What have your machine controls done for yyyou …...– Have you identified and implemented...

What have your ymachine controls done for you lately?y y

Jim Miceli

Copyright © 2010 Rockwell Automation, Inc. All rights reserved.

Topics

1. Sustainability

2. Safety

3 Predictive Maintenance3. Predictive Maintenance

4. Productivity Software

5. Machine Design Efficiency

22Copyright © 2010 Rockwell Automation, Inc. All rights reserved.

Topics

1. Sustainability

2. Safety





Sustainable Production

Safety

• Worker, machine & product safety

• Standards Environment

• Sustainability

compliance

Energy

A ti t f

scorecard by product• Waste recycling• Materials content

tracking• Active management of energy

• Smart Grid readiness

tracking• Carbon footprint

Sustainable production is an imperative for the future

Why Manage Industrial Energy?

• The Industrial sector consumes more energy than any other.• Motors consume about half of all electricity, about 70% of industrial electricity in the U.S.

Total World Energy Consumption by SectorIndustrial Transportation Residential Commercial

15%

8%

dust a a spo tat o es de t a Co e c a

50%

27%

15%

Source: US Energy Information Agency: http://www.eia.doe.gov/oiaf/ieo/ieoenduse.html

27%

(Confidential – For Internal Use Only) 5

The Energy Challenge

• Use Less• Spend LessSpend Less

• Optimize

6

You can find substantial savings … if you know where to look.


Energy Usage vs. Production

• Energy usage is traditionally metered to the Factory wall as part of facilities infrastructure• Limitations:

– Difficult to correlate energy consumption with real-time production informationDifficult to compare energy used during different batches– Difficult to compare energy used during different batches

– Difficult to compare energy costs for a particular product run• What is happening within a manufacturing facility ‘with’ the energy resources being consumed is

typically a ‘black’ boxWhat am I actually making with all of these resources?– What am I actually making with all of these resources?

– How much electricity was used during this production run?– How is the power quality?– How much energy is consumed during peak?

Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 7

‘Measured to the Building’

Production Energy Profiling

• Metering monitors energy consumption and quality from the point of use in a production process (KW/h per product, per line)process (KW/h per product, per line)• Collects data to establish process baselines, ‘golden batch’

RSEM• Establishes equipment performance baselines for energy and asset management• Presents production data against established

S

5 batches consumed 38% of the energy to manufacture this product on thi d M i di t lit i

p gprocess standards for deviation analysis this day. May indicate a quality issue

such as equipment out of calibration.

Monitor the consumption of energy by equipment to

Base load constant 24/7 b t

energy by equipment to establish economic cost profiles of compressors motors, fans

8

Base load constant 24/7 but increases as temperature exceeds 30 deg F - May indicate a cooling capacity issue on a product line.

At the Component Level

For every 10°C temp

rise, capacitor life drops 50%

Right Size your Panel Components:Can power supply selection impact enclosure sizing?

Option “A” 10A, 24VDC Option “B” 10A, 24VDC Option “C” 10A, 24VDC

enclosure sizing?

Efficiency = 93%Heat Loss = 18W



9

Lower Energy Consumption, Smaller Panel, Longer Life for electronic Components

Energy Management Strategy: Questions

• Production Considerations– Does your production schedule match your optimal energy footprint?– Are you leveraging price incentives for load management?– Do you know where your energy dollars go throughout the production process?– Have you identified and implemented “quick-hit” opportunities for savings, i.e. y g

variable frequency drives, behavioral changes, visualization?

• External ConsiderationsExternal Considerations– How will you minimize risks from volatile energy prices and supply?– How will you adapt production to meet new regulatory requirements?

10(Confidential – For Internal Use Only) Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

Topics

1. Sustainability

2. Safety





Safety Drivers

• Risk reduction / Reduced liability • Company / Brand imageCompany / Brand image• Social responsibility• SustainabilitySustainability• Changing standards• Lean manufacturing• Lean manufacturing• Information enabled manufacturing • Globalization• Globalization• Increased productivity

M d i i i d fM d i i i d fMany reasons are driving an increased focus on Many reasons are driving an increased focus on Machine SafetyMachine Safety

Analogy: Bicycle Helmet Safety

Past Present Performance

• Functionally Safe!• Comfortable (Pads)

• Functionally Safe!• Uncomfortable

• Functionally Safe!• ComfortableComfortable (Pads)

• Light (Foam or Composite)

Uncomfortable• Heavy

• Hot

Comfortable• Light• Cool

• Cool (Ventilation) • Performance Enhancing!

