Copyright © 2012 Rockwell Automation, Inc. All rights reserved.Rev 5058-CO900C Optimising Your Machine for Differentiated Value

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.Rev 5058-CO900C

Optimising Your Machine for Differentiated Value

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

Why We Are Here Today

We want to show you how you can design a high performance system at a cost effective price

We want to show you how you can reduce the time and cost it takes to integrate your equipment into the end user environment

We want to show you how you can do the above while also delivering equipment that provides differentiated value to your end users

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Design Optimisation

Simplified Integration

Differentiated Value


Manufacturing Drivers Today

Solutions

End UsersOptimise the Operation of Production

Line

OEMsOptimise the Effectiveness of Equipment

Building

FlexibilityFaster Commissioning,

ReconfigurationIntegration & SimplificationControl, Safety, Information/IT

Optimum Asset Utilisation

Global SupportServices Cost

Total Lifecycle Cost

FlexibilityFaster Commissioning,

Reconfiguration Integration & SimplificationControl, Safety, Information/IT

PerformanceEquipment

Effectiveness

Global SupportServicesCost

Total Cost to Design, Develop,

& Deliver

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Response: Machine and Equipment Builder Performance

Commissioning Global Service & Support Reliability & Quality Machine Performance

Design Design Productivity Extensible Engineering Scalability Global Standards Risk Assessment Design for Sustainability

Develop Deliver Time to Market Supply Chain Efficiency Flexible Equipment Models Simplified Integration Design Optimisation

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Machine Builders today are challenged to

differentiate themselves amidst global competition

and rapidly evolving technology.

To achieve greater profitability, Machine Builders

must improve their overall operational performance.


Design, Develop & Deliver Examples

Maximise design productivity with extensible engineering

Use scalable control architectures Provide extensive industry & application expertise

Optimise Your Machine Design Leverage product selection & configuration tools Easily select hardware & generate bills of material Size & select an optimal motion system Use scalable technology

Meet global safety & environmental standards Meet functional safety standards with

integrated safety solutions Harness the inherent value of intelligent safety solutions

with a Safety Lifecycle Approach

Avoid redesign changes – Perform risk assessments up front

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Optimise & reuse your machine design Improve machine flexibility with

modular programming techniques Develop reusable equipment modules with Modular

Programming Retrieve code to use as a foundation

Simplify Integration Integrated Architecture solutions with a single network Scalable control solutions reduce

engineering time & eliminate risks Reduce number of programming and configuring

software packages

Supply Chain Efficiency Local sales & support “Preferred parts” availability consultation Reduce time & costs using a single supplier Reduce BOM

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Improve time to market to meet customer delivery commitments


Reduce Overall Installation & Commissioning Easily integrate with your customer’s information systems Link real-time reporting from machine-level to IT infrastructure with standard EtherNet/IP Provide an accurate view of plant operations

Improve Reliability & Quality Remotely monitor machine system status & perform authorised program changes Achieve higher levels of business performance with Network & Security Services

Provide Global Service & Support 24 x 7 multi-lingual support Connect to your machines globally with remote managed services Start up, warranty, emergency and more via Field Support Options

Online & Phone Support | Training | OnSite Support | Repair Services | MRO Asset Management | Safety | Energy | Network & Security | Managed Services

80 Countries I 20 Languages I 6 Remote Support Centers I 10 Remanufacturing Depots I 9 Exchange Hubs I Average 13+ Years Experience


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Continuing to Enhance Our Capabilities

Rockwell Automation recently released a number of new products designed to help

OEM’s increase their business performance

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Motion Analyzer 6 Kinetix 350 CompactLogix 5370Controllers

PanelView Plus 6Terminals

Kinetix 5500 and VPL Motors*coming soonStratix 5700LDAT Linear Thruster

PowerFlex 525

L1 L2 L3


Equipment Builder Performance

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Commissioning Global Service & Support Reliability & Quality Machine Performance

Design Design Productivity Extensible Engineering Scalability Global Standards Risk Assessment Design for Sustainability

Develop Deliver Time to Market Supply Chain Efficiency Flexible Equipment Models Simplified Integration Design Optimisation

Kinetix 350 CompactLogix 5370Controllers

PanelView Plus 6Terminals

Kinetix 5500 and VPL Motors*coming soon

Stratix 5700LDAT Linear Thruster

Motion Analyzer 6 PowerFlex 525

L1 L2 L3


Mechatronics and Machine Design

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Mechanical Design

Control Design

Motion System Design

“synergy of several engineering disciplines…”

