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Copyright © 2009 Rockwell Automation, Inc. All rights reserved. Compact Machine Solutions Increased capabilities to maximize your small and medium size machines

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Page 1: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

Compact Machine Solutions

Increased capabilities to maximize your small and medium size machines

Page 2: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

3Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

1. Compact Machine Solutions

2. CompactLogix Architecture

3. Compact Machine Applications

4. Available CMS Tools

5. Questions

Agenda

Page 3: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 4

•• Direct Costs Direct Costs •• Indirect CostsIndirect Costs

REDUCE COST REDUCE COST --• Lower Total Cost to Design, Develop, and DeliverSM (TCD)

– Reduce costs involved in machine production• Use standard components (SCALABILITY)• Reusable Engineering content (MODULAR PROGRAMMING)

– Reduce costs after delivery• Remote access to devices below the controller for maximum diagnostics capabilities

• Faster Time to Market– Shorter design, test and commissioning cycles – Provide custom machinery within standard build cycle (FLEXIBILITY)

BETTER MACHINES BETTER MACHINES --• Improved Machine Innovation, Throughput and Performance

– Increasing competitive machine requirements – Differentiate on reliability and OEE effectiveness– Information enabled machines– Flexible machines

• Intellectual property protection

•• SpeedSpeed•• PerformancePerformance

•• OEEOEE

COMPETITIVENESS COMPETITIVENESS

What is important for OEMs?

Page 4: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

5Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

How can CompactLogix help you?

• Combine multiple control disciplines (Discrete, Motion and Process) in a single controller– Reduce hardware cost, development cost and integration cost

• Configurable from simple, general purpose discrete control to demanding coordinated motion applications

– Provide a scalable and common platform for a wide range of applications• Use modular local I/O or a distributed I/O network all with built-in diagnostics

– Increase uptime by getting faster machine diagnostics• A single programming software environment for all control disciplines, RSLogix5000

– Reduce training, integration and documentation cost• Connect all automation devices needed with a single network, EtherNet/IP

– Reduce commissioning time and costs to integrate machines to information systems• Use a scalable visualization platform, PanelView Plus, with direct tag access

– Reduce development cost and hardware spare parts

Page 5: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

OEM Market Characteristics Machine/Equipment Continuum

6

Low(Mechanical)

High(Electrical)

Mid(Hybrid)

e.g. Gen 1 – Mechanical motion with single drive shaft using cams, sprockets, gears and pulleys.

e.g. Gen 2 – Retrofit some mechanical axes with servo motors and drives.Typical 2-3 Motion Axis Max., many times with AC Drives instead of Servos

e.g. Gen 3 - All mechanical motion replaced with servo motors and/or synchronized VFDs on each of multiple individual axes using integrated motion and logic control.

1 2 3Technology Adoption

Upst

ream

(Pro

cess

/Ass

embl

y/Pow

er

Cent

ric)

End

of L

ine

(Pac

kagi

ng / C

PW / M

at

Hand

)

Low end equipment, low end controller, hardwired devices or low level network, low end HMI, simple pneumatics, simple analog instrumentation or gauges, hardwired drives or on/off control

Mid level equipment, Rack based controller with DIO, simple networked field devices, local/mid HMI, analog instrumentation, networked drives

Low Mid HighHigh end equipment, fast/redundant controller with DIO, FF/Hart smart instrumentation, SCADA, information enabled, intelligent motor control, robotics

Component Basic IA ComplexBuying Behavior

Page 6: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

Compact Machine Solutions spaceCompact Machine Solutions space

Integrated Architecture Solutions for Machine Control

7

Integration ContinuumLow High

Multi axis motionIncreased controller capabilitiesMix of mechanical and electrical

controlsLow engineering costs

Multi axis motionRobotic Feeders

Electronic Line ShaftingAdvanced connectivity

Advanced information capabilitiesSimple Logix controlPackaged controller

EtherNet/IP

Flexible controlCapable controller

EtherNet/IPPredominant mechanical

control

Page 7: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

An Integrated Architecture Class Machine leverages:

