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Automation Insights

Technical articles, tutorials, and industry news for modern automation engineers.

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Inside AutomationView Fault Injection: A Technical Guide to Validating PLC Edge Cases

AutomationView 
%%{init: {'theme':'dark', 'themeVariables': { 'background': '#001c38' }}}%%
flowchart LR
    A["PLC Sequence"]:::blue -->|Inject Fault| B["AutomationView Simulator"]:::green
    B -->|Analyze Response| C["Error Handling Logic"]:::red
    classDef blue fill:#2563eb,stroke:#1d4ed8,stroke-width:2px,color:#ffffff
    classDef green fill:#16a34a,stroke:#15803d,stroke-width:2px,color:#ffffff
    classDef red fill:#dc2626,stroke:#b91c1c,stroke-width:2px,color:#ffffff
AutomationView Icon AutomationView
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Inside AutomationView Fault Injection: A Technical Guide to Validating PLC Edge Cases

In industrial control systems, a single unchecked edge case can result in catastrophic mechanical failure or prolonged downtime. Validating that a Programmable Logic Controller (PLC) responds correctly to sensor failures, communication drops, and unexpected logic states is notoriously difficult in live production environments. AutomationView Fault Injection allows control engineers to deliberately introduce errors within a […]

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Inside Centrifugal Pump Efficiency: A Technical Guide to Hydraulic and Shaft Power Calculation

Calculator 
%%{init: {'theme':'dark', 'themeVariables': { 'background': '#001c38' }}}%%
flowchart LR
    A[Hydraulic Power Ph] --> B[Pump Efficiency]
    B --> C[Shaft Power Ps]
    C --> D[Motor Drive Losses]
    D --> E[Wire-to-Water Efficiency]
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Inside Centrifugal Pump Efficiency: A Technical Guide to Hydraulic and Shaft Power Calculation

Calculating centrifugal pump efficiency goes beyond plugging numbers into a formula. On the plant floor, operating away from the Best Efficiency Point (BEP) accelerates mechanical wear, increases vibration, and wastes significant energy. This guide details the rigorous methods for centrifugal pump efficiency calculation, focusing on hydraulic power, shaft power, and practical system performance. Understanding the […]

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Inside Enterprise HMI SSO: Architecting OAuth 2.0 and OIDC for SCADA Security

HMI 
%%{init: {'theme':'dark', 'themeVariables': { 'background': '#001c38' }}}%%
flowchart LR
    A[Operator] -->|Auth Request| B(OIDC Provider)
    B -->|ID Token + Access Token| C{SCADA HMI}
    C -->|API Calls| D[Historian / PLC]
    style A fill:#003c71,stroke:#fff,stroke-width:2px,color:#fff
    style B fill:#0055a4,stroke:#fff,stroke-width:2px,color:#fff
    style C fill:#0072ce,stroke:#fff,stroke-width:2px,color:#fff
    style D fill:#4a90e2,stroke:#fff,stroke-width:2px,color:#fff
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Inside Enterprise HMI SSO: Architecting OAuth 2.0 and OIDC for SCADA Security

Historically, securing industrial control systems meant relying on isolated networks and shared generic credentials like “Operator1” or “Admin”. However, as IT/OT convergence accelerates, this perimeter-based security model is no longer sufficient. To achieve true Zero Trust architecture in modern industrial environments, engineers must move toward centralized identity management. Implementing SCADA HMI SSO OAuth 2.0 and […]

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Mastering OPC UA PubSub over MQTT: A Practical Guide

Learning 
%%{init: {'theme':'dark', 'themeVariables': { 'background': '#001c38' }}}%%
flowchart LR
    subgraph ot_network ["OT Network"]
        PLC["Legacy PLC"]:::blue
        Edge["Edge Gateway"]:::green
    end
    subgraph it_network ["IT Network"]
        Broker["MQTT Broker"]:::red
        Cloud["Cloud Analytics"]:::blue
    end

    PLC -->|Modbus/TCP| Edge
    Edge -->|"OPC UA PubSub over MQTT"| Broker
    Broker -->|Subscribe| Cloud

    classDef blue fill:#2563eb,stroke:#fff,stroke-width:2px,color:#fff;
    classDef green fill:#16a34a,stroke:#fff,stroke-width:2px,color:#fff;
    classDef red fill:#dc2626,stroke:#fff,stroke-width:2px,color:#fff;
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Mastering OPC UA PubSub over MQTT: A Practical Guide

