Automation · Industry is steering a course toward an optimised global-reaching standard that will...

InsideMedium-Voltage Drive Helps Water Provider Save on Energy Bills

Automation Enables Builders of Flexographic Machines to Achieve Higher Productivity

Two Key Safety Standards Are Merging

PowerFlex 527 AC Drives Simplify Machine Development and Use

Compac Sorting stays ahead of the pack

November 2015

Delivering

Data-DrivenPower

to Critical AssetsSee page 6

AutomationAutomationTODAY ASIA PACIFIC

Australia & New Zealand

CONTENTSEDITORIAL

Automation Today is published byROCKWELL AUTOMATION SOUTHEAST ASIA PTE LTD

2 Corporation Road, #06-01 Corporation Place,Singapore 618494

Tel: (65) 6622 5141 • Fax: (65) 6622 5100Editor: Victor Lim – [email protected]

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Copyright© 2015 Rockwell Automation Inc. All rights reserved. The contents of this publication may not be reproduced in whole or part without the consent of the copyright owner.

Allen-Bradley, ArcShield, Automation Fair, CENTERLINE, Compact GuardLogix, CompactLogix, ControlLogix, Dynamix, E300, FactoryTalk, GuardLogix, Guardmaster, IntelliCENTER, Integrated

Architecture, Kinetix, MP-Series, PanelView, PartnerNetwork, PhaseManager, PowerFlex, PowerMonitor, Rockwell Automation, Rockwell Software, RSLogix 5000, SmartGuard , Stratix 5400, Studio 5000, and Studio 5000 Logix Designer are trademarks or registered trademarks of Rockwell

Automation, Inc.

CIP, EtherNet/IP and DeviceNet are trademarks of the ODVA.

Trademarks not belonging to Rockwell Automation are property of their respective companies.Tom O’Reilly, President | Rockwell Automation, Asia Pacific Region

Intelligent Motor Control in The Connected Enterprise

Rockwell Automation has long served our customers in Asia Pacific. Today, we are seeing increased customer demands

about optimizing production, improving energy efficiency and exploring overseas markets. Rockwell Automation solutions supporting the Connected Enterprise – which integrates IT functions and plant-floor processes – can optimize production, create higher added value and improve global competitiveness.For example, Intelligent Motor Control solutions from Rockwell Automation are the foundation of an integrated manufacturing enterprise. These solutions provide the data from throughout the plant to help with decision-making. With the ability to quickly gather, organize and analyze information from your operations, Intelligent Motor Control devices allow you to maximize your asset availability and improve time to market.Whether the motors are fixed speed (using across-the-line starters or soft-start control), variable speed (from low-voltage and medium-voltage drives to complete engineered drive solutions), part of a servo-driven motion system, or part of a packaged solution, Intelligent Motor Control fully integrates motor control within the wider control system.Further benefits are gained by combining the advanced system-wide communication capabilities of Integrated Architecture® with the Intelligent Motor Control portfolio. This allows you to implement a single solution plant-wide to address the key market challenges of productivity, innovation, globalization and sustainability.The technology behind Intelligent Motor Control also can provide an impact on energy use. In variable torque applications, manufacturers can save up to 50 percent in energy consumption by replacing full-voltage starting with PowerFlex® drives, helping reduce speed by 20 percent. Intelligent Motor Control solutions also provide energy monitoring control and reporting tools that help companies model their energy profiles before committing capital expenditures for new systems or equipment.In addition, Intelligent Motor Control solutions can help mitigate risk and reduce downtime. For instance, Motor Control Centers with ArcShield™ technology and Safe Torque-Off functionality in drives demonstrate how Rockwell Automation helps to protect personnel and assets. Integrated Safety -- now available for the PowerFlex 527 AC drive and Kinetix® 5500 servo drive – helps streamline system configuration and provides ready access to safety faults and diagnostic data without additional contactors or relays.This issue of Automation Today Asia Pacific describes how the Intelligent Motor Control portfolio operating in the Connected Enterprise can drive faster time to market and improve decision-making. Learn how customers as diverse as Kia Motors Corporation and Thames Water have benefited from implementing innovative Intelligent Motor Control solutions. Integrated control and information solutions from Rockwell Automation can build seamless communication throughout manufacturing facilities, across enterprises and eventually with customers and the supply chain.Rockwell Automation is committed to developing and deploying open network technologies to integrate industrial systems with information systems. We believe this open approach will facilitate smart manufacturing throughout the region. Contact your local Rockwell Automation sales office to find out how we deliver the Connected Enterprise through our highly scalable Integrated Architecture system; world-class Intelligent Motor Control products portfolio; and a range of consultative, design, integration and support solutions and services.

3 News & EventsRockwell Automation developments from around the world.

4 Country NewsNews & events from around Australia & New Zealand.

6 Cover Story – Delivering Data-Driven Power to Critical AssetsIntelligent Motor Control from Rockwell Automation can extend to a new level of manufacturing intelligence – and power – to critical assets.

8 Event ReviewPowerTechED 2015 - motor control technology event.

10 Application StoryCompac Sorting Equipment stays ahead of the pack.

12 Technology WatchA single control platform and development environment help manufacturers reduce development time and cost.

14 Technology WatchIndustry is steering a course toward an optimised global-reaching standard that will help OEMs build safer, more competitive machinery.

16 Application StoryCAMA Group leverages single, unified platform to deliver simplified, high-speed solutions.

18 Technology WatchHarnessing the power of information.

19 Value PropositionBy using an integrated medium-voltage drive solution from Rockwell Automation, Thames Water creates a more resilient water infrastructure.

20 Product FocusRecent additions to the Rockwell Automation product portfolio.

Tom O’Reilly

2 November 2015 AUTOMATION TODAY ASIA PACIFIC

NEWS & EVENTS BRIEFS

The Connected Enterprise Boosts Smart Manufacturing

Throughout Asia Pacific, Rockwell Automation hosts various key industry events dedicated to industrial and information automation. The company, along with PartnerNetwork™

Members, recently presented Rockwell Automation® on The Move™ in China and Taiwan.

Rockwell Automation on The Move enables attendees to learn how smart, safe and sustainable solutions can turn their marketplace challenges into advantages. The event features hands-on labs, technical sessions, and product and technology exhibits.

In China, for example, Rockwell Automation on The Move attendees gained insight into The Connected Enterprise, a manufacturing strategy that integrates information and operations to improve productivity, sustainability and profitability to boost Smart Manufacturing. The Connected Enterprise builds seamless communication throughout a manufacturing facility, across the enterprise and eventually with customers and the supply chain.

Ken Kofsky, managing director of Rockwell Automation Greater China, points out that The Connected Enterprise is well-aligned with the Chinese government initiative of “Made in China 2025.” Kofsky says, “Rockwell Automation is committed to developing and deploying open network technologies to integrate industrial systems with information systems. We believe this open approach will facilitate Smart Manufacturing throughout China and will enable China to achieve its stated manufacturing goals in a rapid fashion. We deliver the realities of The Connected Enterprise today with our technologies, and we are proud to see our open technologies being used to help China achieve the promise of Smart Manufacturing.”

Taiwanese attendees of Rockwell Automation on The Move also learned about The Connected Enterprise – and its ability to integrate control and information for faster innovation and optimisation – as well as the Internet of Things (IoT). The IoT, an important element of The Connected Enterprise, refers to the billions of devices that can connect to the Internet and share data.

Accord ing to John Wat ts , Rockwell Automation marketing director of Asia Pacific, the need to achieve optimisation and enhance productivity at the supplier end will create opportunities for IoT applications. Rockwell Automation solutions and services can help original equipment manufacturers (OEMs) to realise the potential of design productivity and “reduce the overall cost of machinery design, development and delivery.”

NEWS & EVENTSRockwell Automation Named One of World’s Most Ethical Companies

For the seventh time, the Ethisphere Institute has named Rockwell Automation one of the world’s most ethical companies. This recognition honors companies that continuously improve ethical leadership and corporate behavior at every level of their organisations.

Keith D. Nosbusch, Rockwell Automation chairman and CEO, says, “Ethics and integrity are deeply rooted and ingrained in our culture. I’m proud of our employees who consistently do the right things, the right way, every day. They differentiate our company, giving us a competitive advantage.”

Also, Rockwell Automation recently reported that its 2014 Corporate Responsibility Report is now available online and in print.

For more information, visit www.rockwellautomation.com/about-us/sustainability-ethics/overview.page.

PartnerNetwork Program Grows in Asia Pacific

The Rockwell Automation PartnerNetwork™ program provides an integrated team of system integrators, machine and equipment builders, and best-in-class suppliers who work collaboratively to solve manufacturing and automation challenges. Encompass Product Partners help manufacturers quickly respond to industry changes and shifting market demands by making it easier to find the best-fit technologies that enhance, complement and extend Rockwell Automation solutions.

Ampcontrol, a global leader in electrical and electronic products for the mining industry, is a new Encompass Product Partner in Asia Pacific.

