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 Volume 27, No. 9 table of contents

20
cover story

Where do
I fit in?
Not all robots are the same,
so how do you integrate them
with factory machinery?

Mike Bacidore, editor-in-chief

31
product roundup

Safety by the numbers

Numerous devices make machines and systems safer

Control Design is published 9 times by Endeavor Business Media, LLC. 1233 Janesville Ave., Fort Atkinson, WI 53538. POSTMASTER: Send address changes to Control Design, PO Box 3257, Northbrook, IL 60065-3257.
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publishers, unless so stated. The publishers do not warrant either expressly or by implication, the factual accuracy of the articles herein, nor do they so warrant any views or opinions by the authors of said articles.

ControlDesign.com / October/November 2023 / 5

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 Volume 27, No. 9 table of contents

Easy and secure Remote

Access to your machines

COLUMNS
9 editor’s page 16 component considerations
AI will change Enhancing control-
manufacturing system security
Mike Bacidore, editor in chief Shawn Cox, contributing editor

11 embedded intelligence 33 real answers

From barcodes to Exploring operator-

RFID and beyond interface options
Jeremy Pollard, CET

42 automation basics
12 technology trends
Why Ethernet is the
Innovations in backbone of protocols
electric-motor Joey Stubbs, contributing editor

technology
Rick Rice, contributing editor

ad index
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Process improvement is like climbing.
With a strong partner, you can overcome
any obstacle.
Just as athletes rely on their teammates, we know that partnering with our
customers brings the same level of support and dependability in the area of
manufacturing productivity. Together, we can overcome challenges and achieve
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and environmental protection. Let’s improve together.

Do you want to learn more?

www.us.endress.com
 editor’s page
Endeavor Business Media, LLC
30 Burton Hills Blvd, Ste. 185,
Nashville, TN 37215
800-547-7377 Mike Bacidore
ceo
editor in chief
Chris Ferrell
president
[email protected]
June Griffin
cfo
Mark Zadell
coo
Patrick Rains

AI will change manufacturing

cro
Reggie Lawrence
chief administrative and legal officer
Tracy Kane
chief Digital Officer
Jacquie Niemiec
evp / group publisher
ARTIFICIAL INTELLIGENCE (AI) WILL have numerous applications in the manufacturing
Mike Christian sector—from digital twins and quality control to production efficiency and predictive
vp / group publisher
Keith Larson
analytics. The future will surely have AI’s fingerprints all over it. Generative AI, which
uses algorithms to generate content, such as text, images, video, code or 3D designs, has
editorial team specific applications in industrial manufacturing, such as writing programs and creating
editor in chief
efficient designs. The development of these generative applications are primarily coming
Mike Bacidore
[email protected] from upstream of the factory or plant. Original equipment manufacturers (OEMs), such as
managing editor
machine builders and system integrators, are curious about AI, but the use cases are com-
Anna Townshend
[email protected] ing from the automation suppliers.
digital editor
A supplier can provide automation that replaces technically skilled workers or elimi-
Madison Ratcliff
[email protected] nates the need to create that same technology on your own. ChatGPT, a well-known
contributing editor
generative pre-trained transformer
Rick Rice
[email protected] (GPT), costs $700,000 a day to run,
contributing editor
according to SemiAnalysis. These
Joey Stubbs
two factors could lead to an AI-as-
ChatGPT, a well-known generative
contributing editor
Shawn Cox a-service business model, joining pre-trained transformer (GPT),
[email protected]
editorial assistant software-as-a-service, robotics-as-a- costs $700,000 a day to run.
Lori Goldberg service and production-as-a-service.
[email protected]
columnist Emerson, for example, has re-
Jeremy Pollard leased an AI-based software called
[email protected]
Revamp, which runs in the cloud, that converts DeltaV control-system and safety-system
design/production code in plant modernization projects.
production manager The Advanced Robotics for Manufacturing (ARM) Institute is one of the manufacturing
Anetta Gauthier
[email protected]
institutes linked together within Manufacturing USA. It recently announced eight projects
ad services manager for second-round funding with plans to award nearly $1.5 million, bringing the total con-
Rita Fitzgerald
[email protected]
tribution to around $3.3 million across these eight projects.
art director A project team representing Ohio State University, CapSen Robotics, Yaskawa and Rob-
Derek Chamberlain
ins Air Force Base designed and deployed an AI robotic system capable of producing com-
ponent geometries for metal-forming in automotive manufacturing, factory machinery,
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circulation requests / classifieds and paste-like materials more safely, replacing humans with robots.
Lori Goldberg
[email protected]
Beckhoff’s TwinCAT Chat Client for its TwinCAT XAE engineering environment makes it
possible to use large language models (LLMs), such as ChatGPT from OpenAI, to develop a
sales team TwinCAT project in control programming. The TwinCAT Chat Client enables AI-supported
Account Manager
engineering to automate tasks such as the creation or addition of function-block code, and
Greg Zamin [email protected]
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Jeff Mylin [email protected]
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ControlDesign.com / October/November 2023 / 9

 embedded intelligence

Jeremy Pollard
[email protected]

From barcodes to RFID and beyond

WE, AS HUMANS, can talk and gesture, but a bag of peas cannot. Radio-frequency identification (RFID) systems are similar to bar-
So, when two Drexel University students went looking for a codes in that they identify. That bag of peas could, in the modern
method of providing better inventory management for grocery era, actually have an RFID tag in or on the bag. Radio-frequency
stores, as well as a better customer checkout experience, the identification devices come in different flavors—passive and active.
barcode was born. One of the main differences in coding techniques is de-
Now the bag of peas had a name that could be recognized structive vs. non-destructive programming. Barcodes that
by a static object called a barcode reader. Oops, there really are printed onto a product or device are there forever and
wasn’t one back in those days that could actually work as far cannot be changed—destructive.
as the design of the circular barcode helping a supermarket RFID tags can be repurposed and thus reprogrammed, which
create a self-checkout line. is non-destructive. The data is
It really wasn’t until the 1970s that associated with an RFID tag. The
an oscillating mirror laser could read Active tags have their own power application determines the extent
barcodes and interface into the inven- supply and can transmit signals of the programming.
tory system along with the develop- with higher power. A passive tag needs to have
ment of the vertical UPC code that we power induced by the reader itself,
know and love. which limits the distance away
The first scan of a pack of gum from the reader. Consider your
took place in 1974. What the checkout system needed to know credit card that has RFID embedded, so you have to place the
was the product code, which was set up in a database so the card right onto the reader. Also consider the fact that a criminal
pricing and other pieces of information tagged to that pack of can have a reader in pocket and brush up against your pocket
gum could be accessed. Voila! The receipt was printed, money or purse and read your card, so the technology is really cool, but
exchanged, and the customer left the building. potentially harmful to your bank account.
Any sort of code essentially does the same thing—identify. Active tags have their own power supply and can transmit
The limitation comes from the form factor of the code. A bag signals with higher power, so the reader can be farther away.
of peas from Del Monte vs. Green Giant would have different One project tracked carts in a distribution warehouse. The
price points, bag size, vendor name, store SKU, and maybe even cart was loaded with a disparate product destined for Store A.
large vs. small peas. The barcode to be read would be very long. If the truck that was destined for Store A was ready but waiting
Do we really need that capability on the code itself? Not if we for a last batch of product, a forklift driver would know where it
have access to a database that can be pointed into and grab all was and then drive by the carts to find the one, pick up the pal-
that data in an instant. let and deliver it to the truck for efficiency.
Access to information has always been the holy grail. The Once the product was shipped, the tag would be reset to
:CueCat device was issued by Radio Shack—for free, I might default, ready for reuse.
add—to read a barcode beside an ad in a magazine, which led Radio-frequency identification allows any operation to be
you to a web page that advertised that product or technology. dynamic with the movement of equipment and/or stock. We are
Quick-response (QR) codes are an extension of the barcode getting closer to the ability to have all data that used to be in a
technology, but they give the ability of alphanumeric data database be resident in the tag itself. Power requirements are
that can be scanned. This will become very handy when getting smaller. Distances to be read are increasing. There’s no
scanning with a smartphone to access a URL to get to a telling where identification technology will end up.
webpage on the internet in a restaurant so you can see the
menu. It was 1974 when this code was created. Readers were JEREMY POLLARD, CET, has been writing about technology and
clumsy at best. The QR code currently in use was developed software issues for many years. Pollard has been involved in control
in 1999 in Japan. system programming and training for more than 25 years.

ControlDesign.com / October/November 2023 / 11

technology trends

Rick Rice
contributing editor
[email protected]

Innovations in electric-motor technology

WHEN I WAS GOING to college to earn my diploma, I spent a So, what is going on in the world of motors and drives? The
couple of co-operative education terms working for an electri- general target of any technical revolution is to make something
cal motor repair shop. For a young person just getting into what better using fewer resources. Plainly stated, we want to make
would become a career, this was a perfect work placement. something that runs on less energy, and we also use less energy
We were located just two minutes away from a major cereal- to make that something.
and-corn-starch-production facility, and we were the emergency Here are some examples of innovation to consider.
repair point for large or customized electrical motors. Anything An induction motor is called that because we use the specific
from a fractional horsepower single-phase induction fan or placement of loops of wire—windings—around a metallic core
pump motor up to 100 hp or more came across my work bench. to produce an electromagnet field when electricity is applied to
While I was primarily the initial those windings. The stator—that
testing technician and could perform collection of windings around a
bearing changes and brush replace- As control designers, we always core—induces magnetic fields that
ment, I was keenly fascinated by the want to choose from the latest cause the rotor to turn when the
rewind operation just across the aisle product offerings. fields of the stator interact with the
from my work bench. fields on the rotor. The net result
Prior to working there, I had no idea causes rotation that can be used to
that one could bake a rotor or stator in put things in motion.
a high-temperature oven to burn off all the insulation and then Let’s talk about those windings for a minute. The traditional
remove the windings in order to rebuild the motor. winding is just that, a length of wire wound around a specific
The most amazing memory of that experience was what the path that is then laid into the gaps in the core of the stator.
90-year-old owner, Art Jenkins, had stored in his mind from his Each winding has the same length of wire of a specific cross-
life experience. You could tell him the number of poles, desired section—gauge—wound in the same geometric shape so that,
horsepower and speed of any motor, and he would tell you the when complete, each winding will produce the same electro-
gauge of wire, number of windings and configuration of the magnetic field when power is applied to it. Now we can’t just
windings that were required to restore that motor to operation. take bare wire and wrap it around a shape to make these wind-
This wasn’t done by looking it up in a book or chart. Art could ings. The wire must be insulated.
rhyme it off from memory. My fascination of Art’s core under- Now, imagine that conformed loop of wire. Wire is round,
standing of motors was a key element in propelling me into this and then we dip it in an insulating material. We want enough
field of control design. insulation to allow for the flow of electricity but with enough
As control designers, we always want to choose from dielectric strength so that the electricity doesn’t want to jump
the latest product offerings of our component vendors. The from one loop of conductor to another. The net result of all
primary reason for this is to take advantage of the latest those loops of wire is, no matter how accurately we position ad-
technical advances. Secondary to that is the need to replace a jacent loops, there will always be a bit of air gap between them.
defective component. The less compact the wire bundle is, the weaker the magnetic
When it comes to machine control design, conventional field generated. One manufacturer proposed to use square wire.
and servo motors take up a large space in the budget, and an As one can imagine, square wire, with square shaped insulation
equally significant consideration in the approach to the controls around it, nestles quite nicely into the adjacent loops of conductor.
we choose for the application. Advances in this technology tend The net result is less air gap and better magnetic fields being
to fly under the wire. The automation world tends to focus on generated. So, for the same physical area, the motor can be
the brains of the system like programmable controllers and more powerful because the magnetic fields that are generated
operator stations, and the corporate world is all tied up in the are better. Conversely, for the same power output, the motor
Internet of Things (IoT), digital twins and big data. size can be smaller.

