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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900E
PUBLIC INFORMATION
T28 - The Latest in On-Machine™ Solutions
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION 2
Agenda
Armor™ ControlLogix® , Armor™ GuardLogix® & ArmorBlock® Guard I/O™
ArmorStart® Distributed Motor Control
New On-Machine™ Products
What is On-Machine™?
ArmorStratix™ 5700
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
What is an On-Machine™ Approach?
A design philosophy that moves
industrial controls and hardware closer
to the application or on the machine
Reduces the size of panels and MCC
Reduces wiring time
Increases uptime at a lower total cost
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Reduce costs, accelerate start-up and boost reliability
On-Machine™ products are characterized by:
Enhanced environmental ratings
On board diagnostics
Plug-and-play electronics
Modular wiring connections
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
A Wide Range of Benefits
4
“By developing an alternative to our traditional, chassis-based I/O, we have been able to reduce the installation time of our conveying systems by more than 50 percent,” said Ron Newlum, engineering manager for AEC.
On-Machine™ solutions offer:
Re-usable solutions
Ease of design
Simplified testing
Faster maintenance/repair
Re-configurability
Reliability
Optimized floor/cabinet space
Quicker installation with fewer
mistakes
Nick Mercorella, plant engineer at Continental P.E.T. Technologies Inc., states: “We were able to install our entire system without ever screwing a wire down, thus eliminating any potential miss-wiring and the system debugging cost associated with such problems. It’s true plug-and-play, which is exactly what we needed.”
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Not an All-or-Nothing Proposition
On-Machine™ solutions are scalable –
varying degrees of On-Machine™
connectivity can be used to suit the
application:
Mix of hardwiring and components with
connectors
System with complete set of
connectors
Networks
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
OEMs improve productivity, lead times, commissioning time, testing and delivery
Time to market
Improved quote-to-cash
Increased Overall Equipment Efficiency (OEE) for competitive edge
Build more machines and impact top line
End users improve OEE
Reduced downtime
Simplified troubleshooting and easy replacement
Scalability, modularity, expandability
A consortium of European manufacturers and machine tool technology groups concluded that On-Machine™ assembly costs are up to 30% less than conventional methods.
On-Machine™ Solutions: Addressing Your Top Priorities
6
Through On-Machine™ solutions…
The larger and more complex the machine, the greater the potential savings.
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A Real-Life Example…
A coil handling and press feeding automation systems OEM was able to significantly reduce the number of potential failure points attributed to connection errors by using On-Machine™ products.
For a single proximity switch connection:
Before On-Machine™ products After On-Machine™ products
8 connections (with 19
potential failure points)
before the device was
seen by the controller
2 connections (with only
6 potential failure points)
before the device was
seen by the controller
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION 8
On-Machine™ Solution Gains
Controls Advancements Gains Achieved
Junction boxes 97% reduction (30 boxes down to 1)
Feet of cable (comms & power) 70% reduction (from 10K ft to 3K ft)
Hard-wire termination points 87% reduction (from 348 to 45 points)
In-house network comms setup 93% reduction (from 72 to 5 hours)
In-field network comms setup 86% reduction (from 8 to 1 hours)
In-house wiring time (man-hrs) 50% reduction (from 1800 to 900 hrs)
No. of control enclosures 16% reduction (from 6-door to 5-door)
Control hardware component cost 25% reduction
Potential failure points per switch 68% reduction (from 19 to 6 points)
By applying On-Machine™ products, the same OEM made substantial gains in a variety of areas:
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION 9
Scrap and Time Reductions
This image shows cable scrap from the installation of a single line not using On-Machine™ products.
With On-Machine™ products there is NO scrap, since all connections are plug-in.
The OEM’s On-Machine™ enabled lines were wired a minimum of 50% faster and communications are established 86% faster than conventional control architectures.
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
On-Machine Savings Calculator
ab.com
► Product Directory
► Motor Control
► Contactors & Starters
► Low Voltage Starters
► Distributed
► ArmorStart™ Distributed
Motor Controllers
Select the Resources tab
Simple calculator that estimates the installation
savings in time and dollars
Project requires 205hrs fewer hours.
