Controleng MayJune2024

CONTROLENG.
COM
PID series part 5: Good/bad tuning | 33

Back to the future of PLCs, programming | 34, 63
Drives; Cybersecurity | 38, 42
Networking; Testing application | 44, M1
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Vol. 71 • No. 3
Contents MAY/JUNE 2024
16-30 How to develop

automation engineers
How are you getting, training and keeping qual-
ified engineers? See our annual workforce and
development salary survey research and advice
section. Cover image courtesy: CDM Smith
INSIGHTS ANSWERS
7 | May article sampling of headlines, 26 | How to progress in engineering,
authors, companies, links automation: 3 phases
9 | Market Update: Mergers in automation 28 | Solving the skills shortage requires
an innovative approach
10 | Technology Update: Choosing the right
computing paradigm for industrial 30 | Spectacular performers fly with motion
p.34
transformation controls, STEM, not CGI
33 | Advanced process control: One page of
NEWS PID spotlight, part 5; Seven pages online
12 | Automate 2024 roundup, recap: 34 | Back to the future of the PLC
How to accelerate automation’s benefits
38 | Power quality, harmonics: How to select
a variable frequency drive (VFD)
15 | Think Again: Control Engineering, in
its 70th year, joins WTWH Media 42 | Crafting the right IT/OT cybersecurity p.42
strategy for the journey ahead
44 | Picking the right MES or automation
ANSWERS solution for a life sciences application
62 | Product of the Year: What would make
16 | Results are in: Control Engineering
your job easier?
Career and Salary Survey, 2024
20 | Get engineering salary survey advice
from Control Engineering research INSIDE MACHINES (after 45)
p.M1
22 | Automation engineer pipeline: The M1| Make exponential gains now:
making of an automation professional Automation, I/O, mechatronics
CONTROL ENGINEERING (ISSN 0010-8049, Vol. 71, No. 3, GST #123397457) is published bimonthly by: WTWH Media, LLC; 1111 Superior Ave., Suite 2600, Cleveland, OH 44114. Periodicals postage paid at Cleveland, OH and additional mailing offices.
POSTMASTER: Send address changes to CONTROL ENGINEERING, 1111 Superior Ave., Suite 2600, Cleveland, OH 44114. Scott McCafferty, Co-Founder. CONTROL ENGINEERING copyright 2024 by WTWH Media, LLC. All rights reserved. CONTROL ENGINEERING is
a registered trademark of WTWH Media, LLC, used under license. Circulation records are maintained at WTWH Media, LLC, 1111 Superior Ave., Suite 2600, Cleveland, OH 44114. Telephone: 630/571-4070. E-mail: [email protected]. Publications Mail Agreement No.
40685520. Return undeliverable Canadian addresses to: WTWH Media, LLC, 1111 Superior Ave., Suite 2600, Cleveland, OH 44114. Email: [email protected]. Rates for nonqualified subscriptions, including all issues: USA, $165/yr; Canada/Mexico, $200/yr (includes
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errors result from negligence, accident or any other cause whatsoever.
control engineering — www.controleng.com May/June 2024

| 3
Vol. 71 • No. 3
Contents MAY/JUNE 2024
INNOVATIONS
Control Engineering eBook series,
New Products for Engineers now available: Summer Edition
Too many for print this month: Go online for these
products and more! Industrial USB hub series (a
AppliedAutomation
world’s first, says Moxa), process gas analyzer, circuit breaker
eBook
Topics include:
ystem with EtherNet/IP, Embedded IoT device for automation and
Next-generation,
industrial applications, fanless open-frame power supplies, 1kW open automation
wireless charging system for robotics, high-resolution thermal infrastructure con-
cameras, SCADA software. troller; Think redun-
See more products online www.controleng.com/products dantly about auto-
mation controllers
without high costs;
63 | Back to Basics: How to reduce workload using Control system integrators: How to excel with
reusable PLC components automation upgrades; New cost analysis: Open
Multiple programmable logic controller (PLC) platforms support process automation saves 52% versus DCS.
pre-packaged code to reduce programming time. Learn more at: www.controleng.com/ebooks
NEWSLETTERS ONLINE uProtecting Critical Infrastructure eBook

Control Systems Newsletter Topics include: How
to lower industrial
• Back to the future of the PLC; cybersecurity risk:
PID spotlight; Four benefits of Help from CISA, INL,
software-defined controls ARC Advisory Group;
CE Edge & Cloud Computing Overcoming SCADA
Newsletter integration cyber-
security challenges;
• Speed up reactions with 8 steps to defend
edge computing. against foreign and
hidden threats in industrial operations; Six best
5 selections from the editor CE Newsletter
practices for OT cybersecurity.
• Best of Control Engineering last month. PLC webcast, videos,
More topics at: www.controleng.com/ebooks
PID series, future cybersecurity
Stay ahead. Subscribe! www.controleng.com/newsletters
uControl Engineering digital edition
Reading on paper? Also
uGlobal System Integrator Report take advantage of useful
links in the digital edition.
Did you see profiles about companies receiving Click on headlines to see
the System Integrator of the Year award, case online version with more
studies and more? text and often more imag-
www.controleng.com/GSIR es and graphics. Also
download a PDF version.
Contact: www.controleng.com/
[email protected]; magazine
[email protected].

| 5
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It’s kind of a big deal: ultra-compact

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With blink-and-you’ll-miss-it dimensions, the CX7000 provides powerful automation anywhere it’s
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tasks previously handled by bulky PLCs. Beyond the configurable options of 8 digital inputs, 4 digital
outputs, 2 encoder inputs, 2 analog 0…10 V inputs and 2 PWM outputs built in, the CX7000 directly
connects to a gargantuan range of Beckhoff I/O terminals.
Now that is a big deal.
Learn how to clean

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Online Highlights
controleng.com
INSIGHTS
u NEW RESEARCH Part 1: Made in America research shows enhanced production efficiencies (A)
www.controleng.com/made-in-america
www.controleng.com/webcasts/research-review-control-systems-hmi-scada-and-plcs
u INTERNATIONAL: CE China: How to produce flexibly using mobile robots, machine vision
u WEBCASTS
(A)
www.controleng.com/articles/more-answers-about-how-to-advance-intelligent-data-sharing-analytics
www.controleng.com/articles/webcast-preview-how-to-achieve-operational-excellence-in-modern-monitor-and-control-with-edge-computing
www.controleng.com/articles/webcast-preview-iiot-automation-sensors-to-fit-edge-applications
www.controleng.com/webcasts/motors-and-drives-are-you-advancing-automation-efficiencies-with-smarter-components-systems
u Watch www.controleng.com/webcasts for:

July 16: SCADA: Incremental upgrades or replacements? Ask these questions for best results; Jason Israelsen, PE,
senior control engineer, APCO Inc.; Joseph Mazzola, general manager, McEnery Automation
Aug. 1: How to automate: The mechanics of loop tuning; Ed Bullerdiek, control engineer, retired
NEWS (B)
u Top 5 Control Engineering content: May 20-26; Manufacturing in space: Funding for ISS
www.controleng.com/articles/top-5-control-engineering-content-may-20-26-2024
www.controleng.com/articles/funding-for-technology-development-for-iss-announced
ANSWERS
u PID spotlight, part 4: How to balance PID control for a self-limiting process;
Ed Bullerdiek, retired control engineer
www.controleng.com/articles/pid-spotlight-part-4-how-to-balance-pid-control-for-a-self-limiting-process (C)
u Gaining the edge: Reducing costs, improving outcomes with edge AI; Lindsay Hilbelink
is global strategic marketing manager for Eurotech. (B)
www.controleng.com/articles/gaining-the-edge-reducing-costs-improving-outcomes-with-edge-ai
u Choosing technology for streamlined engineering; Kyle Harrison, HMI product

manager, Siemens. (C)
u Impact of CMMC on the DoD supply chain; Joe Coleman, cybersecurity officer,
Bluestreak Consulting
www.controleng.com/articles/the-impending-impact-of-cmmc-on-the-dod-supply-chain
u How to safely, sustainably absolve industrial malodors; Lisa Haupert, Ph.D.,

chief scientific officer, Ecosorb (D)
www.controleng.com/articles/how-to-safely-sustainably-absolve-industrial-malodors-with-standardized-formulations
u Forging open and unified industrial network architecture with TSN and single-pair ethernet;
Lisa Chang, product manager, Moxa Inc.
www.controleng.com/articles/advancing-industrial-connectivity-with-tsn-and-single-pair-ethernet/
u Benefits of using mixed valves in processing, industrial applications; Christine Tarlecki

is a marketing coordinator at ThermOmegaTech (D)
www.controleng.com/articles/benefits-of-using-mixing-valves-in-processing-industrial-applications (E)
u Industrialrobot safety considerations, standards and best practices to consider;
Herbert Post is VP of health and safety at TradeSafe (E)

| 7
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INSIGHTS
MARKET UPDATE
Industrial networking
Automation mergers, acquisitions, groups merge to advance
integration technology,
capital markets analysis in April automation
uORCHARD ROBOTICS Premiere cut, Massachusetts, aiming to drive techno- FIELDCOMM GROUP
Automation, RedViking and Siemens were logical advancement and market expansion. (www.fieldcommgroup.org) and FDT
among companies involved in recent merg- 4/1/24 Lincoln Electric Holdings Inc. Group (www.fdtgroup.org) plans to cre-
ers and acquisitions. The automation mar- acquired RedViking, a privately held auto- ate one business aimed at advancing
ket continues to experience a tremendous mation system integrator based in Plym- integration technology and harmonizing
number of mergers and acquisitions (M&A) outh, Michigan. RedViking develops and control system applications across mul-
and capital markets activity because of integrates autonomous guided vehicles tiple protocol topologies supporting pro-
automation market growth, consolidation (AGVs) and mobile robots, custom assem- cess and factory automation. Subject
‘
opportunities and strength bly and dynamic test sys- to the completion of a definitive agree-
ment, the new business will continue to
of many of the companies. The automation tems and manufacturing
Bundy Group’s relationships execution system (MES) support existing FieldComm Group and
include control system inte-
market continues software. FDT Group technologies, including Field
Device Integration (FDI), Field Device
gration, robotics, automated to experience 3/28/24 Orchard Robot-
Tool / Device Type Manager (FDT/DTM),
material handling, automa- a tremendous ics, the company enabling
Process Automation Device Information
tion distribution, artificial precision crop manage-
intelligence and cybersecuri- number of mergers ment with robots and AI, Model (PA-DIM), HART and Foundation
Fieldbus. FieldComm Group will acquire
ty; more activity is expected. and acquisitions announced their $3.8M all FDT technology and resources; an
raise, across a seed round
(M&A) and capital independent Strategic Integration Com-
April 2024 automa- led by General Catalyst, and mittee will be formed to guide future
’
tion transactions markets activity. a pre-seed led by Contrary. directions for protocol-independent
4/21/24 Siemens AG 3/26/24 Vinci Energies device integration. ce
agreed to acquire the industrial drive acquired Premiere Automation LLC., an
technology (IDT) business of ebm-pa- industrial controls and robotics specialist – Edited from an FDT Group press
pst. The business, which employs around in Charleston, South Carolina. Premiere release by WTWH Media. FDT Group is
650 people, includes intelligent, integrat- Automation provides project manage- a WTWH Media content partner.
ed mechatronic systems in the protective ment, controls and robotics integration Page 15 has more acquisition news.
extra-low voltage range and motion con- and training services.
trol systems. The planned acquisition will 3/21/24 SER, a leading global Intelli- tems for red meat, fish, poultry, cheese, pet
complement the Siemens Xcelerator port- gent Content Automation software vendor food, and other food markets.
folio and strengthen Siemens as a provider in the Enterprise Content Management 3/11/24 John Henry Foster Minneso-
of flexible production automation. market, announced that TA Associates, a ta Inc. a strategic collection of engineers,
4/11/24 Graham Partners, an invest- global private equity firm, agreed to make support and service teams, compressed air
ment firm focusing on advanced manufac- a strategic growth investment. experts and automation and robotics solu-
turing, has acquired E Tech Group. Based 3/20/24 Sonepar agreed to acquire the tions provider, acquired HTE Technologies,
in West Chester, Ohio, E Tech is an indus- Michigan-based distributors, Madison an automation supplier operating in Kansas,
trial automation systems integrator serving Electric Co. and Standard Electric Co., Missouri, and Illinois, to be run as an inde-
life sciences, data centers, consumer pack- distributors of electrical and industrial pendent division remaining with headquar-
aged goods, industrial and other sectors. E products and services to contractor and ters in St. Louis. ce
Tech helps customers integrate and support industrial customers.
automation in regulated environments. 3/18/24 Fortifi Food Processing Solu- Clint Bundy is managing director, Bundy
4/8/24 Industrial Device Investments tions, provider of food processing equip- Group, which helps with mergers, acquisi-
LLC initiated a strategic partnership with ment and automation solutions, completed tions and raising capital. Edited by Chris
Wasik Associates LLC, a manufacturer of acquisition of Reich Thermoprozesstechnik Vavra, Control Engineering senior editor,
Electron Beam Processing Systems in Dra- GmbH, a provider of thermoprocessing sys- [email protected].

| 9
INSIGHTS
TECHNOLOGY UPDATE: CLOUD AND EDGE COMPUTING
Choosing the right computing

paradigm for industrial transformation
There has been a rapid increase in data volume tuations in demand. Whether experiencing a sud-
den surge in data processing requirements or scaling
collected by manufacturers. They are examining down during periods of reduced activity, cloud plat-
forms provide the agility needed to optimize costs
the advantages and limitations of cloud and edge and maintain operational efficiency. This adaptability
computing and the potential benefits of a hybrid is particularly beneficial for businesses with varying
workloads or evolving data processing demands.
approach to optimize operational efficiency • Cost-effectiveness: A hallmark advantage of
cloud computing is cost-effectiveness. By outsourcing
and decision-making. the management of software and back-end infrastruc-
T
ture to cloud providers organizations can sidestep the
he 2023 MLC data mastery and analytics need for dedicated IT personnel and costly hardware
survey found that more than one-third of investments. This translates to substantial cost savings
manufacturers say the volume of data they’re and a reduction in operational complexities.
collecting has at least doubled in the last two • Accessibility: Cloud computing enhances acces-
years and nearly 20% say the amount of data has at sibility by enabling seamless data access and collab-
least tripled. While this surge of data presents oppor- oration from virtually any location with an internet
tunities for manufacturers, it also presents a critical connection. This flexibility is crucial, allowing teams
question: where should manufacturers process and to work collaboratively and access data in real time,
analyze this ever-growing volume of information? without geographic boundaries. Cloud-based appli-
Cloud and edge computing are distinct approach- cations facilitate remote work, empowering employ-
es to data processing in the industrial data man- ees to be productive and make informed decisions
agement landscape. Cloud computing, with its regardless of physical location.
centralized servers and vast storage capacity, offers In contrast to cloud computing's centralized
scalability and accessibility. Edge computing brings approach, edge computing embraces a decentralized
processing power closer to the data source, enabling architecture that processes and stores data closer to
real-time decision-making and low latency. Cloud its source. Edge computing has gained significant
and edge computing each has advantages and lim- traction in recent years, with Gartner predicting
its. Understanding these nuances help with decisions that over 75% of enterprise data will be created and
aligned with industrial digital transformation goals. processed outside the data center or cloud in just
Online
u
controleng.com Cloud versus edge computing
the next five years. This shift toward the edge offers
significant benefits to manufacturers, including:
Cloud computing has revolutionized data manage- • Reduced latency: A key advantage of edge com-
KEYWORDS: Control ment by shifting away from on-premises infrastruc- puting is its ability to reduce latency by processing
Engineering, edge computing,
cloud computing, rockwell ture. This computing paradigm allows manufacturers data at its source. This translates into a significant
automation, efficiency, hybrid to transmit vast amounts of industrial data to infor- reduction in network travel time, making it a game-
approach, data, cloud and
edge
mation technology (IT) and operational technolo- changer for applications where speed is of the essence.
See other ways cloud and
gy (OT) applications through an internet connection, • Enhanced security: The decentralized nature
edge helps manufacturing unlocking a range of benefits: of edge architecture means that sensitive data is
on the Control Engineering • Scalability: Cloud computing offers unparal- processed and stored locally, minimizing the need
robotics page.
leled flexibility to adapt to dynamic business needs. for extensive data transfers over networks. Edge
https://www.controleng.com/
mechatronics-motion-control/ The scalability of cloud services allows organizations computing's localized data processing and storage
robotics to easily adjust computing resources based on fluc- approach means that sensitive information remains
10 | May/June 2024 control engineering — www.controleng.com

within the confines of the organization, drastically Hybrid edge-cloud computing
reducing the surface area for potential cyberattacks. Both edge and cloud computing offer unique
• Improved reliability: Edge computing plays a advantages, however the "best" choice hinges on
pivotal role in ensuring the reliability of critical sys- the specific needs and priorities of manufacturing
tems. In traditional cloud computing models, dis- organizations, which involves careful consider-
ruptions at the central data center can impact the ation of factors such as cost, security, latency and
entire system. With edge computing, the decentral- the reliability of internet connections.
ized architecture distributes computing power across Industrial leaders may find cloud solutions
multiple edge devices, reducing the risk of a single more advantageous when dealing with applica-
point of failure. A distributed approach enhances sys- tions that demand extensive computational power
tem reliability and ensures continuous operation even and storage capacity. Large-scale data analytics, —Manish Jain,
Rockwell Automation
during network outages or disruptions. machine learning and centralized data processing
‘
are instances where the scalabil-
Cloud and edge limits Constant internet ity and flexibility of cloud infra-
While cloud and edge computing structure can shine. Conversely,
offer immense potential for business-
access isn't always edge computing is the more fit-
es, they have challenges. guaranteed in remote ting choice for industrial leaders
Cloud computing’s dependence on when real-time processing and
connectivity can be a significant hur- locations, factories reduced latency are crucial. Edge
dle for industrial settings. Constant or situations with computing is ideal for manufac-
internet access isn't always guaran- turing use cases where split-sec-
teed in remote locations, factories or fluctuating network ond decision-making is critical,
’
situations with fluctuating network strength. such as in autonomous robotics, —Achim Thomsen,
strength. This can lead to disruptions quality control on the production Rockwell Automation
in operations, delays in decision-making and hinder line and equipment monitoring.
overall efficiency. The volume of data generated by A hybrid approach combines cloud and edge
industrial processes can make cloud-based processing computing to take advantage of the strengths of
expensive. Constant data flow incurs high costs and each. A manufacturer can use edge computing
creates bottlenecks and potential processing delays. for real-time sensor data processing and anom-
Perhaps the most critical limitation of cloud comput- aly detection to trigger immediate maintenance
ing for certain applications is its inherent latency. The actions and send non-critical data to the cloud
time it takes for data to travel to the cloud, be pro- for long-term storage, analysis and optimiza-
cessed and return with instructions can range from tion insights. This hybrid approach empowers
seconds to minutes. This delay is unacceptable for manufacturers to seamlessly navigate industri-
applications demanding real-time responses, such as al demands, leveraging the strengths of each to Learning
automated industrial processes. In time-sensitive sce- optimize operational efficiency, enhance deci- uObjectives
narios, a minor delay can impact operational efficien- sion-making processes and ultimately drive inno-
• Identify the significant
cy and potentially compromise safety. vation. Make informed architectural decisions increase in data
While edge computing offers solutions to cloud's early in the process. This includes planning for volume collected by
limitations, it comes with its own set of consider- hybrid deployments, considering total cost of manufacturers and
its impact on data
ations. Managing a vast network of edge devices and ownership and ensuring alignment with security processing needs.
sensors distributed across various locations adds sig- needs. Such planning helps manufacturers to more
• Compare the advantages
nificant complexity to the IT infrastructure. This easily determine if cloud computing, edge com- and limitations of cloud
requires specialized expertise and can strain existing puting or a combination is the best option. ce and edge computing in
the context of industrial
IT resources, especially for smaller organizations. data management.
The additional hardware and software needed
• Explain the importance
to implement edge computing can also translate to Manish Jain is the product leader for edge analytics of a hybrid approach
higher costs compared to traditional cloud-based and AI applications and Achim Thomsen is the direc- combining cloud and edge
architectures. This can be a barrier for organizations tor of common connected applications both at Rockwell computing to optimize
operational efficiency
with limited budgets or those hesitant to invest in a Automation. Edited by Tyler Wall, Control Engineer- and decision-making in
new infrastructure. ing associate editor, [email protected]. manufacturing.

