ap11: loram: stays on track with mobile data collection and reporting
DESCRIPTION
Loram, a leading supplier of train track maintenance machinery and services, needed to better track performance of mobile rail maintenance trains. Leveraging the FactoryTalk software suite, Loram remotely collects critical performance data from each train for real-time troubleshooting, maintenance and electronic reporting. Each train is equipped with over 100,000 data inputs, and Loram typically collects 2,100 data tags per report. Using Historian and the Rockwell Automation GPS Time Module, Loram also tracks North American trains through wireless connection, displayed on Google Maps. Loram is implementing this feature on all new rail grinder trains.TRANSCRIPT
®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability
Loram: Stays on Track with Mobile Data Collection and Reporting
Eric Manninen
Principal Engineer Electrical
®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability
2. Machine Design System Layout
4. Rockwell Software Products Overview
5. FactoryTalk Solution Implementation
6. Loram’s VantagePoint Portal Demonstration
1. Loram Company Overview
3. Business Drivers for Information Enabled Solution
Agenda Overview
7. Related RSTechEd Sessions and QNA?
®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability
� Office Headquarters arelocated in Hamel, MN
� Employs over 850 people� Builds Leased and OEM
Machine Equipment� Outstanding Safety Record Provides Railway Maintenance Services
to Major Commercial Railroads and
Passenger Rail Markets across North
America and the World through:► Rail Grinders
► RailVacs
► Ditchers
► RailTrains
► Track Lifters
► Track Undercutters
► Rail Inspection Vehicles
► Shoulder Ballast Cleaners
Loram - Company Overview
®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability
For more information, visit us at:
www.loram.com
RailVac Light-Rail Grinder
Shoulder Ballast Cleaner Rail Grinder
Loram – Representative Machine Types
®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability
Loram Rail Grinder Video Demonstration
®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability
Physical Layout of typical Rail Grinder Machine
►Typical Length of 800 feet (244 m)
►43 Liter Diesel Engine Generator Set
►4920 KW Power Generated on Machine
►Power Bus draws up to 4000 Amps
►120 - 30 HP Grind Motors
►Travels up to 70 miles/hour (113 km/h)
►Operates at 20 miles/hour (32 km/h)
►10,300 Gallons of Diesel Fuel stored
►50,000 Gallons of Water stored on
Machine for Fire Suppression System
►26,400 feet (8047 m) of total wire used
®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability
Controls Layout of typical machine:RG400 Series Rail Grinder
►5 ControlLogix 1756-L73 Processors located in the Control Car & 4 Grind Cars
►5 ControlLogix (1756) Distributed Input/Output 17-Slot Remote Racks
►4 Flex (1794) Distributed Input/Output Remote Racks in the Control & Support Cars
®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability
Rail Grinder Rockwell System Architecture
Controller System
1,000,000 Controller Tags
145,000HMI Tags
2,100 Data Historian Tags
EtherNet/IP Network
HMI Communication
Data Collection
ControlNetNetwork
Distributed I/O
PLC Messaging
DeviceNetNetwork
Motor Protection
®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability
Machine Operators
– Crew is not technically trained with Automation skill-set
– Troubleshooting information from crew is not reliably Accurate
Mean Time to Repair
– Diagnosis of component failure was a slow multiple day process
– Failure analysis was not real-time capable
Historical Data Logging
– Legacy datalogs only stored locally on machine for 30 days
– Datalogs must be manually removed and sent to engineering
– Format is not easily readable, customizable, or searchable
Machine Diagnostic Logs
– Manual hand-written logs off Chart recorders, Metering, and Gauges
– Predictive Maintenance was not able to be implemented
Reliability Data and Remote Diagnostics are limited
– Most downtime situations require a remote site visit by field service personnel
Loram’s Business Challenges:Pre-Machine Historian implementation
®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability
Software Solution Needs OverviewWhat we needed to add to the architecture
EnterpriseData Historian
Server
Machine Historian Machine Historian Machine Historian Machine Historian Machine Historian
Web DashboardReporting Interfacefor Diverse Clients
Operations
Field Service
Controls
Engineering
®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability
Engineering and Controls:Information System Requirements
Engineering• Long-Term Corrective action planning for component failures
– Diagnosis of historical component product life
– Real-time failure analysis of current system
• Key Performance Indicator Data– Electronic Historical Datalogs provide machine performance data remotely
– Data that is easily accessible, sortable, and searchable in a variety of reports
– A system that can handle multiple months worth of local storage before upload
– Historical Trending verification of Machine Runtime Performance to Design
Controls• Controller Tag Data Reporting
– Electronic Historical Datalogs provide sequence of event data remotely
– Data is easily accessible, sortable, and searchable in a variety of reports
– Determination of root cause analysis of complex machine control faults
– Diagnostics reports determine operator, code, or machine component issues
®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability
Operations and Field Service:Information System Requirements
Operations
• Collection of Reliability Data and Remote Monitoring
– Electronic Datalogs of totalizer data on engine run hours, historical generator
loads, and other important KPIs.