Save 25 days of installation time!!
http://ab.rockwellautomation.com/Motor-Control/Low-Voltage-Distributed-Starters
Example
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
Wrapping up the On-Machine™ Approach
Centralized power distribution panel
Many manual connections
Long conduit and cable runs
Long commission time
Limited status & diagnostic help
Harder to troubleshoot
Longer repair or replacement time
Limited scalability of design
On-Machine™ motor control solutions
Plug and play connections
Scalable, modular, & expandability
Faster installation
Reduced engineering time
Optimized production floor space
Simplified troubleshooting
Reduced downtime
Quicker component replacement
Lower total installation cost
Traditional
More than 8 days
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
A complete On-Machine™ solution
Programmable Controllers
Ethernet Switches
Connection Systems and Network Media
Distributed I/O
Sensors, Switches, Push Buttons and Signaling
Power Supplies
Distributed Motor Control
Motion
Safety
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Rockwell Automation® offers a complete portfolio of Allen-Bradley® On-Machine™ products:
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900E
PUBLIC INFORMATION
ArmorStart® On-Machine™ Distributed Motor Control
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
Distributed Motor Control
Robust, hardened enclosure for harsh environments
Provide local disconnecting means
Variable frequency, solid-state, or direct on line motor control
Intelligent with networking capabilities
Embedded inputs, outputs, analog
Machine safety functionality
Easily installed at or near the motor application
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Pre-engineered motor starting solutions
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
ArmorStart®Distributed Motor Control Solution
Robust UL Type 4/12, IP66 or IP67 enclosure
UL Listed disconnect with LOTO
6 points of embedded input and outputs
Quick disconnects for I/O, communications, motor,
three-phase and control
Flexible networking options
Premiere integration with Studio 5000® software
Local logic functions via DeviceLogix™
Easy to install, setup and commission
Automatic device recovery after replacement
Accepted and certified for global installations
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Cost-effective, simple solution for your On-Machine™ architecture
ArmorStart®
ArmorStart® LT
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION 16
ArmorStart® PortfolioE
the
rNet/
P
Devic
e L
eve
l R
ing
(D
LR
)
Functionality
Co
st
LT
LT
• Compact • Full Voltage/Reversing• Embedded I/O• Local Disconnect• 0.37KW (1/2HP) to 4KW(5HP)
• VFD,SVC• Embedded I/O• Local Disconnect, High SCCR• 037KW(1/2HP) to 4KW(5HP)
• Full Voltage/Reversing• Embedded I/O• Local Disconnect, High SCCR• 0.37KW(1/2HP) to 7.5KW(10HP)
• VFD, V/Hz• Embedded I/O• Local Disconnect• 0.37KW(1/2HP) to 1.5KW(2HP)
DeviceNet Safety PLe Category 4
DeviceNet Safety PLe Category 4
ArmorConnect®
Round 3-Phase and
Control Media
(UL2237, UL2238)
Devic
eL
og
ix™
De
vic
eN
et
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
ArmorStart® LT
Compact Distributed Motor Control Solution
CONTROL ENGINEERING2013 Engineers' Choice Awards: Spotlight on InnovationArmorStart® LT recognized in the “Best automation, control, and instrumentation products” category
• Compact Size
• Low Cost
• Premiere Integration
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
ArmorStart® LT
Variable Frequency Drive
At-Motor
Disconnect Switch
Wiring Access
Power and Motor
Connection
6 User Configurable
I/O Points
Network
Connection
Status & Diagnostics
with Reset
Device Address
Hand-Off-Auto
Option
381mm(15in)
206m
m(8
.1in
) 202mm(8in)
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
ArmorStart®
Variable Frequency Drive
Motor QD with
Supplied 3M Cable
At-Motor
Disconnect Switch
Wiring Access
Power and Motor
Connection
User I/O Points
4/2
Network Connection
Status & Diagnostics
with Reset
Hand-Off-Auto
Option
DB QD
Connection
EM Brake QD
Connection
Control Module
can be removed
without unwiring
base
420mm(16.6in)
268m
m(1
0.6i
n)
236mm(9in)
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Premiere Integration with EtherNet/IP
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Only 1 software for programming
EtherNet/IP
Embedded switch technology
Plant-wide network using industry-standard technology
Easier connectivity to the enterprise
Enables real-time control and information
Studio 5000® Add-on Profile
Built-in web server capability
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
Virtual Brochure
http://www.ab.com/armorstart/virtual-demo
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
ArmorStart® Applications
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Automotive:
Paint, Body, and Assembly lines
Engine and Power Train lines
Rotary tables
Overhead conveyors
Vertical position (lift) table
Finish (board) conveyor
Transportation:
Passenger baggage handling
Circular storage
EDS (Explosive Detection Systems) lines
Baggage claim
Tilt truck
Tray trolley
Material Handling:
Warehouse distribution and sorting conveyors
Assembly and process lines
Gapping
Palletizing
Solar panel assembly
Palletizing and de-palletizing machines
Food, Beverage, and Tobacco:
Processing and fill line
Palletizing
Pack and Unpack
PET Air transportation
Packaging:
Case and Packing
Packaging
Rotary tables
Freezer
Other potential Application
Pumps
Fans
Compressors
HVAC
Mixer
Storage and retrieval
Postal & Parcel Delivery
Filling, Sealing, Punching
Process Skids
Marine
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900E
PUBLIC INFORMATION
Armor™ GuardLogix®, Armor™ ControlLogix® & ArmorBlock® Guard I/O™
