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Designing Innovative Machines with the Rockwell Automation Midrange Architecture System
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Designing Innovative Machines with the Rockwell Automation Midrange Architecture System Designing Innovative Machines with the Rockwell Automation Midrange Architecture System Presentation Transcript

  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900DDesigning Innovative Machines with theRockwell Automation Midrange ArchitectureSuccess Stories
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. 2AgendaMidrange System Success – Proven Capabilities & Real ValueMachine and Equipment Types / ApplicationsMidrange System OverviewCritical Business Issues – Value PropositionsTools for Success
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Baker PerkinsConfectionary Depositor Machine3• Simplify machine design• Reduce cleaning time• Ease equipment changeover• Scalable control platform reducestraining• Set up and monitor the machine at atouch of a button via Human MachineInterface (HMI)• Maximize precision and continuousoperation• Real time historical trending and alarmmanagement• CompactLogix™ ProgrammableAutomation Controller (PAC)• PanelView™ 1250+ Human MachineInterface• MPAI actuators and Kinetix® servo drives• PowerFlex ® AC drives“Rockwell Automation can always be relied upon to keep up with new technology and, indeed, driveit forwards. And it does so while helping us to reduce cost and complexity.”- Keith Graham, marketing manager, Baker Perkins
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.• CompactLogix ProgrammableAutomation Controller (PAC)• Kinetix Servo Drive• PanelView Plus 6 Human MachineInterface• PowerFlex AC Drive with Safe-OffThiele TechnologiesTop-load Case Packer4 Reduce maintenance time Improve efficiency Meet safety standards• Eliminated the need for a dedicatedmotion network• Improved operator safety• Enhanced machine efficiency• Eased machine monitoring and statusupdates“Our needs are met seamlessly by Rockwell Automation and its partners. We’re constantly gettinginformation on what new technologies are available to us and how we can use them to better oursystems, not to mention the level of continued education Rockwell Automation offers ourengineers.” - Kip Boie, Vice President of Sales and Marketing
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.TRIpackShrink Sleeve Applicator• Ease system integration• Ease programming and trainingrequirements• Simplify maintenance andtroubleshooting• PAC delivered powerful processing in acompact, cost-effective and easy to configuredesign• Motion precision and accuracy• Human Machine Interface provides easyaccess to information about machine activityand productivity along with quick identificationof issues• CompactLogix Programmable AutomationController (PAC)• Kinetix 350 Servo Drives• PowerFlex 4M AC Drives• PanelView Plus 1000 HMI“Our customers are familiar with Rockwell Automation controls, which help them integrate TRIpackpackaging machinery with existing equipment upstream and downstream.”- Dave Himmelmann, Senior Electrical Engineer, TRIpak
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.• CompactLogix Programmable AutomationController (PAC)• PanelView Plus 6 Human Machine Interface• PowerFlex 40 AC drives• FactoryTalk ® ViewPointvonGalPalletizer6• Provide flexible, compact machines• Simplify machine design• Ease equipment changeover• Reduce costs• Simplified design reduced costs whileallowing the machine to handle the same loadas previous designs• Scalable control solutions meets a variety ofcustomer demands• Maximize uptime and minimize maintenancewith remote monitoring“By using the latest in industrial automation technology, we’ve not only been able to give ourcustomers a leg up, we’ve streamlined design and installation for faster machine startup.”- Paul Probst, General Manager, vonGAL
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Wulftec M.J. MaillisAutomated Stretch Wrapper7• Ease integration• Reduce downtime• Simplify machine adjustment• Continuous-operation film reloading• Scalable control platform reduces trainingcosts• Reduction of inventory requirements• Monitor key performance indicators via HumanMachine Interface (HMI)• Maximized uptime and minimized maintenance• CompactLogix Programmable AutomationController (PAC)• PowerFlex 525 AC drive• PanelView Plus 1000 Human Machine Interface(HMI)“Customers are eager to hear about our partnership with Rockwell Automation. It reassures them toknow that we build quality machines with quality control and automation components.”- Guy Lopes, Director of Operations, Wulftec
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Linkx SystemsPackaging Machine8• Control Costs• Occupy smaller footprint• Machine performance requirement of up to7-9 times the normal throughput duringpeak demand periods• Compact solution that suited the size of themachine• Excellent motion performance in a small footprint• Single control platform across five machinesdoing three different jobs• Significant reuse of code, cutting projectdevelopment time• Achieved 40-trays-per-minute capacity – doublethe customers requirement• CompactLogix Programmable AutomationController (PAC)• Kinetix Servo Drives• PowerFlex AC Drives• PanelView Plus Human Machine Interface• EtherNet/IP Architecture“Probably the most impressive part of this project was the reuse of existing code. We were able toreuse a significant portion of our existing code, including CAM profiles.”- David Hayward, Technical Director
