factorytalk -enabled solutions - designautomation · factorytalk-enabled solutions rsview...

FactoryTalk™-EnabledSolutions

Enhancing the Value of yourSoftware Investment

Integrate. Communicate. Collaborate.

What happens when the many pieces that make up a complex automation

system share an integrated FactoryTalk architecture? They communicate.

The people who design, operate, maintain, and optimize the system can all share the

same information—without duplicated effort. Integration enables communication.

What happens when the people who run an integrated automation system

communicate? They collaborate. Working together, they can do more and do it faster.

They can make more informed decisions, and they can better serve their customers.

Communication enables collaboration.

FactoryTalk —it enables more than systems —it enables the people who run them.

D E S I G N O P E R A T E M A I N T A I N

1

Cont

ents

1 DESIGN1.1 Define tags once and reuse them throughout a

FactoryTalk-enabled system 2

1.2 Streamline HMI development with a common editor 4

1.3 Collaborate on complex projects with multi-user support and version controls 6

1.4 Build control systems quickly with libraries of reusable objects 8

1.5 Simulate automation systems and predict “best case” outcomes 10

2 OPERATE2.1 Define graphic displays once and reference

them throughout a distributed system 12

2.2 Assure virtually non-stop monitoring with built-infailure detection and recovery 14

2.3 Optimize manufacturing operations and integrate data across an enterprise 16

3 MAINTAIN3.1 Audit and manage changes to

FactoryTalk-enabled systems 18

3.2 Diagnose and troubleshoot the health of devices throughout a facility 20

F a c t o r y Ta l k - E n a b l e d S o l u t i o n s

2

1.1

Define tags once and reuse themthroughout a FactoryTalk-enabled system

A conventional control system requires creating and maintaining twoseparate databases: one for the programmable logic controller andanother for the HMI application. With Rockwell Software productsenabled by FactoryTalk Directory™, tags can be defined just once,and then referenced and reused anywhere within a distributed system.

Conventional SolutionIn a conventional automation system, programming PLC tags and then using them inan HMI software editor is a complicated, multi-step process.

1. Program PLC tags using a programmable logic control editor, such as RSLogix™.

2. Export tags from RSLogix into a file, and then import the tag file into an HMI editor.

3. Duplicate any changes made in the PLC editor in the HMI software. Adding only afew new tags to the PLC program typically requires running a completeexport/import batch operation.

4. As additionalcontrollers and otherdevice tags areimported into the HMIsoftware, continuemanaging theexport/import processand synchronizingmultiple tag databases.

Example

Logic Programming HMI Developer

Two Databases

PLC HMI

Manualimport/export

23

4

1

3


FactoryTalk-Enabled SolutionWith a FactoryTalk-enabled automation system, simply program PLC tags and thenreference them anywhere in the system.

1. Program PLC tagsusing RSLogix, andthen save the project.

2. Use the tags createdin the PLC programdirectly in the HMIwithout creating anHMI tag database.

That’s it. Tags are available for immediate use anywhere within the FactoryTalk-enabled system, even before the ladder logic program is downloaded to the controller.As the ladder program is edited, most tag information is updated, and new tags areavailable immediately across the FactoryTalk-enabled system. Tags are not held withina common database, nor are they duplicated in multiple databases. With ControlLogix™

controllers, tags reside right within the hardware. With Allen-Bradley™ PLC-5™ andSLC 500™ devices, and with third-party controllers, tags reside within OPC (OLE forProcess Control®) Data Access servers. Tags can reside on a single computer or onmultiple computers connected to a network.

• Reduces initial development time and ongoing maintenance costs• Eliminates importing and duplicating tag databases• Avoids a common database with a single point of failure• Supports tag databases distributed across multiple computers connected

to a network

BENEFITS OVER CONVENTIONAL SOLUTION

• RSView™ Enterprise Series software suite (RSView Supervisory Edition™, RSView Machine Edition™, RSView Studio™)

• RSLogix & RSLinx™

• RSBizWare™ software suite (RSSql™)• FactoryTalk Directory (used within Rockwell Software products)• OPC (OLE for Process Control) Data Access v. 2.05-compliant servers

PRODUCTS & TECHNOLOGIES

Logic Programming HMI Developer

FactoryTalkDirectory

21

4

1.2

Streamline HMI development witha common editor

The RSView Enterprise Series software suite provides a common userexperience that spans stand-alone machine-level applications upthrough supervisory-level HMI applications across a network. Reusemachine-level applications in large-scale distributed HMI systems—without recreating graphic displays, tags, or other project elements.