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

http://en.wikipedia.org/wiki/Image:Logo_gif_800x800.gif


Time to Market Improvements – Motion Analyzer

Tuning Simulation Decrease / eliminate Prototype builds

by testing scenarios in Solidworks and Motion Analyzer

Code Generation Motion Analyzer can both export and

import project as .L5X Enables fast and reliable exchange of

data with RSLogix5000 Partially supports Product Lifecycle

Management

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Download Motion Analyzer Here

http://www.ab.com/linked/motion/software/get/MotionAnalyzer.zip


Time to Market Improvements – Drives and Motion Accelerator Toolkit

Drives and Motion Accelerator Toolkit (DMAT) design wizard can automate file selections and importation.

To speed development, the wizard asks questions about your application and produces the tools to start YOUR application WITHIN MINUTES.

Tell the Wizard which controller, drives, HMI and I/O your application will use. The Wizard then runs and generates.

A Bill of Materials of the products you specified A Folder of Wiring Diagrams and Panel Layout footprints ready your CAD

program A Logix program with the configuration and basic control needs for your products A starting HMI application with adaptation instructions for your application

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Download DMAT Here

How much faster can you bring your machine to market with the DMAT Wizard to help start your design?

https://download.rockwellautomation.com/esd/download.aspx?downloadid=1.17.02-DMAT-DVD



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The DMAT includes automation engineering design tools for the entire machine control application development.

Bill of Material, CAD, Logic, HMI, Quick Start

The DMAT allows Machine Builders to significantly reduce design time and cost; allowing them to concentrate on the intellectual property that produces compelling and differentiating machine features.

Bill of Material Files

Wiring Diagrams and Panel Layout Drawings

HMI Screens for status and diagnostics

Quick Start for Base System Setup

Programming for control and configuration



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Quick Start for Base System Setup

The DMAT Wizard was used to develop the base application files for a 4 axis example.

The Designer Wizard produced files ready for the application details after 16 minutes of work

65 catalogue numbers

15 Wiring Diagrams7 pages of panels / product lines Models

22 HMI Screens Covering4 Drives, Alarming /Machine Control

425 Lines of Code6 Products configured5500+ Program &

Diagnostic Tags



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Advantages

Designers can spend their time optimising their machine operations for better performance and higher profits

Initial Project setup Time needed for an example 4 axis system

TaskTime w/o DMAT

AcceleratorTime Using DMAT Wizard

Turning specifications into catalog numbers and accessories 4 Hours 5 Minutes

Produce initial base set of CAD drawings 80 Hours 5 Minutes

Produce initial base program 40 Hours 3 Minutes

Produce initial base HMI set 80 Hours 3 Minutes

From 204 hours to 16 minutes !!!!!


Simplifying Your Design – Single Network, Global Standards

Standard Unmodified Ethernet Lower wiring costs Simplified Integration of the entire control solution on one network. including HMI, PAC,

I/O and motion. Safe Torque Off standard Scalable Platform to meet global machine standards

120V, 240V - single and 3 phase 460V – 3 phase

Designed as a System Controller, Motion, HMI

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Simplifying Your Design – Motion Simplification

50% reduction in size Efficient motors reduce size and cost

Up to 2 Sizes Smaller Drive Single Cable Design reduces installation (60%) & procurement costs (27%) Induction Motor support reduces inventory, and simplifies design Energy efficient drive/motor match and green shunt Zero stacking, no backplane Two EtherNet/IP ports to support Device Level Ring (DLR) Designed as a System

Controller, Motion, HMI

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Simplifying Your Design – Linear Thruster

Replace complex transmissions with linear actuators. Eliminates weeks of engineering, design and

documentation time per custom designed actuator axis.

Vastly reduces the amount of components that need to be purchased from multiple vendors for custom actuators.

Eliminates the time needed to assemble a custom actuator into a machine.

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Reduces Engineering, Purchasing and Assembly Efforts!


