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© 2005 Fairmount Automation, Inc. All Rights Reserved. Reduce Cost, Size, and Weight Programmable Automation Controllers (PAC) July 21, 2005.

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Presentation on theme: "© 2005 Fairmount Automation, Inc. All Rights Reserved. Reduce Cost, Size, and Weight Programmable Automation Controllers (PAC) July 21, 2005."— Presentation transcript:

1 © 2005 Fairmount Automation, Inc. All Rights Reserved. Reduce Cost, Size, and Weight Programmable Automation Controllers (PAC) July 21, 2005

2 © 2005 Fairmount Automation, Inc. All Rights Reserved. 2 Founded in 1996 Located in Suburban Philadelphia, PA OEM of Programmable Automation Controllers Products Installed on Over 30% of U.S. Navy Fleet Leadership Role in Design and Development of Automated Damage Control Systems for DD(X) About Fairmount Automation Engineering Services Product Development

3 © 2005 Fairmount Automation, Inc. All Rights Reserved. 3 Designed and implemented leading-edge Autonomic Fire Suppression System (AFSS) Based on embedded smart-valve technology Distributed device-level control (LonTalk protocol) Successful Weapon Effect Test (WET) on ex-USS Peterson (first ever) Successful live-fire tests on ex-USS Shadwell Anticipate central role in DD(x) Flight I ADCS design Process improvement initiative underway to achieve CMMi Level 3 assessment (sponsored by Raytheon) DD(X) AFSS

4 © 2005 Fairmount Automation, Inc. All Rights Reserved. 4 First Generation FAC-2000 MIL-SPEC Grade A Shock, MIL-SPEC Vibration Programmable Digital Multi-Loop Controller User-Friendly, Hardened Integral Operator Interface Initially Installed in 1997 to Overhaul Legacy Controls Reactor Secondary Steam Plant Controls Catapult Accumulators Primary Boiler Controls Main Feed Pumps Distilling Plants Evaporators USS John F Kennedy

5 © 2005 Fairmount Automation, Inc. All Rights Reserved. 5 Over 1500 Loops of Control Aircraft Carriers Amphibious Assault Amphibious Transport Destroyers Cruisers Frigates Combat Support Ships Submarine Supply Ships Current Installed Base USS Boone

6 © 2005 Fairmount Automation, Inc. All Rights Reserved. 6 Installed Applications Propulsion Boilers Feed Pumps Distilling Plants Waste Heat Boilers Condensers Evaporators Oil and Fuel Heaters Steam Turbine Aux. Diesel Generator Aux. Force Draft Blowers Deaereating Feed Tanks Chilled Water Plants Catapult Accumulators Compressors Purifiers Compressors Shaft Speed Indication USS Ticonderoga

7 © 2005 Fairmount Automation, Inc. All Rights Reserved. 7 Chameleon: New Controller Platform

8 © 2005 Fairmount Automation, Inc. All Rights Reserved. 8 Key Characteristics MIL-SPEC qualified out-of-the-box Eliminates need for costly, bulky, and heavy enclosures Distributed processor architecture enhances survivability Open connectivity to industry standard protocols and networks Flexible and modular architecture with versatile I/O suite Easy to assemble, install, and maintain Integrated user-interface with prominent displays and buttons Wireless device configuration and data retrieval

9 © 2005 Fairmount Automation, Inc. All Rights Reserved. 9

10 10 Chameleon PAC Installations 350+ Chameleon Modules In Service (U.S. Navy) Currently Installed on 20 U.S. Navy Ships: USS IWO JIMAUSS VANDERGRIFTUSS DUBUQUE USS BOONEUSS JOHN HALLUSS WASP USS DOYLEUSS UNDERWOODUSS PONCE USS DEWERTUSS KAUFFMAN USS FORD USS GARY USS ESSEXUSS SIMPSON USS BRADLEYUSS CLEVELANDUSS PELELIU USS NASHVILLEUSS MCINERNY

11 © 2005 Fairmount Automation, Inc. All Rights Reserved. 11 FFG-7 Class SSDG Aux. Control Decentralized Control Architecture 5 Networked Chameleon Nodes 9 PCM-1, 6 NIM-1, 5 ACP-1 Installed on 10 Ships; Approved for Entire Class Control Loops Include Fuel Oil Transfer and Service Heaters Main Engine Lube Oil Purifier Heater, Start Air Cooler Main Engine Lube Oil Cooler, Lube Oil Pressure Hot Water Tank SSDG Waste Heat Temperature SSDG Jacket Water Temperature Networked to flat screen to provide plant-wide information and remote control USS Doyle