12 / October/November 2023 / ControlDesign.com

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technology trends

Here is another innovative idea. Traditionally, a rotor will

be cast out of aluminum. Aluminum doesn’t conduct electric-
ity nearly as well as copper, for example, so why would we
cast the rotor out of aluminum? Well, it comes down to the
properties of the metal.
Aluminum melts at a far lower temperature (1,220 °F) than
copper (1,981 °F). This means that the processes used to form
the rotor can do so at much lower temperatures. Lower tem-
perature means lower cost to produce. We can produce far more
efficient motors that use less energy to produce and use less
energy to operate.
Another facet of motor technology that has improved power
and efficiency of motors is the use of permanent magnets. In
a traditional induction motor, there are no magnet fields until
energy is applied to the windings. By embedding a strong, rare
earth or ceramic magnet in the rotor of a motor, the magnetic
field is already there before power is even applied. stepper or servo in a linear actuator can make the action faster,
A permanent magnet motor has torque-to-weight ratios with more control over the end device and greater accuracy
that are double what an induction motor can produce, and the over the motion due to the ability to use an encoder to provide
motor can spin at various speeds, as well as generate a higher direct feedback of the movement.
magnetic field in a smaller package. The electric-car market is Hydraulics are messy to work with and, while powerful, need
benefitting from this technology because the motor is so power- to be large to achieve the goal. Stronger motors in smaller pack-
ful and efficient that it can be used in applications where it can ages make many things possible that would have been prohibi-
eliminate the need for a costly and inefficient gearbox. tive in the not-too-distant past.
Other manufacturers are playing with the flux field to im- We often focus on the control side of the equation when it
prove function. Flux is the magnetic field that is generated in a comes to control design. The servo or variable-frequency drive
motor. Traditional motors generate a radial flux that is perpen- is where the smarts are located, but the core function of the
dicular to the rotation of the motor. To make more powerful motor is what makes the object move. Smaller motors that are
motors, you need to either make the circumference of the motor more powerful and more efficient mean you don’t have to have
larger to house more loops in the windings or make the motor such a large drive in your control cabinet.
longer to achieve the same thing. This makes it possible for some drives to have multiple-axis
By making the flux field axial—parallel to the rotation of the control in the same physical package. The enclosure can be
motor—the motor design can be much more compact. Another smaller, or you can do more with the same size enclosure.
manufacturer is working on technology to make a trapezoidal The focus on a greener tomorrow has placed the spotlight
radial flux. The concept, again, results in a smaller motor pack- clearly on the electric-vehicle market. The benefit of that
age for the same power output. focus is bouncing right back into the controls industry as
All of these innovations are targeted at improving power the desire to operate a vehicle off a battery has given us the
while reducing the size of the package and, importantly, creat- ability to make complex machines that cost less and give us
ing devices that use less energy. The smaller the package, the more freedom in design.
more can be done with it. I often wonder what my good friend Art would think about
Motors and servos are everywhere in technology. This has what we are doing with motors. I think he would be happy
progressed far enough that traditional pneumatic or hydraulic about how far we have come.
applications can use motors for the same result.
Producing air costs money, so eliminating the use of pneu- RICK RICE is a controls engineer at Crest Foods (www.crestfoods.com),
matic devices in a design is a desirable objective. The use of a a dry-foods manufacturing and packaging company in Ashton, Illinois.

14 / October/November 2023 / ControlDesign.com

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component considerations

Shawn Cox
contributing editor
[email protected]

Enhancing control-system security

SECURING CONTROL SYSTEMS is paramount in our intercon- compatibility and disruptions. To handle patches well, focus
nected world. Safeguarding critical infrastructure from cyber on vital updates, test thoroughly and prepare rollback plans.
threats is vital to avert disruptions and ensure the continuous Outdated software risks include vulnerabilities, compatibility
operation of essential systems. problems and limited functions. Staying current offers better
Control systems are susceptible to outdated software, weak security, performance, new features and tech compatibility.
authentication and absent encryption. These gaps expose sys- Employees are pivotal in upholding control-system security.
tems to cyber threats, aiding unauthorized access and critical They follow protocols, stay vigilant for anomalies and report
infrastructure compromise. Incidents like the Stuxnet worm concerns promptly. Invaluable ongoing training educates em-
hitting Iranian nuclear sites and the Ukrainian power grid cy- ployees on best practices, enhancing their ability to spot and
berattack underscore the dire conse- counter risks, bolstering security.
quences of breached control systems. Threats like phishing, malware
A multi-layered security strategy An effective incident response plan and social engineering require
for control systems involves the in- should include critical features such cautiousness. Employees should
stallation of many security measures, as clear roles and duties. scrutinize emails, update antivirus
such as firewalls, access limits, intru- software and report oddities to IT.
sion detection systems and regular A well-defined incident re-
upgrades to give full safeguards sponse strategy is critical for
against possible breaches. Network security, access controls companies to address security problems quickly and prompt-
and physical security work together. Network security pro- ly. It assists in minimizing damage, reducing downtime and
tects against cyber threats; access controls restrict unauthor- ensuring a quick recovery, ultimately protecting the organi-
ized access; and physical security safeguards against physical zation’s reputation and consumer confidence.
tampering or sabotage. A well-defined incident-response plan mitigates the impact
Securing control-system networks entails techniques like of a security breach by providing precise instructions on how to
air-gapping for critical system isolation, network segmentation restrict the intrusion, mitigate its effects and restore systems
based on function and firewall use to filter and track traffic. and data as soon as possible. It aids in limiting the spread of the
Vigilantly monitoring network activity is vital for spotting and breach and decreases the risk of future injury.
thwarting security breaches. Rapidly identifying anomalies An effective incident response plan should include critical
and unauthorized access empowers organizations to promptly features such as clear roles and duties, a defined chain of com-
counter risks and fortify their systems. mand, communication protocols, event detection and reporting
Robust access controls and authentication are vital. Tech- methods, and frequent testing and updates.
niques like multi-factor authentication and role-based access Fostering a security culture is critical because it improves
control ensure only authorized users access critical resources, awareness, promotes best practices and encourages workers to
reducing risks of breaches. Role-based access control assigns prioritize security, lowering the chance of breaches.
permissions based on user roles. Two-factor authentication Collaboration between departments, from information tech-
improves security by demanding two kinds of authentication, nology to operations, improves overall control-system security
such as a password and a cellphone code. Effective control by allowing information exchange, assuring uniform security
enforcement with minimal disruption involves regular per- procedures and enabling a coordinated reaction to possible
mission reviews, educating staff, monitoring access logs and threats and vulnerabilities.
automated access management.
Maintaining up-to-date control system software is vital for Shawn Cox is a licensed master electrician/PLC programmer.
peak security. Regular updates patch vulnerabilities, minimiz- He was co-owner/operator of Bobby Cox Electric for 15 years
ing unauthorized access risks. Updates can be tricky due to and is currently employed by BMW Manufacturing as an ESA.

16 / October/November 2023 / ControlDesign.com

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We define sustainability in terms of both the transparency can provide data-driven insights that
environment and our workforce. Sustainability in can help us improve our offerings and support the
terms of our workforce is all about expanding the interconnection of people-centric technology and
talent pool, becoming more diverse and inclu- systems. We create new value by evolving automa-
sive, providing our employees with an excellent tion components, systems and integrated solutions
and rich employment experience and increasing based on customer issues and needs. By collect-
the productivity of our workforce so that we can ing data from corporate, vendor and customer use
do more with less. cases, we can identify opportunities where new
In terms of environmental sustainability, industry resources can be employed for further improve-
is responsible for 30% of global CO2 emissions ments. We also return value to customers and help
and 37% of global energy consumption, according solve society challenges with customers. Environ-
to the World Economic Forum. mental sustainability is not something one person,
As a global manufacturer, we have an important one company or one country can fix. We must all
role to play in keeping our planet safe for future do our part to help mitigate climate change and en-
generations. That’s why Mitsubishi Electric, our able a sustainable future.
parent company, is making sustainability a corner-
stone of the company. The goal is to become more Q: Can you give us a few examples of how Mit-
sustainable in all aspects from energy consumption subishi Electric Automation helps companies
to pollution reduction, and adoption of digitization have their digital transformation cake and sus-
is helping to lead the way toward that goal. tainability, too?

18 / October/November 2023 / ControlDesign.com

 SPONSORED CONTENT

A: Drinking-water and wastewater plants are typically the largest

energy consumers for many municipal governments. We’re helping
water municipalities across the country move to more automated,
data-driven and energy-efficient operations. American Water helps
municipalities through modernization.
More than 90% of energy consumed in producing and deliver-
ing drinking water is used for pumping. Our variable-frequency
drives, which are used in all aspects of water operations, provide
up to 30% overall reduction in energy consumption.
Modernizing water operations can address many other prob-
lems that plague water municipalities, including pump clogs, wa-
ter pressure, leak detection and equipment breakdowns. ENERGY CREATION
SCADA systems can bring additional energy savings and The SUSTIE net Zero Energy Building reduced energy consumption by 115%.
also help municipalities meet compliance with government
regulation and reporting requirements as well as right-size
chemical dosing, extend the life of equipment through load net Zero Energy Building reduced energy consumption by 115%,
balancing and predictive maintenance, and help with pond technically creating energy versus using it.
management to be prepared to store excess water in advance A lot of innovative technologies come together to make this
of extreme weather events. incredible result possible. Smart devices capture data from every
Another interesting example is the modernization of LaGuar- process and every piece of equipment—the SUSTIE building
dia Airport, where they are driving comfort in a more intelligent has approximately 330 data points that monitor and control the
way. Using SCADA, they are able to take building automation to building environment. Smarter energy distribution and utilization
new levels. The system looks at flight data to monitor the num- software help facilitate the use of clean and flexible energy. Ubiq-
ber of people in the terminal and know expected peak loads, al- uitous sensors measure things like temperature, humidity, CO2
lowing them to manage HVAC systems based on the passenger concentration, pollen and other variables. Enhanced connectiv-
volume, saving energy when need is low and keeping passen- ity, real-time networks and IoT devices such as blinds control
gers and staff comfortable; monitor waste-bin levels and bath- air-conditioning use. And data contextualization and visualization
room maintenance to have appropriate staffing levels; and have software monitor and improve the total amount of electricity used
proper staffing for vendors. by the facility and the amount of energy created by solar panels.
With these examples, the systems go through continuous com- This integrated use of power-saving and power-regenerating
missioning making ongoing adjustments to optimize how the sys- technologies makes net-zero emissions practical and possible. The
tem runs, implement rules and adjust as the systems degenerate. design principles used in the SUSTIE building can be applied not
just to office buildings, but also to factories, warehouses, public
Q: How do we move the needle and accelerate green initiatives? utility systems and the operation of a city’s infrastructure.

