K. Hall -Technology Trends

8/22/2019 K. Hall -Technology Trends

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Copyright 2005 Rockwell Automation, Inc. All rights reserved. 1

Five Technologies ThatWill Drive The Future OfIndustrial Automation

Sujeet ChandSr. Vice President & Chief Technical Officer

Kenwood Hall

Vice President Architecture and Systems


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2Copyright 2006 Rockwell Automation, Inc. All rights reserved.

Technology and Architecture Trends

How Will Technology Trends Transform Industrial Automation?

Q & A

Manufacturing Trends


Outline


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Technology Predictions:1954 Popular Mechanics Magazine

Scientists from the

RAND Corp have created

this model to illustrate

how a

home computer couldlook like in the year 2004.

However the needed

technology will not be

economically feasible for

the average home. Withteletype interface and the

Fortran language, the

computer will be easy to

use.

Scientists from the

RAND Corp have created

this model to illustrate

how a

home computer couldlook like in the year 2004.

However the needed

technology will not be

economically feasible for

the average home. Withteletype interface and the

Fortran language, the

computer will be easy to

use.


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Prediction in 1968 of the year 2001

Space travel - common placeSpace travel - common placeComputers Big single computer,Computers Big single computer,

Arthur C. Clarke

Stanley Kubrick

possible erratic behavior


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The FactoryThe Factory


Cost / EnergyEfficiency

Safety/Security

RegulatoryCompliance /

Mandates

Productivity/ Quality

Supply ChainIntegration

FlexibleManufacturing Customer

Demand

Customer

Demand

Supply Chain Integration and Flexible Manufacturing Are Driving

The Integration of Factories With Business Enterprise Systems

Supply Chain Integration and Flexible Manufacturing Are Driving

The Integration of Factories With Business Enterprise Systems

Business Enterprise SystemsBusiness Enterprise Systems

SuppliersSuppliers


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Manufacturing Trends and Drivers

Total System CostLowest Procurement Cost

Functional AssetsPhysical Assets

GlobalLocal

Integrated SystemLoosely Coupled Design & System

Supply Chain SynchronizationDiscrete Supply Chain

Mass CustomizationMass Production

ToFrom


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Manufacturing Drivers Today

FLEXIBILITY:Faster Commissioning,

ReconfigurationINTEGRATION:Control, Safety,Information/IT

GLOBALSUPPORTServices

OPTIMUMASSET

UTILIZATION

COST:Lifecycle Cost

End UsersOptimize the

Operation of the

Production Line


Operation of the

Production Line


ReconfigurationINTEGRATION:Control, Safety,

Information/IT

COST:Product Cost

& Reusable Components


OEMsOptimize the

Effectiveness

of MachineBuilding

OEMsOptimize the

Effectiveness

of MachineBuilding

Many Common Drivers for OEMs and End UsersMany Common Drivers for OEMs and End Users

SolutionsSolutions

PERFORMANCE:Machine

effectiveness


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What Do Manufacturing Companies Want?

Major Food Company

(INTEGRATION) IT and factory control becoming integratedRolling out ERP (focus on supply chain integration)

Regulatory Mandates: Walmart and FDA

(COST) Into second wave of driving productivity of manufacturing plantsLooking to save about $750M / year

Plants are efficient today; however, significant annual waste still exists

(FLEXIBILITY) Moving to new, healthier products will require newprocesses and smaller batches

Rapid re-configuration of automation equipment

Walmartscompetitors demanding customized products

Long-term vision: flexible and integrated manufacturing customized trail mix for every consumer

Long-term vision: flexible and integrated manufacturing

customized trail mix for every consumer


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Outline

Manufacturing Megatrends



Q & A

Technology and Architecture TrendsTechnology and Architecture TrendsTechnology and Architecture Trends


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The Five Key TechnologiesFor Industrial Automation

Machine

(Factory)

Line

(Manufacturing

Solutions)

Plant

(Enterprise)

