CT233 - Intelligent Motor Control The Connected Enterprise

Transcription

1 CT233 - Intelligent Motor Control The Connected Enterprise John Eddington Rockwell Automation Rev 5058-CO900E

2 The Connected Enterprise

3 at A GLANCE 22,000 EMPLOYEES 80+ COUNTRIES $6.62B Fiscal 2015 Sales Leading global provider of industrial power, control and information solutions 20+ INDUSTRIES Serving Customers for 111 Years Technology innovation Domain expertise Culture of integrity & corporate responsibility Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 3

4 By billion new middle class consumers will add $8T to consumer spending Increased Demand on Industrial Production GLOBAL POPULATION TRENDS INCREASE DEMAND FOR Manufacturing Resources Infrastructure EMERGING MARKET CONSUMERISM 30% 100% More Water More Vehicles 80% More Steel 50% More Energy RESOURCE PRODUCTIVITY INVESTMENT $1T Annually Source: McKinsey Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 4

5 Connected Enterprise Delivers Optimized for Rapid Value Creation Supply Chain Integration Collaborative, Demand Driven Compliant and Sustainable $ Faster Time to Market COMPANY CONFIDENTIAL - Internal Use Only Lower Total Cost of Ownership Improved Asset Utilization Enterprise Risk Management Copyright 2012 Rockwell Automation, Inc. All rights reserved.

6 Disruptive Technology in Industrial Applications Enablers for the Connected Enterprise INDUSTRIAL Internet of Things Machine to machine coordination high speed Mission critical assets safety Integrated Control and Information Smart Things Data Analytics Scalable Computing/Cloud Mobility Security Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.

7 <14% PRODUCTION In the U.S. have tied their facilities to the enterprise network. SOURCE: Industry Week Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.

8 8 Traditional Approach Hardwired connections to motor control devices Individual I/O connections for motor control devices Basically limited to interlocking, no additional functionality High costs: Design, Hardware, Installation in large industrial systems Wiring & installation as significant % of cost per machine Design PLANT WIDE SYSTEMS - Engineering and documentation costs (very significant in large systems) MACHINE SYSTEMS - Different Software tools for Controllers and Devices (significant for machine builders) - Very limited reutilization of application code Hardware - Digital I/O card for every 16 points - Analog I/O card for every 6/8 variables Installation - Wiring and accessories - Installation labor - Commissioning time to verify all connections

9 9 Intermediate approach Master Slave I/O networks 2 layers of digital communication Supervision I/O control Master/Slave protocol Lower installation cost than traditional approach Costs generated by limitations in the use of information from devices Application development - Need PLANT to handle WIDE data SYSTEMS tables and/or create logic to move information MACHINE SYSTEMS - Additional engineering labor and documentation costs - Possibility of address mismatches during commissioning/operation - Different Software tools for Controllers and Devices (significant for machine builders) - Very limited reutilization of application code Maintenance & troubleshooting - Remote access limited to master devices - Need to transfer information to master for remote diagnostic - No access to other masters from remote I/O location - Unless Supervision network is extend to I/O locations

10 10 Intelligent Motor Control The current approach Simultaneous real-time control, configuration and data acquisition... Integrated Architecture is our differentiator

11 Agenda Agility Faster Time to Market Faster Commissioning and startup Time

12 12 Intelligent Motor Control Energy information at the device level LV E300 Overload Relay Full Voltage starters --Fixed speed - Intelligent overload relays Soft starters -Reduced voltage -Fixed speed Variable Frequency Drives - Variable speed Motor Control Centers -Single assembly for multiple starters

13 13 E300 Electronic Overload Relay The E300 Electronic Overload Relay is the latest technology for motor protection that will help reduce your motor control investment and keep your plant running Intelligent Motor Control Native Ethernet/IP connectivity with easy commissioning, control, and monitoring. Scalable Solutions Modularity in the design provides the right solution for your specific needs Diagnostic Information Motor diagnostics to reduce unplanned downtime