Example

Supervisory-Level HMI Developer

Machine-Level HMI Developer

Conventional SolutionIn a conventional environment, developing both machine-level and supervisory-levelHMI applications requires using completely different development tools, each with itsown user interface, navigation tools, and learning curve. Sharing graphic displays,tags, and other project elements between the two environments is difficult.Although graphics can often be imported, neither tags nor commands convert cleanly,leaving much tedious work still to do. Typically, most customers find it easier todevelop the two types of applications completely separately—which often nearlydoubles development time.

5


RSView Enterprise SolutionWith RSView Enterprise Series, all of the software products in the suite are built on thesame integrated, scalable architecture. RSView Studio, a common developmentenvironment, supports developing both machine-level and supervisory-level HMIapplications. Import entire machine-level applications into supervisory-levelapplications, or dragindividual components anddrop them right intosupervisory projects.

For example, while operatorsmanage machine-level datafrom dedicated operatorterminals and industrialcomputers on the plant floor,maintenance engineers caneasily monitor the samemachine-level data fromtheir supervisory stations in remote locations—without having to recreate any graphicdisplays or tags. From an RSView SE station, an engineer can simply drag graphicdisplays from an RSView ME application, drop them into a supervisory-levelapplication, and immediately begin monitoring plant floor data.

• Reduces development time • Offers common development environment with consistent operator interface

and navigation features across multiple platforms• Makes it easy to reuse machine-level applications within

supervisory-level projects


• RSView Enterprise Series software suite (RSView Studio, RSView MachineEdition, RSView Supervisory Edition)

• Allen-Bradley VersaView™ CE and VersaView industrial computers• Allen-Bradley PanelView™ Plus dedicated operator terminals


6

1.3

Collaborate on complex projects withmulti-user support and version controls

RSAutomation Desktop™ includes built-in controls for managingcomplex industrial automation projects. A team can work together on aproject concurrently without fear of overwriting each other’s work.Because the versioning system is tied into an underlying FactoryTalkAudit™ capability, messages about changes to any element of theproject are available immediately across the entire automation system.

Conventional SolutionPost-it notes, scribbles on scratch pads, email threads, spreadsheets, and lots ofmanual comparisons across numerous documents — managing multiple users andversions of an industrial automation project is often a hodgepodge today.With different versions of various project elements, and with different peopleworking on the same things, managing complex projects is difficult, time consuming,and error prone.

Example

product

electrical

control

HMI

Information is not shared efficientlyamong applications and users!

simulation

7


FactoryTalk-Enabled SolutionWith RSAutomation Desktop, every element in a project has a version numberassociated with it. To work with a project element, a developer checks it out from acommon database. Other team members can view the project element but cannotedit it. When the project element is checked back in, the system assigns a newversion number and generates an audit message that includes optional authorcomments, along with details about who made the change, what was changed,and when it was changed. The audit trail makesit easier to comply with the USgovernment’s 21 CFR Part 11specification. It also makes itpossible to analyze project changesacross time and restore a projectback to any state.

• Eliminates conflicting edits and duplicated efforts from multiple project team members

• Comprehensive audit trail makes it easy to track who made changes to project elements, when, and why

• Allows restoring any historical version of an industrial automation project• Makes messages about project changes available across an entire

automation system


• RSAutomation Desktop• FactoryTalk Audit (used within Rockwell Software products)


product

electrical

controlHMI

simulation

8

1.4

Build control systems quickly withlibraries of reusable objects

In a conventional automation system, reusing control system designelements to build a new automation project can sometimes requiremore work than starting from scratch. With RSAutomation Desktop,system elements can be created once, stored as templates, and reusedto quickly build or extend an automation system. Reusing objects andeliminating redundant tag entries and repetitive testing can slashproject development costs by as much as 40%.

