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AutomationAutomationJanuary 2012

TODAY ASIA PACIFICAustralia & New Zealand

Delivering

New Dimensions of Scalability

See page 6

InsideHow Global StandardsAffect Machine Builders

Making the MostOut of Mechatronics

Oil & Gas OEMSees Concrete Resultsfrom Control Solution

Control System PowersWind Turbines

Designing Machines That Are Energy-Effi cient

EDITORIAL

Scott Summerville

CONTENTS EDITORIAL

ROCKWELL AUTOMATION SOUTHEAST ASIA PTE LTD2 Corporation Road, #06-01 Corporation Place, Singapore 618494

Tel: (65) 6622 5188 • Fax: (65) 6622 5100Editor: Steven Goh – [email protected]

ROCKWELL AUTOMATION AUSTRALIA LTDTel: +61 3 9757 1111 • Fax: +61 3 9729 1418

Contact: [email protected]

Copyright© 2011 Rockwell Automation Inc. All rights reserved. The contents of this publication may not be reproduced in whole or part without the consent of the copyright owner. Allen-Bradley, ArmorBlock, CompactLogix,

ControlLogix, Dynamix, FactoryTalk, Integrated Architecture, Kinetix, LDC-Series, LDL-Series, Micro800, MicroLogix, MP-Series, PanelView Plus, PartnerNetwork, RDD-Series, Rockwell Automation, Rockwell Software, RSLogix, Stratix

and TL-Series are trademarks or registered trademarks of Rockwell Automation, Inc.

The Right Control InfrastructureDrives Success

Many machine builders and manufacturers use multiple control platforms to meet their

diverse business needs. Doing so creates unnecessary complexity because each platform has a unique design environment, user interface and vendor support model. It’s a costly strategy. Forward-thinking machine builders and end users, however, leverage a single control infrastructure that scales to match their application requirements – and to drive success.

Through the Rockwell Automation Integrated Architecture™, manufacturers and end users can apply one scalable infrastructure to drive effi ciency and productivity gains across all layers of the organization. Our Logix Control Platform addresses a range of control needs, from discrete to process control and from small to large-scale applications. In addition, one common Ethernet layer allows the integration of plant information with enterprise systems, using standard Cisco technology for security. This multi-disciplined control platform has evolved to the information layer, the safety layer and deeper into discrete, motion and process control.

As you will read in this issue of Automation Today Asia Pacifi c, Rockwell Automation® is committed to delivering the “right-sized” control system to its customers. Recently, we introduced the Micro800™ line, a family of micro programmable logic controllers that provide control capabilities geared for lower-end, original equipment manufacturer (OEM) applications. We continue to expand our Integrated Architecture portfolio with the introduction of a new family that provides the same fl exibility, reduced development time and ease of use as larger scale systems from Rockwell Automation.

The new offerings include a series of scalable CompactLogix™ programmable automation controllers (PACs), servo drives, I/O, visualization and simplifi cation tools. These solutions are suited for applications with fewer than 200 I/O that require high performance and up to 16 motion axes – typical of the work carried out in Asia Pacifi c. They complement our ControlLogix® PACs, which are geared to applications that have up to 10,000 I/O and 100 motion axes.

The scalability of our Integrated Architecture platform enables users to select the right-sized solutions for their requirements. Rockwell Automation has brought the benefi ts of our Integrated Architecture to smaller applications so that users can now run motion and safety applications on a single control platform using a single network. This simplifi es the design, operation and maintenance of equipment.

The benefi ts of this control approach are far-reaching. We invite you to contact Rockwell Automation to learn how you can benefi t from our scalable Integrated Architecture platform – and drive your company’s success.

Bob Ruff

Bob Ruff, PresidentRockwell Automation, Asia Pacifi c RegionB b R ff P id t

Features3 News & Events Rockwell Automation® developments from around the world.

4 Country News News and events from around Australia & New Zealand.

6 Cover Story – Rockwell Automation Delivers New Dimensions of Scalability Applications with fewer than 200 I/O can leverage the Allen-Bradley CompactLogix™ controller for intergrated motion, safety and standard control.

8 Feature Story – How Global Standards Affect Machine Builders Complying with international safety standards gives machine builders a competitive advantage while providing manufacturers machines with excellent reliability.

10 Technology Watch A design approach that links mechanical control and electric design

helps machine builders to lower design and development costs.

11 Value Proposition A control solution based on the Rockwell Automation Integrated

Architecture™ platform helps keep oilfi eld cementing equipment in continuous production.