• Integrated Motion – Highly integrated speed & position solutions

• Advanced programming techniques– Modular Programming– Libraries– Specific Instructions & Faceplates

• ISA S88 / PackML– State modeling, Modular control

• Device Premier Integration (i.e. PowerFlex Drives)– Reduced development, commissioning and maintenance costs

• Information access over EtherNet/IP– Immediate integration with end-user’s information system– Web, email capabilities, remote diagnostics

8

Page 8: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

9Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

1. Compact Machine Solutions

2. CompactLogix Architecture

3. Compact Machine Applications

4. Available CMS Tools

5. Questions

Agenda

Page 9: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

10Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

Page 10: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

11Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

CompactLogix: Part of Logix Control Platform

• Multi-disciplined control– Discrete, Motion, Process and Drives

• Scalable– Different platforms to address any control application

• Information-enabled– Data available throughout the architecture

• Common Programming environment– RSLogix 5000

• Multi-language– Ladder, Function Block Diagram (FBD), Sequential

Function Chart (SFC) and Structured Text (ST)

CompactLogix Family

Page 11: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

13Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

The CompactLogix Family Positioning

A range of controllers for simple stand-alone machines to some of the most demanding applicationsA range of controllers for simple standA range of controllers for simple stand--alone machines alone machines to some of the most demanding applicationsto some of the most demanding applications

Stand-alone and smallpackaged control

Machine and general purpose control

High performance motion control

L2x System

L3x System

L4x System$$

ff

• Models: L31 (2 RS232)L32C & L35CR (1 ControlNet + 1 RS232)L32E & L35E (1 EtherNet/IP + 1 RS232)

• Memory: 512Kb – 1.5Mb• Local I/O: 16-30 Modules up to 3 banks• Remote I/O: Networked FLEX or POINT I/O

Comms: EtherNet/IP, ControlNet, DeviceNet or 3rd Party

• Models: L23E-QB1B (Ethernet + RS232)L23E-QBFC1B (Ethernet + RS232)L23-QBFC1B (2 RS-232)

• Memory: 512Kb • Built-in DC I/O: 16in, 16out• Built-in Analog I/O: 4in / 2out• Built-in Counter: (4) - 250Khz• Expansion: (2) 1769 I/O modules or (1)

communication module• Remote I/O: Networked FLEXTM or POINT I/OTM

• Comms: EtherNet/IP, DeviceNet or 3rd Party • Models: L43 (4-axis motion & 1 RS232)L45 (8-axis motion & 1 RS232)

• Memory: 2Mb-3Mb• Local Exp: (2) 1768 slots available for (2) Motion,

(1) Motion & (1) Network or (2) Network• Local I/O: 16-30 Modules up to 3 banks• Remote I/O: Networked FLEX or POINT I/O• Comms: EtherNet/IP, ControlNet, DeviceNet or 3rd

PartyApplication Size, Performance, Communications, Motion Integration

Page 12: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

14Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

Logix Controllers OfferingVa

lue

Valu

e Va

lue

FunctionalityFunctionality

1769-L31

1769-L32C

1769-L35CR1769-L35E

1769-L32E

1769-L23E-QB1B

1769-L23-QBFC1B

1769-L23E-QBFC1B

1769-L43

1769-L45

NEW

NEW

NEW

NEW

Page 13: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

15Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

CompactLogix Benefits

• Symbolic Addressing for self-documented code

• User Defined Structures to provide Data Encapsulation.

Single Data Model

Compact I/O

• IEC61131-3 interface choose the best language for the function being performed

Multiple Programming Languages

Wide Variety of NetLinx Connectivity Options

EtherNet/IP, ControlNet & DeviceNet

Single Programming and Network Package

Providing re-use of programming code

Page 14: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

16Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

CompactLogix L23

PowerFlex 4 AC Drive

Output to Pneumatic Operated Sealing Jaw

Film Unwind

PanelView PlusCompact EtherNet/IP

Encoder

Same programming software as the more demanding systems: Re-use of same code

Smaller, Intermittent machine - Now

CompactLogix L2x

Page 15: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

17Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

CompactLogix L23

PowerFlex 4 AC Drive

Film Unwind

PanelView PlusCompact EtherNet/IP

Same programming software as the more demanding systems: Re-use of same code

Digital I/O from L2x (for Enable-Ready etc)

