04 Cover story Open to universal stan- dards OPC UA Phoenix Contact supports the "Open Platform Communications Unifi ed Architecture" (OPC UA) standard, recommended by VDMA [the Ger- man Mechanical Engineering Indus- try Association] as the basis for open and standardized communication in the digital future. OPC UA is an integral component of PLCnext Tech- nology, and will be compatible for integration into third-party systems in the long term. OPC as a standard- ized interface makes communication far simpler. AutomationML and eCl@ss Phoenix Contact uses the Automa- tionML and eCl@ss standards for the optimized development and manu- facture of control cabinets, amongst other applications. programs: these are all now available. An example keyword: Condition monitoring. The hunt for the market Of course, it is not bits and bytes that make machines and systems run faster. Rather, said machines and systems should be made to start up more quickly and to carry out production with a failsafe performance for as long as possible. Reducing the time-to-market and safeguarding the unlimited capability for delivery at any time are therefore urgently required. In these days of global and ever stronger competition, it is the worst possible scenario for every manufacturing company if there are no production systems in place for a newly announced product because the controllers have yet to be programmed. There is great potential right here. Programmable logic controllers are still programmed in IEC 61131 languages. Many controller providers have integrated high-level language code via C interfaces into the IEC 61131 core. It could, however, be even more convenient: operator convenience and user friendliness are increasingly coming to the fore as a result of the complex subject of Industrie 4.0. And, with regard to control technology, this does not just stop at engineering processes. Today's PLC programmers often come from other technological disciplines that they would naturally like to use. They are fully at home in the Windows and Linux environments, have experience with high-level languages, and with tools such as Eclipse, Microsoft Visual Studio, and Matlab Simulink. Against this backdrop, PLCnext Technology from Phoenix Contact is groundbreaking. With PLCnext Technology, PLC programmers can use the classic IEC 61131 environment, but at the same time can also program in high-level languages and use other tools. The real-time capability, the stability, and the startup behavior are, at the same time, equivalent to that of a classic PLC. I am convinced that the market will reward this new openness in programming convenience. Michael Lind is a freelance PR consultant. He was editor-in-chief of the trade magazine "automation", published by Henrich Publikationen, until 2016
UPDATE 3|17 Technology 07 Code without limits PLCnext Technology as the new platform for future-proof automation solutions With PLCnext Technology, Phoenix Contact has developed a platform that opens up a whole new level of freedom in terms of programming languages and tools as well as the integration of open-source functions. And the best part is that the advantages of the classic world of PLC programming are maintained. Ever more IT applications, such as communication with databases, cloud computing, and direct connection to ERP systems are becoming part of classic control technology. Integrating functions available on the open-source market into most PLC platforms is, however, a very complex process. The programmer must first transfer them with numerous adaptations into the appropriate engineering system, where they are executed in a real-time environment. However, most of these applications use packet-oriented Ethernet communication, and it is therefore not easy to predict fully how they will behave in the context of a manufacturing automation process with demanding co-participants. Against this backdrop, Phoenix Contact considered what a future-capable control platform should look like. Three requirements crystallized: 1. Access to the open-source community 2. Faster automation of applications 3. Freedom in the selection of engineering tools. Furthermore, every user should be able to work as with a classic PLC. The result is the completely redeveloped PLCnext Technology technology platform, which is unique in this form. With and without real time The operating system must be real-time capable for use in a controller. When selecting the operating system, it is also decisive whether source code, libraries or complete applications are freely available. On the basis of these conditions, Phoenix Contact decided on Linux with real-time extension for PLCnext Technology. Thus, code can be executed both within and outside of the real-time context. With Linux, programs for machine control systems can be executed deterministically, while, for example, communication with databases is executed outside of the real-time context. As of the end of November 2017, the AXC F 2152 controller will be the first device with PLCnext Technology The user normally writes the machine control system program in IEC 61131-3. Now, however, he would like to integrate, for example, a controller created with Matlab Simulink® or C++ into the application, without having to translate this into IEC 61131-3. This is often necessary because most systems do not