12 Technology Watch To build effective solar tracker equipment, OEMs need an

automation system with excellent reliability.

14 Technology Watch The Rockwell Automation Integrated Architecture™ system helps a

manufacturer simultaneously control multiple turbines.

15 Saving Energy Seven principles help lead the way to energy-effi cient machine

design that benefi ts OEMs and end users.

16 Manufacturing Advances Manufacturing environments are rapidly evolving due to global

competition and changing customer requirements.

18 Technology Watch Convergence with EtherNet/IP™ helps simplify control and

information fl ow from the machine to the customer’s IT enterprise.

19 Product Focus Recent additions to the Rockwell Automation® product portfolio.

2 January 2012 AUTOMATION TODAY ASIA PACIFIC

Guide Helps Machine Builders Deploy Integrated Motion with EtherNet/IP

A75-page addition to the Converged Plantwide Ethernet Design and Implementation Guide helps machine builders and manufacturers deploy integrated motion using EtherNet/IP networking technology. The new

chapter of the guide, developed by Rockwell Automation® and Cisco, provides detailed design guidance, recommendations and best practices to help control system engineers synchronise their motion applications within the plantwide architecture.

Traditionally, machine builders and manufacturers have used a dedicated network for motion applications, a design strategy that requires specialised hardware and often leads to a more isolated system design where information is not easily accessible. EtherNet/IP™ is designed and established to connect from the device level all the way up to the end customer’s IT infrastructure and across applications including discrete, process, safety, motion and drive control.

For applications requiring highly integrated motion control, such as packaging, pick-and-place, converting, assembly and robotics, the network infrastructure must be capable of managing time-synchronisation services and delivering data between devices in a timely manner. The new chapter of the Converged Plantwide Ethernet Design and Implementation Guide addresses both of these tasks while leveraging the EtherNet/IP network.

To download a free copy of the Guide, visit http://literature.rockwellautomation.com/idc/groups/literature/documents/td/enet-td001_-en-p.pdf.

Frost and Sullivan Award for Rockwell Automation

R ockwell Automation received the prestigious 2011 Frost and Sullivan Company of the Year Award for the Programmable Logic Controller in the South Pacifi c and

South East Asia region.The award recognises the leading role Rockwell Automation has played in

developing cost-effective technology solutions with improved safety for programmable logic controllers (PLCs). It also confi rms the commitment Rockwell Automation has made to the industry and the company’s position as a major participant in automation systems across many industries.

To qualify for the award, a company is measured on fi ve key criteria: market share position, growth implementation, degree of innovation with products and technologies, gain in market share and leadership in customer value. Rockwell Automation scored consistently high in all fi ve categories for the South East Asia, Australian and New Zealand region.

“Rockwell Automation winning this award confi rms that the company’s customer value strategies are recognised by the automation industry, and in turn by the broader market,” said Twain Drewett, managing director Rockwell Automation Australia and New Zealand. “The PLC is continuing to evolve into a product that meets the customer’s requirements for plant-wide optimisation and sustainable production, while simultaneously helping to converge the IT arena into the manufacturing space. This value-add of Rockwell Automation Customer Services and Solutions and the strength of our network of partners, has provided the PLC with ‘Best in Class’ differentiation,” concluded Drewett.

The Company of the Year Award, now in its fourth year, is presented by Frost and Sullivan, a global industry analyst and growth consulting company with nearly 50 years experience. Frost and Sullivan are specialists in research and analysis that assists clients in making critical business decisions. The organisation’s reputation for rigorous research and methodology to identify best practices and world class performance has earned their awards global recognition from industry, media and investors.

NEWS & EVENTS

BRIEFS

Rockwell AutomationChristchurch Re-Opens On the 1st December, Rockwell Automation Christchurch, New Zealand, celebrated the offi cial re-opening of the local offi ce. Following the damage sustained by the Earthquake last February, we took the opportunity to renovate and are now back in full force to support our Christchurch and South Island customers.The refurbished building provides a central location for training, presentations and customer meetings and is also the base for the South Island Sales and Engineering teams.

Rockwell Automation480C Moorhouse Avenue,Christchurch

Tel: 0800 272 725

An Innovative Company Forbes magazine has named Rockwell Automation® among the “world’s most innovative” companies. The magazine used an “innovation premium” to calculate the ratings. The innovation premium measures the difference between the value of a company’s existing business compared with expectations of future innovations (new products, services and markets).