| 11
INSIGHTS
NEWS
Automate 2024 Recap:

How to accelerate automation’s benefits
uAutomate 2024 in Chicago and resources make open-source
focused on bringing people and more accessible to industry through
technologies together and making collaboration, said Matthew Rob-
automation better and more focused inson. Video: 3 notes about open-
on process and results. The event, by source robotics. www.controleng.
A3, the Association for Advancing com/articles/advance-plant-floor-
Automation, emphasized improv- robotics-three-ways-with-ros-indus-
ing automation using IIoT, AI, and trial-tools
ML to make better decisions and
address workforce shortages. Auto- • Humanoid robots help improve
mation innovation includes having automation, narrow labor gaps:
the right strategy, technology and www.controleng.com/articles/
people. Safety and cybersecurity Adding a second set of blades to this 50-year-old con- how-humanoid-robots-can-help-im-
remain major focuses and compa- crete mixer required a lot of thought because many prove-automation-narrow-labor-gaps
nies can find the right solutions to safety solutions weren’t practical or were too expensive,
problems applying standards lower said Jenny Tuertscher, VP of technical safety for Fortress • Reducing risks for workers
risk to workers and processes. Safety in the presentation “Risk Reduction Is Not Always without making major changes:
www.controleng.com/articles/auto- About Changing Your Control System” at Automate 2024 See photo. www.controleng.com/
mate-2024-recap-how-to-acceler- in Chicago. Courtesy: Chris Vavra, WTWH Media articles/reducing-risks-for-workers-
ate-automations-benefits without-making-major-changes
ino promoted how open-source technology
Gary Cohen, Mark Hoske, Amara Roz- and platforms can help drive technology • Manufacturing’s long-term future looks
gus, Anna Steingraber, Chris Vavra and and innovation. Arduino touted its indus- bright after rough 2023: www.controleng.
Tyler Wall are Control Engineering and trial line and interoperability benefits. www. com/articles/manufacturings-long-term-fu-
WTWH Media editorial team members who controleng.com/articles/arduino-touts-indus- ture-looks-bright-after-rough-2023
covered the following at Automate 2024. trial-line-interoperability-at-automate
• Four steps to designing for future
• Advice to get started with industrial • How to determine where, when, why of OT cybersecurity challenges: www.con-
mobile robots: Select, integrate industri- a first robot purchase: Mitsubishi Electric troleng.com/articles/four-steps-to-design-
al mobile robots, from Dynamic Horizons Automation answers questions related to: ing-for-future-ot-cybersecurity-challenges
Automation Solutions. See basic terms. "Should you install a robot?" www.contro-
www.controleng.com/articles/advice-to-get- leng.com/articles/how-to-determine-where- • Automation innovation award winners
started-with-industrial-mobile-robots when-why-of-a-first-robot-purchase announced: A3 announced AMD, ECM
and GrayMatter Robotics as the winners of
• How to transform manufacturing • How to get more from automation the inaugural Automate Innovation Awards.
four ways with AI: Artificial intelligence with AI, digital threads: End-users, sys- www.controleng.com/articles/automation-in-
(AI) helps engineering, data analysis, pro- tem integrators and original equipment novation-award-winners-announced
gramming, troubleshooting in manufactur- manufacturers should expect more from
ing, said Microsoft and OPC Foundation. automation, said Siemens. www.contro- • VIDEOS with ABB, Arduino, Beckhoff
www.controleng.com/articles/how-to-trans- leng.com/articles/how-to-get-more-from- Automation, Bundy Group, DigiKey, Inter-
form-manufacturing-four-ways-with-ai automation-with-ai-digital-threads act Analysis, Raymond Corp., Sick, Unitron-
ics, Wago and Weidmuller. www.controleng.
• Arduino touts industrial line, interoper- • Advance plant-floor robotics three ways com/articles/automate-2024-video-inter-
ability at Automate: Guneet Bedi of Ardu- with ROS-Industrial tools: ROS-I tools view-recap-roundup ce

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Mark T. Hoske, Control Engineering
Content Specialists/Editorial
Mark T. Hoske, editor-in-chief
847-830-3215, [email protected]
Tyler Wall, Associate Editor,
Control Engineering, in 70th year,
joins WTWH Media
Emily Guenther, Webinar Coordinator
[email protected]
Amanda Pelliccione, Marketing Research Manager
WTWH Media LLC acquired CFE Media LLC on May 1 to bring

Gary Cohen, Senior Editor
[email protected]
Chris Vavra, Senior Editor greater engineering resources and opportunities to subscribers.
[email protected]
Contributing Content Specialists

Control Engineering’s Control Engineering began
Suzanne Gill, Control Engineering Europe opportunities to serve sub- in September 1954 as part
[email protected]
scribers and other stakehold- of McGraw-Hill and; 50th
Agata Abramczyk, Control Engineering Poland
[email protected] ers interested in automation, anniversary cover shows first
Lukáš Smelík, Control Engineering Czech Republic
[email protected]
controls and instrumentation cover with key anniversaries.
Aileen Jin, Control Engineering China increased as WTWH Media Courtesy:
[email protected]
acquired CFE Media LLC Control Engineering
for an undisclosed amount
Editorial Advisory Board
www.controleng.com/EAB on May 1. WTWH stands as new branding and demand
Doug Bell, president, InterConnecting Automation,
www.interconnectingautomation.com for willing to work harder. generation opportunities for
David Bishop, chairman and a founder CFE stands for content for our marketing partners.”
Matrix Technologies, www.matrixti.com
Daniel E. Capano, senior project manager, Gannett Fleming
engineers. Patrick Lynch, CEO of
Engineers and Architects, www.gannettfleming.com “Combined with the recent CFE Media, said: “Our opti-
Frank Lamb, founder and owner
Automation Consulting LLC, www.automationllc.com acquisition of Engineering. mism for the future has never
Joe Martin, president and founder com, this partnership adds editorial excellence been stronger. We believe the partnership with
Martin Control Systems, www.martincsi.com
Rick Pierro, president and co-founder
across critical engineering disciplines, expands WTWH Media will benefit our team, audi-
Superior Controls, www.superiorcontrols.com audience reach of technical engineers and indus- ence, and marketing partners. Together with
Eric J. Silverman, PE, PMP, CDT, vice president, senior
automation engineer, CDM Smith, www.cdmsmith.com try executives, and bolsters WTWH Media’s WTWH Media, we are strategically aligned in
Mark Voigtmann, partner, automation practice lead offerings to support B2B [business to business] building the preeminent data-driven, tech-en-
Faegre Baker Daniels, www.FaegreBD.com
marketers in reaching the right audience at the abled B2B media platform with a full suite of
WTWH Media Contributor
right time,” said WTWH Media. B2B demand solutions. We are excited to help
Guidelines Overview Teams at Control Engineering and CFE drive growth across several new brands and
Content For Engineers. WTWH Media focuses on engineers Media look forward to finding ways to expand strategic initiatives, including Packaging OEM,
sharing with their peers. We welcome content submissions
for all interested parties in engineering. We will use those our educational services to automation, con- Automated Warehouse, the Digital Transfor-
materials online, on our Website, in print and in newsletters to
keep engineers informed about the products, solutions and trols and instrumentation subscribers as part mation Forum event, and WTWH’s Branded
industry trends.
* https://tinyurl.com/ControltEngineeringSubmissions
of the WTWH Media engineering group, Content Studio.”
gives an overview of how to submit press releases, products, which includes 3DCAD & Digital Manufactur- Jim Langhenry and Steve Rourke, CFE
images and graphics, bylined feature articles, case studies,
white papers and other media. ing, Design World Network, Electronics Engi- Media co-founders, added: “Since founding
* Content should focus on helping engineers solve problems.
Articles that are commercial in nature or that are critical of
neering Network, Fluid Power World, R&D CFE Media in 2010, we have seen Control Engi-
other products or organizations will be rejected. (Technology
discussions and comparative tables may be accepted if
Network and Robotics Network. neering, Plant Engineering, Consulting-Specify-
nonpromotional and if contributor corroborates information
with sources cited.)
Scott McCafferty, co-founder and CEO of ing Engineer, and Industrial Cybersecurity Pulse
* If the content meets criteria noted in guidelines, expect to WTWH Media said: “We are thrilled to add grow into the marquee brands in their sec-
see it first on the website. Content for enewsletters comes
from content already available on the website. All content for the CFE Media team and brands to WTWH tors. We are excited to join the WTWH family,
print also will be online. All content that appears in the print
magazine will appear as space permits, and we will indicate in
Media to expand our engineering audience which shares our core values and mission.”
print if more content from that article is available online. reach and offerings to this growing and critical Think again about sharing knowledge as
* Deadlines for feature articles vary based on where it
appears. Print-related content is due at least three months in market. The addition of CFE Media will help we do so at WTWH Media. www.controleng.
advance of the publication date. Again, it is best to discuss all
feature articles with the content manager prior to submission. WTWH Media provide more relevant and crit- com/connect/how-to-contribute ce
Learn more at:
https://tinyurl.com/ControlEngineeringSubmissions
ical news, value-added insights, and skill-de-
veloping information to our audience as well Mark T. Hoske, editor-in-chief
May/June 2024
| 15
2024
WORKFORCE
DEVELOPMENT
Results are in:

Control Engineering Career
and Salary Survey, 2024
Benefits and salaries increased. Leading automation technologies
help resolve economic challenges and workforce shortages.
S
alaries and benefits increased for 2023. Lack of investments for equipment, gies likely indicate increased interest. Like
Control Engineering subscribers software upgrades or replacements was last year, no technology listed was separat-
responding to the 2024 Control Engi- at 10% among concerns, twice the 5% in ed from its neighbor by a percentage great-
neering Career and Salary Survey 2023. Financial compensation has the most er than the margin of error for the research,
and Report, while supply chain concerns impact on job satisfaction at 33% followed at +/-6.7% at 95% confidence in 2024.
for manufacturing continued to fall. Salaries by the next six criteria in a statistical tie for These were among other key findings in the
increased to an average $114,771 (Figure second (Figure 6). research.
1), up from $111,345 among those taking
the survey in 2023, about a 3% increase, Automation resolves challenges Anticipated increases
compared to 7% increase in the 2023 sur- What technologies can help in the com- Automation, controls and instrumen-
vey. The average of those receiving bonuses ing year? (Figure 5) Remote controls and tation help manufacturers operate more
increased to $16,125 in 2024 (Figures 2, 3) monitoring moved to first from seventh efficiently and fill the skills gap, and often
from $15,929 in 2023. The economy (41%) while artificial intelligence and machine those with automation expertise mirror
moved ahead of lack of available skilled learning (AI/ML) moved from to third demands for technologies. About two-
workers (33%) as the leading threat to man- from eighth. Six automation-related offer- thirds of respondents (66%) expect a base
ufacturing business in 2024. Last year, they ings, including those two, were statistically annual salary increase in 2024, compara-
were tied, given the margin of error. Lack tied for first. Power quality and reliabili- ble to the last two years.
of necessary materials/parts fell signifi- ty increased to fifth from 17th. Significant Personal performance increased to tie
cantly to 11% in 2024, down from 30% in shifts in ranking relative to other technolo-
Compensation
Expected change to 2024 Expected change to 2024 summary 2024
base annual salary bonus compensation SALARY
Decrease 3% Increase more than 6% Average $114,771
Increase more
Minimum $20,000
than 6% Stay the same Increase 4% Decrease
to 6%
6% 6% 7% 10% Maximum $360,000
18% 31% NON-SALARY COMPENSATION
18%
Average (>200k) $11,840
59% Average (>0, <200k) $16,125
42%
Percentage receiving bonus 75%
Increase 1% to 3%
FIGURE 3: In 2024, the average salary
Increase 4% to 6%
Increase 1% to 3% Stay the same
of respondents is $114,771, up from
FIGURE 1: 66% of respondents expect a sal- FIGURE 2: 31% of respondents expect an $111,345 in 2023, up from $104,071 in
ary increase in 2024. increase in 2024 bonuses. 2022. Bonuses increased also.

company profits at 51% as the dominant 48% worked 40 to 44 hours What technologies are
criteria for bonus compensation (Figure (42% in 2023, 43% in 2022) most likely to help you in
4). In 2023, leading criteria for bonuses the coming year?
were 55% company profitability and 43% 18% worked 45 to 49 hours
PERCENT TECHNOLOGY
personal performance. (24% in 2023, 29% in 2022)
29% Remote controls, monitoring
Job satisfaction, hours for 13% worked 50 to 54 hours 28% Analytics: Data analytics
those working with automation, (14% in 2023, 9% in 2022) 28%

Artificial intelligence (AI) and machine
learning (ML)
controls
27% Automation applications/upgrades
While financial compensation is the 3% worked 55 to 59 hours
25% Power quality and reliability
highest impact for job satisfaction in (same in 2023, 2022)
Process design, measurements,
2024, the next six criteria were tied for 25%
optimization
second: Ability to work from home, flex- 6% worked 60 or more 23% Process optimization
ible work hours, technical challenge, feel- (8% in 2023, 5% in 2022). Industrial internet of things (IoT),
ing of accomplishment, relationship with 19% such as more interconnected sensors,
monitoring, data collection
colleagues and workload. In 2023, three Diverse automation helps
Analytics for predictive or prescriptive
factors with greatest impact on job sat- Control Engineering subscribers devel- 18%
maintenance
isfaction were technical challenge and op, integrate and use a wide diversity of 18% Cloud computing
financial compensation tied at 30% and controls, automation and instrumentation Industrial communications: faster and
16%
feeling of accomplishment was at 25%. to create solutions; subscribers selected easier among devices and systems
Hours worked trended lower. from among 23 technologies in the ques- 15% Better HMI and SCADA designs
tion: “What technologies are most likely 15% Cybersecurity technologies
11% worked fewer than 40 to help you in the coming year? Check all 15%
Sustainability metrics, measurements
and related optimization
(9% in 2023, 11% in 2022) that apply.” Seven replies were in a statis-
Automation: Motion control optimization
tical dead heat for the top spot (Figure 5). 14%
with advanced actuators, drives
Industrial communications: Wireless
14%
Criteria for 2024 bonus compensation networking
Resilient and redundant designs
14%
Company profitability for critical infrastructure
Automation: Robotics, collaborative
12%
robotics, mobile robotics
Personal performance
New business, sales increase, commission
Advanced integrated industrial safety,
11%
Customer feedback fail-safe technologies
11% Digital twins and simulation
Quality metrics
8% Edge computing
Company stock performance
Advanced process controls (APC)

Product profitability
6%
Better system integration, information flow optimization
6% Vision system optimization
Uptime/downtime
2% Other
Plant or line productivity
Reducing plant costs
Safety metrics FIGURE 5: While seven technologies likely
Application of industry standards to help most tied for first in 2024, power
Energy efficiencies or other sustainability metrics quality and reliability made the largest gain
Increased line flexibility since 2023 (10 percentage points), followed
IT/OT collaboration by remote controls and monitoring and
Other
artificial intelligence and machine learning
(four percentage points each).
Not applicable (no bonus received)
0% 10% 20% 30% 40% 50% 60%

All graphics courtesy: Control Engineering
FIGURE 4: In 2024, company profits and personal performance were tied as the leading crite-
research, WTWH Media
ria for non-salary compensation; profits lead among 2023 criteria.

| 17
2024
WORKFORCE
DEVELOPMENT
Compared to last year, the following three ing Career and Salary Report resulted from 2018); and 3% expect a salary decrease (1%
made the largest increases: an emailed survey to subscribers, produc- in 2023 and 2022; 3% in 2021; 1% in 2020
ing 211 qualified responses from April 17 and 2019; 2% in 2018).
• Power quality and reliability increased to May 6, 2024, for a margin of error of For base salary compensation, the mini-
to 25% in 2024 from 15% in 2023. +/-6.7% at a 95% confidence level. Survey mum was $20,000 ($22,000 in 2023; $20,000
respondents were invited to anonymously in 2022; $28,000 in 2021), and the maxi-
• Remote controls and monitoring provide their annual compensation infor- mum was $360,000, ($300,000 in 2023;
increased to 29% from 25% in 2023. mation and opinions on the current state $266,700 in 2022 and $250,000 in 2021).
of their facilities and industries along with For bonus compensation (Figure 2),
• Artificial intelligence and machine advice for peers. (See next article.) 18% expect an 1% to 3% increase (15%
learning (AI/ML) increased to 28% in 2023); 6% expect an increase of 4% to
from 24% in 2023. Engineering salary, bonuses 6% (same as 2023); 7% expect an increase
In Figure 1, 42% expect a salary increase greater than 6% (8% in 2023); 59% expect
Twenty-three percentage points sepa- of up to 3% in 2024 (45% in 2023 and 2022; about the same (57% in 2023); and 10%
rate the top from the bottom technology 51% in 2021; 52% in 2020; 63% in 2019; expect less (14% in 2023).
in 2024, while 13 percentage points sepa- 56% in 2018); 18% expect an increase of 4% For those receiving bonus compensation
rated top from bottom last year, possibly to 6% or more (19% in 2023; 12% in 2022; (Figure 3), the 2024 average received was
suggesting more focus on particular tech- 14% in 2021; 18% in 2020; 11% in 2019; $16,125 ($15,929 in 2023, $19,162 in 2022).
nologies in the coming year. 19% in 2018); 6% expect more than 6% The 2024 average across all respondents is
increase (7% in 2023; 10% in 2022); 31% $11,840, ($11,518 in 2023). In 2024, 25%
Survey methods expect the same (28% in 2023; 32% in 2022 received no bonus, (27% in 2023).
Research for the 2024 Control Engineer- and 2021; 30% in 2020; 25% in 2019; 23% in
Engineering bonus criteria
What 3 factors have the greatest impact on your job satisfaction? Two leading criteria for non-salary com-
pensation were tied: company profitability
Financial compensation at 51% (55% in 2023), and personal per-
Ability to work from home formance at 51% (43% in 2023), the larg-
Flexible work hours
est increase in percentage points from last
year); see Figure 4. New business/sales at
Technical challenge
17% (23% in 2023); customer feedback at

Feeling of accomplishment
15% (10% in 2023); quality metrics at 14%

Relationship with colleagues
(17% in 2023); company stock performance

Workload
at 10% (13% in 2023) and product profits at

Relationship with boss
9% (19% in 2023), among other responses.

