design automation solutions

7/29/2019 Design Automation Solutions

http://slidepdf.com/reader/full/design-automation-solutions 1/48

DE01DE01 – – Design Automation SolutionsDesign Automation Solutions

Presenter: Jason Weber – Automation Product Manager)



Introduction, Session Agenda• Introduction

• System Layout

• Tying HMI and Logix together

• Security

• Configuration Management



Objectives• At the end of today’s session…

– have a better understanding of Design Automation solutions

– see how the Integrated Architecture and FactoryTalk integrates into industrial automation



Design AutomationDesign Automation for Manufacturing is an initiative from Rockwell Software to support our customers inmeeting their critical time to market needs, improving manufacturing system performance and reducing the

costs of design integration..

Customer Value

Facilitate Better Decisions,Sooner & Faster

Reducing costs by Linkingthe Specification, Creation,Commissioning, andOperation of Automation

Support Re-Use of knowledge and effort



Where is the Value

Spec/

BidCreate

Test/

Validate

Get / Keep

WorkingProjectKick Off

End-Customer

DefineStandards

Define Specs

Prove Conceptand SystemOperation to

3rd Party

Quicklyidentify rootcauses aspieces fail

Machine

Builder/ System

Integrator

GenerateDesign

Concept

Compile BOM

Write a

Proposal

Create Code

Create HMI

CreateMechanicalDrawings

CreateElectricalDrawings

CreateCabinets

Assemble HW

MilestoneAcceptance

Test

FactoryAcceptance

Test

Quicklyintegrate andcommission

system



Key Values

• Reduce Design Time

– Collaborative simultaneousTooling and Controls Design

– Digital exchange of mechanicaland controls desi n information

• Reduce Commissioning Time– Try it before you build it to find

problems early

– Complete logic and operator interfacediagnostics available at tryout

to expedite design decisions– Design less; reuse more

– Enter data once

• Reduce Downtime– Complete diagnostics that reduce time

to diagnose faults

– Standardized fully commented

Controls Code that is easy tounderstand

“On average, companies using digital manufacturing can reduce time to

market by 30 %, design changes by 65 %, and time spent inmanufacturing planning process by 40 % “ CIMData Study



How Design Automation Provides Value

Spec/

BidCreate

Test/

Validate

Get / Keep


DefineStandards

Define Specs

Prove Conceptand SystemOperation to

3rd Party

Quicklyidentify rootcauses aspieces fail

End-Customer

GenerateDesignConcept

Compile BOM

Write aProposal

Create Code

Create HMI

CreateMechanicalDrawings

CreateElectricalDrawings

CreateCabinets

Assemble HW

MilestoneAcceptance

Test

FactoryAcceptance

Test

Quicklyintegrate andcommission

system

Machine

Builder/ System

Integrator



The Design Automation Suite of Products

IABIAB

Pro osal BuilderPro osal Builder

ArenaArena

Spec/

BidCreate

Test/

Validate

Get / Keep




IAB/Proposal Builder

• Part Number Creation

• Pricing Information

Tools to help you specify your system before you purchase it.

• Network layout

• Hardware wizards

• BOM creation



Modeling Simulation

• Process Design and Simulationbegins with Arena:

– A complete scalable, enterprisewide solution for simulating any

aspect of a business.

– Build an accurate model of your

planned or existing operations and

simulate to investigate “what-if”scenarios” and select the best

manufacturing strategies.




FactoryTalk

IABIAB

Proposal BuilderProposal Builder

ArenaArena

RSNetWorxRSNetWorx

View Studio View Studio

RSLogixRSLogix

Spec/

BidCreate

Test/

Validate

Get / Keep


Vision SystemConfig

Vision SystemConfig

Bar Code ConfigBar Code Config

DriveToolsDriveTools

FF Net ConfigFF Net Config

RSBatchRSBatch

MCADMCAD

ECADECAD

3rd Party Network Config




RSLogix

• One editor for all forms of the Logix family of hardware• Efficient programming tools