Stay updated with Rockwell AutomationeNewsletters Get the most up-to-date news about products, events, services, training and any special offers from Rockwell Automation in Australia and New Zealand - direct to your desktop.Sign up today to receive future issues - our online registrat ion s y s t e m allows all users to create or update their profi le. Follow the link to the eNewsletter subscription page under News & Events on the company websites at either: Australia - www.rockwellautomation.com.au

New Zealand - www.rockwellautomation.co.nz

AUTOMATION TODAY ASIA PACIFIC January 2012 3

Twain Drewett


South Pacifi c Head Offi ce relocates to new facility

NEWSCOUNTRY

Following a period of more than 25 years, Rockwell Automation has made the move… the company’s South Pacifi c head offi ce has recently relocated to a new purpose built facility in Bayswater, Victoria. This move will provide more amenable environments for our local and regional customers and offer up-to-date employee facilities.The new building includes a modern customer training facility to support industry, a dedicated engineering workshop to conduct proof-of-concept demonstrations to clients, along with a test and repair facility. Another highlight is the leading edge Customer Briefi ng Room, featuring a 9 metre wide display wall focussing on the theme of ‘Plant Wide Optimisation’ and ‘Machine Builder Performance’.

The new location at Bayswater will provide Rockwell Automation the space it needs to accommodate its growing team. An offi cial opening at the new Bayswater location is being planned for early in 2012.

New Address:841 Mountain HighwayBayswater Vic 3153

Contact:Tel: 03 9757 1111Fax: 03 9729 1418

Customer Care:Tel: 1800 ROCKWELLTel: 1800 762 593

Nyrstar Hobart awards $2.5M+ process order to Rockwell Automation PlantPAx process automation system incorporates 7,000+ distributed input/output connections in complex DCS conversion. Nyrstar Hobart, a leading global multi-metals company, has awarded a $2.5 million+ order to Rockwell Automation and its Global Solutions team to replace a distributed control system (DCS) at the company’s zinc smelting operation in Hobart, Tasmania, Australia with the Rockwell Automation PlantPAx™ process automation system. “This win represents a milestone for us given the size and complexity of the DCS conversion”“Our current DCS would be cost-prohibitive to upgrade. Hardware was failing and repairs were becoming expensive and requiring longer lead times. The Rockwell Automation solution provides us with better integration between different process areas, improved diagnostics, increasing plant uptime and more accurate plant performance reporting,” said Jeremy Kouw, General Manager, Nyrstar Hobart. According to research performed by the ARC Advisory Group, the global

process industry loses approximately $20 billion annually, or about fi ve percent of annual production, due to unscheduled downtime from aging DCS systems Rockwell Automation won the order by developing a three-year phased integration with a back-up option that uses custom input/output cabling to ensure process continuity, coupled with technical support for the existing installation. NHP Electrical, a Rockwell Automation authorised distributor, provided long-term committed support to the project, which also weighed in the favor of Rockwell Automation. “This win represents a milestone for us given the size and complexity of the DCS conversion,” said Terry Gebert, Vice President and General Manager, Rockwell Automation Global Solutions. “We won the order over two major process automation companies, based on the excellent support we provide for the existing operation and a clear vision of control

conversion to a long-term sustainable operation. The order includes project management, application engineering, system cutover engineering, hardware and software. Our experience, domain expertise and global resources will help Nyrstar Hobart in this critical conversion from a legacy DCS system.” Nyrstar Hobart’s Australian facility is one of the world’s largest zinc smelters with a capacity of 280,000 tonnes. It produces zinc and zinc alloys that are exported primarily to Asia. The existing DCS operates process control for roast-leach purifi cation electrolysis, acid plant and water treatment.

About Nyrstar: Nyrstar is an integrated mining and metals business, with market leading positions in zinc and lead, and growing positions in other base and precious metals; essential resources that are fuelling the rapid urbanisation and industrialisation of our changing world.

