T61 Leveraging Integrated Architecture Using Kinetix and PowerFlex Drives

Transcription

1 T61 Leveraging Integrated Architecture Using Kinetix and PowerFlex Drives PUBLIC INFORMATION Rev 5058-CO900E Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.

2 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Integrated Architecture System Business Enterprise Systems Improves productivity & reduces costs OEM CORPORATE HEADQUARTERS OTHER PLANT Integrates control, networking, visualization & information technologies SUPPLIER Integrated Architecture CUSTOMER Addresses full range of control & information needs CONTROL ROOM MATERIAL HANDLING RECEIVING PROCESSING BATCHING / BLENDING PACKAGING SHIPPING The Factory UTILITIES Extends performance gains across your enterprise Provides unparalleled functionality, flexibility & scalability

3 Industrial Network Convergence Corporate Network Corporate Network Back-Office Mainframes and Servers (ERP, MES, etc.) Human Machine Interface (HMI) Control Network Gateway Supervisory Control Office Applications, Internetworking, Data Servers, Storage Back-Office Mainframes and Servers (ERP, MES, etc.) Controller Office Applications, Internetworking, Data Servers, Storage Phone Controller Camera Supervisory Control Safety Controller Robotics Motors, Drives Actuators Robotics I/O Motors, Drives Actuators Safety I/O Sensors and other Input/Output Devices Human Machine Interface (HMI) Sensors and other Input/Output Devices Industrial Networks Industrial Network Traditional 3 Tier Industrial Network Model Converged Plantwide EtherNet/IP Industrial Network Model EtherNet/IP - Enabling/Driving Convergence of Control and Information COMPANY INTERNAL - Internal Use Only Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 3

4 PUBLIC INFORMATION Copyright 2013 Rockwell Automation, Inc. All Rights Reserved. Complete Machine Control on EtherNet/IP

5 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 6 Classic Drives vs. Motion When do you choose an A/C drive and when do you choose a servo? Traditionally, an A/C drive was chosen for velocity applications And servos were chosen for position (and torque) applications Most machines contained a mix of A/C drives and servos Each are programmed with their own tool set Not many look and feel the same What about applications where the lead drive is an A/C drive? How would you gear or cam the servos to this lead drive? How much cost is added by adding an encoder to the drive? How do relate positions for servos to speed/time of the drive?

6 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 7 Drives and Motion Product Portfolio Leveraging EtherNet/IP CompactLogix Stratix 5700 Stratix 8000 ControlLogix 1783-ETAP GuardLogix Ethernet Distributed I/O Chassis I/O Encoder PowerFlex 755 PowerFlex 527 Kinetix 5500 Kinetix 350 Kinetix 6500

7 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 9 Customer application Lets take a look!

8 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 10

9 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 11

10 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 12 Agenda What is Integrated Motion? Terminology How Does CIP Motion Work? CIP Motion Products Examples of Applied CIP Motion

11 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 13 Agenda What is Integrated Motion? Terminology How Does CIP Motion Work? CIP Motion Products Examples of Applied CIP Motion

12 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Integrated Motion on EtherNet/IP Single network solution: No dedicated motion network required Flexible network layout Utilize existing Ethernet infrastructure CIP Motion & CIP Sync: CIP Sync distributes time on wire Enables event time stamping Enables scheduled outputs Increased diagnostics Covers both Kinetix and PowerFlex products

13 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Studio 5000 Configuration, Programming, Commissioning, Diagnostics, Maintenance Axis/Drive management Graphical motion profile editor Instruction based programming Kinetix, PowerFlex, and I/O via EtherNet/IP Drive status and diagnostics

14 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Studio 5000 Motion Configuration Drive/Axis configuration Add up to 100 axes Position Loop configured drive Application type and loop response for optimizing out of box defaults EtherNet/IP drives Vhz configured drive

15 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Studio 5000 Motion Commissioning Application settings customize out-of-box defaults no need to tune for most applications Integrated Manual tune Integrated Auto tune

16 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Studio 5000 Motion Diagnostics Time stamped faults and alarms log Drive/Axis Motion and I/O status Drive/Axis status and diagnostics Network connection diagnostics