Two Encompass Partners, after expanding into the Asia Pacific region, have become Global Encompass Partners. Apex Dynamics manufactures and delivers high-precision, helical planetary gearheads. SMC Corporation manufactures pneumatic valve technologies for control network solutions.

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AUTOMATION TODAY ASIA PACIFIC November 2015 3

NEWSCOUNTRY

Students from around the world had 45 days to brainstorm, design, prototype, build and program a robot that put their mechanical, physics, programming and business skills to the test at the annual FIRST (For Inspiration and Recognition of Science and Technology) world championship. Held in St. Louis Missouri, the championship attracted more than 40,000 people and was the culmination of the 2015 FIRST season.

For the Australian teams, the journey to the Championship started at FIRST’s Australian regional competition held in Sydney in March. The first regional competition to be held in Australia was a huge success attracting participants from not only around Australia but also other countries including, Hawaii, Brazil, Taiwan, China and Singapore. This was followed by the regional competition in Hawaii where teams from Australia and around the world took part in the FIRST Robotic Challenge (FRC) regional event.

‘Recycle rush’, the 2015 game, was a recycling-themed game played by two alliances of three robots each. Robots score points by stacking totes on scoring platforms, capping those stacks with recycling containers, and properly disposing of pool noodles, representing litter.

Teams from FIRST Australia were excited to achieve some unprecedented successes in the world’s largest robotic event. The Macquarie University based team; ‘Thunder Down Under’ won

both the robot game and the overall Engineering Inspiration Award for outreach and community engagement in their division from a field of 76 robots representing the top FRC teams this year. This qualified the ‘Thunder Down Under’ team to play in ‘Einstein’, the elite grand final competition.

“To the best of our knowledge this is the best any team has ever done in divisional play. We are the first Australian team to get this far and the only international team to play for the grand final. We were eliminated in the quarterfinals but did not get the wooden spoon at this most prestigious level. Our performance made us one of only four teams from nearly 3000 total to receive a NASA sponsorship and an automatic berth at next year’s championship,” said Michael Heimlich, CORE Professor at Macquarie University.

“FIRST has really only been in Australia for about six years so to be able to play at the highest level (Einstein) really makes a statement about how far Australian FRC has come in a few short years,” he continued.

FIRST’s mission is to inspire young people to be science and technology leaders, by engaging them in exciting Mentor-based programs that build science, engineering and technology ski l ls , that inspire innovat ion, and that foster well-rounded life capabilities including self-confidence, communication, and leadership.

Rockwell Automation is a key global sponsor for FIRST and is committed to encouraging students to study a science, technology, engineer ing or maths (STEM) field at university. The program gives teams the opportunity to design and build mechanical , electrical and software controls systems, as well as integrate them all into one remote-controlled machine.

The FIRST program in Australia has really taken off in leaps and bounds.

Participants meet every Friday night and work through school holidays during the build season. The program encourages students to pursue education and careers in STEM-related fields, inspires them to become leaders and innovators, enhances their 21st century work-life skills and most importantly, the kids love being involved.

Katherine Allen, aged 17 years, FIRST participant and member of ‘Thunder Down Under’ commented, “Our team achieved more than we ever thought possible at championships.

Playing on Einstein was something that I thought I would only ever dream about. It was seriously cool to be standing on the floor of the dome, looking up at nearly 40,000 people, all watching you and your team’s robot. If someone told me five years ago that I would work on a robot in a packed football stadium, I would have told them that they were nuts!

I was down on the floor when the Engineering Inspiration award was announced. To be standing shaking hands with someone from NASA while watching the rest of my team join me on the floor was just incredible, an experience that I will never forget.” Katherine exclaimed.

FIRST Robotics Australia shares in the world Championship success


Katherine Allen receiving the Dean’s List Finalist Award, the highest and only individual student award presented.

Kosiusko robot, used by the Thunder Down Under team.

AUSTRALIA & NEW ZEALAND

Delivering a state of the art crushing and processing plant that incorporates the latest technologies in intelligent motor control.

Gordyn & Palmer are proud to announce their success in winning a prestigious Excellence Award hosted by peak Australian industry body the National Electrical and Communications Association (NECA) for their work in designing and constructing a new 600tph crushing and processing plant for Mountain View Quarries in Point Wilson, Victoria.

The award was granted in the industrial project category which may include, but is not limited to, undertakings of a civil, mining, high voltage, manufacturing or process nature where the contract value is greater than one million dollars and less than eight million dollars.

According to Terry Hickey, managing director at Gordyn & Palmer, “Our biggest accomplishment was bringing the latest technology in motor control to the forefront of the quarry industry while still maintaining a simple and intuitive user interface to allow operators to run the plant to its maximum potential.

The extensive electrical and software development completed in-house have resulted in a completely integrated system which is robust enough for the harsh environment it operates in and will serve the client for many years to come.”

The solution features the latest technologies in networked intelligent m o t o r c o n t r o l f r o m R o c k w e l l Automation including ControlLogix and the latest E300 Electronic Overload Relays, connected over an Ethernet communications network. The real time diagnostics are transformed into actionable information that allows for preventative maintenance to minimise downtime of the crushing and processing plant.

“Gordyn & Palmer should be congratulated on being early adopters of new technologies, they are at the forefront of the latest advances in technology. This project is an excellent example of how a completely integrated intelligent motor control system can deliver flexibility, reliability and maximised uptime,” said Rob Campbell, OEM account manager at Rockwell Automation.

Working closely with NHP Electrical Engineering, the distributor for Rockwell Automation, Gordyn & Palmer were the first in Australia to utilise the new E300 electronic overload relay. According to Nasser Hojok, automation sales supervisor at NHP, “Being one of the early adopters of the E300s proved to be a valuable investment in consideration of the benefits that it would bring to their customer. Gordyn & Palmer continue to be on the forefront of the latest technologies to help their customers maximise throughput with minimal downtime.”

This technology enabled motors to be accessed and configured remotely via both the plant network and a web interface replacing the former method of manually testing and configuring. The solution delivered a new level of diagnostics and meant that every motor across the site was connected via the plant network.

According to Ivo Rigoni, project engineer at Barro Group, “It is without reservation that we commend Gordyn & Palmer on a well-planned and managed project from design, supply, installation and safety management. Their experience with the requirements of a modern large scale quarry crushing plant has enabled them to deliver a plant that they should be very proud of. We have no doubt that as the end user, we will continue to appreciate the systems that have been put in place to assist with achieving maximum plant throughput with minimal downtime.”

The plant is now successfully producing over 600tph of blended aggregate and the finished product is highly functional, robust and boasts a state of the art control system putting it amongst the most advanced quarries in Australia.

“We’ve enjoyed working closely with Barro to deliver a plant that met and exceeded their expectations and look forward to working with them again in the future,” said George Boloutis, automation systems manager at Gordyn & Palmer.

Gordyn & Palmer wins NECA award for crushing and processing plant


Allen-Bradley MCC Control Panel featuring the E300 Electronic Overload Relays.

Today, manufacturers still face significant integration challenges when designing systems that use different control disciplines, systems and software. Bridging

the gap between the platforms can increase training costs, decrease productivity, lessen connectivity and reduce the ability to customise.

This is where Intelligent Motor Control from Rockwell Automation offers a distinct motor control advantage. By combining the advanced, system-wide communication capabilities of the Integrated Architecture® system with Intelligent Motor Control devices, companies can implement a single solution across their plant or machine portfolios, providing unprecedented access to contextual, meaningful asset information -- and driving real business value throughout an application’s lifecycle.

Efficient Motor ControlPremier Integration is a key feature of Intelligent Motor

Control. Made possible by Rockwell Software® Studio 5000 Logix Designer® software, this platform combines engineering and design elements in one common framework. It allows Logix controllers and Allen-Bradley® motor control devices,

such as PowerFlex® AC drives, to use a single, integrated environment for system configuration, operation and maintenance.

With the introduction of the PowerFlex 527 AC drive, Premier Integration has gone a step further. The PowerFlex 527 drive uses the same embedded motion

instructions as Allen-Bradley Kinetix® servo drives, so both can be programmed with Studio 5000® software through the controller using common techniques.

This approach eliminates address mismatch errors, simplifies commissioning, and eases machine synchronisation. Companies can also develop modular code and reuse it from project to project. Premier Integration is part of an efficient approach to motor control designed to drive a faster time to market.

Bridging Safety and ProductivityManufacturers must also be diligent in their training

practices and highly selective in their technology choices to improve workplace and machine safety. The good news: Intelligent Motor Control is making it easier with an expanded array of solutions designed to help mitigate risk and reduce downtime.

Providing remote monitoring solutions that separate personnel from high-energy equipment is just one of the ways in which Rockwell Automation helps to protect personnel and assets. Motor Control Centers with ArcShield™ technology and Safe Torque-Off functionality in drives are other examples.

Intelligent Motor Control from Rockwell Automation

can extend a new level of manufacturing intelligence

– and power – to critical assets.

