Optimising Your Machine for Differentiated Value

Simplified Integration Why We Are Here Today We want to show you how you can design a high performance system at a cost effective price We want to show you how you can reduce the time and cost it takes to integrate your equipment into the end user environment We want to show you how you can do the above while also delivering equipment that provides differentiated value to your end users Design Optimisation Simplified Integration Differentiated Value

Manufacturing Drivers Today Flexibility Faster Commissioning, Reconfiguration Flexibility Faster Commissioning, Reconfiguration Integration & Simplification Control, Safety, Information/IT Integration & Simplification Control, Safety, Information/IT Optimum Asset Utilisation End Users Optimise the Operation of Production Line OEMs Optimise the Effectiveness of Equipment Building Performance Equipment Effectiveness Solutions Original white paper content works: What Machine Builders Care About Most Of 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 Support Services Global Support Services Cost Total Cost to Design, Develop, & Deliver Cost Total Lifecycle Cost 3 3

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. Commissioning Global Service & Support Reliability & Quality Machine Performance Design Design Productivity Extensible Engineering Scalability Global Standards Risk Assessment Design for Sustainability Develop Deliver Time to Market Supply Chain Efficiency Flexible Equipment Models Simplified Integration Design Optimisation

Design, Develop & Deliver Examples Maximise design productivity with extensible engineering Use scalable control architectures Provide extensive industry & application expertise Optimise Your Machine Design Leverage product selection & configuration tools Easily select hardware & generate bills of material Size & select an optimal motion system Use scalable technology Meet global safety & environmental standards Meet functional safety standards with integrated safety solutions Harness the inherent value of intelligent safety solutions with a Safety Lifecycle Approach Avoid redesign changes – Perform risk assessments up front

Design, Develop & Deliver Examples Optimise & reuse your machine design Improve machine flexibility with modular programming techniques Develop reusable equipment modules with Modular Programming Retrieve code to use as a foundation Simplify Integration Integrated Architecture solutions with a single network Scalable control solutions reduce engineering time & eliminate risks Reduce number of programming and configuring software packages Supply Chain Efficiency Local sales & support “Preferred parts” availability consultation Reduce time & costs using a single supplier Reduce BOM Improve time to market to meet customer delivery commitments

Design, Develop & Deliver Examples Reduce Overall Installation & Commissioning Easily integrate with your customer’s information systems Link real-time reporting from machine-level to IT infrastructure with standard EtherNet/IP Provide an accurate view of plant operations Improve Reliability & Quality Remotely monitor machine system status & perform authorised program changes Achieve higher levels of business performance with Network & Security Services Provide Global Service & Support 24 x 7 multi-lingual support Connect to your machines globally with remote managed services Start up, warranty, emergency and more via Field Support Options Online & Phone Support | Training | OnSite Support | Repair Services | MRO Asset Management | Safety | Energy | Network & Security | Managed Services 80 Countries I 20 Languages 6 Remote Support Centers 10 Remanufacturing Depots 9 Exchange Hubs Average 13+ Years Experience

Continuing to Enhance Our Capabilities Rockwell Automation recently released a number of new products designed to help OEM’s increase their business performance L1 L2 L3 Motion Analyzer 6 Kinetix 350 CompactLogix 5370 Controllers PanelView Plus 6 Terminals Kinetix 5500 and VPL Motors *coming soon Stratix 5700 LDAT Linear Thruster PowerFlex 525

Equipment Builder Performance Kinetix 350 CompactLogix 5370 Controllers PanelView Plus 6 Terminals Kinetix 5500 and VPL Motors *coming soon Stratix 5700 LDAT Linear Thruster Motion Analyzer 6 PowerFlex 525 L1 L2 L3 Commissioning Global Service & Support Reliability & Quality Machine Performance Design Design Productivity Extensible Engineering Scalability Global Standards Risk Assessment Design for Sustainability Develop Deliver Time to Market Supply Chain Efficiency Flexible Equipment Models Simplified Integration Design Optimisation

Mechatronics and Machine Design Control Design Motion System Design Mechanical 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.

Time to Market Improvements – Motion Analyzer Tuning Simulation Decrease / eliminate Prototype builds by testing scenarios in Solidworks and Motion Analyzer Code Generation Motion Analyzer can both export and import project as .L5X Enables fast and reliable exchange of data with RSLogix5000 Partially supports Product Lifecycle Management Download Motion Analyzer Here

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 specified A Folder of Wiring Diagrams and Panel Layout footprints ready your CAD program A Logix program with the configuration and basic control needs for your products A starting HMI application with adaptation instructions for your application Download DMAT Here How much faster can you bring your machine to market with the DMAT Wizard to help start your design?

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 Start The 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 Files Programming for control and configuration Wiring Diagrams and Panel Layout Drawings HMI Screens for status and diagnostics Quick Start for Base System Setup

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 work 425 Lines of Code 6 Products configured 5500+ Program & Diagnostic Tags 65 catalogue numbers 15 Wiring Diagrams 7 pages of panels / product lines Models 22 HMI Screens Covering 4 Drives, Alarming /Machine Control Quick Start for Base System Setup

Time to Market Improvements – Drives and Motion Accelerator Toolkit Advantages Designers can spend their time optimising their machine operations for better performance and higher profits Initial Project setup Time needed for an example 4 axis system Task Time w/o DMAT Accelerator Time Using DMAT Wizard Turning specifications into catalog numbers and accessories 4 Hours 5 Minutes Produce initial base set of CAD drawings 80 Hours Produce initial base program 40 Hours 3 Minutes Produce initial base HMI set From 204 hours to 16 minutes !!!!!