A: The only way to get universal buy-in on sustainability is by Q: How does digital transformation ensure sustainability?
helping companies achieve business goals while also solving so-
cial challenges. A: We start as a company and work our way out. In our company,
A perfect example of this is the SUSTIE net Zero Energy Build- by 2030, we’ll reduce greenhouse gas emissions from facto-
ing in Japan. Mitsubishi built and operates this medium-sized ries and offices by 50% or more. In our extended operations, by
office building, which combines energy-generating, regenerating 2050, we’ll have net-zero greenhouse-gas emissions in our entire
and energy-saving technologies through energy-efficient HVAC value chain. In society, we’re committed to making our compa-
and lighting, water heating elevators, solar panels on the roof ny’s entire value chain carbon-neutral by supporting a circular
and other places, and dc versus ac power distribution system for economy where resources are sustainably sourced, recovered
optimized use of solar power; simultaneously enhances occupant and reused wherever possible.
health, comfort and wellbeing; and achieves new levels of digita-
lization and sustainability. After a year of operation, the SUSTIE For more information, visit us.mitsubishielectric.com/fa/en.

ControlDesign.com / October/November 2023 / 19

cover story

ROBOTS ARE EVERYWHERE—from

by Mike Bacidore, editor in chief fac- ronments, designed to ensure safety and amounts of data and also being orches-
tory and plant floors to warehouses create tightly controlled conditions.” trated through dynamic software.”
and distribution centers. The industrial Autonomous mobile robots (AMRs), The companies that hold on to the way
landscape has seen an escalated number on the other hand, provide the flexibility things have always been done, resisting
of robots in all shapes and sizes. to stitch together the work of individual the latest technologies like cloud, artifi-
Integrators have increased their cre- cells, offering flexibility beyond what a cial intelligence (AI) and the Industrial
ativity by designing and building more traditional conveyance would provide, Internet of Things (IIoT), are being left
work cells that include robots as part of Pestoni notes. “AMRs can thus become behind by those that embrace the power
the equipment or use robots to transfer the glue that makes the flow of material of software, Pestoni predicts.
materials to and from the work cell or throughout a facility work, while also
even within it. sharing space with people and manually The more things change
This increase in interoperability has operated vehicles.” “In the past two years, specifically, the
given rise to standards and software de- The lines between traditional opera- pandemic has fueled the need for new
signed to allow these robots to communi- tional technology (OT) and informa- business thinking, along with utilization
cate. Autonomous mobile robots (AMRs), tion technology (IT) are being blurred, of new technologies, including workplace
for example, can be integrated into an says Pestoni. “I call it the big collision, robots,” explains Rob Kutner, vice presi-
existing control architecture used in a because this is not without tension,” dent of sales, Ava Robotics. “Mobile and
machine-tending or palletizing or welding he warns. “This is evident in manufac- intelligent technologies have powered ro-
or other type of manufacturing cell. turing environments, which are under bots to augment human presence during
“Robotics cells with industrial robots pressure to handle smaller batches and times of extreme restriction and rapid
are great at doing one specific job over a higher mix of increasingly personal- workplace iteration. Additionally, this
and over, such as depalletizing a specific ized products. OT has traditionally been technology delivers on reliable, scalable
type of product mix,” explains Florian all about fi xed production lines, while automation for repetitive or dangerous
Pestoni, co-founder and CEO of InOrbit. IT is data-driven. Modern robots are functions that allow humans to focus on
“They typically work in enclosed envi- data machines, both generating massive higher-level, more-productive work.”

20 / October/November 2023 / ControlDesign.com

 cover story

Figure 1: Telepresence robots allow people to be Figure 2: Spontaneous, personalized interaction

more present during virtual interactions, which is allows for a more immersive, meaningful avenue
now more important than ever. for people to collaborate and connect.

Intelligent workplace robotics solves Robotic systems are increasingly of-

not only complex, short-term chal- fering new ways to adapt to application
lenges, but also helps drive operational requirements, explains Matt Prellwitz,
productivity and cultural sustainability drive technology product manager,
for years to come, says Kutner. “Telep- Beckhoff Automation. “Emphasizing
resence robots allow people to be more modularity and customizability in this
present during virtual interactions,” he way benefits machine builders, integra-
explains (Figure 1). “With robotic telep- tors and equipment end users alike,” he
resence, remote users can autonomously says. “Robots can take up less space, use
navigate to a desired workplace location only the number of axes required and of-
Figure 3: People-centric technology and design
and interact with others through ad- fer easy motion teaching. The amount of
allows for safe, immersive and meaningful interac-
vanced video conferencing capabilities. flexibility now, particularly with ATRO, tions, as well as inclusive access.
Spontaneous, personalized interaction is incredible. You don’t have to make
allows for a more immersive, meaning- your application fit the robot; you can
ful avenue for people to collaborate and make the robot fit your application.” “Beyond that, its innovative approach
connect (Figure 2).” Beckhoff’s ATRO, the automation tech- to routing media feeds for communica-
Engaged workers promote retention, nology for robotics, is a modular, custom- tion, power and fluids internally enables
Kutner advises. “Integration, interoper- izable concept for robotics applications, endless rotation of the modules, so the
ability and acceptance of telepresence which allows users to select the exact robot never needs to stop to unwind, for
robots help businesses offer a more re- number of axes needed for the applica- example, a compressed vacuum line or
tainable and satisfying experience in the tion, including up to 16 robotic arms (Fig- Ethernet cable (Figure 5).”
workplace,” he explains. “People-centric ure 4), explains Prellwitz. “The solution’s Programming takes place in the stan-
technology and design allows for safe, flexible robot kinematics fit essentially dard TwinCAT engineering environment,
immersive and meaningful interactions, any application with payloads up to 10 kg resulting in seamless synchronization
as well as inclusive access (Figure 3).” and reach of up to 1.3 meters,” he notes. with advanced mechatronics, like XTS

ControlDesign.com / October/November 2023 / 21

cover story

and XPlanar, as well as other motion

systems (Figure 6), continues Prellwitz.
“With simple robot assembly, intuitive
teaching and TwinSAFE Motion func-
tionality onboard, ATRO delivers a new
approach to industrial robotics,” he says.
“This do-it-yourself (DIY) approach gives
engineers greater control while gaining
even more capabilities.”
Fraunhofer Institute for Manufactur-
ing Engineering and Automation IPA is
a German research organization with
a strong focus on technology transfer.
The organization in total has more
than 29,000 employees and more than
70 institutes. “Here at the Fraunhofer
Institute for Manufacturing Engineer-
ing and Automation IPA in Stuttgart,
Germany, around 100 scientists develop
software and hardware technology for Figure 5: This modular system can route power, communication and fluids internally in an innovative
design that enables endless rotation. (Source: Beckhoff)
innovative robot systems (Figure 7),”
says Dr. Werner Kraus, head of the Robot
and Assistive Systems department at support humans with so-called service Kraus sees the combination of ma-
Fraunhofer Institute. “In general, we robots that work for example in logistics, chine learning (ML) with robots as one
do research to offer the most innova- health care or agriculture.” of the biggest advances of late. “Machine
tive and efficient solutions with robots, A very important topic at Fraunhofer learning is the subfield of artificial
be they in industrial applications, such is the field of cognitive robotics. “The intelligence (AI) that is currently being
as handling, welding or assembly, or to vision behind this is the ‘automation applied and researched the most,” he
of automation,’” explains Kraus. “The explains. “Particular attention is being
robots of the future will be networked, paid here to deep learning—deep neural
able to act and react as cyber-physical networks. Thanks to the intelligent
systems; thanks to sensors and actua- use of data, they have the potential to
tors, they will enable versatile produc- provide an enormous boost to pro-
tion and be more intuitive to use than ductivity and innovation, not only but
before. They will require less explicit especially in robotics. Machine learning
programming but will understand is currently attracting a huge amount
implicitly what they have to do and how of attention and will remain one of the
they solve a problem. Artificial Intelli- most influential technologies in industry
gence and machine learning in particu- for the near future.”
lar will play a key role here. As a result, In robotics, machine learning is both
robot operation will require less expert promising but also challenging because
robot knowledge. Especially with de- robots interact with a wide variety of
Figure 4: Modular automation technology
creasing batch sizes in mechanical and environments and training data is very
for robotics systems can adapt to tasks with
plant engineering, robots can thus be expensive to obtain or scarce, warns
any number of axes and is freely scalable,
customizable and expandable. reprogrammed more quickly and used Kraus. “Simulation will play a key role
(Source: Beckhoff) economically.” here. In unstructured environments,

22 / October/November 2023 / ControlDesign.com

 cover story

such as the home or warehouse, humans guarding that software, which deterred carry them around in our pockets on our
are still about three to five times faster innovation. Now, robot vendors use phones,” he observes. “All of this has
than robots, and robots also require application programming interfaces led to improved vision system capabili-
extensive programming by experts,” he (APIs), which can be tapped into by other ties, enabling task-switching, signifi-
explains. “In the future, AI will enable vendors. This gives the newer players cantly reducing time to deployment and
robots to independently solve tasks set access to software innovations from introducing cloud connectivity. These
by humans and achieve human-like different industries around the world, enhancements allow newer players in
execution speeds.” allowing them to create enhanced, dy- the market to orchestrate intelligence
At a very high level, software has namic software stacks.” systems, cameras, sensors, grippers and
been the biggest driver of growth and In addition to software innovations more to provide instantaneous value to
innovation in robotics in the past several becoming more accessible, robotics customers at a much lower cost than
years, says Jordan Kretchmer, co-founder hardware, such as sensors, light-de- traditional automation.”
and CEO, Rapid Robotics. “Traditionally, tection-and-ranging (LiDAR) cameras Regarding grippers, 3D printing has
robotics integrators program the robots and harmonic drives have also become been another game-changer for the
they deploy using proprietary software increasingly inexpensive due to the robotics space, notes Kretchmer. “It al-
that original equipment manufactur- economy of scale, Kretchmer adds. lows robotics vendors to create their own
ers (OEMs) provide,” he explains. “They “LiDAR cameras, for example, used to customized components like fixtures and
functioned as walled gardens, safe- be thousands of dollars; now we all grippers,” he says. “One of the biggest ben-