Delivering

Data-Driven Powerto Critical Assets


Now, a new advanced type of safety – Integrated Safety – is available for the PowerFlex 527 AC drive and Kinetix 5500 servo drive. Utilising an Allen-Bradley GuardLogix® PAC on an EtherNet/IP™ network, this SIL3/PLe solution helps streamline system conf igurat ion and provides ready access to safety faults and diagnostic data without additional contactors or relays.

Improving Asset UtilisationAll industries are reevaluating business operating

procedures to minimise waste and maximise performance. Implementing strategic asset management, especially with motor-related assets, can deliver significant savings and improve overall equipment effectiveness.

Embedded diagnostics, a capability common across the entire Intelligent Motor Control portfolio, keep manufacturers informed on equipment performance such as load conditions, mechanical unbalance, process anomalies and more. Intelligent Motor Control can detect these conditions – and trigger manual or automatic intervention before equipment damage or unplanned downtime occurs.

And when a faulty Intelligent Motor Control device must be replaced, automatic device configuration helps quickly bring equipment back into operation.

For critical large rotating equipment, the Virtual Support Engineer™, a remote monitoring service, helps to keep PowerFlex medium-voltage applications up and running.

Increasing Energy EfficiencyThe technology behind Intelligent Motor Control –

including variable frequency drives, intelligent software and networked motor condition monitoring devices – can provide both an immediate and measurable impact on energy use and operational efficiency.

For example, replacing full-voltage starting with PowerFlex drives in a variable torque application can help reduce speed by 20 percent – and help save up to 50 percent in energy consumption.

Energy Intelligence provides another way to improve energy performance. IntelliCENTER® Motor Control Centers come preconfigured with FactoryTalk® EnergyMetrix software to enable the real-time energy monitoring you need to manage consumption down to the device level (see Energy Monitoring and Better Decision-Making sidebar).

From across-the-line starters, soft starters and drives to packaged power solutions, Intelligent Motor Control from Rockwell Automation can optimise a broad range of low- and medium-voltage applications. With Intelligent Motor Control, manufacturers are assured the data they need to help improve the performance of their motor-driven applications — and manufacturing intelligence to drive bottom-line results. AT

Energy Monitoring and Better Decision-Making

Intelligent Motor Control solutions provide energy monitoring control and reporting tools that help

slash energy consumption. Logix controllers provide a common collection point for data from Intelligent Motor Control devices such as motor controllers, switches and protective relays. The controllers work with the PCs running the human-machine interface and logging software to automate data collection and concentrate power monitoring data.

This approach enables companies to model their energy profiles by measuring peak demands and power quality parameters; determine demand patterns; correlate energy consumption to weather patterns; aggregate loads; and calculate energy costs by business group, department or site. Such modeling saves a significant amount of money because solutions can be verified before committing capital expenditures for new systems or equipment.

CENTERLINE® Motor Control Centers (MCCs) with IntelliCENTER® technology use built-in networking, pre-configured and tested software to enhance performance through system-wide communications, share diagnostic information for predictive maintenance and initiate warnings before potential faults occur. IntelliCENTER technology enhances the intelligence of an MCC using built-in networking to capture information used for predictive maintenance, process monitoring and advanced diagnostics.

By diagnosing the problem early and identifying where it is, production losses can be dramatically reduced. Unplanned downtime is cut to a minimum, and preventive maintenance can be scheduled to avoid further issues and downtime. In addition, reduced maintenance and increased energy efficiency help to achieve sustainability goals.

Energy savings, combined with data-driven technology that protects motors, enable higher motor performance and increases efficiency. This approach provides greater cost savings benefits and helps to support sustainable production programs.


As technology continues to advance at a rapid rate, fuelled by enabling technologies such as the Internet

of Things, leveraging new technologies to stay ahead of the competition is now more important than ever.

To showcase new trends and technologies in motor control, Rockwell Automation recently held the inaugural PowerTechED event on the Gold Coast. This educational event focused on the latest integrated MCC, safety and energy monitoring trends and technologies in an interactive learning environment.

PowerTechED featured hands-on labs, workshops and presentations, and attracted people from a wide variety of industries such as food & beverage and manufacturing through to mining and heavy industries.

“It was great to see the event so well attended with people from a variety of industries. There was a good mix of EPCs, system integrators, equipment builders and endusers, which provided a solid basis for networking and information sharing. As a result of the success of this year’s event, we will be taking PowerTechED to Perth in May next year, ” said Matthew Treeby, commercial marketing manager at Rockwell Automation.

Austmine’s ceo, Christine Gibbs Stewart, delivered an informative k e y n o t e p r e s e n t a t i o n , t i t l e d ‘Delivering New Value from Mining’. In the presentation she discussed the important role that innovation and technology plays to help increase productivity and also described the vision that the organisation is working towards to make Australia a global mining equipment, technology and services (METS) innovation hub.

“In today’s tough market environment,

companies need to be at the forefront of advancements in technology and innovation to be competitive. Power Te c h E D p r o v i d e d t h i s opportunity by bringing together key experts and s h o w c a s i n g t h e l a t e s t innovations in power and energy. The hands-on workshops gave participants a great understanding of new technologies, while providing practical examples of how they could be applied. Conferences like Power TechED greatly contribute to advancing industry development and technology dissemination,” said Gibbs Stewart.

PowerTechED was held in association with Rockwell Automation distributors, NHP Electrical Engineering and Rexel Industrial Automation. Both distributors displayed complementary products to the Rockwell Automation offering which provided attendees with a complete picture of how these devices can be connected together to deliver an integrated solution.

“In addition to our distributors, our Encompass Partners, Panduit and Prosoft Technology were also on hand to discuss specific applications. Being able to bring together all this expertise and equipment under the one roof provided our customers with an understanding of how these devices and solutions can work together to provide real business value,” said Rosanne Sabiston, business manager power control business at Rockwell Automation.

“Motors use up to 50 percent of the world’s energy consumption so naturally a key topic discussed at the event was energy management. Energy monitoring and efficiency technologies

are advancing their real time data capabilities and mobility, which provides the opportunity to leverage the intelligence that already exists in many ‘smart’ motor control and energy devices. This information can deliver real actionable insights to help optimise energy usage,” she explained.

Paul Brodie, principal at Brodie Engineering Services, delivered a practical keynote on the second day of the event that provided information about how to prepare an effective energy management plan. He discussed some practical examples detailing how measuring key parameters and analysing this data can provide significant energy savings to a plant.

“Intelligence was another key focus of the event as motor control devices are gaining improved integration and connectivity. Through interactive Ethernet networking and automation workshops, attendees were able to update their skills in this area and really see firsthand how leveraging real time data can help improve productivity,” said Treeby.

I n a d d i t i o n t o n e x t y e a r ’s PowerTechED event in Perth, there will also be a power-focussed stream at Rockwell Automation TechED in Auckland next March. AT

REVIEWEVENT

Rockwell Automation powers hands-on motor control technology eventPowerTechED showcased the latest integrated MCC, safety and energy monitoring technologies.


[email protected]

For more information, please visit psft.com/A5P

A S I A P A C I F I C | A F R I C A | E U R O P E | M I D D L E E A S T | L A T I N A M E R I C A | N O R T H A M E R I C A

Where Automation Connects

FeaturesBuilt-in Digital and Analog I/O

Secure VPN Tunnels over the Internet

Alarms and daily production reports by SMS

Program your machine from anywhere in the world

Need to get notifi cations when you’re away from the machine?

Fruit and vegetable equipment manufacturer Compac Sorting Equipment has established a

renowned, international reputation since it was established in 1984. The company has a track record in the development of leading edge technology and software.

As a market l eader in the development, manufacture and supply of smart produce handling solutions and equipment to packing operations around the world—Compac’s software and technology is continually under development and improvement to meet and exceed customer requirements.

However, the global market for fruit and vegetable manufacturing has become increasingly competitive. To

hold its position in the market, Compac needed to improve productivity by reducing time and costs associated with engineering disparate machine components.

The company engaged Rockwell Automation and NHP Electrical Engineering Products (NZ) Ltd to help streamline their machine engineering and design capabilities.

Established working relationship

Compac Sorting Equipment was already using some programmable logic controllers (PLCs) from Rockwell Automation and was familiar with the company and their technology. To improve productivity and maintain

their competit ive edge, Compac Sorting decided to call on the expertise of Rockwell Automation together with NHP to design a solution that would help to reduce time and costs associated wi th eng ineer ing disparate machine components.

“ To g e t h e r , w e worked with Compac

Sorting to understand

their challenges, which included implementing new technology and the need for local service and support,” said Prasad Nory, industry manager at Rockwell Automation. “We then worked together with NHP to design a solution for Compac Sorting centred on how we could streamline their machine engineering and design capabilities for equipment destined for New Zealand, Canada and the US.”

