Designing Innovative Machines with Rockwell Automation Mid-Range Architecture System

Transcription

1 Designing Innovative Machines with Rockwell Automation Mid-Range Architecture System Prakash Balaguru Solution Architect - South 11 th Feb 2015

2 Agenda Critical Business Issues Midrange Portfolio Mechatronics overview Network & Information ready machine Summary 2

3 Machine Builder Critical Business Issues (CBIs) More cost competitive machine (with improved performance) Reduce time to market (Ease of configuration, programming and training requirements) Optimize performance through design (But, Scalable) Increase competitiveness and enter new markets (Innovation & Smarter) Reduce Maintenance time & cost 3

4 Midrange-best out of cost & performance Components & Intelligent Motor Control Integrated Architecture Connected Components Mid-Range Solutions Advanced Machine Solutions Simple Connectivity Mechanical linked machine Stand alone machine Low cost Just enough control Multi axis motion Increased controller capabilities Mix of mechanical and electrical controls Low engineering costs Coordinated Multi axis motion Robotic Feeders Electronic Line Shafting Advanced connectivity Advanced information capabilities Low Integration Continuum High Broadest offering available for Machine Builder (OEM) needs

5 Midrange system overview CompactLogix TM 5370 Programmable Automation Controllers Scalability of the Logix family Dual Ethernet port 2 to 16 axis of integrated motion 80 to 960 I/O points Integrated kinematics functionality 1 or 2 G flash memory card (1 G shipped with controller) 5

6 CompactLogix 5370 PACs Hardware Overview Faster CPU Existing CompactLogix 5370 controllers ~2x Integrated Motion support (ERM models) Fully scalable motion solution with at least one ERM catalog in each series Up to 16 axis supported on unmodified Ethernet network Average 2axis/ms with 2x faster application program execution Support all motion instruction including Kinematics Optional Device Level Ring (DLR)

7 CompactLogix 5370 PACs Hardware Overview Dual Ethernet Port Linear/Star/Ring Topology capable Ethernet switch that supports Device Level Ring (DLR) allows user to connect the Ethernet network in a ring topology provides resiliency from loss of one network connection allows replacement of devices one at a time without stopping production (similar to star topology) includes ring supervisor capability (same as ETAP or 1756-EN2TR) reduces the number of Ethernet switches in the system which reduces cost Open socket capabilities up to 32 sockets available supports packets size of up to 500 bytes send using existing MSG command Modbus/TCP supported programmatically using sample code

8 CompactLogix 5370 PACs Hardware Overview USB Type B port USB 2.0 communicating at full-speed (12mb/s) Improved performance for flashing firmware, uploads and downloads, on-line edits, and bridging to the backplane Device only, not a host no ASCII communications via USB for ASCII applications use 1769-ASCII or 1769-SM2 or 1734 ASCII module no connection to visualization or other USB devices Connect to PC using a standard USB Type B cable Typical usage: Flash firmware Upload/Downloads Mode changes Bridge to the backplane Online edits Performance improvement for firmware flashing 15 x faster firmware flashing speed compared to serial ports

9 CompactLogix 5370 PACs Hardware Overview Removable Secure Digital (SD) memory card Industrially rated and certified Secure Digital card 1784-SD1 (1GB) Ships with controller 1784-SD2 (2GB) Faster reads and writes compared to Compact Flash Auto load of program upon power up New capabilities in the 5370 controllers Application/Project storage Firmware Supervisor Runtime tag data read/write Fault Dump during MNRF(Major Non Recoverable Faults) Battery-less Energy Storage Eliminates maintenance, transportation and environmental issues associated with lithium batteries Embedded in every new CompactLogix5370 controller

10 Midrange Product Portfolio PanelView Plus 6 Enhanced run-time performance and operator experience Reducing deployment time and costs New extensive graphics library Enhanced color animation capability Multi-language font library Granularity & 6 is configured terminal inch are modular terminal Display & logic module. 10

11 PanelView Plus Product Features PVP 400/600 PVP 6 Compact PVP 6 400/600 PVP FactoryTalk Machine Edition Y Y Y Y ViewPoint - TBD Y Y Memory RAM / Flash 64MB/64MB 256MB/512MB 256MB/512MB 512MB/512MB PDF Viewer - Y Y Y Active X Controls ( , DataStorePlus, Recipe) - Y Y Y Remote Terminal Control (Based on VNC) - Y Y Y FTP Server - Y Y Y Font Library (Inc. Arial Unicode) - Y Y Y USB device/client download port - Y Y Y Restore Factory Default Option - Y Y Y USB Audio Speaker *N *N Y MPEG Video playback - N O (6" Only) O Microsoft Office Viewers - N O (6" Only) O Microsoft Internet Explorer - N O (6" Only) O Remote Desktop Services - N *O (6" Only) O Higher Performance and New Features Y = Standard supported features, N = Unsupported features O = Optional supported feature set *Some features may be unavailable at initial release 11

12 Extend Customer Content with PanelView Plus 6 Improved w/ April 2012 Firmware Would productivity increase by allowing your operators remote access to terminal data from a remote location? New Server Enablement on PanelView Plus 6 supports two VNC client connections PVP available today PVP available March 2013 Variety of remote connection technologies, including terminal-to-terminal communication Technology ViewPoint VNC Knowledgebase Note Click Here FTP

13 Midrange System - Servo drive Kinetix 5500 Servo Drive & VP Low Inertia Motor 600 W to 15 kw Power range Torque rating Nm Common AC/DC bus V AC input Embedded safe torque off Single cable with digital feedback 13