Distributed Centralized

F u n c t i o n a l i t y

RSLogix



RSLogix Architect

• Focused at providing system level visualization and configuration– Network view

Provides graphical and tree representations of system (multiple networks and controllers)

Launch to appropriate tool with Context– Augments RSLogix and RSNetWorx to improve system management and maintenance



RSLogix Architect Control Hardware Layout

• Simple System Layout

(Networks, Controllers,

Devices…)

• Drag and drop networks,

controllers and communication

mo u es

• Launch with Context toappropriate tools



Produced/Consumed (P/C) Tag Management

• Manage P/C Tags from one location

• Manages connections count and RPI

• Matches data types (including UDT’s)

• Tag filtering options available



View Studio

A Unified and Extensible HMI Architecture to Reduce Total Cost of Ownership and Improve Productivity

•Leverage All RA HMI Products & Expertise

•Common Look, Feel & Navigation•Scalability Across Platforms

•Portability of Application

VersaView CEComputer

PanelView Plus

MobileView

VersaViewWin 2000/XP

Computer

Multi-ClientMulti-Server




FactoryTalk

IABIAB


ArenaArena

RSNetWorxRSNetWorx


RSLogixRSLogix

RSLogixEmulateRSLogixEmulate

RSTestStandRSTestStand

Spec/

BidCreate

Test/

Validate

Get / Keep


Vision SystemConfig

Vision SystemConfig




RSBatchRSBatch

MCADMCAD

ECADECAD





RS TestStandA modeling tool to validate your logic and alarm conditions to drastically reduce your start-up time andhelp train operators

Key Features

Control Model

devicesFlowchart Editor and other tools to build newmodels

3D graphics capability to enhance visualization

Integrated linkage to PLC’s and EmulatorsConnect to PLC



TestStand Capabilities

Solenoid

TestStandPLC

O

P

The 3D Model

Roller Bed

ClampDrive

& Motor

OP

C



RSTestand/RSEmulate

RSTestStand Simulation

PLC Logic

A modeling tool to validate your logic and alarm conditions to drastically reduce your start-up time

and help train operators

RSEmulate

er ca on

OperatorTraining

RSView HMI

SystemOptimization

RSLogix



The TestStand Value Curve

Cell LevelModelingSystem Level

ModelingSystem Level

Modeling

OptimizationOptimization

ToolsTools

ConnectivityConnectivity

l u e


Cell Level

ModelingRSTestStand EnterpriseRSTestStand Enterprise V

a

Complexity



Key Benefits

Reduced Start-Up Time

Testing of subroutines, modules andfunctions within the PLC. E.g: SafetyCircuits, Homing Conditions, etc

I/O and Tag check-Out

HMI Configuration Check-Out

Training Tool

System Visualization for the operator

The Process Sequence Analysis

System reaction and diagnostics couldalso be explained and studied

Optimization

High Speed Data Acquisition and learningtools allows for detecting timing slack

between key sequence events

System level integration such asintegration with Robotic Controls andLine feed models allows for line levelcycle time optimization

OEM Coordination

OEM Code Validation by running itagainst a test criteria developed in

TestStand

Multiple levels of validationLevel 1 is validation of OEM code

Level 2 is the integration of OEM code

with the base application



Why RSTestand?

Typical reduction in start-up times: 30 – 40%

Go beyond Emulate – Test your complete process or application

Completely portable testing environment – No Hardware

Comprehensive Visualization for Training; Also Electronic logging of OperatorActions and Results

Introduce New Code Modules with confidence

Validation of Panel View applications without connecting to the Process



TestimonialBusiness OEM for Hydro Electric Generating SystemsEnd Customer NY Power Authority, St. Lawrence-Franklin D. Roosevelt

Project Details Power Project , 16 hydroelectric generators using ControlLogix controllers

RSTestStand Role Unit Testing of software for each of these Generators

Results and comments about RSTestStand by

Darryl Stevenson, Project Leader

1. “RSTestStand saved us 40 to 50% of the time we would normally spend testing basicstuff like testing I/O.