AUSTRALIA & NEW ZEALAND


Rockwell Automation on the Move to showcase ‘hands on’ industry solutions Rockwell Automation on the Move returns in 2012 to Melbourne, Sydney, Brisbane and Perth. Visitors will have the opportunity to see and hear about best industry practices, new technologies, products and services and talk to industry experts in the areas of automation, process control and safety solutions. Showcasing a combination of ‘hands on’ lab sessions and presentations from industry specialists, the event will also feature a comprehensive Safety Forum—‘an event within an event,’ highlighting

leading industry automation safety and process control applications. Process control, software, intelligent motor control, power, components, services and support solutions will be exhibited. Attendees will have the opportunity to converse with noted industry leaders from Rockwell Automation and its partner network. See, hear and touch the latest developments in plant-wide optimisation and safety solutions. The event will be home to a seven metre automation wall, displaying the

integration of the latest technology solutions in plant-wide optimisation.The tour of this FREE two-day event commences at the Melbourne Park Function Centre on 6-7 March, 2012. Rockwell Automation on the Move will then progress to Sydney (2-3 May), Brisbane (22-23 May) and Perth (6-7 June). Full details of the Safety Forum, ‘hands on’ lab sessions, presentations and interactive pavilions will be revealed in the coming months.

RSTechED 2011 inspires innovation through education The recently held RSTechED 2011 presented by Rockwell Automation in Sydney, builds on the company’s commitment to bring together OEMs, System Integrators and industry partners in a forum for education, inspiration and discussion.The three day event demonstrated the latest trends and advancements from Rockwell Automation in the industrial control environment. By combining hands-on practical training and seminar presentations, the company aimed to ‘inspire, educate and innovate’. “The program is designed to give attendees an in-depth knowledge of our software applications and an understanding of how the various modules can work together to create an integrated software system,” said Dean Tresidder, Solution Architect – Software, Rockwell Automation. “Our labs offered an opportunity to explore the possibilities available and how these solutions may be applied to a range of industries.”The event was opened by Bob Ruff, Vice President Asia Pacifi c, Rockwell Automation, followed by a keynote

speech presented by Mukund, Product Manager, Software, Asia Pacifi c, discussing the benefi ts of manufacturing intelligence to create a competitive advantage for industry in the marketplace. Lion Nathan New Zealand, a key customer for Rockwell Automation, gave a presentation that was particularly well received. The demonstration highlighted the possibilities and effectiveness of asset management and third-party integration within an integrated architecture environment. With over 40 labs and presentations, RSTechED 2011 is part of a global event presented by Rockwell Automation. “Many of our labs focussed on PlantPAx and FactoryTalk suite of products, with varying levels of complexity. This enabled the attendees to interact with the software at an introductory level and progress to more intricate enterprise level environments,” said Tresidder.RSTechED 2011 offers the opportunity to share knowledge and bring together a diverse range of peers in an interactive atmosphere. The range

of products and technology solutions presented by Rockwell Automation at RSTechED 2011 demonstrates to companies how to achieve the very best that they can be.

RSTechED returns to Auckland in 2012Inspire. Educate. Innovate. Plan early - Rockwell Automation RSTechED is scheduled for 21-23 February, 2012, in Auckland, New Zealand.Only RSTechED provides advanced education and application business workshops focused on optimisation, competitive differentiation and compliance.Don’t miss the opportunity to create your competitive advantage. Subject matter experts will show cutting edge, emerging technologies. Participants will also learn from their peers as they share experiences. RSTechED is designed for users and managers at all levels within an organisation. The Auckland event will take place at the Waipuna Hotel and Conference Centre. Don’t miss out on your seat at this premier event, registrations open in December. For more information or to register visit www.rockwellautomation.co.nz


Following on the recent release of the Micro800™ controllers, Rockwell Automation® has

signifi cantly expanded its Integrated Architecture™ portfolio for smaller applications with a series of scalable CompactLogix™ programmable automation controllers (PACs), servo drives, I/O, and visualisation and simplifi cation tools. With high-performance features such as integrated motion, safety, EtherNet/IP™ connectivity and re-usable development tools, Rockwell Automation gives users the ability to standardise on a single control platform for small to large-scale applications.

Featuring integrated motion on EtherNet/IP, the CompactLogix controller family can provide the same fl exibility, reduced development time and ease of use as larger scale systems from Rockwell Automation. For machine builders, the new solutions can help reduce the costs and complexities of their machines and provide a more competitive offering around the globe. Meanwhile, end users can standardise on a single control platform for small to large-scale applications.

Right-Sized ControlJohn Watts, Rockwell Automation

director, Integrated Architecture, Asia Pacifi c, explains that a “right-sized” control system helps original equipment manufacturers (OEMs) and their customers cost-effectively match their application needs. The Rockwell Automation portfolio expansion gives users the ability to scale from 48 to 10,000 I/O using a

single control platform and common user experience.