ElectronicsElectronicsElectronics MaterialsMaterialsMaterials

SoftwareSoftwareSoftware

Commercial

Electronics

On-Machine

Commercial

Electronics

On-Machine

Al ternate

Materials

Nanocoatings

Al ternate

Materials

Nanocoatings

Software

Integration /

Web Services

High

Reliability

Software

Software

Integration /

Web Services

High

Reliability

Software

Control /DiagnosticsControl /Control /

DiagnosticsDiagnostics

Advanced

Control

Prognostics

Autonomous

Systems

Advanced

Control

Prognostics

Autonomous

Systems

CommunicationsCommunicationsCommunications

Wireless

RFID

Wireless

RFID


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Technology Evolution

Nano& Virtual

2010to .

Nano& Virtual

2010to .

InformationTechnology

1960to 2010

InformationTechnology

1960to 2010

Industrial

1800to 1960

Industrial

1800to 1960

Agriculture

10K BCto 1800 AD

Agricul ture

10K BCto 1800 AD

Hunting/Survival

Million BC

to 10 BC

Hunting/Survival

Million BCto 10 BC


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Trends Impacted By Information TechnologyEvolution

Integrated Control, Safety, Security, andInformation

Information-Enabled Control Platforms with IntegratedSafety and Security

Ethernet

Industrial Ethernet Becomes the Dominant Network

Adoption of World-Wide Web Software

Standards

WWW Data Exchange and Software IntegrationStandards for Industrial Automation


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Outline

Manufacturing Megatrends



Q & A

How Will Technology Trends Transform Industrial Automation?How Will Technology Trends Transform Industrial Automation?How Will Technology Trends Transform Industrial Automation?


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Machine

(Factory)

Line

(Manufacturing

Solutions)

Plant

(Enterprise)



Commercial

Electronics

On-Machine

Commercial

Electronics

On-Machine

Al ternate

Materials

Nanocoatings

Al ternate

Materials

Nanocoatings

Software

Integration /

Web Services

High

Reliability

Software

Software

Integration /

Web Services

High

Reliability

Software

Control /

DiagnosticsControl /Control /

DiagnosticsDiagnostics

Advanced

Control

Prognostics

Autonomous

Systems

Advanced

Control

Prognostics

Autonomous

Systems


Wireless

RFID

Wireless

RFID


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Copyright 2006 Rockwell Automation, Inc. All rights reserved.

Advanced Control

Trend toward application-specific

advanced control methods that optimize

performance and energy effic iency

Trend toward application-specific

advanced control methods that optimize

performance and energy efficiency

Simulator

Cheese CookCycle Control

Increased product ion -shortened average cook cycleduration by 10%

Increased efficiencyNew control algorithmenabled stabilizing watercontent in the cheese to

the maximum allowed.The manufacturer producesmore cheese for the samecost.


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Prognostics Application At A FoodManufacturer

Remote Analysis of Pump OperationRemote Analysis of Pump OperationRemote Analysis of Pump Operation

Discharge Pressure

Suction Pressure

Bearing Temperature

Fluid Temperature Vibration

Barometric Pressure

Current (future)

Discharge Pressure

Suction Pressure

Bearing Temperature

Fluid Temperature Vibration

Barometric Pressure

Current (future)

MonitoringMonitoringMonitoring

Customers Problem:Pump Li fe Unloading Rail Cars

Customers Problem:Customers Problem:Pump Li fe Unloading Rail CarsPump Li fe Unloading Rail Cars

Bearings, pump cavitation, vibration monitoring

Spectral signature analysis, Neural Networks

Motor condition monitoring

Bearings, pump cavitation, vibration monitoring

Spectral signature analysis, Neural Networks

Motor condition monitoring

Pump diagnostics & prognosticsPump diagnostics & prognosticsPump diagnostics & prognostics

Growing trend towards prognostics and remote monitoring of machinery, e.g., nonstop,operator-free operation