Encoder Emulated Pulses From U3K to L2x Embedded High Speed Counter

Simple U3K (Non-Index, Non-SERCOS, Non- DeviceNet)

Analog output (+ -10V) From Point I/O to U3K

Smaller, Intermittent machine – Now w/ Servo

CompactLogix L2x

Page 16: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

18Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

EtherNet/IP

Kinetix 300 Servo Drive

Film Unwind

CompactLogix L23

Same programming software as the more demanding systems: Re-use of same code

PanelView PlusCompact

PowerFlex 4 AC Drive

Film Unwind

CompactLogix L2x

Smaller, Intermittent machine – Future

Page 17: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

19Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

CompactLogix L3x

Comes standard with built in RS-232 port(s)

Comes standard with built in RS-232 port(s)

Cost-effectively integrate a simple machine into a plant- wide control system

• Maximum of 3 banks

• Supports up to 30 modules

• Mix and match analog, digital or intelligent modules

Local I/O

Built in EtherNet/IP or ControlNet network optionsBuilt in EtherNet/IP or ControlNet network options

DeviceNet connectivityDeviceNet connectivity

• Ideal solution for stand alone machine-level control or system-connected applications– Economical, reliable control system solution

Built in network ports to reduce system costs

Built in Built in network network ports to ports to reduce reduce system system costscosts

Page 18: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

20Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

CompactLogix L3x

System Overview• Choose the controller that best fits your needs

– L31, L32C, L32E, L35CR, & L35E • User memory ranging from 512K to 1.5Mb • Complete connectivity options

– EtherNet/IP, ControlNet, and DeviceNet– RS-232 Port

• DF1, DH-485, ASCII protocols and 3rd party• Local I/O capacity – ranging from 16 to 30 local 1769 I/O modules

– Up to 3 banks of expanded I/O racks– Ability to mix and match any combination of digital, analog & intelligent

modules• Expanded capability to control Distributed I/O and Drive systems

– EtherNet/IP, ControlNet, & DeviceNet

Page 19: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

21Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

CompactLogix L3x

• Integrated Advanced Networks– Ideal for general control applications– Seamless integration to existing

ControlLogix Controllers– One common Integrated Architecture

• Scalable Network Controllers– Complete NetLinx offering– EtherNet/IP, ControlNet, DeviceNet

Application Overview• Machine Level, Standalone Control

– Economical Logix Options– Compact and Flexible

Page 20: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

22Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

CompactLogix L4x PAC

• Addition of an advanced high speed communications 1768 bus structure– For motion and high performance communications

Expands CompactLogix family to address simple motion applications or multiple network communications

Integrated Serial port

SERCOS motion module

Same I/O as the L3x system

Same I/O as the Same I/O as the L3x systemL3x system

• Up to 8 modules on the local bank

• Maximum of 3 banks for a total of 16 modules

• DeviceNet connectivity

Local I/O

Modular design provides the

flexibility to select the right modules to

fit the application

Modular design Modular design provides the provides the

flexibility to select flexibility to select the right modules to the right modules to

fit the applicationfit the application

Network modules for EtherNet/IP & ControlNet

Page 21: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

23Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

CompactLogix L4x PAC

Integrates Discrete and Motion Control into single package

Supports discrete logic and motion in

the same controller

Supports Supports discrete logic discrete logic and motion in and motion in

the same the same controllercontroller

Multiple software packages

Multiple Multiple software software packagespackages

Single software package

Single Single software software packagepackage

Dedicated programming

languages

Dedicated Dedicated programming programming

languageslanguages

Programming language

with support for logic and motion

Programming Programming languagelanguage

with support for logic with support for logic and motionand motion

Hardwired or network connection

between logic and motion controller

Hardwired or network Hardwired or network connectionconnection

between logic and motion between logic and motion controllercontroller

No connection required - control

executes logic and motion

No connection No connection required required -- control control

executes logic and executes logic and motionmotion

Dedicated controller for

discrete logic & dedicated

controller for motion

Dedicated Dedicated controller for controller for

discrete logic & discrete logic & dedicated dedicated

controller for controller for motionmotion

• simplifies design, commissioning, start up, and support

Page 22: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

24Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

CompactLogix L4x PAC

• Multiple axis support – Up to 8 coordinated servo axis– 2 Auxiliary feedback axis

