OPC UA TSN Field Testing Success

The B&R Technology Magazine
11.16
OPC UA:
Ready for real time
TSN field testing successful
mapp Technology Mastering options in machine software
openSAFETY meets OPC UA Safe Line Automation

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Smart factory solutions for your production
< aproL enMon –
Energy consumption at a glance
< aproL conMon –
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publishing information
automotion:
The B&R technology magazine, Volume 16
www.br-automation.com/automotion
Media owner and publisher:
Bernecker + Rainer Industrie-Elektronik Ges.m.b.H.
B&R Strasse 1, 5142 Eggelsberg, Austria
Tel.: +43 (0) 7748/6586-0
automotion@br-automation.com
Managing Director: Hans Wimmer
Editorial staff: Alexandra Fabitsch
Editorial staff: Craig Potter
Authors in this edition: Eugen Albisser,
Françoise Albasini (Emballage Digest),
Franz Joachim Rossmann, Heike Henzmann,
Stefan Hensel, Elmar Zimmerling, Franz
Kaufleitner, Carmen Klingler-Deiseroth,
Michaela Stern, Craig Potter, Raimund Ruf,
Sebastian Sachse
Graphic design, layout & typesetting:
Linie 3, www.linie3.com
Printing: VVA Vorarlberger Verlags-
anstalt GmbH, Dornbirn
Edition: 100,000
Published at: B&R Strasse 1
5142 Eggelsberg, Austria
Cover photo: shutterstock
All articles published in this magazine are
protected by copyright. Translation,
reproduction and duplication are prohibited
without the expressed permission of the
publisher. B&R assumes no liability for any
errors they may contain.
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editorial
0111.16
Dear Reader,
We live in a world of accelerating change. As more and more
of the physical world is digitized and moves online, informa-
tion now spreads to the global masses in a matter of sec-
onds rather than days. People and devices communicate
with increasing ease and efficiency, and the resulting deluge
of data is filtered to provide each user with the relevant in-
formation they need.
New technologies, unprecedented transparency and evolving sociocultural values are
opening up new business opportunities – but new risks as well. Who could have pre-
dicted, for example, that the success or failure of a company might one day hinge on
the number of “Likes” it is able to attract on Facebook.
We can feel the impact of these transformations on our private lives, but they’re also
influencing the way manufacturers design and automate their production processes.
B&R has earned its reputation as a pioneer in automation by carefully analyzing global
trends and harnessing the combined potential of the absolute latest hardware and
software technology to generate solutions that drive the digital industrial revolution.
Our international teams of industry experts have the experience and insight it takes to
infuse existing assets with the technology of tomorrow. Enabled by the convergence
of operational technology (OT) and information technology (IT) and achieved through
the OPC UA TSN communication standard – seamless connectivity is an essential fea-
ture of these solutions.
With B&R at your side, you’ll experience the digital age as an era of new connections and
transparent communication between your company, your people and your equipment.
Come join us at the SPS IPC Drives in Nuremberg from November 22–24 (Hall 7, Booth 206)
as we explore the digital world of automation. We look forward to seeing you there!
Happy reading,
Sebastian Sachse
Technology Manager, Open Automation

04
02
16
12
cover story
04 OPC UA TSN – Field-tested, field-proven
OEMs and system integrators have high hopes for OPC UA TSN.
B&R and its partners have now confirmed that it meets com-
munication requirements from the line to the ERP-level.
08 OPC UA is ready for real time
New extensions are bringing real-time capability to OPC UA.
Matthias Damm (OPC Foundation) and Sebastian Sachse
(B&R) tell us what this means for networked factories.
11 No access for unauthorized users
The user role system in Automation Studio makes it easy to
manage OPC UA permissions and prevent unauthorized users
from modifying data.
12 Safe Line Automation
Industry 4.0 demands modular, flexible production lines. The
combination of OPC UA and openSAFETY is B&R’s answer for
seamless safety throughout automated production lines.
report
28 Machines à la carte
Blow molding specialist 1Blow offers a flexible portfolio of
compact, energy-efficient machines and comprehensive
service it has developed with automation partner B&R.
36 The self-powered future
Using control technology from B&R, Provitec developed an
innovative concept based on photovoltaic power that
helped it achieve complete energy autonomy.
40 Standard vs. Proprietary
Switching from proprietary to standard pays off. A flexible
B&R controller allows Blech-Tec to integrate new functions
at considerably reduced development costs.
48 Don’t have a cow
When controller failure brought a feed mill to a halt, Weibel &
Partner got it up and running again quickly with solutions
from B&R.
54 The perfect atmosphere for innovation
Energy-efficient, environmentally-friendly building auto-
mation based on the B&R APROL DCS allows MB Telecom
employees to focus on their innovative R&D projects.
inhaltcontents

11.16 03
5840
32 48
featured topic: safety
16 One safety application, countless variations
Batch-size-one construction of series-produced machines?
Modularity makes it possible, but has proved problematic
when safety enters the picture. Until now, that is.
20 The key to keyless mode selection
HMI-integrated safe mode selection is poised to replace
the conventional key-operated selector switch with a more
efficient, more elegant solution.
24 Making time
To handle increasing demands for speed and flexibility in
watchmaking, Lécureux equips all new developments with
B&R automation technology.
technology
32 Maximum flexibility
With scalable hardware and software, it’s easier than ever
for existing systems to grow and adapt without compromis-
ing continuity.
44 6th
generation of top performance
Advanced automation demands flexible technology with
maximum performance. New Core i processors give B&R’s
Automation PC 910 more computing power than ever.
58 Keeping auto production in the fast lane
Together with experts from the automotive industry, B&R
has developed an innovative HMI device that offers signifi-
cant improvements for day-to-day production operations.
62 Mastering options in machine software
With market requirements changing rapidly and software
versions multiplying out of control, it’s time for a new ap-
proach to options management.
interview
52 Converging the worlds of IT and automation
Where is the overlap between Industry 4.0 and the Internet
of Things? Tony Shakib (Cisco), Stefan Schönegger (B&R) and
Marc Ostertag (B&R) speak about the potential for synergy.

cover story featured topic report technology interview04
OPC UA TSN
Field-tested,
field-proven

11.16 cover story featured topic report technology interview 05
OEMs and system integrators have high
hopes for OPC UA TSN. So far, those hopes
have been based on theoretical concepts
and technologies still under development –
but not any longer. Together with its
partner companies, B&R has proven the
ability of OPC UA TSN to meet communication
requirements from the line level up to
the ERP level under real-world conditions.
Over the past few months, B&R has performed intensive field test-
ing together with TSN network specialist TTTech. “The results are
impressive,” reports Sebastian Sachse, technical manager of
B&R’s Open Automation business unit. “In some aspects, OPC UA
TSN has even outperformed our expectations.”
Time-critical applications at the line level, such as synchroniza-
tion of conveyor belts with various other equipment, require cycle
times as low as two milliseconds. “We’ve gone even lower than
that on our test installations,” says Sachse. With jitter measure-
ments as low as 100 nanoseconds, the results were on par with
the best fieldbus systems on the market today.
Networks without borders
“The other impressive thing about our test installations is their
stability,” emphasizes Sachse. “After all, we’re working with tech-
nology so new that its IEEE specification hasn’t even been com-
pleted yet.” B&R’s test installations will soon join those of other
participants in the IIC’s TSN Testbed to examine the interoperabili-
ty of components on a multi-vendor OPC UA network with TSN. Oth-
er TSN Testbed participants included: National Instruments, Cisco,
Schneider, Bosch, GE, Intel and TTTech.
Low resource intensity
Pivotal criteria for practical OPC UA applications will be its code
size and resource requirements. “If OPC UA were only able to run
on powerful industrial PCs and controllers, use in machinery and
equipment would be out of the question,” explains Sachse. By im-

data to the network (publish) and every cli-
ent can receive this data (subscribe). This
eliminates the need for a permanent con-
nection between client and server, which is
particularly resource intensive.
B&R is actively participating in the OPC
Foundation working group developing the
specification for OPC UA’s publisher-sub-
scriber model. “I expect the specification to
be completed by the end of the year – and
rapidly implemented by many manufacturers
soon thereafter,” says Sachse.
OPC UA as a standard
The momentum behind the OPC UA move-
ment is evident in the number of standards
organizations basing their work on the ven-
dor-independent protocol. EUROMAP, the
leading developer of global standards for
the plastics industry, recently defined OPC
UA as the basis for two new EUROMAP inter-
faces, and more are on the way.
The umbrella organization for the packag-
ing industry, OMAC, will also be integrating
plementing OPC UA on a bus controller from
its X20 system, B&R has clearly demon-
strated the feasibility of I/O-level applica-
tions for OPC UA servers and clients. “It
proves that OPC UA is perfectly scalable to
any conceivable task at the line-level and
beyond.”
Reduced network traffic
With its bus controller implementation,
B&R has also tested an important new fea-
ture of the OPC UA specification. The pub-
lisher-subscriber (pub/sub) model plays a
key role in allowing OPC UA TSN to achieve
the necessary performance.
Until now, OPC UA has used a client/server
mechanism, where a client requests infor-
mation and receives a response from a
server. On networks with large numbers of
nodes, traffic increases disproportionately
and impairs the performance of the system.
The publisher-subscriber model, in con-
trast, enables one-to-many and many-to-
many communication. A server sends its
OPC UA into its PackML standard and is al-
ready working on specific implementations.
“It really is astonishing how quickly such
well-established industry standards are
now turning to OPC UA,” says Sachse. “The
performance demonstrated by our field
testing with OPC UA TSN confirms that
they’re moving in the right direction.”
The IIC and its TSN Testbed
The Industrial Internet Consortium (IIC) aims
to enable the intelligent networking of ma-
chinery, equipment and facilities. One of
the primary goals of founders GE, IBM, Intel
and Schneider is to accelerate adoption of
the Internet of Things (IoT).
To identify which technologies are best
suited to IoT applications, the IIC organizes
testbed groups, where these technologies
are evaluated on multi-vendor test instal-
lations. B&R has been an IIC member since
2006 and is participating in the TSN Test-
bed, where the combination of TSN and OPC
UA is being evaluated for the first time in an
industrial environment.
With a client-server mechanism, a client requests information and receives a response from a server.