Conventional SolutionIn a conventional automation system, engineers use a number of methods to duplicateand reuse parts of existing systems, but all of the methods require significant effortand expense. Copying and pasting ladder logic, graphic displays, systemdocumentation, and other project elements is one method, but it requires manualrework and tedious testing. The same drawbacks apply to importing and exportingelements among projects. Using custom software is yet another method, but this oftenrequires dedicated staff and is expensive to maintain.

Example

New Project and FilesError Prone

Tags need to be fixed upLots of testing needed

Copy/PasteCopy/Paste

Home GrownSolutions

Home GrownSolutions

9


RSAutomation Desktop SolutionRSAutomation Desktop allows nearly any element of an automation system to besaved in a reusable template. As part of creating a template, RSAutomation Desktopreplaces the tags in each system element with placeholders. When a template isdropped into a project, RSAutomation Desktop replaces the placeholders with tagsand creates new object names, based on user-defined naming rules.

A compound template representing a motor device might be made up of manyseparate templates, including a faceplate display, pushbuttons, PLC programmingcode, and Microsoft® Word documents that explain how to operate the motor.When the template is dropped into an automation project, RSAutomation Desktopnames all of the objects, creates new tags, and fills the placeholders with values.

• Dramatically reduces initial development time• Eliminates the need to manually enter tags and object names for reused

system components• Reduces the need to test underlying code components


• RSAutomation Desktop• Microsoft .NET™ Framework


1.5

Simulate automation systems and predict “best case” outcomes

Will adding another production line overwhelm warehouse anddistribution capabilities? Will reducing maintenance staff causeequipment repair costs to rise? Will adding front office staff relieveorder-fulfillment bottlenecks? Rockwell Software offers products thatmodel the impact of process changes, without disrupting currentbusiness. Simulate systems, try “what-if” scenarios, and accuratelypredict outcomes—all on a desktop.

Example

10

?

Conventional SolutionTrial-and-error. Intuition. Past experience. These are common tools for planningcontrol systems, implementing automation processes, and optimizing systemperformance in a traditional industrial automation environment. Guesswork andmanual investigations are expensive, time consuming, and error prone.The consequences of making poorly informed decisions could befinancially disastrous.

11


Rockwell Software SolutionRockwell Software offers two products, RSBizWare™ Arena‚ and RSTestStand™,that cover the full range of system modeling, from factory-floor control programs tocomplex business systems.

RSTestStand allows testing control programs on a desktop by replacing field inputsand outputs to programmable logic controllers with virtual operator panels andcontrol logic. Comprehensively test a control system for device failures andresponses to out-of-range conditions from a desktop, before deploying it on the plant floor.

RSBizWare Arena offers a completely scalable, enterprise-wide solution forsimulating any aspect of a business. For example, model expensive and criticalresources such as staff and equipment. Build an accurate model of current systems,add real-world data, run the simulation, analyze simulation results, investigate“what-if” scenarios, and select the best alternative. Customers typically realizea return of more than 15 times their investment in Arena—within a few weeksor months.

• Visualize, test, and optimize control and process scenarios from a desktop, without risking production.

• With RSTestStand, train operators and technicians without tying up equipmentor halting production

• Accurately predict the impact of proposed changes to a system—before implementing the changes.

• With Arena, share facility, process, and product data with the RSBizWare suite of software products.


• RSBizWare Arena• RSTestStand• FactoryTalk Data Model™ (used within the RSBizWare suite of

software products)• OPC (OLE for Process Control) 2.0-compliant devices


12

Define graphic displays onceand reference them throughout adistributed system

With the RSView Supervisory Edition software, design graphicdisplays once and reference them at design time and at runtime from anyclient station on a network—without copying, importing, converting,or re-entering tags or commands. Because graphic displays arereferenced, not duplicated, edits update automatically across the system.

Conventional SolutionA traditional HMI typically includes multiple stations, with each station hosting itsown HMI project. It is often convenient to use some of the same graphic displaysacross multiple projects. The more projects in which a graphic display is copied,however, the greater the maintenance burden to keep all of the duplicated displaysidentical. Copying a graphic display into multiple HMI stations typically requiresmultiple steps:

1. Export the graphic display to a file.

2. Import the graphic display into one or more HMI projects on multiple stations.

3. In each project where the graphic display now resides, manually fix tagmismatches, correct conversion errors, and test thoroughly.