Benefits
Job security
Company's financial health
Location Engineering job
Feeling of recognition satisfaction, threats
Advancement opportunities Leading factors influencing job satisfac-
Company size tion for engineers often are technical chal-
Leading a team lenge and feeling of accomplishment, except
Managing people
when financial concerns push compensation
to the lead. While deaths and disruptions
Physical or ergonomic environment
from COVID-19 created many workplace

Relationship with subordinates
challenges, it showed many organizations

Travel
that working from home and flexible hours

Other
0% 5% 10% 15% 20% 25% 30% 35% were possible for some positions, and highly
FIGURE 6: Top factor for job satisfaction is financial compensation in 2024, followed by six valued, say some respondents.
criteria in a statistical dead heat for second. Ability to work from home and flexible hours When asked which three factors had
among the six made the largest increases from 2023. greatest impact on workplace satisfac-

u Online
controleng.com
For more information, see this article online

and download the Control Engineering 2024
Career and Salary Report.
CONSIDER THIS
What are the 3 biggest threats to manufacturing today? On the next pages, see related articles with
advice on:
Economy • Advancement skills and advice
• Workforce training, mentoring
• How technologies help workforce
Lack of available skilled workers
Competition development
Government/political interference • STEM skills for staging motion control
KEYWORDS: 2024 salary survey, career
advice
Regulations, codes, standards, etc.
Energy costs LEARNING OBJECTIVES
Learn about trends in salary and benefits
from the 2024 Control Engineering Career
Lack of necessary materials, parts
and Salary Survey.
Lack of investments for equipment,
software upgrade/replacement
Examine perceived threats to manufacturing
and changes from prior years.
Inadequate management
Outsourcing, offshoring
Compare and benchmark your career
progress with peers in the online version of
this study.
Taxes, tariffs on products
ONLINE
Don't know
Lack of investments for workflow, If reading the digital edition, click on the
headline to access and download the full 2024
manufacturing design upgrades
Downsizing Control Engineering Career and Salary Survey
Union pressures, restrictions and Report to see the benchmarking tables.
www.controleng.com/magazine
Other www.controleng.com/research
https://www.controleng.com/system-integration/
workforce-development/#pillar-article-header
None
0% 10% 20% 30% 40% 50%
FIGURE 7: Leading perceived threats to manufacturing is the economy, moving up from sec- and 10% at 30 or more years (15% in 2023;
ond in 2023 and third in 2022. Lack of available skilled workers was a solid second, down 13% in 2022).
from the top spot in 2023. Years in current industry trended down-
ward slightly: 14% at 9 or fewer years (9%
tion, financial compensation at 33% Slightly younger engineers in 2023); 19% 10 to 19 years (14% in 2023);
(30% in 2023) was the clear lead. Sec- Control Engineering research provides 20% at 20 to 29 years (24% in 2023); 27%
ond place, given the margin of error, was demographics as context, and extra figures 30 to 39 years (30% in 2023) and 20% 40
a six-way tie among ability to work from online provide benchmarking. years or more (23% in 2023).
home at 25% (up from 15% in 2023), Younger subscribers increased and older Highest level of education complet-
flexible work hours at 25% (19% in subscribers decreased in several age groups, ed were: <1% high school diploma (3% in
2023), technical challenge at 23% (30% a trend that’s reflected in recent www.con- 2023), 2% trade/technical school diploma
in 2023), feeling of accomplishment at troleng.com online analytics, as well, as (4% in 2023), 6% associate degree (8% in
20% (25% in 2023), relationship with col- older, more experienced workers retire. 2023), 5% college attendance (10%), 56%
leagues at 20% (19% in 2023) and work- Among those surveyed, 5% are under 30 had a bachelor’s degree (39% in 2023; 48%
load 20% (16% in 2023). See Figure 6 for years of age (2% in 2023; 1% in 2022); 15% in 2022), 24% had a master’s degree (30%
13 other criteria. at 30 to 39 years of age (9% in 2023; 7% in in 2023; 23% in 2022), 5% dual bachelor’s
Post-pandemic concerns about avail- 2022), 18% at 40 to 49 years of age (15% in degrees (2% in 2023) and 1% a doctoral
able material and parts available contin- 2023; 16% in 2022); 22% at 50 to 59 years of degree (4% in 2023). ce
ued to decrease as a manufacturing threat: age (29% in 2023; 32% in 2022); and 40% at
11% in 2024 (30% in 2023 and 42% in 60 and older (45% in 2023; 42% in 2022). Mark T. Hoske is editor-in-chief, Control
2022). In addition, lack of available skilled Years working for current employer Engineering, WTWH Media,
workers, while a solid second among per- trended downward with 50% at 9 years or [email protected]. Amanda Pellic-
ceived threats, became less of a concern less (36% in 2023; 43% in 2022), 23% at 10 cione, marketing research manager, WTWH
in 2024 at 33% (48% in 2023 and 57% in to 19 years (29% in 2023; 26% in 2022), 17% Media, conducted the research and assem-
2022). See other threats in Figure 7. at 20 to 29 years (20% in 2023; 18% in 2022) bled the related report available online.

| 19
2024
WORKFORCE
DEVELOPMENT
Get engineering salary

survey advice about
Control Engineering careers
Respondents to the 2024 Control Engineering Career and Salary Survey
provide advice about skills needed to get ahead and technologies they’ll use.
D
evote more time to improv- dents for advice. Among survey respon- Learning and skills development
ing skills and knowledge and dents, 54 offered advice on skills; 38 You need to spend more time improv-
use artificial intelligence (AI) provided technology-related advice. ing skills and knowledge and not be dis-
and data analytics to help opti- tracted by games, TV, sports and other
mize vast amounts of information from Skills needed to get ahead things. Buy books and read!
automated operation. These were among Please provide advice about skills need- Always look for learning opportunities.
advice 2024 Control Engineering Career ed to get ahead in your areas of respon- Try to present on the information and
and Salary Survey and Report. Two sibility today, including how and why. skills that you have learned. Teach others
write-in questions asked survey respon- Responses, edited slightly for style follow. when possible.
More financial expertise is needed.
Skills needed to advance Education via mini-MBAs is helpful. As
we advance, we do less of what we were
trained to do in a university and more of
Engineering
Communication/presentation
the strategic and company financial areas.
Project management I have found that a good place to start is
Computer having an interest in what you do for a liv-
Team-building ing, without it being all consuming, and
System integration finding life balance. Reading and compre-
Language hending work-related materials are essential.
With the over-abundance of infor-
mation out there, it is difficult to navi-
Marketing/sales
gate. There are so many paths to choose,

Finance/accounting
it becomes challenging to know if you are

Recruitment
even on the right path.

Other
Don't know
0% 10% 20% 30% 40% 50% 60% 70% 80% Engineering project management
FIGURE 1: Survey asked: What skills do you or others in your areas of responsibility need to Engineering and project management,
get ahead in their profession today? (Select up to five options.) Top skills to get ahead are conceptualizing an entire project lifecycle
engineering skills, communication/presentation skills, project management skills tied for first, and key participants. Collaborate across
considering the margin for error for the study. In 2023, the engineering skills answer lead at work groups in different departments.
72% with communications and project management tied for second at 62% and 61% respec- To ensure timely project completion
tively. Largest gains in 2024 were communications, project management and computer skills, you need to be able to work with custom-
all up by seven percentage points. Courtesy: Control Engineering research, WTWH Media ers and contractors to ensure project goals

are completed in a manner to meet cus- How to advance skills
tomer expectation and stay within budget.
Learn to manage responsibilities: This Hands-on experiences
goes beyond time management; it’s about Continuing education

only committing to and taking on tasks Being mentored
that you should take on. If someone else Reading industry publications, sites, email
can do it or should do it, allocate it. newsletters, digital guides, vendor, research
and association sites and materials
Engineering communication
Networking at conferences, memberships
Develop very good communications

in industry organizations, participation in
standards bodies and other industry groups
skills. Being able to communicate with Mentoring others
others and to communicate your project
needs and how to implement those needs
Search engines and online AI
are crucial to project successes. Proper

Other
grammar and spelling are critical. Don't 0% 20% 40% 60% 80%
always rely on autocorrect. FIGURE 2: Best ways to advance skills are hands-on experiences and continuing education,
followed by being mentored and industry publications. All options scored 20% or more.
Process design, analytics Courtesy: Control Engineering research, WTWH Media
Ensure you have a solid, rigorous pro-
cess design and data analytics back- but understand it is here to stay. I see vir- mation relating to emerging technologies.
ground. These skills are the basis for tual reality (VR) becoming more of a use- Trade publications are a good resource.
manufacturing productivity. ful tool for performing equipment layouts, Cybersecurity, firewalls, malware and
We need new data-driven decision-mak- power and controls. Getting the bean other internet safety-related technologies
ing skills to increase strategic decision-mak- counters to see spending benefits is hard. are what I am most interested in. ce
ing while aligning operational processes to Integrate more AI simply because of
work with new decision processes. the time savings. Mark T. Hoske is editor-in-chief, Control
Upgrade computer hardware, software Engineering, WTWH Media,
Controls and IT troubleshooting and production equipment; Hire more [email protected]. Amanda Pel-
Troubleshooting communications in net- employees. liccione, marketing research manager,
works and controls helps with knowledge WTWH Media, conducted the research
and accessing knowledge in the company. Automation, trends and assembled the related online report.
Continuing education relating to IT/ Increased IoT provides exponential
OT remains a large skills gap for more tra- growth of feedback-loop optimization and u Online
controleng.com
ditional/senior controls technicians. opportunity to streamline new systems of
controls while deprecating less beneficial KEYWORDS: 2024 salary survey, career advice
What technologies will help methods by removal or derating. LEARNING OBJECTIVES
A question asked about technologies like- More automation and integrating Learn from automation skills advice provided by
peers taking the 2024 Control Engineering Career
ly to help over the next year and why. operator and user interfaces for process
and Salary Survey.
improvement will help.
Discern applicable advice from peers about
AI, analytics, productivity More automation to make and design technologies needed to advance in engineering.
AI and data analytics are quickly becom- products for friendly field commissioning. CONSIDER THIS
ing essential to optimize vast amounts of Apply wireless sensors that communi- What automation, controls and instrumentation
information. Tools like these will help us cate directly to the PLC/DCS controllers. skills and technologies are adding or mentoring?
improve decisions. Apply sound judgment Know about new and upcoming tech- ONLINE
and eliminate AI generated garbage. nologies. Find ones that are a good fit and See 2024 salary survey research starting on p. 16.
AI will become a big tool in the com- that don’t cost more time and money to See 2023 salary survey advice.
www.controleng.com/articles/engineering-related-
ing year I believe. I just don't know-how implement. skills-automation-technologies-to-get-ahead-
or when yet. I am not a big AI proponent Look for lesser-known conduits of infor- in-2023

| 21
2024
WORKFORCE
DEVELOPMENT
Automation engineer pipeline:
The making of an
automation professional
Strategic automation engineering assumed to behave at steady state and changes in
the process result in a new steady state. However,
professional workforce planning requires in process controls, the dynamics of the process’
transition from steady state to transient state were
developing the necessary talent for current heavily analyzed. This approach introduces more
and future needs. realistic scenarios, requiring students to balance the
roles of engineer and operator for the first time.
T
As I began applying for jobs in instrumentation
he complexity of technologies for industri- and controls engineering, I noticed employers primar-
al control systems is increasing, and oper- ily sought candidates with backgrounds in electrical
ators are becoming more reliant on these or mechanical engineering. However, now, as a junior
systems to efficiently monitor and control automation engineer, I see how interdisciplinary the
Online
u
controleng.com
the related processes. Securing these industrial con-
trol systems in the cyber world also is becoming
automation field truly is. Entering the field of automa-
tion engineering, I was met with a landscape that was
more challenging and time-consuming. Due to the expansive, challenging, yet incredibly rewarding.
KEYWORDS: Workforce
development, automation expanding scope of their work, the technical skills My initial field training (Figure 1) focused on
engineering of automation engineers are in higher demand than foundational concepts such as understanding pip-
LEARNING OBJECTIVES ever. However, the methods firms use to recruit, ing and instrumentation diagrams (P&IDs), input/
Understand that having train and retain automation engineers are not output (I/O), interlocks, human-machine inter-
diverse background for
automation engineers are a evolving as quickly as the demand. face (HMI) graphics, writing specifications and
necessity and a strength of One strategy is to create three distinct pathways reviewing submittals. Navigating the realm of auto-
the discipline. to becoming an automation professional from the mation felt like diving into a sea of diverse knowl-
Learn that there’s a need to perspectives of an entry-, mid-, and senior-level edge, making it a challenge to even take the initial
advertise automation as a
career path to students and engineer. Data from a recent survey of automation plunge. Fortunately, mentors have played an invalu-
young professionals. engineers details how they entered the workforce able role in helping me unravel its complexities and
Demonstrate the and their suggestions for developing the future grasp an intricate web of concepts.
importance of creating automation workforce. Mentorship emerged as a crucial pillar of support
mentorships among entry-
, mid-, and senior-level during my journey in automation engineering. Learn-
staff that help guide career Meet an entry-level automation ing from experienced mentors and peers has provided
development.
engineer, Amal Khan invaluable insights into different career paths and pos-
CONSIDER THIS
How does your company
In my final semester of pursuing a degree sibilities within the field. I’m uncertain about the exact
enrich those with in chemical engineering, I enrolled in a course trajectory of my career and enthusiastic about the
automation-related called Process Dynamics and Controls. This class opportunities for growth and development.
responsibilities?
departed from my usual curriculum, as it focused Automation engineering offers a dynamic and
ONLINE
See more in the online
specifically on a control system’s basic design, ever-evolving environment, where the pursuit of
version of this article: methodology and implementation. It significant- knowledge is not just encouraged but necessary
Another graphic, more ly shifted my perspective on my chemical engi- for success. I look forward to embracing the excit-
on field training and on
automation engineering neering degree and the broader field of process and ing opportunities that await in this constantly
as a career path. plant design. In traditional classes, the process is evolving field.

Meet a mid-level automation
engineer, Giselle Villar
My automation journey began six years ago,
fresh out of college with a degree in Engineering
Science and Mechanics. During my studies, there
was one mechanics lab that taught what I would
later understand to be automation through basic
function-block programming using a program-
mable circuit board. It was such a small portion of
my education, and none of my instructors took the
time to explain automation as a potential career
path. Consequently, I nearly forgot about it until
I found myself in an interview for an automation
position almost three years later.
During that interview, two automation engineers
provided me with my first real introduction into and
appreciation for automation. What enticed me was the fire hose without formal education on instrumenta- FIGURE 1: Field training
extreme variety of the work; I would be doing design tion or controls in school. is the most valuable form
and programming, be in the office and the field, col- Recently, I have transitioned into a role between of training for automation
laborate with small and large project groups and no mentor and mentee. With my own mentors, there engineers, and fostering
project would ever require the same solution. The has been a shift toward partnership and increased mentoring relationships
automation discipline is the perfect place to satisfy an independence. Being just outside the comfort zone across different experience
engineer’s innate desire to solve problems. helps mid-level engineers develop the technical levels is crucial for knowl-
Throughout my career, I’ve found several excep- and interpersonal skills needed for automation. edge exchange and growth.
tional mentors. Half these mentorships developed I actively work with junior engineers to identify Courtesy: Giselle Villar,
through our company’s structured mentoring pro- areas of improvement in their technical and profes- CDM Smith
gram, while the other half are with teammates who sional training and connect them with people and
volunteer time and effort to help me, and other young resources within the firm so they can build a fulfill-
automation engineers, succeed. These are the people ing career path. It’s crucial to involve junior staff in
who turn project work into learning opportunities. meaningful tasks from the outset, as they may lack
‘
In college, there’s an expectation that your employ- experience but are eager to contribute and grow.
er will teach everything you need to know for your Being just outside
role. However, I quickly realized that this wasn’t Meet a senior-level automation
always the case upon entering the workforce. Instead, engineer, Padraic Gray the comfort zone,
I found that my most memorable and effective train- My first job out of college introduced me to the helps mid-level
ing occurred not through coursework, but through world of industrial controls. I was hired as a commis-
hands-on experience in the field. Just two days into sioning field engineer for an industrial equipment engineers develop
my job, I found myself immersed in the startup of a manufacturer. Much of the equipment I encountered
new plant along the local team. That’s where I found was hydraulically operated with a complex network the technical and
myself nearly every day for the next several months. of actuators, motors, pistons and proportionally con- interpersonal
Seeing the “end product” clarifies prior work. trolled pumps. Although my mechanical engineer-
Because of that experience, I have a better under- ing degree was intended to be used for learning the skills needed for
standing of different design decisions and how the hydraulic power components of the equipment and
’
reality of things don’t always align with how you ultimately working in the research, design and man- automation.
think something should be done. I highly encour- ufacturing, it was the automation aspect of the equip-
age all junior staff to get field experience as early as ment that captivated me. Coincidentally, the company
possible (Figure 2 shows Giselle Villar’s mentee), had a need to fill. Controls were kept at a theoretical
but know firsthand that it can like drinking from a level during my education in a couple controls-relat-

| 23
2024
WORKFORCE
DEVELOPMENT
ed classes. Seeing the magic of a controls system work

firsthand got me hooked into wanting to learn more
and do more. (Figure 3: Padraic Gray is one of Giselle
Villar’s mentors.) During my commissioning activ-
ities, I extensively collaborated with the automation
group within the company. My first exposure to work-
ing on the controls systems involved learning how to
make small changes to the equipment’s programmable
controller and graphic display. My involvement with
controls deepened unexpectedly when I found myself
required to interface with a plant control system at
one of the sites I was working on. As the sole engineer
on-site with an anxious customer awaiting results, I
learned on the fly to make the system operational. FIGURE 4: Distribution of college degrees among
In many ways, I was fortunate to be in the right CDM Smith’s automation engineers shows electrical
FIGURE 3: Padraic Gray, one place at the right time for finding an opportuni- engineering in the lead. Courtesy: CDM Smith
of Giselle Villar’s mentors ty as a controls engineer. First and foremost, I had
(shown), played a pivotal a strong mentor that was able and willing to teach automation industry and elsewhere.
role in equipping her with me the basics. Additionally, due to the urgent need
the technical knowledge to fill the position and the scarcity of suitable can- Background diversity helps
and confidence needed to didates, the company agreed to provide me with The wide variety of educational backgrounds
assume responsibility for a advanced training and the opportunity to grow into among our surveyed automation engineers under-
support contract with a local the role. Automation became my chosen discipline scores the strength of diversity within the profes-
client. Courtesy: Padraic more by chance than by design. sion. Each discipline brings valuable insights and
Gray, CDM Smith skills to the table, enriching the field of automation
Survey of automation engineers engineering in unique ways. Among findings:
To gain insight into the pathways individuals • Electrical engineering is relevant in automation
take to enter the automation career field, we con- engineering as motor, signal and wiring knowledge
ducted a survey involving over 100 automation is crucial for interfacing between equipment.
engineers at various stages of their careers, with an • Mechanical engineering details how the equip-
average of 20 years of experience in automation. ment parts work individually and how the compo-
The survey results reveal that our stories are not nents move and behave.
unique. The survey data and comments illustrate • Computer science and information technology
what has worked well for the participants in their encompasses the behavior of a network, including
careers and what they felt could be improved. switches, routers and firewalls.
Notably, fewer than half the respondents were • Chemical engineering describes the process
aware of a career in automation or pursued a cur- and aids with plant wide optimization.
riculum focused on automation during their college Mentoring in a welcoming environment is essen-
education. Instead, most engineers were intro- tial for attracting and retaining new talent in the
duced to the automation field through career fairs profession. See more with this article online. ce
or job search opportunities, rather than actively
seeking out positions in automation. Many profes- Padraic Gray, senior automation engineer and auto-
sionals transitioned into automation after gaining mation discipline leader; Amal Khan, automation engi-
experience in process engineering, environmen- neer with an interest in control theory; Giselle Villar,
tal engineering and other related fields, where they automation engineer with interests in young profession-
had opportunities to collaborate with automation al development, all with CDM Smith. Edited by Mark
engineers. Figure 4 illustrates the experience levels T. Hoske, content manager, Control Engineering, CFE
of the surveyed automation engineers, within the Media and Technology, [email protected].