08 Technology UPDATE 3|17 Several developers can work on one project independently of one another with different development tools permit access from the high-level language program to operating system functions. Hybrid operation of IEC 61131 and high-level language code In modern applications, there will therefore be an increase in the hybrid operation of IEC 61131 programs and high-level language components, which are executed both within and outside of the real time context. Furthermore, the programmer must ensure that the data are transferred consistently from one process to the next. This is demanding, even for experts. The temporal relationship between the various processes in the system is frequently known only imprecisely, resulting in incorrect priorities being assigned. Or else resources are not blocked, leading to errors in the application. PLCnext Technology offers an advantage here, in that it includes, amongst other applications, the Execution and Synchronization Manager (ESM) and the Global Dataspace (GDS). With the ESM, the user can configure programs that are written in IEC 61131, C++ or Matlab Simulink in an XML file and thus define the execution cycle of program steps and the sequence of said steps. Thus, it is possible for a typical PLC with high-level language or IEC 61131-3 programs to function in a hybrid operating environment. The GDS is much more than just a shared memory. This service provides functions such as publishing and subscribing, intelligent buffer mechanisms, and simple configuration via an XML file that humans can read. Standard debugging mechanisms PLCnext Technology also features an intelligent data logger that is also configured via an XML file and can be saved directly in SQL databases. Thus, process data can be logged in synchronous cycles upon a trigger, and thus, for example, all key data can be recorded in the event of limit values being exceeded. Furthermore, PLCnext Technology includes an OPC-UA server and client, as well as the Profinet controller und device functionality. In addition, all debugging mechanisms that the programmer is used to are supported. Thus, an Eclipse programmer can use tracing to display the system utilization. He is also able to recognize any problems that may arise with the task priorities and interruptions and that result from them.
UPDATE 3|17 Technology 09 Open to open source With PLCnext Technology, the user can draw on the open-source community. He thus has access to one of the largest software pools in existence. For example, an OpenVPN client or server can be installed, and a database on the device or any runtime environment can be set up, for example for visualization purposes. Thus, PLCnext Technology opens up clear added value in comparison with solutions rigidly integrated into the IEC 61131 runtime environment, and provides the user with the freedom necessary to implement his application. At the same time he can also only move within the IEC 61131 environment, which for all PLCnext Technology devices means PC Worx Engineer. Graphical linkage of the process data If the user uses PC Worx Engineer as one of the tools for creating an application, the system can be configured graphically there, instead of using the XML file described. Tasks, programs and process data can be linked graphically. This also applies to high-level language programs that also have graphic representation as an instance. For example, the programmer of the machine application can add a closed-loop control circuit written in a high-level language as a program instance in PC Worx Engineer, which will then be represented as a block there. The process data are then linked graphically. PLCnext Technology also has a consistent security concept. This starts with a trust anchor, which is applied to the devices in the form of a trusted platform module (TPM). A user and group management system allows the customized adaptation of the access rights up to the process date. Data is transmitted to the engineering system in an encrypted and authenticated manner. Furthermore, there are regular security updates that can be installed either via a device management system or manually. Michael Gulsch works in Market Management for Control Systems Web code: #1509 Application for the Early Adopter Program With the AXC F 2152 Axiocontrol controller, the first controller with the PLCnext Technology open platform will be available from November 2017. We now invite you to familiarize yourself with the controller as part of our Early Adopter Program and to test the advantages of this new openness to your own automation ideas. We look forward to your feedback and ideas for further developing our control platform. You can apply for the program at phoenixcontact.com/earlyadopter. Selected participants will receive a starter package, training for the system, and access to the Early Adopter community for the open exchange of information. Vote for PLCnext Technology The publisher VDE VERLAG has organized a competition in cooperation with the ZVEI [German Electrical and Electronic Manufacturers' Association] and the Hannover Messe for the most innovative product in the context of Industrie 4.0. From all of the entries, the expert jury has already selected PLCnext Technology as one of the top ten candidates. The second round has now begun, via online voting. You can now vote for PLCnext Technology via the open automation website until October 31. The prizes will be awarded during the SPS IPC Drives 2017 in Nuremburg, Germany. All participants in the vote will be entered into a prize draw with a chance of winning a smart watch and other prizes. Vote online at: openautomation.de/industrie-40/industrie-40-award