14 Midrange System Drives & Software PowerFlex 525 AC Drives Power ratings of kW / Hp Global voltage classes V Embedded safe torque-off Automatic Device Configuration Digital and Analog control I/O Embedded EtherNet/IP 14

15 Midrange system Reduce time to market S88 Standard Program S88 Standard Program Face Plates Single Program Enviornment 15

16 Mechatronics and Machine Design Optimizing design Control Design RSLogix 5000 Motion Design Motion Analyzer 3D CAD Design SolidWorks synergy of several engineering disciplines Mechatronic design is a collaborative venture between mechanical, electrical, and control design engineers the outcome is a machine design optimized for high performance controls

17 Rockwell Automation s Mechatronic Offering Virtual Design Tools Motion Analyzer links mechanics with controls. Analyze, optimize, simulate, and select in a virtual environment before committing to a final machine design Products Comprehensive motion offering including direct drive motors, linear stages, stacked stages, and electric servo actuators that deliver a superior mechatronic outcome Expertise Mechatronic support and services to augment your existing design team

18 What Is Motion Analyzer? Prior to Motion Analyzer, sizing a servo system was manual process Slow Complex Error prone Rule of thumb based decisions Motion Analyzer automates the servo sizing process Fast Simple Accurate Fact-based decisions Design optimisation Copyri

19 Motion Analyzer Machine Example System Efficiency Analysis Helps boosts machine performance and reduce energy consumption. System Tolerance Analysis Provides an insight into a machine s ability to cope with change. Emergency Stop Analysis Maximize output without compromising safety System Thermal Modeling Especially useful for machine builders exporting to countries with hot weather. Ratio Design Analysis Guides designers to an optimized solution. System Tuning Simulation Helps reduce design error and can save time during machine commissioning. Supply Voltage Tolerance Analysis Reduces chance of machine issues in the field that result in costly support. 3D CAD Integration Download models of motion product and verify motion profiles at the mechanical design phase. Lifetime Estimation Size an integrated linear stages and automatically get an L10 service life estimation. 19

20 Benefits of a Mechatronic Approach Increased Machine Value The value of a machine is closely tied to it s ability to produce (PPM x OEE) Design optimization often results in increased machine throughput at no additional cost Sustainability Machine owners & operators are increasingly concerned with sustainability issues Efficiency analysis can help decrease energy consumption and reduce waste Greater Innovation Agility Offering a shorter lead time can often help win the order and even command a premium Virtual prototyping reduces the time to Design, Develop & Deliver Risk Mitigation Any design change carries an associated risk Simulation helps reduce risk by predicting the likely outcome of design changes before they occur Using this approach we can reduce our physical prototypes from 20 to around 2-3 and can trim hundreds of thousands of dollars from development costs [Leading packaging OEM] Finding & fixing design flaws late in the development cycle can cost 10 to 100 times what it costs to make changes early [Major tire OEM] Copyri 20

21 Midrange Smarter Info ready Production rate Operating mode Efficiency Stratix 5700 Industrial Ethernet Switch Six, 10, or 20 port managed switch SD card for device config storage Input/output alarms Fiber-ready SFP slots Configurable port security IT Standard Cisco Inside Machine State Raw materials available Alarm Status 3 rd Party Device Sustainability 3 rd Party Device 3 rd Party Device 21

22 NAT Overview Network Address Translation Send message to Machine 2 PAC at Send address message to Machine 1 PAC at address Improve Continue system to send uptime messages by adding to a Machine Ring using 1 PAC REP at address when broken connection Cable break Provides Stratix to 1 IP address REPtranslations Maximum 1 subnet and 127 single translations Translations provided on uplink ports NAT Translation One or both ports for ring support Machine = Translation table is stored as part of switch configuration Machine 1 Line Controller NAT Translation = Easily integrate machines into existing network architectures Can help segment machine network from plant network

23 Network Hardening: Stratix 5900 Network Architecture Enterprise-wide Business Systems Levels 4 & 5 Data Center Enterprise Zone Level IDMZ Site-to-Site Connection Stratix ) Site-to-Site Connection Cisco access switch Stratix ) Cell/Area Zone Firewall Plant-wide Site-wide Operation Systems Level 3 - Site Operations Physical or Virtualized Servers Industrial Zone FactoryTalk Application Servers & Services Platform Network Services e.g. DNS, AD, DHCP, AAA Remote Access Server (RAS) Call Manager Storage Array Stratix ) OEM Integration Levels 0-2 Cell/Area Zones Remote Site #1 Local Cell/Area Zone #1 Local OEM Skid / Machine #1 23

24 Summary More cost competitive machine Midrange architecture-high end solution in lower foot print Reduce time to market Sample code, Accelerated tool kit, single design environment, faceplate etc. Optimize performance through design Motion analyzer sizing, scalable architecture, scalable to 3 rd party device. Increase competitiveness and enter new markets Mechatronics products, Ethernet info ready machine, Network security. Reduce Maintenance time & cost Standard code, Remote diagnostics, ADC, Firmware supervisor, leverage global support. 24

25 Questions 25

26 Global Solutions Bringing you a world of experience Global Execution Consistent methodology deployed in all locations The right team for your project from our worldwide talent Domain Expertise All major industries Any production environment Combining technology & application knowledge Helping you exceed your business goals Project Management Based on PMI PMBOK Certified project managers Repeatable, measurable, auditable Risk management Information Process Discrete Automation Power Motion Sustainable Production Technology Migration Hardware Integration 80 Countries 20 Languages Employees Average 13+ Years Experience Single point of contact 27

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