The solution comprised Micro85® PLCs, PowerFlex® 4M and 40 drives and industrial c o n t r o l g e a r. A c c o r d i n g t o Nory, the team demonstra ted t h e v a l u e o f t h e s o l u t i o n using Rockwell Automation and NHP technical r e s o u r c e s , i n c l u d i n g C o n n e c t e d Components Accelerator Toolkit and One-stop Sample Shop. They have also started using Micro820™ PLC’s for other smaller equipment applications.

O n e - s t o p S a m p l e S h o p i s a Rockwell Automation commercial program; through it , customers receive free product samples to try

STORYAPPLICATION


Compac Sorting Equipment stays ahead of the pack with Rockwell Automation solution

Rockwell Automation helps Compac Sorting improve productivity and reduce engineering costs

Typical Control Panel for a Compac Sorting Machine

in their application. The Connected Components Accelerator Toolkit helps OEMs reduce design overheads so they can instead concentrate on making their machine the best in the market.

“This is a low risk and easy option for customers to try our component products like small PLCs, industrial control and safety products,” said Nory. “Through these programs, detailed discussions and a successful field trial, Compac realised the value of our Connected Components solution.”

According to Baden Crabb, senior electrical engineer at Compac Sorting Equipment, “It’s been really good working with Rockwell Automation, they support their product by providing plenty of training and support.”

“In addition, being able to ‘try before we buy’ was very beneficial, allowing us to see firsthand how the products work and could add value to our solutions,” said Crabb.

Simpler and faster machine building

OEMs and machine manufacturers are facing a wide variety of technological trends in what is a revolutionary era for industrial automation based in motion control, communications and intelligent vision systems – all of which can significantly help improve machine performance and processes.

In particular, the packing sector has gone through a strong technological revolution as new technology provides the ability to offer higher performance and increased productivity. To maintain their position as a global leader in post-harvest solutions, Compac Sorting invests in cutting edge technology to deliver high performance sorting and packing solutions for the fruit and vegetable industry.

The C onnected Com ponent s Accelerator Toolkit helps companies reduce machine design time by providing guidance for the entire machine control application development. It allows OEMs to concentrate on the intellectual property that produces compelling and differentiating machine features.

“The Connected Components Workbench Software is one of the reasons we decided to use the Micro800

series of PLCs; it’s powerful, and code can be written in ladder, function block diagram or structured text,” said Crabb.

“The Micro820s are great for applications with low I/O requirements and one of the very few PLCs on the market that provide great value, delivering Ethernet capabilities and serial modbus control of variable speed drives. The scan time is about three milliseconds in our application which is very fast,” he said.

The Co nne c te d Co mpone nts Workbench software offers controller programming, device configuration and integration. In addition to the many existing function blocks that are available, the software also has advanced encapsulation abilities with function blocks that are simple to create and then use in the graphical function block diagram programming environment.

“Micro820 is gaining popularity among small machine builders, providing a cost effective automation solution. It delivers sufficient control for small applications with Ethernet capability,” said Nory.

“The Connected Components Workbench Software being a free download enables the operation and commissioning team to carry a copy with them to site. This increases the flexibility and enables quick response to

issues onsite for the machine builders and provides a better service to their end users,” he said.

Wide-spread benefitsReduced engineering times together

with the flexibility to handle different requirements are the key benefits of the solution. In addition, Compac has also seen the benefits of having a single software package for configuring the drives, PLCs and safety components. The new solution is module and scalable to meet varying plant requirements.

According to Crabb, “The training and support provided by Rockwell Automation and NHP for the Connected Components Workbench Software helped us to convert the code in-house with the help of their support divisions.

Now entirely commissioned and installed at various Compac Sorting sites, the equipment manufacturer is winning more business as a result of the cost-effective solution.

“We’ve used this gear on about 50 projects so far and it has allowed us to reduce our engineering time by as much as 80 percent. Having non-licensed software is a real advantage for us, allowing us to distribute it to all our service technicians around the world. We’re now able to produce control systems much more quickly with the same amount of staff,” said Crabb. AT


Micro820™ Programmable Controllers are designed for small standalone machine control and remote automation applications

The vast, ever-growing demand for commercial and industrial packaging and labeling products

has created an enormous business opportunity for machine builders worldwide. The global markets for package printing – only involving pliant materials such as foils, films, paper or flexible sheeting to form a container – increased in 2014. In 2015, the growth rate is expected to climb, so it is easy to see why machinery builders are demanding innovative automation and control solutions capable of meeting their customers’ precise performance, accuracy and time-to-market requirements.

Flexography, or flexo, is a key process used in the package printing market. Flexo gets its name from the requirement that the printing plate surface maintain contact with the web (paper, nonwovens or film), which it does by being flexible. The method is commonly used on flexible packaging, cartons, shopping bags, food and hygiene bags, self-adhesive labels and wallpaper.

The Flexo Printing ProcessA multi-station flexographic printing

press is designed to precisely apply water-based or ultraviolet (UV) ink droplets from an anilox roll to a plate roll containing the image. The image is then transported to the substrate via contact with the impression roll. The ability to apply a dot of ink precisely onto another dot of ink is what defines

color print registration and determines whether something is in focus to the human eye. It’s an important measure of quality on the finished film, paper or carton.

A typical multi-station flexographic printing press consists of the following sections: • Dual Tension Unwind keeps the

web under precise tension control and velocity regulation through the infeed pacing section of the press.

• Infeed transports the web and isolates the tension before presenting the web to the first print deck.

• Print Deck (the first print deck station) applies a printed registration bar to the web as well as the first color. Subsequent print decks individually apply colors one at a time using the printed registration bar for guidance.

• Outfeed follows the last print deck and isolates the web once again with precise tension control and velocity regulation.

• Converting sections are modules for die-cutting, punching, embossing, trimming or slitting the web prior to rewinding the product and are common post-processing operations.F lexographic pr in t ing o f fers

numerous advantages. First, the plates are inexpensive to make and are disposable, accommodating the frequent end-user changes common with packaging printing. Second, plates are mounted easily on the machine. Third, flexo printing produces quality images.

Flexographic printing does offer some

challenges. For example, nip pressure can distort the flexible plate material, thus affecting the image quality. Also, pressure control is very important. Even with good control, plate material wears faster than with other technologies.

Market DriversIncreasing competitiveness and

market pressures are causing converters to demand more flexibility, higher productivity, better yields and less waste from their converting machinery investments. This is a challenge, as press machine builders are already approaching 750 to 1,200 feet/min (229 to 365 m/min) web speeds and maintaining +/- 0.002 to 0.005 inch (0.05 to 0.13 mm) print registration tolerances. They’re also keeping scrap to the length of the full press plus one print deck during machine make-ready. Web throughput will continue to increase as new drying system technologies are designed.

To meet changing styles and packaging requirements, end users are seeking machines with interchangeable sections and variable-size print roll sleeves. Since flexible packaging and label print images, unlike newspapers or magazines, vary widely in size as well as in substrate and material requirements, the ability to quickly change machine sections or roll size is critical.

OEMs must meet additional end user requirements such as: • Compensation for gear-marking

generated by the machine’s mechanics. • Eliminating pull -out, as print

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Automation Enables Flexographic Printing Machine Builders to Achieve Higher ProductivityA single control platform and development environment help manufacturers reduce development time and cost.

registration must be held during speed changes of the web.

• Registry with and without electronic registration correction (ERC).

• Re-registration of a pre-printed web for insetting and additional color application.

• Compensation for printing long and short due to web variation.

• Constant sampling and trending of the error in the web for ongoing correction.

• Web guide for cross register control in certain applications. Combine these challenges with

changing substrates, inks and drying systems, and one begins to fully understand the demands of printing for the packaging and label printing industry.

A Common Control and Development Environment

The Rockwell Automation Integrated Architecture® system provides a proven solution to meet the challenging demands of the packaging and web label printing industry. Kinetix® Integrated Motion leverages the Logix Control Platform to seamlessly integrate with Allen-Bradley® Logix family controllers, servo drives, servo motors and actuators. Kinetix drives reduce programming time, improves information flow between components, and brings flexibility to machine design and efficiency to the manufacturing floor.

Components of the Rockwel l Automation Integrated Architecture include the Logix controller, Rockwell S o f t w a r e ® S t u d i o 5 0 0 0 ® L o g i x Designer, Kinetix 5500 servo drives, Allen-Bradley PanelView™ Plus human machine interface (HMI) terminals and CIP™ Motion.

The Logix controller combines motion and sequential control into a single multi-tasking controller platform, helping result in lower system costs, easier maintenance and simplified system installation. The Allen-Bradley ControlLogix® processor delivers the speed, resolution and accuracy needed for reliable web control and axis synchronisation via the fully digital, SERCOS-based Kinetix servo system.

Rockwell Software Studio 5000 software is used for both motion and sequential control, removing the need for multiple programming tools. The Power Programming methodology utilises the Studio 5000 development software powered with PhaseManager™ and Add-On Instructions (AOIs) to implement the integrated torque, velocity and position requirements of the unwind, infeed, print, outfeed, converting and rewind press sections.

