Designing Innovative Machines with the Midrange Architecture System

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1 Designing Innovative Machines with the Midrange Architecture System John Riess Global Marketing Leader Brian Fieseler Program Manager Rev 5058-CO900B Copyright 2012 Rockwell Automation, Inc. All rights reserved.

2 Copyright 2012 Rockwell Automation, Inc. All rights reserved. 2 Agenda Critical Business Issues Midrange System Overview Machine and Equipment Types / Applications Midrange System Capabilities Address CBIs Tools for Success

3 Copyright 2012 Rockwell Automation, Inc. All rights reserved. 3 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 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

4 Copyright 2012 Rockwell Automation, Inc. All rights reserved. 4 Agenda Critical Business Issues Midrange System Overview Machine and Equipment Types / Applications Midrange Capabilities that Address CBIs Tools for Success

5 Copyright 2012 Rockwell Automation, Inc. All rights reserved. 5 Midrange Architecture System A scalable right-sized control and information platform on a single network architecture providing a familiar user experience across the customer s applications

Controllers Scalability of the Logix family 2 to 16 axis of integrated motion 80

Kinetix 5500 Servo Drive & VP Low Inertia Motor 600 W to 15 kw Power range Torque

6 Copyright 2012 Rockwell Automation, Inc. All rights reserved. 6 Midrange Product Portfolio CompactLogix TM 5370 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 Kinetix 5500 Servo Drive & VP Low Inertia Motor 600 W to 15 kw Power range Torque rating Nm Common AC/DC bus V AC input Embedded safe torque off Single cable with digital feedback

Midrange System PowerFlex 525 AC Drives Power ratings of 0.4-22kW / 0.

Device Configuration Digital and Analog control I/O Embedded EtherNet/IP Studio

events Controller based alarm log reduces missed alarms Project documentation

7 Midrange System PowerFlex 525 AC Drives Power ratings of kW / Hp Global voltage classes V Embedded safe torque-off Automatic Device Configuration Digital and Analog control I/O Embedded EtherNet/IP 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 Copyright 2012 Rockwell Automation, Inc. All rights reserved. 7

Midrange Product Portfolio PanelView Plus 6 Enhanced run-time performance and

library Enhanced color animation capability Multi-language font library Stratix

device config storage Input/output alarms Fiber-ready SFP slots Configurable port

8 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 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 Copyright 2012 Rockwell Automation, Inc. All rights reserved. 8

9 Copyright 2012 Rockwell Automation, Inc. All rights reserved. 9 Agenda Critical Business Issues Midrange System Overview Machine and Equipment Types / Applications Midrange Capabilities that Address CBIs Tools for Success

27 Copyright 2012 Rockwell Automation, Inc. All rights reserved. 27 Agenda Critical Business Issues Midrange System Overview Machine and Equipment Types / Applications Midrange System Capabilities Address CBIs Tools for Success

28 Copyright 2012 Rockwell Automation, Inc. All rights reserved. 28 Baker Perkins Confectionary Depositor Machine Simplify machine design Reduce cleaning time Ease equipment changeover CompactLogix Programmable Automation Controller (PAC) PanelView Human Machine Interface MPAI actuators and Kinetix servo drives PowerFlex AC drives 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 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

29 Copyright 2012 Rockwell Automation, Inc. All rights reserved. 29 Thiele Technologies Top-load Case Packer Reduce maintenance time Improve efficiency Meet safety standards CompactLogix Programmable Automation Controller (PAC) Kinetix Servo Drive PanelView Plus 6 Human Machine Interface PowerFlex AC Drive with Safe-Off 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

30 Copyright 2012 Rockwell Automation, Inc. All rights reserved. TRIpack Shrink Sleeve Applicator Ease system integration Ease programming and training requirements Simplify maintenance and troubleshooting CompactLogix Programmable Automation Controller (PAC) Kinetix 350 Servo Drives PowerFlex 4M AC Drives PanelView Plus 1000 HMI 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 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

31 Copyright 2012 Rockwell Automation, Inc. All rights reserved. 31 vongal Palletizer Provide flexible, compact machines Simplify machine design Ease equipment changeover Reduce costs CompactLogix Programmable Automation Controller (PAC) PanelView Plus 6 Human Machine Interface PowerFlex 40 AC drives FactoryTalk ViewPoint 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