OPC UA TSN
From a technical standpoint, it would cer-
tainly be feasible to add real-time capabil-
ity to OPC UA itself, but doing so would in-
volve considerable effort and would still
have disadvantages. That’s why a large
group of automation and robotics manu-
facturers have joined forces to move in a
different direction. OPC UA will take advan-
tage of Time Sensitive Networking (TSN).
TSN is a set of extensions currently in de-
velopment that will later be included in the
IEEE 802.1 standard. The goal is to provide
real-time data transmission over Ethernet.
A significant advantage of the TSN stand-
ard is that the automotive industry is be-
hind it. That means that the required sem-
iconductor components will be available
very quickly and relatively inexpensively.
The amount of data being transmitted in
automobiles has skyrocketed in the past
several years. Conventional bus systems
don’t have nearly the bandwidth to handle
it. The first step for the automotive indus-
try was adoption of the 802.1 AVB (Audio
Video Bridging) standard, which enables
synchronized, prioritized streaming of au-
dio and video files. This allows images from
rear view cameras mounted on the back
bumper to be transferred via Ethernet.
To pursue the goal of reaching new indus-
tries and broadening the spectrum of ap-
plications, the AVB working group became
the TSN initiative. The automotive industry
would also like to handle all control tasks
and applications that require functional
safety over Ethernet. For this to be possi-
ble, they will need cycle times in the re-
al-time range and deterministic network
behavior. These are the exact same re-
quirements faced in the automation of pro-
duction lines.
OPC UA TSN bridges the gap between the IP-
based world of IT and the field of factory
automation. OPC UA TSN is the perfect solu-
tion for all applications in factory automa-
tion. With sub-millisecond synchronization,
it offers sufficient precision for tasks such
as line synchronization, SCADA system inte-
gration, basic control tasks or even convey-
or belt operation and I/O integration.
With OPC UA extending its reach to the level
of line automation in the coming years, there
will be some dramatic changes to the archi-
tecture of machinery and equipment. It will
likely mean the end of factory-level field-
bus systems as we know them today.
With a publish-subscribe model, a server sends its data to the network (publish) and every client can receive this data (subscribe).
Sebastian
Sachse
Technology
Manager, Open
Automation
“OPC UA TSN has outperformed our
expectations.”

Interview
OPC UA is ready
for real time
Matthias Damm, head of the OPC Foundation’s pub/sub working group and Sebastian Sachse, technical manager of B&R’s Open Automation business unit,
explain the advantages of the OPC UA pub/sub extension for industrial networking.

Matthias, what’s the reason for developing
the pub/sub extension for the OPC UA
specification?
Matthias Damm: Today, OPC UA is fast – but
not deterministic in terms of automation.
For the applications where OPC UA is cur-
rently being used, the emphasis is on deliv-
ering data reliably without any loss of infor-
mation. When it comes to communication
between controllers, real-time capability
becomes much more important. With the
publish-subscribe model, data exchange is
a lot closer to what you get with a real-time
system. Combine the publish-subscribe
model with a real-time physical layer – Eth-
ernet with the TSN extension – and what
you get is real-time capable OPC UA.
What advantages does the pub/sub
extension bring to OPC UA?
Damm: Until now, OPC UA has used a client/
server mechanism, where a client requests
information and receives a response from a
server. With this approach, data is ex-
changed asynchronously and you run into
problems when the network has a large
number of nodes. The publish-subscribe
model opens up the additional possibilities
Until now, OPC UA has had its
limitations when it comes to
complex processes with
real-time requirements. That’s
why the OPC Foundation is
working on two extensions that
will give the OPC UA communi-
cation standard real-time
capability: time-sensitive
networking and the publish-
subscribe model. We sat down
with Matthias Damm, head
of the OPC Foundation’s pub/
sub working group, to find out
what these extensions will
mean for the future of industrial
networking. B&R introduced
its first pub/sub-enabled
product in the spring of 2016.
Sebastian Sachse, technology
manager of B&R’s Open Auto-
mation business unit, reveals
the company’s underlying
motivation.

of one-to-many and many-to-many communication. It allows de-
velopers to define a fixed time window in which the data is to be
exchanged – that’s one of the biggest advantages.
Sebastian, why has B&R chosen to get involved in the pub/sub
working group?
Sebastian Sachse: The OPC Foundation’s TSN and pub/sub working
groups have greatly accelerated the spread of OPC UA into industrial
applications. OPC UA is now entering into areas where cyclic com-
munication with real-time requirements is fundamental. B&R has a
lot of experience in these areas, so we saw a chance to make an
active contribution. By pooling expertise with other partner compa-
nies, we’re helping to create the best technology possible.
What impact will the OPC UA extensions have on the future of
industrial networking?
Damm: When you build a plant that includes machines with differ-
ent automation technology and fieldbus systems, it’s historically
been difficult to get them to work together at the control level.
Today’s model of OPC makes it much easier to implement commu-
nication across these multi-vendor lines.
So what’s the added benefit of the publish-subscribe model?
Damm: When you have a very large, decentralized architecture,
one-to-many and many-to-many communication gives you a huge
advantage in terms of speed. This is a fundamental requirement
for integrated systems such as packaging lines.
How far along is the pub-sub specification?
Damm: At the moment we have a stable draft version that includes
the majority of the definitions. In projects like this, it’s important to
have pilot implementations occurring in tandem with development
of the specification. At the Hannover Messe in April, we already
had various manufacturers presenting the first demo applications.
We expect the specification to be completed by the end of 2016.
And when will we be seeing the first products?
Damm: With manufacturers already prototyping as we develop the
specification, verification will go relatively quickly. I think it’s very
likely that we’ll see products hitting the market by early 2017.
Sebastian, B&R introduced the first pub/sub-enabled field device
for OPC UA at the Hannover Messe exhibition. Why are you working
on a field device so soon?
Sachse: As Matthias said, early implementation helps accelerate the
specification process. The practical experience gained on testing
equipment flows right back into the working groups and is incorpo-
rated into the specification. Getting to market early also gives us a
head start and allows us to serve our customers at a very early stage.
What kind of applications is the field device designed for?
Sachse: The bus controller is perfect for factory automation and
can be used there for almost any purpose. The new pub-sub model
distributes data particularly efficiently and allows connections to
the cloud via any Ethernet infrastructure. This is helpful whether
you’re retrofitting an existing plant or building a new one.
What development goals has B&R set for itself with regard to
OPC UA?
Sachse: OPC UA has already had a significant impact on the indus-
try and continues to spread quickly. In the short term, B&R’s prior-
ities are completing the specifications for pub/sub and TSN and
integrating them into relevant products. Beyond that, as OPC UA
conquers new areas of application, B&R will play an active role in
those developments as well. Essentially, we share the goal of the
OPC Foundation itself: To establish OPC UA as the open standard
for IIoT communication from the sensor to the cloud.
Are customers requesting additional OPC UA products?
Sachse: Our customers are fully on board with OPC UA technology
and are already designing machinery and plants accordingly. The
many new possibilities and functions it offers are inspiring new
ideas for potential applications. With our products, we’ll be help-
ing them turn those ideas into reality.
How hard is it to upgrade an existing OPC UA system with the
pub/sub extension?
Damm: If you have an OPC UA hardware or software implementation
without real-time requirements, the extension can be added by
simply updating the library used for the implementation – so it’s
relatively painless.

even possible to completely hide a node so
that it is invisible to members of a specific
role group. To make configuration even
easier, the rights of a parent node can be
inherited by its children.
User role system
A user is assigned one or more roles, with
additional protection provided by an en-
crypted password. The user role system
can also be updated during operation. This
includes, for example, assigning a user-
name and password to a new system oper-
ator. These functions are available directly
in the application program on the control-
ler using function blocks.
Security with certificates
In order to ensure secure and trusted data
exchange, digital certificates in accord-
ance with the X.509 standard can be used
in the OPC UA system. The Transport Layer
Security (TLS) subsystem in Automation
Studio and Automation Runtime support
the management of these certificates. Cer-
tificates can be displayed, created and
transferred to the certificate store on the
OPC UA server.
Easily and securely manage users and roles
in OPC UA
The new user role system in the B&R Auto-
mation Studio software development envi-
ronment simplifies management of OPC UA
access rights. This feature prevents unau-
thorized users from accessing an OPC UA
system, modifying data or performing cer-
tain actions.
Any number of roles can be defined, which
can then be assigned individual access
rights for each node. Typical access rights
include reading, writing or browsing. It is
News
No access for
unauthorized users
A user can be assigned one or more roles.

openSAFETY meets OPC UA
Safe Line Automation
Photo:iStock

or individual components from the machine network without hav-
ing to reprogram the safety application. “It would even be conceiv-
able to create a self-validating line,” says Kaufleitner.
To allow the safety network to self-organize – while continuing to
meet all the requirements for safety and security – there are a
number of measures that need to be implemented. “This is where
the particular advantages of OPC UA and openSAFETY really come
to bear.”
How it works
When a new piece of equipment – be it an entire machine, an indi-
vidual part or even a robot – is added to the machine network, OPC
UA security mechanisms begin by establishing a secure connection.
“In theory it is certainly possible to join machines from different
vendors in a single safety network,” explains Franz Kaufleitner,
product manager for integrated safety at B&R, “but doing so re-
quires an extensive amount of factory-floor programming.” Once
the line is up and running, any time you add, remove or modify
equipment, you would need to reprogram and recheck the safety
application. “That’s just not a viable solution in real-world condi-
tions,” says Kaufleitner.
High level of flexibility required
That’s why B&R is working on a concept that will open up a whole
new realm of solutions: self-organizing safety networks based on
OPC UA and the open source safety protocol openSAFETY. This
technology will make it possible to add or remove entire machines
Industry 4.0 demands modular, flexible production lines. While these qualities are being implemented
successfully at a functional control level, achieving comparable levels of flexibility in line-level
safety technology has so far seemed an insurmountable hurdle. With the combination of OPC UA
and openSAFETY, B&R aims to change that – providing seamless safety for production lines.
The combination of OPC UA and openSAFETY is B&R’s answer for
seamless safety throughout automated production lines.