In addition, standardising on a single control platform simplifi es the design, operation and maintenance of equipment. A single development environment, along with consistent tools and technology, also reduces time to market when creating new machine designs.

What’s more, selecting a right-sized control system enables users to address critical business issues such as network architecture, integrated safety, security, sustainability and performance. Building a control strategy on a single network architecture such as EtherNet/IP, for instance, enables machine builders to help their end customers effectively converge machine-level data with business-level data. This capability improves management and decision-making across an organisation.

With regard to integrated safety, leveraging EtherNet/IP enables users to run motion and safety applications on a single control platform. The CompactLogix system embeds many advanced safety functions such as safe stop and speed monitoring, removing special gateways along the way.

Many users are worried about protecting intellectual property. The built-in security features Rockwell Automation provides can help machine builders protect their source code and help end users protect their manufacturing processes.

With this new offering, machine builders can utilise smaller components to reduce the overall footprint of the cabinets and machines

while leveraging drives that are more energy-effi cient. These actions contribute to sustainability. To help drive performance and agility in smaller-size machines, OEMs can employ the integrated servo technology and robotic control that are included.

An Expanded PortfolioThe expanded Rockwell Automation

portfolio features the following products:

• New CompactLogix PACs:Provide standard and integrated motion on EtherNet/IP in a single controller, using the same confi guration, networking and visualisation environment as the ControlLogix®-based system. This provides scalable motion options for a wider range of machines.

• Kinetix® 350 Servo Drive on EtherNet/IP: Simplifi es the network architecture by removing the need for a separate motion network, providing a high-performance, cost-effective solution for low-axis machines. This new drive will also feature a power range up to 3 kilowatts.

• PanelView™ Plus 6 and PanelView Plus Compact Human Machine Interface (HMI): The cost-effective, operator interface provides advanced integration with Logix-based controllers.

• RSLogix™ 5000 Design and Confi guration Software: Provides a single development environment for the above products and includes high-integrity add-on instructions (AOIs) and Integrated Motion on EtherNet/IP capabilities.

Applications with fewer than 200 I/O can leverage the Allen-Bradley

CompactLogix controller for integrated motion, safety and standard control.

Rockwell Automation Delivers

New Dimensions of Scalability with Integrated Architecture

The Rockwell Automation Integrated Architecture™ features the Allen-Bradley ControlLogix® and

CompactLogix™ controller families. The ControlLogix programmable automation controller (PAC) is suited for applications that have up to 10,000 I/O and 100 motion axes. The expanded CompactLogix family targets applications with fewer than 200 I/O that require high performance and up to 16 motion axes. Featuring integrated motion on EtherNet/IP™, the CompactLogix controller family can provide the same fl exibility, reduced development time and ease of use as larger-scale systems.

Additional products and services enhance the expanded Integrated Architecture offering:

• Mechatronics Design Portfolio:Comprised of Motion Analyzer 6.0 software, RDD-Series™ direct drive

rotary servo motors, LDC-Series™

and LDL-Series™ linear servo motors, MP-Series™ and TL-Series™ electric cylinders, linear thrusters and MP-Series integrated linear stages. These offerings help engineers better collaborate and reduce development time by providing a common forum where design input from the mechanical, controls, software and electrical engineers can be more easily gathered.

• Design Tools: The Drives and Motion Accelerator Toolkit (DMAT) with the Kinetix® 350 joins a range of design tools, including Accelerator Toolkits, Product Selection Toolbox and Sample Code Library.

• Migration Tools: Rockwell Automation Ethernet adapters and toolkits help convert competitive solutions and/or migrate older platforms to CompactLogix while maintaining

the existing fi eld wiring and physical footprint of the control cabinet.

• Stratix 2000™ and 6000 Switches:The two new switches, powered by Cisco technology, provide high-performance switching capability with tools familiar to IT professionals to help simplify integration into the infrastructure.

• ArmorBlock® Dual Port EtherNet/IP QuickConnect: Allows for quick connection between the controller and ArmorBlock module (within 500 ms).

• Global Solutions and Services: Suppliers best serve their customers by offering a scalable range of support options, allowing them to select the service level that best matches their corporate goals, internal technical capabilities and budgets. Rockwell Automation® provides one of the most comprehensive service portfolios in the industry.