Bicycle Helmet Safety has evolved from a pure focus on safety to an Bicycle Helmet Safety has evolved from a pure focus on safety to an integral tool for improving athletic performanceintegral tool for improving athletic performance

Machine Safety Solutions

Past Present Performance

• Functionally Safe!• Easy to apply

• Functionally Safe!• Cumbersome

• Functionally Safe!• Flexible• Easy to apply

• Safety Rated Products

• Cumbersome• Difficult to apply• Difficult to use

• Flexible• Task Oriented• Productivity

• Local DiagnosticsDifficult to use

• Often BypassedProductivity Enhancing!

Machine Safety is also evolving ... from a pure safety Machine Safety is also evolving ... from a pure safety approach to a valuable productivity enablerapproach to a valuable productivity enabler

Safety and Productivity – Lockout Tagout

P ll tRobot

Service Entrance

Pallets

SlipSheetsve

yor P

ower

Exit ConveyorRobot

Palle

t Loa

d Ga

tes

Sheets

Conv

Overhead Entry Conveyor

Exit

Con

veyo

r

Robot PowerPneumaticPower

• Pallets replaced every 60 minutes• Lock & Unlock procedure takes 90

seconds• 5 pallets / hour

• 1 pallet = $1,000 profit• $300 / hour lost production• $2 400 / shift

Shipping

• 5 pallets / hour• 90 seconds = 0.3 pallets

• $2,400 / shift• $1.2 Million per year!

Safety and Productivity – Zone Control

P ll tRobot

Service Entrance

Pallets

SlipSheetsve

yor P

ower

Exit ConveyorRobot

Palle

t Loa

d Ga

tes

Pallet Load ZoneSheets

Conv

Overhead Entry Conveyor

ntro

lne

l

• Operator uses Control Panel to selectExit

Con

veyo

r

Robot PowerPneumaticPower

• Pallets can be loaded without any

Con

Pan

Operator uses Control Panel to select “Load Pallet” mode

• Robot is restricted to “Pallet Load Zone”If R b t t l t f P ll t L d Z

• Pallets can be loaded without any requirement for Lockout Tagout

• “Pallet Load” gates held shut with Guard Locking switch unless “Load Pallet”

Shipping

• If Robot travels out of Pallet Load Zone power is removed and motion is stopped

gmode is selected

Benefits of a Contemporary Safety Solution

• Reduced time to design, program, install and start-up • Wiring reduction, wiring simplification and network

integrationintegration• Improved operator diagnostics and increased

opportunities for alternative methods to Lock-Out-Tag-Out for routine tasks (where applicable)Out for routine tasks (where applicable)

• Accommodates future process or safety changes• Accommodates tasks and processes and does not

encourage workers to “work around” the safetyencourage workers to work around the safety system,…reducing risk

Protecting people and profitsProtecting people and profits

Topics

1. Sustainability

2. Safety





Drive Level Predictive Diagnostics

Predictive Diagnostics• Today’s frequency drives can be programmed to keep

track of information that affects the life of its cooling fanstrack 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– Provides data on estimated life expectancy for fans and relays

– Provides configuration for customer motor and system bearing data for drive monitoringbea g da a o d e o o g

– Provides advanced notification to help prevent unplanned downtime

• Thermal manager - oversees and protects the g poperational temperature of the power structure and aids in extending the overall quality and reliability of the drive.

Improve productivity with scheduled downtimeCopyright © 2009 Rockwell Automation, Inc. All rights reserved.

