New Machine Control Technology:

Transcription

1 New Machine Control Technology: Doing More With Less. Joe Martin Packaging Sales Manager Beckhoff Automation

2 The Evolution of Technolgy is Normal. Learn from yesterday, live for today, hope for tomorrow. The important thing is to not stop questioning. Albert Einstein

3 1950s 1960s Thru 1990s and beyond New Machine Control Technology: Doing more with less. Historically, Machine Controls Have Evolved, but not without resistance Automation was performed by hardwired logic relays The PLC Emulated a relay panel electronically and was programmed in relay ladder logic The PAC was an enhanced PLC with one software to control all modules Relays Next? PLCs PACs

4 Relay Logic The Good Easy to install Easy to diagnosis components Simple logic- If/Then The Bad Takes up a lot of space- Cabinets were big Faster processing then previous design, but markedly slower to new technology Not flexible. Requires wiring to change anything

5 PLCs- Programmable Logic Controller The Good Much faster then relays Software emulates relay logic by programming in Ladder Logic. Very flexible Rugged The Bad Although electronic, it still is a foot race to emulate the relay panel Requires a matching of control firmware to software revision. Yearly updates to sw licenses are needed and costly Adding new functions to machine requires more hardware and slows down the control, unless you add another processor in the rack

6 PAC s- Programmable Automation Controllers The Good Mostly the same hardware as PLC One software package to control entire rack of modules Very flexible Rugged The Bad Although electronic, it still is a foot race to emulate the relay panel Requires a matching of control firmware to software revision. Yearly updates to sw licenses are needed Adding new functions to machine requires more hardware and slows down the control, unless you add another processor in the rack

7 PAC/PLC Approach: Added CPUs for Added Functions Other Other Additional Networks Additional Software Increasing Integration I/O PAC Safety CPUs Additional Cost Life Cycle Mgmt Issues Reliability Issues Motion HMI PAC

8 Misconceptions About Existing Control Architectures Commonality of spares Scalable controls Scalable software Network openness Technology is decreasing the costs of controls, thus your control costs should be going down

9 PC s The NEXT Thing The Good Fast, powerful processors allow for multiple functions to be performed without added modules Can be stand alone, din rail mounted, or in an HMI panel Processor chips are commonly used in all facets of life Volume of chip production reduces cost while increasing functionality The Bad Misunderstood assumed to be too complex Assumed to be Non-Industrial Paying for failures 20 years ago by Soft PLC companies

10 Motion Safety Other PLC HMI New Machine Control Technology: Doing more with less. PC Control Simplifies Automation By The Convergence of Control Functionality Other Other Safety Central, Motion Powerful IPC HMI PLC Do More with Less Software Modules IPC

11 PC Techology Simplify Do More With Less One powerful controller for Motion, Sequencing, HMI, Safety, Data and Robotics One high speed network (EtherCAT) for I/O, Safety and Drives One flexible, modular I/O design for all local and distributed systems with Integrated Safety One powerful scalable programming and configuration tool One drive for servos, VFD and Safe Motion Control The Power of One Do more with less!

12 Real life example

13 Part II The Buzz You ve all been hearing about it Internet of Things (IoT) Industry 4.0 Big Data Cloud Computing What does it all mean?

14 IoT Definition

15 IoT Definition (from IT point of view)

16 Industry 4.0: Definition Industry 4.0 is: The fourth Industrial Revolution A future-oriented project which is part of the high tech strategy of the German Federal Government promotes the computerization of traditional industries such as manufacturing. The ambition is the intelligent factory (Smart Factory) which is marked by adaptility, resource efficiency and ergonomics as well as much more highly integrated and connected business processes. A technological concept that includes elements such as cyberphysical systems and the Internet of Things. Source: Wikipedia [ ]

17 Industry 4.0: 4 stages of Industrial Revolution Drivers Quality of life Engineering Sciences 1st steam engine GB 1782 Power generation Mechanical automation Mobility US 2nd conveyor belt 1913 Industrialization µelectronics 3rd Computer, NC,PLC ICT 4th Cyber Physical Systems EU US/EU Smart Electronic Automation Automation Source: Acatech, Final report of the Industrie 4.0 Working Group, April 2013

18 So where does PC-based control fit in with all this?

19 x 20xx New Machine Control Technology: Doing more with less. Convergence of Automation and IT Technologies Automation Technology (AT) Information Technology (IT) PC based Control + Special RTOS Stand Alone Controls Special AT communication + Internet, CPS, Cloud, Big Data Industry 4.0 Control Architecture 19 19

20 Convergence of Automation and IT Technologies PC-based Control: engineering environment and runtime on one PC TwinCAT: has been used in thousands of applications in different industries over more than 16 years TwinCAT 3 - the integration platform: I/O, PLC, C++, Matlab/Simulink, motion, safety configuration in one dynamic set of tools TwinCAT 3 Runtime: ONE runtime with highly deterministic real-time for the execution of PLC, C++, Matlab/Simulink modules, motion and safety Modern Software Engineering: integration into Microsoft Visual Studio serves as the basis for integrated engineering over the entire product lifecycle The Automation System for Industry

21 Where do I start? with EtherCAT! IEC Standard communication network Ethernet based, 100 Mbaud, for fastest responses Cost effective no adapters needed in the controller Easy to implement no switches, no IP addresses required, standard CAT5 cable Easy to use self configuring Point level diagnostics Flexible topology line, tree or star or mixed Over 65K devices on single segment, 100M between devices (CAT5), up to 20kM between devices (fiber) Versatile replace other devices, use legacy devices Master clock function for time stamping Well proven 11+ years of installations ETG Largest Fieldbus organization in the world- Over 3000 supplier members

22 EtherCAT is the fastest fieldbus! Remember: A faster machine is a more precise machine!

23 Speed does count: Husky Injection Molding Systems EtherCAT precision and accuracy leads to more precise processes and less waste. Source: Husky Injection Molding Systems

24 Where next? OPC UA: the secure communication standard Global communications standard for secure sensor to cloud communication Built-in security and data-encryption (no need to be an IT security expert) Implemented globally in Smart Factories and facilities that embrace Industry 4.0 concepts OPC Unified Architecture (IEC )

25 OPC UA: The Experts Choice for Industry 4.0 Who: Federal Office for Information Security (German Government, BSI) What: Security Evaluation of OPC-UA OPC Unified Architecture (IEC )

26 Where next? PackML: The Standard for the Packaging Industry Powerful machinery standard promoted by ISA and OMAC (Organization for Machine Automation and Control) Provides a common look and feel to packaging control architectures and programming Two key components provided by PackML: State machine PackTags (as a communications interface)

27 PC-based Control: Standards on top of standards. The time is NOW to implement a standardized control hardware platform, automation software and industrial Ethernet fieldbus for packaging machines Why not implement the only automation platform that can efficiently and cost-effectively implement all of these standards today? If the question is: What is the ideal Industry 4.0 system? The answer is: Open, PC-based control

28 Thank you. THANKS FOR YOUR TIME!!