T28 Introduction to GuardLogix Integrated Safety Systems

Size: px

Start display at page:

Download "T28 Introduction to GuardLogix Integrated Safety Systems"

Gloria Gardner
6 years ago
Views:

Agenda Safety Perspectives Company Perspectives Evolving Technologies Integrated

Traditional Perspective of Safety: Safety and Productivity are Mutually Exclusive Objectives SAFETY Reduced Machine Utilization Reduced Operational Efficiency Increased Labor Costs

3 Traditional Perspective of Safety: Safety and Productivity are Mutually Exclusive Objectives SAFETY Reduced Machine Utilization Reduced Operational Efficiency Increased Labor Costs Increased Mean Time To Repair Increased Nuisance Shutdowns PRODUCTIVITY Belief is safety = increases cost and impacts productivity. Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 3

4 The Perception of safety has changed! SAFETY PRODUCTIVITY PRODUCTIVITY Reduced Machine Utilization Reduced Operational Efficiency Increased Labor Costs Increased Mean Time To Repair Increased Nuisance Shutdowns SAFETY Improved Machine Speed & Utilization Improved Operational Efficiency Reduced Maintenance Downtime Reduced Nuisance Shutdowns Reduced Healthcare & litigation costs In the past, Safety was seen as counter-productive, now it s seen as an ENABLER and is a key factor to success. 4 Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 4

A major reason for the change in perception is because of the improvement in

In the past safety was difficult to apply and hard to troubleshoot but now: It

Basic Safety Cumbersome Difficult to Apply Inflexible Difficult to

Modular Easier to Apply More flexible Easier to trouble-shoot Diagnostics at

Modular & Networkable Easiest to Apply Most Flexible Easiest to trouble-shoot

5 A major reason for the change in perception is because of the improvement in technologies. In the past safety was difficult to apply and hard to troubleshoot but now: It enhances productivity! Basic Safety Cumbersome Difficult to Apply Inflexible Difficult to Trouble-shoot Diagnostics at the relay Often Bypassed Semi-integrated Safety Modular Easier to Apply More flexible Easier to trouble-shoot Diagnostics at the relay and at local diagnostic screens User friendly Integrated Safety Modular & Networkable Easiest to Apply Most Flexible Easiest to trouble-shoot Maximum diagnostics Task Oriented User friendly Today machine safety is easier to apply, easier to troubleshoot and provides more efficient machine control. Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 5

Investment in establishing a positive safety culture and using contemporary

6 The Aberdene study is proof that safety and productivity are complimentary attributes. Investment in establishing a positive safety culture and using contemporary methods and technologies will have a significant contribution to profit. Safety = Productivity = Profit Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 6

Companies are being asked to do more with less!

improvement to drive sustainability & profitability.

Provide Traceability Increased productivity Increased asset intensity Reduced Injuries Reduced risk Design Processes for

7 Companies are being asked to do more with less! Manufacturers today must leverage their automation investment to create an environment for continuous optimization, and improvement to drive sustainability & profitability. Production Design Quality Safety Reduce TCO (Total Cost of Ownership) Provide Flexible Operations Provide Sustainable Operations Provide Traceability Increased productivity Increased asset intensity Reduced Injuries Reduced risk Design Processes for Flexibility, Agility, Modularity and Repeatability Reduced labor costs Improved diagnostic feedback Change management status Systematic health checks Continuous analytics Provide Robust Information to Operators, Quality, Maintenance & Managers Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 7

The days of discrete and isolated manufacturing are gone. The global trend is for smarter machines that are faster, safer, more flexible and more productive.

8 The days of discrete and isolated manufacturing are gone. The global trend is for smarter machines that are faster, safer, more flexible and more productive. Global competition and fiscal responsibility are driving companies to improve performance and value. Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 8

One way of doing this is by leveraging their safety & automation investment to maximize OEE.

