Presentation on theme: "Optimising Your Machine for Differentiated Value"— Presentation transcript:
1 Optimising Your Machine for Differentiated Value
2 Simplified Integration Why We Are Here TodayWe want to show you how you can design a high performance system at a cost effective priceWe want to show you how you can reduce the time and cost it takes to integrate your equipment into the end user environmentWe want to show you how you can do the above while also delivering equipment that provides differentiated value to your end usersDesign OptimisationSimplified IntegrationDifferentiated Value
3 Manufacturing Drivers Today FlexibilityFaster Commissioning, ReconfigurationFlexibilityFaster Commissioning,ReconfigurationIntegration & SimplificationControl, Safety, Information/ITIntegration & SimplificationControl, Safety, Information/ITOptimum Asset UtilisationEnd UsersOptimise the Operation of Production LineOEMsOptimise the Effectiveness of Equipment BuildingPerformanceEquipment EffectivenessSolutionsOriginal white paper content works:What Machine Builders Care About MostOf course, knowing your customer type and determining their drivers is essential to successful selling. So, how do you distinguish what matters to a machine builder versus an end user? What do machine builders care about most?While the differences between end users and machine builders may seem obvious, there is actually significant commonality between the two audiences in terms of business drivers. For example, integration and simplification, as well as flexibility, are essential drivers for both customer types. Whether putting in a new line at a production facility or developing a machine, there’s a need for flexibility – and a scalable architecture.However, the distinction between these two audiences becomes apparent when you examine how each audience actually views their use of automation equipment. For end users, the focus is on optimum asset utilisation and total lifecycle costs. However, while a total cost of ownership discussion may be completely appropriate for an end user, it will not necessarily resonate well with a machine builder. After all, an OEM is a machine builder – not a machine owner.For OEMs, the primary driver is performance, and more specifically, performance/price ratio. Simply put, machine builders are looking for the best value when they choose an automation solution.Machine Builders measure value not only by enhanced machine performance – but also by how the solution optimises their machine building process.Global SupportServicesGlobal SupportServicesCostTotal Cost to Design, Develop, & DeliverCostTotal Lifecycle Cost33
4 Response: Machine and Equipment Builder Performance Machine Builders today are challenged to differentiate themselves amidst global competition and rapidly evolving technology.To achieve greater profitability, Machine Builders must improve their overall operational performance.CommissioningGlobal Service & SupportReliability & QualityMachine PerformanceDesignDesign ProductivityExtensible EngineeringScalabilityGlobal StandardsRisk AssessmentDesign for SustainabilityDevelopDeliverTime to MarketSupply Chain EfficiencyFlexible Equipment ModelsSimplified IntegrationDesign Optimisation
5 Design, Develop & Deliver Examples Maximise design productivity with extensible engineeringUse scalable control architecturesProvide extensive industry & application expertiseOptimise Your Machine DesignLeverage product selection & configuration toolsEasily select hardware & generate bills of materialSize & select an optimal motion systemUse scalable technologyMeet global safety & environmental standardsMeet functional safety standards with integrated safety solutionsHarness the inherent value of intelligent safety solutions with a Safety Lifecycle ApproachAvoid redesign changes – Perform risk assessments up front
6 Design, Develop & Deliver Examples Optimise & reuse your machine designImprove machine flexibility with modular programming techniquesDevelop reusable equipment modules with Modular ProgrammingRetrieve code to use as a foundationSimplify IntegrationIntegrated Architecture solutions with a single networkScalable control solutions reduce engineering time & eliminate risksReduce number of programming and configuring software packagesSupply Chain EfficiencyLocal sales & support“Preferred parts” availability consultationReduce time & costs using a single supplierReduce BOMImprove time to market to meet customer delivery commitments
7 Design, Develop & Deliver Examples Reduce Overall Installation & CommissioningEasily integrate with your customer’s information systemsLink real-time reporting from machine-level to IT infrastructure with standard EtherNet/IPProvide an accurate view of plant operationsImprove Reliability & QualityRemotely monitor machine system status & perform authorised program changesAchieve higher levels of business performance with Network & Security ServicesProvide Global Service & Support24 x 7 multi-lingual supportConnect to your machines globally with remote managed servicesStart up, warranty, emergency and more via Field Support OptionsOnline & Phone Support | Training | OnSite Support | Repair Services | MRO Asset Management | Safety | Energy | Network & Security | Managed Services80 CountriesI20 Languages6 Remote Support Centers10 Remanufacturing Depots9 Exchange HubsAverage 13+ Years Experience
8 Continuing to Enhance Our Capabilities Rockwell Automation recently released a number of new products designed to help OEM’s increase their business performanceL1L2L3Motion Analyzer 6Kinetix 350CompactLogix 5370ControllersPanelView Plus 6TerminalsKinetix 5500 and VPL Motors*coming soonStratix 5700LDAT Linear ThrusterPowerFlex 525
9 Equipment Builder Performance Kinetix 350CompactLogix 5370ControllersPanelView Plus 6TerminalsKinetix 5500 and VPL Motors*coming soonStratix 5700LDAT Linear ThrusterMotion Analyzer 6PowerFlex 525L1L2L3CommissioningGlobal Service & SupportReliability & QualityMachine PerformanceDesignDesign ProductivityExtensible EngineeringScalabilityGlobal StandardsRisk AssessmentDesign for SustainabilityDevelopDeliverTime to MarketSupply Chain EfficiencyFlexible Equipment ModelsSimplified IntegrationDesign Optimisation
10 Mechatronics and Machine Design Control DesignMotionSystem DesignMechanical Design“synergy of several engineering disciplines…”Mechatronic design is a collaborative venture between mechanical, electrical, and control design engineers – the outcome is a machine design optimised for high performance controls.