ENHANCING THE INTEGRATED ARCHITECTURE PLATFORM


Mike Burrows, Rockwell Automation market development director, Integrated Architecture, says that application areas for the new portfolio include material handling, packaging, pharmaceutical and biotech, automated assembly, food and beverage, and automated inspection. In addition, the portfolio includes performance differentiators such as faster controllers, better machine design (using the Motion Analyzer and the Drive and Motion Accelerator Toolkit) and better precision (with a shared backplane for sequential and motion control).

What’s more, by leveraging EtherNet/IP for coordinated motion, the system can manage all communication needs with a single network architecture. To further enhance usability, manufacturers can leverage a single design environment and consistent tools for their system, regardless of size.

Craig Resnick, research director, ARC Advisory Group, says, “In the past, machine builders and manufacturers who needed high-performance features, such as integrated motion, were faced with choosing a system that was oversized for their actual

application needs. By bringing the benefi ts of Integrated Architecture to smaller applications, users can now run motion and safety applications on a single control platform using a single network – simplifying the design, operation and maintenance of equipment.” AT

on the web

For more information on the new

CompactLogix offerings, visit: http://ab.rockwellautomation.com/Programmable-Controllers


International safety standards are reshaping how global machine builders approach machine safety

system design. Do machine builders need to comply?

The answer depends on the machine builder’s competitive goals and customer base. For those serving or seeking to do business with global customers, the answer is a defi nitive “yes.” For those aiming to satisfy customer demands for machinery with improved safety and excellent reliability, the answer also is “yes.”

Machine builders who currently only serve the needs of their domestic end users should also follow international standards as a guideline for best practices — not only to gain a competitive edge domestically but also to prepare in case they later expand to pursue global customers.

Today’s Key StandardsIncreasingly, global and

multinational manufacturers around the world are moving toward following internationally accepted machine-safety system standards to improve fl exibility and takeadvantage of technologies supported by updated standards.

The European Union standards’ bodies (CEN and CENELEC) elected to mandate two of the most rigorous machine safety standards: the International Organization for

Standardization (ISO 13849-1/2) and the International Electrotechnical Commission (IEC 62061). As a result, any machines shipped into or out of Europe must comply with one of the two standards after the fi nal withdrawal of EN 954-1 in 2011.

In addition, many machine builders that design machines destined for Europe will need to comply with the European adoption of these international standards.

Increasingly, manufacturers, especially global ones, are seeking machine builders that understand how to design machines in line with these international standards, according to Mike Miller, FS TÜV expert, global safety market development, Rockwell Automation. In some cases, it’s mandated to do so in order to

manufacture in these countries. More and more, manufacturers

follow internationally accepted standards to streamline their plants globally. These global manufacturers can be assured they’re investing in safe machinery with excellent reliability that helps protect workers and equipment. They understand the inherent business value in investing in contemporary machine safety systems and standardising their plants worldwide. These upfront investments help reduce incidence, minimise

training and maintenance costs, and often increase productivity.

The Role of Time and Risk Requirements

Historically, machine control-system safety standards were prescriptive in nature, simply providing guidance on the structure of control systems to help meet safety requirements. The newer international safety system standards are more rigorous in their design requirements and provide a more quantifi able methodology to help attain overall safety system performance and integrity.

Miller explains that the international standards add two very important elements to the defi nition of the reliability of the machine’s safety function: time and risk. These two elements help machine builders take advantage of a more methodical approach to safety system design.

Both international standards require machine builders to identify and document the potential hazards associated with a machine and the risk levels the hazards present to users. The safety system is then designed to the level of risk associated with the hazards present on the machine. This allows the machine designer to design the safety system to the correct functional level.

Appropriate documentation proves a machine’s level of safety, and designers can better justify a need for a safety system upgrade. In addition, operators can be more confi dent in the reliability of a machine’s safety system.

Just how easy is it for machine builders to comply with these standards? The requirements are summarised below.

Complying with international safety standards gives machine builders a competitive

advantage while providing manufacturers machines with excellent reliability.

How

Global StandardsAffect Machine Builders

The newer international safety system standards are more rigorous in their design requirements and provide a more quantifi able methodology to help achieve overall safety system performance and integrity.


ISO 13849-1. To comply with ISO 13849-1, a machine builder is required to defi ne and document the statistical probability of an unwanted occurrence or dangerous failure, or the calculated mean time to dangerous failure (MTTFd). A machine builder must also defi ne and document the machine’s structure, or hardware confi guration (often called categories), and its ability to detect dangerous failures, called diagnostic coverage.

Each component in a safety system must have an assigned probability of, or mean time to, dangerous failure. By adding the “time” element and the ability to detect dangerous failures to the existing safety structure approach, the ISO 13849-1 standard forces the designer to validate that the control system does what is required of it.