Then the OPC UA discovery service and
server capability identifiers are used to
search for servers that offer safety func-
tions, after which OPC UA browsing services
identify the functions and corresponding
attributes available on each server. In this
way, any OPC UA server is able to obtain a
complete map of the network without re-
quiring a single line of code to be written.
“This process can already be implemented
using OPC UA,” notes Kaufleitner.
Automatic check
Next, the safety application checks whether
the new component is already known, or if –
with regard to safety – it matches a previ-
ously validated configuration. If so, there is
nothing else for the machine operator to do.
If significant differences are identified, the
user is asked to confirm via the HMI appli-
cation whether the new configuration is
correct. This input is saved, so the next
time the same configuration will be recog-
nized automatically.
Testing response times
“This is where openSAFETY comes into
play,” explains Kaufleitner. Each compo-
nent checks the plausibility of the configu-
ration. “This process is the same as the
checks that are generally performed when
a machine is started up.” This includes a
test of whether the response times and cy-
cle times are fast enough to ensure relia-
ble execution of the respective safety
functions. Once these checks have been
completed, exchange of safety-relevant
process data via openSAFETY begins and
the production line can resume operation.
Devices react automatically
As a minimum requirement for implementing
safe line automation, each device needs to
support openSAFETY’s E-stop profile. If an
E-stop button is pressed, all devices in the
openSAFETY network are notified automat-
ically. Each of them decides independently
whether to enter an E-stop state or if it’s
possible to continue running. “This would
be the case, for instance, if the event af-
fected a different E-stop zone.”
A linear profile is currently in development
that will allow individual components of the
machine or line to communicate directly
with their neighbors. If one machine com-
ponent enters a safe state, its immediate
neighbors decide autonomously whether
they need to enter a safe state as well, or
if they are able to continue running, possi-
bly at reduced speed. “All the components,
throughout the entire line, communicate
with each other without any intervention
from a higher-level system or operator,”
says Kaufleitner.
How does openSAFETY communicate via OPC UA?
The open source safety protocol openSAFETY can use any fieldbus or Industrial
Ethernet network as its transport medium. The black channel principle ensures
that openSAFETY data is transported completely independently of other traffic.
openSAFETY exchanges data using the OPC UA publish-subscribe model. As a
result, openSAFETY nodes can communicate with each other directly and
achieve extremely fast response times. Additionally, OPC UA method-calling
functionality is used transfer openSAFETY data via OPC UA in order to check the
plausibility of the safety application.
openSAFETY exchanges data using the OPC UA publish-subscribe model.

VALIDATED
VALIDATED
SAFE MACHINE
VALIDATED
VALIDATED
SAFE MACHINE
VALIDATED
VALIDATED
SAFE MACHINE
VALIDATED
VALIDATED
SAFE MACHINE
www.br-automation.com/Safety
VALIDATED
VALIDATED
SAFE APPLICATION
One safety applicatiOn,
cOuntless variatiOns
Modular machinery has unique requirements in terms of
safety technology. Master the multitude of options and
variants with an integrated safety solution from B&R.

Agile safety technology
One safety application,
countless variations
Batch-size-one construction of series-produced machines sounds like a contradiction.
With a modular design, however, OEMs are able to offer each customer a machine
tailored precisely to their needs at a competitive price. Unfortunately, this approach
has proven problematic when safety technology gets involved. Until now, that is.

special requests. Instead, they meet their
customers’ diverse requirements by offer-
ing each machine series with a variable set
of options. They’re able to do this by de-
signing the machines with modular hard-
ware and software.
From a safety standpoint, this unfortu-
nately means that each variant represents
an entirely unique machine that must be
tested, maintained and certified separate-
ly. This is both costly and time consuming.
On top of that, every changeover process
that is automated adds to the number of
axes and I/O modules required for the ma-
chine. “As you do this, the safety applica-
tion grows more and more complex,” ex-
The trend toward product personalization is
going stronger than ever. Automotive man-
ufacturers lead the way, allowing their cus-
tomers to pick and choose from a vast array
of features and options until their car is
virtually one-of-a-kind. Food and beverage
as well as sporting goods producers are
following suit with customization options of
their own. Producing these goods requires
machinery and processes with new levels
of flexibility that place heightened de-
mands not only on the hardware and soft-
ware, but the safety technology as well.
Modularity makes it possible
OEMs can’t afford to go back to the drawing
board for every machine just to satisfy
plains Franz Kaufleitner, B&R’s product
manager for integrated safety technology.
“For every machine function there is an un-
derlying safety function.” To be successful,
manufacturers of machinery and equip-
ment must therefore find a way to ensure
safety without undermining productivity.
Once-and-done verification
The only way to achieve this is to make the
safety application just as modular as the
machine control software. B&R has devel-
oped a solution that does precisely that –
built around a set of certified safety com-
ponents that includes user interface tem-
plates as well as function libraries and
services. The safety solution for a new

machine series begins in B&R’s universal engineering environ-
ment, Automation Studio, where this set of pre-certified compo-
nents is used to program a single, maximum configuration that
covers all of the options available for the machine. “This configu-
ration may include 100 safety nodes, even if any given machine
will seldom have more than 30 safe axes and I/O modules,” notes
Kaufleitner.
The safety application that corresponds to the machine’s maxi-
mum possible configuration only needs to be tested and verified
once. “This way, we cover all conceivable machine variants,” says
Kaufleitner, emphasizing the key advantage of B&R’s solution over
the traditional approach. He adds that “with conventional applica-
tions, each new machine configuration must be tested and veri-
fied individually.” The impact of this is particularly severe when it
comes to maintaining a multitude of safety applications. “With the
variety of options offered on today’s machines, maintenance
costs can quickly take on monstrous proportions,” says Kaufleit-
ner. In contrast, B&R’s solution leaves the OEM with only a single
safety application to maintain for the entire machine series.
Easily enable or disable machine options
Not only that, but working with this modular safety application could
hardly be easier. Machine options with safety functionality, such as
light curtains or safe drives, are simply selected or deselected in
the configuration file created for the machine’s maximum configu-
ration. This can be done by the OEM prior to delivery, or set up by a
service technician on the HMI screen during commissioning.
“Some of our customers have even integrated the generation of
this XML file into their order management system,” explains Kau-
fleitner. When the configuration file is copied to the safety control-
B&R’s modular X20 system facilitates the construction of series-produced machines with countless options and variants.
Safe communication with openSAFETY
The safety protocol is no exception. It, too, must support
the machine’s modular architecture. That’s why B&R bases
its safety communication on openSAFETY, which operates
over the real-time POWERLINK network.

ler, the system knows immediately which machine configuration it
is dealing with and which options are available. In this case, all the
on-site service technician has to do is confirm via the HMI screen
that the configuration matches the actual machine. “There’s no
longer any need for a safety programming tool,” says the B&R safe-
ty expert. “That’s unprecedented in our industry.”
Essential to this concept is the availability of a safety protocol
that supports a modular machine architecture. “That’s why we
base our safety communication on openSAFETY,” explains Kau-
fleitner, “which operates over the real-time POWERLINK network.”
To add a palletizer robot to a packaging machine, for instance, you
would need only a single network cable to create a safe connec-
tion offering up to SIL3 / PL e / Cat. 4.
Upgrade globally
With this solution, new machine options and the associated safe-
ty applications can be installed on site, anywhere in the world.
B&R safety functions are certified through internationally recog-
nized bodies such as TÜV Süd, Underwriter Laboratories (UL) and
Germanischer Lloyd (GL). This makes machines more flexible and
suitable for worldwide use, as well as reducing commissioning and
changeover times.
All the service technician has to do is install the new mechanical
component in the field and enable the corresponding configuration
option via the machine’s HMI panel. Alternatively, the machine
manufacturer can generate an updated configuration file and send
it to the customer on a flash drive along with the mechanical com-
ponents. The customer then simply installs the components and
runs the software update. “A machine builder in Germany can in-
stall a new function in India – safety technology and all – without
ever having to send out a field technician,“ illustrates Kaufleitner.
“With benefits like this, both OEMs and machine operators will find
that B&R safety technology makes life a whole lot easier.”
Once the safety application has been tested, the results are valid for all variants of the machine.
Franz Kaufleitner
Product Manager –
Integrated Safety, B&R
“Safety technology must not
undermine the productivity of
machinery and equipment.”

