Download - T28 - The Latest in On-Machine™ Solutions · to the application or on the machine ... ControlLogix® On-Machine Control Features ... IP67 On-Machine™ Industrial Switch.

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

3

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


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.”


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


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.


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


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:


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.


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


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


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

12

Rockwell Automation® offers a complete portfolio of Allen-Bradley® On-Machine™ products:


PUBLIC INFORMATION

ArmorStart® On-Machine™ Distributed Motor Control


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

14

Pre-engineered motor starting solutions


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

15

Cost-effective, simple solution for your On-Machine™ architecture

ArmorStart®

ArmorStart® LT


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


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


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)


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)


Premiere Integration with EtherNet/IP

20

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


Virtual Brochure

http://www.ab.com/armorstart/virtual-demo

C:/Program Files (x86)/Mozilla Firefox/firefox.exe

C:/Program Files (x86)/Mozilla Firefox/firefox.exe


ArmorStart® Applications

22

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


PUBLIC INFORMATION

Armor™ GuardLogix®, Armor™ ControlLogix® & ArmorBlock® Guard I/O™


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

24


Armor™ GuardLogix® and Armor™ ControlLogix®

Controllers Expanded Offering

25

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


Sustainability

26

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


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


1732ES Application Overview

Component connectivity – the full range of safety inputs, same as 1732DS

Network architecture

28

Optional DLR

Optional Daisy Chain power (10Amp limit)


PUBLIC INFORMATION

ArmorStratix™ 5700IP67 On-Machine™ Industrial Switch


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


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


The ArmorStratix™ 5700 Offering

32

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


8-port 16-port

24-port

ArmorStratix™ 5700 Base Offering

33

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


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

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

www.rockwellautomation.com

Follow ROKAutomation on Facebook & Twitter.Connect with us on LinkedIn.

Rev 5058-CO900F

PUBLIC INFORMATION

Thank You for Attending!