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Joa Overview


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Introduction to Joa machine technologies

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Joa Overview

  1. 1. Curt G. Joa, Inc. Standard Machine Platform ~ Electrical Controls and Technology~ OVERVIEW PRESENTED BY: Kevin Zeinemann, PE Electrical Engineering Department Manager Curt G. Joa, Inc.
  2. 2. Who We Are…The Curt G. Joa, Inc. Engineering Department <ul><li>Established by Curt G. Joa, Sr. over 75 years ago as a engineering-driven group of problem solvers. </li></ul><ul><li>We are professional engineers, designers, and technicians with a passion for making things work! </li></ul><ul><li>Widely regarded as the industry leader, we practically invented the market for disposable sanitary napkin and diaper machines. What problems can we solve for you? </li></ul>
  3. 3. Joa’s Marketplace Challenges <ul><li>Cost Containment!!! </li></ul><ul><li>Provide fast customer response and shortened delivery times </li></ul><ul><li>Remain a BEST-IN-CLASS full-service solutions provider. </li></ul><ul><li>Keep up with customization demands; i.e. scalable designs for both diverse and unique needs. </li></ul><ul><li>Continue to embrace emerging “State of the Art” technologies. </li></ul><ul><li>Develop software/hardware/design commonality. </li></ul><ul><li>Offer Simplicity and elegance in design. </li></ul><ul><li>Provide “Future Proof” upgrades that can withstand the onslaught of the “Next Great Technology”. </li></ul><ul><li>Maintain pre/concurrent/post-design support mechanisms. </li></ul><ul><li>Offer a partnership of ideas, NOT supplier exclusivity. </li></ul><ul><li>Did we mention Cost…..Cost…..Cost? </li></ul>
  4. 4. Special Machines for Special Customers <ul><li>Unlike most of our competitors, Joa has no “standard“ machine models. </li></ul><ul><li>Every application is special to us, so every new machine order gets a fresh run through our engineering department. </li></ul><ul><li>Some of the proven core competencies we offer: </li></ul><ul><ul><ul><li>Continuous web-fed processes </li></ul></ul></ul><ul><ul><ul><li>Converting and Laminations </li></ul></ul></ul><ul><ul><ul><li>Pick and place </li></ul></ul></ul><ul><ul><ul><li>Form fill / seal </li></ul></ul></ul><ul><ul><ul><li>Packaging </li></ul></ul></ul><ul><ul><ul><li>Ultrasonic bonding </li></ul></ul></ul><ul><ul><ul><li>Laser cutting and welding </li></ul></ul></ul>
  5. 5. The Right Technology at the Right Time <ul><li>Since all our machines are made to order, we must maintain a good working knowledge of virtually all available automation platforms. </li></ul><ul><li>Because of the large scale of our projects and the high profile our machines achieve in the marketplace, automation vendors are always eager to work with Joa as technology partners. </li></ul><ul><li>This gives Joa an inside track to key emerging technologies that may not be available to the general public. </li></ul><ul><li>We’re proud of our accomplishments, but we didn’t get where we are now by jumping into the pool without testing the waters first. </li></ul><ul><li>All machines go through our exhaustive testing and shakedown process. This ensures that no technology winds up in our customers’ hands until it is truly production ready. </li></ul>
  6. 6. What technologies can be found on a typical Joa machine? Control Logix PLC Platform with Safety PLC and Integrated motion control 8 L64 CPU +1 Safety PLC Kinetix 6000 / 7000 Servo Drives >160 Servo Axes Flex / Point I/O GuardLogix Safety I/O >1000 I/O POINTS Joa2.0 Joa 2.0 Object-Oriented Programming Advanced Networking Technologies flexHMI Operator Interfaces
  7. 7. Rockwell Automation “Logix” Platform <ul><ul><li>Advanced feature set and a global support network makes the Logix PLC our platform of choice. </li></ul></ul><ul><ul><ul><li>Supports user-defined data types - custom tag structure </li></ul></ul></ul><ul><ul><ul><li>Allows custom “add-on instructions” (AOI) </li></ul></ul></ul><ul><ul><ul><li>Easily connects to third-party devices using CIP object model </li></ul></ul></ul><ul><ul><ul><li>Integrated motion and machine safety functions </li></ul></ul></ul><ul><ul><ul><li>RSLogix programming/maintenance environment – best in class PLC software package </li></ul></ul></ul>
  8. 8. A Unified Network Structure MCC UNFILTERED NETWORK PORTS FILTERED NETWORK PORTS <ul><li>We have seen the future, and it is wired! Joa takes advantage of a unified network architecture that ties the entire process together. </li></ul><ul><li>Advanced technologies from the IT world find their way to the production floor. </li></ul><ul><li>A “switched star” network topology is used, placing a discrete layer-2 switch inside every junction box and network access point. </li></ul>JB JB MOC UPLINK TO ENTERPRISE NETWORK SECTION I/O ANCILLARY EQUIPMENT
  9. 9. Rockwell Automation Kinetix Multi-Axis Motion Control Kinetix 6000 offers up to 22 kW continuous output power and 8 axis modules on a common power rail MPL motors with multi-turn high resolution encoders offer high torque and performance in small footprint Kinetix 7000 can drive synchronous (servo) or asynchronous (induction) motors up to 150KW. <ul><ul><li>Kinetix brings sophisticated multi-axis motion control directly into the PLC programming environment. </li></ul></ul><ul><ul><li>Combines the versatility of SERCOS-based motion control with the simplicity of ladder-logic. </li></ul></ul>Logix integrated motion