The key to keyless
mode selection
HMI-integrated safety

Today’s machinery and equipment increasingly requires
special operating modes for tasks such as setup, cleaning
and troubleshooting. Conventionally, key-operated selectors
have been necessary to prevent these modes from being
misused. Integration of safe mode selection into the HMI
application now offers a solution that is more efficient and
more elegant.

that is by disabling certain safety func-
tions,” notes Franz Kaufleitner, product
manager for Integrated Safety at B&R. As a
result, access to these operating modes
must be restricted to employees with spe-
cial training.
Adapting safety to special operating modes
“Until now, the only way to guarantee that
only authorized personnel are able to se-
lect special operating modes has been with
a key-operated switch,” explains Kaufleit-
ner. To prevent special operating modes
with reduced levels of safety from being
misused for normal production runs, spe-
cial operating modes generally involve re-
duced production rates or single-step op-
eration.
Today’s machinery and equipment fre-
quently requires a variety of special oper-
ating modes, each authorized for use by
specific personnel. These solutions would
traditionally require multiple key switches.
“In larger plants, you also need to have each
of these switches positioned in multiple lo-
cations,” adds Kaufleitner. The time and
cost involved in wiring the hardware – and
later in managing the respective keys and
authorization levels – multiplies quickly.
Integrated in the HMI application
“A much more elegant approach is to inte-
Plant operators and service technicians
use special operating modes to set up,
test or correct the behavior of a system.
Doing so requires them to open safety
doors and covers without immediately
stopping the machine. “The only way to do
Operating modes are selected conveniently on the HMI screen using the precoded and certified widget.
mapp Technology
The mapp software framework is comprised of modular blocks that handle basic
machine functions. Software developers can implement user management, alarm
systems or even control functions for motion axes with no more than a few clicks.
Relieved of these repetitive, low-level programming tasks, they can instead focus
their energy on implementing and optimizing the machine’s core value-adding
processes.
mapp components are fully networked and exchange data automatically. The au-
dit trail and user management components, for example, work together to log the
who, what and when of any changes to the system – without the developer having
to write a single line of code. Of course, the same now also applies to operating
mode changes made using mapp SafeOPTION.

where key switches can be an unwelcome
distraction. B&R has solved this problem
elegantly by integrating mode selection
into the HMI application.
grate mode selection into the HMI applica-
tion,” says Kaufleitner. Until now, there
hasn’t been a product on the market that
would permit such a solution. With mapp
SafeOPTION, however, B&R has finally made
it possible to safeguard input via the HMI
application without requiring dedicated
safety hardware.
Certified and approved
mapp SafeOPTION consists of a mode se-
lector widget for use in the HMI application
and a corresponding function block for the
safety application. “Both of these elements
are certified and approved for use in safety-
related applications,” says Kaufleitner. The
secure data exchange and confirmation
sequences this requires are completely
precoded.
As part of the mapp Technology software
framework, the widget is automatically
linked to the application’s user manage-
ment system. To integrate the widget into
the HMI application, all that remains for the
software engineer to do is link the operating
modes to text objects and the roles defined
in the user management system. Machine
operators can then authenticate their iden-
tity using a password, RFID tag or fingerprint.
Seamless user management
“The result is a seamless solution for con-
trolling all access to a machine or plant,
including its special operating modes,”
summarizes Kaufleitner. The need for key
switches is eliminated without any com-
promise in safety. mapp Technology offers
the additional option of logging and archiv-
ing all mode changes along with an exact
timestamp and user ID.
Technicians have to cover much less
ground when servicing particularly large
plants since they can set the operating
mode at any terminal rather than having to
walk all the way to the next key switch.
“These days you also can’t underestimate
the design aspect,” adds Kaufleitner. Mod-
ern machinery is more and more frequently
being subjected to strict design guidelines
Safe mode selection via the user interface works independently of the specific hardware used. Users are free to choose whichever B&R Automation Panel best suits
their needs.
The safety application runs on the SafeLOGIC con-
troller, which also monitors safe mode selection.

From its home in Biel, Switzerland, Lécureux supplies
the watchmaking industry with automated systems for
the assembly of watch movements. To meet steadily
increasing demands for speed and flexibility, the
company equips every new development, including
its modular AUTHOR assembly tables, with automation
technology from B&R. Nevertheless, CEO Daniel
Affolter is confident that manual watchmaking won’t
be disappearing entirely anytime soon.
Photo:iStock
Making time
Watch movement assembly

What does an aquarium pump have to do with watchmaking? More
than you’d expect, actually. Back in 1961, Bernhard Lécureux used
an aquarium pump to build the first prototype of a power screw-
driver – an invention that would soon become an indispensable
tool for the watchmaking industry. The young watchmaker had the
brilliant idea to convert the pump from his fish tank to function as
a vacuum and connect it to a specially constructed screwdriver.
The suction holds the tiny screws used to assemble the intricate
mechanical components of a watch – known as the movement – in
place on the tip of the screwdriver. With the addition of a small
motor, the electric screwdriver had been born. More than 50 years
later, it is still the flagship product of the Lécureux company,
which now has 100 employees around the world.
New AUTHOR table featuring B&R technology
In addition to its trademark screwdrivers, the Lécureux portfolio
includes complete lines able to assemble up to 1,000 watch
movements per day. Many of these began featuring B&R automa-
tion components in 2010.
Since 2014 this has included the AUTHOR series. This modular sys-
tem of watch movement assembly tables can be installed individu-
ally, as an island with multiple stations or as a complete assembly
line. Up to six lifting tools per table – or three per table when installed
as a line – bring the workpiece into position. Each year, Lécureux
delivers between 15 and 100 AUTHOR systems around the world.
Small modules, strong support
Prior to the cooperation with B&R, Lécureux had used a controller
developed in-house for the AUTHOR table. As the demands on the
controller grew in scope and complexity over the years, the com-
pany decided to tighten its focus on its core competencies and
seek an external controls supplier.
“When selecting the new controller, size was a decisive criteria for
us,” explains Affolter. “The equipment used to assemble watch
movements is very small, so we needed a supplier whose portfolio
includes very compact modules. The X20 controller from B&R of-
fers exactly that.”
According to Affolter, service also played a key role in the company’s
decision. With the nearby B&R office, technical support is always
close at hand. “At B&R, we’re not just a number,” says Affolter.
“They take our matters very seriously as a customer.” The compa-
ny’s positive experience with B&R dates back to an earlier project,
where a B&R was used for a specialty machine. “The decision to
head down this new path with B&R as our supplier for automation
hardware was an easy one.”
More speed, precision, convenience and flexibility
The transition to the new automation hardware went, well, like
clockwork. “We started off by sending our programmers to a very
well-organized seminar at B&R,” recalls Affolter. “They benefited
greatly from that and were confident developing software for the
new controller within a week. The few times we did run into trouble,
we were able to rely on quick and competent support from B&R.”
Lécureux customers have enjoyed the advantages of the new B&R
controller for several months now, with the new model offering a
The AUTHOR series of assembly tables built by Lécureux in Orpund, Switzerland can be installed individually, in an island, or – as pictured here – as a complete line
for manual or semi-automated assembly of watch movements.
Source:DanielChristen

considerable boost in speed and positioning precision as well as
improved data traceability.
Users of the new AUTHOR table also have access to a wider range
of configuration options. The AUTHOR system offers intuitive oper-
ation via a state-of-the-art HMI application running on a 7” B&R
terminal. Still, there’s no need for customers using the predeces-
sor model to worry: the generations are fully interoperable and can
be combined seamlessly.
X20 system: The heart and mind of the AUTHOR
Every station, whether manual, semi-automated or fully automat-
ed, is controlled and monitored by an X20 controller with two giga-
bytes of CompactFlash memory. The I/O modules are connected
via POWERLINK. B&R also provides the stepper motors and the cor-
responding controllers for the lifting tools. The stepper motor
module allows the winding currents to be controlled independent-
ly, which has a positive effect on energy consumption, thermal
stress and service life throughout the entire system. Individually
configurable values for holding, maximum and nominal current
provide maximum flexibility. A CAN interface makes it possible to
connect complex auxiliary devices.
Assembly still needs a helping hand
Although it would be possible to design a watch movement that
could be assembled on a fully automated line, Affolter is convinced
that the conventional design will continue to require human inter-
vention. “If you look at the gear train,” he says, “you’ve got two
gearwheels that don’t mesh, so they can be placed automatically.
The third gearwheel has to mesh with the first two, so it and the
bridge that goes over it are assembled manually. This takes a kind
of finesse that robots have so far been unable to imitate.”
Particularly in cases like this, where you have a direct hand-off
between automated and manual processing steps, a well-de-
signed safety solution is essential. A safety controller from B&R
gives the AUTHOR table safe input channels that can be used to
read digital signals in safety-related applications up to PL e / SIL 3.
The future of watch movement assembly
Watch movement assembly will continue to be shaped by the fac-
tors of flexibility, modularity, multi-caliber capability, retrofitability
and plug-and-play functionality. “B&R technology gives us the
flexibility we need to master whatever challenges the future
brings,” concludes Affolter. That’s why his company will be equip-
ping future projects and products with B&R controllers. When it
comes to installing the watch movement into the case, however,
automation is still out of the question. Although the mounting of
the face and hands could be automated with sufficient precision,
the marriage between movement and case is a matter watchmakers
prefer to take into their own hands.
With up to six different lifting tools per AUTHOR table, workpieces can be posi-
tioned quickly and precisely as needed for each assembly step.
Daniel Affolter
CEO, Lécureux
“B&R technology gives us the flexibility
we need to master whatever challenges
the future brings.”
A safety controller from B&R gives the AUTHOR table the safe input channels it
needs to read digital signals.