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2024
WORKFORCE
DEVELOPMENT
How to progress in engineering,

automation: 3 phases
Mentor automation and controls FIGURE: Three phases of careers in
automation, controls and instrumen-
professionals, share advice. tation careers are foundation, prac-
W
tice and mastery, as explained by Eric
hat are the vari- J. Silverman, PE, PMP, CDT, vice pres-
ous career stages ident, senior au-tomation engineer,
in automation and CDM Smith. Courtesy: CDM Smith
engineering, and
what does a typical career path look practice phase, many tasks and
like? See also “Mentoring auto- as-signments that were once part of
mation and controls professionals entry-level responsibilities are del-
by sharing advice, experiences” in egated to entry level staff, allowing
the January/February issue of Control Engineering. the opportunity to take on projects to call your own.
CDM Smith delineates career ladders into foun- During this exciting time, you should be thriving in
Online
u
controleng.com
dation, practice and mastery phases. As someone an environment that fosters growth and further devel-
who occupies a senior engineering and managerial ops strengths and interests. The practice phase adds
KEYWORDS: Automation, role in the latter part of my career, I can fondly look the role of mentor while continuing as a mentee.
controls, instrumentation, back and reflect on these three phases and their
engineering career
development
profound impact on my personal growth and devel- Mastery phase
opment. I’ve come to understand that patience, In the mastery phase, you’re recognized as a
LEARNING OBJECTIVES
Understand the three commitment and consistency were the keys to my leader or subject-matter expert, carrying signi-
phases of careers in success. Each journey will differ. fi-cant responsibility. People rely on your expertise,
automation, controls and
instrumentation careers:
and you’re now in a position to more widely men-
Foundation, practice and Foundation phase tor and give back to others, helping to shape the
mastery. The foundation phase, or what I like to call the next generation of professionals. Embracing change
See more examples of “sponge” phase, is where you should explore every and maintaining a mindset of continuous learning
how foundation, practice
and mastery career phases available type of work within your company, build- are essential to staying engaged in an industry that
progress with this article ing technical and professional skills along the way. For has evolved significantly since entering the work-
online. the engineers on my team, this involves gaining expo- force. Avoiding complacency is key! In my journey,
Share questions or sure to everything we do in automation as design- I pursued additional certifications and transitioned
reflections about careers in
automation, controls and ers, programmers, field technicians and consultants. into a role managing a team, which opened new
instrumentation. This phase includes development of career-serving doors and opportunities. In addition, I volunteered
CONSIDER THIS soft skills, such as time management, organization, to lead automation initiatives within my company
Need with your automation, technical writing and professional communications. and contribute to Control Engineering.
instrumentation and
controls career? Ask Eric at It took several years of trying everything to hone my Where are you in your career journey? ce
SilvermanEJ@cdmsmith. strengths, which empowered progression.
com.
Eric J. Silverman, PE, PMP, CDT, is vice president,
ONLINE Practice phase senior automation engineer, CDM Smith, and a Con-
www.controleng.com/
system-integration/ During this phase, the level of responsibility and trol Engineering Editorial Advisory Board member.
workforce-development independence increases, while leveraging strengths Edited by Mark T. Hoske, editor-in-chief, Control Engi-
www.cdmsmith.com and forming a strong professional network. In the neering, WTWH Media, [email protected].

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2024
WORKFORCE
DEVELOPMENT
Solving the skills shortage

requires an innovative approach
New technologies help with challenges and opportunities in the
manufacturing workforce, including recruitment and employee retention.
W
hat were once warnings about put more students on the pathway to a career in the
impending talent shortages in the sector by promoting the career opportunities that
industrial sector are now real chal- await them and showcasing the innovative work that
lenges for many companies. In they can be a part of, from driving digitalization proj-
December 2023, U.S. manufacturers had 601,000 ects using disruptive technologies to helping create
open positions, according to the U.S. Bureau of cleaner, greener industries. Industry can help colleges
Labor and Statistics. In the National Association of and universities by working with them to evolve their
Courtesy: Rockwell Automation
Manufacturer’s latest quarterly survey, more than 7 programs to address changing talent needs. Examples
in 10 manufacturers said the inability to attract and exist across the country of such collaboration.
retain employees was one of their biggest challenges. At the Purdue Polytechnic Institute, industry
The changing nature of production is a key con- advisers and partners have supported the new Smart
tributor to the skill shortage. Shifts to more digitalized Learning Factory, which provides high-tech, hands-
and sustainable operations are creating a greater need on experiences for students to learn about intelligent
for workers with specialized skills and knowledge who production operations, and new learning pathways for
are in short supply. Experienced workers continue to students, like a major in smart manufacturing indus-
Online
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controleng.com
retire, and not enough people are entering the indus-
trial workforce to replace them.
trial informatics. University of Wisconsin-Milwaukee’s
Connected Systems Institute (CSI) bolsters the smart
There isn’t a single issue causing the talent short- manufacturing talent pipeline through education, col-
KEYWORDS: Skills age, nor a single solution. Companies need a multi- laborative research and state-of-the-art lab facilities.
shortage, labor shortage,
workforce development faceted strategy with talent and technology to Industry is using new and nontraditional talent
LEARNING OBJECTIVES build, support and empower their workforces. sources such as retired military members. The Acad-
Understand the current emy of Advanced Manufacturing is helping upskill
challenges faced by the Tapping multiple talent wells U.S. military veterans in just weeks to prepare them
manufacturing sector in
filling open positions and Industry has long relied on colleges and univer- for roles in advanced manufacturing. Companies hir-
retaining employees. sities to supply new generations of engineers and ing employees from these programs can gain peace of
Identify the reasons why other talent. But considering how much is chang- mind by filling key roles and take pride in the fact that
careers in manufacturing
are perceived to offer limited
ing in industrial operations and in the workforce they’re providing career opportunities to veterans.
career prospects. today, academic institutions could use an assist Companies must look inward for ways to develop
Learn about the projected from industry to help keep the talent pipeline flow- talent in today’s tight labor market. In the area of sus-
growth and opportunities ing with candidates who want to pursue a career in tainability, the number of skilled workers isn’t keeping
in the manufacturing
workforce despite existing
the sector and have the right skillsets. pace with the rising number of jobs. Manufacturers
recruitment difficulties. While perceptions of manufacturing have will need to help upskill current employees who have
CONSIDER THIS improved in recent years, too few people are still view- similar skills or a passion for sustainability.
Addressing the talent gap in ing it as a preferred career option. About 6 in 10 con- Digitalization is creating demand across indus-
manufacturing could unlock
significant growth and
sumers think manufacturing offers limited career tries for specialists in areas like data and analyt-
innovation in the sector. prospects. Companies can change this mindset and ics. Beyond hiring for these roles, companies are

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also upskilling their existing employees in a vari-
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employees use data and analytics in their jobs.
Technology as a workforce enabler

The digital transformation of industrial opera-
tions that’s underway puts new demands on work-
ers, requiring them to learn new technologies and
thrive in more data-driven roles. Systems and devices
can layer easy-to-use tools and intuitive user experi- Courtesy: Rockwell Automation
‘
ences over complex technology. These can simpli-
fy how workers interact with technologies and help connected workers, companies can create more Technologies
them work efficiently. Smart objects are configured empowered workers who can act faster and solve
in control system design tools and can significantly problems in new ways. that reduce risks
ease data management for engineers by organizing Bringing design and development work into the
data and automatically triggering data collection. cloud allows engineers to collaborate on projects to employees
Robot integration solutions can help engineers across offices and time zones. Allowing production while minimizing
more easily connect robot and control systems or operators to connect with remote experts in an aug-
combine them into one system. This can help accel- mented reality (AR) environment, they can get help environmental
erate deployments, ease access to analytics and troubleshooting complex issues and do unfamiliar
simplify operations. New capabilities that digital tasks. Technology like a computerized maintenance footprint can help
transformation makes possible can simplify work management system (CMMS) can also help automate
companies attract
for engineers and the end users they serve. maintenance tasks, allowing maintenance teams to
One of those capabilities is a digital twin, or a vir- work more efficiently and spend less time on tasks, prospective
tual replica of a physical entity or process. With a dig- like creating and translating work orders, tracking
ital twin of a machine, engineers can build, test and down operators and digging through filing cabinets. employees and
prove their machine first, before they order parts for it This transformative moment is also an opportuni-
or cut steel. Later, the digital twin can be used to vir- ty for companies to align their priorities with those of
retain current
’
tually commission the machine to help uncover issues their workforce in a way that benefits both sides. ones.
before the machine is built and sent to a custom- Companies need only look at two topics that
er. Once the machine is operational, the digital twin go hand in hand: safety and sustainability. Clearly,
can be used to detect anomalies and test production employees care about their own safety. A majority
changes before they’re physically implemented. of employed adults also say they want the compa-
Smart capabilities built into drives provide predic- nies they work for to invest in sustainability.
tive analytics. The drives can help prevent unplanned Today, technologies like contemporary safe-
downtime by modeling the predicted life of their cool- ty systems can help employees work safely with-
ing fans and notifying personnel when a fan reaches a out reducing productivity. Using technologies that
certain percentage of that predicted life. Some indus- reduce risks to employees while also taking steps to
trial control systems have special coding that allows minimize their environmental footprint can help
energy data from drives and other devices to be made companies attract prospective employees — and
instantly available. This allows the devices to operate retain current ones — by showing them that they
as smart meters, giving users better insights into ener- share the same values and goals. ce
gy use for sustainability efforts.
Steve Ludwig is the global strategic marketing man-
Embracing workforce transformation ager at Rockwell Automation. Edited by Tyler Wall,
Overcoming today’s widespread skills shortage associate editor, Control Engineering, WTWH
requires rethinking what work is. By creating more Media, [email protected].

| 29
2024
WORKFORCE
DEVELOPMENT
Spectacular performers fly with

motion controls, STEM, not CGI
Theatrical experts and engineers are required to keep the magic in theatrical
productions: Professor and technical director at Northern Illinois University.
T
hose interested in the mechanical behind- engineers in his projects, making people, objects
the-scenes magic of theatrical produc- and props fly for productions such as Mary Pop-
tion can earn a good living with strengths pins, Peter Pan, Seussical the Musical, The Wizard
in science, technology, engineering and of Oz, Aladdin, Beauty and the Beast and others.
math (STEM) fields, according to Tracy Nunnally, “Math is an important part of what we do,” say-
MFA, Northern Illinois University (NIU) professor, ing that he re-read his grade school physics book
technical director, head of design and technology, cover to cover when he began this line of work.
School of Theatre and Dance. That includes mak-
Tracy Nunnally, MFA,
ing actors and props fly and delivering a performer Engineers wanted, safety
is Northern Illinois Uni-
on a free-floating zipline from atop an open-air sta- “I love to assist creative people to bring their
versity (NIU) professor,
technical director, head dium to the stage at more than 50 mph. visions to life. I think about how to engineer the effect,
of design and technol- Nunnally said it doesn’t feel like work as he brings then work with other experts, including engineers, as
ogy, School of Theatre the visions of theatrical creatives to life with flying needed, to make it happen,” Nunnally said. Many peo-
and Dance. He owns rigs, motion controls and automation special effects ple have specialties in theater, including for lighting,
Vertigo, a company that for theater, concerts and other venues. He has a mas- but specialists in rigging and automation are compar-
provides automation, ters degree in fine arts (MFA), multiple industry-spe- atively rare. The help-wanted sign is often flying out
motion control and
cific certifications, appreciation and common-sense front, at the intersection of theater and engineering.
special flying effects.
Courtesy: Mark T. Hoske,
application know-how for math, physics and safety, as Safety is foremost in any production, and insurance
Control Engineering he explained at an April 17 STEM Café presentation, coverages are high to protect performers and those
“Theatrical Special Effects: Engineering Spectacle.” around them. Nunnally works carefully with creatives,
Online
talent, underwriters and engineers on risk analysis,
u
controleng.com
Motion controls and rigging risk reduction and associated documentation.
Nunnally talked about “How to apply the engi- Nunnally is involved in the Entertainment Servic-
KEYWORDS: Engineering neering to get the effect you want,” ranging from es and Technology Association (ESTA), a non-prof-
for theater, theatrical motion
control
manual to automated, including making actors fly it organization that writes entertainment industry
LEARNING OBJECTIVES
without computer-generated imagery (CGI). standards for American National Standards Institute
Learn that engineers Nunnally’s discussion included stories relat- (ANSI). Nunnally helps write standards and has two
and engineering-minded ed to his NIU professor/technical director posi- third-party Entertainment Technician Certification
creative help is wanted in
theatrical applications with tion at NIU School of Theatre and Dance, DeKalb, Program (ETCP) certificates for specific areas and a
knowledge of engineering Illinois, and as owner of Vertigo, one of just a few third certificate for teaching.
constraints, safety, physics companies in North America that provides automa- The industry is rapidly changing, with more use
and solutions.
tion, motion control and special flying effects ser- of advanced design technologies, simulation soft-
CONSIDER THIS
Theatrical production firms vices to theatrical productions. MFA studies can ware and artificial intelligence, and Nunnally wel-
also need engineering help. include a specialty in one or more specific areas of come younger outside experts to help apply that
ONLINE fine arts. While Nunnally doesn’t have an engineer- knowledge to his work. ce
Longer online version of ing degree, he uses math, physics, engineering prin-
this article includes many
motion control applications, cipals, industry-based certifications and a healthy Mark T. Hoske is editor-in-chief, Control Engineer-
photos, video and links. respect for safety to know when and how to employ ing, WTWH Media, [email protected].

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Entries are due Friday, August 30

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Who should enter?
If you’re a system integrator with demonstrable industry success, Control Engineering and
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Past System Integrator of the Year winners—Class of 2024, Class of 2023, and Class of
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2021 System Integrator of the Year 11 | SI Giants 19
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the Year:
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MASTER FILE,
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A supplement to CONTROL ENGINEERING and
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PLANT ENGINEERING magazines
2012_GSIR_COVER_V2msFINAL.indd 1 11/23/20 10:17 AM
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www.controleng.com/siyapplication
ANSWERS
TUTORIAL: ADVANCED PROCESS CONTROL
PID spotlight, part 5: Ed Bullerdiek, process control engineer, retired
What does good

and bad controller
tuning look like?
See seven take-aways for better PID tuning.
T
here are reportedly some 400 to 500 pub- settling time is about 4
lished loop-tuning methods. Each suppos- minutes. Ideally, once we
edly provides “ideal” tuning constants. In close the loop (place the
reality, no process is ideal; the best that any controller in Auto) the controller should get the pro- FIGURE 1: See an open-
control loop tuning method can do is provide a good cess variable (PV) to match the setpoint (SP) at least loop response of a self-
starting point. This is not to disparage any loop-tun- as fast, and preferably faster, than the 4-minute open limiting process to a OP
ing method, including those to be discussed later in loop settling time. change and a disturbance.
this series. Each method offers unique insight into Courtesy: Ed Bullerdiek,
proportional-integral-derivative (PID) controller per- Seven take-aways for better PID tuning retired control engineer
formance, and each has advantages and disadvantag- Seven reminders to improve PID tuning are:
es. Knowing each methods and when to use them is 1. A well-tuned control loop will respond to a SP
an essential skill and will greatly improve loop-tuning change faster than open loop.
results. They will rarely give a final answer. 2. Conversely, a poorly tuned control loop will
Control loop tuning is as much art as science; settle the PV on SP slower than open loop.
therefore it is in our best interests to build up some 3. Too much controller gain, integral, or deriva-
intuition about how proportional, integral and deriv- tive will cause oscillatory control behavior (swinging)
ative work together. You should know what a well- regardless of how the other two tuning constants are
tuned PID controller looks like. You also should be set. Getting two out of three right is not good enough.
able to tell when a controller is not well tuned and, 4. Too little gain or integral will result in slug-
based on the controller’s response, be able to draw
some conclusions about what the PID constants ought
gish controller response regardless of how the other u
tuning constants are set.
Online
controleng.com
to look like; that is, to have some intuition about what 5. In the limited number of situations where deriv-
KEYWORDS: Proportional-
needs to be changed. This comes down to pattern rec- ative can help adding derivative permits more aggres- integral-derivative, PID tutorial
ognition, which forms the core of the heuristic con- sive overall tuning, which will improve response to SP LEARNING OBJECTIVES
troller tuning method that will be discussed. changes and rejection of process disturbances. Understand how too much
controller gain, integral,
First we need to know what patterns we are look- 6. Therefore, it is important to get all three tun- or derivative will cause a
ing for. Before we discuss what “good” looks like let’s ing constants correct. controller to swing regardless
look at one way to benchmark good controller per- 7. When a tuning constant is set improperly of how the other two tuning
constants are set.
formance, comparing it against the process response there is a unique control loop response. This results
CONSIDER THIS
when the controller is turned off. Most loop tun- in a unique visual signature that you can use to Can you use visual cues
ing methods assume that a self-limiting process has identify the incorrect tuning constant. This can be to identify controller
deadtime and only one lag, also known as first order used to guide our loop tuning efforts using heuris- performance issues?
plus deadtime (FOPDT). Figure 1 shows a process tic tuning methods. ce ONLINE
This 7-page article online
that has three lags, therefore most tuning methods links to parts 1-4, and sign up
will give an approximate set of tuning constants. Ed Bullerdiek is a retired control engineer with for an Aug. 1 RCEP webcast:
This isn’t a problem. It only means that you may 37 years of process control experience in petro- How to automate series:
The mechanics of loop
have to trim the tuning constants using heuristics leum refining and oil production. Edited by Mark T. tuning www.controleng.com/
to get the response you need. Note that open loop Hoske, editor-in-chief, Control Engineering. webcasts

| 33
ANSWERS
PROGRAMMABLE LOGIC CONTROLLERS (PLCS)
Jeff Payne, AutomationDirect
Back to the future of the PLC

