The document discusses the evolution of technology related to smart systems, highlighting the rise in use of Ethernet and wireless communication methods, as well as advancements in safety standards. It emphasizes the importance of energy efficiency and the impact of design on material and energy consumption. The document also touches on the transition in safety standards from older EN standards to modern EN ISO standards, underscoring the need for engineers to be knowledgeable about Ethernet basics and wireless technologies.

1. Norman Dziedzic

2. Smart
Everything
Wires, What Energy
Wires? Revolution
Ethernet Safety up
Everywhere Front

3. Maybe You Should Too 

4.  What is Smart?
 Extended/Expanded Functionality
 Multi-Functionality
 Self Diagnostics
 Configurability
 Connectivity




5.  ARM vs. Intel
It took Intel 30 YEARS to sell 1 Billion processors &
another 4 years to sell its 2nd Billion
ARM sold (licensed) 2.8 BILLION processors (cores) in
2009 (That’s around 90 every second)
High End Processing Power is
stampeding down into smaller
and smaller devices!

6.  Smart Relays

7.  Smart Sensors
RFID

8.  Do Everything HMIs…
• Data Logging / Database Connection
• Recipes
• Security / Audit Trail
• Language Change
• Passthru Data
• PLC Functionality
• Remote Access
• Multiple PLC Configurations

9.  Smart Drives /
Motors /
Valves

10.  Vision
 Measurement
 Tagging

11.  Smart Phones?

13.  Smarty Pants
•Is Smarter Always Better?
•What Does it Take to be Smart?
•What is Smart Management?

14. Less Power to the People

15.  Thin is In!
Weight is being rung out of almost everything
resulting in great material and shipping savings.
Now the challenge is handling these more fragile
products
 It’s Hip to be Square
To increase packaging density, more square and
rectangular designs are in vogue
New gripper and fixture designs are required as
parts move away from round shapes. Changeover
can be more complex as well with square shapes.

16.  Conservation of the Basics
 Compressed Air
Minimize Pressure or Change to Electric
 Electricity
New AC Motor Standards EISA End of 2010
Regenerative Drives Re-Capture Deceleration
Energy
 Water
In 1930 In 2005
Producing Producing
1 Ton of Steel 1 Ton of Steel
Required Required
200 Tons of Water 5 Tons of Water

17.  The Energy Ripple Effect of a Thinner/Lighter
Part Design
Less Raw
Material
Less Energy to Less Energy to
Recycle at End Process The
of Life Material
Now the
challenge is to
Less Energy to Less Energy to
handle these
Ship Part to
Customer
Ship Material
to Plant
lighter, thinner
parts through
manufacturing
Lower Energy
Required to
Produce Part
and shipping.

18.  The Energy Ripple Effect of Efficient Panel
Design
Less Raw
Material for
Enclosures
Less Energy to Less Energy to
Recycle at End of Fab Enclosures
Life & Make Wire
Less Energy to
Cool Enclosures Less Energy to
Ship Enclosures
& Wire to Plant
Less Energy to Smaller
Ship Machine to Machine
Customer Footprint

19. Safety Up Front
And
A Game of Standards Musical
Chairs?
Do you know your MTTFd?

20.  Traditional Machine Building
Commission Light
Mechanical Test Measure Hard
Build
Field Wiring Curtains or
by Hand Guard
Debug Scanners

21.  New Machine Design & Building
Select Safety
Consider Safety Components Safety is not an
Risk
During Setups, Based on “Add On” or
Assessment
Changeovers, Required Rushed at End
Early in Process
Maintenance Performance of Project
Level

22. Safety Up Front
Safe Motion Functions
• Safe Standstill/Safe Operational Stop
• Safely Reduced Velocity / Increment
• Safe Direction of Movement
• Safely Limited Absolute Position
• Safe Brake Management

23. Safety Up Front
Safety Controllers
• Consolidate Wiring
• Multiple Safety Devices
• One or Multiple Outputs
• Multiple Functions Curtains
Mats
Scanners
Rope Pull
2 - Hand

24. Safety Standards Musical
Chairs
Out with the old – Sort of…
• EN954-1 Going… Going… Gone (Dec 31, 2011)
In with the New – Sort of…
• EN ISO 13849-1 … Meet the new boss.
You can, and probably should be using
EN ISO 13849-1 Now

25. Safety Standards Musical
Chairs
New (EN ISO 13849-1) Old (EN 945-1)
Performance Levels Categories

26. Safety Standards Musical
Chairs
New Buzz Words
• SRP/CS: Safety-Related Parts of Control Systems
• PFHd: Probability of a dangerous Failure per Hour
• PLr: Performance Level Required
• MTTFd: Mean Time to Dangerous Failure
• DC: Diagnostic Coverage
• CCF: Common Cause of Failure
New Tools
• SISTEMA: Software Tool to determine Performance Levels
• Manufacturer Databases: Data on MTTFd to use in SISTEMA

27. Thank You Ether Bunny! 

28.  What is “Ethernet?”
 Cables?
 Connectors?
 Computers?
 Networks
 World Wide Web?

29.  Industrial Ethernet generally means a specific
Protocol
 Sercos III
 Ethernet/IP
 Modbus/TCP
 EtherCAT
 ProfiNet
 Powerlink
 …

30. Proliferation of cheap laptops and netbooks means
Ethernet hardware is easy to access and use.
• Many devices now include a Web Interface for
configuration
• Only a web browser is required for setup
The Good:
Ethernet can provide a connection to anywhere in
the world
The Bad:
Ethernet can provide a connection to anywhere in
the world

31. Knowledge of Ethernet basics is now absolutely
essential for the controls engineer!
• Can you change the IP
address of your
computer?
• Do you know what a
sub-mask is?
• Do you know how to
ping an address?

32.  Pulling the Old Switcheroo…
• How about the difference between
managed and unmanaged Ethernet
switches?
• What about routers?
• Can you secure your network?

33. Wires, we don’t need no stinking
Wires! 

34.  A multitude of Options
 802.11a/b/g/n (Wi-Fi)
 900 MHz
 Bluetooth
 GSM Modems
 HART (highway addressable remote transducer)
 ISA 100.11a
 ZigBee
 Light Flashes?

35.  Why Wireless?
 Ease of Installation
 No Need to run Wires
 Remote Locations
 Rotating Equipment

36.  There is general acceptance of Wireless for
Monitoring Functions
 But Less willingness to use wireless for
Control. Users want “Determinism”
(generally 10msec response – guaranteed)
 Site Survey is the key to installation success
 Security is also an issue

37. Range
How far will it go?
Circles of Success
Received Signal Strength
Performance Zone
Path Engineering Required
Wireless Conduits up to 20 miles
Common Sense Zone
Success with Experience
Receiver Wireless Conduits up to 1/2 mile
Threshold
No Worry Zone
This is “Electricians’ Territory”
Wireless Conduits up to 1/4 mile
Distance

38. Intentional Interference
Eavesdropping | Data Injection | Data Manipulation
Public Standards Proprietary Systems
 Radio “language”  Non public air interface.
is known.  Equipment available to
 Equipment is “insiders”.
readily available.  Un-known technology is
 Encryption is the a significant barrier.
only protection.  Encryption helps.

39. Smart
Everything
Wires, What Energy
Wires? Revolution
Ethernet Safety up
Everywhere Front