10 Interview UPDATE 3|17 Programmed transformation Openness to new technologies is not a question of age to ask more experienced colleagues for help. Programming is a team eff ort, and I have often benefi ted from the experience of older colleagues." … on technological advancements in automation "Because PLCnext Technology is based on Linux, we can install each module retroactively and thus extend the functions of the controller. We were already able to integrate the C++ program code, but now we can also combine this with IEC 61131-3 programs. Furthermore, we can now theoretically integrate a database, a webserver, a cloud link, an With PLCnext Technology, Phoenix Contact opens up automation programming to future generations. UPDATE has taken the opportunity to ask a "Baby Boomer" and a member of "Generation Y" who are involved with control technology at Phoenix Contact: How do you program, and what can you learn from the other generation? Oliver Warneke … … on high-level language programming and IEC 61131 "During my studies and vocational training as an electronics engineer, I learnt four programming languages practically simultaneously. Which program language I use just depends on the particular project. Nobody would program hardware-related functions such as an I/O link in C, because there are prepared functions available in ST (Structured Text) or a fully programmed function block that needs only to be confi gured. On the other hand, it is advantageous that I am able to work with Matlab or C for more complex algorithms or control applications." … what I can learn from my older colleagues about programming "If I cannot fi nd a solution to a programming issue on my own – and there is always a point like that in a tricky project – then I am happy Oliver Warneke Oliver Warneke, born in 1991, came to Phoenix Contact as a cooperative study electrical engineering student. Since completing his Bachelor of Science degree in 2016, he has worked as a Control Technology Specialist in the support team at Phoenix Contact Electronics. He advises customers and colleagues who have questions about programming software for automation systems.
UPDATE 3|17 Interview 11 image processing system, a fi rewall, a VPN tunnel and much more into a hardware platform, and control these modules specifi cally from the PLC logic." Götz Jäckel … … on high-level language programming and IEC 61131 "Young people hardly ever come into contact with IL - that is to say instruction list - anymore, or with the visual programming languages function plan and ladder diagram. They are happy when they fi nd ST code. In some situations, however, the visual programming languages are benefi cial, for example in service instances. With the graphical representation, you can gain an overview of the data fl ow and discover errors in the input parameters much more easily. Ultimately, it is the mixture of the programming languages that gives you power. Wherever I urgently need determinism and data consistency at all points in a machine, I am more effi cient with PLC-based programming." … what I can learn from my younger colleagues about programming "My younger colleagues have a completely diff erent, playful approach to web technologies. This is a benefi cial characteristic that is not to be underestimated - especially for applications in which we integrate data from the Internet via open interfaces and then combine said data with functions from the process to be controlled. Together, we can thus develop solutions that help the customer, for example for predictive maintenance or for business intelligence, more quickly." … on technological advancements in automation "A point comes around approximately every three years, where, at the beginning, I say "This is now beyond me", but it is part of my job to penetrate new technologies and then also pass this on in my training programs. I then impart to the course participants the exact path that I followed to understand the innovations - omitting the detours that I initially took." The interview was conducted by Christoph Manegold, Editor-in-Chief Götz Jäckel Götz Jäckel, born in 1953, is a classic example of someone moving laterally into automation technology. Having qualifi ed as a French and Social Sciences teacher, he switched to C programming in 1986 and, through a number of positions, arrived at Phoenix Contact, where he now trains users around the world in the programming software PC Worx.