4. To edit the graphic display, eitherrepeat the same changes manually foreach duplicated display in eachproject, or take the system offlineand repeat the export/importprocess and manually re-entertags and commands.

Example

HMI Client

COPYCOPYCOPYCOPY COPYCOPYCOPYCOPY COPYCOPYCOPYCOPY

HMI Server

HMI Client HMI Client

Eng. Station Client

2.1

13


FactoryTalk-Enabled SolutionWith RSView Supervisory Edition, displays do not need to be copied into multipleHMI stations. Instead, any graphic display can be referenced from any other display,on any HMI station, within a networked system.

1. From any graphic display, browse any computer in the system, select anothergraphic display, and create a reference link to it.

2. To make updates to arunning system,simply open and editthe original graphicdisplay, and then savethe changes.The changes takeeffect the next time thedisplay is accessed on anycomputer in the system.

• Significantly reduces development time and ongoing maintenance costs• Eliminates importing and duplicating graphic displays• Supports projects distributed across multiple servers on multiple computers

connected to a network• Makes it easy to update graphic displays across an operating

automation system


• RSView Supervisory Edition• FactoryTalk Directory (used within Rockwell Software products)


RSView SE Client RSView SE Client RSView SE Client

One DisplayOne Displayfor the Entire Systemfor the Entire System

One DisplayOne Displayfor the Entire Systemfor the Entire System

RSView SEServer

RSView SEServer

RSView SEServerEng. Station Client

14

2.2

Assure virtually non-stop monitoring withbuilt-in failure detection and recovery

When the connection to a primary computer running in a distributedautomation system fails, what happens to the rest of the system?In a traditional scenario, the entire system may suddenly becomeunresponsive and inoperable. In a FactoryTalk-enabled system,operators may barely notice the switch to a backup computer.Underlying FactoryTalk services quickly detect server failures,seamlessly failover to backup computers, and reconnect to recoveredservers—all automatically behind the scenes.

Conventional SolutionIn a traditional automation system, engineers spend considerable time and effortwriting custom code for each different software product to allow it to handle serverfailures and switchovers between primary and backup computers. During runtime,the custom code on each host computer detects failures and notifies its associatedclient components. Each client component then independently fails over to a backupcomputer. Because different pieces of custom code use different algorithms todetermine failures, some client components may failover to a server on a backupcomputer while others do not. As a result, client workstations may end up using

more than one computer as theactive server, which can scrambledata and halt system operations.

Example

“Uh-oh, the server’s down again! $10K every minute....

$20K, $30K, $40K.......we can’t afford this.”

15


FactoryTalk-Enabled SolutionA FactoryTalk-enabled systemdoes not require any customcoding for redundancy.RSView Supervisory Edition HMIservers, RSLinx and other OPCData Access 2.0 servers,and FactoryTalk Directory serverscan all be quickly and easilyconfigured to run on both primaryand secondary computers.Once configured, each redundant

pair of servers is available to all FactoryTalk-enabled clients within the system.Adding additional clients does not require any additional configuration. Duringruntime, if the connection to a primary computer fails, FactoryTalk automaticallyswitches all clients to a backup computer within 30 seconds, and can automaticallyswitch them back to the primary computer when the connection is restored—allwithout any custom programming, client configuration, or operator intervention.

• Ensures a high level of system availability, with automatic failure detection and synchronized failovers

• Enables system-wide redundancy options, with no custom programming required• Eliminates “out-of-sync” conditions where some client components failover to

backup computers at different times• Provides a consistent way to configure redundant host computers; allows setting

up redundancy options only once for each server pair• Makes redundant server pairs available to all FactoryTalk-enabled clients in a

system, without requiring any client configuration


• RSView Supervisory Edition• RSLinx• FactoryTalk Live Data™ (used within Rockwell Software products)• FactoryTalk Directory (used within Rockwell Software products)• OPC (OLE for Process Control) v. 2.0-compliant data servers


“Wow, the primary server was down for 15 minutes. Looks like

this redundant system saved me $150K, just today.”