9 This has changed the way companies look at manufacturing and machinery! Companies are connecting their entire enterprise and are looking for ways to improve performance. One way of doing this is by leveraging their safety & automation investment to maximize OEE. Optimization, speed, innovation, flexibility and cost are the key underlying factors to success in this competitive global market! Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 9

Today: Integrated Controls & Safety Hardware Physically Combined

Future: Integrated Controls & Safety Architectures

13 Machine Safety Technology is evolving. Preventing Access Detecting Access Controlling Access Guards Safeguards Integrated Safety Technology is more flexible, easier to apply, and smarter. Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 13

14 Integrated & Contemporary Safety Automation solutions maximize machines performance by harmonization. A machine control strategy that includes harmonized safety and production control systems. Harmonizing your safety and production control systems offer tremendous opportunities to improve productivity Shared diagnostics on common HMI for faster troubleshooting A flexible manufacturing system that changes parameters based on conditions Zone control to enable continued production flow when one zone is shut down Better shut down and restart of production systems after a safety event A common control solution that allow provides an environment of continuous improvement thru connectivity and traceability. Control System Operating Equipment Safety System Improving performance thru the use of advanced technologies. Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 14

Companies are moving toward integrated & contemporary

FactoryTalk Integrated Production & Performance Suite

Configuratio n Production Management Data Managemen t

Industrial Architecture InfrastructureSystem Performance

Thir d Part y Logix Control Platform Legacy System s

Visibility Components Control Critical Platform Plant

Companies are connecting their entire enterprise from

Copyright 2016 Rockwell Automation, Inc.

15 Companies are moving toward integrated & contemporary control of entire facilities with complete traceability in order to drive optimization. Plant-Wide Information Enterprise Business Systems SCM ERP CRM PLM... Enterprise Interoperability Infrastructure FactoryTalk Integrated Production & Performance Suite Control Systems Plant Management Engineering Design & Configuratio n Production Management Data Managemen t Quality & Compliance Asset Management TM Integrated Industrial Architecture InfrastructureSystem Performance & Visibility Discrete Motion Process Batch Safety Drives Thir d Part y Logix Control Platform Legacy System s Operations Discrete Motion Safety Drives Connectivity Visibility Components Control Critical Platform Plant Assets Partners Machines & Processes Maintenance Companies are connecting their entire enterprise from the shop floor to the production control systems! Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 15 (Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved. 15 Copyright 2008 Rockwell Automation, Inc. All rights reserved. 15

Companies are doing this by using smarter solutions that are more flexible & easier to troubleshoot!

ControlLogix chassis DeviceNet EtherNet/IP Safety functionality Data & diagnostics can now be integrated

Stratix 8000 E T A P PV+ EOI Safety System PowerFlex 755 Less training. POINT I/O Streamlined maintenance.

16 Companies are doing this by using smarter solutions that are more flexible & easier to troubleshoot! Benefits Information enabled. Fewer components. ControlLogix chassis DeviceNet EtherNet/IP Safety functionality Data & diagnostics can now be integrated can be displayed into on GuardLogix. one HMI. Stratix 8000 E T A P PV+ EOI Safety System PowerFlex 755 Less training. POINT I/O Streamlined maintenance. Optimal connectivity with multiple networks. Armor Block I/O Safet y Relay Kinetix 6000 Safety An ethernet relays & contactors switch may may not be required. Safet y Relay Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 16

17 Integrated Solutions Enhance Performance by and simplifying the control solution. Integrated Motion, Safety and Kinematics Robot Integrated Motion and Safety SW Robot Controller Complete machine control with a single platform Safety Robot Integrated Motion SW Safety Controller SW Robot Controller PLC Motion Safety Robot SW PLC SW Motion Controller SW Safety Controller SW Robot Controller Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 17 Copyright 2010 Rockwell Automation, Inc. All rights reserved. 17

Integrated Safety Strategy Safety Everywhere All IA Controller Platforms

integration into more end devices than traditional control & I/O Scaled

SIL3 and PLe I/O PLd/PLe configurable via single channel or dual channel

18 Integrated Safety Strategy Safety Everywhere All IA Controller Platforms Support Integrated Safety All I/O Platforms Support Safety CIP Safety integration into more end devices than traditional control & I/O Scaled Safety Safety Primary Controllers support SIL2 and PLd Safety Partner for SIL3 and PLe I/O PLd/PLe configurable via single channel or dual channel wiring Performance & Scalability Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 18

