the context of Industry 4.0 and big data applica- tions, machine data acquisition and analytics are becoming increasingly important. The information needs to be presented in a clear and efficient man- ner and the machine control system has to cover a wide range of other smart components. TwinCAT Scope software provides optimum support for such integrated data acquisition across heterogeneous system environments. A standardised OPC UA communication channel enables this charting tool

to analyse data from diverse sources such as Twin- CAT controllers and third-party components. TwinCAT 3 Scope consists of Scope View for the graphical display of signal curves, and Scope Server for the actual data logging. The Scope Server can be installed on a target device for au- tonomous logging (without the View component if preferred) or on the corresponding engineering system together with Scope View for remote log- ging. The latter solution offers the advantage that

1. TwinCAT Scope software from Beckhoff supports integrated data acqui- sition across different systems. Take Note! 2

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is suitable for an even larger group of users and more di- verse application scenarios. Also new at Hannover Other products presented by Beckhoff at the trade fair included:

no additional software needs to be installed on the target device. As a result, no updates to TwinCAT controllers are required and devices without Twin- CAT do not have to be modified in order to display their data graphically in Scope View. For logging measured signals, the Scope Serv- er now not only features a TwinCAT-specific ADS channel, but also offers support for another stand- ardised communication channel, which is realised as an OPC UA client. The widespread use of OPC UA in automation technology enables TwinCAT Scope to acquire and display measured data in a vendor- independent way. With OPC UA, this can be achieved reliably and securely, especially if certifi- cates are used. The TwinCAT Target Browser, which is used for managing the connected data sources in TwinCAT Engineering, has also been expanded with OPC UA support. It enables browsing in the name- spaces of connected OPC UA servers. This fea- ture can be used to select the desired variables for logging by the Scope Server with configuration options for certificate-protected access. A TwinCAT 3 Engineering installation always in- cludes a ScopeView and a local Scope Server. Both software components are included free of charge in the basic version, which enables testing of the OPC UA communication. With a rich set of fea- tures including multi-core support, triggers, chart synchronisation and numerous zoom functions, the tried and tested charting tool, now equipped with these latest communications enhancements,

- the ultra-compact C6032 industrial PC, a flexi- ble, high performance device in modular design - the AMP 8620 IP65 supply module, an addition to the AMP8000 distributed Servo Drive system that supports the implementation of modular ma- chine concepts. With the new AMP8620 supply module, drive technology can be implemented entirely without control cabinets, reducing floor space and cabling requirements for the entire machine and providing further savings on materi- als, assembly work and ongoing operations - a TwinCAT 3 machine learning solution that is seamlessly integrated intoTwinCAT 3 software and supports machine learning in real-time, providing machine builders and manufacturers with a foundation to enhance machine perfor- mance through prescriptive maintenance, for example, process optimisation and autono- mous detection of process anomalies.

With an OPC UA communication channel, the high-performance TwinCAT Scope multi-core oscilloscope can be used as a charting tool for diverse data sources, such as Beckhoff control technology and third- party components in different control systems.

For more information contact Beckhoff Automation, email: press@beckhoff.co.za or visit: www.beckhoff.co.za

CC-Link IETSN at Hannover Messe The CC-Link Partner Association (CLPA) participated at Hannover Messe for the first time this year, pro- moting CC-Link IETSN, the first open industrial Ethernet to combineTime Sensitive Networking (TSN) with Gigabit Ethernet to deliver a futureproof network for Industry 4.0 applications.

T he association’s strong international growth over the past several years has led to a glob- al installed base of around 24 million devices. CC-Link IE TSN will help to continue this trend as industry increasingly adopts Industry 4.0 ap- proaches to manufacturing. CC-Link IE TSN provides a solution for the fac- tories of the future. It offers a high-performance ability to handle both time critical deterministic traffic and other data such as less sensitive TCP/IP information on the same network. This is achieved by combining Gigabit bandwidth, first introduced

with CC-Link IE, and TSN capabilities, as defined by the IEEE 802.1 standards. The resulting open industrial communications network is fast, reliable and scalable, and ensures interoperability among devices from different vendors. The benefits of CC-Link IE TSN were demon- strated at the fair in the first fully operational prod- ucts from Hirschmann and Mitsubishi Electric, along with an overview of the third party develop- ment support ecosystem. John Browett, General Manager of CLPA Europe, said: “Having our first stand at the

3. Open industrial Ethernet combining Gigabit band- width and TSN capabili- ties supports Industry 4.0 applications. Take Note! 3

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Hannover Messe marked a further step in our commitment to offer advanced industrial commu- nications technologies for futureproof applications. Our family of networks is growing in acceptance and popularity worldwide, as a result of its open- ness, interoperability and Gigabit bandwidth. CC-Link IE TSN illustrates how the CLPA is leading the way in offering high productivity and flexible net- working architectures to manufacturing industries.”