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efits of this practice is that it makes these tive during setup and programing. There
components more reliable; we can print is a vast support network developing
parts that fit perfectly and are more du- standardized mechanical and software
rable. These components can be designed solutions, similar to mobile phone ap-
intricately, making robots applicable plications, that support the fast and easy
to more tasks. In addition to increased deployment of robots.”
functionality, the use of additive manu-
facturing dramatically reduces the cost Innovation and efficiency
of obtaining components necessary for There are many innovative and effi-
robotic integration, which, at present, is cient robotics applications in industry,
significant when added on top of already but machine learning has to be toward
expensive equipment. Instead of waiting the top, explains Schunk’s Royster.
months for customized pieces to come in “Combining vision technology, flex- Figure 7: At Fraunhofer IPA, around 100 scientists
and paying thousands of dollars, busi- ible gripping mechanics—like a human develop software and hardware technology for
innovative robot systems.
nesses can 3D-print what they need in a hand is flexible—and AI, wide ranges of
matter of hours for a fraction of the cost.” unstructured workpieces can be handled
Robots are constantly improving, reliably and even improve over time,” he in terms of workspace, acceleration and
becoming faster and stronger, and of- notes. “This brings much needed auto- payload,” explains Fraunhofer’s Kraus.
fering features allowing users to easily mation into intralogistics, food handling “With 348-kW drive performance it
integrate for specialized tasks, explains and other nontraditional robot use.” reaches accelerations of up to 1.5 g.”
Aaron Royster, product manager, Sc- Robotics technology in and of itself End effectors of cable robots can be
hunk, which focuses on end-of-arm tool- has only improved incrementally over freely moved with high accuracy by up to
ing. “More manufacturing companies the years, explains Rapid’s Kretchmer. eight cables and winches. In the cable-
look to robots to ease pressures of labor “What’s valuable is how that technol- driven simulator, the motion of the cabin
shortage and supply-chain dependabil- ogy has been applied to different use is controlled by eight steel cables attached
ity,” he says. “Many of these new users of cases through software enablement and to winches. “This reduces the moving
automation struggle to gain the needed business-model innovation,” he says. mass, and the workspace can be scaled to
confidence and technical experience. “In many cases, the most mundane of any size,” explains Kraus. “As a result, the
Robot producers are answering the call applications can be the most impressive simulator is used for virtual-reality appli-
by making their equipment more intui- because of the required technology preci- cations like driving or flight simulations,
sion and durability and the impact of that but also to neurologically study motion
automation on the bottom line. For me, perception processes with humans.”
subscription-based, as-a-service models Cable robotics has always been a very
are revolutionary for the robotics space exciting topic, says Kraus. “Around the
because of the possibilities they enable. same time when the cable-drive simulator
There’s a lot more to them than this, but was developed, I worked as a research fel-
in essence this evolution enables robotics low at Fraunhofer IPA and wrote my PhD
companies to become powerful exten- thesis on the force control of cable-driven
sions of their customers’ workforces.” parallel robots,” he notes. “These cable
In 2015, the Tübingen-based Max robots have more cables than degrees-of-
Planck Institute for Biological Cybernet- freedom of the platform and therefore be-
ics and Fraunhofer IPA co-developed long to the class of redundant robots. This
a cable-driven parallel robot. “It was allows tensing the cables against each
Figure 6: As demonstrated at Automatica 2022,
a modular robot offers seamless integration with
the first cable robot system capable of other. In my thesis, I proposed a control
advanced motion and mechatronics solutions. transporting humans while also setting approach to synchronously control the
(Source: Beckhoff) new standards for a motion simulator platform position and the cable forces.”

24 / October/November 2023 / ControlDesign.com

 cover story

Beckhoff’s Prellwitz says he’s seen either side to cover each separate work remains necessary. But this change is a
many impressive robot applications plane,” he notes. “But the manufacturer moving target. Ava is excited to play an
over the years, including the Pickfeeder was able to implement one robot, work- active role in the innovation erupting
unscrambling machine from Spanish ma- ing at faster speeds, that could switch across industries.”
chine builder Packfeeder. “The machine work planes—reverse its normal points For healthcare, mobile, intelligent
identifies bottles with GigE cameras, then of reference on the fly. This solution sped and autonomous technology provides
uses pick-and-place Delta robots to set up production by 50% and reduced robot benefits in two key areas: improving
them onto XTS movers, creating a syn- costs by 50%.” care access and quality of communica-
chronous outfeed,” he explains. “By using The COVID pandemic feels like an- tion within healthcare systems (Figure
a fully integrated control platform with cient history, but its effects still linger. 8), says Kutner. “As a smart, practical
EtherCAT, well known as an ideal motion The shutdown demanded new, urgent solution for hybrid healthcare operations
bus, machine builders can implement protocols, disrupting existing services, and collaboration, telepresence robots
many innovative robotics applications.” processes and communication, explains enable telehealth in hospital systems,
While he was a Beckhoff application Ava’s Kutner. “Consider the resource, remote satellite locations, long-term care
engineer, Prellwitz also worked on a scheduling and availability barriers in communities such as assisted living,
project for a large window manufacturer, workplaces,” he notes. “From hospitals memory care and hospice, labs/research
where a robot milled window frames. and healthcare facilities to warehouses centers and medical equipment/service
“The job used to take two robots, one on to conference centers, change was and workplaces,” he notes.
cover story

“Telepresence robots serve to close response,” he explains. “For human ally, employee satisfaction and retention
gaps in healthcare education for hos- resources and employee experience, demand long-term virtual technology
pitals and other care facilities,” says hybrid work changes hiring conditions efficacy,” he says.
Kutner. “There is a natural application and candidate expectations. As distrib- “For disinfection and sanitation, the
for new, robust technology in the world uted candidates prioritize flexibility appetite for UVC disinfection robots
of healthcare and clinical simulation, and choice, technology must elevate the in response to the pandemic tracks
especially when it comes to improving virtual recruiting experience, for both with the accelerated adoption of other
user experience and learning outcomes candidates and hiring teams, beyond a workplace technologies and solutions,”
for healthcare professionals training vir- static screen.” continues Kutner. “Corporate offices,
tually. Tele-simulation to enable hybrid Intelligent, mobile telepresence robots warehouses, hotels, schools, retail
education, training and assessment, is a feature people-centric technology that locations, a wider range of healthcare
growing trend in healthcare.” allows for safe, immersive and mean- facilities—pretty much anywhere busi-
Robotics also delivers increased ingful interactions, as well as inclusive ness is conducted—place new emphasis
productivity, improved access and cost access, explains Kutner. “With recruit- on health and safety solutions to benefit
management without sacrificing dy- ing and hiring being one of the most employees, customers and clients.”
namic human interaction between the people-forward functions within a busi- The immediate business benefits of
medical community, patients and fami- ness, technology solutions that cross UVC disinfection robots are straightfor-
lies, says Kutner. “The medical world has over into this side of the house must be ward: eliminate harmful particles in the
needs far beyond the scope of pandemic centered around experience. Addition- air and on surfaces to mitigate spread
and contamination. “Less obvious are the
intangible, long-term benefits UVC robots
provide people, places and processes,” ex-
plains Kutner. “Mobile UVC robots provide
disinfection where HVAC doesn’t circulate
air, and automated UVC treatments won’t
miss as many spots as human hands.”
The complexity of the workplace is
presenting in many forms, building a
continuous backlog, he adds. “Focusing
on a formal return to work at this point
is wasteful,” notes Kutner. “Businesses
must solve for and prioritize workplace
productivity and health and safety with
agility, iterating in real time.”

Keep your distance

Remote monitoring and connectivity al-
low robots to make workplaces, facilities
and businesses safer, healthier and more
efficient, notes Ava’s Kutner. “Robotic
security applications, for example, can
help businesses focus more on response
to threats and physical breaches and
less on routine observation,” he says.
“Robots bring efficiencies to security
operations while increasing operational
Figure 8: As a smart, practical solution for hybrid healthcare operations and collaboration,
telepresence robots enable telehealth in hospital systems.

competencies beyond security in ways With a fully integrated, PC-based control

Ethernet Cable
that were once thought impossible,” platform, that’s not an issue. And by le-
explains Kutner. “In satisfying monoto- veraging an end-to-end engineering and Developed to meet the demands of
nous and repeated security tasks, such runtime platform, it’s easier to design, the North American market, our 600V
as observing, reporting and patrolling, monitor and make changes to a robot
Industrial Ethernet cordsets utilize UL
listed cables with stranded conductors
with objectivity and precision, security application. The same software provides
and a foil and braided shield.
robots can conduct autonomous event PLC, IoT and robot kinematics, as well as
response, send automatic alerts, and fol- all other advanced machine functionality. The 4 and 8-pole cordsets are avaliable in
low and track suspicious activity.” Resulting from research at Fraunhofer a variety of configurations including:
Workplace robots integrate with other IPA, spinoff NODE navigation is designed
monitoring tools and systems, as well to offer plug-and-play software for au-
• Single or Double ended cable
as people managing specific initiatives, tonomous intralogistics, explains Kraus.
Kutner assures. “This allows for a more “The focus is on driverless transport • Straight or 90° M12 Male and Female
comprehensive and efficient solution to vehicles and mobile robots, which are • RJ45 Connectors
workplace challenges; intelligent work- turned into multi-vendor, autonomous
• Lengths to 65m (Cable Types S4U &
place robots extend existing technolo- and collaborative fleets,” he says. “The S4W) in .1m intervals
gies, including monitoring and connec- software solutions provide the basis for
tivity capabilities, to mobilize a smarter the widespread use of autonomous mo-
• Lengths to 100m (Cable Type S7V)
in .1m intervals
workplace,” he says. bile robots in production and intralogis-
“We find that the main barrier to suc- tics. For example, the German car manu-
All cable types meet CAT5e requirements
cessful robot implementation is connec- facturer BMW already deploys more than and are resistant to a variety of media
tivity,” explains Beckhoff’s Prellwitz. “Can 400 AMRs with the NODE navigation. including welding sparks. Our hex nut
the machine controller easily, securely Smart fleet management and a shared design combined with our torque wrench
communicate to higher-level systems? map of the manufacturing plant ensure ensures an IP67 seal.