Blow molding
Machines
à la carte
Photo:iStock

The flexible portfolio of French blow molding specialist 1Blow allows custom-
ers to select exactly the functionality and service options they need. The
young company has earned rapid acceptance in markets around the world
with a design philosophy based on compact dimensions, energy efficiency
and comprehensive service – qualities it has developed with its automation
partner B&R.
Imagine heading to the concession stand
of a major sporting event to get a snack and
getting to watch a custom PET bottle
formed and filled with a new soft drink right
before your eyes. This impressive marketing
stunt is just one example of what you can
do with a compact blow molding machine
from 1Blow. The machine’s small footprint
allows it to be moved with a forklift and in-
stalled right where it is needed. Combined
with a filler, a 1Blow machine could produce
thousands of custom bottles each day of
an event.
Global markets take notice
Since its founding in 2010, 1Blow has al-
ready sold 52 machines all around the
world. The blow molder’s compact dimen-
sions and reliable operation have certainly
contributed to its success overseas. The
biggest advantage of the machines, how-
ever, lies in their flexibility. With five stand-
ard platforms that mold PET preforms up to
12 liters, the company offers machine
functionality à la carte.
Big names in the beverage market have
taken an interest in the innovative design
concept. Danone, for example, uses a
1Blow machine at its R&D center in Evian.
Coca-Cola uses 1Blow machines for its
markets in Africa, and a large cosmetics
group is currently exploring new packaging

ACOPOS P3 servo drive. With a housing no larger than a convention-
al single-axis drive, the three-axis P3 helps reduce the size of the
control cabinet by two-thirds and make 1Blow machines even more
compact.
“The central engineering platform allows us to reduce development
times and lower costs throughout the whole project lifecycle,” adds
Bernard, referring to the B&R Automation Studio software develop-
ment environment, which provides universal access to everything
from controls and drives to HMI and safety technology. “While ulti-
mately helping us move toward autonomy,” says Bernard, “B&R has
provided outstanding engineering support along the way.”
Green performance
1Blow’s all-electric machines highlight the company’s emphasis
on energy efficiency. Once a bottle has been blow molded, excess
compressed air is routed to a tank that feeds other functions re-
quiring lower pressure. Together with B&R, the company is cur-
rently exploring a solution to retrieve energy from the stretch rods
using the principle of regenerative braking. 1Blow machines also
feature an Eco program – which sets the machine into sleep mode
when there is no preform in position – as well as an ISO 50001-com-
pliant energy consumption metering card.
Integrated B&R systems have clearly proven their benefits in terms
of energy efficiency. At one customer, 1Blow ran a side-by-side
comparison, molding 750-milliliter bottles with its own 2-cavity
machine versus a comparable machine from a big-name compet-
itor. “Seeing the 54% difference in energy consumption really hit
home with that customer,” recalls 1Blow’s managing director
Benoît Sanchez.
solutions with a 1Blow machine. To handle the growing demand,
the company will be opening a testing lab for its customers by the
end of this year. “This secure R&D cell will include a pilot machine
for testing different molds and materials, as well as a grinder,”
reveals 1Blow’s sales director Olivier Perche.
Flexibility and more
1Blow machines already meet the primary demands of what has
been called “Consumption 4.0” – namely proximity, customization
and environmental friendliness. 1Blow’s versatile portfolio allows
customers to design machines that can mold complex bottle
shapes with handles or angled necks, bottles that can be filled
with hot liquid or printed directly at the machine’s outfeed.
But the young machine builder isn’t satisfied offering variety
alone. Looking to add ten-minute mold changeover times to its
repertoire, the company set out to find a partner for automation
and process control. At B&R, 1Blow found a specialist that shared
its focus on technological innovation. As one of the very first com-
panies to combine control, HMI and motion technology into a sin-
gle device, B&R’s products offer higher speeds, better reliability
and faster response times through seamless integration.
Integration and engineering
“Given the output rate of our machines, B&R offers the technologi-
cal benefits our customers are looking for,” says Fabrice Bernard,
automation engineer at 1Blow. “Moreover, we can have complete
control over every aspect of the automation system.” The fully inte-
grated B&R solution allows 1Blow to control the communication of
all machine components – a key factor when it comes to perfor-
mance optimization. Further optimization came with B&R’s new
1Blow’s blow molding machines have such a small footprint that they can easily
be moved with a forklift.
Step-by-step preventive maintenance via the touch screen uses pictures and
color coding to unmistakably identify parts and their replacement intervals.

Flexible maintenance
B&R has proven its ability to anticipate future trends like the inte-
gration of intelligent maintenance, fitting 1Blow molders with a to-
tally secure maintenance solution. Spare parts are displayed on the
touch screen in the form of photos, operators are guided through
step-by-step maintenance and troubleshooting and can browse
documentation using keywords and pictograms – features that
shorten the learning curve for beginners and temporary workers.
By integrating the new B&R remote maintenance solution into its
blow molders, 1Blow makes diagnostics and maintenance even
easier still. “Customers with a secure remote maintenance connec-
tion can choose to have us take over control or request preventive
remote maintenance,” adds Perche. “Essentially, we’re now able to
offer an á la carte service contract with our machines that accom-
modates any maintenance needs our customers may have.”
A bright future
B&R solutions help 1Blow react more flexibly to changing market
demands by making it easy to add options, such as a leak test fea-
ture to ensure optimum bottle quality. At the moment, the two com-
panies are working on a solution that will allow its machines to com-
municate with other blow molders or other equipment on the same
line such as secondary packaging machines or palletizing cells.
It is undeniable that the flexibility offered by B&R systems – which
has already won over major industry players like Krones and Sidel –
saves time and costs on the long term through more economical
operation and maintenance. With export sales accounting for 80%
of 1Blow’s turnover (€3.2 million in 2015), markets the world over are
clearly taking notice.
Olivier Perche
Sales Director, 1Blow
“As our single source automation partner for 1BLOW PET blow molders, B&R’s expertise in every
aspect of the automation system makes our machines reliable, fast and reactive – qualities
our customers really appreciate. B&R’s worldwide presence builds customer confidence and
contributes to the success of our export sales, which today represent 80% of our business.”
1Blow’s all-electric blow molding machines are equipped with a complete auto-
mation solution from B&R, including servo drives and frequency inverters con-
trolled via a POWERLINK network.

Scalable process control
Maximum flexibility
Photo:iStock

Process control technology is notorious for its complexity and rigidity. Expanding or adapting an
existing plant is often a costly and time-consuming ordeal. Systems with a scalable hardware
and software architecture are able to adapt to changing requirements with much greater flexibility
and without sacrificing system continuity.

includes more than a hundred ready-to-
use modules for a wide range of control
functions.” The smallest APROL automation
solution would consist of the system soft-
ware, an industrial PC and a few I/O mod-
ules. “Even with this minimal arrangement,
you have access to the full range of APROL
functions,” says Reichinger.
Since the price of the software license is
based on the number of I/O modules, cost
benefits can be achieved even on very
small systems. “If you expand the plant or
scale it up, you can carry over all the exist-
ing hardware and software,” he adds. Any
new hardware and corresponding I/O li-
censes are simply added on. “This is con-
siderably easier than the conventional ap-
proach, where you need a different system
at each step,” says Reichinger, highlight-
ing the benefits of B&R’s scalable solution.
Open to all communication protocols
APROL can also be coupled with existing
DCS and SCADA systems in large plants.
These plants generally incorporate compo-
nents from various vendors and use a vari-
Ever-shrinking time-to-market constraints
have many companies – particularly in the
chemical and pharmaceutical industries –
looking for new ways to make their plants
more agile and responsive. “Traditionally,
when a new product or changed recipe re-
quires implementation of a new process,”
explains Martin Reichinger, manager of the
Process Automation business unit at B&R,
“you find yourself at the beginning of a
long journey.”
From bench-scale to full-scale
It all starts with lab testing of the new pro-
cess on a small, bench-scale version of
the plant. This is then scaled up to a pilot
plant, where the process parameters are
optimized. Finally, the process is trans-
ferred to a full-scale plant where the prod-
uct can be mass produced.
“This process is essential to achieving op-
timal utilization of the expensive full-scale
plant, but consumes a great deal of time
and money along the way,” explains Re-
ichinger. One reason for this is that each of
the three steps often requires its own au-
tomation and process control technology.
“In extreme cases you end up rewriting the
software twice and swapping out the con-
trol hardware twice,” notes Reichinger.
The answer to this is a flexible hardware
and software architecture that grows right
along with the plant. B&R’s open APROL au-
tomation platform is a perfect example of
this. “With a B&R solution,” Reichinger ex-
plains, “the automation technology in a lab
system with only a handful of I/O channels
can easily be scaled up for a demanding
pilot plant and then again for full-scale
production with well over 100,000 chan-
nels.” Ultimately, this ensures maximum
return on investment for the system soft-
ware and hardware as well as for engineer-
ing work.
Cost benefits even for small systems
The APROL automation platform is based
on the Linux operating system and offers
all the functionality of a full-fledged dis-
tributed control system (DCS). “In addition
to core components like the alarm, graph-
ics, reporting and trend systems, this also
B&R automation hardware integrates optimally with APROL systems.