11 Time to Market Improvements – Motion Analyzer Tuning SimulationDecrease / eliminate Prototype builds by testing scenarios in Solidworks and Motion AnalyzerCode GenerationMotion Analyzer can both export and import project as .L5XEnables fast and reliable exchange of data with RSLogix5000Partially supports Product Lifecycle ManagementDownload Motion Analyzer Here
12 Time to Market Improvements – Drives and Motion Accelerator Toolkit Drives and Motion Accelerator Toolkit (DMAT) design wizard can automate file selections and importation.To speed development, the wizard asks questions about your application and produces the tools to start YOUR application WITHIN MINUTES.Tell the Wizard which controller, drives, HMI and I/O your application will use.The Wizard then runs and generates.A Bill of Materials of the products you specifiedA Folder of Wiring Diagrams and Panel Layout footprints ready your CAD programA Logix program with the configuration and basic control needs for your productsA starting HMI application with adaptation instructions for your applicationDownload DMAT HereHow much faster can you bring your machine to market withthe DMAT Wizard to help start your design?
13 Time to Market Improvements – Drives and Motion Accelerator Toolkit The DMAT includes automation engineering design tools for the entire machine control application development.Bill of Material, CAD, Logic, HMI, Quick StartThe DMAT allows Machine Builders to significantly reduce design time and cost; allowing them to concentrate on the intellectual property that produces compelling and differentiating machine features.Bill of Material FilesProgramming for control and configurationWiring Diagrams and Panel Layout DrawingsHMI Screens for status and diagnosticsQuick Start for Base System Setup
14 Time to Market Improvements – Drives and Motion Accelerator Toolkit The DMAT Wizard was used to develop the base application files for a 4 axis example.The Designer Wizard produced files ready for the application details after 16 minutes of work425 Lines of Code6 Products configured5500+ Program & Diagnostic Tags65 catalogue numbers15 Wiring Diagrams7 pages of panels / product lines Models22 HMI Screens Covering4 Drives, Alarming /Machine ControlQuick Start for Base System Setup
15 Time to Market Improvements – Drives and Motion Accelerator Toolkit AdvantagesDesigners can spend their time optimising their machine operations for better performance and higher profitsInitial Project setup Time needed for an example 4 axis systemTaskTime w/o DMAT AcceleratorTime Using DMAT WizardTurning specifications into catalog numbers and accessories4 Hours5 MinutesProduce initial base set of CAD drawings80 HoursProduce initial base program40 Hours3 MinutesProduce initial base HMI setFrom 204 hours to 16 minutes !!!!!
16 Simplifying Your Design – Single Network, Global Standards Standard Unmodified EthernetLower wiring costsSimplified Integration of the entire control solution on one network. including HMI, PAC, I/O and motion.Safe Torque Off standardScalable Platform to meet global machine standards120V, 240V - single and 3 phase460V – 3 phaseDesigned as a SystemController, Motion, HMI
17 Simplifying Your Design – Motion Simplification 50% reduction in sizeEfficient motors reduce size and costUp to 2 Sizes Smaller DriveSingle Cable Design reduces installation (60%) & procurement costs (27%)Induction Motor support reduces inventory, and simplifies designEnergy efficient drive/motor match and green shuntZero stacking, no backplaneTwo EtherNet/IP ports to support Device Level Ring (DLR)Designed as a SystemController, Motion, HMI
18 Simplifying Your Design – Linear Thruster Replace complex transmissions with linear actuators.Eliminates weeks of engineering, design and documentation time per custom designed actuator axis.Vastly reduces the amount of components that need to be purchased from multiple vendors for custom actuators.Eliminates the time needed to assemble a custom actuator into a machine.Reduces Engineering, Purchasingand Assembly Efforts!