murrinc.com
cover story

the connectivity. The robots can also

connect via cloud. Remote monitoring
plays a vital role: Experts can perform
remote ramp-up support and analysis According to Rob Kutner, vice president of sales, Ava Robotics,
as a human-centered, integrated technology, the interpersonal
with the recorded data of the AMR.”
features and benefits of workplace robotics have both
For traditional robotics integra-
operational and cultural impact:
tors, not much has changed because of
•inclusive, accessible technology that promotes meeting
remote monitoring and connectivity,
workers and customers where they are
as their programming still only lives • s eamless workplace integration that enhances existing
on the robots themselves, assures Juan technology capabilities
Aparicio, vice president of product, •g  reater focus on health and wellness, building
Rapid Robotics. “I haven’t seen a motiva- workforce trust and confidence.
tion or urgency from them to exploit
these capabilities,” he says. “This lack of
urgency, traditionally, stems from the critical, observes Aparicio. “These ca- monitoring can offer quick recovery
reluctancy of some end users to connect pabilities allow RaaS vendors to provide for when an automation system stalls.
the equipment to the cloud. However, higher levels of customer support in the Another benefit is flexibility. Remote ac-
that reluctancy is waning as people form of service and innovation: support cess enables manufacturing managers to
increasingly come to realize the many tickets can be resolved remotely, some- make on-the-fly decisions to command
benefits this approach offers.” times before the customer is even aware automation systems to adapt to changing
For newer robotics providers in the of an issue; data streams and playbacks demands. Tooling and process changes
market who follow the RaaS model, provide transparency into why exactly can be made to accommodate new infeed
remote monitoring and connectivity are a robot emergency-stopped, whether it of workpieces to be processed.”
be a bug or an employee bumping into Advanced sensing technologies have
the work cell; and over-the-air software been combined with remote-monitoring
updates increase robot value and versa- software to take remote monitoring
tility over time, without impacting the and connectivity to the next level, adds
performance or downtime of the cell,” he Royster. “Software identifies where a
says. “Another key benefit of connectiv- robot is planned to be at any given point
ity is scalability; this ability to service in an automated process and alarms
the robots remotely makes it possible to if anything occurs to move the point
efficiently support thousands of robots, outside of an allowable tolerance,” he
removing the need to physically go says. “One task where this technology
on-site to address each support call. I is extremely useful is welding. Auto-
think the increased bandwidth for robot mated welding applications are not new,
deployment and support resulting from but tracking each weld remotely with
expanded remote monitoring will make pinpoint accuracy to ensure the exact
robotic automation more accessible for position is achieved is a new and excit-
many manufacturers.” ing application in remote monitoring
No automation solution is perfect, and connectivity.”
notes Schunk’s Royster. “When you are
in school and achieve 99/100 on a test, Robots’ soft side
you get an A+ and feel accomplished Software openness and flexibility have
because you scored nearly perfect,” he become more important, explains
Figure 9: Bin-picking robots can use end effectors explains. “In automation, 99% success Beckhoff’s Prellwitz. “Machine builders
to pick up and sort different objects from a box. rate is usually a failing grade. Remote and systems integrators keep accom-

28 / October/November 2023 / ControlDesign.com

 cover story

plishing impressive robotics applica- philosophy for its RC9 system, which found in machines, from conveyors and
tions that were once unimaginable,” he uses an IPC, EtherCAT I/O and TwinCAT servos to XPlanar and XTS.”
notes. “These are complex systems, and as the standard robot controller.” Significant changes have occurred
engineers want to be able to program On the control side of ATRO, Beck- with the increasing use of open-source
disparate technologies—PLC, mecha- hoff’s modular technology for robotics, software at Fraunhofer, explains Kraus.
tronics, machine vision, functional standard automation software simply “The robotic operating system (ROS) is all
safety, machine learning—in the same scans the adapted structures, and the open-source and helps experts and do-it-
environment as the robot kinematics. TwinCAT robotics functions automati- yourself (DIY) amateurs to build their ro-
While some in the industry may still cally create the corresponding control bot applications,” he says. “It consists of a
be surprised that you can handle this application, as well as a digital twin, set of software libraries and tools such as
amount of functionality on one machine explains Prellwitz. “A range of TwinSAFE drivers or state-of-the-art algorithms. Us-
controller, it’s been done successfully Motion capabilities are available for the ing ROS really speeds up the development
in the field for years. Not only does industrial robot, such as SLS, SOS, SS2, process. As ROS uses permissive open-
this save time, but also it ensures the STO and others,” he adds. “Full integra- source licenses, it is easy to combine with
systems will work well together. Beck- tion into the Beckhoff control platform, closed-source software. Broad knowledge
hoff works with the world’s top robot along with EtherCAT communication, is linked into the software project like
manufacturers to make this a reality. enables seamless, synchronized coordi- open CV, point cloud library or Moveit for
For example, Denso has adapted this nation with all types of motion systems trajectory planning.”

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2311CD_ContemporaryControls.indd 1 9/15/23 10:59 AM

cover story

Software development greatly improves connectivity of ro- when they are small and more easily solvable,” he explains.
bots to the processes they serve and also enhances those pro- “These tools can also be used for advanced planning to ac-
cesses, notes Schunk’s Royster. “For example, a robot tending a count for future changes to automation.”
milling machine has to interface with the machine and all the The digital twin really impacts the entire lifecycle of the
peripheral components such as end-of-arm tooling, workpiece production cell, adds Rapid’s Aparicio. “At the beginning of
conveying systems or safety equipment,” he says. “Software is the automation journey with customers, digital-twin plat-
greatly simplifying these device connections and shortening forms help produce concept designs faster and with the right
the time for successful deployments and redeployments. Ap- level of fidelity, so reachability and cycle time studies can
plication software aids the users with short cuts for organizing be quickly generated to ensure the solution meets customer
common robot path routines.” expectations,” he explains. “When programming robots and
automation components, digital-twin technology allows you to
Digital twins simulate the task you want to automate, rather than having to
One of the worst things that can happen when investing build a robot and physically program it in the real world, taking
in new automation is to purchase and build the equipment significant time and human labor.”
only to discover you cannot perform the necessary task due In the support phase, vendors can have the digital twin in
to physical interferences or cycle times being unmet, adds the lab to monitor the robots remotely, making it easier to ad-
Schunk’s Royster. “Digital-twin and other simulation tools are dress a bug or error in the field by reviewing playbacks of that
an excellent way to work through challenges ahead of time, simulation, explains Aparicio. “Digital-twin models are only
just beginning to make their mark in manufacturing automa-
tion, but the opportunity is massive,” he says.
“Real-life data for training robots can be very expensive to
obtain,” notes Fraunhofer’s Kraus. “Therefore, we often work
Interested?
The Cable Entry 360° Get your with simulations, for example, for skill training in the field of

With the new distribution box, free sample assembly. We also develop technologies for bin picking, where
now: the robot can pick up and sort different objects from a box
centrally routed cables can be
distributed 360° in all desired (Figure 9). A real-life training would be very time-consuming,
directions. which is why we use a physics simulation to prepare the robot.”
Digital-twin technologies are accelerating success for a
IP54 number of Beckhoff customers. “Robotics is no exception,” says
Prellwitz. “As we prepare for the full ATRO product launch,
we are continuing to add functionality, including in this area.
Already the TwinCAT robotics functions generate a digital twin
automatically after scanning the adapted structure and creat-
ing the control application.”
During programming, you can also pull in the CAD file of
the machine or fixture where the ATRO unit will be installed
and simulate motion profiles, explains Prellwitz. “You can then
build an orbit around sensitive equipment, such as expensive
sensors or other robots, to ensure the system will not enter
that area or cause any damage,” he says. “We also have incor-
porated the same web-based live-view technology that’s built
into our XTS and XPlanar technologies. So you can connect to
the ATRO system to analyze what the robot is doing, how well
its performing and what the EtherCAT diagnostics show to as-
sess potential optimizations.”

icotek@MiA23
 product roundup

Safety by the numbers

Numerous devices make machines and systems safer

SC10 series safety controller/relay hybrid Banner SLC4 series

Banner Engineering’s SC10 series safety control- Banner Engineering’s SLC4 Series are Type 4
ler is designed to replace the functionality of safety light curtains specifically designed to safe-
two or more safety relay modules and features guard smaller points of operation and access on
an intuitive user interface and advanced diag- compact machines. They measure just 160 mm in
nostic capabilities. The SC10 series safety con- length and have a low-profile design that fits eas-
troller is designed to work for crowded machine ily in small spaces. SLC4 safety light curtains have
control cabinets and smaller machines. an end-to-end sensing design that eliminates
DigiKey / www.digikey.com detection blind zones and maximizes the sensing capabilities
of these compact safety systems. They are available in models
with 14 mm or 24 mm resolution to detect objects as small as a
AutomationDirect Comepi safety switches finger or a hand attempting to access the doorway.
AutomationDirect has expanded its safety products line with RS / us.rs-online.com
additional Comepi safety switches. This offering includes sole-
noid locking tongue interlock
safety switches and RFID- Wago electronic circuit breakers
coded solenoid locking tongue Wago’s electronic circuit breakers are designed to focus on
interlock safety switches. All safety with reliable protection against overload and short
switches have a 1,200 N hold- circuits. They also enable activation of high-capacity loads
ing force and require the sole- without the need to increase the nominal current setting. All
noid to be energized to unlock models have 0.5 to 12 A current ratings that offer the flexibility
the switch. The RFID-coded needed for setting the nominal
models are uniquely coded for additional tamper resistance. The current to suit individual applica-
new Comepi safety switches come with a one-year warranty. tions. With a maximum width of
AutomationDirect / www.automationdirect.com/ 45 mm (1.772 inches), these ECBs
are designed to channel density.
Wago / www.wago.com
Industrial framing for robotics and machine safety
Industrial framing and support systems are essential to
the structural integrity, efficiency and effective operation Pepperl+Fuchs USi-safety ultrasonic sensors
of automated robotics and machines. They also provide The USi-safety ultrasonic sensor system from Pepperl+Fuchs
a safe and secure environment for employees working is designed so that machines and vehicles can be reliably pro-
with or nearby various automated machine tected using state-of-the-art ultrasonic technology and all of
systems. Durable aluminum the advantages this brings. A miniature sensor unit detached
machine bases and frames are from the control interface allows the USi-safety to be used
ideal for light-, medium- and even in confined installation situations. The design
heavy-duty machine applica- of the converter allows the sensor to
tions. Custom framing can be cover an elliptical, three-dimensional
created using anodized and sound field with opening angles of ± 17°
powder-coated finishes and is and ± 5°, providing an improved
available in various colors. level of safety.
Motion Ai / ai.motion.com Pepperl+Fuchs / www.pepperl-fuchs.com