via the open Industrial Ethernet protocol
POWERLINK. B&R’s integrated safety tech-
nology can also be incorporated in the
APROL system to achieve safety response
times under five milliseconds.
Add user functions
APROL’s flexibility doesn’t end there. In ad-
dition to its ready-to-use solutions featur-
ing tested, documented and field-proven
standard control modules, APROL also al-
lows users to create their own copy-pro-
tected functions. By providing users with
the same development tool it used to pro-
gram its standard modules, B&R ensures a
consistent look and feel that gives users
maximum flexibility for implementing their
processes.
ety of communication profiles, fieldbus
systems and Industrial Ethernet protocols.
“That’s no problem for the APROL platform,
since it has interfaces for all the commonly
used communication protocols,” explains
Reichinger.
This openness makes APROL particularly
interesting for plant operators looking to
implement special solutions such as ener-
gy monitoring or condition monitoring. “For
these cases we’ve developed the ready-
to-use APROL EnMon and APROL ConMon
solutions,” says Reichinger. Assuming all
the necessary data can be obtained from
existing sensors, the only additional hard-
ware needed to set up a complete energy
monitoring system is an industrial PC run-
ning APROL. The reports, trends and alarm
system are automatically included, so
APROL EnMon and ConMon can be imple-
mented alongside existing DCS and SCADA
systems.
Modular functional expansion
The flexibility of B&R’s open automation
platform comes not only from its scalabil-
ity, but also from its modular design. “Once
you’ve set up an energy monitoring sys-
tem, you can easily add new functions at
any time – or even expand it into a full-
fledged distributed control system,” ex-
plains Reichinger, pointing to further ad-
vantages of APROL when combined with
B&R control hardware: “APROL users bene-
fit from the performance, robustness and
scalability of our control technology, which
exceeds what you’ll find in most DCS com-
ponents.”
B&R I/O modules have onboard intelligence
that allows them to compute fast Fourier
transforms directly and handle certain
open and closed-loop control tasks re-
motely in the field. The data is transferred
Martin Reichinger
Business Manager – Process Automation, B&R
“APROL can be scaled seamlessly from a handful of
I/O channels to well over 100,000 channels.”
An Automation PC 910 running the ready-to-use APROL EnMon solution is all you need to set up a full-fledged energy monitoring system.

Energy autonomy
The self-powered
future
The Energiefabrik includes three charging stations for electric vehicles. The charging schedule and power source
are selected and controlled automatically based on digitally stored travel plans.
Photo:FranzRoßmann

When the new office and workshop complex opened for business,
Provitec’s managing director Robert Endress suffered some sleep-
less nights. Called “Die Energiefabrik” (The Energy Factory, or EnFa
for short), the complex operates completely independently of the
public power grid – thanks to the innovative energy supply system
developed jointly by Provitec and builder-owner Friedhelm Wid-
mann. The boldly futuristic design of this system was what had
Endress on edge as the building began operation.
Yet, since the ribbon was cut in the summer of 2014, the building’s
supply network has yet to experience a single shortage or outage.
For both Widmann and the companies leasing space in the com-
plex, it’s not only the reliable supply of energy, but also the cost
savings that are decisive.
As low as 6 cents per kilowatt-hour
“With our design, a self-sustained energy supply system like this
has electricity production costs ranging from 6 to 20 cents per
kilowatt-hour, depending on the constellation of energy sources
used,” says Endress. “So in very many cases, it pays off even with-
out government subsidies.”
The Energiefabrik’s 350 square meters of workshop space and 600
square meters of office space are supplied with electricity, heat-
ing and cooling from 100% renewable energy sources. The energy
supply system is designed so effectively that it has no need for
backup from the public grid, making the energy not only environ-
If you have enough space for solar panels,
then – with the right design, networking
and control – you can take your energy
supply system off the public grid entirely
and enjoy a permanent reduction in energy
costs. Using B&R control technology,
Provitec has done just that. Its innovative
concept for electrically self-sufficient
buildings is perfect for logistics centers,
office complexes, retail stores and other
less energy-intensive enterprises.

mentally friendly, but also extremely inexpensive. Building owners
also avoid the fees and taxes that some countries charge for solar
power systems connected to the public power grid.
The right blend of sustainable sources
The building owes its energy autonomy to a custom blend of ener-
gy sources and storage media. The roof and facade are clad with
solar panels that deliver a rated output of 112 kilowatts (under
standardized testing conditions). Electricity that is not used im-
mediately is stored in a battery bank with a capacity of 400 kilo-
watt-hours. This covers approximately 80% of the building’s ener-
gy needs and stabilizes the supply of power.
During periods of insufficient sunlight, a biogas-fired combined
heat and power (CHP) unit with an electrical output of 40 kilowatts
kicks in. Three heat pumps are used to heat and cool the building’s
rooms. When the solar power runs low, thermal energy from the
CHP unit can be used for heating.
Located just north of Stuttgart in Neuenstadt, this innovative en-
ergy supply system produces enough surplus energy to feed three
charging stations for its fleet of four electric cars – at under 10
cents per kilowatt-hour.
Forecasted energy requirements
“Intelligent control of the individual components is essential to
the efficiency and effectiveness of the system as a whole,” em-
phasizes Endress. The ability to forecast energy supply and de-
mand based on meteorological data plays a key role here. As does
the evaluation of data from a project management system – which
makes it possible to turn off the lights and reduce the tempera-
ture in unused rooms. The system also uses business trip sched-
ules to coordinate the charging cycles for the fleet of electric ve-
hicles with the goal of optimizing utilization of the various energy
sources and avoiding bottlenecks.
Convergence of disciplines
“One of the biggest challenges of this project,” recalls Endress,
“was bringing together data from disciplines as diverse as building
automation, personnel management, weather forecasting and
ERP systems.”
The higher-level controller that manages the system has to com-
municate with numerous interfaces and data formats, allow data-
base connections and be able to handle certain tasks from the
control components. To solve these demanding requirements,
Provitec called on its extensive experience from dozens of auto-
In the main control room, an IP65-rated Automation Panel 900 with 8.5” multi-
touch screen serves as the operator interface for the Energiefabrik.
The Energiefabrik stores surplus energy in a battery bank with a capacity of 400
kilowatt-hours, which can then be tapped during periods of insufficient sunlight.
Photos:FranzRoßmann
Robert Endress
Managing Director, Provitec GmbH
“We’re convinced that the B&R solution gives us more technical possibilities than we would have
with the competition. Nevertheless, the biggest advantage is the quality of their service. With all
the difficulties that you’d expect to run into in the course of such a complex undertaking, B&R
never once failed to come through.”

mation projects as well as its experience programming and imple-
menting the Prodaisi MES system, on which it based the new
Proenergic energy management solution.
As the hardware platform for its database-intensive software,
Provitec’s engineers quickly zeroed in on the Automation PC 910
from B&R, an industrial PC that packs immense processing power
in a small form factor. For the higher-level controller, Provitec se-
lected a top-hat rail mounted CPU from the modular X20 system,
which manages various system components ranging from the
heat pumps and charging stations to the lighting. It communi-
cates via POWERLINK with three X20 substations that have a total
of 440 I/O points distributed throughout the building.
The operator panel in the control room is pendant-mounted on a
swing arm and is based on an IP65-rated Automation Panel 900
with 18.5” multi-touch screen and stainless steel housing. It is
also possible to control the system remotely via the Internet.
The right controller for any situation
“B&R’s control technology offers the openness and flexibility we
need to accommodate all our different interfaces and data for-
mats,” adds Endress. Yet that wasn’t the only reason B&R was
able to establish itself as the clear choice so early in the planning
phase. At least equally important was the effortless scalability of-
fered by the fine-grained portfolio of fully interoperable industrial
control modules. “It allows us to cover the full spectrum – from the
very simple to the highly complex.”
The automation expert also praises B&R’s integrated engineering
environment: “We’ve grown along with Automation Studio, so it
might be easy to take for granted how powerful it is and how much
it simplifies our work.”
Faster results
Endress appreciates the many details that contribute to stream-
lining the engineering process, such as an integrated web server
and SQL interface that give the controller direct access to data-
bases and ERP systems without the hassle of programming the
access from the ground up or purchasing it separately.
“We’re convinced that the B&R solution gives us more technical
possibilities than we would have with the competition. Neverthe-
less, the biggest advantage with B&R is the quality of their ser-
vice. With all the difficulties that you’d expect to run into in the
course of such a complex undertaking, B&R never once failed to
come through.”
Solar panels may be on the outside of the building, but they play a central role
in Provitec’s Energiefabrik concept for autonomous building supply. (Photo: Pro-
vitec GmbH)
Even on rainy days, the Energiefabrik’s energy supply system provides enough
power for a fleet of electric vehicles.
The control system based on B&R hardware uses weather forecasts to predict
energy requirements and select an appropriate mix of energy sources.

Renowned panel builder Berker and other users of the BT-150 are able to produce prototypes and
small batches of bent components faster and cheaper.
Standard vs.
Proprietary
Flexible control
Photo:BerkerGmbH &Co.KG
Switching from a proprietary embedded solution to a
control solution based on standard components pays off
even in a price-sensitive market. Blech-Tec demonstrat-
ed that with the second generation of its compact
bending machine for intricate sheet metal workpieces.
With its new controller – selected from B&R’s extensive
portfolio of industrial-grade solutions – Blech-Tec
benefits from considerably increased flexibility, is able
to integrate new functions with considerably lower
development costs and enjoys the support of a controls
partner with a strong global presence.

“Adding functionality to an embedded
solution is extremely expensive, if it’s even
possible at all,” notes Ralf Beger, Blech-
Tec’s founder and managing director. He
learned this lesson the hard way, having
selected a proprietary controller for the
first generation of the BT-150 small parts
bending machine back in 2005. At the time,
the hardware costs for this solution were
lower than for a standard PC-based con-
troller. Typical of embedded solutions,
however, the fixed functionality quickly be-
gan impeding further development of the
machine and generating unforeseen
costs – making it difficult for Blech-Tech to
enter new markets or even strengthen its
position in existing ones.
Proprietary has lost its cost advantage
Much has changed since then. It is now
possible to find standard components that
combine low hardware costs with a high
degree of flexibility. Leading the way is B&R
with its fully scalable portfolio of modular,
interoperable industrial control products.
Both the hardware and software elements
of the control solution can be trimmed to
fit the task at hand with no dead weight,
and expanded effortlessly when the time is
right.

