The Future of Machine Building is NOW!

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This presentation discusses the future of machine building that is taking place today; trends in integrated automation and how designers are developing more energy-efficient and cost-effective machines while maximizing their performance; trends such as remote monitoring, energy management, how you can gain a better understanding of your energy situation, and how this constraint can be an opportunity for growth.

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The Future of Machine Building is NOW!

  1. 1. The Future of Machine Building is NOW!Ed Sandlin, Ashish Patwardhan & Alec GraingerSchneider ElectricIndustry NOW Express Schneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 1
  2. 2. Agenda 1. Simplicity 2. Remote monitoring 3. Energy efficiency 4. MachineStruxureSchneider Electric - Industry Business – The Future of Machine Building is NOW! –2012
  3. 3. The Mobile Phone EvolutionSchneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 3
  4. 4. Machine Control EvolutionSchneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 4
  5. 5. The Future of Machines… Integrated Automation Now 1900’sSchneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 5
  6. 6. Integrated Automation Defined●“The convergence of previously distinct automation functions… Anintegrated platform uses one programming environment to handle allrequired functions” – Aaron Hand, Control Design and Industrial Networking●More complete, sophisticated and flexible software environments●Greater hardware flexibility and integration in machine control●Simplified and more readily accessible physical machine configurationSchneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 6
  7. 7. Integrated Automation Then Multiple Now software Single suites PLC software suite Prop. Cable Drive Motion I/O HMISchneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 7
  8. 8. Software TIA Portal CCW Workbench CX-One SoMachine Automation Studio TwinCat 2 & 3 MELSOFTSchneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 8
  9. 9. One Software: SoMachineWith SoMachine, you can develop andmaintain the complete application in asingle software environment includingcontrol, motion, drives, HMI, sensors,application libraries and networkautomation functions. Schneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 9
  10. 10. Hardware Flexibility Drive PLC PLC HMI Motor Drive HMI-PLC Integrated Motor Drive-PLC “Integrated motor-drivescould overtake standalone “HMI-PLCs will gain in systems” Schneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 popularity and drop in price” 10
  11. 11. Architecture Simplification What is Needed? The Fix1 Training 1 Training manuals2 Programming 2 Sample code & templates3 Wiring 3 Sample architectures4 3rd party components 4 White papers5 Testing 5 Simulation mode Schneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 11
  12. 12. Solutions for MachinesSave up to 50% in design timeReady-to-use architectures for optimum resultsPredetermined equipment listsTested ● Applications tested by our experts to ensure that they work in all possible configurationsValidated ● Fully functional compatibility of devicesDocumented ● Full user manual containing all the required information for installation and assembly, including CAD and wiring diagrams Schneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 12
  13. 13. Customizable MachinesValue Innovative Controls Engineering●Flexibility●Scalability●RepeatabilitySchneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 13
  14. 14. What Does Simplicity Mean?With MachineStruxure solutions, you can answer your customers’ challengesand help them remove complexity from their businesses. Reduce time to market Save 50% in control design time 100% flexibility & optimization of your machinesSchneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 14
  15. 15. You remember the Bass Model…● Ability to forecast future sales and the rate of adoption● Bass Model Frank Bass 1926-2006Schneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 15
  16. 16. Bass Modelf(t) = portion of Mthat adopts at time t Total AdoptionsF(t) = portion of M that at Time thave adopted by time t M = the potential market p = the coefficient of innovation q = the coefficient of imitationSchneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 16
  17. 17. Bass Model Generalization The “S Curve” of changeSchneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 17
  18. 18. Rogers’ Diffusion of Innovation ● Different consumers make it through the steps at different speeds Everett Rogers 1931-2004 Sales over time Schneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 18