CC-Link IE TSN is the first open industrial Ether- net to combine Time Sensitive Networking (TSN) with Giga- bit Ethernet to deliver a future- proof network for Industry 4.0 applications.

For more information contact CLPA, email: john.browett@eu.cc-link.org or visit: https://eu.cc-link.org

The next level of digital transformation Under the banner ‘Digital Enterprise – Thinking industry further’ Siemens presented a number of additions to its Digital Enterprise portfolio supporting the next level of digital transformation in the discrete and process industries.

K laus Helmrich, Member of the Managing Board of Siemens AG and CEO of Digital In- dustries, said at the fair, "With the integration of cutting-edge technologies into our portfolio, we can help industrial companies to benefit from rapidly growing data volumes in new ways. Using technol- ogies such as artificial intelligence, edge computing and additive manufacturing, we are paving the way for the future of industry.We are also rethinking pro- cess control technology and introducing the web- based Simatic PCS neo process control system." Companies of any size can use industry-specific solutions to increase their flexibility and productivity and develop new business models. Helmrich high- lighted too that innovation partnerships between large companies and SMEs are just as essential as cooperation between business, science and politics. The basis for Siemens cutting-edge techno- logies is the availability of data. Through digital twins, which map and link together all the steps of industrial manufacturing in a virtual world, com- prehensive data pools can be created. "The cru- cial factor is using the data from the digital twin of the product, production and performance in an innovative way that creates new potential for pro- ductivity. When automation, software, hardware, cloud platforms and cutting-edge technologies are integrated and combined seamlessly, the data can be converted into valuable knowledge – increasing performance and flexibility. This is the next step of digital transformation," Helmrich said.

One example is a new module with an integrat- ed AI-capable chip for the Simatic S7-1500 control- ler: through the use of machine learning algorithms, robot-based handling processes can be optimised. Artificial intelligence (AI) requires large volumes of data for the learning process and this data is only available if processes have been digitalised and linked together seamlessly. With Industrial Edge, Siemens has extended its Digital Enterprise auto- mation platforms – Simatic and Sinumerik – to in- clude a data processing solution on the shop floor – and it is scalable from the shop floor to the Mind- Sphere open, cloud-based IoT operating system. At Hannover Messe, Siemens showcased an example from automotive manufacturing to demonstrate how the use of cloud and edge-based data analysis, together with other technologies such as additive manufacturing or autonomous manufacturing systems, create new opportunities for the efficient and flexible production of electric cars and batteries. The company is supporting the automotive industry with software and automation systems for the transformation to e-mobility. It also helps companies to meet the challenge of growing demand for increasingly customised products and alternative drive concepts. Digitalisation cannot be implemented without protecting industrial plants from cyber-attacks. In future, AI and edge computing will also improve security, as data analysis can be used to detect cyber-attacks more quickly and reliably.

4. The new 5G commu- nications standard will provide the powerful communications infra- structure required for Industry 4.0 applications. Take Note! 4

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Industrial 5G and establishing several 5G inter- operability test centres under actual OT conditions.

In process automation, Siemens introduced Si- matic PCS neo, a new software package which uses the hardware portfolio and application architecture of the powerful Simatic PCS 7V9.0 process control sys- tem. It offers companies in the process industries ac- cess to global web-based cooperation in engineering and operations. The system is scalable from small process modules through to big process plants. Looking to the future, Siemens also presented a number of potential industrial applications us- ing new and developing technologies. Blockchain, for example, can be used to improve traceability in the food supply chain. And the new 5G com- munications standard will provide the powerful communications infrastructure – delivering relia- ble, high-performance broadband transmission to enable the efficient transfer of high volumes of OT and IT data – required for Industry 4.0 applications. Siemens is running its own research projects for

Siemens presented a number of new additions to its Digital Enterprise portfolio at Hannover Messe 2019.

For more information contact Siemens: https://new.siemens.com/global/en.html

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Change management key to Industry 4.0 transition

At the opening of the Connected Industries Conference, which will run alongside the Africa Automation Fair, 4 to 6 June in Johannesburg, Toubøl will present some of Lego’s Industry 4.0 learnings in his area of expertise, with practical advice on key technologies, managing change and the competencies needed in the workforce. Marius Smit, event organiser at Reed Exhibitions, says Indus- try 4.0 is a priority for South African enterprises seeking to grow efficiencies and become more competitive internationally. “Ad- dressing local concerns and Industry 4.0 ambitions, the Connected

While South African enterprises are moving to embrace Industry 4.0 models and technologies to enhance efficiencies and remain competitive, adapting to these new models is not without chal- lenges. However, migration to this new world does not have to take place in a ‘big bang’ manner. Jesper Toubøl, Vice President, Elements and Moulds at Lego, says traditional business culture and a lack of effective change man- agement can test efforts to move to an Industry 4.0 environment. Toubøl was speaking ahead of the Africa Automation Fair and Con- nected Industries Conference coming up in June, where he will de- liver the keynote address on Industry 4.0. “Key to transitioning to Industry 4.0 effectively is to shift from a traditional waterfall approach to an agile approach. It is not necessary to do massive rollouts: development and change can be implemented faster in small stages,” he says. “It is also important to demystify what Industry 4.0 means, particularly among workforces, and to emphasise the business case and workforce benefits of moving to an Industry 4.0 environ- ment. So effective change management is crucial.” Toubøl notes that industry is confronted with the rapid advent of Industry 4.0 at the same time as older pre-internet management faces the arrival of a wave of millennials and ‘digital natives’ in the workplace, resulting in myriad cultural and operational changes in industrial environments. “Enterprises need to accept new ways of working,” he says.

