designing innovative machines with the midrange ... set up and monitor the machine at a touch of ......

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. Rev 5058-CO900B

Designing Innovative Machines with the Midrange Architecture System

John Riess Global Marketing Leader Brian Fieseler Program Manager

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 2

Agenda

Midrange System Capabilities Address CBIs

Machine and Equipment Types / Applications

Midrange System Overview

Critical Business Issues

Tools for Success

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

Machine and Equipment Builder Critical Business Issues (CBIs) More cost competitive machine

Simplify machine design

Reduce cleaning time

Ease equipment changeover

Ease of configuration for flexible application

Optimize performance through design

Ease programming and training requirements

3

Commission and start-up ease for equipment builder

Decrease machine time to market

Increase competitiveness and enter new markets

Requires a partner that can deliver and support a reliable control system

Reduce maintenance time


Agenda

Midrange Capabilities that Address CBIs




Tools for Success


Midrange Architecture System

5

A scalable right-sized control and information platform on a single network architecture providing a familiar user experience across the customer’s

applications


Midrange Product Portfolio

CompactLogixTM5370 Programmable Automation Controllers Scalability of the Logix family 2 to 16 axis of integrated motion 80 to 960 I/O points Integrated kinematics functionality 1 or 2 G flash memory card

6

Kinetix 5500 Servo Drive & VP Low Inertia Motor 600 W to 15 kW Power range Torque rating 0.4 - 31.5Nm Common AC/DC bus 195 – 528V AC input Embedded safe torque off Single cable with digital feedback


Midrange System PowerFlex 525 AC Drives

Power ratings of 0.4 - 22kW / 0.5 - 30 Hp Global voltage classes 100 – 600V Embedded safe torque-off Automatic Device Configuration Digital and Analog control I/O Embedded EtherNet/IP

7

Studio 5000 Single design platform Logix extended tag properties Updated alarms & events Controller based alarm log

reduces missed alarms Project documentation storage

with better revision mgmt


Midrange Product Portfolio

PanelView Plus 6 Enhanced run-time performance and

operator experience Reducing deployment time and costs New extensive graphics library Enhanced color animation capability Multi-language font library

8

Stratix 5700 Industrial Ethernet Switch Six, 10, or 20 port managed switch SD card for device config storage Input/output alarms Fiber-ready SFP slots Configurable port security IT Standard “Cisco Inside”


Agenda

Midrange Capabilities that Address CBIs




Tools for Success


VFFS

10


HFFS

11


Cartoners

12


Case Packers

13


Labelers

14


Bag Makers

15


Shrinkwrap and Wraparound

16


Extrusion / Blown Film

17


Bottle & Can Fillers

18


Beverage Lines

19


Slitters

20


Laminators

21


Coating Lines

22


Tire Building Machines

23


Manufacturing - Curing

24


Process Skid

25


Process Equipment

26


Agenda





Tools for Success


Baker Perkins Confectionary Depositor Machine

28

• Simplify machine design • Reduce cleaning time • Ease equipment changeover

• Scalable control platform reduces training • Set up and monitor the machine at a touch of

a button via Human Machine Interface (HMI) • Maximize precision and continuous operation • Real time historical trending and alarm

management

• CompactLogix Programmable Automation Controller (PAC)

• PanelView 1250+ Human Machine Interface • MPAI actuators and Kinetix servo drives • PowerFlex AC drives

“Rockwell Automation can always be relied upon to keep up with new technology and, indeed, drive it forwards. And it does so while helping us to reduce cost and complexity.” Keith Graham, marketing manager, Baker Perkins



• Kinetix Servo Drive • PanelView Plus 6 Human Machine

Interface • PowerFlex AC Drive with Safe-Off

Thiele Technologies Top-load Case Packer

29

Reduce maintenance time Improve efficiency Meet safety standards

• Eliminated the need for a dedicated motion network

• Improved operator safety • Enhanced machine efficiency • Eased machine monitoring and status

updates

“Our needs are met seamlessly by Rockwell Automation and its partners. We’re constantly getting information on what new technologies are available to us and how we can use them to better our systems, not to mention the level of continued education Rockwell Automation offers our engineers.” Kip Boie, vice president of sales and marketing


TRIpack Shrink Sleeve Applicator

• Ease system integration • Ease programming and training

requirements • Simplify maintenance and

troubleshooting

• PAC delivered powerful processing in a compact, cost-effective and easy to configure design

• Motion precision and accuracy • Human Machine Interface provides easy access to

information about machine activity and productivity along with quick identification of issues


• Kinetix 350 Servo Drives • PowerFlex 4M AC Drives • PanelView Plus 1000 HMI

“Our customers are familiar with Rockwell Automation controls, which help them integrate TRIpack packaging machinery with existing equipment upstream and downstream.” Dave Himmelmann, senior electrical engineer, TRIpak



• PanelView Plus 6 Human Machine Interface

• PowerFlex 40 AC drives • FactoryTalk ViewPoint

vonGal Palletizer

31

• Provide flexible, compact machines • Simplify machine design • Ease equipment changeover • Reduce costs

• Simplified design reduced costs while allowing the machine to handle the same load as previous designs

• Scalable control solutions meets a variety of customer demands

• Maximize uptime and minimize maintenance with remote monitoring

“By using the latest in industrial automation technology, we’ve not only been able to give our customers a leg up, we’ve streamlined design and installation for faster machine startup.” Paul Probst, general manager, vonGAL