  19. 19. Technology Adoption CurvesSchneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 19
  20. 20. Remote Interaction: Internet● NetMeeting / Skype / Google Hangouts / TeamViewer / DropboxSchneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 20
  21. 21. Remote Interaction: Machines● Machine: recipe management, trouble shooting, remote monitoring● Shop floor to office to service connectivity● SCADA / Web servers/ Web Gate / FTP servers/ USB keys… Ethernet NetworkSchneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 21
  22. 22. Future? The Cloud – EngagementEngaging with customers, partners, and employeesMicrosoft / IBM / Oracle /Salesforce.comFord Focus connectingonboard WiFi with ATT Schneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 22
  23. 23. The Cloud for Machine Builders: M2MEngaging with machines and business● Automation specialists offering dedicated M2M services ● GE: GE Remote Condition Monitoring Center ● HMS: RemoteCom ● ETIC ● Schneider Electric● Large OEM companies developing their own solution with equivalent features ● Daikin ● Carrier● M2M companies offering Cloud-based services ● Ewon: Talk2M ● M2MDatacorp ● Ei3Schneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 23
  24. 24. OptiM2M – How it works Architectures & infrastructure Data center Data center Kelowna - CANADA Les Ulis - France Web browser Vpn https M2M Portal Web browser Private APN The OEM + encrypting services Vpn Modbus master Modem RS 232 Modbus protocol Machine PLC Stand alone architecture Schneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 24
  25. 25. Cell Phone RevolutionConnecting with peopleSchneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 25
  26. 26. Cell Phones for Machine BuildersConnecting with machines / factoriesSCADA / PLC / HMI / SoftwareExample: Aluma TowerSchneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 26
  27. 27. Smartphone – Smart Devices RevolutionKnowledge, empowerment and connectivityApple / Samsung / Blackberry / LG / Google / Microsoft / Amazon / …Schneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 27
  28. 28. Smart Devices for Machine BuildersKnowledge, empowerment and connectivitySelection Apps / Control Apps / HMI Web Gate AppsExample: Palladium Technologies Schneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 28
  29. 29. The Future? NOW!Consumer & Machine BuildingCompletely automated machines and robots Rodney Brooks http://www.youtube.com/watch?v=rjPFqkFyrOYSchneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 29
  30. 30. Why Energy Optimization?Schneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 30
  31. 31. The Energy Dilemma The facts The need vs Energy demand CO2 emissions to by 2050 avoid dramatic climate Electricity by 2030 changes by 2050 Source: IEA 2007 vs. 1990 level Energy management is the key to address the dilemmaSchneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 31
  32. 32. Recent ArticlesThe push to achieve reductions in energy consumption is a significant global trend● MGM Resorts Hits the Energy Efficiency Jackpot ● Design World, SEP 2012● Energy Management Strategy, Roadmap Needed? ● Automation World, SEP 2012● Don’t Leave Energy Projects ROIs on the shelf ● ControlDesign, MAY 2012● Energy Efficiency: The Secret to Sustainable Machines ● Automation World, MAR 2011Schneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 32
  33. 33. Trends● The focus for machine design is no longer simply maintaining acceptable production rates at an appropriate level of quality.● Automation professionals are now deploying technologies in clever ways to improve the energy efficiency of their automated machinery.● In fact, companies that endorse energy efficiency and sustainability in their thinking experience stronger loyalty from their customers, produce better quality machines with improved machine performance, and find more opportunities for new business even in a tough economic environment. Source: Automation World Schneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 33
  34. 34. Energy Efficiency as a Source of Energy Fuel Consumer 100 units 35 units 33 units 3 units saved at the 1 unit saved at energy source consumer plugSchneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 34
  35. 35. The Power of a Combined SolutionGreater efficiency, smarter grid, and cleaner generation● Over 50% of CO2 emission abatement will come from end user efficiency World energy-related CO2 emissions abatement Source: World Energy Outlook 2010, OECD / IEA Schneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 35