Growing trend towards prognostics and remote monitor ing of machinery, e.g., nonstop,

operator-free operation


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Next Generation Control Systems Architecture:Autonomous Control Systems

Autonomous Systems(Modular, Adaptive Systems)

Today Future

Difficult to expand

Faults Stop Operation

Manual Recovery Minimal Redundancy

Hierarchical

Easy to expand

Fault-Tolerant

Self Recovery

High Redundancy Distributed

Competitive

Differentiation

Competitive

Differentiation

Flexible AutomationFlexible AutomationFlexible Automation

Fixed AutomationFixed AutomationFixed Automation


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Small applications

with high-

complexity nodes

Looking at the Evolution of Agent Technology

(1995-1998)

(1998-2000)

(2000-2006)

Large systems with

low- complexity

nodes

Agent population size

Highly distributed& heterogeneous

Heterogeneous

systems with

diverse complexity

nodes

(Future)

Intra & Inter

Autonomous Control

(WWW)

Initial proofInitial proof--ofof--

concept andconcept and

conceptualizationconceptualization

J am preventionDynamic rerouting of packages

Agent firmwareAgent firmware

integrated withintegrated with

LogixLogix OSOS

DevelopmentDevelopment

environment andenvironment and

optimized firmwareoptimized firmware

CommercialCommercialDeploymentDeployment

SurvivabilityReduced manning

Water / Waste Water

Optimum configurationsConsiderable reductionof scrap material

Multi component multiobjective controlProcess optimization


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Autonomous Control Systems Application:Shipboard Automation

CHWPLANT 2

CHWPLANT 1C&D

EQPT

AN/SPY1-DPORT ARRAY

AN/SPY1-DSTBD ARRAY

SLQ-32EQPT

400 HZCNVTR 2

IC/GYRO 2

400 HZCNVTR 1

IC/GYRO 1

LPACDHYR 1

SONAREQPT

HVAC (NV)CLS 1 HVAC (NV)

CLS 2

LPACDHYR 2

CICEQPT 2 CIC

EQPT 1

Combat

400 Hz Electrical Power

Interior Communication

Chilled Water

Low Pressure Air

HVAC

Test Reconfigurable Shipboard

Automation Architecture

V001

V004

V234

HVAC

CLS 1

V230

V122

V006

V002

PORT

ARRAY

STBD

ARRAY

V603

V127

IC/

GYRO 1

400 HZ

CNVTR 2

LPAC

DHYR 1

HVAC

CLS 2

V121

CIC

EQPT 2

CIC

EQPT 2

LPAC

DHYR 2

SLQ-32

V601

V231

V204

CHW

PLANT 2

V103

CHW

PLANT 1

V003

IC/

GYRO 2

SONAR

EQPT

400 HZ

CNVTR 1

C&D ELEC

EQPT

V005

Test and debug automatically generated agents Test Agent Behavior for different configurations

Agent Based Solution DevelopedAgent Based Solut ion DevelopedAgent Based Solut ion DevelopedNavy Requires

Highly Survivable System

Navy RequiresNavy RequiresHighly Survivable SystemHighly Survivable System

Agent based prototype developedAgent based pro to type developedAgent based prototype developed Demonstrateon the Navys Land based Simulator

DemonstrateDemonstrateon the Navys Land based Simulatoron the Navys Land based Simulator

Potential future applications: Automated, self-adjusting manufacturing lines to optimize

throughput

Potential future applications: Automated, self-adjusting manufacturing l ines to optimize

throughput


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Machine

(Factory)

Line

(Manufacturing

Solutions)

Plant

(Enterprise)



Commercial

Electronics

On-Machine

Commercial

Electronics

On-Machine

Al ternate

Materials

Nanocoatings

Al ternate

Materials

Nanocoatings

Software

Integration /

Web Services

High

Reliability

Software

Software

Integration /

Web Services

High

Reliability

Software

Control /

DiagnosticsControl /Control /DiagnosticsDiagnostics

Advanced

Control

Prognostics

Autonomous

Systems

Advanced

Control

Prognostics

Autonomous

Systems


Wireless

RFID

Wireless

RFID


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Wireless Industrial Applications