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.CKC EngineeringMedical Microbore Tubing Spooler9• Multi-axis control of microbore tubingextrusion (100 different geometries) & windupof varying lengths• Very small footprint permitted for mobilewindup system• Traverse axis travel speed control for smoothwindup with varying spool velocity and criticaltension control• Compact solution needed for the size of machine• Integration of HMI, PAC & motion components onsingle EtherNet/IP network significantly reduceddesign time and simplified debug effort• Installed Rockwell Automation PAC, HMI, & ServoDrive systems with very small footprint• Achieved full production six months ahead ofschedule• CompactLogix Programmable AutomationController (PAC)• Kinetix Servo Drives• PowerFlex AC Drives• PanelView Plus Human Machine Interface (HMI)• EtherNet/IP Architecture“By coupling the Logix controller with the Kinetix drives, we got the high-performance, integrated-motion package we needed in a small footprint.”- Carl DiPietro, Vice President and Controls Engineering Manager
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. 10AgendaMidrange System Success - Proven Capabilities & Real ValueMachine and Equipment Types / ApplicationsMidrange System OverviewCritical Business IssuesTools for Success
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Machine and Equipment BuilderCritical Business Issues (CBIs) More cost competitive machine Simplify machine design Reduce cleaning time Ease equipment changeover Ease of configuration for flexibleapplication Optimize performance through design Reduce maintenance time11 Ease programming and trainingrequirements Commission and start-up ease forequipment builder Decrease machine time to market Increase competitiveness andenter new markets Requires a partner that can deliverand support a reliable controlsystem
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. 12AgendaMidrange System Success - Proven Capabilities & Real ValueMachine and Equipment Types / ApplicationsMidrange System OverviewCritical Business IssuesTools for Success
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. 13Whose Requirements Are Being Met?
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Continuing to Enhance Your Capabilities Rockwell Automation recently released a number of new productsdesigned to help OEMs increase their business performance14Motion Analyzer 6Kinetix350 CompactLogix 5370ControllersPanelView Plus 6Terminals Kinetix 5500 and VPL MotorsStratix 5700™LDAT Linear ThrusterPosition DrivenOutputs (PLS)
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Midrange Architecture System15A “right-sized” control & information platform on a single networkarchitecture providing a familiar user experience across the customer’sapplications
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Midrange Product Portfolio CompactLogix5370 ProgrammableAutomation Controllers Scalability of the Logix family 2 to 16 axis of integrated motion 80 to 960 I/O points Integrated kinematics functionality 1 or 2 G flash memory card16 Kinetix 5500 Servo Drive & VP Low Inertia Motor 600 W to 15 kW Power range Torque rating 0.4 - 31.5Nm Common AC/DC bus 195 – 528V AC input Embedded safe torque off Single cable with digital feedback
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Midrange Product Portfolio PowerFlex 525 AC Drives Power ratings of 0.4 - 22kW / 0.5 - 30 Hp Global voltage classes 100 – 600V Embedded safe torque-off Automatic Device Configuration Digital and Analog control I/O Embedded EtherNet/IP17 Studio 5000 Software with Logix Designer Single design platform Logix extended tag properties Updated alarms & events Controller based alarm log reducesmissed alarms Project documentation storage withbetter revision management
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Midrange Product Portfolio PanelView Plus 6 Enhanced run-time performance andoperator experience Reducing deployment time and costs New extensive graphics library Enhanced color animation capability Multi-language font library18 Stratix 5700 Industrial Ethernet Switch Six, 10, or 20 port managed switch SD card for device config storage Input/output alarms Fiber-ready SFP slots Configurable port security IT Standard “Cisco Inside”
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. 19AgendaMidrange System Success - Proven Capabilities & Real ValueMachine and Equipment Types / ApplicationsMidrange System OverviewCritical Business IssuesTools for Success
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Vertical Form Fill and Seal20
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Horizontal Form Fill and Seal21
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Cartoners22
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Case Packers23
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Labelers24
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Bag Makers25
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Shrinkwrap and Wraparound26
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Extrusion / Blown Film27
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Bottle & Can Fillers28
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Beverage Lines29
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Slitters30
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Laminators31
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Coating Lines32
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Tire Building Machines33
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Manufacturing - Curing34
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Process Skid35
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Process Equipment36
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. 37AgendaMidrange System Success - Proven Capabilities & Real ValueMachine and Equipment Types / ApplicationsMidrange System OverviewCritical Business IssuesTools for Success