• Configure for position control or master input for camming and gearing functions

– 6 Virtual Axis• Simulated axis in controller memory with fully functional motion

planer• SERCOS Motion optimized communications

– Configurable ring communications to 4 or 8MHz – Auto configure for optimal performance

• RSLogix 5000 drive configuration, commissioning and programming– Course update configurable down to 0.5msec – 38 advanced motions functions

• Simplified configuration tools for Kinetix SERCOS drive systems• Expand the system with VHZ and simple position/indexing functions

using PowerFlex drives

Extends RSLogix configuration and monitoring to the

actuator

Extends Extends RSLogixRSLogix configuration and configuration and monitoring to the monitoring to the

actuatoractuator

Capacity and performance to meet demanding motion application requirements, and advanced features to simplify integration

Page 23: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

25Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

CompactLogix L4x PAC

• Time Camming (TCAM) allows complex motion profiles to be executed

• Position Camming (PCAM) allows complex position locked motion of up to 4 axes

• Powerful instructions provide easy programming while supporting a high degree of configurability

– Multiple position lock options– Profile blending– Slave and master profile scaling

• Support for linear and cubic spline interpolation– Cubic spline interpolation provides smooth motion

with a minimum number of profile points• Graphical profile editor provides easy development

and display of complex profiles• Support for registration detection and phase

correction

LinearLinear

SplineSpline

Enter points directly from a spreadsheet

Enter points Enter points directly from a directly from a spreadsheetspreadsheet

Complex multi axes camming functions made simple

Page 24: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

26Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

CompactLogix L4x PAC

Application Overview

• Integrated discrete and motion control– Small & mid-sized stand alone machines– Information enabled with the complete

NetLinx offering– Scalable, Modular, Configurable, and

Compact

• Enterprise wide network platforms– Separate the device level and plant

wide or enterprise networks– Ideal for distributed applications– One common Integrated Architecture

Business System

EtherNet/IP

EtherNet/IP or ControlNet

Page 25: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

27Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

CompactLogix Communication Capabilities

• NetLinx Network Interfaces– EtherNet/IP

• Full implementation of the EtherNet/IP standard– ControlNet

• Single or redundant media options– DeviceNet via scanner module

• Up to 64 nodes• Easy configuration

• Built-in RS-232 port protocols– DF1 Full Duplex/Master/Slave

• Connect operator interface devices; dial-up, leased line, or radio modems; programming terminals

– DH-485 protocol• Connect to DH-485 networks

– ASCII• Allows CompactLogix to read and write with ASCII devices such as barcode readers,

weigh scales and printers

Page 26: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

28Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

CompactLogix on EtherNet/IP

• Complete support of the popular, powerful and established EtherNet/IP standard– 100Mbit/sec Ethernet connection – Simultaneously and seamlessly handles multiple HMI and I/O connections

• Complete support of standard Ethernet and web services – Supports the standard TCP/IP web based protocol– Up to 32 simultaneous TCP/IP connections– Supports web browsing, Email, and integrated diagnostics

• Open socket connection, FTP, web data access / XML (L4x controllers)– Develop custom web pages for enhanced diagnostics and data monitoring– Provides access to 3rd party Ethernet devices

Advanced EtherNet/IP capability allows control of the plant floor with a single network

EtherNet/IP

BusinessSystem

Custom Web Pages

Page 27: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

29Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

Cat. No. Memory Comms Local IO Slots Availability

1769-L45 3Mb EtherNet/IP. ControlNet, DeviceNet, Sercos, 3rdP

4 x 1768 & 30 x 1769 NEW !