This standard applies beyond electric/electronic systems to include mechanical, hydraulic and pneumatic safety-related parts of the control systems.

IEC 62061. To comply with IEC 62061, a machine builder is required to describe the amount of risk to be reduced and the ability of a control system to reduce that risk in terms of safety integrity level (SIL).

The machinery sector uses three SILs; SIL 1 is the lowest and SIL 3 is the highest. A SIL applies to a safety function. The subsystem making up the system that implements the safety function must have an appropriate SIL capability. Conducting a risk assessment helps a designer defi ne the amount of risk to be reduced and

the SIL claim limit that safety-related control function must meet.

Both the documentation process and the performance-based approach help make it easier for designers to quantify and justify the value of safety.

Previously, a designer might have had diffi culty understanding – or explaining – why a costly or seemingly sophisticated safety system was needed for a particular application. Now, with the ability to quantify circuit reliability through specifi c performance and system integrity calculations, the designer can show the value in terms of actual risk reduction, thereby, more easily justifying the value of safety. Furthermore, machine designers can leverage the required documentation to cost-justify a system upgrade that includes a more effective safety solution.

Requiring designers to document risks and the control system’s ability to reduce those risks also increases a machine builder’s confi dence in the reliability of the safety components. Because the standards are designed to assess risk over a prolonged period, a machine’s safety system can be more predictable in the long term. This can help enhance a machine operator’s confi dence while operating a machine and, in turn, can help increase protection and productivity on the job.

Ultimately, a more predictable machine is a machine with improved safety. A machine with improved safety is a more productive machine.

Helping Machine Builders In support of the industry’s move

toward internationally accepted standards, automation suppliers are taking measures to help machine builders fully understand the benefi ts and meet the requirements of machine safety control systems standards. These include getting safety products certifi ed and offering education, training programs and tools.

For example, Miller explains that Rockwell Automation® provides a product library fi le designed for use with the SISTEMA calculation tool from Germany’s IFA, and a PDF fi le designed for manual calculation. Functional safety data, including the SISTEMA calculation tool and library, can be downloaded at the Rockwell Automation Safety Solutions Portal (www.rockwellautomation.com/services/safety/). Also available on the Rockwell Automation Safety Solutions Portal are white papers, animations on safeguarding techniques and technologies, and archived versions of a functional safety webinar series (http://discover.rockwellautomation.com/SA_EN_Functional_Safety.aspx).

Miller sums up the importance of international standards: “The machine safety world continues to change, and the European Union’s mandate of rigorous international safety standards represents the global trend toward standardisation. Ultimately, this will provide more fl exibility to achieve and cost-justify designs, safe machine control systems and more consistency across plants.” AT


Making the Most Out of Mechatronics

A design approach that links mechanical control and electric

design helps machine builders to lower design and

development costs.

As original equipment manufacturers (OEMs) continue to tap the benefi ts offered by today’s

advanced automation, they are looking for ways to more effectively link the mechanical and control worlds. One approach that continues to gain momentum is mechatronics – the combination of mechanical and electrical engineering. This article will summarise the concept of mechatronics and how machine builders can benefi t from using it.

Defi ning MechatronicsIn traditional machine building,

individual mechanical, control and electrical design teams work independently to produce separate pieces of the overall machine. To optimise the available mix of technologies, there needs to be a synergistic blend between the different engineering disciplines. This is precisely what mechatronics aims to deliver.

It is an interdisciplinary approach that allows machine builders to bring engineering processes closer together, improving communication and expanding the available knowledge base. Designers can more easily address confi guration and integration issues up front in the product development cycle and minimise the chance of encountering problems in subsequent stages. The results of this concurrent engineering approach are lower design and development costs, expanded functionality and a more robust, balanced design.

In addition, development time is reduced through the use of automation tools. Software, for example, provides performance and simulation analysis that helps machine builders to select

mechanical designs – along with the optimum controls and software – that will maximise machine performance.

Analysis AssistanceMotion Analyzer

software from Rockwell Automation® helps OEMs evaluate design alternatives for robotic motion control applications. In addition to its sizing, selection, optimisation and simulation capabilities, Motion Analyzer software offers performance evaluation features including ratio, torque and tolerance analysis.

• Ratio analysis helps mechanical design engineers make a mechatronics selection of gearboxes, timing belts and ball screws. It provides an“at-a-glance” view of any necessary trade-offs and guides users to an optimised solution.