Smart technology: The Phoenix Contact Industry Solution Center in Bad Pyrmont, Germany, uses the IoT- based Emalytics building management system. The technology results in greater cost savings in operation and in a comfortable working environment.
14 On site UPDATE 3|17 Open architecture Digital building services management is combined with energy management and business intelligence in the Industry Solution Center The new Phoenix Contact Electronics building in Bad Pyrmont provides visitors and employees with high levels of comfort and security. The company consistently takes full advantage of the benefi ts that result from a fully networked building infrastructure with open interfaces, saves energy, and pushes forward the optimization of numerous business processes. The result is nothing less than a showcase for the possibilities of IoT-based building management. Visitors to the new building covering 18,000 square meters will fi nd modern architecture with plenty of glass and a generously sized atrium that is spread over all four stories. The openness is also refl ected in the building infrastructure and its ability to adapt the ambient conditions to individual requirements. Energy supply, heating, cooling, and the production areas are intelligently connected and ensure energy-effi cient operation. Due to the well- thought-out supply process, the building does not need an intrinsic heating or cooling system. The two combined heat and power plants (CHP) and a photovoltaic system on the roof with integrated energy storage contribute to this. The building is completed by an E-Mobility charging station that is powered by the PV modules. Simple facilities integration The company-internal Facility Management department uses in-house components and systems for the operation of the Solution Center. The foundation is the IoT-based building management system Emalytics, which connects the control engineering to the active energy management system. The superordinate system of 27 ILC BI 2050 Inline controllers, which are equipped with IoT technology, receives the fi eld- level data. Its task is to transfer all the data from the facilities in a standardized form to the Emalytics building services management system. The special feature is that both classic sensor and actuator technology and new, intelligent IP-based fi eld devices can be integrated into the system simply and quickly. For this purpose, the controller supports the most common building technology standards, such as BACnet IP, BACnet MS/TP, M-Bus, KNX/ TP, SNMP, LON and oBIX. With functional terminals for the Inline system, common bus systems such as Dali, Modbus/TCP and Modbus/RTU can be connected to the controller. By means of the protocol- independent integration of the fi eld devices into the IoT-based controller, the engineering and cabling are simplifi ed considerably. Benefi cial analyses Based on the data recorded, the Emalytics building management system allows predictive maintenance of the installed devices and notifi es the operator of potential disturbances. Emalytics analyses for example the characteristic values of the spark plugs in the combined heat and power plant and recommends a preventative replacement. The useful life is thus optimized. The elevators in the new building are also integrated into the building management system. Emalytics does not just visualize their current location. Based on the data collected, their routes are optimized, which shortens the waiting times for employees and visitors. Furthermore, elevator maintenance work is commissioned automatically via the SAP system.