2. “It saved us 25 to 30% of the time we would normally spend doing sequential testing. Ittook quite a few weeks off our schedule”

3. We were able to test faster; set up was easier. We didn’t have to rewire when we ran outof lights and switches. We also found problems that we normally wouldn’t have founduntil we go out to the field. It’s much easier to fix a problem in the shop than out in thefield!”



Testimonial

Business Large Material Handling OEM

RSTestStand Role Modeling and Simulation of Entire MH Lines

Results and comments about RSTestStand byCurtis Doane, Controls Tech Manager

1. “We were ver im ressed that it took us onl two weeks to develo the SRMemulation, especially since none of us were formally trained on RSTestStand”

2. With its first RSTestStand test on a retrofit project, HK Systems reduced on-site startup and debug time by three days—a 40 percent savings in

installation time”




FactoryTalk

IABIAB


ArenaArena

RSNetWorxRSNetWorx


RSLogixRSLogix



Spec/

BidCreate

Test/

Validate

Get / Keep


RSNetWorxRSNetWorx


RSLogixRSLogix

Vision SystemConfig

Vision SystemConfig




RSBatchRSBatch

MCADMCAD

ECADECAD






FactoryTalk

IABIAB


ArenaArena

RSNetWorxRSNetWorx


RSLogixRSLogix



Spec/

BidCreate

Test/

Validate

Get / Keep


RSNetWorxRSNetWorx


RSLogixRSLogix

Vision SystemConfig

Vision SystemConfig


Automation Desktop



RSBatchRSBatch

MCADMCAD

ECADECAD





Centralized Project Organization

• System Equipment Features

– Design equipment layout model for a plant.– Lines, Stations, Machines can be stored and

reused.

– Simple means for storage of all system files.

–

The center of the RSAutomation Desktop Project

FactoryTalk Directory is at the root of all projects



Multi-User Support and Versioning

• Only one users edits at a time • All Objects are versioned with history

Other Features

• Project Archiving – To not have to look for old projects

• Project Labeling – To recreate projects “as-built” later

Multi-User support for less conflict and greater project management.

Changes are published to FactoryTalk Audit



Templates

Simple Objects System and Subsystems

HMI Graphics

Files

Motors

Conveyors

My Plant

Word Documents

Ladder Logic

Etc.



Reuse Your Work with Templates

• Store reusable pieces that you have created and tested in the past

• Use them efficiently reuse that work in future

• Update tags and values automatically

• Build entire subsystems quickly

• Enter custom control logic using the traditional editors

• Provide tools standardization

Improved automation system quality

v y• Tags

• Logic

• Faceplates/HMI

• Field Devices• Documentation

• Files



Control Hardware Layout and I/O Configuration

• Multiple Processor and Network Support

• Configure I/O Card Ownership

• Configure Produced/Consumed Tags

• Synchronize with existing RSLogix 5000 Projects

• Generate I/O Lists and BOM’s automatically




FactoryTalk

IABIAB


ArenaArena

RSNetWorxRSNetWorx


RSLogixRSLogix



Spec/

BidCreate

Test/

Validate

Get / Keep


RSNetWorxRSNetWorx


RSLogixRSLogix

RSAsset Security

Bar Code ConfigBar Code ConfigAutomation Desktop



What Is Security?

• Security means different things to different people

– Our Definition:

“Security applies to any action that can disrupt normal business activity” Loss of assets including product, plant, production, IP, life, etc

Damage to environment, company reputation, etc.

– Actions can be either internal or external

– Disruptions can be either malicious or accidental

RA’s Goal:

Help our customers safeguard the Reliability and Cyber Security of thecritical assets embodied within their industrial automation systems.



RSAssetSecurity™ Key Features

• Allows central administration of corporate security policies– User Authentication and Authorization managing access to Rockwell Software tools

“Who can carry out what operations, on whichautomation resources, and from where”

– Tool Level Security (outer ring)

• Provides single security solution across all products

• Part of Factor Talk Architecture and works in concert with Director Live DataDiagnostics (audit)……..