That’s why, in 2015, Blech-Tec turned to
automation specialist B&R for the second
generation of its controllers. According to
Beger, the decision was influenced by more
than just technical criteria. “B&R had been
recommended to us emphatically by nu-
merous friends in the industry, who praised
their dependable hardware, reliable deliv-
ery and outstanding support. That’s what
ultimately tipped the scales for us.”
Maintenance-free controller with
custom design
Developed in close cooperation with B&R’s
experts, the BT-150’s new controller was
ready for action in no time. It is based on a
C70-series Power Panel with a 10.1” analog
resistive touch screen in portrait format.
Like all devices in this series, it is equipped
with an Intel Atom CPU, 256 MB DDRAM, 16 KB
FRAM and a 2 GB onboard flash drive. With
no hard drives, fans or batteries, C70-series
devices are entirely maintenance free. The
front side, featuring Blech-Tec’s custom
overlay design, offers IP65 protection.
Four 2-axis ACOPOSmicro modules are used
to control the machine’s eight stepper mo-
tors. The drive modules communicate with
the controller via X2X. “The new controller is
a much simpler construction than our em-
bedded solution,” Beger is pleased to report.
Even so, they have been able to integrate
decisive new features, which had previously
B&R smooths market entry
The fact that Beger is now getting his con-
trol components from a well-known suppli-
er helps clear the initial hurdles when en-
tering new markets. “Our users are happy
to see an internationally renowned compa-
ny handling our control components, be-
cause it means they can expect ongoing
innovations and a reliable supply of re-
placement parts anywhere in the world.”
Blech-Tec also contributed its fair share to
the international success of the BT-150.
After all, it allows users to form light-gauge
sheet metal without any specialty tools.
For prototyping and short-run production,
manual lever presses are still the tool of
choice. Typically, a separate tool insert is
produced for each bend, which is rendered
useless as soon as you modify the work-
piece or changeover to a new product. Un-
able to accommodate even minor adjust-
ments, this can be a costly and time-con-
suming way to produce small batches and
substantially altered prototypes. The foot-
print of the required machinery should also
not be underestimated. After all, a sepa-
rate manual lever press is frequently used
for each bend so that each workpiece can
be fully formed without having to swap out
tools.
Progressive stamping tools, on the other
hand, are only economical at higher produc-
not been possible due to the lack of flexibil-
ity and high development costs associated
with the embedded solution. Some of the
new features include remote maintenance
and data transfer via Ethernet and USB. The
ability to interact directly via the touch
screen rather than with hardware keys
makes the machine noticeably easier to
use. “Entering text is something that has
improved considerably,” says Beger. “Not to
mention that we’ve made controlling the
bending process itself more convenient.”
Language support for more effective
internationalization
Blech-Tec uses the graphics capabilities
of the Power Panel C70 to guide the user
through the bending process. The various
bending stations are displayed, showing
the user how the tools are installed and
which tool should be used for the next
bend. Other new features include monitor-
ing functions, such as an operating time
counter and an alarm history.
The greatly expanded language support
made possible with the new B&R solution is
a decisive advantage for the BT-150 on the
global market. “We used to have a limited
number of languages, which directly af-
fected the regions we were able to make
sales in,” explains Beger. Luckily, that is no
longer an issue. Blech-Tec has even begun
implementing Japanese and Chinese ver-
sions of its user interface.
The BT-150 is designed to form intricate workpieces out of sheet metal. A Pow-
er Panel C70 from B&R with a customized design provides control and HMI func-
tionality. (Photo: Blech-Tec)
Since the eight stepper motors in the BT-150 are controlled by four 2-axis
ACOPOSmicro modules, there is no longer a need for homing after a disruption or
product changeover. (Photo: Franz Rossmann)

tion volumes due to their high price. These
tools are also extremely inflexible, and can
only be used effectively once it is absolute-
ly certain that there will be no further modi-
fications to the shape of the product.
Prototypes and small batches without
high tooling costs
With the BT-150, parts can be produced
using standardized toolkits, eliminating
the preliminary step of making custom
tools. Changes in length and angle can be
fine-tuned, and even changes to the
gauge of metal being processed can be
accommodated without switching tools.
The BT-150 allows most bends to be per-
formed sequentially with no changeover. It
also ensures an extremely high level of re-
peat precision. Once a program has been
created, it can be reused quickly, easily
and reliably.
Berker is one of a growing number of inter-
nationally renowned companies that use
the Blech-Tec machine in their R&D depart-
ments. Manufacturers of power switches
used to have to die-bend their prototypes
in quantities of 1 to 250 out of stainless
steel and nonferrous metal in thicknesses
of 0.2 to 2 millimeters on a knuckle-joint or
screw press.
Today, around 75% of all bent components
can be created with a BT-150, and the
costly and time-consuming use of auxiliary
tooling is largely obsolete. That is also
what has made it an indispensable mem-
ber of Berker’s R&D team. Judging by the
large amount of interest that has already
been expressed in the machine with the
new controller, there will soon be many
more companies who can no longer im-
agine life without the BT-150.
The touch screen on the Power Panel C70 helped
Blech-Tec simplify operation and greatly expand
the range of supported languages. (Photo: Franz
Rossmann)
With its new controller, the BT-150 is now able to
show the user which station should be used to
make the next bend. (Photo: Krinner engineering
office)
Ralf Beger
Founder and CEO, Blech-Tec GmbH
“B&R had been recommended to us emphatically by
numerous friends in the industry, who praised their
dependable hardware, reliable delivery and out-
standing support. That’s what ultimately tipped the
scales for us.”

Automation PC 910
6th
generation
of top performance

An industrial PC is much more than just a
consumer PC in metal housing. With its ro-
bust construction, it is designed to oper-
ate 24/7 in a harsh industrial environment.
“These are precisely the requirements we
had in mind while designing our Automa-
tion PC,” says Raimund Ruf, manager of
B&R’s HMI business unit. “Robust, reliable
performance and guaranteed long-term
availability are our top priorities.”
With the integration of Intel’s latest Core i
technology, the Automation PC 910 is more
powerful than ever. The 6th
generation of
Core i-series processors are all multi-core
processors and have the graphics unit di-
rectly integrated in the processor.
Increased performance
“The fully modular design of the Automa-
tion PC 910 made integrating the latest
generation of processors nearly effort-
less,” explains Ruf. The initial rollout will
include a fanless Core i3 and a Core i5 pro-
cessor. The Core i5 now has four processor
cores and outperforms all of the Core i7
processors of the preceding generation,
while simultaneously offering reduced en-
ergy consumption. Up to 32 gigabytes of
DDR4 SDRAM provides fast exchange of
data between CPU and memory.
Modern HMI applications place high de-
mands on graphics performance. “In the
past, this has increasingly required instal-
lation of a graphics card in the industrial
PC,” reports Ruf. These drive up costs and
frequently need to be cooled by an addi-
tional fan. The graphics system integrated
in the new Core i processors is powerful
enough that a graphics card is frequently
no longer necessary.
Fully customizable
The specific features that a given OEM is
looking for in an industrial PC can vary dra-
Today’s most advanced automation solutions demand
flexible PC technology with maximum performance. Industrial
applications depend on robust hardware, reliable operation
and guaranteed long-term availability. With the addition
of 6th
-generation Core i processors to its Automation PC 910
portfolio, B&R now offers machinery and equipment builders
even more computing power for their most demanding
applications.

matically, so the devices need to be highly
customizable and configurable. The Auto-
mation PC 910 is available in three sizes
offering from one to five PCI/PCI Express
slots. Optional interface cards offer count-
less possibilities, whether you want to add
a third Gigabit Ethernet interface, connect
a fieldbus like POWERLINK or include an in-
tegrated UPS.
The Automation PC 910 also offers maxi-
mum flexibility when it comes to data stor-
age, offering solid-state drives, conven-
tional hard drives or compact CFast cards
easily accessed behind the front cover.
“We give the user 100% freedom to opti-
mize data storage,” explains Ruf. This al-
lows them to do things like isolate the op-
erating system from the process data.
Optimized cooling system
Fans are moving parts subject to wear,
tear, dirt and grime. A fanless device offers
huge advantages in an industrial environ-
ment. “By optimizing the convection cool-
ing, we have managed to offer the majority
of our Automation PC 910 variants without
fans,” says Ruf. Only the high-end systems
at the top of the performance spectrum
still require fan-cooling.
Here, the fan directs a stream of air right
through the integrated cooling fins to en-
sure maximum efficiency. As processors
shrink in size, heat is generated on a
smaller and smaller surface area. To deal
with this, heat pipes are the best way to
provide maximum heat dissipation. These
are hollow tubes filled with a liquid that
uses the processes of evaporation and
condensation to efficiently transfer large
amounts of heat away from a small sur-
face area. Heat pipes are very light and
take up very little space within the PC
housing.
Simple cabling
More and more often, groups of machines
are being integrated to form complex pro-
duction systems. These systems need
solutions in place that allow workers to op-
erate them efficiently and ergonomically.
This creates two challenges for machine
builders: Not only must data cover longer
distances between PC and operator panel,
the cables must also be compact enough
to be routed through swing arm systems.
B&R’s Smart Display Link 3 (SDL3) offers the
optimal solution to this challenge.
SDL3 transfers all the data over a single
cable. The ability to span up to 100 meters
allows for optimal placement of Automa-
tion PCs and operator panels, even in more
expansive systems. The standard CAT6/
CAT7 cables used for SDL3 data transfer
are particularly advantageous during ca-
bling. The slender RJ45 connector is easy
to feed through very tight spaces. This is
especially helpful when swing arm systems
are involved.
Like SDL, SDL3 transfers not only display
data, but also the communication chan-
nels for the touch screen, LEDs and keys as
well as service data such as the backlight
brightness setting. In addition, thanks to
the increased bandwidth of the integrated
USB connection, SDL3 now also transfers
USB 2.0 data. The SDL3 transmitter can be
integrated as an modular option with the
new Automation PC 910. The type of touch
technology being used doesn’t matter;
SDL3 supports both projected capacitive
multi-touch panels and analog resistive
touch screens.
Easy access to system information
“Automation PCs are open systems that
provide the user easy access to a wide
range of information,” explains Ruf. For ex-
ample, it’s possible to evaluate the tem-
perature behavior of B&R’s new box PC as
early as the implementation phase. It pro-
vides both internal component tempera-
ture values as well as measurements from
additional sensors. It’s easy to update the
firmware or software, or to upgrade the PC
or any connected Automation Panels.
Ruf also points to the interesting potential
for pairing B&R hardware with a unique ID.
The Automation PC 910 is available in three sizes offering from one to five PCI/PCI Express slots.