Industries Conference will assess South Africa’s progress in this re- gard and consider Industry 4.0’s potential impact on South African manufacturing. For more information, visit: www.reedexpoafrica.co.za or www.africaautomationfair.com

Jesper Toubøl, Vice President, Elements and Moulds at Lego.

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Selecting the smart PLC vendor and system. In cases where space is at a premium, PLC and HMI all-in-one control- lers have an advantage. Some PLC manu- facturers provide PLC and HMI controllers with on-board or snap-on I/O modules, which save space and reduce wiring. Data communication and more Flexibility is key – the more protocols the selected brand of PLC supports, the great- er its scope of interoperability with existing applications and third-party devices. Impor- tant industrial data communications proto- cols include Modbus, Ethernet IP, CANopen and various CAN bus dimensions such as CAN layer 2, and others. The PLC manufac- turer should also provide software utilities that enable you to implement proprietary third-party data-com protocols such as se- rial RS232/485, or TCP/IP. The visibility of operating data and diagnostic information is another important consideration, as is re- mote access via the web server with sup- port for SMS messaging or email. Intelligent software Intelligently designed software can help save time. In this regard, there are two particularly important factors to consider: ease of use – such that the programmer does not need to search for elements when programming and can understand the programming steps intuitively; and re-usability – which should apply for all pro- gramming functions – the ability to re-use your work across projects will save a lot of time.

There are a number of manufacturers of programmable logic controllers (PLCs) for automation control projects. However, most of us have a preferred brand, a plat- form that we return to time and again. This is because familiar = fast. You know the hardware range. You know the software. You know what to expect and you have a sales representative on speed dial. For these reasons, selecting the manufacturer that stands behind a brand of controllers is important – just as important as deciding on your central processing unit (CPU) and input/output (I/O) requirements. ACDC Dynamics suggests the following factors should be considered in selecting a smart PLC vendor. A range of PLCs The selected brand should have a com- plete product range that can meet the requirements of your customers. PLCs must be able to supply sufficient memo- ry to support I/O, log and manipulate his- torical data, as well as execute the con- trol program. Where execution speed is critical, the CPU processing speed must be considered as well. Other considera- tions should take account of the sector’s standards, whether or not the application needs to comply with hazardous environ- ment standards, CFR-21.11, or the spray- and-wipe standards of the food and bev- erage industry. Influenced by the mobile industry, customers are likely to expect HMI colour touch-panels to provide the communication window between operator

Service and support It is important to look for PLC manufactur- ers that offer a high level of customer care in both technical and sales support. Per- sonal support – from people, as opposed to automated systems – on a 24/7 basis, is also valuable. It can make the difference to meeting deadlines and retaining custom- ers. Support documents, specifications and guides should be readily available too. And ideally, this support and documenta- tion should be available at no extra charge. Total cost of ownership Cost is never limited to the purchase price of the PLC. Development costs and future maintenance can make or break your profit margin. When buying a PLC, it’s important to remember that you are also selecting the company that stands behind that PLC – and that this decision, over the long run, can have a major impact on your success in industrial automation projects. Enquiries: ACDC Dynamics, email: info@acdc.co.za

In selecting the right PLC for automation projects it’s important to consider the support services too.

Easy planning of I/O stations

The result is shown directly in the main window of the software. Once users have finished configuring the I/O station, they have an I/O station that is technically correct along with the corresponding bill of materials (including detailed product descriptions). To mark the I/O station or configure a complete terminal strip, the configured result can be exported from Project+ and completed

Version 3 of the Project+ planning software from Phoenix Contact is available to download. I/O stations from the Axioline F and Inline product families can be configured using the software, without re- quiring extensive system knowledge. The software offers users a choice of possible connection sce- narios based on the automation-related signal types they have se- lected and those that correspond to the I/O devices they intend to connect. Based on this selection, Project+ determines the device combination for all required connection scenarios. The software optimises the selection according to various as- pects such as price, station width and the number of devices. Us- ers do not need to be familiar with specific configuration rules. Every time the user enters or changes the signal types, the software selects the appropriate I/O product for the I/O station.

in the PROJECT complete planning and marking software from Phoenix Contact. Enquiries: Phoenix Contact. Tel. +27 (0)11 801 8200, or email info@phoenixcontact.co.za

Project+ Version 3 planning software is now available.

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