Programmable logic controllers (PLCs) This discussion is especially relevant consider-
ing the rapid—and sometimes seemingly exponen-
are not going away any time soon, and tial—acceleration in computing hardware, software,
intelligent measurement, cloud accessibility and
improving technologies combined with user communications connectivity. With these and other
advances, information technology (IT) has prolifer-
demands will continue their evolution as a ated steadily into the formerly isolated operational
technology (OT) realm.
foundational automation platform. While the article discussed the dramatical-
ly increasing importance of communications and
A
connectivity, it did not specifically include the
lmost 10 years ago, I wrote about the term “industrial Internet of Things” (IIoT), but
“Future of the PLC” for this publica- today IIoT capabilities are essential for nearly any
tion. Even back then, it was important application.
to mention that programmable logic In light of these developments, here are a
controller (PLC) technology was mature at near- few thoughts on what the next decade may hold
ly 50 years old. A decade later, a fair question is for PLC evolution and industrial automation
whether today’s PLCs have fully entered senior applications.
citizen status, and if future iterations are destined
for the grave. Remaining true to the task
The core mission of a PLC remains the same as
always: To deliver deterministic control and reli-
able monitoring of physical field devices, even
under challenging operational conditions. This has
been achieved using specialized processors, operat-
ing systems, and programming environments, built
into hardened platforms. Yet economies of scale
continue to drive the adoption of mainstream con-
sumer and commercial technologies into the PLC
role, wherever it is practical. The “smaller, faster,
better” maxim has held true and will continue to do
so, but mostly around the faster and better aspects,
as the trend to further miniaturization has leveled
off over the past decade.
Many benefits of electronic component, proces-
sor, and solid-state memory advances—reduced
cost, shrinking size, minimized power consump-
tion, and increased capability—have already been
incorporated into PLCs and other industrial elec-
FIGURE 1: Now that contemporary open-source processor platforms are avail-
tronics. While marginal size, cost, and power
able in industrial-grade form factors, such as the AutomationDirect Productivi-
improvements will continue, the real advances will
tyOpen, end users have options for integrating traditional automation methods
be around capabilities.
with more modern IT-based languages. Images courtesy: AutomationDirect
At this point, platform size is largely constrained
by the need for physical wiring to interface with

FIGURE 2: Today, even a low-cost PLC automation platform like the AutomationDi-
rect CLICK PLUS is packed with advanced logic capabilities, essential motion control,
wired/wireless connectivity, a range of IT/OT communications protocols, and more.
PLC input/output (I/O) modules. Traditional wired if it can deliver proven real-time control, while
I/O remains necessary, but in many cases, the con- providing other required advanced computing
nectivity with field devices is shifting to digital net-
works and distributed remotely using technologies
capabilities. Online
u
controleng.com
like IO-Link and wireless. Reconciling flexibility with consistency
KEYWORDS: PLC,
Multi-core processors incorporated PLC designs Although Windows-based systems dominate the programmable logic
now enable deterministic control to be supplement- consumer and commercial PC world, and are promi- controller
ed with extensive additional computational and nent for the industrial visualization realm, this is not LEARNING OBJECTIVES
Understand how
communication function. For over 20 years, the the case for real-time control. PLC/PAC platforms
programmable logic
term programmable automation controller (PAC) typically run a specialized operating system, although controllers (PLCs) have
has been used loosely to describe an industrial con- there are some Linux-based options. In very general evolved since 2014 and
what their role in automation
troller with greater capabilities than a classic PLC. terms, users must balance their desire for openness— facilities is now.
While a PAC may have initially seemed like a which provides great flexibility and low product Learn how communication
distinct product compared with a PLC, time has costs—with the requirement for industrial-grade reli- protocol advances and
proven that automation engineers are less con- ability historically delivered only by proprietary sys- artificial intelligence/machine
learning (AI/ML) also are
cerned with the nomenclature and much more tems. These proprietary systems also provide a high changing PLCs.
interested in performance and available features degree of cybersecurity, albeit primarily through ONLINE
when specifying industrial automation. obscurity and to an extent unfamiliarity to hackers. See additional PLC stories
While market offerings range from basic PLCs For many years there has been a trend, or at at https://www.controleng.
com/control-systems/
to complex PACs, the concept of an industrial con- least great interest, towards more open industrial plcs-pacs/
trol platform has largely merged into a continu- systems, both in terms of hardware platforms and Also: See Jeff Payne’s 2014
ous spectrum of capabilities. Moving forward, users for programming languages. Some end users have article “Future of the PLC” at
will be willing to consider most any type of under- applied generic Raspberry Pi and Arduino hard- https://www.controleng.com/
articles/future-of-the-plc/
lying hardware platform or operating system as an ware to implement automation and data handling
CONSIDER THIS
automation platform—which may continue to be projects. Others have avoided experimenting in this Where do you see the future
called a PLC but will actually be so much more— way with consumer-grade products due to concerns of the PLC heading?

| 35
ANSWERS
PROGRAMMABLE LOGIC CONTROLLERS (PLCS)
industrial automation functions, and its widespread

familiarity provides other advantages.
Today most hardware platforms support lad-
der logic—whether proprietary or implemented via
another IDE such as CODESYS—and many also
allow other types of coding methods, which can be
mixed-and-matched as needed. Various coding lan-
guages have their own strengths and weaknesses for
specific tasks, and most users like to apply their own
judgement when choosing the best tool for solving
a problem, while balancing flexibility against com-
plexity. An added bonus for users is moving outside
of proprietary languages enables them to curate a
library of code, which can be deployed on any type
of target hardware, minimizing rework.
The main point today and looking ahead is users
desire automation platforms offered and backed by
trusted and experienced industrial suppliers, with
provisions for supporting any type of preferred pro-
FIGURE 3: Robotics rep- about reliability, but now a few versions of these gramming language.
resents a fast-growing area platforms have been hardened into industrial-grade
of industrial design, and the devices (Figure 1). Users are showing great demand Tying it all together with
demand for capable auto- for the ability to combine contemporary program- communications
mation platforms and asso- ming platforms with proven industrial I/O and Some of the greatest industrial automation
ciated sensing technologies hardware. strides over the last decade are associated with
will increase as users seek to With such a range of hardware options, the next communications improvements, leading to a truly
thoroughly integrate robot- hurdle for openness has been homogenizing the connected factory. As with controller hardware
ics into their operations. programming environment. Classic PLCs used ven- and programming, the story has been one of mov-
dor-specific programming that was difficult to port ing away from proprietary implementations and
to other brands. The IEC 61131-3 standard intro- towards a more open offering.
duced ordered PLC programing languages and data Traditional OT-centric fieldbuses, such as
types, but vendor-specific implementations still DeviceNet, had long offered the reliability and
hampered code portability among brands. Eventu- installation form factors demanded by users. But
ally, the CODESYS integrated development envi- now wired, and even wireless, Ethernet variants are
ronment (IDE) offered a more consistent way to dominating, with several leading industrial com-
create code using the standard languages to deploy munications protocols available. Physical form fac-
it cross-platform on industrial controllers. tor improvements, such as washdown-rated and
However, none of these initiatives addressed the connectorized components and power over Ether-
fact that programmers entering the workforce often net (PoE) now enable Ethernet installations to be
preferred to code in more modern IT-based lan- suitable for industrial environments.
guages such as C++ or Python. Certain OT protocols such as EtherNet/IP, PRO-
Despite all these efforts heading to openness FINET, and Modbus-TCP are associated with
and modern programming languages, it seems safe makes and models of field devices, while others
to say that classic ladder logic is here to stay for are optimized for types of automation tasks (such
the foreseeable future. Ladder logic enjoys a mas- EtherCAT for motion control). While EtherCAT is
sive installed base, and it remains a simple coding not new, the incorporation of this protocol native-
methodology preferred by many electricians, tech- ly into more capable PLCs now means low- and
nicians, and even developers. Its graphical style medium-complexity motion applications are can
lends itself to basic troubleshooting and typical be integrated natively into an automation platform

without requiring separate motion controllers. AI’s role in the PLC’s future
‘ PLCs will add even
better programming
Ethernet-APL is an OT-optimized media, which No future-looking industrial auto- and connectivity
makes it easier to deploy wired Ethernet out to field mation article written in 2024 could
devices. IO-Link is on the rise as a streamlined overlook the potential impacts of arti- functions to improve
fieldbus—even for basic discrete automation devic- ficial intelligence (AI) and machine
es—with fit-for-purpose communications capabili- learning (ML). However, much of the the user experience
ties and intelligence. current buzz is around using AI/ML and the speed at
Bridging OT to IT to securely enable IIoT appli- in a live “runtime” role to analyze and
cations and data transfer in support of remote visu- react to conditions. As an automation which projects can
alization and analytics requires a different class of platform, PLCs are not currently ideally
’
communication protocols. OPC UA and message suited for this task, but some advanced be delivered.
queuing telemetry transport (MQTT) are dominant versions may be able to run live AI/ML
in this role. While some of their capabilities over- algorithms in the future.
lap, there are optimal use cases for both protocols, Instead, PLCs are well placed to act as the field
and users can choose to implement them simul- interface for higher-level AI/ML resources, pro-
taneously. Other supporting tools, such as Node- viding users with abundant, responsive and con-
RED, have become favored as a graphical method textualized data. They also can implement actions
for processing and pushing data to the cloud for dictated by algorithms.
consumption by other applications. On the other hand, generative AI (Gen-AI) is
From sensor to controller, to on-premises serv- poised to play a bigger role with PLCs in coming
er, to cloud-based resources, to browser, what years from a code creation standpoint. Develop-
does this all mean? In the “old days,” smaller con- ment environments with carefully integrated AI
trollers would have a limited feature set, so larg- support tools could help users—perhaps even rela-
er devices or multiple integration layers were tive newcomers to the field—develop useful auto-
required to achieve complete connectivity. Today mation logic based on libraries and proven code. u Insights
and into the future, users will want these options AI, used as a development tool, could help speed
available in even very basic and low-cost automa- development times, improve code reliability and Programmable logic
tion platforms (Figure 2). minimize redundant or repetitive labor. controllers (PLCs)
PLCs,
u now almost senior
citizens, evolve amidst rapid
The role of integrated robotics The future PLC is one piece technological advancement,
For many years, robotics has largely existed as of an automation platform incorporating mainstream
technologies while
a specialty subset of automation, requiring custom Over the next decade, PLCs as we know them enhancing capabilities,
integration into upstream and downstream sys- will certainly not go away, even if they are referred connectivity, and real-time
tems. This is morphing as robotics in general, and to as PACs, or edge controllers, or automation plat- control functions.
collaborative robotics (cobots) in particular, look to forms, or something else. There will be no single Users
u seek openness
in industrial systems
be among the single largest growth areas through- controller technology that can fulfill all roles at all while valuing industrial-
out all industrial automation over the next 5 to 10 price points. grade reliability. As PLC
years (Figure 3). In a related development, vision Instead, PLCs will continue to evolve based on programming languages
diversify, classic ladder logic
systems have advanced tremendously in the past available technologies and user demand, just as remains prevalent, ensuring
decade, and many are very compatible with robots, they have done so for the past five decades. The simplicity and wide user
acceptance.
allowing easy integration in a host of applications. priority will be delivering real-time control and
Modern automation platforms need to be pre- Robotics, particularly
reliable monitoring, but they will add even bet- u
collaborative robotics
pared to keep up with this changing landscape by ter programming and connectivity functions to (cobots), and artificial
providing the requisite processing power, program- improve the user experience, and the speed at intelligence and machine
learning (AI/ML) represent
ming instructions, and connectivity to seamlessly which projects can be delivered. ce significant growth areas
integrate with robotics and vision. A contempo- in industrial automation.
rary PLC with these capabilities located near field- Jeff Payne is the director of business development at PLCs are poised to integrate
with these technologies,
installed robotics offers a distinct advantage as an AutomationDirect. Edited by Chris Vavra, web content facilitating seamless
automation platform. manager, WTWH Media, [email protected]. automation.

| 37
ANSWERS
POWER QUALITY; MOTORS, DRIVES
Lucas Paruch, Yaskawa America Inc.
Power quality, harmonics:

How to select a variable
frequency drive (VFD)
Part 2: Understand the advantages of
36-pulse input drive topology in medium-
voltage (MV) motor applications, and how
medium-voltage VFD design mitigates
harmonics and improves power quality.
P
umping, compressing, blowing, convey-
ing, extruding and mixing are among most FIGURE 2: In a low-voltage VFD, an L1-L3 charging
common industrial motor applications DC bus acts like a battery, storing energy until needed
using variable frequency drives (VFDs). by the inverter section.
Understanding applications and drive design can
help mitigate harmonics and power-quality chal- VFD fundamentals, how a VFD works
lenges. As explained in part 1, when motors are For every motor, the optimal supply voltage and
started across the line on 60Hz utility power, effi- frequency changes as the speed and torque require-
cient motor operation is limited to a very narrow ments of the application change. When started
window around the rated motor operating speed across the line, a 460V 60Hz motor can only oper-
and torque values. Drives allow motors to operate at the utility supplied voltage and frequency.
ate at their optimal efficiency over a wide range of Drives overcome this limitation by continuous-
speeds, satisfying a wide range of varying torque ly adjusting the output voltage and frequency to
requirements, while reducing motor stress and match the optimal operating conditions for the
starting inrush current. application load. Most common low voltage (LV:
less than 1000V) drives are comprised of three sec-
tions; power flows from left (utility supply) to right
(motor) in Figure 1.
The diode bridge converts three-phase util-
ity supply power from alternating current (AC) to
direct current (DC).
The DC bus acts as a battery. The bus stores the
energy it receives from the diode bridge until that
energy is needed by the inverter section.
The inverter IGBTs (insulated-gate bipolar tran-
sistors) are switches that turn on and off at a very
FIGURE 1: Six-pulse drive topology for a low-voltage high rate of speed. By using pulse width modula-
VFD is shown. All images courtesy: Yaskawa tion (PWM), the drive generates a series of short

FIGURE 4: Three six-
pulse current waveforms
are graphed: Usual, with
reactor and ideal.
FIGURE 3: Non-linear charging current: The first
current hump occurs when L1 conducts to L2, the
FIGURE 5: 36-pulse in a
second hump occurs when L1 conducts to L3.
wiring diagram.
pulses and long pulses that, when averaged, are rep-

resentative of a sine wave voltage waveform.
For more Control Engineering details and dia-
grams about the basics of medium-voltage drives,
see: “How to choose a VFD for medium-volt-
age motors.” www.controleng.com/articles/
how-to-choose-a-vfd-for-medium-voltage-motors
How non-linear loads create

power-quality concerns Online
u
controleng.com
Power quality concerns arise when non-linear
loads are connected to an AC supply. KEYWORDS: Power quality,
A load is considered linear when its impedance is medium-voltage drives,
variable frequency drives,
constant, and the current waveform follows the sinu- VFDs
soidal supply voltage waveform. An electric resis- of the fundamental 60Hz supply frequency. These LEARNING OBJECTIVES
tance heater is an example of a linear load. When frequences are described as the harmonic frequen- Review variable frequency
drive (VFD) fundamentals and
supplied by a 60Hz sinusoidal voltage, a resistive cies. The “third harmonic” is three times the funda-
how a VFD works on the way
heater will draw a 60Hz sinusoidal current. Because mental, or 180Hz, the “fifth harmonic” is five times to understanding how non-
the current is purely sinusoidal, linear loads have no the fundamental, or 300Hz, etc. linear loads create power-
quality concerns.
high frequency harmonic content, and do not con- Ohm’s Law shows that supply voltage drop is a
Understand harmonic filtering
tribute to harmonic voltage distortion. function of current. The high frequency harmon- and how a VFD can help.
The diode bridge on a typical low voltage six- ic components of the non-linear current result in
Examine medium-voltage
pulse drive is a non-linear load because the imped- non-linear voltage drop, and corresponding distor- 36-pulse drive topology
ance changes suddenly as the diodes turn on and tion of the voltage waveform. and how it reduces risk of
equipment malfunction by
off. Following Ohm’s Law, if the diodes switch the reducing harmonic stress.
impedance at frequencies other than 60Hz, the cur- Diode bridge allows current CONSIDER THIS
rent waveforms drawn from the supply must follow to flow one way Are your VFDs mitigating
the changing impedance, and therefore, the current Diodes are semiconductor devices that allow cur- harmonics and improving
power quality and lifespan for
no longer follows the three-phase supply voltage. rent to flow in only one direction. When the forward motors?
The resulting non-linear current is non-sinusoidal. voltage across each diode is positive, the diode con- ONLINE
While these bumpy non-linear current wave- ducts current. When the voltage is not positive, the See part 1 in this series: How
forms (Figure 4) may appear to be random, Fou- diode stops conducting and opens the circuit. to choose a VFD for medium-
voltage motors.
rier analysis shows that these seemingly irregular In Figure 1, the diodes shown in red will only
www.controleng.com/articles/
waveforms are comprised of a theoretically infinite conduct when the 3-phase L1 voltage is posi- how-to-choose-a-vfd-for-
number of sinusoidal waveforms at odd multiples tive, the L3 voltage is negative, and the difference medium-voltage-motors

| 39
ANSWERS
POWER QUALITY; MOTORS, DRIVES
between the two is great- lems in power distribution systems if not properly
er than the DC bus volt- mitigated.
age. At this moment, the Adding a large linear load (such as a resistive
charging circuit is simpli- heater) to a power system will produce a linear
fied to that shown in Fig- voltage drop. The magnitude of the sinusoidal sup-
ure 2 (the other 4 diodes ply voltage will decrease, but the shape remains
are not conducting, cur- sinusoidal.
rent flows from L1 to L3). The addition of a non-linear load, with vary-
The diodes are arranged ing non-sinusoidal current demand, will produce a
to ensure that, as the non-sinusoidal voltage drop on the power system,
3-phase supply voltag- distorting the voltage waveform of the supply. Dis-
es alternate from positive tortion of the supply voltage impacts every piece
to negative, the potential of equipment connected to the supply. In particu-
FIGURE 6: 6-pulse current waveform (3 voltage wave-
seen at the DC bus termi- lar, line-connected motors depend on a clean sinu-
forms): In the 6-pulse topology, two pulses are gen-
nals is always positive. soidal source. Distortion of the supply voltage can
erated for each of the 3-phase input waveforms. The
As load is increased, negatively impact the operating speed and torque
current waveform on each supply phase resembles
the IGBTs will draw characteristics of all line-connected motors on the
the distorted “rabbit ears” waveform.
more energy from the system, and result in increased motor heating and
bus, which will cause the reduced efficiency.
bus voltage to decrease relative to the supply, and Non-linear waveforms are comprised of a large
charging current will increase. When loaded, a six- number of harmonic frequencies. The more a wave-
pulse drive will experience six charging pulses in form is distorted, the greater the amplitude of the har-
each electrical cycle. The DC bus will charge when: monic frequencies. Harmonic currents do not reach
the motor, and they do not contribute to creating
L1-L2 > Vbus, L1-L3 > Vbus mechanical power. Harmonic currents flow between
FIGURE 7: 36-pulse the power source and the drive, increasing the over-
current waveform (18 L2-L1 > Vbus s, L2-L3 > Vbus all current load on the supply, as well as increasing the
voltage waveforms): In a I2R losses of the supply transformer, and all wiring
36-pulse topology, two L3-L1 > Vbus, L3-L2 > Vbus. between the power source and the drive.
bus charging pulses are IEEE 519 provides a method to quantify the
generated for each of the Figure 3 shows the charging current that occurs effects of total harmonic distortion (THD) and
18-phase voltage input when the L1 voltage is positive. The first current establishes thresholds of acceptability. THD is
waveforms, for a total hump occurs when L1 conducts to L2, the second defined as the ratio of the root mean square of the
of 36 pulses per cycle, hump occurs when L1 conducts to L3. harmonic current to the fundamental current. In
moving the waveform For clarity, only the current influenced by L1 other words, it is the ratio of the undesirable cur-
closer to ideal. is shown. Including charging current from L2 to rent (that does no work), to the desired current
L3, and from L3 to L2, (that produces mechanical torque).
a total of six charging Where I1 represents the magnitude of current at
events occur in each the fundamental frequency (that is, 60Hz), and In
60Hz electrical cycle. represents the magnitude of the harmonic current
This is known as a “6 at the nth multiple of the fundamental frequency
pulse” drive. (that is, I3 = 3rd harmonic = 180Hz), it can be seen
that reducing the magnitude of the harmonic con-
Power quality, tent has a direct impact on reducing the severity of
harmonics, current and voltage waveform THD.
non-linear loads
The application of
non-linear loads can
cause reliability prob-