Wulftec M.J. Maillis Automated Stretch Wrapper

32

• Ease integration • Reduce downtime • Simplify machine adjustment

• Continuous-operation film reloading • Scalable control platform reduces training costs • Reduction of inventory requirements • Monitor key performance indicators via Human

Machine Interface (HMI) • Maximized uptime and minimized maintenance


• PowerFlex 525 AC drive • PanelView Plus 1000 Human Machine

Interface (HMI)

“Customers are eager to hear about our partnership with Rockwell Automation. It reassures them to know that we build quality machines with quality control and automation components.” Guy Lopes, director of operations, Wulftec


Linkx Systems Packaging Machine

33

• Control Costs • Occupy smaller footprint • Machine performance requirement of

up to 7-9 times the normal throughput during peak demand periods

• Compact solution that suited the size of the machine • Excellent motion performance in a small footprint • Single control platform across five machines doing

three different jobs • Significant reuse of code, cutting project

development time • Achieved 40-trays-per-minute capacity – double the

customer's requirement


• Kinetix Servo Drives • PowerFlex AC Drives • PanelView Plus Human Machine Interface

(HMI) • EtherNet/IP Architecture

“Probably the most impressive part of this project was the reuse of existing code. We were able to reuse a significant portion of our existing code, including CAM profiles.” David Hayward, Technical Director


Agenda





Tools for Success


Mechatronics and Machine Design

3D CAD Design SolidWorks

Control Design RSLogix 5000

Motion Design Motion Analyzer

Mechatronic design is a collaborative venture between mechanical, electrical, and control design engineers – the outcome is a machine design optimized for high performance controls

“synergy of several engineering disciplines…”


Rockwell Automation’s Mechatronic Offering

Products Comprehensive motion offering including direct drive motors, linear stages, stacked stages, and electric servo actuators that deliver a superior mechatronic outcome

Virtual Design Tools Motion Analyzer links mechanics with

controls. Analyze, optimize, simulate, and select in a virtual environment before committing to a final machine design

Expertise Mechatronic support and services to augment your

existing design team

http://www.rockwellautomation.com/rockwellsoftware/design/rslogixarchitect/images/architect.jpg

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. Copyri

What Is Motion Analyzer?

Prior to Motion Analyzer, sizing a servo system was manual process Slow Complex Error prone Rule of thumb based decisions

Motion Analyzer automates the servo sizing process Fast Simple Accurate Fact-based decisions Design optimisation…


System Thermal Modeling Especially useful for machine builders exporting to countries with hot weather.

Ratio Design Analysis Guides designers to an optimized solution.

System Efficiency Analysis Helps boosts machine performance and reduce energy consumption.

Motion Analyzer – Machine Example System Tolerance Analysis Provides an insight into a machine’s ability to cope with change.

Emergency Stop Analysis Maximize output without compromising safety

System Tuning Simulation Helps reduce design error and can save time during machine commissioning.

Lifetime Estimation Size an integrated linear stages and automatically get an L10 service life estimation.

Supply Voltage Tolerance Analysis Reduces chance of machine issues in the field that result in costly support.

3D CAD Integration Download models of motion product and verify motion profiles at the mechanical design phase.

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. Copyri

39

Benefits of a Mechatronic Approach Increased Machine Value

The value of a machine is closely tied to it’s ability to produce (PPM x OEE)

Design optimization often results in increased machine throughput at no additional cost

Sustainability Machine owners & operators are increasingly

concerned with sustainability issues Efficiency analysis can help decrease energy

consumption and reduce waste

Greater Innovation Agility Offering a shorter lead time can often help win the

order and even command a premium Virtual prototyping reduces the time to ‘Design,

Develop & Deliver’

Risk Mitigation Any design change carries an associated risk Simulation helps reduce risk by predicting the likely

outcome of design changes before they occur

Finding & fixing design flaws late in the development cycle can cost 10 to 100 times what it costs to make changes early [Major tire OEM]

Using this approach we can reduce our physical prototypes from 20 to around 2-3 and can trim hundreds of thousands of dollars from development costs [Leading packaging OEM]


Drives & Motion Accelerator Toolkit

The Drives & Motion Accelerator Toolkit (DMAT) is designed to get you up and running faster and more efficiently by: Assisting with product selection Jumpstarting the CAD

documentation Providing sample machine and

application code

Using this tool results in significantly reduced development time

40

Your Machine

Sample Code

PowerFlex & Kinetix

Drives


Files Available Using the Drives and Motion Accelerator Tool

41

DMAT includes engineering design tools for:

Bill of Material - CAD – Logic – HMI - Quick Start Allows Machine Builders to reduce design time and cost, allowing them to concentrate on the intellectual property that produces compelling and differentiating machine features. Bill of Material

Files

CAD HMI Quick Start

Logic


DMAT Time Savings to start system design

Advantages Designers can spend their time optimizing their machine operations

for better performance and higher profits

Initial Project setup Time needed for an example 4 axis system

42


Saving Time with the DMAT Wizard

Design Wizard can automate the file selections

Wizard asks questions about and produces the tools to start your application

43

How much faster can you bring your machine to market with the DMAT Wizard?


DMAT Time Savings to start a system design

44

Advantages

• Designers can spend their time optimizing their machine operations for better performance and higher profits

• Initial Project setup Time needed for an example 4 axis system


Integrated Architecture Booth #915

45


OEM Solutions Booth # 901

46

1

2

3 5

4

Design

Messaging: - Videos - Success Stories

1

2

Cooperative Partnerships: • PartnerNetwork Program • OEM Program • Service & Support

5

Develop 3

Deliver 4

designing innovative machines with the midrange ... set up and monitor the machine at a touch of ......

Documents