  10. 10. <ul><li>MECHANICAL LINESHAFT </li></ul><ul><li>Lineshaft, gearboxes and fixed pulley ratios </li></ul><ul><li>Mechanical windup, maintenance, fixed draws </li></ul><ul><li>ELECTRONIC LINESHAFT </li></ul><ul><li>Drives follow “virtual master” </li></ul><ul><li>Reduced mechanical maintenance issues </li></ul><ul><li>adjustable draws and torque limits </li></ul><ul><li>Drives can be organized into independent “groups” </li></ul>“ An imaginary lineshaft position reference that can be used to synchronize multiple variable speed drives” Virtual Masters and Electronic Lineshaft
  11. 11. Good engineering requires good tools Joa uses “State of the art” CAD/CAM integration to streamline the design process. Rockwell Software tools like RSLogix and FactoryTalk View are key components to our object-oriented approach.
  12. 12. Machine Safety is “on board” <ul><li>Coordinated machine safety thanks to SafeLogix and Kinetix </li></ul><ul><ul><li>SafeLogix dual processor solution (1oo2 Architecture) offers SIL3 safety levels using standard PLC logic. </li></ul></ul><ul><ul><li>Kinetix drives with integrated “safe off” simplifies safety system implementation. </li></ul></ul><ul><ul><li>Drives last longer because bus power doesn’t have to drop in order to achieve “safe state”. </li></ul></ul>
  13. 13. Standardized Bills Reduce Design Time <ul><li>Commonly used components are grouped into pre-engineered “bills of material” by special teams devoted to developing engineering standards. </li></ul><ul><li>Designers then order assemblies as needed using a standard BOM for each machine section. </li></ul>+ = Standard BOM Standard Drawings/Schematics Standard Assembly
  14. 14. What Is Joa 2.0? <ul><li>Joa 2.0 is our plan to leverage emerging technologies into a versatile automation platform that can satisfy the rapidly changing needs of our customers, while bringing the economies of an object-oriented and collaborative design environment to the factory floor. </li></ul><ul><li>Standard building blocks of logic are created for typical machine functions and are teamed up with standard HMI “widgets”. </li></ul><ul><li>Taking advantage of standardized and rigorously tested PLC logic and HMI objects greatly reduces the time required for design and commissioning. </li></ul><ul><li>Standard PLC logic is developed by specialists working in dedicated “technology teams”. </li></ul><ul><li>By embedding versioning tags in these design elements, we can determine what logic has been used on a particular machine to make sure that the engineering is up-to-date. </li></ul>2.0
  15. 15. Modular Object-Oriented Add-On Instructions <ul><li>Standard logic routines are stored in Add-On instructions that we call “J-BLOCKS”. </li></ul><ul><li>J-Blocks are used wherever code can be replicated for similar applications that are commonly found in the control system. </li></ul>Standardized Releases Reduce Design Time <ul><li>Data for J-Blocks is set up in arrays allowing for future expansion. </li></ul><ul><li>J-Block tags provide “hooks” for HMI widgets </li></ul>
  16. 16. HMI Control “Widgets” <ul><li>Control “Widgets” are pre-configured HMI objects designed to be easily dropped into a FactoryTalk View Studio project. </li></ul>Standardized Releases Reduce Design Time <ul><li>Widgets are distributed in a centralized library file stored on a network share on the Joa Intranet. </li></ul><ul><li>instructions for use, dependencies and versioning information are included in the libraries. </li></ul>
  17. 17. The Link Between Widgets and J-Blocks <ul><li>J-Blocks and HMI Widgets are intimately related; they rely on each other to provide a versatile and flexible design base. </li></ul>Standardized Releases Reduce Design Time
  18. 18. Descriptive Text Comes From String Tags in the PLC <ul><li>Since the Widget’s descriptive text lives in the PLC data table, standard HMI screens can be used for many different applications without having to revise the HMI programming. </li></ul><ul><li>ASCII “String” tags are used extensively to provide the HMI widgets with their descriptive text. </li></ul>
  19. 19. Application Example: 100% Quality Inspection <ul><li>Every product receives a quality inspection from a machine vision system. </li></ul><ul><li>Products are tracked through the entire production process, at speeds exceeding 1200 products per minute. </li></ul><ul><li>Automatic cull systems reject any product that doesn’t meet specifications. </li></ul>Vision System
  20. 20. CIP Motion (Ethernet) KINETIX 6000 SERVO DRIVES KINETIX 7000 SERVO DRIVES Typical Control System Architecture Motion Control Logix PLC(s) Supervisory Safety Logix PLC Ethernet and Ethernet/IP Networked PC (Maintenance/ Engineering) Ancillary Equipment Managed Switch Safety I/O Point I/O NTP (Network Time Protocol) Managed Switch Integrated “Logix” PLS One network to rule them all! Large Format Message Display Embedded XP HMI Clients Direct IP Safety Devices Ethernet/IP Pneumatic Valve Banks Direct IP “Smart” Devices Network Attached Storage Appliance (Online Documentation) Embedded XP HMI Client
  21. 21. Always Striving to Maintain a Careful Balance <ul><li>Joa engineering is uniquely qualified to achieve the perfect balance between bleeding-edge technology and conservative sensibilities. </li></ul><ul><li>Concern for the “bottom line” and designing for user-friendliness rounds out our suite of core competencies. </li></ul>At Curt G. Joa, Inc. we don’t try to predict the future of industrial automation, we make it happen! For more information, visit Joa on the web! Point your browser to