1769-L43 2Mb EtherNet/IP. ControlNet, DeviceNet, Sercos, 3rdP

2 x 1768 & 16 x 1769 in stock

1769-L35E 1.5Mb EtherNet/IP, DeviceNet, 3rdP 30 in stock

1769-L35CR 1.5Mb ControlNet, DeviceNet, 3rdP 30 in stock

1769-L32E 750Kb EtherNet/IP, DeviceNet, 3rdP 16 in stock

1769-L32C 750Kb ControlNet, DeviceNet, 3rdP 16 in stock

1769-L31 512Kb Serial, DeviceNet, 3rdP 16 in stock

1769-L23E-QBFC1B 512Kb EtherNet/IP, DeviceNet, 3rdP 2 NEW !

1769-L23-QBFC1B 512Kb Serial, DeviceNet, 3rdP 2 NEW !

1769-L23E-QB1B 512Kb EtherNet/IP, DeviceNet, 3rdP 2 NEW !

Summary: CompactLogix Family

Page 28: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

30Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

1. Compact Machine Solutions

2. CompactLogix Architecture

3. Compact Machine Applications

4. Available CMS Tools

5. Questions

Agenda

Page 29: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

31Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

Packaging – Typical Applications

Primary Packaging Secondary Packaging End of Line• Vertical Form Fill & Seal• Horizontal Form Fill &

Seal• Blister, Skin, Vacuum

Packaging• Capping, Liding,

Seaming & Sealing• Filling & Closing• Wrapping• Robotic (Pick & Place)

• Cartoning• Case & Tray Forming• Conveying &

Accumulating• Feeding & Orienting

•Top Loader• Palletizers• Labelers• Wrappers

Page 30: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

32Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

Packaging – Vertical Form Fill & Seal (VFFS)

Vertical Form Fill & Seal (VFFS)

• Customize your hardware design to your machines’ requirement using the same CompactLogix program

Page 31: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

33Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

JawFeed

ServodriveUltra 1500

Operator TerminalPanelView Component

ProcesadorMicroLogix 1400

ServodriveUltra 1500

Packaging – Vertical Form Fill & Seal (VFFS)

Vertical Form Fill & Seal (VFFS) - Intermittent < 30 Packages / Minute

Page 32: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

ServodriveUltra 3000

Terminal OperadorPanelView Plus

ProcesadorCompactLogix L2x/L3x

JawFeed

ServodriveUltra 3000

Packaging – Vertical Form Fill & Seal (VFFS)

Vertical Form Fill & Seal (VFFS) - Intermittent < 60 Packages / Minute

Page 33: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

35Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

Feed

Terminal OperadorPanelView Plus

Jaw Dosing

ProcesadorCompactLogix L4x

ServodriveKinetix

Packaging – Vertical Form Fill & Seal (VFFS)

Vertical Form Fill & Seal (VFFS) - Intermittent > 60 Packages / Minute

Page 34: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

36Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

Packaging – Palletizer

Scalability based on your machines’ requirement…

Page 35: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

37Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

Packaging - Palletizer Benefits

• CMX and Integrated Architecture offer a unique control solution that allows to customize the drive/servo hardware to the machines’ specific needs while reusing the same program.

• With using coordinated motion, much smoother moves will result in a extended life of the mechanics.

• coordinated axes are easy and simple to program

• Application Tech Note and correlated Add On Instruction (AOI) is available on the Sample Code Library

Page 36: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

38Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

Linear Actuators• One technical trend is to integrate

mechanics and electronics, (i.e.) using CompactLogix and RA Linear Actuators gives your machine more flexibility.

Pick & Place• One PAC (i.e. L45) is able to control the

sequential logic as well as the Delta robot

Filler• i.e. to avoid foaming, synchronize the

vertical position of the filler nozzle with the current level of the liquid, taking into consideration/calculating the shape of the bottle

Packaging – more Solutions

Cartoner• To achieve a higher flexibility of the

machine, the handling of different carton formats was simplified based on using CMX User Defined Datatypes (UDTs).

Page 37: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

39Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

Material Handling - Flying Shears with CMX L43

• In a continuous application the cutting tool needs to accelerate, synchronize with the material, cut, desynchronize and move back…

• The tricky part is to position the cutting tool and keep it synchronized with the material and the line speed for the entire length of the cut.