The Kinetix 5500 servo drives provide the required dynamic performance for print registration accuracy. The multi-axis servo drive combines advanced control capability with innovative design features to significantly improve system performance and reduce integration and setup costs.

An Allen-Bradley PanelView Plus terminal is used to monitor, control and display critical application data and production and process information graphically, allowing operators to quickly understand the real-time status of the press operation.

New CIP Motion makes the network simple and reliable (DLR Technology), thus delivering high performance, deterministic control required for closed-loop drive operation, using standard, unmodified Ethernet. Clock synchronisation of better than 200 ns can be readily achieved, meeting the needs of the most demanding motion control applications.

Integrated RegistrationRockwell Automation Integrated

Architecture can seamlessly integrate the registration function in the ControlLogix or work with a third-party registration controller.

As an integrated platform, Studio 5000 software makes it easy to integrate print mark automatic registration together with our Kinetix servo system. The Kinetix 6000 servo drive offers high registration accuracy with 3 µs uncertainty time and 500 ns capture time. The servo drive and automatic registrat ion system integrat ion approach removes the need for an independent automatic registration system by leveraging the PLC and servo drive system.

Using a third-party registration controller can also be an option with the Integrated Architecture system. In this approach, the controller detaches the print error by double-mark registration and uses a specific algorithm to calculate the adjust distance value of the print roller.

Leveraging AutomationFlexographic printing machines need

to combine high production output with reliable, consistent product quality in addition to low manpower requirements and low maintenance costs. The Rockwell Automation Integrated Architecture solution contributes to machine builder efficiency and machine optimisation.

For example, standard, reusable software modules and AOIs reduce engineering time. In addition, the Integrated Architecture provides seamless connectivity of control components.

For machine optimisation, Kinetix drive integrated motion provides excellent print registration, precise tension control and smooth operation. The Logix control and integrated motion allows machine builders to adapt more quickly to a broad range of substrate characteristics.

For converters, the Logix Control Platform delivers improved production capabilities and reduces total cost of ownership by providing functionality, flexibility and scalability. It allows them to respond more quickly to customer or market demands, reduce maintenance costs and downtime, and gain access to actionable plant and production information for improved management and decision-making.

For printing OEMs, the Logix Control Platform is a powerful system of control, networking, visualisation and information technologies that delivers a lower Total Cost to Design, Develop and Deliver® machinery. It provides fully integrated, scalable solutions using a single control platform and a single development environment, enabling machine builders to efficiently reuse engineering designs to reduce development time and cost and enhance business performance. AT


How much time do you have to prepare for the EN ISO 13849 and IEC 62061 merger? These

two safety standards for machinery control are scheduled to merge into one global standard, IEC/ISO 17305. For original equipment manufacturers (OEMs), preparing now is easier than they might think. According to Derek Jones, Rockwell Automation business development manager/functional safety engineer – TÜV Rheinland, it will help them build safer, higher performing and internationally competitive machinery while helping to take cost out of the multinational safety-compliance process.

The adoption target of 2016 allows two years of transition to 2018, although the standards organisations may need additional time to finalise IEC/ISO 17305. The target date for completion is seen by some to be too optimistic.

Some OEMs, especially those located outside of the European Union (EU), might question the need and relevance of the merger. Understandably, many OEMs have a keen interest in confirming that the potential gains from the merger justify climbing what might appear to be another standards mountain. These gains, for example, might include capitalising on advanced technologies and minimising technical barriers in global trade.

Developing Safer MachineryOEMs should be optimistic, however.

The merger, creating what will become IEC/ISO 17305, signals the summit in terms of challenges related to global machinery safety control standards.

The basic methodology and essential requirements introduced in ISO 13849

and IEC 62061 shouldn’t require significant alterations. Unifying them should simply combine the best achievements from both, simplifying and making a single, more user-friendly standard. It might also resolve some known issues and grey areas identified during the last six years of using the two existing standards.

OEMs likely will find that having navigated the previous safety-standard migration was a useful preparation to adopting IEC/ISO 17305. With the EN 954-1 to EN ISO 13849-1 experience in hand, OEMs will find the next transition to be more manageable. They can leverage any lessons learned from continued use of the existing ISO and IEC standards to help streamline their

transition to conformity with IEC/ISO 17305.

OEMs moving from the simple safety categorisation of EN 954-1 to the significantly more complex ISO 13849 or IEC 62061 standards didn’t greet the transition with universal acclaim. At the same time, however, there was a consensus that increasingly sophisticated safety automation technology clearly required parallel and robust enhancements to safety standards.

Growing worldwide adoption of the ISO and IEC standards that superseded EN 954-1 at the end of 2011 is validating that prediction. The new generation of complex electronic and programmable safety automation technology exceeds

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Industry is steering a course toward an optimised global-reaching standard that will help OEMs build safer, more competitive machinery.

What OEMs Need to Know About the Merger of Two Key Machinery Safety Standards

the ability of the relatively simple and semi-prescriptive EN 954-1, which essentially provided guidance on control system structure.

The newer, more comprehensive functional safety standards enable confident use of new technology by requiring designers to assess all aspects relevant to the long-term reliability of safety components, explains Jones.

More rigorous documentation requirements combined with a quantitative calculation for assessing reliability increases the complexity. However, those types of trade-ups resulted in a methodical approach that’s helping OEMs develop safer machinery — using standards that allow use of contemporary technology and can be used to show compliance across worldwide markets — with more predictable performance, greater reliability and availability, and improved return on investment.

All Indicators “Go”It’s becoming harder for OEMs to

find reasons to take a wait-and-see position on IEC/ISO 17305. The most obvious indicator that a unified standard will emerge is the approaching end of development activity on ISO 13849 and IEC 62061 as separate standards. The IEC/ISO 17305 preliminary planning process already has started. Other leading indicators for a single global safety standard include:

ISO and IEC are relevant to U.S. machinery and equipment building. One particularly compelling, mainstream precedent exists on this topic: ISO 12100 is a basic principle-machinery safety standard providing a best-practice framework to identify risk and minimise hazards during the design stage. It demonstrates that what have been perceived as “European standards” are truly international. Not only is ISO 12100 a consensus standard in the United States, some of its major influences are provided by U.S. OEMs, machinery users and safety device manufacturers.

Many national standards already have provisions in common with the equivalent ISO and IEC versions. An increasing number of regions

around the world are adopting ISO and IEC standards as national standards. Consider a U.S. manufacturer selling to China and the European Union, or a China-based company exporting to the United States. The different standards that come into play — from UL and ANSI to EN and GB — might appear to be silo-creating guidelines that complicate life for global exporters and importers alike. However, current standards often are similar — sometimes up to 90 percent similar from one to the next. What are the most frequent commonalities? Predictably, they share significant elements with ISO and IEC standards.

There’s no “going back” based on complexity and data demands. Today’s safety function often isn’t a simple case of switching off the power. Safety-capable logic that enables intelligent safety operations is only one example of the flexible, advanced functionality requiring greater provisions against mistakes and faults. The increased complexity and requirements for reliability calculations did create some understandable frustrations, not the least of which has been a lack of data. In many cases, however, this issue now has been resolved.

There’s no benefit to delay, hoping that the complexity will disappear. It won’t. Understanding the existing ISO 13849 and IEC 62061 will certainly allow easier transition to IEC/ISO 17305.

The Move to Global Standards

The bottom line: Global trade means global standards. The IEC/ISO 17305 is scheduled to publish by 2016. The time between now and then is spent best getting familiar with its ISO 13849 and IEC 62061 foundations. Organisations familiar with the two standards will be comfortable with what’s in the unified standard.

The merger process won’t introduce any significantly different requirements. According to Jones, it will clarify and simplify. Industry simply is steering a course toward an optimised global-reaching standard that will help OEMs build safer, more competitive machinery. AT

Tools Assist in Development of Safety Functions

Rockwell Automation provides machine and original equipment

manufacturers (OEMs) with a range of tools to help them deliver complete safety solutions while streamlining development, improving compliance and reducing cost:

Safety Automation Builder (SAB) Tool. This software reduces the time to design, develop and deliver safety solutions. It enables users to lay out machine hazards and access points; define safety functions and select safety products; and export data to SISTEMA for evaluation. Outputs of the tool include conceptual safety layout drawings, SISTEMA project files and bills of material. Visit http://www.marketing.rockwellauto-mation.com/safety-solutions/en/Machine-Safety/ToolsAndDownloads/Safety_Auto-mation_Builder

Safety Function Documents. To support the SAB Tool, Rockwell Automation has released pre-engineered design documents containing detailed information for safeguarding methods including specific functionality, PL and required input, logic and output components. These documents also include parts lists, electrical drawings, a SISTEMA project file and verification and validation plans. Visit http://www.marketing.rockwellauto-mation.com/safety-solutions/en/Machine-Safety/OurSafetySolutions/safety_functions

Safety Accelerator Toolkit for GuardLogix and SmartGuard 600 Systems. This toolkit provides easy-to-use system design, programming and diagnostic tools to help in the rapid development and deployment of safety systems using Rockwell Automation GuardLogix®, Compact GuardLogix®, or SmartGuard™ 600 controllers, Guard I/O and safety devices. It includes a risk assessment and system design guide, hardware selection guide, CAD drawings, safety logic routines and operator status and diagnostic faceplates. Visit http://www.rockwellautomation.com/global/products-technologies/integrated-architecture/tools/overview.page?#/tab5


One of China’s largest yogurt producers. Italy’s No. 1 maker of single-serve “capsule” coffees.