The Emalytics building management software displays the relevant data on site on the PC as well as on all smart devices High levels of comfort and eﬃ ciency Sensors are installed in the conference rooms and seating areas to register when they are occupied, so that the Facility Management department can evaluate the utilization of individual rooms and areas. Furthermore, the employees can view unoccupied rooms and areas via the building management system, thus saving unnecessary journeys. Each employee can call up the temperature and lighting at his own workstation and adjust it accordingly. The lighting is switched on and off automatically via motion detectors and light sensors. The climate control and shading of the building also run automatically, and faults are reported by telephone. The four offi ce and production buildings in Bad Pyrmont are supplied with energy via a ring concept, in which all generators, loads and storage systems are interconnected. The exhaust heat generated by the CHPs is used to heat the rooms. Furthermore, the heat can be converted into cool air, in order to cool the buildings to a comfortable temperature in the summer. Intelligent networking of generators, loads and storage systems All instantaneous operating values of the combined heat and power plants, the heating and cooling systems, the E-Mobility charging stations, and the PV energy system on the roof are brought together and can be displayed to a high level of detail. The evaluation and the interlinking with further processes at the site, for example with production data or the current weather, opens up enormous potential for saving energy costs and optimizing processes. Farina Georgi is the Product Manager in Industry Management Building Technology
16 Technology UPDATE 3|17 Converting between worlds Proficloud and network-capable signal conditioners pave the way to the Internet of Things (IoT) with measured-value acquisition Those who wish to perform valid evaluations based on their process data need a reliable signal chain from the sensor up to company level. Data models for the acceleration and optimization of business processes are used in industry. There is a demand here for providers who are in command of the known world of acquiring signals in the field, transmitting them to the interface level and making them available on the Internet. With the network-capable Mini Analog signal conditioners and the Proficloud IoT platform, Phoenix Contact provides exactly what is required. Thanks to the new Mini Analog Pro signal conditioner, which features a bus and network connection, the data is transmitted from the field to the network faster and more simply than ever before. Up to eight freely combinable signal conditioners, which can be easily plugged in, are connected via gateway to the industry- standard Modbus and Profibus fieldbus systems. The otherwise standard signal-specific input cards are no longer required. The advantages of electrical isolation – essential for good signal quality – and the potential of digital communication are combined in this way. The now digitalized signal flow from the fieldbus will then be transmitted to Proficloud via cloud-IoT gateway, which mediates between the Internet world and automation. There are numerous interesting applications for cloud-based automation in the water management industry
UPDATE 3|17 Technology 17 After a one-time registration, the gateway automatically connects to the cloud and the "magic" begins: the values of individual measurement signal conditioner channels can be viewed on the web server of the gateway. They can be provided with informative names, such as "Boiler 1 pressure", "Boiler 1 temperature". The system fitter can create the visualizations for his first dashboard – for example maximum values, mean values, progress curves – with just a few mouse clicks. In comparison with other known solutions for an open IoT operating system, no additional programs or training are necessary for creating the visualization. With Proficloud, the focus is on ease of control by the user himself. The advantage for the operator: The investment expenditure for the equipment is low in comparison with conventional technology. The operator's own personnel can try out the new possibilities with practically no risk and then transfer these into regular operation with customized pay-per-use models. The uncomplicated provision of operational data for visualization on all Internet-capable devices - right down to smart watches - is normally the first level at which users approach the subject of IoT. Very soon, however, further wishes arise: it is possible, for example, to monitor the threshold level of critical system parameters and to send messages regarding said levels to the service personnel via push notification. With knowledge-based algorithms, the operating data collected form the basis for predictive maintenance. The system recognizes imminent failures and orders the required replacement part automatically. The full power of IoT-based automation can be seen when the acquired operating data is linked with other knowledge sources, thus establishing the prerequisites for autonomous intelligent decisions. In the Netherlands, there is an Internet platform that provides the fill levels of the current and expected water levels in waterways as publicly accessible data. An independent system integrator has developed a Proficloud service via the SDK (software development kit) which allows easy access to this data and its evaluation via Proficloud. The The cloud-IoT gateway and the Mini Analog Pro network-capable signal conditioner simplifies the path to the cloud service calls up the current or expected water level data and makes this available to the user as a virtual Profinet device. Thus, the PLC programmer can integrate this data into his PLC programming quickly and simply without additional specialist knowledge. Discover the possibilities IoT-based automation concepts support the trend for agile system development in a practically ideal way. Whereas in the past, teams of developers worked for years at great cost and risk towards a goal that was no longer questioned, engineers today work in rapid development cycles, analyze the intermediate results weekly and adjust the planning at regular intervals. With the introduction of IoT-based automation technology, new functions can be created and adapted, tested and - where necessary - discarded, without much expenditure. This is made possible by scalability, the virtualization of computer power and standardization with open interfaces that are accessible via the Internet. Christoph Manegold Web code: #0949