CompactLogix 5370 Programmable Automation Controllers (PACs)

Expanding on the scalability of the Logix family of controllersThe CompactLogix 5370 PACs offer:

A wider variety of options to provide best-fit alternatives for specific application requirements A strong motion solution when combined with Kinetix® servo drive for customers requiring high

performance in a compact and affordable package Common and consistent features across all three platforms (L1, L2 and L3); scalability between

the Logix families (CompactLogix and ControlLogix)19


5370 CompactLogix Summary

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Integrated Motion, 2x performance increase, >25% improvement in network and many more……in a compact form factor provides a right size control for your application needs

Battery-less Operation

2x Scan Time Performance Increase

Embedded DLR EtherNet/IP Switch

Sockets communication

>25% improvement in network Packets Per Second (PPS)

SD Flash for Program and Data Storage

Integrated Motion in L1,L2and L3 “M” controllers

(CIP Motion / CIP Synch)

All models (L3, L2, L1)

Local Expansion with up to 6 or 8 POINT I/O

Modules

L1

Local Expansion with up to

4 1769 Modules

Much smaller form factor for L2 Controllers

Universal Analog Input (C, V, Thermocouple, RTD),

14 bit resolution

L2USB port

for programming

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 21

The Power of Logix

AOI


Simplified and Scaled Architectures

CompactLogix chassis

PowerFlex

SERCOS

EtherNet/IP

DeviceNet

PanelView Plus

Kinetix 6200

POINT I/O

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Stratix

ArmorBlock I/O



CompactLogix chassisStratix 5700

EtherNet/IP

Kinetix 5500

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PowerFlex

PanelView Plus 6

POINT I/O

ArmorBlock I/O



CompactLogix chassisStratix 5700

EtherNet/IP

Kinetix 5500

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PowerFlex

PanelView Plus 6

POINT I/O

ArmorBlock I/O

To Line or Enterprise


Kinetix 5500 Servo Drive

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Single cable eliminates Hardware and wire

terminations

Innovative Common AC/DC bus

eliminates hardware, reduces installation time

and lowers costs

Induction motor (V/Hz) support simplifies inventory

and maintenance

50% smaller

Clamp design prevents installation mistakes

and enforces 360° bonding for noise immunity

Supports 195 – 528 VAC input,

reducing inventory


PowerFlex 525 AC Drives

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USBConnectivity for Faster Configuration

HIMThe LCD Human Interface Module supports multiple Languages and feature scroling text

Embedded Ethernet PortProvides Premier Integration into the Logix environment

Safe Torque-OffA standard feature of the PowerFlex 525 Drives

Simplified ProgrammingEasy to use Software and MainsFree programming via USB

Modular DesignOffers ease of installation and programming

Power Range115V to 600V0.37 to 22kW


Stratix 8000 & 5700 Family Layer 2 & 3 Managed Switches w/ Cisco Technology Inside

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Best for the Plant Floor Environment Easy to Integrate and Maintain

– Default configurations for Industrial Automation– Removable storage cards for one step device replacement

Best of Rockwell Automation Premier (CIP) interface to Integrated Architecture

– Studio 5000 for configuration (AOP)– Predefined Logic tags for diagnostics– FactoryTalk View Faceplates

Best of Cisco Secure integration with plantwide network

– Cisco internetworking operating system (IOSTM)– Cisco CatalystTM switch architecture and feature set– Familiar tools for IT professionals: command line interface (CLI), Cisco Network Assistant (CNA) and Device Manager

Stratix 5700

… integrating the IT and Industrial Environments

A unique product family in the market….

+

+Stratix 8000/8300


Switch Tools and Integration

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Equipment Integration

How do you overcome the challenges?• Simplified architectures

• Standard unmodified Ethernet

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contact a remote service engineer?

Differentiation – Smart Machines

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Differentiation – Smart Line

Lowers Lifecycle TCO

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Summary

You design a machine with less parts, and lower inertia, which leads to lower cost motors and drives

Less parts and smaller motors and drives means a smaller footprint

Increased scalability of controllers allows you to only pay for the control and features you need

Simplified equipment allows you to turn over jobs faster, meaning getting paid faster

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Design Optimisation


Summary

Using standard, unmodified Ethernet allows you to easily integrate into an end user environment

Cisco enabled switches promotes easy adoption by end user IT departments

Fast integration means less time at end user site

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Simplified Integration


Summary

Because back in design you optimised, you deliver a machine with less parts, requiring less spares, less maintenance, less energy usage and longer uptime

Providing a smart machine gives a competitive advantage to your end users and differentiates your equipment in the market

Providing information enabled equipment allows the customer to get the information they need to optimise operations and meet their efficiency goals

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Differentiated Value


More Information

If you would like more information on our midrange platform, you can visit

www.scalabletechnology.eu

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http://marketing.rockwellautomation.com/midrange


www.rockwellautomation.com

Follow ROKAutomation on Facebook & Twitter.Connect with us on LinkedIn.

Rev 5058-CO900C

Questions?

Documents

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.Rev 5058-CO900C Optimising Your Machine for Differentiated Value