A renowned Russian confectionery. These are just three of the companies worldwide that have chosen the CAMA Group to custom design, engineer and build their secondary-packaging systems.

“Our strength lies in combining robot technology with packaging machinery,” says Paolo Mosca, electronic department manager at CAMA Group. The company delivers solutions primarily for the bakery, dairy and coffee industries, and increasingly for manufacturers of non-food consumer items such as cosmetics and toiletries.

CAMA Group’s specialised robot technology is among the most advanced

in the secondary-packaging industry. The company engineers four types of robotic-loading units, ranging from two to four axes, each with a different payload capacity and application capability.

“These aren’t just generic robotic arms that pick things up and put them down along the production line,” Mosca explains. “They are robot machines that carry out complex technical tasks such as managing and loading products on a continuous motion packaging line.”

For example, CAMA Group’s Triaflex robot – coupled with an intelligent vision system – can work in three dimensions, with 360-degree head rotation, picking random products from the production line belt and positioning them correctly in the packaging. The Triaflex robot is

equipped with four controlled axes and carbon-fibre arms for gripping or placing products in all positions at up to 150 cycles per minute. Manufacturers use the robot to load a moving flow pack into a horizontal cartoning machine, for example.

“We design and develop our own line of robots in-house and integrate them with an array of automated packaging machines,” Mosca says. “The result is a complete packaging and handling solution tailored to each customer’s unique requirements.”

Seeking Simplified ControlsI n c r e a s i n g l y, C A M A G r o u p ’s

customers have asked for packaging systems with simplified controls. In response, the company decided to embark on a research and development project a imed at migrat ing the automation and motion control systems used by its robots from a mix of multi-brand technologies to a single, unified platform.

“We strongly believe that the uniformity of our systems is absolutely fundamental, especially in gaining authority in the market and the trust of customers,” Mosca says. “If the machines on a line are different with regard to hardware architecture, software design and motor type, product reliability can’t be optimised, and more importantly, neither can the price for the customer.”

CAMA Group’s engineers recognised that a single platform would be much easier to commission, operate and manage for customers’ engineers, technicians and maintenance personnel. And, they wanted to meet customers’ consistent need for more compact packaging systems.

However, simplification and a smaller footprint couldn’t come at the expense of performance. “There’s enormous pressure in our industry to give the

STORYAPPLICATION


CAMA Group switches from mix of proprietary technologies to full suite of Rockwell Automation hardware and software.

Packaging OEM Leverages Single, Unified Platform to Deliver Simplified, High-Speed Solutions

customer a high-speed solution they can’t find anywhere else in market,” Mosca says. “And we can never compromise the accuracy and efficiency of packaging processes.”

Such market competition created a compressed time frame to develop and deliver a new solution that standardised on a common control system that could meet all these needs.

Integrating Logic and Motion on a Single Platform

The CAMA Group’s research and development team, along with its mechanical and electronic engineering department, teamed up with the Global OEM Technical Consultants (GOTC) at Rockwell Automation.

“We know the cha l lenges of the market, so we gave Rockwell Automation specific production line requirements. And, of course, we gave them a very ambitious time target,” Mosca explains. “Rockwell Automation helped us understand exactly how the system would perform. We teamed together to attain the highest speed for the application we were requesting.”

Rockwell Automation engineers decided on a modular approach to help CAMA Group adapt the solution to unique specifications of different manufacturing processes.

“From a technical point of view, we wanted to integrate logic and motion on a unique automation platform,” Mosca says. “The robot automation and control system had to fit different requirements: speed and flexibility in handling operations, synchronisation of different axes in the plant, and easy product changeovers.”

At the outset of the project, the blended team defined techhnical specifications to size the programmable automation controller (PAC), I/O, motors, servo drives, AC drives and operator interfaces. At the heart

of the system is the Logix Control Platform with integrated motion. The single control platform allows users to manage many different robot kinematics at the same time and fully synchronise separate tracking, handling and vision systems. It includes an Allen-Bradley® 1756-L72 ControlLogix® controller with a Serial Real-time Communications System (SERCOS) interface motion module.

End users can easily share production information across all equipment through a s ing le EtherNet / IP ™ network. EtherNet/IP uses the same TCP/IP protocol suite that is used for the Internet, delivering the open connectivity and global acceptance of standard Ethernet, along with the real-time performance and security of fieldbus solutions.

CAMA Group engineers are also able to link their optical character recognition and optical character verification vision systems to the Rockwell Automation products in the robotic cell via EtherNet/IP.

The system uses Allen-Bradley Kinetix® 6000 and Kinetix 6500 servo drives, which help remove the need for a dedicated motion network and allow users to support high-performance drives, I/O, smart actuators and any other EtherNet/IP-connected device on a common network.

In addition, Allen-Bradley PowerFlex® drives with safe-off function reside on the same EtherNet/IP network for simplified machine design and production line operation. The Allen-Bradley MP Series™ Low Inertia servo motors fit compact space requirements while meeting the demands of the high-performance motion system.

Another important goal of the project was to improve operator safety and deliver a system compliant with global safety standard EN ISO 13849-1. The Rockwell Automation team conducted a

safety risk assessment and implemented an Allen-Bradley GuardLogix® integrated safety system, which allows for safety and standard control on a single platform, alleviates complicated hardwiring, and reduces engineering time.

As part of the Rockwell Automation Integrated Architecture® system, the GuardLogix PAC uses the same conf igurat ion , networking and visualisation environment as the rest of the system. This integration provides users with fewer spare parts to maintain, while the control platform’s openness helps ease integration into an existing plant.

Unlike hardwired systems, the integration of safety and standard control provides operators and maintenance personnel with visibility to all machine events – including safety events – via an Allen-Bradley PanelView™ Plus human-machine interface. The knowledge and insight provided by the integrated system allows users to respond quickly and return the machine or line to full production.

To manage safety on smaller, individual machines with the robot system, the team adopted Allen-Bradley Guardmaster® safety relays.

“The new control platform gives our customers a linear and lean production line,” Mosca says. “Furthermore, the modular approach allows us to apply the standard platform in future projects, saving design and development time.”

CAMA Group has just begun installing the new system in customers’ factories, but already one customer has requested the same architecture on an additional packaging line. The Rockwell Automation GOTC team has worked alongside its CAMA Group collaborators all the way. “If help is requested by a customer, Rockwell Automation reacts very, very quickly,” Mosca says.

But the most successful element of the relationship, Mosca says, was the clear definition of specifications and targets – thanks to the highly skilled teams involved – and the shared project management methods. “Rockwell Automation allowed us to meet time-to-market requirements and keep costs under control,” Mosca says. AT


CAMA Group designs and develops its own line of robots in-house and integrates them into an array of automated packaging equipment, such as the robotic cartoning system pictured here.

Michael Vlahos, OEM sales lead at Rockwell Automation, discusses the benefits that the

Connected Enterprise delivers to help packaging machinery builders and their customers remain competitive.

The recent acceleration of the Internet of Things enables new levels of connectivity for people, processes, data and things-ultimately providing greater productivity, better utilisation of assets, and improved decision-making to industrial companies. The magnitude of this evolution is momentous with more than 80 billion Internet-connected devices projected to be in use in 2024, up from less than 20 billion in 2014.

Establishing a Connected Enterprise can help manufacturers optimise their production and supply chain by integrating information technology (IT) with operations technology (OT) to improve business performance and minimise risks.

To achieve this, endusers are looking to machine builders to provide smart machines that can provide real time access to production information, enable flexibility in relation to changing markets and demands and also easily integrate into their facility.

Seamless connectivityThere is a growing need for our

customers to merge their information technology and operational technology to harness rea l t ime data and improve productivity and agility. This convergence improves connectivity across enterprise operations and provides the platform to integrate information across business systems and the plant floor.

To support and accelerate this network convergence, Rockwell Automation and Strategic Alliance Partner Cisco®, have collaborated on products, services and educational resources. The EtherNet/

IP™ communications platform enables manufacturers to converge their network infrastructure and tightly integrate technical and business systems.

Tackling the packaging challenges

One of the main challenges facing packaging machine builders is getting the right data out of machines that can be used to help manufacturers make real time decisions. Establishing a Connected Enterprise helps address this by collating real time data across applications including, safety, motion, process and drive control.