12 © 2005 Fairmount Automation, Inc. All Rights Reserved. 12 FFG-28 Installation Pictures

13 © 2005 Fairmount Automation, Inc. All Rights Reserved. 13 LHA-1 / LHD-1 Class SSTG Aux. Control Decentralized Control Architecture 3 Networked Chameleon Nodes 5 PCM-1, 3 NIM-1, 3 ACP-1 Installed on 4 Ships; 2 more to begin in October Control Loops Include SSTG Hotwell Level SSTG Recirc Temperature SSTG Gland Seal Pressure Control Fully networked Plant-wide information accessible at any node via wireless infrared interface USS Peleliu

14 © 2005 Fairmount Automation, Inc. All Rights Reserved. 14 LHD-1 Installation Pictures

15 © 2005 Fairmount Automation, Inc. All Rights Reserved. 15 LPD-4 Class Chilled Water Control Decentralized Control Architecture 5 Networked Chameleon Nodes 9 PCM-1, 5 NIM-1, 5 ACP-1, 2 UCM-2AMI Installed on 3 Ships Expanded system to be installed on LPD-9 in Q4 Control Loops Include Flow rate thru chiller pump with local A/M control Cooling water for condenser Monitor expansion tank level and pressure Monitor condenser outlet pressures Networked to flat screen to provide plant-wide information and remote control USS Cleveland

16 © 2005 Fairmount Automation, Inc. All Rights Reserved. 16 Automatic Burner Ignition System Two Nodes (4 DAM-2, 2 PCM-1, 2 NIM-1, 2 ACP-1) Installed on USS IWO JIMA (LHD-7); LHD-2 next Burner light-off system for main propulsion boiler Monitors atomization pressure, windbox pressure, fuel-oil pressure, and port-use fan speed Controls burner fuel flow, ignition arm position, and ignition spark Coordinated control from burner front, EOS, or both Future expansion to include Full burner management system Integration with FAC2000-based Automatic Boiler Controls Fully automated throttle control from the bridge USS Iwo Jima

17 © 2005 Fairmount Automation, Inc. All Rights Reserved. 17 Manual Boiler Light-Off

18 © 2005 Fairmount Automation, Inc. All Rights Reserved. 18 Shaft-Speed Indication System Two Nodes 2 PCM-1, 2 NIM-1, 6 ACP-1, 4 UCM-1, 2 NBM-1 Installed on USS PONCE (LPD-15); LCC-19 next Port and starboard shaft quadrature encoders inputs Calculates RPM and maintains shaft revolution count Provides redundant power supplies for remote RPM displays Interfaces with external display using NMEA protocol Implemented with our user-defined ASCII messaging Applicable to every ship in the Fleet USS Ponce

19 © 2005 Fairmount Automation, Inc. All Rights Reserved. 19 LPD-15 Installation Picture

20 © 2005 Fairmount Automation, Inc. All Rights Reserved. 20 Key Characteristics: Packaging MIL-SPEC qualified out-of-the-box High Impact Shock: MIL-STD-901D (Grade A, Class I) Mechanical Vibration: MIL-STD-167B Electro-Magnetic Interference: MIL-STD-461E (Pending) Power Spikes: MIL-STD-1399 Designed for shipboard environments Operating Ambient Temperature Range: -40°C to 65°C Keypad & Housing: NEMA 4X, 6, and 13 Eliminates need for costly, bulky, and heavy enclosures Easy to assemble, install, and maintain Integrated user-interface with prominent displays and buttons

21 © 2005 Fairmount Automation, Inc. All Rights Reserved. 21 Key Characteristics: Packaging

22 © 2005 Fairmount Automation, Inc. All Rights Reserved. 22 Key Characteristics: Modular Design Multi-Processor architecture enhances survivability Each module is self-contained controller Deterministic performance (sub 10ms) Facilitates future technology insertion Open connectivity to standard protocols and networks Versatile I/O suite All modules are hot-swappable Highly granular redundancy I/O connections Control execution Power sources Network connections

23 © 2005 Fairmount Automation, Inc. All Rights Reserved. 23 Key Characteristics: Modular Design

24 © 2005 Fairmount Automation, Inc. All Rights Reserved. 24 Key Characteristics: Design Flexibility Local controller for OEM equipment Strainers Chillers Pumps Generators Valves Remote I/O drop Connectivity to central PLC Potential integration with Smart Carrier program Decentralized and highly-survivable ship-wide machinery control and monitoring system