  36. 36. Energy Efficiency for IndustryHas Already Started Consumer Packaged Retail Goods • 3% year-over-year reduction in energy, water, and waste. We are committed to reducing our waste and use of non-sustainable energy and water. • Sustainable in a generation. We are committed to a zero carbon footprint, zero impact in the use of water and zero waste to landfill at our sites by 2040. y bilit aina Material Handling S ust Buildings Going Green MGM Resorts Hits the Energy Efficiency UPS has become the first major package delivery Jackpot: In Las Vegas, one of the leading and logistics company to earn Gold Status corporations in the “entertainment capital of the certification from the Leadership in Energy and world” is staying true to the city’s visionary Environmental Design (LEED) along with an history by anticipating the need for sustainable Energy Star certification for its corporate and energy-efficient structures well ahead of headquarters complex many of its competitors. Schneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 36
  37. 37. Easily Identifiable Energy Efficiency OpportunitiesIndustrial companies don’t have sufficient information to know where to look beyond the easily identifiable energy efficiency opportunities Less obvious, higher impact: energy efficiency through process and machine efficiency… …to reduce the energy consumed per unit of output!Schneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 37
  38. 38. Solving the Energy Equationwith a focus on energy efficiency 1 Energy audit Find out what the challenge is… & metering Model fully compliant with EN 16001 & ISO 50001 Passive energy efficiency Active energy efficiency 2 3 Optimize through 4 Monitor, Fix the basics automation maintain, & regulation improve Low consumption devices, Variable speed drives, Meters installation insulation material, power HVAC control, and integration, factor correction machine controllers for supervisory services, production optimization EE analysis software Passive + Active EE solutions = Sustained Energy SavingsSchneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 38
  39. 39. Why Improve Energy Efficiency inMachines?● Energy efficiency is an increasing concern “Together with Schneider Electric we realized the in the global strategy of your new SP2 NG – an energy customers. By offering them machines that efficient machine, bringing tangible improvements save energy you will have a definite to the end user in energy advantage over the competition. usage, in terms of consumed watts per manufactured unit, enabling up to 30% energy savings compared to ●MachineStruxureTM solutions help you traditional machines.” design more energy efficient machines ACMA while increasing: Flowpack Division ●Machine performance ●Machine attractiveness for end users Schneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 39
  40. 40. End-users Have Already Shifted to “Green”● Energy savings in 2007 in 2011 is now the 1. Price 1. Price second 2. # of operators 2. Energy savings 3. Saving use of consumables 3. Saving use of consumables criteria 4. Packing material reduction 4. # of operators considered when 5. Energy savings 5. Packing material reduction choosing a machine How is your● In 2011, 77% investment in of end users sustainable increased or development maintained their evolving? investment towards “Green”Europack-Euromanut (+300 enterprises in Packaging-Consumers Industry) Summer 2011 Schneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 40
  41. 41. How to Boost EnergyEfficiency in MachinesSchneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 41
  42. 42. Machine Energy Optimization 1In Four Sustainability Steps ISO 50001 2 3 4● Follow the 4 energy efficient principles adapted to the machine life cycle to support energy savings and obtain immediate results● Make your machine an enabler for end user compliance to EN 16001 & ISO 50001 standards 10 to 15% Up to 8% per year is lost 5 to 15% 10 to without monitoring and 2 to 8% 15% 5 to maintenance program 15% 2 to 8% Up to 12% per year is lost without regulation and control systemsSchneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 42
  43. 43. Machine Energy OptimizationIn Four Sustainability Steps1- Audit your machine energy 4- MonitorIdentify energy waste in your machine and energyrecommend optimization solutions consumption2- Fix your machine basicsSelect relevant motor optimizer motor control  Use variable speed drives  Use Servo-drives and synchronous motors3- Optimize your machineEnergy operating modes: high value mechanismwith no additional hardware cost  Energy management functions in controllers and HMI  Energy optimization guidelines for machines in targeted applications (HVAC&R, packaging, conveying, hoisting, etc.) Schneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 43
  44. 44. Focus on Energy Monitoring Libraries for MachinesSchneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 44
