226 Designing Innovative Machines with Rockwell … reads and writes compared to Compact Flash ......

$: 226 Designing Innovative Machines with Rockwell … reads and writes compared to Compact Flash ... New Server Enablement on PanelView Plus 6 ... TS14 \226 Designing Innovative Machines$
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

Designing Innovative Machines with Rockwell Automation Mid-Range Architecture System

Prakash Balaguru

Solution Architect - South

11th Feb 2015

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 2

Agenda

Summary

Network & Information ready machine

Mechatronics overview

Midrange Portfolio

Critical Business Issues


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


Midrange-best out of cost & performance

Integration Continuum

Connected Components Mid-Range Solutions Advanced Machine Solutions

Low High

• 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

Components & Intelligent Motor Control Integrated Architecture

Broadest offering available for Machine Builder (OEM) needs


Midrange system overview

� CompactLogixTM5370 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


CompactLogix 5370 PACs Hardware Overview

~2x

Optional Device Level Ring (DLR)

� Faster CPU

Existing CompactLogix

5370 controllers

� 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


� 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




� 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



� 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


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 4’’-15’

� 4” & 6” is configured terminal.

� 7”-15 inch are modular terminal – Display &

logic module.

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PanelView Plus 6 400-1500

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Product Features PVP 400/600 PVP 6 Compact PVP 6 400/600 PVP 6 700-1500

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

(Email, 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

Y = Standard supported features, N = Unsupported featuresO = Optional supported feature set*Some features may be unavailable at initial release

Higher Performance and New Features


� 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� PVP6 700–1500 available today

� PVP6 400-600 available March 2013

� Variety of remote connection technologies, including terminal-to-terminal communication

Extend Customer Contentwith PanelView Plus 6

Improved w/ April 2012 Firmware

Knowledgebase Note 466394 – Click Here

Technology

FTP

VNC

ViewPoint


Midrange System - Servo drive

13

� Kinetix 5500 Servo Drive & VP Low Inertia

Motor

� 600 W to 15 kW Power range� Torque rating 0.4 - 31.5Nm� Common AC/DC bus� 195 – 528V AC input � Embedded safe torque off� Single cable with digital feedback


Midrange System – Drives & Software

� PowerFlex 525 AC Drives

� Power ratings of 0.4 - 22kW / 0.5 - 30 Hp

� Global voltage classes 100 – 600V

� Embedded safe torque-off

� Automatic Device Configuration

� Digital and Analog control I/O

� Embedded EtherNet/IP

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Midrange system – Reduce time to market

15

S88 Standard Program

S88 Standard Program

Face Plates

Single Program Enviornment


Mechatronics and Machine Design –Optimizing design

3D CAD Design SolidWorks

Control DesignRSLogix 5000

Motion DesignMotion Analyzer

Mechatronic design is a collaborative venture between mechanical, electrical, and control design engineers – the outcome is a machine design optimized for high performance controls

“synergy of several engineering disciplines…”


Rockwell Automation’s Mechatronic Offering

ProductsComprehensive motion offering including direct drive motors, linear stages, stacked stages, and electric servo actuators that deliver a superior mechatronic outcome

Virtual Design ToolsMotion Analyzer links mechanics with

controls. Analyze, optimize, simulate, and select in a virtual environment before committing to a final machine design

ExpertiseMechatronic support and services to augment your

existing design team

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.Copyri

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…

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 19

System Thermal ModelingEspecially useful for machine builders exporting to countries with hot weather.

Ratio Design AnalysisGuides designers to an optimized solution.

System Efficiency AnalysisHelps boosts machine performance and reduce energy consumption.

Motion Analyzer – Machine ExampleSystem Tolerance AnalysisProvides an insight into a machine’s ability to cope with change.

Emergency Stop AnalysisMaximize output without compromising safety

System Tuning SimulationHelps reduce design error and can save time during machine commissioning.

Lifetime EstimationSize an integrated linear stages and automatically get an L10 service life estimation.

Supply Voltage Tolerance AnalysisReduces chance of machine issues in the field that result in costly support.

3D CAD IntegrationDownload models of motion product and verify motion profiles at the mechanical design phase.

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.Copyri20

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

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]

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]


Midrange – Smarter Info ready

21

� 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”

3rd Party Device

3rd Party Device

3rd Party Device

Raw materials available

Production rate

EfficiencyOperating mode

Machine State

Alarm Status

Sustainability


Provides 1 to 1 IP address translations� Maximum 1 subnet and 127 single translations� Translations provided on uplink ports

� One or both ports for ring supportTranslation table is stored as part of switch configuration

NAT OverviewNetwork Address Translation

Line Controller

Send message to Machine 2 PAC at address 10.10.11.2

192.168.1.2 192.168.1.3 192.168.1.4 192.168.1.5

Machine 1 NAT Translation

192.168.1.2 = 10.10.10.2

192.168.1.2 192.168.1.3 192.168.1.4 192.168.1.5

Machine 2 NAT Translation192.168.1.2 = 10.10.11.2

Stratix 8300

Send message to Machine 1 PAC at address 10.10.10.2

REP

Cable break

Improve system uptime by adding a Ring using REP

Continue to send messages to Machine 1 PAC at address 10.10.10.2 when broken connection

Easily integrate machines into existing network architectures

Can help segment machine network from plant network


Network Hardening:Stratix 5900 Network Architecture

23

Enterprise-wideBusiness Systems Levels 4 & 5 – Data Center

Enterprise Zone

Level 3 - Site OperationsIndustrial ZonePhysical or Virtualized Servers

• FactoryTalk Application Servers & Services Platform• Network Services – e.g. DNS, AD, DHCP, AAA• Remote Access Server (RAS)• Call Manager• Storage Array

Levels 0-2Cell/Area Zones

Level 3.5 - IDMZ

Remote Site #1 Local Cell/Area Zone #1

Local OEM Skid / Machine #1

Plant-wideSite-wide

Operation Systems

Stratix 59001) Site-to-Site Connection

Site-to-SiteConnection

Stratix 59003) OEM

Integration

Stratix 59002) Cell/Area Zone Firewall

Cisco access switch


Summary

24

� 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 3rd 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.


Questions

25


Global SolutionsBringing you a world of experience

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� Consistent methodology deployed in all locations

� The right team for your project from our worldwide talent

� All major industries

� Any production environment

� Combining technology & application knowledge

� Based on PMI ® PMBOK®

� Certified project managers

� Repeatable, measurable, auditable

� Risk management

Domain

Expertise

Global

Execution

Information | Process | Discrete Automation | Power Motion | Sustainable Production | Technology Migration | Hardware Integration

80 Countries | 20 Languages | 2500+ Employees | Average 13+ Years Experience | Single point of contact

Project

Management

Helping you exceed your business goals


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226 Designing Innovative Machines with Rockwell … reads and writes compared to Compact Flash ......

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