• Based on a CompactLogix control platform, the power requirements can be adjusted to your machine needs using K6K, K7K or PF700S.

Page 38: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

40Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

Material Handling – Crane Control

Crane – Acceleration / Deceleration • Critical in a crane control system is

the trajectory control that keeps the load in balance during acceleration and deceleration.

• For efficient equipment use, the acceleration / deceleration time need to be kept a a minimum.

• RA offers a Fuzzy Logic based solution for trajectory control.

• Don’t miss to see a live demo here at the AU in Room G – 15.15 hrs.

Page 39: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

41Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

Renewable Energies

• RA actively engages in this fast growing segment with providing a perfect product fit, reference architectures, and solutions for renewable energy applications.

• References range from Solar to Wind parks with a variety of control platforms

• For example a Solar Follower application, RA solutions use either a centralized control system or independent small controller systems for each Follower to calculate its optimal position.

• Specifically for Wind turbines, RA offers additional real-time vibration monitoring using our Condition Monitoring products.

Page 40: Compact Machine Solutions...OEM Market Characteristics Machine/Equipment Continuum 6 Low (Mechanical) High (Electrical) Mid (Hybrid) e.g. Gen 1 – Mechanical motion with single drive

42Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

• The Rockwell Automation Competency Centres has been designed to help machine builders save time, money and resources by providing the engineering experience and support for their applications, and to provide optimum machine performance through advance testing and simulation processes.

• Two Locations: EMEA North (Hamburg), EMEA South (Bologna)

• Visitors can see a range of demonstrations relating to the automation industry.

• The purpose of the OEM Competence center is to provide specific OEM’s:

– Consultancy for new machine applications– Machine architecture/design recommendations– Code architecture– Proof Of Concepts

• Code • Sizing

OEM Competency Center

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43Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

1. Compact Machine Solutions

2. CompactLogix Architecture

3. Compact Machine Applications

4. Available CMS Tools

5. Questions

Agenda

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(Confidential – For Internal Use Only) Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 44

In ONE Single Manual…Shows the user which chapters to read based on which products they

are using

Available in Multiple Languages (IASIMP-QS001x)

Available in Multiple Available in Multiple Languages (IASIMPLanguages (IASIMP--QS001x)QS001x)

System Quick Start Manual

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(Confidential – For Internal Use Only) Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 45

• Simplifies the design, manufacturing, start-up and support of Rockwell Automation motion control systems

• The KAT CD provides the basic panel layout, wiring diagrams, Logix programs, HMI screens, selection tools and Quick Start literature to speed time to market of a new machine design.

Reduce OEM engineering and integrations costsEnable innovation

Reduce OEM engineering and integrations costsReduce OEM engineering and integrations costsEnable innovationEnable innovation

Kinetix Accelerator Toolkit

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(Confidential – For Internal Use Only) Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 46

• Tools that allow OEMs understand the information infrastructure of their customers and enables the design for machines ready for integration

• Deliverables include: – Design guides — Documented best practices and

recommendations - tested and verified– Whitepapers — Technology trends and application

topics – Education series — Webinars, Seminars, profiles,

presentations– Goal - to help eliminate guesswork and decrease

implementation costs while providing security, flexibility and visibility of information plantwide.

– Where to go: www.ab.com/networks/architectures.html

How will your machine integrate into your customer’s infrastructure?

How will your machine integrate into your customerHow will your machine integrate into your customer’’s s infrastructure?infrastructure?

EtherNet/IP Reference Architectures

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(Confidential – For Internal Use Only) Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 47

• Power Programming is the suggested Base Template for Rockwell Automation’s Sample Code Library

• The Basic Templates includes– A PackML conforming Code Standard using S88 Terminology– An Interface for Using and Developing Modular Programs for Machines– Hooks to build own Application Notes and use Rockwell’s build-up of

distributable code• Power Programming can help OEMs to:

– Increase design efficiency (up to 50% reduction in design time) – Simplify field maintenance and save up to 40% on field maintenance next year– Create scalable systems using the same code base. – Provide improved access to production and diagnostic information– Show how efficiently the machine is running.