17 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 19 Automatic Device Configuration Built Right In Natively part of Integrated Motion: Configuration stored in controller No additional steps required All parameters sent to drive at power up Even IP addresses can be automatically obtained via BOOT/DHCP: Managed switch DHCP persistence ports Firmware Supervisor supported, not required

18 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 20 Agenda What is Integrated Motion? Terminology How Does CIP Motion Work? CIP Motion Products Examples of Applied CIP Motion

19 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 21 Terminology CIP Motion is and open standard administered by ODVA Integrated Motion on EtherNet/IP is a Rockwell Automation concept Rockwell Automation is the only vendor using CIP Motion today For today s talk: CIP Motion = Integrated Motion on EtherNet/IP = Integrated Motion

20 Copyright 2012 Rockwell Automation, Inc. All rights reserved. Built on Open & Global Standards from ODVA Taking the advantage of the EtherNet/IP knowledge and mastering. Over the last several years, Rockwell Automation has been developing Integrated Motion on EtherNet/IP (CIP Motion) products that integrate with Logix control system. Time synchronization on EtherNet/IP o +/- 100ns precision, o IEEE 1588 technology Motion synchronization and time dependent services support Profile support for drives control and peer-peer motion synchronization services o AC and SERVO drives o Position, velocity, torque, Vhz Peer-peer motion synchronization

21 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 23 Terminology I/O Mode or CIP Motion? Premier Integration (I/O Mode) PowerFlex 523 with Card PowerFlex 525 PowerFlex 7-Class with Card (Legacy) PowerFlex 753 with Card Kinetix 300 Integrated Motion on EtherNet/IP (CIP Motion) Kinetix 350 Kinetix 5500 Kinetix 6500 Kinetix 5700 (Future) PowerFlex 527 (Future) PowerFlex 755

22 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 24 Agenda What is Integrated Motion? Terminology How Does CIP Motion Work? CIP Motion Products Examples of Applied CIP Motion

23 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 25 How Does CIP Motion Work? Here s a Simple Analogy Meeting Conf Rm 2:00 pm CIP Motion coordinates devices in a manner that s similar to our own methods for coordinating meetings and events All members (devices) have clocks to compare time to an absolute base and scale A destination (position) is targeted for the event A time (timestamp) is set for when the event shall occur A message is sent to each member (device) to meet at a given place at the pre-determined time Not all messages will arrive at precisely the same time

24 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 26 How Does CIP Motion Work? Here s a Simple Analogy Conf Rm CIP Motion coordinates devices in a manner that s similar to our own methods for coordinating meetings and events All members (devices) have clocks to compare time to an absolute base and scale A destination (position) is targeted for the event A time (timestamp) is set for when the event shall occur A message is sent to each member (device) to meet at a given place at the pre-determined time Not all messages will arrive at precisely the same time but all members arrive in the proper destination at the proper time for the meeting to take place.

25 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 27 Synchronized Time Example ControlLogix (Grandmaster Clock) The Feedback Command Each clocks Time device stamped are data all has from synchronized to inputs a clock drives PowerFlex 755 ArmorBlock I/O Timestamp Fdbk Timestamp Position Timestamp Data Timestamp Fdbk Timestamp Position Kinetix 6500

26 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 28 Agenda What is Integrated Motion? Terminology How Does CIP Motion Work? CIP Motion Products Examples of Applied CIP Motion

27 COMPANY INTERNAL - Internal Use Only Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Controllers 5370 CompactLogix (ERM) Support for up to 16 axes of Coordinated Motion Embedded Dual-Port Ethernet ControlLogix/GuardLogix Up to 100 Axes/Controller 1756-EN2Tx (8 Axis) 1756-EN3Tx (Up to 128 Axis) RSLogix/Studio 5000

28 COMPANY INTERNAL - Internal Use Only Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Kinetix 350 Multiple Voltages Up to 3 kw Indexing Drive EtherNet/IP Safe Torque-Off CIP Motion RSLogix 5000

29 COMPANY INTERNAL - Internal Use Only Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Kinetix 5500 Universal Power Bus Connection Options Up to 15 kw CIP Motion Compact Size