16

2.3

Optimize manufacturing operations andintegrate data across an enterprise

In a traditional manufacturing environment, a variety of software toolsare used to improve different areas of an automation system. Each toolserves only a single, specific purpose and provides only a limited viewinto just one facet of the system. RSBizWare software products notonly optimize specific areas of an automation system, they alsointegrate as a suite and seamlessly share data, providing a completeup-to-the-minute view of the entire enterprise.

Conventional SolutionA traditional solution requires configuring and maintaining a number of differentoptimization software tools, including a data historian, downtime tracking system,a scheduling system integrated with an ERP (enterprise resource planning) system,simulation software, and a data transaction manager. Integrating and maintainingthese various software tools typically requires significant manual rework,repetitive data entry, and expensive investment in custom code.

Example

Analyze Operational Data

Plant Efficiency

Plant Simulation

Capacity Management

Plant Data Management

Order Flow Management& Scheduling

17


RSBizWare SolutionEach RSBizWare software module can be applied independently to solve a specificbusiness issue, minimizing up-front costs and providing a quick return on eachinvestment. For example, depending on immediate business needs, choose modulesto manage order flow, improve uptime, analyze operational data, manage capacity,predict the impact of changes, and integrate information between control systemsand business applications. Unlike a traditional solution, each RSBizWare module alsoworks together with others as an integrated suite, sharing data via an underlyingFactoryTalk architecture. Because dataentered once can be immediatelyreused by any module in thesuite, time and cost savingsgrow incrementally asadditional RSBizWaremodules areimplemented into thesystem. And becausethe modules areintegrated, the addition ofeach new module deepensand broadens the overallview into the entireenterprise.

• Reuse manufacturing data across multiple software modules to analyze and improve manufacturing processes

• Achieve an integrated view into an entire enterprise without expensive custom code or duplicated data entry


• RSBizWare suite of software products• FactoryTalk Data Model (used within the RSBizWare products)


Common Factory Model

Analyze Operational Data

Plant Efficiency Plant Simulation

Capacity Management

Plant Data Management

Order Flow Management & Scheduling

18

3.1

Audit and manage changes to FactoryTalk-enabled systems

Who did what? when? where? why? The answers to these questionsare critical when changes to an automation system cause unforeseenside effects, and often necessary to maintain regulatory compliance. In a FactoryTalk-enabled system, Rockwell Software productsshare an audit capability, which makes it easy to maintain acomprehensive, central record of all changes made throughout themanufacturing system.

Conventional SolutionIn a traditional automation system, each software product typically has its own changetracking system associated with a separate database. For example, changes to PLClogic are tracked in one system while changes to an HMI are logged in a completelydifferent system. Suppose a maintenance technician makes a change to a ladder logicprogram to solve a problem on a packaging line. The change triggers problems in twoother areas of the system several hours later. Engineers scramble to uncover whichchange in which program caused the failure—while the system remains disabled,at considerable cost to the company.

Example

HMI software Logging Destination

Logging Destination

Logging Destination

Messages

Logic programming software

Other software

19


FactoryTalk-Enabled SolutionIn a FactoryTalk-enabled automation system, Rockwell Software products throughoutan enterprise monitor system changes, generate detailed audit messages, and thenroute those messages to a central database, where they are available for tracking andanalysis. During the normal course of operations, FactoryTalk-enabled products,such as RSLogix, generate audit messages when users log into the system, changedata configurations, or change I/O configurations. Other areas of the system generateaudit messages when recipes, logic programs, or batches are downloaded orconfigured, and when other normal operation activities cause changes to the system.All of these messages are routed from all participating products to a central audit logfor storage and analysis.

When a system change causes unintended side effects, supervisory staff can useRSMACC™ (Maintenance Automation Control Center) software to quickly pinpoint whathappened and where it happened. Maintenance staff can restore an earlier,unchanged version of the ladder logic program and get the plant running again.Meanwhile, supervisory staff can analyze why the change caused problems andsuggest alternatives.