Simplifying Your Design – Single Network, Global Standards Standard Unmodified Ethernet Lower wiring costs Simplified Integration of the entire control solution on one network. including HMI, PAC, I/O and motion. Safe Torque Off standard Scalable Platform to meet global machine standards 120V, 240V - single and 3 phase 460V – 3 phase Designed as a System Controller, Motion, HMI

Simplifying Your Design – Motion Simplification 50% reduction in size Efficient motors reduce size and cost Up to 2 Sizes Smaller Drive Single Cable Design reduces installation (60%) & procurement costs (27%) Induction Motor support reduces inventory, and simplifies design Energy efficient drive/motor match and green shunt Zero stacking, no backplane Two EtherNet/IP ports to support Device Level Ring (DLR) Designed as a System Controller, Motion, HMI

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, Purchasing and Assembly Efforts!

CompactLogix 5370 Programmable Automation Controllers (PACs) Expanding on the scalability of the Logix family of controllers The CompactLogix 5370 PACs offer: A wider variety of options to provide best-fit alternatives for specific application requirements A strong motion solution when combined with Kinetix® servo drive for customers requiring high performance in a compact and affordable package Common and consistent features across all three platforms (L1, L2 and L3); scalability between the Logix families (CompactLogix and ControlLogix)

5370 CompactLogix Summary Battery-less Operation Integrated Motion in L1,L2 and L3 “M” controllers (CIP Motion / CIP Synch) All models (L3, L2, L1) L1 2x Scan Time Performance Increase SD Flash for Program and Data Storage L2 USB port for programming >25% improvement in network Packets Per Second (PPS) Embedded DLR EtherNet/IP Switch Universal Analog Input (C, V, Thermocouple, RTD), 14 bit resolution Sockets communication Local Expansion with up to 6 or 8 POINT I/O Modules Much smaller form factor for L2 Controllers Local Expansion with up to 4 1769 Modules Integrated 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

The Power of Logix AOI

Simplified and Scaled Architectures CompactLogix chassis PanelView Plus Stratix EtherNet/IP SERCOS DeviceNet POINT I/O ArmorBlock I/O PowerFlex Rotary Knife CompactLogix 2 Aux Feedback support provides the ability to easily input web material speeds Supported 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 CompactLogix Cartoner Absolute 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

Simplified and Scaled Architectures CompactLogix chassis PanelView Plus 6 Stratix 5700 EtherNet/IP POINT I/O ArmorBlock I/O Kinetix 5500 PowerFlex Rotary Knife CompactLogix 2 Aux Feedback support provides the ability to easily input web material speeds Supported 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 CompactLogix Cartoner Absolute 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.

Simplified and Scaled Architectures To Line or Enterprise CompactLogix chassis PanelView Plus 6 Stratix 5700 EtherNet/IP POINT I/O ArmorBlock I/O Kinetix 5500 PowerFlex Rotary Knife CompactLogix 2 Aux Feedback support provides the ability to easily input web material speeds Supported 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 CompactLogix Cartoner Absolute 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 5500 Servo Drive 50% smaller Supports 195 – 528 VAC input, reducing inventory Innovative Common AC/DC bus eliminates hardware, reduces installation time and lowers costs Single cable eliminates Hardware and wire terminations Induction motor (V/Hz) support simplifies inventory and maintenance Clamp design prevents installation mistakes and enforces 360° bonding for noise immunity

PowerFlex 525 AC Drives Modular Design USB HIM Power Range Offers ease of installation and programming USB Connectivity for Faster Configuration HIM The LCD Human Interface Module supports multiple Languages and feature scroling text Power Range 115V to 600V 0.37 to 22kW Embedded Ethernet Port Provides Premier Integration into the Logix environment Safe Torque-Off A standard feature of the PowerFlex 525 Drives Simplified Programming Easy to use Software and MainsFree programming via USB

+ + A unique product family in the market…. Stratix 8000 & 5700 Family Layer 2 & 3 Managed Switches w/ Cisco Technology Inside A unique product family in the market…. Stratix 8000/8300 Best of Rockwell Automation Premier (CIP) interface to Integrated Architecture Studio 5000 for configuration (AOP) Predefined Logic tags for diagnostics FactoryTalk View Faceplates Best of Cisco Secure integration with plantwide network Cisco internetworking operating system (IOSTM) Cisco CatalystTM switch architecture and feature set Familiar tools for IT professionals: command line interface (CLI), Cisco Network Assistant (CNA) and Device Manager Stratix 5700 + + Best for the Plant Floor Environment Easy to Integrate and Maintain Default configurations for Industrial Automation Removable storage cards for one step device replacement … integrating the IT and Industrial Environments

Switch Tools and Integration

Equipment Integration How do you overcome the challenges? Simplified architectures Standard unmodified Ethernet

Differentiation – Smart Machines contact a remote service engineer?

Differentiation – Smart Line Lowers Lifecycle TCO

Design Optimisation Summary You design a machine with less parts, and lower inertia, which leads to lower cost motors and drives Less parts and smaller motors and drives means a smaller footprint Increased scalability of controllers allows you to only pay for the control and features you need Simplified equipment allows you to turn over jobs faster, meaning getting paid faster Design Optimisation

Simplified Integration Summary Using standard, unmodified Ethernet allows you to easily integrate into an end user environment Cisco enabled switches promotes easy adoption by end user IT departments Fast integration means less time at end user site Simplified Integration

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 uptime Providing a smart machine gives a competitive advantage to your end users and differentiates your equipment in the market Providing information enabled equipment allows the customer to get the information they need to optimise operations and meet their efficiency goals Differentiated Value

More Information If you would like more information on our midrange platform, you can visit www.scalabletechnology.eu

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