The ID can be checked to verify that the
software is installed on the intended hard-
ware and prevent unauthorized duplica-
tion. “This is a simple, yet highly effective
way to safeguard intellectual property,”
says Ruf.
Future-proof operating systems
Microsoft’s current operating system for
industrial devices is Windows 10 IoT Enter-
prise. IoT stands for ‘Internet of Things’,
and highlights Microsoft’s approach to
comprehensive connectivity, manageabili-
ty and easy maintenance.
The Enterprise version offers the same ba-
sic functionality as the consumer variant,
but with fewer restrictions with regard to
activation. Windows 10 will run perfectly
fine on an Automation PC 910, even without
an Internet connection to activate it. “This
simplifies things considerably for the user
compared to Windows 8. Exchanging hard-
ware in the field goes a lot quicker,” ex-
plains Ruf.
Preinstalled and activated
As always, B&R delivers its Automation PC
910 with the operating system preinstalled
and activated. While Windows 7 still came
in special embedded variants, Microsoft
has been using a different structure since
Windows 8. Windows 10 IoT Enterprise no
longer offers the scalable design of the
embedded variants that allowed them to
be adapted perfectly to the hardware for
very streamlined images. The memory re-
quirements have therefore increased to a
minimum of 32 gigabytes. “However, since
inexpensive CFast cards and MLC-based
SSDs are readily available for industrial
use,” continues Ruf, “we don’t view the
Windows 10 memory requirements as a se-
rious obstacle.”
Although the word ‘embedded’ has disap-
peared from the name, Windows 10 IoT En-
terprise continues to offer all of the most
important features you’re familiar with from
the old embedded versions, including Write
Filter, USB Filter and AppLocker. Win-
dows 10 also continues to support mul-
ti-touch panels without any additional
drivers.
Alternatively to Windows 10, B&R Automa-
tion PCs are also available with the Linux
Debian 8 operating system. In cases where
the Automation PC 910 is used as a power-
ful control system, the user can choose
between two versions of the real-time Au-
tomation Runtime operating system: Auto-
mation Runtime embedded or Automation
Runtime Windows. The multi-core archi-
tecture of the processors makes it possi-
ble to dedicate one core to execution of
control tasks while the rest run Windows or
Linux.
Raimund Ruf
Business Unit Manager - HMI, B&R
“The specific features that a given OEM will be looking for in an industrial PC can vary
dramatically, so the devices need to be highly customizable and configurable.”
In addition to the interfaces already integrated in
the Automation PC 910, modular interface cards add
a wide range of other options. Whether you want to
add a third Gigabit Ethernet interface, connect a
fieldbus like POWERLINK or include an integrated
UPS – the options are virtually endless.

After many years of operation, controller
failure brought a feed mill at Swiss animal feed
producer Landi Unterwalden to a grinding halt.
The engineers at Weibel & Partner found
themselves tasked with an emergency retrofit
to get the mill back up and running as quickly
as possible. Equipped with solutions from
B&R, the mill is now more productive than ever.
Don’t have
a cow
Emergency retrofit
Photo:iStock

that this would require. With the first, the
customer takes the time to define what
they want the new system to offer – things
like entirely new functions or a modern user
interface. This involves meetings between
retrofitter and customer to evaluate all the
possibilities.
The second approach is the route you take
when under time pressure to replace the
controller as quickly as possible. “On top of
the problem that there were no replace-
ment parts for the old controller genera-
tion, what you can’t underestimate is the
time-consuming task of getting existing
code to work with the new generation,” ex-
plains Baumann. Another challenge would
be getting the controller to harmonize with
essential equipment such as inverters and
closed-loop controllers, which would have
required too much additional programming
or simply been too expensive to replace.
Active in both food and non-food agriculture, Landi Unterwalden produces animal
feed at its facilities in central Switzerland.
With the help of his team and B&R products, Weibel programmer Oswin Baumann
(right) got the feed mill up and running again quickly.
Machines have a way of breaking down
when we need them most. That’s how it
seemed to Landi Unterwalden when its an-
imal feed production line suddenly ground
to a halt. The leaves were changing, and
livestock was embarking on its ceremonial
journey from alpine pastures back down to
the valley for winter – where it would ur-
gently need a reliable supply of fodder.
“It was the worst possible time for a failure,”
recalls managing director Albert Amschwand.
“Farmers from the area and surrounding dis-
tricts rely on us for fodder,” he explains.
“Failure to get the mill running again would
have forced them to look elsewhere, and we
would have taken a big hit financially.”
Turning to its suppliers for replacement
parts, Landi came up empty handed. The
mill had been built in the 80s and the parts
were simply no longer available.
B&R partnership based on quality
The engineers at Weibel & Partner are spe-
cialized in automation and process control
systems. Several of them have been work-
ing with B&R components for over 25 years
and have developed an exceptional level of
expertise.
“B&R does an outstanding job of managing
their components, and they’re the only au-
tomation specialist that offers the support
that I need as a programmer,” praises devel-
oper Oswin Baumann. “They’re also excep-
tionally innovative – it seems like they have
a solution ready and waiting for every new
technology that hits the market.“
Retrofit under pressure
Baumann faced the challenge of getting
the system up and running without access
to original replacement parts. There are two
possible approaches for the type of retrofit

a smaller footprint in the control cabinet, and
the software can be developed significantly
faster. “Since the components have gotten
smaller, we were able to install the new con-
troller without having to adapt the existing
wiring,” says Baumann. “Another huge ad-
vantage is that the new components have
full availability, so if we have another failure,
a replacement is immediately available.”
750 I/Os replaced in only 2.5 days
To minimize cost and effort, Weibel devel-
oped a converter based on B&R’s Automation
Studio software. Automation Studio provides
an integrated environment for every aspect
of a development project – from machine
and motion control to communication and
HMI – with a sophisticated architecture that
provides optimal support for users during
programming.
The converter allowed the majority of the
legacy software to be reused by converting
it from Instruction List to C code. “It reads
the existing program and translates it into
executable code,” says Baumann. The C
files generated by the converter can then
be added directly to the Automation Studio
project. This tool allows even first-genera-
tion B&R controllers to be replaced by new
ones quickly and easily. For Weibel, it
meant being able to replace and test 750
Compact powerhouse: the B&R solution saves considerable cabinet space.
I/O points and have them back up and run-
ning in only two and a half days.
Fit for the future
When a customer needs an old control sys-
tem replaced with identical functionality as
quickly as possible, the answer is a retrofit.
In addition to the financial benefits this of-
fers, the new controller generation also has
Oswin Baumann
Programmer, Weibel & Partner AG
“B&R does an outstanding job of managing its components. They’re
also the only automation specialist that offers the support that I
need as a programmer. They’re also exceptionally innovative – it seems
like they have a solution ready and waiting for every new technology
that hits the market.”

have important roles to play. The goal of Germany’s Plattform In-
dustrie 4.0 project is to conduct a very detailed examination of the
manufacturing process, to describe it – and ultimately to improve
it. This is some very important groundwork that will serve as a
foundation for many long-term improvements.
Tony Shakib: That’s actually the crux of it: Industry 4.0 deals pri-
marily with theoretical concepts, whereas the Internet of Things
is focused on practical applications. The testbeds operated by
the Industrial Internet Consortium (IIC) are a perfect example.
There you’ll find companies like B&R, Cisco and National Instru-
ments experimenting – under real-world production conditions –
with ways to implement technologies for the smart factory of
the future.
Marc, as president of the American subsidiary of a European auto-
mation supplier, where do you feel more at home: in the Internet of
Things (IoT) – shaped largely by the U.S. – or in the primarily
German-speaking world of Industry 4.0?
Marc Ostertag: First and foremost, I’m at home where my custom-
ers are. I think OEMs on both sides of the pond are driven by com-
mon ambitions – to optimize their processes, to expand into new
markets and to find new ways to solve their customers’ toughest
requirements, such as batch-size-one production. As an automa-
tion provider, what we’re concerned with are the nuts and bolts of
how to turn those ambitions into realities.
That’s where the concepts of Industry 4.0 and IoT come in.
Stefan Schönegger: Yes, and from our perspective, both certainly
Although Industry 4.0 and the Internet of Things (IoT) have long existed in relative isolation,
efforts to align the two concepts are now rapidly gaining traction. We sat down with
Tony Shakib of Cisco and Stefan Schönegger and Marc Ostertag of B&R to discuss the two
approaches’ similarities and differences – as well as the potential for synergy between them.
Interview
Converging
the worlds of
IT and automation

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