– Requires Factory Talk Directory Server (network scope)

Logs automation access information

Authorized and unauthorized access to automation system

Actions attempted, performed, etc.



RSAssetSecurity™ Key Features (continued)

• Compatible with Windows 2000, 2003, XP Professional

• Caches security credentials to support disconnected operation (similar to

Windows)• Supports both Windows user accounts (support “single sign on”) and

RSAssetSecurity user accounts (any combination)

• “ ”

requiring IT intervention

RSA S i ™ U d U G



RSAssetSecurity™ Users and Users Groups

RSA S i ™ Wi d Li k d U



RSAssetSecurity™ Windows Linked User

User Group

RSA tS it ™ C t d C t G



RSAssetSecurity™ Computers and Computer Groups

RSAssetSec rit ™ Prod ct Policies



RSAssetSecurity™ Product Policies

Establish general “corporate”guidelines for usage of the software

Networks and Devices



Networks and Devices

20,PLC-5/46B,6COATER





FactoryTalk

IABIAB


ArenaArena

RSNetWorxRSNetWorx


RSLogixRSLogix



Spec/

BidCreate

Test/

Validate

Get / Keep


RSNetWorxRSNetWorx


RSLogixRSLogix

Automation Desktop

RSI Products offer greater productivity throughout the Design Cycle

due to integration across products

Changes Cause Problems When



Changes Cause Problems When…

• They are not documented• The old configuration can’t be recovered

• The changes are not accessible to all who need them

• Access to configurations is not controlled

• Multiple versions exist without accurate identification

• Multiple people are making independent changes

Managing Your Manufacturing Configuration



Managing Your Manufacturing Configuration• Source code control of your approved manufacturing

configuration– CAD drawings

– Operating procedures

– PLC programs

– Network configuration

– EOI projects

• Perform periodic device configuration comparison withmaster files

PLC programs

EOI programs

Operating procedures– Flexible notification options when differences detected

Email

Printer

Managing Device Configuration Changes



• A license for a device editor ischecked out.

• RSMACC records details of use.

User checks out the Master

application for the device from theArchive.

Information canbe viewed in I.E.5 Browser

System Determines whatactivities that user can perform.

Controls Access

Activity andchanges are loggedby RSMACC

Audit

User saves the changes to theapplication and disconnects from

the device.•The configuration and license arereturned to RSMACC.

•RSMACC Increments the Revision

User logs into the System:

Authentication

Managing Device Configuration Changes

RSMACC

User connects to acontrol device andperforms tasksonline.

All activity and changes arecaptured by RSMACC

AuditArchiveEvent

Later that night the RSMACCVerification Module, uploads allapplications and verifies their

correctness.

Recovery

number and marks the new file as

the master.

Archive

RSMACC reports confirmation of aproperly handled change, andquickly exposes “rogue”operations.

Report

Documenting Configuration Changes



Documenting Configuration Changes

• Supports self-documenting ChangeManagement procedure

– Ability to prove scope of change is limited to

approved change

– Contains information necessary to enable FDA

21 CFR Part 11 compliance Date/Time of audit event

Source (Application)

Location (Workstation)

Username (Domain ID, and Full Name

from Domain Id) Automatically generated description of

change with old and new value

RSI “Design” Solutions



RSI Design Solutions

Design

Collaboration Planning

RSAutomation Desktop – collaborative, multi user design framework that provides

archive and version control of RA and 3rd party design data.

Arena – A complete scalable, enterprise wide solution for simulatingany aspect of a business.

Validation & Test

Controls

Development

Design AutomationDesign AutomationDesign AutomationDesign AutomationDesign AutomationDesign Automation

RSEmulate and RSTestStand – Complete Manufacturing system simulation and

validation - "try it before you build it".

Logix 5/500/5000 – Development and deployment of

controls standards including control code, HMI, network

configuration, diagnostics and ECAD.



Thank you for participating!Thank you for participating!

Please remember to tid u our work area for the next session.

We’re interested in your feedback; please complete the session survey!