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
ControlLogix ® On-Machine Control Features
Offers quick-connect cabling that streamlines system
wiring
Requires no specialized personnel to replace system
components
Is easy to install and maintain
Simplifies troubleshooting which reduces labor and
maintenance costs
Improves time to market, testing and commissioning
for machine and equipment builders
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
Armor™ GuardLogix® and Armor™ ControlLogix®
Controllers Expanded Offering
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Non-volatile Memory and Ingress Protection
Removable Secure Digital (SD) memory card
Provides 1 GB non-volatile memory storage; 2GB
option available
Faster reads and writes compared to Compact Flash
Improves data integrity
Provides easy, portable transfer of machine
programs without software download
Offers configurable parameters to enable automatic
program load from SD card on power up
Ingress Protection (IP67 and NEMA 4) provides environmental protection from the effects of:
Dust
Immersion between 15cm and 1m
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Sustainability
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On-Machine Control with Embedded
Components Reduces overall footprint of control
system
Embedded 24 VDC power pass-through
allows power to be routed from one machine device or module to another
eliminates the need for a power supply for each device
simplifies the overall system architecture
Battery-less Energy Storage Solution Eliminates maintenance, transportation
and environmental issues associated with lithium batteries
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION 27
1732ES ArmorBlock® Guard I/O™ on EtherNet/IP
Module I/O mix, 2 separate catalogs:
12 single channel input (6 dual)+ 2 dual channel bipolar output
12 single channel input (6 dual)+ 2 dual channel sourcing output
Feature overview
EtherNet/IP, supporting unicast and multicast
Dual port: embedded switch for DLR & liner topologies
Rotary switches to set last octet of IP address
Standardized M12 input and output connectors (same as 1732DS)
Separate input and output Power via mini-connector, with pass through
IP67 rated package for use on machine
CE, C-Tick, KCC markings
TUV certified up to Category 4, SIL 3, PLe
Configure with RSLogix 5000
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
1732ES Application Overview
Component connectivity – the full range of safety inputs, same as 1732DS
Network architecture
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Optional DLR
Optional Daisy Chain power (10Amp limit)
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900E
PUBLIC INFORMATION
ArmorStratix™ 5700IP67 On-Machine™ Industrial Switch
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION 30
Products that offer: Technology that offers:
Layer 2 and Layer 3 switching for simple
to complex networks applications
Advanced switching, routing and security
features
Advanced security services Common tools for Controls & IT
Plant floor and Enterprise integration Improved Maintainability
“On-Machine™” Connectivity Flexible design
Wireless integration in hard-to-wire and
remote areas Customization based on your plant’s needs
The Stratix™ Portfolio
Integrating Industrial and Enterprise Environments
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION 31
Stratix™
8000/8300Layer 2, Layer 3
ArmorStratix™ 5700
…as well as
Operations
and IT
Addressing
the needs of
Automation…
Stratix 5900™
Services RouterStratix 2000™
Unmanaged Stratix™ 5100 Wireless
Access Point/Workgroup
Bridge
Stratix 5700™Layer 2
Stratix 6000™Layer 2
Stratix™ ETAPs
The Stratix™ Portfolio
Integrating Industrial and Enterprise Environments
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
The ArmorStratix™ 5700 Offering
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Part of an “On-Machine™” system moving the industrial controls
and hardware closer to the application, or onto the machine
Rugged, IP67-rated design for ideal integration into widely distributed
applications with extreme environment conditions
Enables integration
with enterprise network using
Cisco Internet Operating
System (IOS)
Provides Premier Integration
(CIP-enabled) to the
Rockwell Automation®
Integrated Architecture®
system Costs can be reduced due to minimized
cabinet components and wiring time
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
8-port 16-port
24-port
ArmorStratix™ 5700 Base Offering
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IP67-rated for dust and
washdown protection
8-,16- and 24-port versions
with rugged M12 (D-coded)
Ethernet Connectors
Panel/machine mount design
for on-machine connectivity
outside of the cabinet
Dual Power Input
Console port
SD card for simplified device
replacement
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION 34
Built on Stratix 5700™ firmware with “full” feature set and uses the same configuration and support tools
Includes IP67-rating for protection in extreme conditions
Minimizes hardware in the control cabinet for compact solution
Simplifies device replacement via SD card storing entire configuration
Provides advanced features including Power over Ethernet (PoE), gigabit ports and IEEE 1588 support
Enables integration with enterprise network using Cisco Internet Operating System (IOS)
Provides Premier Integration (CIP-enabled) to the Rockwell Automation® Integrated Architecture® system
Predefined Logix tags to retrieve diagnostics
FactoryTalk® View faceplates for status monitoring and alarming
Studio 5000® Automation Engineering and Design Environment™ Add-on Profiles for configuration and monitoring
ArmorStratix™ 5700In Summary