19 CompactLogix 5370 Programmable Automation Controllers (PACs) Expanding on the scalability of the Logix family of controllersThe CompactLogix 5370 PACs offer:A wider variety of options to provide best-fit alternatives for specific application requirementsA strong motion solution when combined with Kinetix® servo drive for customers requiring high performance in a compact and affordable packageCommon and consistent features across all three platforms (L1, L2 and L3); scalability between the Logix families (CompactLogix and ControlLogix)
20 5370 CompactLogix SummaryBattery-lessOperationIntegrated Motion in L1,L2and L3 “M” controllers(CIP Motion / CIP Synch)All models(L3, L2, L1)L12x Scan TimePerformance IncreaseSD Flash for Programand Data StorageL2USB portfor programming>25% improvement in networkPackets Per Second (PPS)Embedded DLREtherNet/IP SwitchUniversal Analog Input(C, V, Thermocouple, RTD),14 bit resolutionSocketscommunicationLocal Expansion withup to 6 or 8 POINT I/OModulesMuch smallerform factor forL2 ControllersLocal Expansionwith up toModulesIntegrated Motion, 2x performance increase, >25% improvement in network and many more……in a compact form factor provides a right size control for your application needs
22 Simplified and Scaled Architectures CompactLogix chassisPanelView PlusStratixEtherNet/IPSERCOSDeviceNetPOINT I/OArmorBlock I/OPowerFlexRotary KnifeCompactLogix 2 Aux Feedback support provides the ability to easily input web material speedsSupported Logix CAM profile provides smooth speed transitions and exact speed synchronisation when the knife contacts the material.Typical applications requires 1 motor axis and 1 encoder Feedback Axis, perfect fit for CompactLogixCartonerAbsolute feedback enables the cartoner to maintain position, eliminates expensive and time-consuming homing routines.Synchronisation of multiple axes through gearing and camming.Generate virtual axes to use as references for synchronising real axes.Kinetix 6200
23 Simplified and Scaled Architectures CompactLogix chassisPanelView Plus 6Stratix 5700EtherNet/IPPOINT I/OArmorBlock I/OKinetix 5500PowerFlexRotary KnifeCompactLogix 2 Aux Feedback support provides the ability to easily input web material speedsSupported Logix CAM profile provides smooth speed transitions and exact speed synchronisation when the knife contacts the material.Typical applications requires 1 motor axis and 1 encoder Feedback Axis, perfect fit for CompactLogixCartonerAbsolute feedback enables the cartoner to maintain position, eliminates expensive and time-consuming homing routines.Synchronisation of multiple axes through gearing and camming.Generate virtual axes to use as references for synchronising real axes.
24 Simplified and Scaled Architectures To Line orEnterpriseCompactLogix chassisPanelView Plus 6Stratix 5700EtherNet/IPPOINT I/OArmorBlock I/OKinetix 5500PowerFlexRotary KnifeCompactLogix 2 Aux Feedback support provides the ability to easily input web material speedsSupported Logix CAM profile provides smooth speed transitions and exact speed synchronisation when the knife contacts the material.Typical applications requires 1 motor axis and 1 encoder Feedback Axis, perfect fit for CompactLogixCartonerAbsolute feedback enables the cartoner to maintain position, eliminates expensive and time-consuming homing routines.Synchronisation of multiple axes through gearing and camming.Generate virtual axes to use as references for synchronising real axes.
26 PowerFlex 525 AC Drives Modular Design USB HIM Power Range Offers ease of installation and programmingUSBConnectivity forFaster ConfigurationHIMThe LCD Human Interface Module supports multiple Languages and feature scroling textPower Range115V to 600V0.37 to 22kWEmbedded Ethernet PortProvides Premier Integration into the Logix environmentSafe Torque-OffA standard feature of the PowerFlex 525 DrivesSimplified ProgrammingEasy to use Software and MainsFree programming via USB
27 + + A unique product family in the market…. Stratix 8000 & 5700 Family Layer 2 & 3 Managed Switches w/ Cisco Technology InsideA unique product family in the market….Stratix 8000/8300Best of Rockwell AutomationPremier (CIP) interface to Integrated ArchitectureStudio 5000 for configuration (AOP)Predefined Logic tags for diagnosticsFactoryTalk View FaceplatesBest of CiscoSecure integration with plantwide networkCisco internetworking operating system (IOSTM)Cisco CatalystTM switch architecture and feature setFamiliar tools for IT professionals: command line interface (CLI), Cisco Network Assistant (CNA) and Device ManagerStratix 5700++Best for the Plant Floor EnvironmentEasy to Integrate and MaintainDefault configurations for Industrial AutomationRemovable storage cards for one step device replacement… integrating the IT and Industrial Environments
29 Equipment Integration How do you overcome the challenges?Simplified architecturesStandard unmodified Ethernet
30 Differentiation – Smart Machines contact a remote service engineer?
31 Differentiation – Smart Line Lowers Lifecycle TCO
32 Design Optimisation Summary You design a machine with less parts, and lower inertia, which leads to lower cost motors and drivesLess parts and smaller motors and drives means a smaller footprintIncreased scalability of controllers allows you to only pay for the control and features you needSimplified equipment allows you to turn over jobs faster, meaning getting paid fasterDesign Optimisation
33 Simplified Integration SummaryUsing standard, unmodified Ethernet allows you to easily integrate into an end user environmentCisco enabled switches promotes easy adoption by end user IT departmentsFast integration means less time at end user siteSimplified Integration
34 Differentiated Value Summary Because back in design you optimised, you deliver a machine with less parts, requiring less spares, less maintenance, less energy usage and longer uptimeProviding a smart machine gives a competitive advantage to your end users and differentiates your equipment in the marketProviding information enabled equipment allows the customer to get the information they need to optimise operations and meet their efficiency goalsDifferentiated Value
35 More InformationIf you would like more information on our midrange platform, you can visit