14 Motor Control CIP PlantPAx Intelligent Motor Control The E300 is fully integrated into the Integrated Architecture Network connectivity - Native Ethernet/IP reduces hardware and engineering cost Integrated into Logix Device profiles and faceplates reduce engineering time and project development Automatic Device Configuration Reduces time to repair EtherNet/IP Control Visualization Information PUBLIC INFORMATION Simultaneous real-time control, configuration, and data acquisition 14

15 15 Easy Integration into Logix The E300 has an Add On Profile for RSLogix 5000 and Studio 5000 software. Creates meaningful tag names Configures the E300 (supports ADC) Tested to v17 of RSLogix 5000

16 16 Network Connectivity E300 Two Ethernet ports that operate as an Ethernet switch Star Topology Linear Topology Ring Topology (DLR) Embedded web server Supports SMTP messaging

17 17 PowerFlex 520-Series AC Drives Simplified Programming Dynamic Human Interface Module (HIM) LCD QuickView Scrolling Text Multiple Languages Connected Components Workbench Software Free software Application Programming Groups: AppView & CustomView configuration Studio 5000 Logix Designer Application Premier Integration Automatic Device Configuration (ADC) Integrated motion instructions PF523 PF525 PF527

18 18 PowerFlex 520-Series AC Drives Communications PowerFlex 523 AC drives Standard Serial (DSI) port Optional dual port EtherNet/IP card Additional network options PowerFlex 525 AC drives Standard Serial (DSI) port Built-in EtherNet/IP single port Optional dual port EtherNet/IP card Additional network options Adding option cards to the PowerFlex 520-Series does not affect the foot print of the drive Device Level Ring topology helps increase system resiliency in the case of the loss of one network connection. Communication is rerouted to help continue operations PowerFlex 527 AC drives Built-in EtherNet/IP dual port Dual port EtherNet/IP supports DLR topology

19 19 PowerFlex 750-Series Drive Configuration All PowerFlex 750-Series drives can be configured using: Drive HIM module DriveTools SP, DriveExplorer RSLogix 5000 Add-On Profiles Premier Integration Seamless integration with Logix platform Automatic device Configuration (ADC) for PF755 Reduced Engineering and commissioning time PowerFlex 755 drives additionally can be configured using: RSLogix 5000 embedded instructions (CIP Motion) PowerFlex 755 native to RSLogix 5000 Program with motion control instructions CIP Motion technology from 1 to 2000 HP

20 IntelliCENTER Technology IntelliCENTER Software Integration Assistant PUBLIC INFORMATION Provides valuable integration features 1. Automatically build the I/O tree for all Intelligent Motor Control devices in the MCC 2. Auto-generate the device tags using Device AOPs Full integration between power and control for Rockwell Automation products Exclusive integration capabilities

21 23 IA Productivity Tools Add-On Instructions (AOIs) Save time by creating sets of commonly used custom instructions Promote consistency between projects no need to constantly re-invent commonly used control algorithms Example AOI to scale drive engineering units to units operators can understand

22 24 IA Productivity Tools FactoryTalk View Faceplates Available Faceplates from Rockwell Automation Sample Code Web Site: Preconfigured Go to Display Buttons Status and Operator Control Device Configuration Device Diagnostics Operator Help

23 Agenda Productivity Downtime Mitigation Preventative Maintenance

24 26 E300 Motor Diagnostics The E300 provides a wide variety of diagnostic information to monitor motor performance and proactively alert users to possible motor issues This information can trigger either manual or automatic intervention before the occurrence of an unplanned shutdown Voltage, Current, & Energy CIP Energy Enabled Trip / Warning Histories % Thermal Capacity Utilization Motor Winding Temperature Trip Snap Shot Time to Trip Time to Reset Operational Hours Number of Starts