Certified by TÜV Rheinland, Cologne IEC 61508 SIL3 ISO 13849-1 PLe

19 GuardLogix Safety Ratings and Certifications Dual Processor Solution (1oo2 Architecture) GuardLogix Compact GuardLogix Certified by TÜV Rheinland, Cologne IEC SIL3 ISO PLe (Category 4) 19 Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 19

GuardLogix 1oo2 Logic Element ControlLogix Integrated

Protection Unit (MPU) restricts access to safety related

code executes out of different memory and in different

20 GuardLogix 1oo2 Logic Element ControlLogix Integrated Safety Independent Logic Solvers 1oo2 Hardware Memory Protection Unit (MPU) restricts access to safety related logic and data (tags) Safety related application logic and code executes out of different memory and in different locations Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 20

Customer Benefit of Safety Certified Application Instructions This TÜV Certified E Stop Provides the same functionality as: 16 rungs of logic 2 Timers 5 Latching coils

21 Customer Benefit of Safety Certified Application Instructions This TÜV Certified E Stop Provides the same functionality as: 16 rungs of logic 2 Timers 5 Latching coils 3 One shots Significant glue logic Results Significant reduction in memory usage Much easier maintenance Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 21

Safety on EtherNet/IP Standard EtherNet/IP CIP Safety on DeviceNet

22 GuardLogix and CIP Safety Illustration Std. MSG STOP OK to Run EtherNet/IP LC Blocked Clear DeviceNet POWER CIP Safety on EtherNet/IP Standard EtherNet/IP CIP Safety on DeviceNet Standard DeviceNet Discrete Hardwiring 22 Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 22

CIP Safety on DeviceNet Standard DeviceNet Discrete

23 CIP Safety to Servo (or VFD) POWER OK to STOP Run EtherNet/IP CIP Safety on EtherNet/IP Standard EtherNet/IP CIP Safety on DeviceNet Standard DeviceNet Discrete Hardwiring 23 Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 23

Guard I/O Guard I/O is the safety rated I/O for GuardLogix

(IP20) ArmorBlock Guard I/O (IP67) Common benefits of all

network infrastructures Flexibility SIL3 / PLe rated and TÜV

24 Guard I/O Guard I/O is the safety rated I/O for GuardLogix Three versions: Point Guard I/O (IP20) CompactBlock Guard I/O (IP20) ArmorBlock Guard I/O (IP67) Common benefits of all Guard I/O Reduce engineering requirements Use existing network infrastructures Flexibility SIL3 / PLe rated and TÜV certified Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 24

25 A discrete approach vs an integrated approach. Control Discrete Safety Solution Standard Controller Motion Controller Safety Controller Integrated Safety Solution Integrated Safety Controller Software Software Logic Logic Communication & Coordination Logic Discrete solutions typically require 2 or 3 different software packages and 20-30% more engineering and design time than integrated safety solution! Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 25

26 Integrated Motion, Process and Safety All control aspects of a machine / plant in a single Integrated Architecture Same engineering Same diagnosis Same networks (Standard and Safety) Reducing interfaces for communication Simplified programming Synchronization made easy Motion Control Process Safety Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 26

27 Safety PLC System Benefits Benefits of Programmable Safety Solutions Flexibility Productivity Reduce Wiring Costs Zone Control Diagnostics Integration Reliability Expandability Security Certification 27 Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 27

28 Safety Technology is seen as a key to success in manufacturing. Safety has become a integral part of the automation solutions. Integrated & contemporary safety solution enhance performance 3 to 5%. Safety is now a key measure of manufacturing success. Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 28

Introduction to Safety PLCs GuardLogix & CIP Safety

Introduction to Safety PLCs GuardLogix & CIP Safety Jon Riemer Solution Architect Safety & Security Functional Safety Engineer (TÜV Rheinland) Cyber Security Specialist (TÜV Rheinland) 2018 Rockwell Automation