Harmonic filtering and how it works in impedance is off-
Line reactors are commonly used in low-volt- set by another diode
age drive applications to smooth the current switching off. The drive
waveform. A line reactor is a three-phase induc- load becomes nearly lin-
tor installed in series between the supply and ear, with a nearly-sinu-
the drive. Inductors are components that mini- soidal current waveform
mize current fluctuation by storing and releas- following the sinusoidal
ing energy, essentially shaving energy from the supply voltage.
peaks to fill the valleys. Reactors are effective at The measurement of
reducing current distortion (and resultant volt- harmonic current dis-
age distortion); however, they cannot eliminate tortion provides an
harmonic distortion. The filtered waveform more objective measure of
FIGURE 8: 36-pulse current waveform (18 voltage
closely represents the ideal sine wave but remains the relative linearity
waveforms): When summed, the 36 “rabbit ear” sec-
non-linear. When designing line reactors into a provided by a 36-pulse
ondary current waveforms create the nearly sinusoi-
drive system, the additional cost, voltage drop, system. Without addi-
dal supply current waveform.
thermal losses, physical size and weight of the tional filtering or medi-
reactors must be considered. ation, the percentage
of current distortion
Medium-voltage 36-pulse drive topology from a 36-pulse drive
For large motor applications (more than can fall well within the
250HP), multi-Pulse Medium Voltage drives pro- limits established by
vide an alternate drive topology that improves IEEE-519.
power quality by minimizing the impacts of har-
monic distortion at its source by preventing the Less risk of equip-
formation of highly distorted current waveforms. ment malfunction,
A 36-pulse MV drive uses an isolation trans- less harmonic stress
former with six isolated 3-phase secondaries. Each Medium voltage
secondary is phase shifted, creating an 18-phase drives with 36-pulse
output waveform. Each phase shifted secondary topology provide all the
supplies a drive power cell (each cell with its own benefits common to all variable frequency drives, FIGURE 9: 36-pulse
6-pulse bridge as shown in Figure 1). while inherently reducing harmonic stress on the drive harmonic distor-
In the 6-pulse topology, two pulses are gener- supply, and minimizing the risk of equipment tion and IEEE 519 limits:
ated for each of the 3-phase input waveforms. The malfunction or damage from harmonic induced Without additional fil-
current waveform on each supply phase resembles voltage distortion. tering or mediation, the
the distorted “rabbit ears” waveform of Figure 6. For high power applications, selecting a 36-pulse percentage of current
The same principle applies in a 36-pulse topol- drive provides an IEEE 519-compliant solution distortion from a Yaska-
ogy. Two bus charging pulses are generated for without the need to purchase and install addition- wa 36-pulse drive falls
each of the 18-phase voltage input waveforms al input filtering. Because the impacts of harmon- well within the limits
(Figure 7), for a total of 36 pulses per cycle. More ics are cumulative within a facility, considering a established by IEEE-519.
pulses per cycle allow current to be conducted multi-pulse drive that is well below distortion lim-
more evenly and continuously throughout the its can help compensate for legacy equipment with
electrical cycle. The supply sees the sum of the 36 marginal harmonic characteristics and improve the
secondary charging waveforms. When summed, overall power quality of the facility. ce
the 36 “rabbit ear” secondary current waveforms
create the nearly sinusoidal supply current wave-
form shown in Figure 8. Lucas Paruch is product manager, medium volt-
The 36-pulse topology effectively makes the age drives, Yaskawa. Edited by Mark T. Hoske, con-
overall drive impedance more constant by ensur- tent manager, Control Engineering, WTWH Media,
ing that when one diode switches on, the change [email protected].

| 41
ANSWERS
IT/OT CYBERSECURITY
John Clemons, Tim Gellner and Vicky Bruce, Rockwell Automation
Crafting the right

IT/OT cybersecurity strategy
For information technology/operational • An update for a possible vulnerability in PDF
reader software is sent.
technology (IT/OT) network cybersecurity, • The research and development people send a
new recipe that supports a new product and helps
develop strategy, be proactive. improve overall product quality.
T
• The IT people send patches for the computer
he old adage is “crime doesn’t pay.” When operating systems.
that saying originated, no one had ever heard • The IT people send updates to the anti-virus
of cybercrime. The truth is, cybercrime often software and send new whitelists.
pays big. Cybercrimes are increasing, and • The equipment vendor must access the system
cybercrime software is readily available and easy to remotely to help troubleshoot a possible mechani-
use. Despite time and money spent on cybersecurity, cal problem.
it seems cybercriminals stay one step ahead. • Production data must be analyzed to provide
insights into the process and products produced.
Target: industrial, manufacturing There are too many ways in which something
companies or someone can get to the control systems. A more
Online
u
controleng.com
Industrial and manufacturing companies are prime systematic and holistic approach is needed.
targets for cybercriminals. Many industrial and man-
KEYWORDS: Cybersecurity, ufacturing companies are ripe for the picking. Lega- Proactive, successful cybersecurity
IT/OT cy unpatched infrastructure, the use of the Internet of Most industrial companies have more legacy
LEARNING OBJECTIVES Things (IoT) and industrial Internet of Things (IIoT) information technology and operational technol-
Understand why cybercrime
is a major problem for
platforms, insider threats and a lack of operation- ogy (IT/OT) assets than they may even be aware
society at large and al technology (OT) skilled resources create signifi- of, and it’s these legacy assets that are the most vul-
particularly for industrial and cant vulnerabilities for industrial and manufacturing nerable. Most industrial companies tend to defend
manufacturing companies.
companies. An estimated 60% of industrial and against the last attack rather than prevent the next
Learn what’s needed to
take a proactive approach
manufacturing companies worldwide experienced one. Create a simple four-step framework:
to cybersecurity and learn a cyberattack in the past three years. Because many, 1. Assess the situation, inventory the IT/OT infra-
what steps are needed to including critical infrastructure, are unprepared for structure, and analyze any vulnerabilities and risks.
develop a good cybersecurity
strategy. a malicious cyberattack, cybercrime will cost an esti- An important part of the assessment is to be aware of
ONLINE mated $10 trillion this year. current threats against hardware and software assets
Read more with this article by taking advantage of cybersecurity advisories that
online. See the three-part Broken IT/OT cybersecurity are regularly updated such as those from the Cyberse-
series online:
Information technology (IT)/OT cybersecurity curity & Infrastructure Security Agency (CISA).
IT/OT cybersecurity, part 1:
Security challenges, trends solutions, such as firewalls between the business net- 2. Design the cybersecurity to handle the IT/OT
and methods that don’t work work and the controls network and leaving an "air landscape and address vulnerabilities and risks.
IT/OT cybersecurity, part 2: gap," do not work. Control systems consume and pro- 3. Implement solutions, covering people, pro-
Developing a proactive and duce a lot of data that people need. Examples include: cesses and technology, with training, and on-going
successful approach
• The engineering team sends some new logic proactive services to ensure everything works well.
IT/OT cybersecurity, part 3:
Starting the cybersecurity that addresses a manufacturing change and helps 4. Monitor the IT/OT infrastructure continu-
journey reduce asset downtime. ally, looking for changes, identifying new vulnera-

bilities, assessing new risks, upgrading the solutions
and looking for threats in real time, able to respond
in real time to any conceivable threats.
Vulnerability, risk assessment

Performing an in-depth vulnerability and risk
assessment is one of the first steps to create a com-
prehensive overall IT/OT cybersecurity strategy.
Cybercriminals will try everything in their arsenal to
breach the security measures, so it’s a must to look at
all vulnerabilities and risks for all IT/OT assets.
Companies must be proactive, 4 steps

A proactive approach to IT/OT cybersecurity 3. Re-evaluate the effectiveness of existing FIGURE: Every manufacturing
requires looking at the entire attack continuum. The cybersecurity protocols and look for areas of weak- and industrial company is
basic framework is simple: Assess, design, implement ness and opportunities for improvement. vulnerable to a cyberattack
and monitor. It also must contain specific aspects of 4. Review the industry standards and regulatory and most aren’t prepared for
a proactive approach looking at before a cyberattack compliance requirements looking for weaknesses what will happen if they are
occurs, during a cyberattack and after a cyberattack. and areas for improvement. attacked. Courtesy: Rockwell
A proactive approach assesses the current situation, 5. Implement specific remediation measures Automation
identifies the assets that are potentially vulnerable, targeted at the identified risks and vulnerabilities
and takes specific measures to protect those assets. A based on the priorities identified.
proactive approach detects and responds to the cyber-
attack. A proactive approach also responds to the 3. Perform a full network assessment
aftermath of the cyberattack and takes specific steps to Many companies have OT vulnerabilities such as
recover from the cyberattack. Consider four cyberse- OT systems that are unpatched, legacy, unsecured
curity ideas to begin immediate improvements. or obsolete. The OT network is just as import-
ant and just as vulnerable. If a quick vulnerability
1. Perform a vulnerability assessment assessment or a full cyber risk assessment identifies
A vulnerability assessment finds out what’s out the OT network as a particular source of risks, then
there, especially the unknown components and iden- a full network assessment might be in order. u Insights
tify potential vulnerabilities. Vulnerabilities might
ON IT/OT CYBERSECURITY
show up as unsecured network connections, unman- 4. OT penetration testing
Traditional
u IT/OT
aged switches, unpatched legacy systems, or even Performing OT penetration testing will test the cybersecurity measures,
business-critical systems that no one knows about that hard work and reveal which cybersecurity strate- like firewalls and air gaps,
are unmanaged, unpatched, obsolete and vulnerable. gies work and which ones don’t. The goal is to exe- prove ineffective against
sophisticated cyber
The vulnerability assessment needs to examine OT cute some ethical hacking along a wide range of threats in complex control
infrastructure including automation and control sys- attack vectors with the purpose of penetrating the systems. A more holistic
tems, network components, switches, routers, hubs OT environment by simulating real-world attacks, and systematic approach is
imperative for defense.
and any other components in the OT landscape. along a wide range of vectors.
Implementing
u a
comprehensive
2. Perform a full cyber risk assessment With a secured infrastructure and daily vigi- cybersecurity strategy
involves assessing
Next perform a full cyber risk assessment for lance, reduce the risk and impact of cyberattacks. vulnerabilities, designing
a comprehensive view of the organization's cyber At the very least, companies need to begin. ce solutions, continuous
risks, top to bottom. Include these five steps: monitoring and real-time
threat detection.
1. Get deeper into the details of the OT land- John Clemons is a solutions consultant, LifecycleIQ
When
u starting the
scape and vulnerabilities by looking at specific Services; Tim Gellner is a system integration consul- cybersecurity journey,
attack vectors and specific weaknesses. tant; Vicky Bruce is global capability manager for companies need to create
2. Evaluate the entire risk profile by assessing network and cybersecurity services; with Rockwell a full assessment that is
an open and honest look at
the potential impact of attacks and prioritizing the Automation. Edited by Chris Vavra, web content man- what they do and don’t do
risks and vulnerabilities. ager, WTWH Media, [email protected]. well and find solutions.

| 43
ANSWERS
INDUSTRIAL NETWORKING: MES
Christian Berg, Emerson
Picking the right MES

or automation solution for
a life sciences application
Life sciences manufacturers have more the world’s most critical treatments. Though their
approach to automation is more traditional, it is no
automation options than ever, but choosing less important as they strive to shepherd hundreds
or thousands of batches quickly and safely through
the right manufacturing execution system the quality review process.
Because the spectrum of treatment manufactur-
(MES) or software-as-a-service (SaaS) solution ing types is now so broad, life sciences companies
are discovering that a one-size-fits-all approach to
to streamline and improve operations is not automation and operations management is no lon-
ger appropriate. Fortunately, today’s forward-think-
as difficult as it may seem. ing automation suppliers offer a range of options to
T
help companies implement automation solutions
he life sciences industry has evolved over aligned with their needs. Selecting the right auto-
the last decade. Emerging scientific dis- mation technology requires understanding each
coveries have led to advancements in manufacturer’s unique operations management
therapeutics for targeting specific dis- needs and then aligning those needs to the best
eases once considered difficult or impossible to technological solutions to help the manufacturer
treat. Personalized medicine, including cell and optimize product delivery, quality, safety, and cost.
gene therapies, has emerged alongside traditional
population-targeted medications that have been a MES: Reliable repeatability
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controleng.com
treatment staple for decades. In traditional manufacturing of population-tar-
These changes have introduced many new play- geted treatments, operations trend toward making
KEYWORDS: industrial ers in the market, all of whom operate very differ- the same product many times, with limited to no
networks, manufacturing ently from traditional manufacturers. Often, these process changes. The process is often well estab-
execution system (MES)
LEARNING OBJECTIVES
manufacturers start small, and they rapidly iter- lished and the goal of getting treatments into the
Understand the benefits a ate manufacturing processes to deliver novel prod- hands of patients as quickly and safely as possible
manufacturing execution ucts quickly and consistently. As a result, there is is transparent. These large manufacturers are often
system (MES) can bring
to a life sciences facility, an increasing need for life sciences manufacturers producing batches of the same therapy hundreds of
especially when paired with to stay flexible and nimble. This requirement, as times per year.
a distributed control system a result, is changing the way many manufacturers These types of companies typically turn to a man-
(DCS).
approach automation. ufacturing execution system (MES) that is integrated
Understand how software-
as-a-service (SaaS) solutions The need for large-scale production of tradition- with a distributed control system (DCS) to orches-
also can help improve al therapies has not gone away, nor have the man- trate and document batch process activities. This
automation processes. ufacturers making them stagnated. Supply chain automated, closed-loop control of a full-scale MES
CONSIDER THIS issues during the global pandemic made it clear reduces the potential for errors in operation by elim-
How can an MES or
automation solution improve that safe speed-to-market is of the utmost impor- inating as many manual activities as possible.
operation for your facilities? tance for the large-scale manufacturers producing The most advanced systems — those with native

‘ SaaS can be a simple and
scalable way to accelerate
digitization and improve
product lead-time and
’
quality.
DCS integration — can instantiate a batch

on the DCS, while maintaining all batch
characteristics and critical parameters, all
without any operator intervention, reduc-
ing the risk of human error. When the MES
is integrated and validated, the operator
does not need to manually enter or verify individu- umentation, or for simplified recipe authoring and FIGURE: Software-as-a-ser-
al control parameters, thereby reducing opportuni- execution solutions delivered as software-as-a-service vice solutions, like Emerson's
ties for errors and increasing operational efficiency. (SaaS). Such solutions are a simple and scalable way to DeltaV Workflow Manage-
The batch simply shows up on the operator inter- accelerate digitization and improve product lead-time ment, empower operators to
face, ready to run. and quality, without the need for personnel to have quickly create recipe author-
The system is automated from end-to-end, coding expertise to support the system. These solu- ing workflows without any
and batch record review can be simplified to only tions typically do not support integration with auto- coding or IT expertise.
require examination of exceptions that were record- mated process control systems. Courtesy: Emerson
ed during the process. When manufacturers lever- With the best solutions, users leverage drag-and-
age review by exception, they eliminate the time drop recipe authoring elements to create the steps for
spent inspecting batch records, instead focusing a new recipe and automate workflows. These drag-
only on the areas where the pre-validated process and-drop elements are predesigned to conform with
deviated from normal. GMP standards, enabling teams to add new param-
Insights
eters and e-signature requirements to drive quality
Streamlined nimble SaaS control, ensure regulatory compliance, and automati- u
In contrast to large batch facilities, there is still cally generate reliable batch records (Figure).
Automation, MES
a great deal of human involvement in operations
The
u life sciences
in cell and gene therapy and process development Starting from the right foundation industry is undergoing a
spaces due to smaller production scales and rapid A right-sized automation solution exists for any transformative shift and
process optimizations. life sciences manufacturer, regardless of its oper- as a result, automation
adaptability is crucial for
Moreover, many of the manufacturers operating ations. To make the right decision, manufacturers large-scale traditional
in the personalized medicine space, such as those should first evaluate their needs to identify whether manufacturers and smaller,
agile players.
making advanced therapy medicinal products, are a full-scale MES solution or a paper-on-glass recipe
small companies with limited resources to imple- authoring solution best fits their operations, exper- Comprehensive
u
manufacturing execution
ment and support automation technologies. Often, tise, and budget. Once that decision has been made, systems (MES) with native
these manufacturers do not have a deep bench of teams can explore their many options, prioritiz- DCS integration can help
streamline processes,
information technology experts, nor a wide array of ing systems that are feature-rich, and designed for reducing errors and
staff experienced in the coding necessary to config- seamless integration and scalability. This approach enhancing operational
ure and maintain a full-scale MES. will ensure their automation systems serve their efficiency for larger facilities.
However, these small, nimble manufacturers needs over the entire product lifecycle, even as they Manufacturers
u in
personalized medicine often
still need automation features — such as enforced scale and their needs continue to change. ce use software-as-a-service
sequence of operations, segregation of duties, and (SaaS)-based solutions,
robust data integrity — to help ensure good manufac- Christian Berg is an enterprise solutions architect con- emphasizing simplicity and
scalability for improved
turing practices (GMP) are followed. Consequently, sultant for Emerson. Edited by Chris Vavra, senior edi- digitization without
these manufacturers tend to opt for paper-based doc- tor, WTWH Media, [email protected]. extensive coding expertise.