25 © 2005 Fairmount Automation, Inc. All Rights Reserved. 25 MCMS Conventional I/O Drop Enclosure to House PLC or VME-based control hardware Din-rail mounted terminal points Power supplies / conditioners Network media converters Assume 24 x 24 x 8.5 Require shock mounts Coily mounts C-Worthy mounts (adds 5.5 to depth) Angle spot weld studs mount to ship (adds 2 to depth) Signal densities I/O points typical, approximately 160 maximum Assume 100 points per enclosure for this example Total weight 140 lbs typical (including mounts) Assume 90 lbs per enclosure is achieved for this example

26 © 2005 Fairmount Automation, Inc. All Rights Reserved. 26 MCMS Chameleon I/O Drop Integrated Package All power supply, media converters, terminal points, etc. Sample I/O drop configuration 2 power modules, 2 network modules, 8 I/O modules Dimensions: 24 x 24 x 6.5 Chameleon node 3-row mounting bars Angle or studs connect bars to ship Signal density 96 to 144 I/O points with currently available modules Assume 100 points on average for this example Total weight: 40.5 lbs Chameleon nodes 20 lbs, Mounting bars 10.5 lbs, Other 10 lbs

27 © 2005 Fairmount Automation, Inc. All Rights Reserved. 27 MCMS Chameleon Mini-I/O Drop Integrated Package All power supply, media converters, terminal points, etc. Sample mini-I/O drop configuration 1 power module, 1 network module, 2 I/O modules Dimensions: 16.5 x 11.5 x 6.5 Chameleon node 2-row mounting bars Angle or studs connect bars to ship Signal density 24, 30, or 36 I/O points with currently available modules Assume 25 points on average for this example Total weight: 16 lbs Chameleon node 7.5 lbs, Mounting bars 3.5 lbs, Other 5 lbs

28 © 2005 Fairmount Automation, Inc. All Rights Reserved. 28 CVN-21 MCMS I/O Drop Comparison Assume example platform has 20,000 I/O points Conventional I/O Drop 200 drops required Volume: 5.33 ft 3 per drop, 1,067 ft 3 total Weight: 90 lbs per drop, 18,000 lbs total Cost Estimate (Avg.): $25,000 per drop, $5.0MM total Chameleon I/O Drop 200 drops required Volume: 2.17 ft 3 per drop, 433 ft 3 total Weight: 40 lbs per drop, 8,100 lbs total Cost Estimate (Avg.): $15,500 per drop, $3.1MM total Chameleon mini-I/O Drop 800 drops required Volume: 0.71 ft 3 per drop, 571 ft 3 total Weight: 16 lbs per drop, 12,800 lbs total Estimated Cost: $4,500 per drop, $3.6MM total

29 © 2005 Fairmount Automation, Inc. All Rights Reserved. 29 CVN-21 MCMS Example Plant Example plant layout for I/O drop 100 points of I/O Ten pieces of machinery 100ft x 100ft plant All cabling runs to I/O drop Mix of analog and digital cables Assumed cable weights of 0.075lbs/ft and 0.1lbs/ft Estimated cable weight: 269lbs

30 © 2005 Fairmount Automation, Inc. All Rights Reserved. 30 CVN-21 MCMS Example Plant Example plant layout for Mini I/O drop 100 points of I/O (4 mini drops) Ten pieces of machinery 100ft x 100ft plant Network cable runs to Mini I/O drops Assumed average power source within 25ft Assumed average I/O length is 28ft Assumed CAT5e network cable weight 0.065lbs/ft (LSC5OSW-4) Assumed I/O and power wire weights of between 0.075lbs/ft and 0.1lbs/ft Estimated cable weight: 85lbs

31 © 2005 Fairmount Automation, Inc. All Rights Reserved. 31 CVN-21 MCMS Mini I/O Benefits Assume example platform has 200 plants similar to example plant (i.e. 20,000 points of I/O on platform) Total Weight Comparison I/O drop weight Cable: 53,800 lbs I/O Drops: 18,000 lbs Total: 71,800 lbs Mini I/O drop weight Cable: 17,000 lbs Mini I/O Drops: 12,800 lbs Total: 29,800 lbs Weight Savings: 42,000 lbs (over 18 tons or the 1.4 times the weight of one empty F/A-18F jet fighter!)