Draw ing Title:

Creation Date:

File Name:

Auto State Diagram Rev1.0

January 15, 2003

AutoStateModel.vsd

STOPPED1) System powered.2) All Axes Off (Feedback Off)3) Axes must be homed andrepositioned before running.

State=1

ABORTING1) Axes Individually commandedto stop (no coordination)2) After Stopping Axes DisableFeedback.

State=256

READY1) Starting FunctionsComplete2) Axes Geared/Cammed3) Master NOT running

State=4

STANDBY1) Machine armed forproduce conditions tocommence motion.

State=8

HELD1) Holding CommandCompleted2) Axes Remain active.

State=128

HOLDING1) Coordinated stop initiatedon master.2) All axes remain geared orcammed

State=64

ProduceCondition

sMet

ProduceCondition

sBecome

False

StartComman

d

InitializeProcessComplet

e

STARTING1) Axes faults are cleared2) Axes are enabled, Homed& moved to start positions3) Gearing/Cams initialized4) Master not Started

State=2

ABORTED1) All Axes Off (Feedback Off)2) Axes must be homed andrepositioned before running.3) Fault indications remainfor review by operator

State=512

StopProcessComplet

e

Fault

HoldingProcessComplet

e

FaultHoldCommand

FaultFault

FaultFault

Fault

STOPPING1) Stop Initiated on Master2) Once Master Stops All axescommanded to stop anddisable feedback.

State=32

StopCommand

InitializeComman

d

StopCommand

AbortingProcessComplete

StartCommand

StopCommand

From Producing

To S

topp

ing

StopCommand

PRODUCING1) Master Started2) All axes performing automotion3) Bars being packaged

State=16

HoldComman

d

Auto State Model Diagram

StopCommand

StopCommand

Auto Mode InitiatedBY Operator

(START AUTO)

State Transitions

Initialize CommandStart CommandStop CommandHold Command

Initialize Process CompleteStart Process CompleteStop Process CompleteHold Process CompleteProduce ConditionsFault

Power Programming package available on the

Sample Code Website

Power Programming Power Programming package available on the package available on the

Sample Code Website Sample Code Website

Power Programming

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(Confidential – For Internal Use Only) Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 48

samplecode.rockwellautomation.comsamplecode.rockwellautomation.comsamplecode.rockwellautomation.com

• Add-On Instructions & Faceplates• Sample application code• Power Programming templates• Lots of additional examples

Sample Code Library

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(Confidential – For Internal Use Only) Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 49

# of Installs

List Price

Install Price

1 $450 $4503 $900 $3005 $1,375 $275

10 $2,500 $25015 $3,375 $22520 $4,000 $20025 $4,375 $175

• Starting entry point from $3650 down to $450

• eConnect Support Option (incl. Software downloads)

• Access to Online Productivity Tools

•• Starting entry point from $3650 down to $450 Starting entry point from $3650 down to $450

•• eConnecteConnect Support Option (incl. Software downloads)Support Option (incl. Software downloads)

•• Access to Online Productivity ToolsAccess to Online Productivity Tools

NEW

Compact Machine Solutions - CMS Toolkit

Entrance barrier significantly lowered for CMS customers

Please call us to inquire the similar price level in your currency !

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(Confidential – For Internal Use Only) Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 50

DEMO-K2K21

1796-K6K2DEMO-IALCV3#

DEMO-CMXL43#

DEMO BOXES available for your testing

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51Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

Summary of CompactLogix Benefits

• Powerful engine: Logix• Part of the Integrated Architecture

– Logix, NetLinx, & View• Single platform

– Discrete, Process and Motion applications• Scaleable and modular

– Configure to meet your application• Connectivity

– NetLinx, 3rd parties• Premier Integration

– RSLogix 5000, Kinetix, PowerFlex, POINT I/O, and PanelView Plus products

– Save time programming, integrating, commissioning, installing and operating

Configurable from simple, general purpose discrete control to demanding coordinated motion applications

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Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 52

Questions