| 45
ANSWERS
INSIDE MACHINES: MECHATRONICS
Jeff Johnson, Beckhoff Automation
Make exponential gains now:

Automation, I/O, mechatronics
A reimagined production line delivers important not to get stuck in the status quo for Golz
and his team of approximately 40 employees, who
complete flexibility to accommodate build manufacturing equipment, among other tasks.
simultaneous programming and testing Goal: Exponential increase

In fall 2021, Golz’s team and product manage-
of a broad range of terminal types. ment experts reimagined how to perform final
D
inspections of input/output (I/O) components. The
eveloping automation, input/output (I/O) goal was to exponentially increase testing capacity
systems and mechatronics to help compa- in a high-mix low-volume (HMLV) process.
nies rethink what’s possible isn’t enough. The resulting I/O manufacturing system can
Leading by example with an adaptive auto- program, adjust and test 1,200 terminals per hour
mation in-house application can help. Keeping pace (about 10,000 per shift) automatically. This concept
with manufacturing growth is a constant challenge for depends on PC-based control and many EtherCAT
Michael Golz, head of the demo systems department solutions, working in concert with specially devel-
at Beckhoff global headquarters in Verl, Germany. It’s oped firmware and test stations. This mix of tech-
nologies delivers high speed and throughput as well
as flexibility for today and tomorrow.
“On average, a fully tested I/O terminal that is pro-
grammed with the appropriate firmware leaves the
system every 3 seconds, regardless of the type of ter-
minal and the order in which they are delivered,” Golz
said. Currently, the system can program and test
roughly 80% of many terminal types. The prod-
uct mix present in the system at any time has zero
impact on the line’s throughput... that’s huge, he
suggested. Considering the variety of terminals —
with or without field programmable gate arrays
(FPGA), a controller, or with analog channels —
the programming and subsequent function testing
of each terminal require different amounts of time.
“It can take up to 30 seconds for the firmware to
be installed and all analog channels to be adjusted,”
FIGURE 1: The XPlanar-based floating tile motion control system from Beckhoff said Stefan Engelke, whose team developed the uni-
Automation is optimized for maximum throughput with seamless control and versal test cabinets.
monitoring. This ensures efficient programming, adjustment, calibration and Complete freedom in motion available deliv-
function testing in Beckhoff’s I/O production. Beckhoff AMI8100 integrated ered the necessary flexibility for internal logistics and
servo drives infeed and eject trays because of compact size, 48 V operation and infeed of the terminals to the workstations. As a result,
EtherCAT communications. Images courtesy: Beckhoff it no longer matters whether a bus terminal needs to
spend 10 seconds or 1 minute at a firmware program-
M1 | May/June 2024 control engineering — www.controleng.com

FIGURE 2: The programming and test times for an
I/O terminal have not changed, but the throughput
has, significantly: a programmed and extensively
tested terminal leaves the system every three sec-
onds.
ming or testing station. The remaining movers go

to the next free station rather than idling. Individual
delays don’t affect overall system output.
Flexible and transparent FIGURE 3: The bridge with the vision systems which is positioned over the three
The process begins when trays carrying I/O termi- lanes captures the DataMatrix code of each terminal as it passes through, which is
nals move from the infeed station into the picking sta- then “married” to the ID of the XPlanar mover.
tion. A delta robot lifts the terminals and places them
on waiting movers. The system has two main paths mover passes through the reading station a second
leading left and right to the programming and testing time, only this time in the opposite direction.
stations. Stations are located at “parking spaces” along “The terminal is booked out via the renewed
the lanes. Between lanes, movers return to the picker capture of the BIC on the return track,” Engel-
on a third path. With this symmetrical setup, one side ke said. “The installation of the firmware and the
of the system can continue to operate even if the other function test of each individual terminal are docu-
stops. Movers pass the terminals under a reading sta- mented in the central database, including all adjust-
tion to the lateral programming stations. The reading ment values in the case of analog terminals.”
station captures the individual Beckhoff Identification
Code (BIC) of each terminal via multiple company
vision hardware and software technologies.
Tile-based motion control
A system consisting of 100 tiles forms the base of
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“After that, the system knows the terminal type this fast, flexible process. The two main paths with KEYWORDS: mechatronics,
and does everything completely autonomously – two outbound lanes and the return track in the mid- motion control
programming, adjusting the analog channels if nec- dle from six base sets of planar tiles with contactless LEARNING OBJECTIVES
essary and function testing,” said Ulrich Brockhaus, movers, each containing 3 by 4 tiles, Golz said. For Understand the capabilities
of new mechatronics
who is responsible for system programming. the add-ons (programmer and tester), the remaining technologies.
At the same time, the BIC is “married” to the 28 tiles are screwed onto the side of the basic system. Explore the machine design
mover via its ID. The mover ID also can be used to Each mounting position has a standardized interface possibilities made available
track the location of each individual mover or ter- with power supply (400 Vac), safety, Ethernet local by 6D of freedom in motion
control.
minal, even after a power failure. When the mover area network (LAN), as well as EtherCAT.
Prepare for adaptive
reaches a free programming station, it positions the “The interface and the system layout enable manufacturing concepts
terminal precisely under its contact pins. Then, the future expansions without major conversion that will enable mass
corresponding firmware is loaded onto the terminal work,” said Daniel Golz, who is responsible for the customization, high-mix low-
volume production and other
based on its BIC. It then moves to a universal test- mechanical design of the system and the specific capabilities.
ing station, which in turn calls up the device-specific details for terminal contacting. ONLINE
test sequence based on the BIC. If the software has The floating planar motion control system enables Further information:
been loaded correctly and the function test reports highly modular machines while simplifying mechan- www.beckhoff.com/xplanar
no issues, the mover transports the terminal to the ics in many sectors. For example, the programming CONSIDER THIS
How can mechatronics and
picking station's second delta robot, which places the stations use XY precision positioning. As a result, motion control help your
terminal on another tray, via the middle track. The programmers can lower their pins after reaching the operations?

| M2
ANSWERS
INSIDE MACHINES: MECHATRONICS
exact position onto the ter- 1. The 2D product movements individualize

minal contacts and start transport of the terminals and facilitate
loading the firmware. parallel processing in the programming and
At the test stations, testing stations.
another feature reduces 2. XY precision positioning means there is no
the design work: the vari- need for a handling system at the program-
able flight height. When ming stations.
it arrives at the test sta- 3. The transfer of the bus terminals with the aid
tion, the mover lifts first of the Z movement (lifting/lowering) replaces
so that the slide-in unit of complex mechanics in the test stations.
FIGURE 4: The positions the test station can move under the terminal. Then 4. 360-degree rotation enables the mirror-
of the 33 movers hover- the mover lowers its hovering height again, so the ter- symmetrical set-up of the system.
ing over a total of 100 minal comes to rest on the slide-in unit and is drawn
Beckhoff XPlanar tiles into the tester. As such, all contacts are freely acces- Electrical, optical, control functions
are displayed in real sible and can be contacted. After the test, the terminal The testing stations don’t just check the electrical
time in the visualization returns to the mover in reverse order. The option to properties and functions of a terminal.
created with Beckhoff rotate the movers comes into play again during inser- “For terminals with analog signals, the cor-
TwinCAT HMI. tion and removal. Movers can rotate by 180 degrees, responding test sequences and calibrations are
depending on the side of the system used. included too,” Engelke said. An integrated vision
system checks that the prism is present and in the
Four contactless motion benefits correct position and measures the colors and inten-
“This feature has also significantly reduced the sity of the LEDs in the terminals. A very wide range
mechanical complexity and has made space-sav- of EtherCAT terminals, with diverse functions and
ing configuration of the tester and programmer on measuring ranges, can be tested automatically on
both sides possible,” Daniel Golz said. the system using the universal test cabinet. Its com-
The system layout benefits from four properties: plete measurement and testing system is focused on
precise measurement terminals. Mounted in mobile
cabinets and coupled to the system by means of a
plug connector, the test cabinets can be replaced
quickly, without shutting down the entire system.
This needs to be performed regularly, since the ter-
minals are measurement devices which must be
recalibrated and certified in specific cycles.
The strengths of PC-based control are evident
in the overall coordination and evaluation. If a tes-
ter detects a discrepancy on a terminal, this is regis-
tered via the BIC while the tester sends the terminal
back to the programming stations for reconfigura-
tion. If error messages accumulate on a program-
mer or tester, this indicates a malfunction.
“In this case, the tester is reported to the system
as unavailable,” Brockhaus said. “This position is
no longer approached by the movers until the tester
has been examined and, if necessary, replaced.”
Although the system will operate with one less
station, it’s still up and running and not significant-
FIGURE 5: Electric cylinders help insert the terminal carrier, and linear ly slower. “An I/O terminal that could cause any
actuators lower the contact pins. problems for a customer would not leave our sys-
tem,” said Michael Golz.
M3 | May/June 2024 control engineering — www.controleng.com

The system shows how PC-based control can
perform a wide variety of tasks and functions. The
control cabinet industrial server coordinates 33
movers on 100 tiles; 10 ultra-compact Industrial
PCs control the other system components.
Drive technology for the delta robots is handled
with the multi-axis servo system and servomotors.
The design uses “integrated servo drives to
infeed and eject the trays because they are extreme-
ly compact and only require EtherCAT and 48 V to
operate,” Brockhaus said.
Linear actuators are used by the programmers
to contact the terminals, and the testers use elec- duction at Beckhoff. “These are produced in annual FIGURE 7: Most system ele-
tric cylinders to feed in the terminal carriers. All quantities ranging from a few thousand to hundreds ments and the mobile test
machine safety technology is implemented with a of thousands of units. Our objective is to increase pro- cabinets are built from Beck-
system that integrates safe ty technology into the duction output with our current employee numbers hoff portfolio components.
EtherCAT I/O system. EtherCAT measurement ter- and in the space available, which would be impossible
minals are installed in each of the four test cabinets. without automated testing.” ce
“Our I/O terminal portfolio offers a wealth of func-
tionality, from 2-channel digital input terminals to Jeff Johnson, mechatronics product manager, Beck-
compact drive technology, with differing levels of hoff Automation LLC. Edited by Chris Vavra, senior
complexity,” said Michael Klasmeier, head of I/O pro- editor, WTWH Media, [email protected].
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Engineering innovation plays a vital role in the vitality of industrial manufacturing.

You’re invited to explore the profiles on the following pages and celebrate the
success stories of our participating manufacturing innovators:
• Actemium • Endress + Hauser Inc.

• Adaptive Resources • Matrix Technologies, Inc.
• AutomationDirect • Motion
• Beckhoff Automation LLC • SEW Eurodrive Inc.
• Digi-Key Electronics • Skkynet Cloud Systems
• E Tech Group • Trihedral Engineering
ce2024_innovIND_LEADHalf.indd 1 5/22/2024 4:40:08 PM

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Actemium - Your DX Guide
Digital Transformation (DX) is a Our DX and OT upgrade path includes critical components such as:
substantial manufacturing • Plan the route – Setting an OT roadmap for the next 3 to 5 years
mountain to conquer. The course to phase in the priorities of DX at the right pace for your people
you choose has a lot of possible • Make sure your old gear is solid – Have an obsolescence and
paths and many have tried and upgrade strategy that capitalizes on the technology of the future
failed along the way to reach the • Leverage new gear to reach new heights – Implement new layers
of technology (MES, DataOPs, SCADA) to address gaps in your
summit. When undertaking a existing landscape
journey as critical as this one, it’s • Use your GPS – Harnessing the insight and power of operational
important to engage a guide that’s and process data by leveraging AI/ML to drive improvements on
been there and understands how efficiency and productivity
to get to the top successfully. • Keep your team healthy – Addressing the operational and
technology resource challenges that manufacturers face (24x7
support, education of their people, augmentation of key functions)
Actemium is the top guide in the
Operational Technology space to If you are considering starting, or are in the middle of, your DX
navigate your DX undertaking. assent please reach out and find out the difference Actemium can
make in your summit pursuit.
About Actemium: Actemium delivers bespoke solutions and services to clients across 40 countries. Its multi-disciplinary
network combines the expertise of 400 local business units with a global approach to create value throughout the entire
industrial life cycle. Actemium’s 24,400 employees share, alongside their clients, the strong conviction that industry is key
to building a sustainable world and strive to make a positive contribution to global performance.
Contact: Wilfred Misener, Director of

Business Development, North America
[email protected]
Phone: (902) 293-4393
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Adaptive Resources — Industrial Automation Experts
Powerful but Accessible Multi-Variate Control Multi-Variate Model Predictive Batch Control
QuickStudy APC is Adaptive’s proprietary Windows® based QuickBatch APC is Adaptive’s proprietary Windows® based
Control Software that is simple to implement and easy to Control Software that is a multi-variate based closed- loop,
support. QuickStudy creates process models quickly and model-predictive batch control system. It delivers critical
accurately by studying your existing process as it operates. process KPIs, improves product quality, and increases
It doesn’t need costly step tests, long setup times or high- productivity demands. Unique optimization capabilities
level expertise. The result is improvements in productivity, of QUICKBATCH ™ predict end-of-batch quality attributes
efficiency and quality. based on previous end-of-batch processing results.
QuickStudy™ Advantages: QuickBatch™ Advantages:

• Reduces process variability, improving product quality • Initially creates a “Golden Profile” based on historical process
and consistency. data. Once this profile has been established, it automatically
• Minimizes transition times for product change-overs and manages the within-a-batch dynamics in a closed-loop control
line start-ups. manner by implementing self-correcting methods throughout
critical points in the batch trajectory in order to arrive at the
• Allows lines to be run at higher rates, increasing desired end-of-batch required metrics.
throughput.
• Takes into account both quality and productivity metrics
• Tighter control of process decreases raw materials and simultaneously in its decision making process to determine
energy used. the best controller actions to facilitate.
• Increase product quality on existing equipment, • Effectively addresses complex multivariate based interactions
increasing profits and reducing capital expenditures. and interdependencies that take place within a batch.
• Improve plant safety as process variability is reduced
resulting in fewer alarm trips, equipment adjustments • Once previous end-of-batch results are realized, establishes
and shut-downs. optimized process settings to eliminate any drifts in end-of-
batch results; corrective measures can also be taken before
• Enables Sustainability objectives to be achieved. the next batch is completed.
Ask us about past projects and case studies. www.adaptiveresources.com

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AutomationDirect
The company provides online tutorial
videos through their web store at
www.automationdirect.com as well as
their YouTube channel. They also provide
FREE online PLC training to anyone
interested in learning about industrial
controls. A Customer Forum utilized
by tens of thousands of automation
professionals provides peer support on
technical and application questions.
AutomationDirect’s customer support

team has been rated top-notch by its
Company headquarters located just north of Atlanta, GA
customers and has received numerous
industry accolades/awards for providing
A well-recognized name in the industrial automation the best service and support on various
market, AutomationDirect provides quality products products. To ensure their service and
with FREE award-winning in-house sales and techni- support remains superior, they continu-
cal support. AutomationDirect provides customers ously survey customers and have
with quick order and delivery through an online consistently outranked other suppliers.
store and toll-free number. Prices on most products
are well below the industry average and a 45-day
money-back guarantee is offered on nearly all items.
With more than 40,000-part listings, new products

include Endress+Hauser pressure transmitters,
Metal Work valves, WEG Rolled Steel Motors, and
ifm efector barcode scanners, cameras and vision
sensors. The company also offers the CLICK PLUS
PLCs, DURApulse drives, enclosures, circuit
protection, cut-to-length cable, pneumatic supplies
and more. Orders ship quickly from our
state-of-the-art warehouse
The state-of-the-art headquarters facility near
Atlanta is designed throughout for maximum For an in-depth look at
performance. The majority of items are products offered, scan
in-stock and ready for fast shipping; orders the QR code below or visit:
over $49 ship for FREE. Some exclusions apply. www.automationdirect.com.
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Beckhoff Revolutionizes I/O Manufacturing Systems with XPlanar®

At Beckhoff, we develop technologies that help engineer-
ing leaders automate what’s next. But it’s not enough to tell
others what to do. We want to lead by example. So we’re
sharing a look behind the scenes at a recent in-house
application using our XPlanar adaptive automation system.
Our product management experts reimagined how we

perform final inspections of I/O components. The goal was
to exponentially increase testing capacity in a high-mix
low-volume (HMLV) process. The resulting I/O manufactur-
ing system can program, adjust and test 1,200 terminals per
hour (about 10,000 per shift) fully automatically.
The sophisticated concept depends on our XPlanar,

PC-based control and a wide range of EtherCAT solutions, working in concert with specially developed firmware and test
stations. This ideal mix of technologies delivers high speed and throughput as well as flexibility for today and tomorrow.
“On average, a fully tested I/O terminal that is programmed with the appropriate firmware leaves the system every 3
seconds, regardless of the type of terminal and the order in which they are delivered,” says Michael Golz, head of the
Demo Systems department at Beckhoff global headquarters in Verl, Germany.
Currently, the system can program and test roughly 80% of our many terminal types. The product mix
present in the system at any time has zero impact on the line’s throughput. Considering the variety of
terminals – with or without FPGA, a controller, or with analog channels – the programming and
subsequent function testing of each terminal require different amounts of time.
However, the complete freedom in motion available through the use of XPlanar delivered the necessary LEArn MOrE
flexibility for the entire internal logistics and infeed of the terminals to the workstations. As a result, it no
longer matters whether a bus terminal needs to spend 10 seconds or 1 minute at a firmware programming or testing
station. The remaining movers simply move to the next free station rather than idling in a fixed-pitch queue. So individual
delays don’t affect the overall high throughput of the system.
(952) 890-0000 | [email protected]

All images are copyright © Beckhoff Automation www.beckhoff.com/xplanar
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DigiKey Streamlines Procurement for

Engineers and Designers
APIs that enable everything from the initial product
discovery right up to quoting and purchasing.
“We have APIs that can also enable features and

functions in enterprise resource planning (ERP) platforms
that go beyond the purchase point, if necessary,” says
Nathan Pray, manager, digital technology office – B2B
at DigiKey. By leveraging those specific APIs, buyers
can easily see order status, order history and other
vital information.
“We help automate receiving processes by offering

APIs that work with barcodes printed on every DigiKey
packing slip, order and individual part,” Pray states.
DigiKey’s product distribution center expansion “Our APIs also help buyers manage product obsolescence
and change notifications. It’s about enabling the entire
The benefits of using automation to turbocharge manual, purchasing process from discovery to invoice to help
time-intensive and monotonous business processes orders flow seamlessly from system-to-system.”
have been well documented. Companies of all sizes,
across all industry sectors, are reaping the rewards of
automation and can benefit significantly from
these investments. Nathan
Pray
Engineers and designers operating in the evolving manager, digital
technology office –
electronics sector are particularly well positioned to
B2B at DigiKey
benefit from automated business processes. Digital
solutions like application programming interfaces (APIs),
electronic data interchange (EDI) and punchouts give
professionals the tools they need to be able to stay in
front of these changes and make good buying decisions.
When engineers have the data, they need to quickly
source substitutes and backups such as building
resiliency into the actual product design without having
to go online to hunt around for those alternatives. We’re in a period of rapid and disruptive change, and
there’s no better time to stop chasing paper trails and
DigiKey has the EDI capabilities that buyers need to reconciling discrepancies. Instead, use DigiKey’s APIs, EDI
work efficiently, quickly and accurately and provides and other automated tools to create a smooth, streamlined
communication channel across all procurement activities.
SCAN THE
1-800-344-4539
QR CODE
[email protected] TO LEARN
www.digikey.com MORE
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Video Game Development Tools Meet Industry 4.0