Wireless Ethernet, Self-PoweredWireless Sensors

Wireless Ethernet, SelfWireless Ethernet, Self--PoweredPoweredWireless SensorsWireless Sensors

Source: Milwaukee Journal Sentinel 2/8/03

RFIDRFIDRFID


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Self-Powered Mode (no batteries)SelfSelf--Powered Mode (no batteries)Powered Mode (no batteries)

Wireless NetworkWireless NetworkWireless Network

Future Of Wireless:Self-powered Wireless Sensors

Low-power radio

Energy harvesting technology Energy harvesting from machine

vibration and other parasiticmeans

Efficient and reliable generation andsupply of energy to power nodes

Energy Harvesting device withpiezogenerator, power conversionelectronics, & power storage module

Vibration

Power Gen. Power SOC.

Processor / radio moduleswith sensors and signalconditioning

Self-powered, wireless

sensors and sensor

networks for productionmetrics, machine health

monitor ing and remote

asset monitoring

Self-powered, wireless

sensors and sensor

networks for productionmetrics, machine health

monitoring and remote

asset monitoring

http://www.millennial.net


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Key Considerations for Deploying Wirelessin Industrial Automation

Potential interference Existing wireless, legacy radios, microwave

ovens, cordless phones, emerging radios,process, fusion lighting

Achieving proper coverageAntenna placement, reliable bandwidth,

minimize radios, channel usage (3D),redundancy

Environmental compatibility Indoor/outdoor, temperature, contaminants,

wash-down

Guaranteeing security

IEEE 802.11i, 802.1x, TKIP, AES, RADIUS Minimizing cost

Installation, power, communication,enclosures

Customer Value Proposit ions

Example: Rotating Machinery

Monitoring-Lower cost (wiring)-Ease of expansion-Mobility

Customer Value Proposit ions

Example: Rotating Machinery

Monitoring-Lower cost (wiring)-Ease of expansion-Mobility


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Is RFID Revolutionary?

Dynamic -- information can be added ordeleted at every step in the supply chain

Can store significantly more information

Dynamic -- information can be added or

deleted at every step in the supply chain Can store significantly more information

Process TransformationProcess Transformation

RevolutionaryRevolutionary

===

+++StaticStatic

Fixed amount of informationFixed amount of information

Deeply embedded in

existing processes

Deeply embedded in

existing processes

Bar Code TechnologyBar Code TechnologyBar Code Technology RFID TechnologyRFID TechnologyRFID Technology


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RFID For Track/Trace, Genealogy

Read tags

Program / Print Tags oncases/pallets

Provide traceability in supplychain

Integration with MES / ERP

Read Tags

Program / Print Tags Apply real-time control

Production interlocking

Integration with MES / ERP

Read Tags

Program / Print TagsApply real-time control

Production interlocking

Integration with MES / ERPPhase 1

Case and Pallet Tagging

Phase 1Phase 1

Case and Pallet TaggingCase and Pallet Tagging

Phase 2Product / Parts Tagging

Phase 2Phase 2Product / Parts TaggingProduct / Parts Tagging

Provide Traceability In Supply Chain With RFID Embedded In Packaging Material Such AsCardboard, Plastic Caps, Cartons

Provide Traceabili ty In Supply Chain With RFID Embedded In PackaProvide Traceabili ty In Supply Chain With RFID Embedded In Packaging Material Such Asging Material Such AsCardboard, Plastic Caps, CartonsCardboard, Plastic Caps, Cartons


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Machine

(Factory)

Line

(Manufacturing

Solutions)

Plant

(Enterprise)