The gap between the plant floor and the cloud is closing, but moving data reliably remains a core challenge. Integrating OPC UA PubSub over MQTT offers a powerful solution, combining the structured data modeling of OPC UA with the scalable, event-driven messaging of MQTT. This architecture is quickly becoming the backbone of modern IIoT implementations. […]

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Inside PcVue 17: Reshaping SCADA Energy Optimization and Cybersecurity

Automation News 
%%{init: {'theme':'dark', 'themeVariables': { 'background': '#001c38' }}}%%
flowchart LR
    A["PcVue 17 SCADA"]:::blueNode --> B["EmVue Module"]:::greenNode
    A --> C["IEC 62443 Certification"]:::redNode
    B --> D["Energy Optimization"]:::greenNode
    C --> E["Cyber Resilience"]:::redNode

    classDef blueNode fill:#2563eb,color:#ffffff,stroke-width:0px
    classDef greenNode fill:#16a34a,color:#ffffff,stroke-width:0px
    classDef redNode fill:#dc2626,color:#ffffff,stroke-width:0px
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Inside PcVue 17: Reshaping SCADA Energy Optimization and Cybersecurity

Key Takeaways: The July 2026 release of PcVue 17 by ARC Informatique introduces the fully integrated EmVue module for AI-driven energy optimization. Dual certification to IEC 62443-4-1 and IEC 62443-4-2 standards provides an unprecedented level of cybersecurity for critical infrastructure. New cryptographic protection mechanisms mandate a structured migration path for legacy PcVue projects. The Drive […]

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Integrating AutomationView for Headless PLC Simulation via Docker

AutomationView 
%%{init: {'theme':'dark', 'themeVariables': { 'background': '#001c38' }}}%%
flowchart LR
    A[Git Push] --> B[CI/CD Pipeline]
    B --> C[Docker: AutomationView]
    C --> D[Headless PLC Simulation]
    D --> E[Test Report]
    style C fill:#0f4c81,stroke:#fff,stroke-width:2px,color:#fff
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Integrating AutomationView for Headless PLC Simulation via Docker

Key Takeaways: Running AutomationView in a headless Docker container removes hardware dependencies for CI/CD testing. Headless PLC simulation accelerates regression testing by spinning up isolated virtual runtimes. Integrating Python-based `pytest` scripts with containerized OPC UA endpoints ensures deterministic validation. The Shift Toward Virtualized Control Logic Testing Validating complex Sequential Function Charts (SFCs) on physical hardware […]

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Servo Motor Inertia Matching Calculator for Motion Control

Calculator 
%%{init: {'theme':'dark', 'themeVariables': { 'background': '#001c38' }}}%%
flowchart LR
    A["Load Inertia (J_load)"]:::blue --> C{"Inertia Matching Calculator"}:::green
    B["Motor Inertia (J_motor)"]:::blue --> C
    C --> D["Ratio (J_load / J_motor)"]:::red
    classDef blue fill:#2563eb,color:#ffffff,stroke-width:0px;
    classDef green fill:#16a34a,color:#ffffff,stroke-width:0px;
    classDef red fill:#dc2626,color:#ffffff,stroke-width:0px;
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Servo Motor Inertia Matching Calculator for Motion Control

When engineering high-speed motion control systems, one of the most frequent causes of instability and tuning headaches on the plant floor isn’t the PID loop—it’s the mechanical inertia mismatch. A Servo Motor Inertia Matching Calculator allows engineers to quickly determine if a chosen motor can actually control a specific load dynamically, preventing costly hardware redesigns […]

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How IEC 63303 Redefines State-Based HMI Display Strategies

HMI 
%%{init: {'theme':'dark', 'themeVariables': { 'background': '#001c38' }}}%%
flowchart LR
    A["IEC 63303"]:::blue --> B["HMI Philosophy"]:::green
    B --> C["4-Level Hierarchy"]:::blue
    C --> D["State-Based Displays"]:::green
    D --> E["Faster Response"]:::red
    classDef blue fill:#2563eb,color:#ffffff
    classDef green fill:#16a34a,color:#ffffff
    classDef red fill:#dc2626,color:#ffffff
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How IEC 63303 Redefines State-Based HMI Display Strategies

When an operator stares at 400+ process variables during an abnormal event, response time depends entirely on how the HMI presents information. IEC 63303:2024, published by IEC Technical Committee 65 in August 2024, provides the first international normative framework for IEC 63303 HMI design in process automation. It builds upon the established ANSI/ISA-101.01-2015 methodology while […]