ControlDesign.com / October/November 2023 / 31

product roundup

IDEC HT4P Safety Commander Siemens Simatic ET200 Series

The HT4P Safety Commander is an ergonomic device designed A wide variety of I/O systems are
to enable users to securely hold and protect a human-machine available for standard and fail-safe
interface (HMI) tablet. The HT4P can hold tablets ranging from automation. Siemens Failsafe I/O series
10 inches all the way up to a 13 inches using adjustable grippers. is designed to include uniform safety
It can use an onboard wired LAN combined functionality for all Simatic devices,
with a USB-PD connection, with a USB/ one system for standard and safety automation, compact
RS-232C/RS-422 converter option also design to reduce space required, seamless system that is easy
available. External shielded cables to use, external safety solutions are not required and uniform
with connectors are available for the operating capability of the TIA Portal enables intuitive safety
HT4P in lengths of 5 m, 10 m, 15 m function engineering.
and 20 m. The HT4P has three onboard Siemens FA / www.siemens.com
mounting positions, and a guard is
available to protect against inadvertent
operation of the e-stop button. Rockwell Automation GuardLink 2.0 with EtherNet/IP
IDEC / lp.idec.com GuardLink 2.0 is designed to offer advanced diagnostics by way
of the Allen-Bradley 432ES GuardLink EtherNet/IP On-Machine
Interface or a combination of the Dual GuardLink Relay and
Pilz PNOZsigma safety relays EtherNet/IP Interface. GuardLink 2.0 protocol also enables safety-
The PNOZsigma series of safety relays from Pilz offers two- rated control device status reporting and automatic diagnostic
hand, e-stop, safety gates, light barrier, time, safe speed, safe reporting to an HMI using CIP Safety over EtherNet/IP. The 432ES
brake control and safe voltage monitoring. Units are equipped GuardLink EtherNet/IP interface is designed to connect up to
with normally open safety contacts, auxiliary contacts and LED 96 safety devices via three independent safety channels. The
indicators for supply voltage, two-channel input interface can cascade power to additional interfaces and can
status, switch status, safety contacts and keep track of timing and frequency of events to improve
feedback and reset circuits. Safety relays maintenance and create process efficiencies. The
may be used with e-stop pushbuttons, 432ES supports linear, star and Device Level
safety gates and light beam devices. Ring topologies while meeting the highest
Designed to take up less space, they safety ratings up to SIL 3, Cat 4 PLe.
range in size from 12.5 mm to 22.5 mm. Rockwell Automation / www.rockwellautomation.com

Galco / www.galco.com

Mitsubishi MELServo-J5 EtherCAT-compatible amplifiers

KEB Safety PLC Mitsubishi Electric Automation’s MELServo-J5 EtherCAT com-
KEB’s Safety PLC is a Fail Safe over EtherCAT (FSoE) master patible Servo amplifiers are designed to easily integrate safety
that is designed to be used in tandem with the machine PLC devices into a single network. FSoE is a TÜV-certified technology
to execute and monitor the safety functions of the machinery. developed according to IEC 61508, standardized internationally
The Safety PLC connects with other FSoE slave modules like in IEC 61784-3 and can be implemented with an approved Ether-
Safe I/O and Servo Drives with CAT Master module. In the event a machine breaks down or mal-
Safe Motion functionality. Each functions, Fail Safe is designed to revert the
FSoE slave device has four safe servo to safe working conditions
inputs, two safe outputs and by utilizing safety subfunctions
four OSSD outputs. One FSoE (STO/SS1/SS2/SOS/SBC/SLS/
master can control up to SSM/SDI/SLI/SLT).
65,535 slave devices. Mitsubishi Electric Automation /

KEB America / www.kebamerica.com us.mitsubishielectric.com

32 / October/November 2023 / ControlDesign.com

 real answers

Exploring operator-interface options

A CONTROL DESIGN reader writes: I’ve worked in industrial
machine building since before the introduction of the Internet,
when machine operator controls were a switch or a pushbut-
ton. Now, our human-machine interfaces (HMIs) control whole
systems, visualize how we interact with the machines and col-
lect data for further analysis. Our company has adopted rapidly
to new HMI technology, as long as it remains cabinet-mounted.
We’ve yet to try any new options for operator interfaces, such
as wireless devices, cable-connect HMI pads or HMIs on a swiv-
el arm. We do still have remote access via our cabinet-mounted
HMIs, but what might some of these newer options offer that
we’re missing out on? What other options are available? How do
we weigh them against traditional HMI?

Answers

Installation flexibility moves HMIs

outside of the cabinet
Figure 2: For hazardous areas, an HMI workstation may be
There are all sorts of variants of cabinet- or easier to install than a control cabinet.
panel-mounted HMIs, from lower-powered
operator interface panels to high-power
panel PCs running Windows operating Often control cabinets have limited wall or
systems. But in general the core function- enclosure door space to mount an HMI, but if
ality of a cabinet-mounted HMI and an the HMI is a free-standing, separately mounted
HMI with an alternative mounting op- unit, this display size restriction may very well be
tion or no mounting at all is likely very limited. This means larger displays with more screen
similar. So, if operation and function- area and more space for graphics and other software
ality are comparable, then the key benefit elements are possible for operators.
of a non-cabinet-mounted solution or an HMI worksta- Additionally, space may be limited in the area where
tion is, in my view, the installation flexibility. the HMI is to be located. A stand-alone HMI unit may take
By installation flexibility, we mean that you are no up much less space than a cabinet with a comparably sized
longer limited by the size or location of the control panel-mount HMI. In the case of an HMI workstation, as men-
cabinet. You can now mount an HMI in areas where it is tioned earlier, you can connect it to an articulating or swivel
not feasible or practical to install a control cabinet with a arm to position it out of the way when not in use. In addition
panel-mounted HMI (Figure 1). to the ergonomic benefits of being able to move it around for
operators of different sizes. Alternatively, a
complete HMI workstation can often be added
to some sort of mobile cart or trolley,
Figure 1: A complete HMI workstation can
often be added to some sort of mobile which can be wheeled in and out of the
cart or trolley, which can be wheeled in process area as needed—this is particu-
and out of the process area as needed. larly popular in life-science and pharma-
ceutical applications (Figure 2).

ControlDesign.com / October/November 2023 / 33

real answers

For installations that may include ar- mobile devices and can provide a fully Adjustable, wireless or
eas classified as hazardous, an HMI work- mobile HMI option. In addition, there are VR options improve
station may be easier to implement than tablets on the market that are also suitable HMI flexibility and mobility
a control cabinet. Depending on the area for operation in classified hazardous areas, There are currently more options for
classification, everything in the control allowing them to be used throughout the HMIs that could take a company further
cabinet—power supplies, HMI, additional plant. Certainly, there are some potential in terms of usability and flexibility.
components—must either be appropri- hurdles to overcome in terms of charging, Here are some of the newer HMI op-
ately rated for the hazardous area or have security, long-term evolution (LTE) or Wi-Fi tions and how they differ from, or can
an additional type of protection, such networks, but a well-thought-out design be used to complement, traditional
as a purge and pressurization system, and implementation can offer a lot of ben- cabinet-mounted HMIs. In each case,
to keep the cabinet safe (Figure 3). Many efits to operators and engineers. the optimal solution also depends on
HMI workstations are already certified for In summary, each installation is a little the intended use, safety concerns and
use in hazardous areas and are equipped different and has its own set of require- any environmental factors.
with all the necessary safety elements, ments and restrictions, but limiting the
reducing the design and installation ef- installation to only one type of physical • HMIs on a swivel arm
fort for the plant—a ready-to-go option. HMI style can also limit the productivity This option allows the HMI to be
There is also the possibility to take this of the plant. There are certainly many mounted on an adjustable swivel arm
installation flexibility option a step further benefits to panel mount HMI options, but or console that can be easily moved into
and implement a fully wireless option with there are just as many benefits to differ- different positions. This allows operators
tablets and smartphones (Figure 4). Many ent mounting options. to adjust the screen to a preferred work-
control systems have apps and software AARON SEVERA ing position, for example. This solution
that are compatible with Android or Apple product manager, HMI and fieldbus / Pepperl+Fuchs is rather simple from a technical point

Figure 3: A fully wireless HMI option with tab-

lets and smartphones use apps and software
that are compatible with Android or Apple
mobile devices.

Figure 4: HMIs on swivel arm can be easily moved into different positions, allowing operators to
adjust the screen to a preferred working position. (Source: EAO)

34 / October/November 2023 / ControlDesign.com

 real answers

of view, but it already offers added value

to the user and significantly improves
ergonomics (Figure 5).

• Wireless operating devices/handhelds

Portable HMIs without cables establish
a wireless connection to the machines.
These offer more mobility than cabinet-
mounted HMIs because they are not tied to
the control cabinet. This allows operators
to move freely around the work area while
controlling and monitoring the machines.
This provides more flexibility and can
increase operator productivity (Figure 6).
Depending on functional safety or
regulations, portable HMIs could also be Figure 5: Handheld HMIs connect wireless to machines and offer more operator mobility. (Source: EAO)
cabled to the machine and still provide
good user mobility.

• Tablet or smartphone-based HMIs

The use of tablets or smartphones as
HMIs are similar to wireless handhelds
but offer more intuitive operation, as
many users are already familiar with this
technology in a private environment.
This can, for example, reduce training
time for new operators and greatly im-
prove adoption. In addition, it is possible
to use an existing, physical and proven
high-tech module and only develop the
necessary software or interface for the
required application.

• Augmented reality (AR) and virtual reality

(VR) based HMIs
These most advanced HMIs allow op-
erators to interact with machines and
processes through AR or VR glasses.
This can improve operational efficiency
by providing operators with additional
real-time information or visualizing
complex tasks.