Software

Integration /

Web Services

High

Reliability

Software

Software

Integration /

Web Services

High

Reliability

Software


Commercial

Electronics

On-Machine

Commercial

Electronics

On-Machine

Commercial

Electronics

On-Machine

Commercial

Electronics

On-Machine

Alternate

Materials

Nanocoatings

Alternate

Materials

Nanocoatings

Alternate

Materials

Nanocoatings

Alternate

Materials

Nanocoatings

Control /Diagnostics

Control /Control /DiagnosticsDiagnostics

Advanced

Control

Prognostics

AutonomousSystems

Advanced

Control

Prognostics

AutonomousSystems

Advanced

Control

Prognostics

AutonomousSystems

Advanced

Control

Prognostics

AutonomousSystems


Wireless

RFID

Wireless

RFID

Wireless

RFID

Wireless

RFID


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CustomersCustomers

SupportSupport

EnterpriseEnterprise

SuppliersSuppliers

DesignDesign

FactoryFactory

Impact of Software/IT on Manufacturing

Supply Chain IntegrationSupply Chain IntegrationSupply Chain Integration Batch Size of OneBatch Size of OneBatch Size of One

CAD-To-PartCADCAD--ToTo--PartPart Warranty Cost ReductionWarranty Cost ReductionWarranty Cost Reduction

Opt. Asset ManagementOpt. Asset ManagementOpt. Asset Management Data-Information IntegrationDataData--Information IntegrationInformation Integration

The Value ChainThe Value ChainThe Value Chain

The Product LifecycleThe Product LifecycleThe Product Li fecycle

The EnterpriseThe EnterpriseThe Enterprise


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Plant FloorControl Functions

Enterprise LevelBusiness Functions

Software Cust omer Pr oblems Today w it h Informat ion Ar chi t ect ure

Customer Problems Today

(Information Architecture): High cost

Too many servers Custom code Upgrades difficult Multiple copiesof data

Difficult to Operate& Maintain(training, personnel)

Too many custom interfaces Lack of standards

Lack of IntegratedSecurity

Distributed (decoupled)security

No device level security

Customer Problems Today

(Information Architecture): High cost

Too many servers Custom code Upgrades difficult Multiple copiesof data

Difficult to Operate& Maintain(training, personnel)

Too many custom interfaces Lack of standards

Lack of IntegratedSecurity

Distributed (decoupled)security

No device level security

Business Processes

Resources Marketing

SalesCosting

Compliance

DataData

MES GatewayProduction Functions

InformationInformationCommon

Database

Control

Data

IntegrationCosts

EngineeringTime

MaintenanceCosts

IntegrationCosts

EngineeringTime

MaintenanceCosts


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Summary:Impact of The Five Key Technologies On Manufacturing

Flexible Automation Reconfigurable Control SystemsAgent-Based, Autonomous Cooperative Systems Wireless Systems

Integration Information-enabled automationAdoption of WWW standards

Optimum Asset Utilization And Lowest CostAdvanced Control Self-Diagnostics and Maintenance Health, Safety, and Environmentally Responsible

Systems

Modern Manufacturing Systems Will BeModular, Adaptable, Smart, and EfficientModern Manufacturing Systems Will BeModern Manufacturing Systems Will BeModular, Adaptable, Smart, and EfficientModular, Adaptable, Smart, and Efficient


ReconfigurationINTEGRATION:Control, Safety,Information/IT


OPTIMUMASSET

UTILIZATION

COST:Lifecycle Cost


Operation of the

Production Line


Operation of the

Production Line


Reconfiguration INTEGRATION:Control, Safety,Information/IT

COST:Product Cost& Reusable Components


OEMsOptimize the

Effectiveness

of Machine

Building

OEMsOptimize the

Effectiveness

of Machine

Building

SolutionsSolutions

PERFORMANCE:Machineeffectiveness


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Copyright 2005 Rockwell Automation, Inc. All rights reserved. 30

Five Technologies ThatWill Drive The Future Of

Industrial Automation

Questions

Sujeet ChandSr. Vice President & Chief Technical OfficerKenwood HallVice President Architecture and Systems

K. Hall -Technology Trends

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Transcript of K. Hall -Technology Trends