32 Copyright 2012 Rockwell Automation, Inc. All rights reserved. 32 Wulftec M.J. Maillis Automated Stretch Wrapper Ease integration Reduce downtime Simplify machine adjustment CompactLogix Programmable Automation Controller (PAC) PowerFlex 525 AC drive PanelView Plus 1000 Human Machine Interface (HMI) 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 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

33 Copyright 2012 Rockwell Automation, Inc. All rights reserved. 33 Linkx Systems Packaging Machine Control Costs Occupy smaller footprint Machine performance requirement of up to 7-9 times the normal throughput during peak demand periods CompactLogix Programmable Automation Controller (PAC) Kinetix Servo Drives PowerFlex AC Drives PanelView Plus Human Machine Interface (HMI) EtherNet/IP Architecture 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 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

34 Copyright 2012 Rockwell Automation, Inc. All rights reserved. 34 Agenda Critical Business Issues Midrange System Overview Machine and Equipment Types / Applications Midrange System Capabilities Address CBIs Tools for Success

35 Copyright 2012 Rockwell Automation, Inc. All rights reserved. 35 Mechatronics and Machine Design Control Design RSLogix 5000 Motion Design Motion Analyzer 3D CAD Design SolidWorks synergy of several engineering disciplines Mechatronic design is a collaborative venture between mechanical, electrical, and control design engineers the outcome is a machine design optimized for high performance controls

36 Copyright 2012 Rockwell Automation, Inc. All rights reserved. Rockwell Automation s Mechatronic Offering 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 Products Comprehensive motion offering including direct drive motors, linear stages, stacked stages, and electric servo actuators that deliver a superior mechatronic outcome Expertise Mechatronic support and services to augment your existing design team

Prior to Motion Analyzer, sizing a servo system was

based decisions Motion Analyzer automates the servo

37 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

Motion Analyzer Machine Example System Efficiency

compromising safety System Thermal Modeling

and can save time during machine commissioning.

machine issues in the field that result in costly

3D CAD Integration Download models of motion product

38 Motion Analyzer Machine Example System Efficiency Analysis Helps boosts machine performance and reduce energy consumption. System Tolerance Analysis Provides an insight into a machine s ability to cope with change. Emergency Stop Analysis Maximize output without compromising safety System Thermal Modeling Especially useful for machine builders exporting to countries with hot weather. Ratio Design Analysis Guides designers to an optimized solution. System Tuning Simulation Helps reduce design error and can save time during machine commissioning. 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. Lifetime Estimation Size an integrated linear stages and automatically get an L10 service life estimation. Copyright 2012 Rockwell Automation, Inc. All rights reserved. 38

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

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 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] 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] Copyright 2012 Rockwell Automation, Inc. All rights reserved. Copyri 39

40 Copyright 2012 Rockwell Automation, Inc. All rights reserved. 40 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 Sample Code PowerFlex & Kinetix Drives Your Machine

HMI - Quick Start Allows Machine Builders to

to concentrate on the intellectual property

41 Copyright 2012 Rockwell Automation, Inc. All rights reserved. 41 Files Available Using the Drives and Motion Accelerator Tool DMAT includes engineering design tools for: Bill of Material Files 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. Logic CAD HMI Quick Start

42 Copyright 2012 Rockwell Automation, Inc. All rights reserved. 42 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

43 Copyright 2012 Rockwell Automation, Inc. All rights reserved. 43 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 How much faster can you bring your machine to market with the DMAT Wizard?

44 Copyright 2012 Rockwell Automation, Inc. All rights reserved. 44 DMAT Time Savings to start a 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

46 Copyright 2012 Rockwell Automation, Inc. All rights reserved. 46 OEM Solutions Booth # Messaging: - Videos - Success Stories 1 2 Design 3 Develop Deliver 4 5 Cooperative Partnerships: PartnerNetwork Program OEM Program Service & Support

Integrated Architecture Midrange System

Integrated Architecture Midrange System Mr. Puthipong Yimvuthikul Senior Product Support Engineer, Sonic Automation Sonic Automation is the limited distributor in Thailand for Rockwell Automation Thai