• Consolidates system-wide changes into a central database• Makes it easier to maintain compliance with U.S. government regulations,

such as 21 CFR Part 11• Makes it faster to identify and resolve unexpected problems throughout

the system


• RSMACC (Maintenance Automation Control Center)• FactoryTalk Audit (used within Rockwell Software products)


RSView Supervisory EditionFactoryTalk

Diagnostics

Service

Messages

RSView Machine Edition

RSLogix

Other FactoryTalk-Enabled Software

FactoryTalk

Diagnostics

Destination

Log

FactoryTalk

Diagnostics

Destination

Log

FactoryTalk

Diagnostics

Destination

Log

(i.e. local, ODBC or RSMACC Log)

20

3.2

Diagnose and troubleshoot the health ofdevices throughout a facility

Recognizing warning signs and maintaining equipment beforeproblems occur are critical tasks for every manufacturing facility.Rockwell Software offers device-monitoring systems that not onlymonitor each piece of equipment across a network, but also analyzepotential problems and suggest steps for resolving error conditions.Enabled by FactoryTalk Diagnostics, these monitoring systems alsogenerate diagnostic messages and route them to a central database,where they are available for tracking and analysis.

Example

Conventional SolutionIn a traditional manufacturing environment, maintenance technicians often becomeaware of problems with a device—after it’s too late. Even with regularly scheduledmaintenance, recognizing early-warning signs is difficult. Because each device usesdifferent diagnostic parameters, technicians must manually identify relevantparameters, map parameters to warningconditions, and then consult eachmanufacturer’s documentationto resolve diagnosedconditions. Supervisorsanalyze data from eachdevice on eachnetwork separately—there is no way tomonitor the overallhealth of the entirenetwork.

21


FactoryTalk-EnabledSolutionRSNetWorx™ MD software,available for DeviceNet™,ControlNet™, and EtherNet/IP™,scans networks and devices,identifies and analyzes potentialproblem areas, displaysreadable messages with healthindicators for each device,and offers steps for resolving

problems. The software provides an easy-to-read assessment of the health of theentire network. Plant operators become aware of problem areas much sooner andhave both diagnostic and troubleshooting information at their fingertips. Fine-tunethe software by controlling the rate at which RSNetWorx MD requests informationover networks. Schedule RSNetWorx MD to cycle through a series of networks,continuously monitor networks, or use a mix of both options. As the softwaremonitors devices, FactoryTalk Diagnostics™ routes diagnostic messages toRSMACC (Maintenance Automation Control Center) for logging. Supervisors cananalyze system-wide data from multiple devices on multiple networks—all from acentral location.

• Analyzes and diagnoses potential problems with devices and networks• Detects preventive maintenance needs for devices on a network• Generates diagnostic messages and routes them to a central database for

storage and analysis• Provides a diagnostic view that assesses the health of the entire network,

with easy navigation to problem areas• Offers troubleshooting suggestions for resolving diagnosed conditions


• RSNetWorx MD for DeviceNet, ControlNet, EtherNet/IP• RSMACC (Maintenance Automation Control Center)• FactoryTalk Diagnostics (used within Rockwell Software products)• Open DeviceNet Vendors Association’s DeviceNet, and EtherNet/IP networks,

ControlNet International’s ControlNet network


Navigate to troubleshooting information

Generate a hard copy ofdiagnostic &

troubleshooting information

Navigate to deviceproperties

Navigate to any fault onthe network

Rockwell SoftwareFor more information on Integrated Software Solutions, pleasecontact your local Rockwell Automation sales office or Allen-Bradley distributor, or visit us at:

www.software.rockwell.com

©2003 Rockwell Software Inc. All rights reserved. Printed in the United States of America. All other trademarksare the property of their respective holders and are hereby acknowledged.

Doc ID FTVAL-BR001A-EN-P

Integrate, communicate, collaborate—and improve resultsThe FactoryTalk integrated architecture makes it possible for RockwellAutomation products to communicate across boundaries and worktogether collaboratively. Likewise, these FactoryTalk-enabled productsmake it possible for people throughout a manufacturing enterprise tocommunicate, collaborate, and improve the results of their operation.

FactoryTalk Directory—enables a common address book of factory resources,including data tags, HMI displays, and other plant-floor resources.

FactoryTalk Live Data—enables enterprise-wide access to real-time manufacturinginformation.

FactoryTalk Audit—enables a comprehensive, central record of all changes made to amanufacturing system.

FactoryTalk Data Model—enables a modular approach to optimizing shop floorsystems, by using common terms for describing manufacturing operations.

factorytalk -enabled solutions - designautomation · factorytalk-enabled solutions rsview...

Documents