– Predictive maintenance using remote diagnostics (MTTF)
• Historical Machine Efficiency available for comparison study
• Real-time feedback using Ad-Hoc tag reporting on current machine issues
Field Service
• Collection of Reliability Data and Remote Monitoring
– Machine Location tracking for travel and component replacement scheduling
– Real-time failure analysis through Web Portal
– Remote Diagnosis time reduction from 1 or 2 days to hours improving MTTR
– Remote Real-time failure analysis to replace field service travel
– Predictive Maintenance improvement to reduce downtime, save expensive
component failure, and decrease field service call volume needs
®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability
What Rockwell Software can be used to meet all these diverse application needs?
Factorytalk® Historian Site Edition
FactoryTalk® VantagePoint
Factorytalk® Historian Machine Edition
®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability
FactoryTalk Historian Machine EditionIn-rack On Machine Historian
Data collection at the machine level � More granular data
� Data at higher speeds
� Single machine historian
� Reduce network dependency
Improved Reliability� Solid-state data collection
� No computer / OS to maintain
� No moving parts
Remote data capture� Collect data where a computer is not
available or desired
Distributed / modular configuration� Configure one machine at a time
®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability
FactoryTalk Historian Site EditionEnterprise Level Historian Server
15
� Market Leading Historian Technology – Optimized time series data storage and retrieval
– Advance Calculations & Data Access capabilities
� Quick to Deploy and Easy to Own
– Integrated with Logix and FactoryTalk Technology
– Auto Discovery & Configuration
– Low Total Cost of Ownership
� Rich Set of Clients
– FactoryTalk View Site Edition – HMI trending integration with Historian
– VantagePoint EMI – bundled with Historian SE Package
� Distributed Historian Architecture
– Includes a 1756 chassis based Historian
– Data can be aggregated at the site and Enterprise level
– Seamless integration and common client access throughout the portfolio
®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability
� FactoryTalk VantagePoint a
powerful client interface for
Factorytalk Historian:
– Advanced trend tool
– XY Plotter
– Excel Add-in
– Advanced Dashboards
– Portal for thin client access
� Provides Client Access to
Historical, Real-time and Alarm
& Events Data. Aggregating
and Correlating Data Sources
with Common Reporting Tools
FactoryTalk VantagePointWeb-based Client Report Server
®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability
FactoryTalk VantagePoint:Notifications and Reporting on Mobile platforms
� Reporting available on mobile devices:
– Enterprise Reports
– Charts
– Status Indicators
– Grid Reports
� Report Notification
– Event Triggers Email or Text Message
� with Event Data
� with Pre-Built Report
Loram has tested Microsoft Surface Pro Tablets on machine to view data using the FT VantagePoint Mobile Client Application
®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability
Putting it all Together:Loram’s FactoryTalk Implementation
FactoryTalkHistorian Site Edition Server
FT Historian ME FT Historian ME FT Historian ME FT Historian ME FT Historian ME
FactoryTalkVantagePoint
Web Reporting Server
Operations
Field Service
Controls
Engineering
FT Historian ME Modules added to Rail Grinders
FactoryTalk Historian SE Server
Consolidates Historical Tag Data
FactoryTalk
VantagePoint
Turns Historical
Tag Data into
Actionable Reports
Each Group uses
Web Interface to
View their Unique
Report Tool Set
®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability
In-Rack Machine Historian logs data locally even when network is not available. Historian Server provides centralized long term data storage when network becomes available.
Historical Database
Collection Server
and Remote Data
Machine Edition
Historian ModuleIn-Rack Historian:
A FactoryTalk Historian Machine
Edition module collects data from a
PLC using compression and exception
algorithm storage. It collects data from
the controls system even when
network is not available.
Store and Forward:
Collected Data in Historian ME module
is Uploaded to FT Historian Site Edition
Server when network is available for
long-term storage and reporting.
®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability
FactoryTalk VantagePoint visualizes the data from the Historian Server and provides a Web Portal Reporting Interface
Reporting Server
The data collected by
FactoryTalk Historian System is
reported upon through Excel
and Trending Tools. These
reports are then published to
and visualized by FactoryTalk
VantagePoint Web Portal.
Reporting Clients
FactoryTalk VantagePoint makes
these reports available via
a web client dash-board
interface. Allowing a range
of reporting client user groups
to have their different data
wants and needs met.