When weighing these options against Figure 6: Mobile devices running HMI apps can connect wirelessly to traditional or embedded “headless”
traditional cabinet-mounted HMIs, you HMIs, providing great flexibility for creating operator-interface experiences for any type of application.
should consider the following aspects:

ControlDesign.com / October/November 2023 / 35

real answers

• Usability—In my opinion, user-friendli- then to carefully train them to achieve maintaining the reliability and accessibil-
ness should be a top priority, as intui- the intended potential of the new or ity of a cabinet-mounted HMI.
tive operation can increase motivation deployed HMI. Regardless of how HMIs are accessed,
and efficiency. My recommendation DOMINIQUE BURKARD they typically contain graphical pushbut-
here: Test different options in rela- industrial & UX design manager / EAO AG tons, indicators, setpoints, alarms and
tion to the intended use with users to many more objects that allow users to eas-
determine their preferences and suit- Flexible connectivity for ily monitor and control a complex system
ability for the work environment. This operator controls enhances in a straightforward way. This alone is a
can often be worked out at a conceptual data visualization huge advancement from the days of exclu-
stage of the project using, for example, HMI technology has evolved at a rapid sively hardwired controls and indicators.
the design-thinking method. pace, taking us far from the humble However, the most advanced capabilities
• R eliability—Ensure that the options beginnings of exclusively hardwired of HMIs go far beyond appearances. In fact,
selected are robust and reliable to controls and indicators. With any rapid some of the biggest advancements in HMIs
ensure smooth operation, especially technological advancement like this, it is have nothing to do with the display and
in an industrial environment. Also, only natural to experience some possible everything to do with connectivity and
depending on the selected solution, hesitation from users when it comes to processing. See below for a small selection
operation with or without gloves is not adopting the latest features. To address of specific advanced features that add a
an unimportant aspect when it comes this and explore the utility of these great deal of utility to an HMI:
to reliability and efficiency. newer features, it is important to start
• Security—When using wireless or with a quick review of what users typi- • Protocol conversion—In an industrial
Internet-enabled devices, it is impor- cally expect from an HMI. environment, it is common to see dis-
tant to consider the security aspects to The most common image that comes parate communication protocols in use
minimize unauthorized access and po- to mind when talking about a typical HMI from multiple devices that are not able
tential security risks. In addition, items is likely a cabinet-mounted touchscreen to communicate with each other direct-
such as functional safety and applicable display. Cabinet-mounted HMIs are here ly—think of Modbus and distributed-
regulations must also be considered. to stay, as it is critical in many applica- network protocol 3 (DNP3), for example.
• Cost—New HMI capabilities, especially tions for operators to have immediate lo- Some advanced HMIs have the ability to
AR and VR for example, can come at a cal access to machine controls. However, act as fully featured protocol convert-
higher cost. It is important to weigh the local-only control is a clear limitation ers and data concentrators, facilitating
potential benefits against the invest- and users often want more flexibility communication between previously
ment costs and decide whether the when it comes to data visualization. isolated devices.
introduction will pay off in the long Fortunately, some cabinet-mounted •M
 ultiple programming languages—Some
term. Here, it is important to clearly HMIs also allow users to remotely connect HMIs have the ability to execute the
determine from the user’s perspective and interact with them from a tablet, International Electrotechnical Commis-
whether the potential solutions are PC or even cellphone through a simple sion (IEC) programming, which includes
need to have or nice to have. web interface—easily accessible via web ladder logic, function block diagram,
browser while on the same network as the structured text and instruction list,
Overall, more modern HMI solutions HMI. From the web interface, the experi- directly on the unit itself. In some cases,
can offer additional benefits in terms ence is the same as if the user were stand- this can entirely eliminate the need for
of flexibility, mobility and ease of use. ing in front of the physical HMI in terms a programmable logic controller (PLC) in
From my experience, it is beneficial to of both monitoring and control. With the an industrial system. Additionally, some
start with a trial phase and test the use of a virtual private network (VPN) HMIs are able to execute higher-level
options to find out which ones best fit tunnel, this can be accomplished from programming languages such as C.
the requirements. From my experi- anywhere in the world. This type of flex- • I /O expansion modules—There are also
ence, it is very important to involve the ible connectivity opens up nearly limitless HMIs that have slots on them where I/O
users already in the concept phase and possibilities for data visualization while modules can be connected. This allows

36 / October/November 2023 / ControlDesign.com

 real answers

users to monitor physical inputs and and ready to configure. Implementation portable-document-format (PDF) file
control physical outputs directly from can be painless, or much closer to it, readers, Word or Excel displays and video
the HMI, which can eliminate the need when new features are additive, optional playback, allow machine training and
for dedicated remote I/O in some cases. and user-friendly. troubleshooting instruction to be incor-
• Cloud connectors—When thinking of JOE WAGNER porated right on the HMI itself.
making HMI data accessible, consider field application engineer / Red Lion Voice control, which may not be suit-
that some HMIs have built-in cloud able for all industrial environments,
connectors, allowing them to very ef- HMI advances follow allows operators to interact with the
ficiently publish and subscribe to large commercial display market machine with voice commands. This
amounts of data using a cloud broker As with any technological product, new feature can be particularly useful in
and the power of message queuing features are regularly being incorporated situations where operators have limited
telemetry transport (MQTT). This is into industrial HMI devices. Either to take manual dexterity or need to keep their
an easy and cost-effective way to add advantage of new technological capabili- hands free for other tasks.
Industrial-Internet-of-Things (IIoT) ties or to add features that improve the Advanced data visualization is one
connectivity to any system and be pre- user experience, efficiency in operation area that is moving into the realm of
pared for the future. and screen design or both. industrial HMIs. The idea is to create in-
• Data logging—One of the more common Many of the newer features in HMI tuitive interactive screens for the opera-
features to find in an HMI is local data devices take advantage of developments tor. Advanced charting such as treemap,
logging. This allows users to record in the commercial space. Things like circle packing and radar charts along
data in a highly customizable way, widescreen-display HMIs take advantage with colors and sizing are used to assist
and support for secure-digital (SD)/ of the development in the commercial in faster decision-making.
microSD cards allows them to locally display or television market. Multi-touch Security is top of mind for many
store several gigabytes worth of data. and gesture control are features found in manufacturers. Most HMIs have user-log-
For retrieval of these data logs, more mobile devices and are now migrating to in capability and password-screen access
advanced models can act as a file- industrial HMIs. based on roles. Newer recommendations
transfer-protocol (FTP) server, make Some specific features don’t only from the Cybersecurity and Infrastruc-
the data available from a web interface include the HMI, but other parts of the ture Security Agency (CISA) are being
or sync the data to a structured-query- control solution. An integrated develop- incorporated into HMI designs to prevent
language (SQL) database. ment environment (IDE), for example, al- malware intrusions and manage risk.
lows the development of the HMI screens Let’s not forget artificial intelligence
There is no doubt that HMIs will con- along with the rest of the control system. (AI). Along with the introduction of AI
tinue to advance, and new features are This drastically increases productivity into machine control systems, AI has a
always just around the corner. The key to for the design engineers and reduces or place in the HMI. Coupled with advanced
successful user adoption lies in main- eliminates the need to jump between data visualization, AI has the potential to
taining essential legacy features, like HMI and control development environ- make decisions for the operator and dis-
the accessibility of a cabinet-mounted ments entering the same information. play the decision or narrow down choices
HMI, while adding new features that The ability to develop intuitive screens for an operator, driving the intuitive goal
provide clear value without disruption. for the machine operator is a must. Some of machine operation.
For instance, using an HMI web interface of the best HMI products available have Most HMI users probably think of this
for tablet viewing and control should the ability to host animations where already, but weighing whether to invest
typically complement a cabinet-mounted an active visual representation of the in advanced HMI features usually rests
HMI rather than entirely replace it. machine or parts of the machine can be on the type and purpose of the machine
Similarly, other advanced features displayed to the operator. being designed. Factors such as func-
such as protocol conversion and cloud Contextualized help and documen- tion, price and degree of manufacturing
connectors are much easier to adopt tation features, the ability of the HMI integration will all play into the decision
when they are already built into the HMI to host other common tools, such as to use the advanced features.

ControlDesign.com / October/November 2023 / 37

real answers

The HMI is front and center when used hardened option, including touchscreens particular, wireless TSN capabilities can
in any application, one of the first things protected by an industrial-grade hous- help. HMI was one of the initial use cases
visible on a machine. It may make sense, if ing, illuminated e-stop and pushbutton brought up by members to Avnu Alliance
a high-value machining center or integrat- keys, SD card slot and USB interface, that that motivated the development of the
ed multi-line process is being designed, the works with protocols such as Profinet, Wireless TSN testing program.
high-end featured HMI is the best choice EtherNet IP, message passing interface Wireless capabilities enable flexibility
for premium user feature and function that (MPI) and others. These are just a few and mobility for HMI devices, reducing
imparts high value to the machine. examples. There are many more options installation costs. The TSN features can
CLARK KROMENAKER available to you. ensure the time-critical data is prioritized
product manager—HMI, IPC, controllers, software / Omron ERIC HALVORSON and delivered with determinism on a
partnership marketing manager II – strategic programs / shared network with other applications.
Incorporating operational DigiKey By adopting standards-based connectivity
safety and security silicon and protocols with TSN support,
Human-machine interface has evolved Deterministic and low-latency customers can get additional operational
greatly since the days before the Internet. cloud infrastructure for operator benefits in addition to the flexibility en-
And, as you stated, there are a great control virtualization abled for the HMI application.
many more options available than ever Arguably, the HMI is an industrial PC run- Given the progress on TSN-capable
before. These options vary in price, capa- ning an industrial control application. One wireless devices that we’re seeing in the
bility and durability. of the biggest challenges is maintaining Avnu Alliance plugfests, the capabilities
If we look at remote monitoring from and securing those platforms over time, to start deploying and testing wireless
consumer-grade tablets or even smart as they are rarely upgraded or patched. HMI applications exist. Avnu is work-
phones, one of the more attractive fea- One of the exciting developments here is ing diligently to launch the testing and
tures is that operators are able to access the use of cloud infrastructure local to the certification program for wireless TSN
the system utilizing apps. This frees the plant to centralize and virtualize the HMI, devices, and this is an excellent time for
operator to walk the facility, spot check leaving a simple terminal in the field. This interested companies to engage and start
for physical verification of conditions, would allow much simpler upgrading testing these new capabilities and com-
update programming and check errors all and enhancing the HMI, providing more pare them with traditional HMI solutions.
with the ability to pull up data and draw- flexibility and security for the manufac- DAVE CALVACANTI
ings at the swipe of a finger. turer, not to mention the cost reduction president and principal engineer / Avnu Alliance and Intel

However, to be in compliance with from hardware as industrial PCs tend to

safety regulations, a good consumer- be more expensive than server platforms Tethered, wireless or headless
grade HMI product would need to incor- with the same performance. Naturally, HMI provide continuous automa-
porate safety products like emergency the network between the machine and tion visualization
stops (e-stops) and operator-presence the local cloud infrastructure needs to For an industrial environment where
triggers, also known as a dead man’s resilient, secure, deterministic and low- operators need constant local automation
switch, along with internet security. Fire- latency, but that is available. What else visualization, a traditional panel-mount
walls and good operational security are a could we apply that concept to? HMI, using a device able to endure the
must for any wireless product. PAUL DIDIER temperatures, contamination, moisture
Products do exist on the market that solution architect manager / Cisco and other plant-floor conditions typically
satisfy the need for integrating conve- remains the most preferred option.
nience with safety and security, such as Wireless HMI applications HMIs on a swing arm are useful when
solutions that allow the user to utilize an meet TSN devices a large-screen HMI is desired and the
iPad or comparable product and pair an HMI is a use case where delivering data operator needs to be able to interact with
e-stop with an operator-presence trigger with bounded latency and high reliability different points in the machine with both
to ensure compliance with regulatory is extremely important. This is where hands and the HMI without walking back
safety. Some customers may want a more time-sensitive networking (TSN), and in and forth from the machine to the HMI.