While having access to real time data is invaluable from a diagnostic, production throughput, safety, quality and efficiency perspective; increasing connectivity and visibility into the system opens it up to potential security risks that require careful consideration and mitigation.

Effectively developing a complete Connected Enterprise requires a comprehensive approach to industrial security that extends beyond the control system to include policies and procedures that address people, process and technology-related risks.

A d e f e n s e - i n - d e p t h s e c u r i t y architecture is based on the idea that any one point of protection may, and probably will, be defeated. This approach requires multiple layers of defense to help confirm a weakness or flaw in one layer can be protected by strength, capabilities or new variables introduced through other security layers.

To help machine builders incorporate these layers of security into machinery and endusers’ facilities, Rockwell Automation teams with industry leaders, such as Cisco and its other PartnerNetwork™ members. Physical security mechanisms, such as guards

and gates, and a network security framework that includes firewalls, intrusion detection and prevention systems, and managed switches and routers, are the building-block layers of a defense-in-depth approach.

Packaging machine builders are required to integrate machines and equipment into a plant network, protect intellectual property at the machine level and provide secure remote access for the end customer. This allows operators to monitor critical parameters and take action before equipment fails to help keep machines running and saving valuable time and money for machine builders and their customers.

Why connect?The value proposition that the

Connected Enterprise delivers to both machine builders and endusers is focused on information. It provides the technology to dramatically increase the amount of data available for analysis. It enables a variety of opportunities for improving business models and performance for machine builders, from reduced downtime and optimised capacity to improved machine design and monitoring capabilities.

Better information sharing drives better decision-making, exposes process inefficiencies, facilitates best-practice collaboration and uncovers new competitive opportunities. Packaging machine builders and their customers are increasingly realising the benefits that more information, insights and data can offer them to improve profitability in a competitive marketplace. AT

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Harnessing the power of informationGlobal competition is increasingly challenging manufacturers to offer an exhaustive breadth of products to meet rapidly changing customer needs.

PROPOSITIONVALUE

Every day, Thames Water, the UK’s largest water and wastewater services provider, supplies 2,600

million litres of tap water to 8.8 million customers across London and the Thames Valley.

The company’s 4,500 employees operate and maintain 100 water treatment works, 30 raw water reservoirs, 288 pumping stations and 235 clean water service reservoirs and carry out over 400,000 tests per year to make sure its drinking water meets stringent UK and European standards. The company also removes and treats 2,800 million litres of sewage for an area covering 14 million customers.

With such a massive customer base, Thames Water shoulders a huge responsibility and is committed to the upkeep of its network of pipes and delivery mechanisms. One of the proactive steps is to reinforce the resilience of its supply network through investment in new equipment and pipelines, in order to create redundancies within its water supply infrastructure.

In one such instance, as part of a three-site, US$167.2 million campaign, it has deployed a medium-voltage solution from Rockwell Automation to handle the pumping for a new shaft connected to the London ring main.

Space ConstraintsThe brand new shaft connects the

Hampton site to the existing Thames Water ring main – an 80 km-long pipeline that runs underneath London. The shaft itself is 50 m deep and 18 m in diameter.

The major challenge faced by Thames Water at its Hampton works was lack of space, as the demands of the required solution meant that a large footprint,

medium-voltage infrastructure was needed. The company had to find a solution where both the large pumps and medium-voltage equipment could be installed without impacting on existing operations. In the end, the company was able to reutilise existing buildings, with the pumps in one and the medium-voltage equipment in another.

It also had to make sure that current water supplies were not affected, as the existing pumps were still in operation – meaning a phased changeover, which had to be accomplished without any interruption. The pump units were split into high pressure and low pressure, with the low-pressure changeover being the primary concern, as they were the ones connected directly to consumers, and Thames Water had no surface reservoirs in the area on which to fall back.

Medium-Voltage EfficienciesThe fully integrated Rockwell

Automation solution comprised 10 Allen-Bradley® PowerFlex® 7000 medium-voltage drives, coupled to the pumps, each with an Allen-Bradley ControlLogix® programmable automation controller (PAC) on board. These, in turn, were connected to a master controller – another Allen-Bradley ControlLogix PAC – via EtherNet/IP™, which itself was connected to the site’s SCADA solution. Visualisation was provided using Allen-Bradley PanelView™ HMIs running FactoryTalk™ View.

The medium-voltage drives supplied by Rockwell Automation use direct-to-drive technology, removing the need for input transformers; their active front ends mean that there are lower harmonics. With a three-wires-in/three-wires-out concept being used,

the technology is also very user friendly and simpler to install.

This is somewhat of a revolutionary installation, as medium-voltage drives are normally discrete – operating independently from other systems. It is also believed to be one of the largest medium-voltage installations created for the UK water industry.

Control Technology Dividends

As well as providing Thames Water with a highly competent and effective medium-voltage solution, the integrated nature of the equipment also means that the company has a huge amount of real-time information to tap in to. Current information-gathering covers the process control parameters, but Thames Water is looking to expand this to include operational conditioning to encompass predictive and planned maintenance.

Mark Morrison, Thames Water’s project manager, says, “Using the new installation and the new connection to the ring main, we can now pump water from the Hampton site to places all over London, ready to step in should any new outages occur elsewhere.” He adds that, thanks to the modern motors and the control technology within the PowerFlex 7000 drives, Thames Water is realizing electricity savings greater than US$152,000 per year.

“The reliability of the PowerFlex 7000 drives is superb,” Morrison concludes. “Since the installation we have had no major issues...in fact, we have hardly had to touch them at all. The same positives are true of the Rockwell Automation engineers. They have always been very professional and quick to answer any questions I may have.” AT

Water Provider Saves US$152,000 Per Year on Energy BillsBy using an integrated medium-voltage drive solution from Rockwell Automation, Thames Water creates a more resilient water infrastructure.

The London ring main


FOCUSPRODUCT

Enhanced Studio 5000 Software for More Efficient System Development

Rockwell Automation has added three new applications to its Rockwell Software Studio 5000 development environment to help engineers speed development of automation systems as they design a Connected Enterprise. These applications, along with the existing Studio 5000 Logix Designer, bring more functionality together into one environment to help improve automation design productivity. The addition of these applications significantly enhances our integrated development environment, simplifies the design process and reduces the need for multiple tools, providing a more seamless system development experience.

• NEW Studio 5000 Architect application is the central point within the Studio 5000 environment where users can view the overall automation system; configure devices such as controllers, HMIs and EOIs; and manage the communications between the devices.

• Studio 5000 Logix Designer allows design and maintenance for the Allen-Bradley Logix5000 family of controllers and is used to configure discrete, process, batch, motion, safety and drive control.

• NEW Studio 5000 View Designer allows design and maintenance for Allen-Bradley PanelView 5500 graphic terminals, and provides an intuitive environment that helps users build contemporary systems with ease.

• NEW Studio 5000 Application Code Manager speeds system development by helping users build libraries of re-usable code that can be managed and deployed across their entire enterprise.

In addition, Studio 5000 offers enhanced security and localised batch control, allowing more user-authentication and access-control options, and a new privilege escalation capability.

For more information, visit:http://www.rockwellautomation.com/rockwellsoftware/products/studio-5000.page

Evaluation Services Help Organisations Better Manage Assets, Cut Costs and Reduce Risk

The majority of production facilities operating today are a mix of incredibly modern technologies and equipment operating well past its expected life cycle. Many companies are not entirely sure what equipment they have, or the specific risks that are associated with aging equipment. Rockwell Automation has released new software and enterprise evaluation services designed to help manufacturers and industrial operators better manage their assets and reduce risk. This is particularly important as manufacturers converge information technology (IT) and operations technology (OT) systems, and migrate to a unified Connected Enterprise. New services include the Software Inventory Evaluation and Enterprise Installed Base Evaluation services from Rockwell Automation.

The Software Inventory Evaluation service provides organizations a thorough analysis of their plant-floor IT assets – including servers, PCs, laptops and mobile devices – and of the various software installed on those assets. This can help identify potential compatibility risks between specific firmware and software versions as more systems are connected and devices are updated. It can also help close knowledge gaps among support staff regarding which software versions are used across a myriad of equipment, how many licenses are used or unused, and whether software is being properly supported.

“More than a software audit, the Software Inventory Evaluation service includes valuable analytics-based reporting that details areas of risk and provides insights for taking action,” said Andrew Wilber, Installed Base Evaluation service manager, Rockwell Automation. “It can also deliver significant cost savings. For example, it might identify opportunities to eliminate unused software and to migrate to concurrent licenses.”

The Enterprise Installed Base Evaluation service can include a multisite Software Inventory Evaluation service or Installed Base Evaluation service, which is used to analyze critical plant assets to provide a full accounting and analysis of an organization’s IT and OT assets across the enterprise.

