What contributions is automation technology making to the efficiency of machine and system manufacturers?

As a machine or robot builder automation professional, you've been hearing about open systems for years. But you have probably been frustrated if you tried to create an open automation system using components from competing vendors. However, it looks like the worm is turning as automation pros like you are using digital I/O networks as the wedge to pry apart proprietary controller-I/O bonds created by automation vendors.Digital I/O networks were originally created by automation vendors to answer customer demands for reduced wiring, faster troubleshooting, and easier modifications. Automation vendors made money because their more expensive digital products replaced discrete and analog components. Customers made money by taking advantage of the aforementioned benefits.Despite what they say in public, some vendors that make a wide range of automation products don’t like open systems. These vendors want to lock their customers into buying every automation component from them, and open systems are the enemy of that vision.All vendors had to jump onto the digital I/O network bandwagon for competitive reasons, and many initially did so by creating proprietary digital links. But competitive pressures forced them to adopt standard links, in particular Ethernet-based protocols. Doing this let the proprietary cat out of the bag and released the dogs of open I/O systems.

Many machine builder companies employ EEs and MEs, but just a handful of their employees are PEs. The PE label helps machine builder companies in the marketplace. However as companies expand and younger people are brought into the organizations, management faces differing opinions about cost, time and benefit of various certifications the company should or could have their degreed and non-degreed employees earn. The short list includes IEEE's Certified Software Development Professional program, ISA's CAP program and its CCST for technicians, and SME's CMfgE. We'd appreciate hearing what you, as a machine builder, think about the value of these or other programs.

Some automation specifiers tell us they have no choice. They have to buy from the big boys. For a variety of reasons, others just won't consider smaller companies. Is everyone this headstrong?

Read our November cover story "Can Small Vendors Play Big?"

When expanding out of panel building into more complex machine control builds, machine builders are encouraged to upgrade from old and basic electrical schematic software to a more integrated tool set. What are some of the important functions to look for in a good electrical CAD program including how to judge databases, training requirements, upgrades and support?

We experience the world in analog. When you see something with your eyes, for example, that is an analog experience. Analog has its merits, but when you’re garnering data from a machine operation, the application will dictate whether to go analog or digital. We live in a digital society. Decisions often are made to install a digital solution without giving the analog solution consideration because we assume that the digital meter is more advanced. When obsolescence of components becomes an issue, it might be a perfect time to decide what sort of display is best for your application.

 Read our Real Answers article How Much Information Is Enough?

The approaches to designing machines and the methods for building them are naturally as different as the machines themselves. So, when I researched and wrote Control Design's October cover story on modular machines, "Easier Pieces," I found many different levels of understanding about modular machine building. For example, some OEMs build more Lego-like machines, so they can work better within production lines. However, others don't need to plug-and-play multiple equipment because they only run one standalone machine in a small shop. Meanwhile, some builders are adding modular capabilities because their users demand them, while other aren't going modular apparently because their users aren't as demanding or perhaps because a few builders are ignoring their users. It can be hard to tell the difference between not having to innovate and not wanting to innovate or just being asleep. What do you think?

Well, maybe not Python, but how do you define a higher-level language? Is it based on how much the programmer is isolated from the actual code? Is it about a more-powerful control capability? There's little consensus on what a higher-level language is for more complex applications for discrete/machine control. Is it C#, C++ and scripting? Are there others in serious play? What can they do that 61131 languages, for example, can't? Does most automation supplier programming software use higher-level languages for some purposes?

Read our three-part story Higher Ground on high-level control languages and their design.

Data acquisition can serve many purposes. From machine diagnostics to exporting to an ERP system, the use of data is varied. What are your customers using it for?

Read our story Machine Data Acquisition Capabilities Grow.

No matter where you are, machine automation does the same thing, but different areas put different restrictions on those controls. Tell Machine Builder Nation how geography impacts the machine controls you choose.

Read our article Adapt and Go Global.