UPDATE 3|17 Technology 19 more time to recognize attacks and to be able to react to them. The objective is to reduce the eff ects of an attack. For the protection of its system integrity, PLCnext Technology is already equipped with functions such as authorization via user accounts and credentials. Furthermore, secure protocols are used for communication. The consideration of all weak points is decisive After all, the network is only ever as secure as its weakest point. Therefore it is also important to give thorough consideration to general network security; more specifi cally, to the protection of automation networks against unauthorized access, and to the control of all network interfaces and the remote maintenance access points. A sensible approach here is to segment networks down to the smallest cells to minimize the risk of an entire network failure and, at the same time, to increase the security and availability. The use of routers, fi rewalls and encrypted connections has proven to be eff ective in practice. The mGuards from Phoenix Contact, with which the communication surrounding PLCnext Technology can be secured, are ideal here. Via certain rules, these only permit data traffi c with trustworthy sources; all other data traffi c is blocked. Regardless whether IEC 61131, C/C++, PC Worx or many others, the openness remains, as long as access is possible only from trustworthy sources and via trustworthy connections. The ability to recognize anomalies in the network or communication increases the security even further. In this way, data traffi c can be analyzed at the protocol level, through to the detailed analysis of the contents of individual data packets. This means that an evaluation algorithm recognizes whether it is only the intended data that is being transmitted in a protocol element from PC Worx. If this is not the case, an alarm is triggered or a fi rewall is instructed to block this data traffi c. If, then, the most important aspects of cyber security are taken into consideration, such as the analysis of data traffi c and the security of the networks in the PLCnext environment, there are no reservations regarding the openness of PLCnext Technology. Thorsten Vogel is the Head of Security Consulting at Phoenix Contact Cyber Security AG Authentication – User accounts – Authentication of credentials – Authorization Integrity – Principle of least privilege – Defense in depth – Network segmentation A holistic security concept is integrated into PLCnext Technology Confi dentiality – Use of secure protocols – Secure remote maintenance – Cryptography – Protection of expertise Availability – Monitoring und attack detection – Tamper protection
22 News UPDATE 3|17 Hackers are barred 7th mGuard Cyber Security Conference October 17 and 18, 2017 in Essen, Germany With the international mGuard Cyber Security Conference (previously mGuard User Conference), Phoenix Contact has been providing its customers and interested parties with an annual forum for the exchange of current knowledge about and experiences with industrial cyber security since 2011. The conference is aimed at both experienced mGuard users and newcomers, to which important fundamental principles of industrial cyber security are imparted. At this year's event, being held at the Ruhrturm Hotel in Essen on October 17 and 18, security experts and users will be reporting on and discussing current cyber security issues. This will include new approaches and proven best practices for the secure networking of OT (Operational Technology) and IT, as well as secure remote maintenance and further remote services. Participation in the event is free. A smart building for smart solutions Phoenix Contact Industry Solution Center inaugurated After 18 months of construction work, the new Phoenix Contact building in Bad Pyrmont was inaugurated on May 5, in the presence of Stephan Weil, Minister-President of Lower Saxony. In addition to the urgently required office and laboratory spaces, the newest building at the Bad Pyrmont site is also important as a demonstration site. Through the use of automation and intelligent technology, Phoenix Contact can demonstrate to its customers and other visitors the benefits that a building management system has to offer (see also page 14). In his welcome speech, CEO Frank Stührenberg underscored that the Industry Solution Center will be a center of digitalization for Phoenix Contact. "We will develop solutions for the requirements of the future here. We will develop them in this building!" Stephan Weil, Minister President of Lower Saxony, was impressed by the building and the courage to invest: "Phoenix Contact has become a household name when it comes to digitalization. And this building confirms this very clearly. Translating such a vision into reality requires courage on the part of the Executive Board and a certain attitude on the part of the shareholders. It also shows a clear commitment to the sites." Where solutions are within reach: The Industry Solution Center Showroom