32 © 2005 Fairmount Automation, Inc. All Rights Reserved. 32 CVN-21 MCMS Mini I/O Benefits Significant cabling reduction Cable cost savings Installation labor cost savings Design engineering cost savings (simplified drawings) Weight savings: 42,000 lbs Simplified troubleshooting Easier to isolate wiring problems Can operate systems in isolation Dont need to bring up all systems at once Improved survivability Move towards decentralizing control Heartbeat control Mode shedding

33 © 2005 Fairmount Automation, Inc. All Rights Reserved. 33 Chameleon Modules AC Power Module (ACP-1, ACP-1PA) DC Power Module (DCP-1) Process Control Module (PCM-1) Discrete Automation Module (DAM-1, DAM-2) Network Interface Modules (NIM-1, NIM-3, NIM-4, NIM-6) RS-485, RS-422, RS-232 Modbus LonTalk FairNET User-defined ASCII / Binary messaging User Configurable Modules (UCM-1, UCM-2, UCM-2NB, UCM-2AMI)

34 © 2005 Fairmount Automation, Inc. All Rights Reserved. 34 AC/DC Power Modules Single or Multi Power Source Redundant Power with Automatic Switch-over Rugged packaging Spike Tolerance per MIL-STD 1399 Over-current Shut-off Input Circuit Fused ACP-1PA Standalone Power Source

35 © 2005 Fairmount Automation, Inc. All Rights Reserved. 35 Process Control Module (PCM-1) Process and Motion Control Four Analog Inputs Current, Voltage, Resistance, RTD Four Analog Outputs Current, Voltage Two Digital Inputs On/Off, pulse counting Frequency meter, event timing Pulse width, quadrature decoding Two Digital Outputs On/Off, PWM, square-wave generator Four 4-digit numeric displays Eight 3-color LED indicators

36 © 2005 Fairmount Automation, Inc. All Rights Reserved. 36 Discrete Automation Module (DAM-2) Discrete logic, sequence, batch Ten Digital Inputs Broad range of AC or DC signals Configured in software Eight Digital Outputs AC or DC Individually Soft-Configured Hybrid Mechanical / Solid-State Relays Dramatically improved endurance Drastically reduce conducted and radiated EMI produced when switching inductive loads by maintaining zero voltage crossing turn on and zero current crossing turn off Four Push-Buttons Eight 3-color LED indicators

37 © 2005 Fairmount Automation, Inc. All Rights Reserved. 37 Network Interface Modules Network Media Available Today: NIM-1: RS-485, NIM-3: RS-422 NIM-4: RS-232, NIM-6: TP/FT10 Network Protocols Available Today: Modbus (Master/Slave, RTU/ASCII) LonTalk FairNET (FAC2000 Integration) OPC Server (ICAS Integration) Custom ASCII / Binary Protocols NMEA Implementation Adaptable to custom TCP/IP messaging Currently In Development NIM-2: Ethernet w/ 6-Port Switch NIM-5: Ethernet (TCP/IP, Ethernet/IP) NIM-7: ProfiBUS DP (Master/Slave)

38 © 2005 Fairmount Automation, Inc. All Rights Reserved. 38 User-Configurable Modules (UCM-X) Custom modules with buttons, displays, etc. Use as junction box Available in full or half size

39 © 2005 Fairmount Automation, Inc. All Rights Reserved. 39 Development Roadmap Networking Modules in Development: NIM-2: Ethernet with built-in 6-Port Switch NIM-5: Ethernet (support TCP/IP, Ethernet/IP, ProfiNET) NIM-7: ProfiBUS DP (Master/Slave) NRM-1: Multi-port RS-485 Repeater Module Wireless Access Point Module Joint Development Program with 3e Technologies (SBIR) FIPS Certified Wireless Security a/b/g, Zigbee Continue to Expand I/O Module Offering Touch-Screen Interface Module Motor Drive Module Battery Backup Module Direct connectivity to TSCE (DDS Protocol) Integrate C/C++ Programming with Function Blocks Plant-wide Configuration Management

40 © 2005 Fairmount Automation, Inc. All Rights Reserved. 40 Easy to Use Graphical Programming Intuitive Function Block Diagrams Requires Little or No Training State-Transition Diagrams Clear and Concise Method of Programming Reduced Program Size and Complexity Organizes Complex Control into Easy to Program Nuggets Eliminates Multiple Use of Interlocks and Transition Logic Typical Using Ladder Logic Integrated Simulation Platform All signal values continuously displayed during simulation run Simplifies Diagnostics and Check-out by Highlighting Active States Wireless Device Configuration PAC Programming: Design Pad G3

41 © 2005 Fairmount Automation, Inc. All Rights Reserved. 41 Design Pad G3 Demonstration


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