Organizations can use the Enterprise Installed Base Evaluation service to support specific corporatewide initiatives, such as identifying their most critical assets, reducing obsolescence risks, managing corporate storeroom and spare parts initiatives, and ensuring all assets have up-to-date bills of material. For example, an organization can use the service to review its facilities for parts that are running business-critical activities, have no spare parts in inventory, and are also discontinued. This can help create a corporate risk profile that highlights the highest risk for downtime at each site.

“Organizations attempting to do comprehensive evaluations in-house often spend a year or longer just to collect hardware data from a single facility,” Wilber said. “That can be a significant strain on high-value resources, especially when expanded across multiple facilities. It also presents challenges in ensuring a standard methodology is used for collection. With the Enterprise Installed Base Evaluation service, we can collect this data and begin delivering actionable, insights-based reports in mere weeks.”

Enterprise Installed Base Evaluation reports can provide insights across all of an organization’s facilities. They also can be customized based on top at-risk locations and top at-risk machines, or focus on specific business units across multiple facilities.

For more information, visit:http://www.rockwellautomation.com/global/services/consulting-assessment/installed-base.page


PowerFlex 527 AC Drives Simplify Machine Development and Use

The Allen-Brady® PowerFlex® 527 AC drives work exclusively with the Rockwell Automation® Logix Programmable Automation Controllers (PACs) and are configured and programmed in the Rockwell Software® Studio 5000® environment.

The PowerFlex 527 Variable Frequency Drive is a complement to machines using Allen-Bradley CompactLogix™, ControlLogix®, or GuardLogix® PACs and Allen-Bradley Kinetix® servo drives. It uses embedded motion instructions that are shared with Kinetix servo drives, providing the same user experience for configuration, programming and control of both types of drives, thus saving engineering time.

PowerFlex 527 drives offer a lower-cost solution for machines and applications that need simple speed control for induction motors. The servo drives handle the more precise control operations involving speed, torque and position control.

Rockwell Automation now offers Integrated Safety for both the PowerFlex 527 AC drive and Kinetix 5500 servo drive. With Integrated Safety, the drives receive safety commands from an Allen-Bradley GuardLogix PAC via EtherNet/IP™. Having the controller manage safety helps reduce the hardware, wiring and labor costs associated with implementing a SIL 3/PLe safety solution.

For more information, visit:http://ab.rockwellautomation.com/Drives/PowerFlex-527

White Paper Helps Securely Share Plant and Enterprise Data

Many manufacturers segment business-system networks from plantwide networks by using an industrial demilitarized zone (IDMZ). But once segmented, how is data from industrial automation and control systems (IACS) securely shared across this buffer zone?

A new white paper from Cisco and Rockwell Automation, “Securely Traversing IACS Data Across the Industrial Demilitarized Zone,” provides guidance for successfully designing and deploying an IDMZ as part of a Converged Plantwide Ethernet architecture. This allows manufacturers to securely share IACS data from the plantwide network to the enterprise network. The paper explains key IDMZ assets that enable this secure data-sharing, which include application mirrors and remote desktop gateway services.

The white paper summarizes key design principles from a comprehensive design and implementation guide on IDMZ.For more information, visit:http://literature.rockwellautomation.com/idc/groups/literature/documents/wp/enet-wp038_-en-p.pdf

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Ready to elevateyour Rockwell PLCs

www.spectrumcontrols.com | [email protected]

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From Universal to HART analog solutions on all major Rockwell Automation Platforms!

Get the most out of your Rockwell Automation solution with our specialty I/O.

Available on all major Rockwell Automation Platforms!

• 1734 POINT I/O™

• 1746 SLC™ 500

• 1756 ControlLogix®

• 1762 MicroLogix™

• 1769 Compact I/O™

• 1794 FLEX™ I/O

• 2080 Micro800®

• PowerFlex® 755 Drives

Don’t forget to ask about our industrial strength InView Message Displays!

(Coming soon!)


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MobileView Tethered Operator Interface for On-the-Go HMI Access

The new Allen Bradley MobileView tethered operator interface gives plant and industrial personnel the freedom to take a machine’s human-machine interface (HMI) with them to make real-time adjustments to out-of-view applications.

The MobileView tethered operator interface is ideal for maintenance tasks, machine setup or calibration activities, and other HMI applications that require the operator to see the machine. The inclusion of a hardwired e-stop button and three-position enabling switch also supports applications that require local safety functionality.

The MobileView tethered operator interface complements the Allen-Bradley PanelView graphic terminals and FactoryTalk View Machine Edition (ME) HMI software.

For more information, visit:http://ab.rockwellautomation.com/Computers/2711T-MobileView-Tethered-Terminals

Protect and Monitor Rotating and Reciprocating Industrial Machinery

The Dynamix™ 1444 measures and monitors a machine’s critical dynamic and position parameters, helping to assure appropriate actions are performed with the precision, reliability and performance required by industry and regulatory standards.

The system allows users to leverage the Rockwell Automation Integrated Architecture® system, rather than an isolated condition monitoring device, to assess current equipment health, predict potential issues and help avoid damage to critical machinery. It supports EtherNet/IP™ communications, dual port or Device Level Ring.

The Dynamix 1444 Series dynamic measurement module is a four-channel, general-purpose monitor that provides measurements of dynamic inputs such as vibration and pressure as well as static inputs such as thrust, eccentricity and rod drop. Expansion modules for speed, relay and analog output are also available.

For more information, visit:http://ab.rockwellautomation.com/condition-monitoring/dynamix-1444-series-integrated-machinery-monitoring-systems


Graphic Terminals are Designed to Improve Performance

The PanelView™ Plus 7 Standard operator interface is well-suited for applications that require monitoring, controlling and displaying information in dynamic ways, where operators must quickly understand machine status and make decisions.

The graphic terminals are available in a variety of display sizes, including widescreen. Form factor includes sizes from 4 inches to 10 inches. Terminals offer single controller connection and up to 200 alarm messages.

The PanelView Plus 7 Standard models are complementary to CompactLogix™ 5370 controllers. They use less than 2-inch cabinet depth, saving space and reducing cost.

For improved performance, the terminals support Windows CE 6.0 standard features, Ethernet communications for integration from the machine to the enterprise and a PDF Viewer. Email and texting notification capabilities are included. What’s more, users can monitor applications from a secure remote location with VNC connectivity.

For more information, visit:http://ab.rockwellautomation.com/graphic-terminals/2711p-panelview-plus-7-terminals

Industrial Ethernet Switch offering Four 10GB Ethernet Ports

The new Allen-Bradley Stratix 5410 industrial distribution switch offers four 10-gigabit Ethernet ports, providing a high-performance connection to the rest of a facility’s network architecture. The switch can be used as a Layer 2 switch or a Layer 3 routing switch, which allows engineers to use it in various applications.

The expanded Stratix family of switches gives IT and engineering professionals the broad range of switches they need for high-availability network designs. The Stratix 5410 distribution switch offers the performance and flexibility needed for designing future-ready network architectures.

With a 19-inch rack-mount design, the Stratix 5410 switch gives end users a centralized point of network distribution and increased port density. It is ideal for heavy industry applications where resiliency is often required, and has a rugged exterior to help withstand harsh environmental conditions.

For more information, visit:http://ab.rockwellautomation.com/Networks-and-Communications/Stratix-5410-Distribution-Switches

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www.powerohm.com

PowerohmPowerohmType PW Series Modules Type PW Series Modules

for Legacy Drivesfor Legacy Drives

PowerohmPowerohmType PK SeriesType PK Series

BrakingBraking Kits for Legacy Kits for Legacy Drives & Kinetix ServoDrives & Kinetix Servo

PowerohmPowerohmType PW Braking Modules Type PW Braking Modules

for for PowerflexPowerflex DrivesDrives

PowerohmPowerohmType PF Braking Resistors Type PF Braking Resistors

for for PowerflexPowerflex & Legacy & Legacy DrivesDrives

Powerohm Part Number

MFG Part Number

PKA005 1336-MOD-KA005

PKA010 1336-MOD-KA010

PKB005 1336-MOD-KB005

PKB010 1336-MOD-KB010

PKB050 1336-MOD-KB050

PKC005 1336-MOD-KC005

PKC010 1336-MOD-KC010

PKC050 1336-MOD-KC050

Powerohm Part Number

MFG Part Number

PWA018 WA018

PWA070 WA070

PWA115 WA115

PWB009 WB009

PWB035 WB035

PWB110 WB110

PWC009 WC009

PWC035 WC035

PWC085 WC085Voltage: 208-13,800 Amps: 0.5 - 25

Mill Galvanized EnclosureN.C. Temperature Switch2-Point Terminal Block

Powerohm Powerohm Type HRG Type HRG Grounding SystemsGrounding Systems

AC Voltage: 208 – 720VAmps RMS: 50 - 1200A

Featured in Rockwell Featured in Rockwell Automation Design SoftwareAutomation Design Software

Engineering AssistantMotion AnalyzerProposal Builder

FactoryPh.: +01-859-384-8088 Ext. 2Fax: +01-859-384-8099Email: [email protected]

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