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Inside NAMUR Open Architecture: Unlocking Field Data with a Second Channel

Learning 
%%{init: {'theme':'dark', 'themeVariables': { 'background': '#001c38' }}}%%
flowchart LR
  A["Field Devices"]:::blue --> B["Second Channel"]:::green
  B --> C["NOA Gateway"]:::red
  C --> D["M+O Domain"]:::blue
  style A fill:#2563eb,color:#ffffff
  style B fill:#16a34a,color:#ffffff
  style C fill:#dc2626,color:#ffffff
  style D fill:#2563eb,color:#ffffff
AutomationView Icon AutomationView
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Inside NAMUR Open Architecture: Unlocking Field Data with a Second Channel

Process plants generate vast amounts of diagnostic and secondary process data at the field level. Most of this data never leaves the instrument. HART-enabled devices, for example, transmit up to 35 additional variables beyond the primary process value, yet legacy DCS architectures typically ignore them. NAMUR Open Architecture (NOA) provides a standardized method to access […]

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Why Manufacturers Face MES Scaling Challenges in 2026

Automation News 
%%{init: {'theme':'dark', 'themeVariables': { 'background': '#001c38' }}}%%
flowchart LR
    erp["ERP System"]:::blue -->|Production Orders| mes["MES Platform"]:::green
    plm["PLM System"]:::blue -->|BOM & Recipes| mes
    mes -->|Real-Time Execution| ot["OT Systems (PLC/SCADA)"]:::red
    ot -.->|Production Data| mes
    
    classDef blue fill:#2563eb,stroke:#fff,stroke-width:2px,color:#fff;
    classDef green fill:#16a34a,stroke:#fff,stroke-width:2px,color:#fff;
    classDef red fill:#dc2626,stroke:#fff,stroke-width:2px,color:#fff;
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Why Manufacturers Face MES Scaling Challenges in 2026

While 93% of manufacturers have adopted Manufacturing Execution Systems (MES) to optimize their production floors, a staggering 72% still encounter severe MES scaling challenges when attempting to deploy these systems enterprise-wide. The primary roadblock isn’t the software itself, but rather the immense complexity of bridging the gap between high-level IT (ERP and PLM) and the […]

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How to Automate PLC Documentation Generation from AutomationView SFCs

AutomationView 
%%{init: {'theme':'dark', 'themeVariables': { 'background': '#001c38' }}}%%
flowchart LR
    A["AutomationView SFC"]:::blue --> B["Python Extraction Engine"]:::green
    B --> C["Automated Documentation"]:::red
    classDef blue fill:#2563eb,stroke:#fff,stroke-width:2px,color:#fff
    classDef green fill:#16a34a,stroke:#fff,stroke-width:2px,color:#fff
    classDef red fill:#dc2626,stroke:#fff,stroke-width:2px,color:#fff
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How to Automate PLC Documentation Generation from AutomationView SFCs

Key Takeaways: Manual PLC documentation generation is prone to errors and quickly becomes out-of-sync with production code. AutomationView allows engineers to auto-generate comprehensive specs directly from SFC (Sequential Function Chart) and Grafcet logic. Integrating Python-based extraction tools ensures a single source of truth for both code and technical documentation. The Challenge of Keeping PLC Specs […]

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Hydraulic Cylinder Calculator: Force & Speed Sizing

Calculator 
%%{init: {'theme':'dark', 'themeVariables': { 'background': '#001c38' }}}%%
flowchart LR
    pump["Hydraulic Pump"]:::blue -->|Flow Q & Pressure P| cyl["Hydraulic Cylinder"]:::green
    cyl -->|Force F| load["Industrial Load"]:::red

    classDef blue fill:#2563eb,stroke:#fff,stroke-width:2px,color:#fff
    classDef green fill:#16a34a,stroke:#fff,stroke-width:2px,color:#fff
    classDef red fill:#dc2626,stroke:#fff,stroke-width:2px,color:#fff
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Hydraulic Cylinder Calculator: Force & Speed Sizing

Key Takeaways: Accurate hydraulic sizing requires understanding both the full bore area (extension) and the annular area (retraction). Theoretical force output must be derated by approximately 10% to account for real-world seal drag and mechanical friction. Fluid velocity determines cylinder speed; neglecting pressure drops across valves can lead to slower-than-expected cycle times. Sizing fluid power […]

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