30 COMPANY INTERNAL - Internal Use Only Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Kinetix 6500 Modular Multi-Axis Structure 460V Power Up to 22 kw CIP Motion Enhanced Hardwire Safety Options STO, SSM

31 COMPANY INTERNAL - Internal Use Only Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. PowerFlex 755 AC Drive Most Flexible Offering (CIP Motion, Premier Integration, Discrete, Multiple Comms) Up to 2000 HP Multiple Control Modes Multiple Enclosure Offerings Enhanced Safety Options (STO, SSM) Induction Motor or PM Motor Control

32 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Introducing the PowerFlex 527 Drive Expanding your system solutions to include the PowerFlex 527 gives you: A low-cost integrated motion drive Synchronization over the network Induction motor support Configuration, control and monitoring with the same motion instruction sets as Kinetix drives! Time stamping capabilities PLe/SIL3 integrated safety in two formats: Hardwired safe torque-off Network-based safe torque-off

33 COMPANY INTERNAL - Internal Use Only Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. EtherNet IP Switches Stratix Managed/Unmanaged IEEE-1588 Support QOS Support ETAP Consult your Motion/Automation Specialist

34 COMPANY INTERNAL - Internal Use Only Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 842E-CM CIP Motion Encoder Single-Turn / Multi-Turn No Discrete Wiring Diagnostics 18 bit single-turn, 30 bit multiturn (262,144 cts/rev x 4096 revs) Dual Port. Multiple Topologies Ideal for Feedback-Only Axis for Kinetix 350 and 5500

35 1732E CIP Sync / CIP Motion ArmorBlock Modules 1732E-IB8M8SOER 8 CIP Sync Sequence-of-Events input module Inputs are time-stamped 2048 buffer memories per block 1732E-OB8M8SR 8 CIP Sync Scheduled Output sourcing module Outputs are updated at a specific schedule time High accuracy scheduling increments of 1 microseconds Ability to fire multiple outputs at high speed interval of 100 microseconds Support 16 schedules per coarse update period COMPANY INTERNAL - Internal Use Only Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.

36 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 38 CIP Motion Drive Portfolio Scaled for the Application Requirements PowerFlex 527 PowerFlex 755 Kinetix 5500 Kinetix 6500 Focus Control Type Speed Torque, Speed Position, Torque, Speed Position, Torque, Speed Motor Types Induction Open & Closed Loop Induction Open & Closed Loop spm Open & Closed Loop ipm Open & Closed Loop Induction Open Loop spm Closed Loop spm Closed Loop Focus Architecture CIP Motion for Single Axis Control CIP Motion for Single Axis Control CIP Motion for Multi Axis Count CIP Motion for High Axis Count Focus Applications Medium Performance Feeder Conveyors, Pumps, Fans High Performance Web, ASRS, Roll Forming, Chain Conveyors Highest Performance Packaging, Printing, Winder, Filler, Carton Forming Highest Performance Packaging, Printing, Winder, Filler, Carton Forming Safety Hardwired STO, CIP Safety Hardwired STO & Safe Speed (Future CIP Safety) Hardwired STO or CIP Safety Hardwired STO

37 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 39 Product Summary PowerFlex 527 focuses on applications that require only speed control, i.e. pumps, fans, conveyors PowerFlex 755 targets applications that require speed and torque control, i.e. web, ASRS, roll forming Kinetix 5500 is best used on applications that require speed, torque and position control, i.e. winders, filler, carton forming

38 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 40 Agenda What is Integrated Motion? Terminology How Does CIP Motion Work? CIP Motion Products Examples of Applied CIP Motion

39 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 41 Smart Belt Application Overview In-feed conveyor Out-feed conveyor Gapping belts

40 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 42 Smart Belt Application Discussion How would you solve this with an (any) AC drive? In-feed conveyor Out-feed conveyor Gapping belts

41 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 43 Smart Belt Application Discussion How would you solve this with an (any) AC drive? Lots of sensors Lots of math Complex logic What if the drives didn t use Premier Integration? Lots of extra communication logic Multiple configuration tools and software platforms Diagnostics are difficult to get What if the drives aren t on EtherNet/IP? Lots of additional wiring No diagnostics