Manufacturing Resulting in Digital Twin Innovation
E Tech Group digital twins: 3D visual

representation of actual production equipment
on your favorite web browser.
We have all heard the story; embracing Industry Beyond Real-time Virtual Representation
4.0 advancements for the purposes of data-driven There are so many creative ways to extend digital twin technology.
decision making is foundational to running the An additional copy can be created to function using the Unity physics
factory of the future. To make this abstract idea engine to determine the system’s motions based on virtual inputs.
a reality, E Tech Group has taken an innovative Interesting applications include:
approach, developing intuitive visual tools
called digital twins that deliver surprisingly • Virtual software commissioning: Stress-test software via digital twin.
futuristic capability. • System design: Optimize line layout, equipment selection, production
flow virtually.
Reaching outside the industry, E Tech Group’s • Virtual system troubleshooting: View the current state of the line
development team consists of software engineers via digital twin.
with game development experience alongside
manufacturing controls engineers, resulting in a • Virtual sensors for data collection: Monitor particular parameters
second-to-none digital twin. via the digital twin, rather than the actual equipment.
• Training simulation: Use the physics engine to drive the
E Tech Group’s digital twins are twin’s behavior.
built using Unity, a 3D video • Failure prediction and prevention: Apply machine learning algorithms
game development platform. An to model the dataset and predict upcoming points of failure.
unlikely perfect tool for this task,
the digital twins resemble a video As full digitalization of manufacturing occurs, digital twins stand poised
game of the actual system allowing users to fully to become essential tools throughout the life cycle of a production line.
move around the virtual representation in real- This technology innovation is just one way E Tech Group remains
time. The twin is accessible via web interface. committed to making manufacturing easier.
[email protected]
1-855-202-1444 | etechgroup.com
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Efficiency and safety with digitalization and IIoT

The “digitalized future” is now the “digitalized
present.” Companies worldwide understand that
digitalization is essential rather than optional.
While the digitalization journey began some time ago,
the benefits are now clear with how companies’
products send their variables and information to
control and host systems and within their ERP, CRM,
and service management systems. The digitalization
journey has helped companies laser-focus on
end-to-end service and solutions.
According to Jason Pennington, Director of Digital

Solutions at Endress+Hauser USA, digitalization has
enabled companies to digitally connect products to Now, they can go from being connected to utilizing
customers in a way they couldn’t before. connectivity to solve challenges or enhance their
business goals. While it’s up
End-user expectations to companies what they do
Today, instruments can create necessary items such with technology, today’s
as help desk tickets by themselves or produce alarms systems represent devices’
and offer potential solutions. Instruments can now “connected spirit.”
provide a secure means from a remote desktop to
a device to solve customer challenges before they Endress+Hauser and the
even realize they have one. industrial sector will continue
on the digitalization journey.
The more digitized the
industry becomes, the more
shared data can assist in
creating more reliable, safe,
and efficient products Jason Pennington, director of
and systems. digital solutions for Endress+Hauser
Also, device technology providers and their reps

have the opportunity with IIoT, Endress+Hauser’s
Heartbeat Technology, and other remote [email protected] SCAN THE QR
Tel: +1-888-363-7377
diagnostics to support end-users throughout a CODE TO
www.us.endress.com LEARN MORE
product’s lifecycle.
[ the “digitalized future” is now the “digitalized present” ]

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Empower Your Manufacturing Processes

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Problem Solved: How a Fulfillment Center

Got Back on Track
Fulfillment centers and warehouses
use conveyor belts of all sizes, with
roller drive belts being one of the most
important pieces. Located inside the
conveyor and driving the rollers from
underneath, these belts are often hard
to see and inspect. They must be
correctly installed and maintained for
optimal reliability and service.
Tracking issues are the leading causes

of belt failure; other issues are lack of
flexibility and grip, and an unreliable or
inefficient splicing system. Addressing
the belting issues, Motion Conveyance The Novitool® Aero® 325 press automates the recipe and pressure—all with an 18–22-minute cycle time.
Solutions developed RedDrive® 45 and
77, which feature lowered drive tension—typically reduced by 20–25%, but
some cases have neared 50%. For a dependable splicing system, Motion
Conveyance Solutions partnered with Flexco to dramatically improve the
original manufacturer’s equipment, requiring a cycle time of 45–60 minutes.
The Novitool® Aero® 325 press runs on 110 V power, weighs under 50 lbs and
automates the recipe and pressure—all with an 18–22-minute cycle time.
The same team also created the Novitool Pun M ™ NDX ™ belt cutter.
It allows the belt to safely clamp to the cutting deck while the operator
turns the handle to auto-index cut the belt end fingers. This design lowers
preparation time by 80–90%, improves the belt finger cut quality, reduces
operator error and operates considerably safer.
Seth Stoner is the Director of
These essential components created a need for the Motion Conveyance Product Management for Motion
Solutions Novitool RedDrive workstation. This unique system holds required Conveyance Solutions. He has
held many roles in his 28 years
splicing equipment and provides belt storage for a streamlined process.
in the conveyor belting industry.
When downtime minutes count, Motion Conveyance Solutions’ roller-driven
conveyor belt delivers longer life and a dramatically improved splicing process.
Visit MiConveyanceSolutions.com or scan the QR code to learn more.
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Automation Made Easy with SEW-EURODRIVE

More than Just Gearmotors
SEW-EURODRIVE offers more than just gearmotors. We also
manufacture a full line of automation components, controls,
and the software to drive them. Our team of automation
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even the most complex motion control challenges.
MOVI-C Modular Automation System

A flexible one-software, one-hardware, automation
platform that combines fully integrated drive components,
control electronics, and automation software – all from a
single source. The key to this simple-to-use platform is that each of those components is designed
to work together seamlessly, taking the hassle out of machine design, operation, and expansion.
Go Decentralized!
Save time and money with decentralized drive components and controls.
Eliminate costly power and communication cable runs and save floor space
by reducing or eliminating bulky control cabinets. Simplify control functions
with motor- and near-motor mounted inverters. To truly future-proof your
application, a decentralized system provides the most flexibility for process
and configuration changes.
Power and Energy Solutions

Reduce power peaks in your supply grid with SEW-EURODRIVE Power and
Energy Solutions. As part of the MOVI-C® modular automation system, our
power and energy system is suitable for machines and systems that involve
dynamic accelerations and decelerations, which waste energy during braking
and spike energy during startup. Control cabinet inverters compensate for
peaks by temporarily storing the braking energy generated, making the energy
available as needed. This technology stabilizes the energy flow and reduces
spikes. Using an innovative power and energy management system can boost
your system’s energy efficiency and availability.
About SEW-EURODRIVE: Engineering excellence and customer

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Cogent DataHub™ Tunnel/Mirroring solves

DCOM security patch issues
Cogent DataHub™ technology from Skkynet lets you For moving data beyond the plant network, DataHub
network OPC DA data using only local OPC connections, tunnel/mirror technology offers a more secure
and pass the data across the network over TCP, with connection than DCOM. You can configure it to make
optional SSL if needed. A DataHub tunnel/mirror avoids only outbound connections from the OPC server side.
DCOM and solves the Microsoft KB5004442 security This keeps all inbound firewall ports closed, while still
patch problem. allowing the data to flow one way or both ways.
Microsoft took an important step recently toward

keeping industrial systems secure. They made their
KB5004442 security patch for DCOM mandatory. This
affects all systems that network OPC DA, one of the
most widely used industrial protocols in the world. Now
all OPC DA systems that use DCOM across a network
must use the highest security settings. Any networked
connections with lower security settings will fail.
To connect OT to IT for remote access, DataHub
tunnel/mirror technology supports network isolation
through a DMZ. By installing a third DataHub instance
on the DMZ, each side can make outbound connections
through firewalls, and still maintain one-way or two-way
data flow.
To solve this problem, DataHub tunnel/mirroring makes

only local connections to both OPC DA servers and
clients. It passes their data across the network over TCP,
using SSL if required. Both OPC DA server and client
stay connected if the connection goes down, and the
client is informed of the break. This approach completely
eliminates the need for DCOM. Whatever your application, there’s no need to view
Microsoft’s move to secure DCOM as a problem.
DataHub tunnel/mirror technology offers
solutions at any level that are more
flexible and more secure than DCOM.
Find out more.
1-905-702-7851 | sales @ skkynet.com

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VTScada Receives IEC 62443 - ML 2 Cybersecurity

Certification for its Secure Development Lifecycle Process
Some of the largest automation systems in the world rely on VTScada software to ensure system uptime.
For this reason, the VTScada development team has always taken great care to provide advanced cyber
security features and follow software development best practices. Now, after rigorous evaluation by exida,
VTScada has again risen to the high standards required to help keep mission critical infrastructure safe.
VTScada’s Development Environment is now certified

to be compliant with IEC 62443 Security for Industrial
Automation and Control Systems - Part 4-1: Secure
Product Development Lifecycle Requirements for
Maturity Level 2.
This standard defines secure development life cycle

(SDL) requirements for products used in industrial
automation and control systems. This includes
security requirement definitions, secure design,
secure implementation verification and validation,
defect management, patch management, and product
end-of-life.
These can be applied to new or existing processes for

developing, maintaining, and retiring hardware, software,
or firmware.
exida is a world leader
in product certification
specializing in automation
system safety, alarm
management, cybersecurity,
and availability.
See the certificate here:
To learn more about

VTScada’s resiliency
features visit
www.vtscada.com.
Toll-free: 1-800-463-2783 (North America)

Worldwide: 1-902-835-1575
info@trihedral • www.vtscada.com
2024
The best automation, control, and

instrumentation products, selected by engineers
The winners of the 37th annual Control Engineering Product of the Year awards have
been chosen, highlighting some of the most notable technologies in the industry. This year,
companies submitted their latest and most innovative products, launched between Janu-
ary 1, 2023, and December 31, 2023, to compete for this distinguished honor. Our readers
then selected 35 winners, including the 2024 Most Valuable Product, which garnered the
highest number of votes overall. Detailed descriptions of the 2024 Control Engineering
Product of the Year winners, along with the official rules, are available at:
www.controleng.com/events-and-awards/product-of-the-year.
Entries for the 2025 program will open on October 1, 2024, and will include products first
introduced to the North American market within the 2024 calendar year.
Amanda Pelliccione is the marketing research manager for WTWH Media and
its publications, including Control Engineering.

Back to Basics PLC PROGRAMMING
How to reduce workload

using reusable components for PLCs
Multiple programmable logic controller (PLC) platforms now support
pre-packaged code to reduce programming time.
W
riting programmable logic controller (PLC)
programs from scratch is usually time-con-
suming and tedious. Many know about the
long-term costs and frustrations of debugging
and maintaining code, but a method can increase the code's
dependability and quality while streamlining and simplifying
the PLC programming process. Multiple PLC platforms can
use pre-packaged code to reduce your programming time
and support.
Three benefits of pre-packaged code

Pre-packaged code is a collection of pre-made libraries FIGURE: The Library Manager in CODESYS that allows
and functions that let users quickly construct PLC applica- users to add and select pre-packaged code for a project.
tions. Pre-packaged code can help users to: Courtesy: Vision Control & Automation
1. Accelerate your code: Using tested pre-packaged code to
perform common tasks reduces the time spent writing code. There was a case where message queuing telemetry trans-
Due to this, the code may become more responsive, resilient port (MQTT) messaging to an existing PLC program. COD-
and faster. Users also are minimizing errors by using proven and ESYS has several library options, including support for
validated code. This reduces testing and troubleshooting time. Sparkplug B. For this application, the WagoAppCloud library
2. Standardize: Pre-packaged code can be used across hard- and its MQTT support were used to send messages to the
ware platforms and projects. Users can use the same functions MQTT broker.
and libraries for different projects and follow identical coding
conventions and best practices. This can make the code more
Adding SQL database connectivity is
not a feature that comes with the PLC.
u Online
controleng.com
readable, consistent and more accessible for others to support. Multiple libraries can connect to a data-
KEYWORDS: PLCs
3. Reduce support costs: Using pre-packaged code, users base. A hardware-specific library allows
LEARNING OBJECTIVES
can update or replace these packages when needed. For users to connect and send SQL syntax to Understand what pre-
example, if a machine uses pre-packaged code that interacts a database. Using pre-packaged code can packaged code is and how
with an outside platform, users can update the package with- help reduce programming time and sup- it is used for programmable
logic controllers (PLCs).
out redoing the code if it updates its communication spec. port efforts and improve workflow and
Learn benefits, see
CODESYS is a programming software that works with mul- development time. Users benefit from the examples.
tiple PLCs. In the CODESYS, pre-packaged code is available in advantages of pre-packaged code and cre- CONSIDER THIS
the form of libraries. Users can download free libraries; some ate better PLC programs faster and easier What applications could
benefit most from this?
have a cost or work with specific hardware. To use pre-packaged for the next project. ce
ONLINE
code in CODESYS, users need to: www.controleng.com/
Brandon Teachman is an application video/automate-2024-
1. Identify the library that contains the code you need. engineer at Vision Control & Automa- interview-brandon-
teachman-vcawi-on-plcs-
2. Import the library into your project. tion. Edited by Chris Vavra, senior editor, control-systems-and-
3. Write the code to interact with the library. WTWH Media, [email protected]. automation-trends

| 63
Publication Sales
VP, Sales
Matt Waddell [email protected]
312-961-6840
Sales Account Manager

Brian Gross [email protected]
847-946-3668
Advertisers' Index
Richard Groth [email protected]
774-277-7266
COMPANY PAGE# WEB
AutomationDirect . . . . . . . . . . . . . . . . . . . . C2, 1 . . . . . . . . . . . . . . www .automationdirect .com Robert Levinger [email protected]
516-209-8587
Beckhoff Automation LLC . . . . . . . . . . . . . . . . 6 . . . . . . . . . . . . . . . . www .beckhoff .com
CALLING ALL SYSTEM INTEGRATORS… . . .32
Dean Morris [email protected]
www .controleng .com/events-and-awards/system-integrator-of-the-year-program
513-205-9975
DATAFORTH . . . . . . . . . . . . . . . . . . . . . . . . . .64 . . . . . . . . . . . . . . . www .dataforth .com
Digi-Key ELECTRONICS . . . . . . . . . . . . . . . . . 4 . . . . . . . . . . . . . . . . WWW .DIGIKEY .COM Judy Pinsel 847-624-8418
[email protected]
Endress + Hauser . . . . . . . . . . . . . . . . . . . . . . 8 . . . . . . . . . . . . . . . . www .us .endress .com
EZAutomation . . . . . . . . . . . . . . . . . . . . . . 32A-32D . . . . . . . . . . . . www .EZAutomation .net
MOTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . . . . www .Motion .com

Publication Services
ONLOGIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 . . . . . . . . . . . . . . . www .onlogic .com/tacton
SEW-EURODRIVE, Inc . . . . . . . . . . . . . . . . . . C4 . . . . . . . . . . . . . . . www .seweurodrive .com Patrick Lynch, Senior Vice President, Sales & Strategy
SKKYNET . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3 . . . . . . . . . . . . . . . www .CogentDataHub .com
TADIRAN BATTERIES . . . . . . . . . . . . . . . . . . .14 . . . . . . . . . . . . . . . www .tadiranbat .com McKenzie Burns, Marketing Manager
[email protected]
Trihedral . . . . . . . . . . . . . . . . . . . . . . . . Bellyband, 13 . . . . . . . . . . www .VTScada .com/time
VEGA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 . . . . . . . . . . . . . . . www .vega .com/radar Courtney New, Program Manager, Content Studio
[email protected]
WAGO Corp . . . . . . . . . . . . . . . . . . . . . . . . . . .27 . . . . . . . . . . . . . . . www .wago .us
Paul Brouch, Operations Manager
MEDIA SHOWCASE FOR ENGINEERS

Rick Ellis, Director, Audience Growth

Michael Rotz, Print Production Manager

Custom reprints, print/electronic:

Paul Brouch, [email protected]
Information: For a Media Kit or Editorial Calendar,

go to https://www.controleng.com/advertise-with-us.
Letters to the editor: Please e-mail us your opinions to

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CONTROLENG.

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MISSION CRITICAL SOFTWARE

Limited 2024 © Trihedral Engineering Limited 2024

Contents MAY/JUNE 2024

16-30 How to develop

control engineering — www.controleng.com May/June 2024

Contents MAY/JUNE 2024

NEWSLETTERS ONLINE uProtecting Critical Infrastructure eBook

control engineering — www.controleng.com May/June 2024

It’s kind of a big deal: ultra-compact

480 MHz ARM processor

Now that is a big deal.

Learn how to clean

u Watch www.controleng.com/webcasts for:

u Choosing technology for streamlined engineering; Kyle Harrison, HMI product

u How to safely, sustainably absolve industrial malodors; Lisa Haupert, Ph.D.,

u Benefits of using mixed valves in processing, industrial applications; Christine Tarlecki

control engineering — www.controleng.com May/June 2024

Do you want to learn more?

control engineering — www.controleng.com May/June 2024

Choosing the right computing

10 | May/June 2024 control engineering — www.controleng.com

control engineering — www.controleng.com May/June 2024

Automate 2024 Recap:

12 | May/June 2024 control engineering — www.controleng.com

Don’t let the cost and inconvenience of hard-wired

PO Box 471, Downers Grove, IL 60515

WTWH Media LLC acquired CFE Media LLC on May 1 to bring

Contributing Content Specialists

Results are in:

16 | May/June 2024 control engineering — www.controleng.com

those working with automation, (14% in 2023, 9% in 2022) 28%

tion: “What technologies are most likely 15% Cybersecurity technologies

Advanced process controls (APC)

0% 10% 20% 30% 40% 50% 60%

control engineering — www.controleng.com May/June 2024

17% (23% in 2023); customer feedback at

15% (10% in 2023); quality metrics at 14%

(17% in 2023); company stock performance

at 10% (13% in 2023) and product profits at

9% (19% in 2023), among other responses.

from COVID-19 created many workplace

challenges, it showed many organizations

that working from home and flexible hours

18 | May/June 2024 control engineering — www.controleng.com

For more information, see this article online

0% 10% 20% 30% 40% 50%

control engineering — www.controleng.com May/June 2024

Get engineering salary

gate. There are so many paths to choose,

it becomes challenging to know if you are

even on the right path.

20 | May/June 2024 control engineering — www.controleng.com

goes beyond time management; it’s about Continuing education

Develop very good communications

are crucial to project successes. Proper