FactoryTalkVantagePointWeb Reporting
Server
Operations
Field Service
Controls
Engineering
Web-based Dashboard
Reporting Server and
Client User Groups
®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability
History and Progress of this Rockwell Solution
GPS Dashboard Map for Machine Reporting and Tracking in 2011
®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability
What we learned and where we’re going
The Results of this solution implementation today:
– Faster troubleshooting resulting in:
• Shorter downtime
• Increased productivity
• Real-time diagnostics
– Able to decrease field service deployment of technicians
– Implement pro-active maintenance procedure timelines
• Before critical component failures occur
• Saving downtime and decreasing replacement costs
– Provide built-in warranty / legal protection through reporting of machine service record
We are continuing to invest in this technology with its proven results:
– We’ve increased our reporting tag usage as we have identified new KPI data
– Expanded our fleet install to retrofit existing machines and deploy on new start-ups
– We are designing this system into new machine types for the latest generation builds
– Exploring building a customer reporting cloud portal for future OEM machines
Productivity
Downtime
®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability
This unique GPS enabled google maps interface allows tracking of machine progress at a glance and drill-down to machine reports
Since implementing the first
machine historian in 2011,
more information-enabled
machines have been retro-
fitted or started up with this
solution and new machine
types plan to upgrade.
RG402 - 01/19/2012
RG403 - 02/27/2013
RG406 - 03/03/2013
RG405 - 04/04/2013
RG404 - 04/20/2013
RG401 - 06/11/2013
RG408 - 11/15/2013
RG410 - 05/05/2014
RG409 - Planned
RG411 - Future
®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability
Web Dashboard and Reporting DemonstrationLoram’s VantagePoint Web Portal Home Page
Each Machine has
a set of pre-built
reports based on
troubleshooting
experience
Each Machine has
a set of pre-built
reports based on
troubleshooting
experience
®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability
Loram’s Machine Reporting Dashboard
Machine Selection
Machine Overview
Grind Diagnostics
Power Generation
Traction Data
Dust Collection
Hydraulic System
®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability
Machine Efficiency Data Reports – Proactive Improvement Tracking and Comparison
®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability
Framing Historical Data into Event-based Reports provides Warranty / Legal Protection
®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability
Report Tracking Ambient Machine Temperatures can Correlate Potential Heat-related Component Failure
®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability
AdHoc Report created to Troubleshoot Machine and Solve Field Issue Remotely
®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability
Excel Report to Track Fuel Consumption
®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability
Related Sessions at RSTechEd 2014
Introduction to FactoryTalk VantagePoint 1 hour
You’ve heard about Manufacturing Intelligence, but do you have a good base understanding for
what the FactoryTalk VantagePoint EMI reporting and analytics product can really do? Come
take a quick tour of FactoryTalk VantagePoint EMI and learn more about what it has to offer.
FactoryTalk VantagePoint EMI: 50 Minutes to Value 1 hour
If you had 50 minutes, a computer running FactoryTalk VantagePoint, and an information
engineer, what could you do? In this session, the instructor will lead you through solution creation
on the fly. What types of ad-hoc analysis can you do? What types of content are easiest to
develop? Could you really do a full report-package solution with FactoryTalk VantagePoint in the
allotted time? Come see.
Mobility and Portability with Today’s Rockwell Software 1 hour
Bring your own device to work? Need to support mobile workers? Production and operations
management solutions today require various forms of access to their Manufacturing Intelligence
systems including mobile devices and web clients. In this session, see how Rockwell Software
can begin to accomplish these goals with access to FactoryTalk View Site Ediction, FactoryTalk
VantagePoint EMI and eventing on any mobile platform.
®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability
Related Sessions at RSTechEd 2014
Introduction to FactoryTalk Historian 1 hour
A distributed historian strategy produces strong advantages. Learn how FactoryTalk Historian
delivers a scalable, modular, synchronized methodology for collecting, maintaining and analyzing
process data at each level of manufacturing operations. New features and functionality will be
highlighted and compared to similar products in the marketplace.
FactoryTalk Historian Machine Edition 2 hours
Hands-on lab with FactoryTalk Historian Machine Edition covers typical configuration and data
collection in a ControlLogix chassis. The lab will cover the web configuration of the module,
simple web reporting, and the use of thick clients for reporting and analysis of the data in the
historian module. You will also learn about store and forward architecture between Historian
Machine Edition and Historian Site Edition and integration with Rockwell Software Studio 5000
through Add-On Profiles.
FactoryTalk Historian Siting Edition: Data Collection and Reporting Lab 2 hours
Introductory FactoryTalk Historian Site Edition lab covers basic elements of system confi
guration, data collection and reporting tools. Learn how FactoryTalk Historian Site Edition
provides an engine of unmatched performance and scalability. See the power of
autoconfiguration and diverse control system/HMI connectivity.
®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability 33
Questions?
For more information, visit us at: www.loram.com
®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability
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