42 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 44 Smart Belt How Can You Solve This Using CIP Motion? PowerFlex 527 controls induction motor on infeed conveyor Kinetix 5500 controls conveyors for precise movement to evenly space packages PowerFlex 527 Kinetix 5500 Kinetix 5500 Kinetix 5500 CompactLogix Controller CIP Motion and CIP Sync provide common instruction set and coordinated motion for all drives in system

43 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 45 Smart Belt How Can You Solve This Using CIP Motion? Corrective or Offset Moves are easy with incremental move instructions Velocity Time

44 Smart Belt How Can You Solve This Using CIP Motion? PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 46

45 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 47 Smart Belt Benefits of the CIP Motion Solution Easy programming in Logix: All of the motors are commanded at the same speed Correction moves (forward or reverse) are added to the gapping conveyors Reduced wiring Any registration sensor can be used globally by all drives Common instructions and minimized product cost In Feed and Out Feed Conveyors: PowerFlex 527 Gapping Conveyors: Kinetix 5500 Sensors: Sequence of Events Inputs

46 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 48 Pump and Fan Application Overview Pumps Fans

47 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 49 Pump and Fan Application Discussion How would you solve this with an (any) AC drive? Pumps Fans

48 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 50 Pump and Fan Application Discussion Typical approach: Pros: Cons: Dedicated stand-alone drive Start/Stop interlock Preset speed(s) Cheap and simple Works great Hundreds of parameters to sort through for any changes (on HIM) Drive replacement takes a skilled technician Is there a better way?

49 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 51 Pump and Fan How Can You Solve This Using CIP Motion? Pumps Fans PanelView Plus PowerFlex 527 PowerFlex 755 CompactLogix Controller

50 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 52 Pump and Fan Benefits of the CIP Motion Solution CIP Motion approach: Component drive Start/Stop interlock from controller Preset speed(s) from controller Easy programming in Logix Simplified drive replacement There is a better way Pump: PowerFlex 527 Fan: PowerFlex 755

51 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 53 Extruder Application Overview Product transfer conveyor Cut-off wheel Extruding (Tread or Side-wall extruder) Cutting (Tread skiver) Warm Up Mills Extruder Simplex Duplex Triplex Quadraplex Cooling Line Winding (Side-walls)

52 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 54 Extruder Application Discussion How would you solve this with an (any) AC drive? Product transfer conveyor Cut-off wheel Extruding (Tread or Side-wall extruder) Cutting (Tread skiver) Warm Up Mills Extruder Simplex Duplex Triplex Quadraplex Cooling Line Winding (Side-walls)

53 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 55 Extruder How Can You Solve This Using CIP Motion? CIP Motion and CIP Sync provide common instruction set and coordinated motion for all drives in system PowerFlex 527 controls induction motor on the conveyor for product transfer Kinetix 5500 controls cut-off wheel with precise motion CompactLogix Controller PowerFlex 527 Kinetix 5500 Extruding (Tread or Side-wall extruder) Cutting (Tread skiver) Warm Up Mills Extruder Simplex Duplex Triplex Quadraplex Cooling Line Winding (Side-walls)

54 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 56 Extruder Benefits of the CIP Motion Solution Easy programming in Logix: Product conveyor is commanded at desired line speed Cut-off wheel can be cammed to line speed Common instructions and minimized product cost One location for all troubleshooting and monitoring Product Transfer Conveyor: PowerFlex 527 Cut-off Wheel: Kinetix 5500

55 Copyright 2012 Rockwell Automation, Inc. All rights reserved. To take away Support for High performance Servo and AC drives Complete machine on a single and flexible network Studio 5000 provides complete system support for industry leading Easy-Of-Use EtherNet/IP & CIP Motion are open and broadly adopted High system performance using standard EtherNet/IP

56 Questions or Comments? PUBLIC INFORMATION Follow ROKAutomation on Facebook & Twitter. Connect with us on LinkedIn. Rev 5058-CO900F Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.