25 27 Automatic Device Configuration Configuration Firmware IP Address

26 28 Automatic Device Configuration (ADC) A v20 Logix-based feature that allows a user to configure their Logix system to automatically download a large device s configuration - typically after it has been replaced Configuration data for large devices resides in the ACD file and the Logix controller, but the download was a manual process in v16-v19 v20 released January 12 Download button Also compliments: Stratix 6000 & 8000 switches Automatically assigns IP Address (if desired for the application) Firmware Supervisor Add-On Profile (AOP) of desired drive in RSLogix 5000 Flash the drive and/or peripherals (if desired for the application)

27 30 PowerFlex 755 with CIP Motion PowerFlex 755 is native to data structure in RSLogix 5000 Configuration Motion instruction-based programming Commissioning Diagnostics and drive maintenance Position, velocity, or torque control Motion instruction programming Positioning, gearing, camming, interpolation Synchronized drive control Simple and complex profile for 1 drive to 100+ drives Velocity Position with phase control Safety options SIL 3, Cat 4, PLe Safe Torque Off SIL 3, Cat 4, PLe Safe Speed Power range and voltage kw / Hp 400/480V, 600/690V

28 With Intelligent Motor Control Remote Connectivity & Mobility Rockwell Automation Cloud Platform Remotely connect to any part of the system including PUBLIC INFORMATION - Drives - Electronic overloads - Intelligent MCCs Improved remote diagnostics on your smart device Machine builders suggest ways of solving the problem Full access at device level

29 Smart Diagnostics Intelligent Motor Control Devices on the EtherNet/IP network PUBLIC INFORMATION

30 Critical motor experiences overload condition

31 Thermal capacity utilisation of relay rises, motor still operates PUBLIC INFORMATION

32 When warning level is reached: Controller uses EtherNet/IP delivers warning message to HMI stations (PC) Mobility-ready solutions allows to share alarm to electrician PUBLIC INFORMATION

33 Electrician unavailable, alarm escalated to foreman

34 Foreman checks motor, removes cause of overload

35 Intelligent Motor Control Embedded Diagnostics Improve Asset Utilization Embedded diagnostics Remote Monitoring Automatic device configuration Troubleshooting wizards Reduce unplanned downtime Reduce time to repair Centralized maintenance staff Diagnostic data from intelligent motor control devices can trigger either manual or automatic intervention before occurrence of unplanned shutdown. Electric motor current indicating loading conditions Vibration signature indicating mechanical unbalance Torque signature indicating process anomalies PUBLIC INFORMATION 38

36 Agenda Sustainability $ Safety, Reliability & Risk Management Reduced Industrial Footprint

37 40 PowerFlex 520-Series AC Drives Safety Safe Torque-off can help increase safety and machine uptime PowerFlex 525 AC drives: Built-in hardwired safety Certified to SIL2 / PLd Requires the use of any external safety relay to meet ISO PowerFlex 527 AC drives: Choice of safety options Built-in Hardwired Safe Torque-off SIL3/PLe, Cat 3 Built-in Network Safe Torque-off SIL3/PLe, Cat 3 Help protect your personnel and assets with standard built-in Safe Torque-off Helps with faster start ups and reduces wear on motor assets Reduce wiring and installation space with built in safety or integrated safety-- safety over the network

38 PowerFlex 520-Series AC Drives Safety Solutions External Hardwired Network PowerFlex 523 PowerFlex 525 SIL 2 / PLd PowerFlex 527 SIL 3 / PLe PowerFlex 527 SIL 3 / PLe (Network) Safety solutions to meet your needs 41

39 43 Line Up vs Traditional Packaging Power Cabling MCC feeder section1 MCC main MCC feeder section 2 VFD panel CB, filters, ect Drive Panel 1 VFD panel CB, filters, ect Drive Panel 2 VFD panel CB, filters, ect Drive Panel 3 VFD panel CB, filters, ect Drive Panel 4 Total panel width of 7.4 meters plus spacing between panels CB, CB, MCC Main VFD filters, ect VFD filters, ect VFD CB, filters, ect Total panel width of 5.8 meters VFD CB, filters, ect Footprint reduction approximately 30%. Eliminate expensive and time consuming power wiring between panels