38 / October/November 2023 / ControlDesign.com

 real answers

Of course, the HMI needs to be installed in

an enclosure rated for the area, or a Video
Electronics Standards Association (VESA)-
mountable, totally enclosed HMI would be
needed, which can drive up costs.
If the environment allows it, and a
smaller screen size is acceptable, the
wireless or tethered—cable—options
give the operator the ability to move
around the environment while operating,
although they may not have both hands
free. These devices can be easily dam-
aged in the wrong environment.
There are HMIs that support remote ac-
cess via apps. For applications where only
mobile HMI is needed, a headless HMI is
a unique device, which can be mounted
internal to a control panel and support re-
mote connectivity (Figure 7). Many users
find this headless HMI to be an ideal way
to add mobile HMI to their applications in
a cost-effective and protected way.
The mobile device connects via a
wireless network to the headless HMI,
and operators use the app on the mobile
device of their choice to access HMI
Figure 7: A wide range of extensions can be added to ruggedized, industrial HMIs to suit the needs
screens. This way only the mobile HMI is
of an application. (Source: EMAG and Beckhoff)
exposed. The headless HMI can also drive
an external display, fulfilling the previous
installations discussed by connecting an
industrial monitor that is panel-mounted lution on mid-range control applications ture (OPC UA) and support for a variety
or VESA-mounted to a swing arm. and modular-type machines. These of industrial Ethernet fieldbuses, making
BOBBY THORNTON types of devices will control, display, them ideal for modern automation sys-
product engineer for HMI and Click PLCs / AutomationDirect trend and communicate to upper-level tems in a wide range of industries.
systems, if needed. They could poten- ROBERTO SOLIS
Visualization capabilities tially act as your edge controller for IIoT senior product manager, fieldbus technology / Turck
enhance HMIs applications. On top of that, there are
The HMI world has definitely taken device variants rated up to IP67, where Mobile technology is spreading
advantage of smaller and more power- a cabinet is no longer needed. An HMI intelligence across the machine
ful semiconductors like in consumer is no longer a simple display and could It sounds like you’re ahead of the curve.
electronics. Having more powerful become the cornerstone of the control HMI design is often one of the last things
microcontrollers, opens the opportunity system with the appropriate hardware that machine builders and their end
to have HMI devices that not only act as for the application. Available commu- customers focus on. But it significantly
local display and control for the opera- nication interfaces range from Modbus impacts people’s ability to operate ma-
tor, but also as full-blown PLCs with remote terminal unit (RTU) to open plat- chines effectively and their opinions of
visualization. This is a cost-effective so- form communications unified architec- the system overall. Moving forward, you

ControlDesign.com / October/November 2023 / 39

real answers

should watch for several upgrades in solid aluminum and hygienic stainless hurdles in training, considering the
terms of hardware capabilities, software steel, as well as flexibility for custom- ongoing labor shortage.
functionality and machine-design trends. ization (Figure 8). Multi-touch functionality in the
And the concerns about PC-based control We enjoy helping engineers design hardware is critical here, but the HMI
are really perceived risks. Many of our the perfect control panel for their ma- software needs to be up to current
customers have been successfully using chines. That might mean adjusting color programming standards to make things
PC control in the field for decades—spe- schemes and adding logos to fit corpo- like pinch to zoom or swiping through
cific to HMI, most of these customers have rate-branding guidelines. Or it could be screens a reality (Figure 9). And it makes
been able to eliminate the stand-alone PC adding a full range of e-stops, pushbut- it possible to access or operate the ma-
used for the HMI, so there’s an immediate ton extensions, keyed access or radio-fre- chine from different devices via a web
hardware reduction and better synchroni- quency-identification (RFID) readers for interface, scaling this interface to fit.
zation of all HMI and control components. managing credentials, jog buttons and From a software perspective, people
Gone are the days when old-school handwheels for CNC applications. want HMIs to be truly customizable, flex-
screens with single touch and plastic Still, you could make the most incred- ible and adaptable. A fully integrated HMI
bezels reigned supreme. Sure, they’re ible panel out there, but the functional- package should be built from the ground
still around. But the last decade has seen ity has to match the application. I don’t up based on standardized web-based
major advances, and the legacy options’ know many people who like clicking technologies (Figure 10). A modern web
lack of personalization and functionality through 500 commands to set a param- application is every bit as capable as the
make them feel like an afterthought. eter. In fact, most customers and equip- native platform apps of yesteryear, with
Whether it’s on a pole, swivel arm or ment end users tell us their operator the added benefit of compatibility across
built into the cabinet, HMI hardware interface must be as simple as using a any device with a browser. So with a
should be ruggedized with options for smartphone. Otherwise, they face major secure login, you can access the machine
from a smartphone, tablet, wireless pen-
dant or other mobile technology.
This translates to an HMI package that
unlocks all the potential of contemporary
web development. The list of advantages
is long, but it includes responsive de-
sign—one codebase for all devices— un-
limited graphical and styling customiza-
tion, a powerful scripting environment
and open-source software integration.
So, if you’re already doing this, why
does it matter if your HMI hardware is
built into a cabinet or remote? Well, the
machine design is headed toward cabinet-
free concepts. This is increasingly made
possible by IP67-rated control solutions
like industrial PCs, drives and I/O mod-
ules that can mount directly on machines.
Maybe it’s just spreading intelligence
across the machine to make cabinets
smaller. Either way, your HMI will likely

Figure 8: Along with options for mounting and customization, multi-touch functionality delivers an
need to move. A pole mount is great if
intuitive user experience that simplifies operator training. (Source Beckhoff) that panel can be stationary. However,
we’ve seen many swivel arms that help to

40 / October/November 2023 / ControlDesign.com

 real answers

deliver an operator interface that’s physi-

cally connected to the machine but can
move with the operator as they start or
examine different processes.
It all starts with thinking about the
HMI early in the design process—not to
say you couldn’t add a more fitting panel
later. But an industrial control panel
that’s optimized for branding, operation
and machine design can provide the
perfect touch.
ERIC REINER
IPC product manager / Beckhoff Automation

On-machine equipment offers

improved operator ergonomics
and line of sight
When it comes to HMI, on-machine op-
tions are especially attractive. Mount-
ing them on swing arms and attaching
Figure 9: HMI software should be based on web design principles to offer a consistently better optional side handles can help increase
experience no matter the hardware being used. (Source: Beckhoff) operator comfort with improved ergo-
nomics and give operators line of sight
to critical process areas. You can also
combine on-machine terminals and PCs
with hardwired buttons and selector
switches since both include options for
embedded pilot devices, as well as a
hard-wired emergency-stop button. If
your facility already has HMI hardware
and software, rest assured that you can
add on-machine devices while maintain-
ing consistency with your installed base.
On-machine industrial PCs can also run
application software, which offers cloud-
based collaborative HMI development.
On-machine monitors which could be
paired with an enclosure-mounted box
PC or thin client are on the horizon. It’s
an exciting time to be involved in indus-
trial machine building with on-machine
equipment offering you new opportuni-
ties for saving space, time and money.
AL LETOURNEAU
Figure 10: A fully integrated HMI package should be built from the ground up based on standardized
web-based technologies. senior commercial portfolio manager, visualization & com-

puting platforms / Rockwell Automation

ControlDesign.com / October/November 2023 / 41

live wire

Joey Stubbs
[email protected]

Why Ethernet is the backbone of protocols

IF YOU HAVE been paying any attention to the offerings of high- the International Organization of Standardization (ISO) Open
speed fieldbuses at all in the past 10 years, you may have no- System Interconnection (OSI) model.
ticed that most, if not all, of the mainstream offerings are based So, why is this change such a big deal? Well, whether we like
on Ethernet technology. But why is this, and why was Ethernet to acknowledge it or not, the automation industry is not that
chosen in the first place, and what are some of the advantages big, especially compared to the much larger IT community and
of adopting Ethernet as the basis for so many different commu- consumer electronics markets.
nication protocols? Therefore, cabling, connectors, network cards and other in-
In the 1990s, fieldbuses were still a relatively new and frastructure devices become less expensive because there are
game-changing concept. Instead of bundles of individual many suppliers making them, not just one or two. Competi-
home-run wiring that ran from tion drives costs down.
field-device terminal strips or to Another result of using IEEE
local I/O racks, a fieldbus allowed A fieldbus allowed device signals 802.3 as the basis for communica-
device signals to be terminated to to be terminated to I/O located tion is the aforementioned diag-
I/O located remotely in the field near remotely in the field. nostic tools, which were prohibi-
the input/output (I/O) devices them- tively expensive with proprietary
selves, which were then intercon- protocols, become much more af-
nected with a digital fieldbus, which fordable or even free with Ethernet
communicated inputs to the programmable logic controller variants. Frame capture and decoding software utilities from
(PLC) or other type of controller, and was sent the output data. a variety of companies makes examining and troubleshooting
Wiring runs were much shorter, thus saving money on cable, industrial Ethernet protocols very easy, even examining the
conduit and the associated labor costs. timing and jitter of frames, command and response of bits to
In this “fieldbus war,” there were dozens of different propri- individual I/O channels on the network and even detecting
etary, or near-proprietary, fieldbuses offered by many different lost, corrupt or destroyed frames.
automation companies. Many were for simple I/O, some dedi- Another advantage of utilizing a commodity technology
cated to motion, others specifically for process control. Some such as Ethernet comes from who drives the innovations
were based on serial communication, others on optical or coax and improvements of the underlying standard. For the first
cable. There was not a huge incentive to be open, nor to even few decades of industrial fieldbus existence, those duties
support third-party devices. The closed nature of most proto- and associated expense fell to the companies developing
cols was viewed as a way of keeping customers from migrating their own fieldbuses.
to a competitor’s control system. With Ethernet, the larger consumer and IT community steers
Some of the main drawbacks for fieldbus users during this enhancements and developments to the communication stan-
time resulted from the closed nature of the fieldbus systems. dard. Now, those same innovations that help us stream movies,
Dedicated and very expensive fieldbus master cards, pro- synchronize sound to video playback and play games online
prietary cabling and connectors and extremely specialized also help us make advances in industrial communication in
diagnostic and troubleshooting tools could only be used for factories and other industries. In this case, the innovations for
that particular protocol. consumer products help improve our industrial networking.
Around the year 2000, several automation companies and
fieldbus consortiums independently began development of
Ethernet-based fieldbus protocols based on the most widely Joey Stubbs is a former Navy nuclear technician, holds a BSEE
used communication standard in the world—Institute of Elec- from the University of South Carolina, was a development
trical and Electronics Engineers (IEEE) 802.3, Ethernet physical engineer in the fiber optics industry and is the former head
layer, media access control (MAC) and other select layers of of the EtherCAT Technology group in North America.

42 / October/November 2023 / ControlDesign.com

 Sensing • Control • Motion • Connectivity • Safety • Displays • Design

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