Topics

1. Sustainability

2. Safety





Production Management Information

• Collect and analyze data from disparate sources within the production process

• Product tracking and genealogyProduct tracking and genealogy• Resource allocation and status• Performance analysis• Process management• Data collection and acquisitionData collection and acquisition• Quality management• Labor management

• Combine the functionality of multiple disciplines to optimize maintenance and plant operations

• Optimize production schedules• Improve energy usage• Optimize resource loadingOptimize resource loading• Maximize yield• Control quality• Reduce scrap / waste• Enable regulatory compliance

21

Enable regulatory compliance

Measuring Overall Equipment Effectiveness

Time Example Time Lost Causes Key Performance Indicators

Lunch Breaks

Single ShiftSingle Shift

dd Lunch Breaks

Meetings

Equipment Failure

Available TimeAvailable Time Sche

dLo

ssSc

hed

Loss

n en e

Overall Equipment Effectiveness = Availability x Performance x Quality(EA) x (PE) x (QR)

Equipment Failure

Setup & Adjustment

Reduced Speed

Run TimeRun Time Down

Time

Down

Time

d esd es Reduced Speed

Idling & Minor Stops

Rejects

Full CapacityFull Capacity

Spee

dLo

sse

Spee

dLo

sse

GoodGood ctscts Rejects

Reduced Yield

GoodProduction

GoodProduction Re

jecRe

jec

Plant Manager“What is my asset utilization, financial performance, overall downtime?”

Maintenance problem Maintenance problem identified, line shut down identified, line shut down

and work transfer toand work transfer toand work transfer to and work transfer to remedy issue.remedy issue.

Maintenance Manager Identify Causes of Unscheduled Downtime and make recommendations

Compares Compares performance drivesperformance drivesperformance… drives performance… drives business decisions business decisions

based on this based on this information.information.

Sample Reports

Co

Topics

1. Sustainability

2. Safety





Mechatronics and Machine Design

Motion DesignMotion Analyzer

“synergy of several engineering disciplines…”“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

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

M hi & t i i l– 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 premiumVi t l t t i d th ti t ‘D i

Using this approach we can reduce our physical prototypes from 20 to around 2-3

and can trim hundreds of thousands of d ll f d l t t [L di– Virtual prototyping reduces the time to ‘Design,

Develop & Deliver’• Risk Mitigation

– Any design change carries an associated risk Finding & fixing design flaws late in the

dollars from development costs [Leading packaging OEM]

– Any design change carries an associated risk– Simulation helps reduce risk by predicting the likely

outcome of design changes before they occur

development cycle can cost 10 to 100 times what it costs to make changes

early [Major tire OEM]

Virtual Design Tools – Machine Example

System Efficiency AnalysisHelps boosts machine performance and reduce energy consumption.

System Tolerance AnalysisProvides an insight into a machine’s ability to cope with change.

Emergency Stop AnalysisMaximize output without compromising safety

System Thermal ModelingEspecially useful for machine builders exporting to countries with hot weather.

Ratio Design AnalysisGuides designers to an optimized solution. System Tuning Simulation

Helps reduce design error and can save time duringand can save time during machine commissioning.

Lifetime EstimationSize an integrated linear stages and automatically get an L10 service life

Supply Voltage Tolerance AnalysisReduces chance of machine issues in the field that result in automatically get an L10 service life

estimation.field that result in costly support. 3D CAD Integration

Download models of motion product and verify motion profiles at the mechanical design phase.

System Tuning Simulation

Tuning simulation helps predict how machines perform in the real world. Emulates tuning an axis in RSLogix5000 (including ‘Auto-tune’) and then simulates the behavior of the l d t d d i hil f t i iload, motor and drive while factoring in mechanical compliance or backlash to give a realistic result.Helps reduce design error and can save time during machine commissioning.

Before• Almost impossible to predict the

overall performance of a servo

After• Enter information about the

application and size as normal

Business Impact• Gain insight into machine

performance earlier in design cyclepdriven mechatronic system

• Necessary to build a prototype in order to verify system solution

pp• Run tuning simulation to view likely

behavior of system under different conditions

p g y• Reduce number of prototypes• Meet performance goals• Same commissioning time

Dynamic system Simulation

Dynamic simulation with a stiffer coupling

What have your controls done for you lately?

• The focus of control systems is evolving at a rapid rateThe focus of control systems is evolving at a rapid rate• Today’s systems are capable of providing you with terrific

insight into your operation and productivityg y p p y• They can help you control your costs• They can help you design more efficientlyThey can help you design more efficiently• And they can help you become a leaner, greener more

profitable businessp o tab e bus ess

Thank you


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What have your machine controls done for yyyou …...– Have you identified and implemented...

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