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. 38Mechatronics and Machine Design3D CAD DesignSolidWorksControl DesignRSLogix 5000Motion DesignMotion AnalyzerMechatronic design is a collaborative venture between mechanical, electrical, and controldesign engineers – the outcome is a machine design optimized for high performance controls“synergy of several engineering disciplines…”
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation’s MechatronicOfferingProductsComprehensive motion offering including direct drive motors,linear stages, stacked stages, and electric servo actuators thatdeliver a superior mechatronic outcomeVirtual Design ToolsMotion Analyzer links mechanics withcontrols. Analyze, optimize, simulate, andselect in a virtual environment beforecommitting to a final machine designExpertiseMechatronic support andservices to augment yourexisting design team
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.CopyriWhat Is Motion Analyzer? Prior to Motion Analyzer, sizing a servosystem was manual process Slow Complex Error prone Rule of thumb based decisions Motion Analyzer automates the servosizing process Fast Simple Accurate Fact-based decisions Design optimization…
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. 41System Thermal ModelingEspecially useful for machinebuilders exporting to countrieswith hot weather.Ratio Design AnalysisGuides designers to anoptimized solution.System Efficiency AnalysisHelps boosts machine performanceand reduce energy consumption.Motion Analyzer – Machine ExampleSystem Tolerance AnalysisProvides an insight into amachine’s ability to cope withchange.Emergency Stop AnalysisMaximize output withoutcompromising safetySystem Tuning SimulationHelps reduce design errorand can save time duringmachine commissioning.Lifetime EstimationSize an integrated linear stages andautomatically get an L10 service lifeestimation.Supply VoltageTolerance AnalysisReduces chance ofmachine issues in thefield that result incostly support.3D CAD IntegrationDownload models ofmotion product and verifymotion profiles at themechanical design phase.
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Copyri42Benefits of a Mechatronic Approach Increased Machine Value The value of a machine is closely tied to it’s ability toproduce (PPM x OEE) Design optimization often results in increased machinethroughput at no additional cost Sustainability Machine owners & operators are increasinglyconcerned with sustainability issues Efficiency analysis can help decrease energyconsumption and reduce waste Greater Innovation Agility Offering a shorter lead time can often help win theorder and even command a premium Virtual prototyping reduces the time to ‘Design,Develop & Deliver’ Risk Mitigation Any design change carries an associated risk Simulation helps reduce risk by predicting the likelyoutcome of design changes before they occurFinding & fixing design flaws late in thedevelopment cycle can cost 10 to 100times what it costs to make changesearly [Major tire OEM]Using this approach we can reduce ourphysical prototypes from 20 to around 2-3and can trim hundreds of thousands ofdollars from development costs [Leadingpackaging OEM]
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Drives & Motion Accelerator Toolkit The Drives & Motion AcceleratorToolkit (DMAT) is designed to get youup and running faster and moreefficiently by: Assisting with product selection Jumpstarting the CADdocumentation Providing sample machine andapplication code Using this tool results in significantlyreduced development time43YourMachineSampleCodePowerFlex& KinetixDrives
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Files Available Using the Drives andMotion Accelerator Tool44DMAT includes engineering designtools for:Bill of Material - CAD – Logic – HMI - Quick StartAllows Machine Builders to reducedesign time and cost, allowing themto concentrate on the intellectualproperty that produces compellingand differentiating machine features.Bill of MaterialFilesCAD HMI Quick StartLogic
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.DMAT Time Savings toStart System DesignAdvantages Designers can spend their time optimizing their machine operationsfor better performance and higher profits Initial Project setup Time needed for an example 4 axis system45
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Saving Time with the DMAT Wizard Design Wizard can automate the file selections Wizard asks questions about and produces the tools to startyour application46How much faster can you bring your machine tomarket with the DMAT Wizard?
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.DMAT Time Savings to Start a SystemDesign47Advantages• Designers can spend their time optimizing their machine operations forbetter performance and higher profits• Initial Project setup time needed for an example 4 axis system
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Design & Control System Management –Sessions at RSTechED 2013 DE10 - Integrated Architecture Builder & ProposalWorksBeginners Lab (M, T, W) DE11 - Integrated Architecture Builder & ProposalWorks:Advanced Features Lab (M, T, W, Th) DE12 - Size, Select And Configure Kinetix 5500 UsingMotion Analyzer & Studio 5000 (M, W, Th, F) DE13 - Integrated Motion On EtherNet/IP:Solution Overview (M, T, W, Th) DE14 - Integrated Motion On EtherNet/IP:Hands On Lab (M, T, W, Th) DE15 - Integrated Motion On EtherNet/IP:Maximizing Machine Performance (T, W, Th, F)48Are you ready to innovate now?
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900DQuestions?
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900DThank you for participating!Please remember to tidy up your work area for the next session.We want your feedback! Please complete the session survey!