  45. 45. How does it work?Libraries interactions: SoMachine HMIs Machine Energy Dashboard MED Graphical Objects (Vijeo Designer Tool chest) Data Processing Machine FBs production data EE Toolbox library Accumulator Controllers FB Devices Generic Energy Meter Communication FBs FB In the Field Supported field-buses: Power meters Circuit breaker Motor control Other equipment (based on rated power) Schneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 45
  46. 46. Machine Energy Dashboard - Overview● Simple indicators for operator ● Real power: Color ranges for quick detection of any deviation ● Real energy: ● Split by operating mode ● Spent per unit produced ● Peak alert ● Trend indicator ● Ready-to-use and fully customizable (units, thresholds, reset control, etc.) Schneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 46
  47. 47. Machine Energy Dashboard - Overview● Trend Information ● Energy per unit 1. Energy calculated per unit produced 2. Average energy for total amount of units 3. Energy per unit target (constant value) 4. Energy per unit high limit - generates an alarm when reached ● Power and unit 1. Average power per sampling time (hours, minutes, etc.) 2. Amount of units produced per sampling time Schneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 47
  48. 48. EE Monitoring: Improve PredictiveMaintenance  Deviation to target often indicates equipment “pre-failure“ Energy per unit Dec, 21st, 2010 – 18:05:02 Instant Power Last reset 20/12/2010 10:00:00 230 AVERAGE 2.89 Wh Energy per unit 172 Deviation + 0.57 Wh AVERAGE 2.89 Wh 115 200 kW 1 - Analyze over-consumption 58 • Worn mechanical bearings • Motor failure • Electrical issue (insulation, power 0 quality, etc.) • Lack of lubricant • Unexpected temperature increase • Raw material properties change • Dirty filters •… 2 - Fix problem before serious issue occurs – limit impact on performanceSchneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 48
  49. 49. EE Monitoring: Distributed Architectures Machine (Zone 1) PM800 Example of distributed monitoring architecture Zone 2 Zone 2.1 Modbus / CANopen with M258 ATV32 1 ATV32 2 Zone 2.2  ATV71 1 ATV71 2 Zone 3 LXM 32 1   LXM 32 2 PM1200   Zone 4 TESYSU 1 PM1200 Zone 5 On/Off Eqt Schneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 49
  50. 50. Italy - Packaging Machine: “Energy Bar” Schneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 50
  51. 51. Italy - Packaging Machine: “Energy Bar” Schneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 51
  52. 52. Schneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 52
  53. 53. A Comprehensive Automation Solution for Industrial Machines MachineStruxure solutions help machine builders design machines that are optimized for cost, energy efficiency and performanceSchneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 53
  54. 54. Reduce Complexity With One single Unique TVDA* End-to-end Simple and easy software value service support to use environment proposition Integrated software SoMachine: Motion Simplify machine programming & centric commissioning Drive centric Speed up Logic “concept to centric design” 4 hardware control platforms Optimize Embedded Intelligence machine production, flow where it is needed and capacity Optimize on- site intervention costs 6 targeted applications HMI centric Hoisting, Textile, Packaging, Conveying, HVAC&R, Elevators & Escalators Schneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 54
  55. 55. TVD Architectures● Tested ● Tested in laboratory by experts ● Ensuring the right functional performance in all possible configurations● Validated • Fully functional compatibility of the devices● Documented ● Complete user guide giving all the details required for installing and building your application with confidence • Ready to use with e-plan: predefined CAD panel designs & wiring diagrams ● Up to 50% control system design time savings ● Installation time reductionSchneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 55
  56. 56. Innovation for Simplicity Simplified offers Simplified maintenance Modicon controllers Altivar 32 and Lexium 32 drives  MMS  e-mail  Wap  Internet Send-receive configuration everywhere & any time Getting closer and being more responsive to local needs Upload-download configuration with drive Adapting our offer to meet customer needs Monitor-control drive Simplified Self powered wireless push button and Hardware flexibility Magelis STU Ensure permanent availability – battery-less 22mm mounting system Robustness for harsh Ethernet embedded environment Powered by Vijeo Designer Mobile control Simplified assembly Simplified integrationSchneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 56
  57. 57. Helps you manage yourprocess more efficientlywhile using less energySchneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 57