40 44 PF 755 Floor Mounted: Basic Architecture Frame Hp Frame Hp Frame Hp

41 PowerFlex 750-Series AC Drives Conformal Coating Standard Standard on all PowerFlex 750-Series drives In harsh environments increases drive reliability Protects components with micro lead spacings which are otherwise vulnerable to dust and moisture build up Without coating, unintentional conductive paths can be formed, leading to circuit failure Enclosures must still be considered in the overall application of a drive See Conformal Coating for Variable Speed Drives white paper for more information PUBLIC INFORMATION 45

42 PowerFlex 750-Series AC Drives Predictive Diagnostics The PowerFlex 750-Series can be programmed to keep track of information that affects the life of its cooling fans and relay outputs, as well as customer motor and system bearings Provides data on estimated life expectancy for fans and relays Provides configuration for customer motor and system bearing data for drive monitoring Provide advanced notification to help prevent unplanned downtime Real time data provides actual time stamping from the real-time clock Can configure and retrieve data via HIM, software tools, and RSLogix 5000 Information can be transferred to the controller as I/O tags PUBLIC INFORMATION 46

43 47 Heatsink Fan Example

44 48 PowerFlex 750-Series AC Drives - Reliability PF700 & PF70 Thermal Regulator Improvements Thermal management algorithm IGBT junction temperature peak has been lowered during High Load Conditions. Increasing Drive Reliability The Screen shot below was taken with a drive starting into a 150% load and the PWM set to Lowers IGBT Junction Temperature Peaks during High Load Conditions 10kHz. IGBT Temp was measured at 91C versus prior readings at 129C

45 IntelliCENTER Technology IntelliCENTER Software Energy PUBLIC INFORMATION IntelliCENTER Energy is a premier software package with all the features of IntelliCENTER PLUS additional Energy Management benefits powered by FactoryTalk EnergyMetrix : Real-time energy consumption and historical trending down to the device level, all across the network! Ability to monitor and manage energy usage for substantial cost savings

46 IntelliCENTER Technology IntelliCENTER Software Energy PUBLIC INFORMATION 50 Direct access from IntelliCENTER Software to calendar trends of key energy values

47 IntelliCENTER Technology IntelliCENTER Software Energy PUBLIC INFORMATION 51 Collect data for any time period (hourly, daily, weekly, monthly, etc.) Trend key parameters simultaneously Export data for recordkeeping or further analysis.

48 IntelliCENTER Technology IntelliCENTER Software Energy PUBLIC INFORMATION 52 View all key energy values for a particular device on a single screen

49 Intelligent Motor Control Network Technology Motor Control Devices Control & Visualization Control Visualization Information EtherNet/IP Simultaneous real-time control, configuration and data acquisition... Integrated Architecture is our differentiator PUBLIC INFORMATION 54

50 Stratix 5900 The Stratix Family Today Stratix 2000 Unmanaged Port Configurations: 4, 5, 7, & 8 port versions Single fiber options Stratix 6000 Fixed Managed Port Configurations: 4 copper ports, 8 copper ports plus 1 fiber Stratix 5700 Managed Port Configurations: Three port configurations (6, 10 and 20 ) 2 to 4 fiber port options Up to 2 gig ports Stratix 5100 WirelessStratix 5700 Stratix Armor Stratix 8000 / 8300 Stratix 8000/8300 Mod. Managed Port Configurations: 6 to 26 ports 6 & 10 ports base units with 2 port fiber option 8 port copper & fiber expansion options Up to 10 fiber ports 2 gig ports Layer 3 VLAN and subnet routing (8300) Stratix Nat Applications with small, isolated networks Monitor and control distributed devices Plant floor and enterprise integration A unique line of industrial Ethernet switches from plant floor to enterprise level applications PUBLIC INFORMATION 55

51 Questions? Thank you for your time! Rev 5058-CO900E