  58. 58. Solutions for MachinesServices & supportThroughout the complete machine life cycle > Innovation and competitiveness right OEM-specific from the start services and > Speed up « concept to design » support at every step of your machine life cycle Improve your end user customers’ > Optimize machine satisfaction by production flow and maximizing their capacity investments Further develop your sales in a > Maximize machine profitable way continuity of operation > Optimize on-site intervention costs > Generate profit while > Expand business by addressing new keeping end user markets customer satisfied > Access international markets while minimizing associated risksSchneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 58
  59. 59. Solutions for Machines With MachineStruxure solutions you can answer your customers’ challenges and help them remove complexity from their businesses Reduce time to Added value throughout the market entire life of your machine Build a strong automation platform through Save 50% the use of our proven and in control design ready-to-use automation architectures and time application function libraries SoMachine is a single software suite that runs on 100% flexibility & multiple hardware control optimization of your platforms to achieve flexible machines machine control: HMI, motion, drive and logic controllersSchneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 59
  60. 60. AnnexSchneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 60
  61. 61. ISO 50001 StandardPublished in June 2011● ISO 50001 is based on the ISO management system model familiar to more than a million organizations worldwide who implement standards such as: ● ISO 9001 (quality management), ISO 14001 (environmental management), ISO 22000 (food safety), ISO/IEC 27001 (information security)● Follows the Plan-Do-Check-Act process for continual improvement of the energy management system● Provides a framework of requirements enabling organizations to: • Develop a policy for more efficient use of energy • Fix targets and objectives to meet the policy • Use data to better understand and make decisions concerning energy use and consumption • Measure the results • Review the effectiveness of the policy • Continually improve energy management● ISO 50001 can be implemented individually or integrated with other management system standardsSchneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 61
  62. 62. Motor Consumption in the WorldMotor’s energy bill = motor cost x 100 ● in Industry 60% of electricity ● in Building, 30% of electricity Big Motor: 1 Month Energy Bill = Motor Cost Energy 97%Installation & Maintenance: 2% Investment: 1%Global costs during motor life (average 15 years) Schneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 62
  63. 63. Optimizing Energy Efficiencyof ConveyorsSchneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 63
  64. 64. Packaging: The Right Technology forEnergy Efficiency● Create the Energy Footprint of your machine - simulate andmonitor using same software features● Use High-efficiency servo motors with Lexium SH● Share DC-bus using using PacDrive iSH and Lexium LXM62 / ILM62 multiaxis solution● Save cabinet cooling energy by shifting servo drives to the machine frame - integrated servo drives series Lexium ILM● Optimize flexible machines with ATV32 and brushless motors● Design energy efficient motion with ECAM● Design energy efficient path design for robots with PacDrive Robotics library● Use Intelligent Line Shaft and PacDrive libraries to optimize synchronous servo axes consumption● Request Schneider Electric Consulting/Engineering for a comprehensive consulting for machine solutions and engineering services support Schneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 64
  65. 65. Hoisting: Active Front End AllowsEnergy Regeneration ● Active Front End is an option for the frequency inverter to return energy to the mains. It provides 4-quadrant operation and thus it is well qualified for hoisting applications which then generate energy during descent (braking) stages ● Provides a constant DC voltage supply independent of the load situation. ● Resistor-less technology ● Better reliability in harsh environment ● Huge energy saving ● Compactness of equipments ● Reduce losses and disturbances in the mains with a THDI < 4% > More on AFESchneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 65
  66. 66. PowerLogic System PanoramaPerfect forMachinesEnergy « PowerLogic » Power MetersMonitoring PM 9C PM 1200 PM 32xx PM 800 « Acti9 » Energy Meters iEM 31xxv iEM 32xx Current TransformersSchneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 66
  67. 67. Thank You!Schneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 67

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