• Torque analysis shows where the torque produced by the motor is consumed. As design engineers generally focus on how to move the load, they may factor in transmission losses, but rarely cross-reference with load losses. Torque analysis solves this issue by providing rapid “what-if” analysis. If the majority of the torque is being used to move the load, the design is sound. If over 75 percent is being lost in the transmission, it’s back to the drawing board.

• Tolerance analysis provides application data, such as move time, mass, losses and ambient temperature, to be plotted against “health parameters” for the system. The software provides the means to rapidly analyze the system’s tolerance to changes and alerts the engineer to any marginal design issues.

• Simulation analysis helps OEMs determine machine performance criteria such as parts-per-minute, dynamic stability, accuracy and settling time, and it gives design engineers the most realistic prediction of system performance short of building a prototype. System simulation takes into account how a Logix controller, working in conjunction with Kinetix®

integrated motion (consisting of servo drives, servomotors and actuators) will perform for particular load requirements. This approach helps reduce the risk associated with adopting new designs and speeds up the iterative discovery phase, decreasing design-to-ship time.

Simulation tools such as Motion Analyzer not only help reduce design time but also minimise errors that are typically corrected much later in the development process. More importantly, the excellent reliability, optimised performance and faster time to market that mechatronics affords means more satisfi ed customers – and a more favorable bottom line for machine builders. AT

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WATCHTECHNOLOGY

PROPOSITIONVALUE

The high risks in oilfi eld development have led to strict requirements on the reliability

and control accuracy of oilfi eld equipment. Failures at any level can result in huge losses. That is why many forward-thinking oilfi eld developers are switching to automated solutions to improve well-drilling, whose process requires the use of cement equipment.

Previously, four to six cementing machines and a dozen auxiliary machines were needed for the successful completion of the cementing process. With technology improvements in control automation, only two machines now are required – one on-duty and the other on stand-by.

SJS Limited, an original equipment manufacturer (OEM) based in Jingzhou, Hubei Province, Central China, makes oilfi eld cementing equipment as well as pumps for oil-well service plunger and centrifugal pump applications. The company has incorporated modern automation solutions and control systems in their equipment for a decade.

Jidong Ye, SJS operations manager, explains that in oil fi eld operations, continuous production is of the utmost

importance, as well as delivering equipment to customers on time: “Our customers expect us to deliver our equipment to them on time so they could start production on time. Also, we cannot afford to let technical issues impact our schedule, so we need our automation vendor to be able to provide timely support whenever we need it.”

In ControlTo meet their internal standards and

customers’ expectations, SJS selected Rockwell Automation® programmable automation controllers (PACs) and programming software based on the Rockwell Automation Integrated Architecture™ platform. At the heart of this system are Allen-Bradley ControlLogix® and CompactLogix™

PACs, which leverage common programming and development tools; RSLogix™ 5000 programming software; network protocols; and a service-oriented architecture.

“ControlLogix is well-known for its excellent reliability,” says Jidong. “Furthermore, our customers also recognise the excellent quality of Rockwell Automation products in the Oil & Gas industry.”

The SJS engineering team uses RSLogix 5000 to deploy control algorithms and codes in their equipment. The open programming platform helps the team to complete their source code deployment on time and to easily integrate third-party equipment. Under the software platform, add-on instruction (AOI) features help protect their programming source code.

Concrete ResultsThe ease of Rockwell Automation

solutions enables SJS to gain better control of their machines. The OEM has been able to deploy effective control strategies to manufacture equipment that is stable with excellent reliability. More importantly, SJS customers, the oilfi eld developers, are able to minimise downtime and avoid production errors.

SJS cementing equipment is now reaching the level of 180-1000 hp, with the pressure equipment reaching a level of 400-3000 hp. According to Jidong, the company has developed a network control system that connects up to 40 individual machines, with a maximum power that can reach upto 100,000 hp.

Moving forward, SJS expects a tighter collaboration with Rockwell Automation in terms of system optimisation and new product development. For example, the company is looking at building intelligence into the automation system so junior staff can operate and maintain machines easily. Other efforts include moving into intelligent data management, providing onlineservices and deploying variablespeed drives into new product development initiatives. AT

A control solution based on the Rockwell Automation Integrated Architecture

platform helps keep oilfi eld cementing equipment in continuous production.

Automation Solution Delivers Concrete Results for a Chinese Oil & Gas OEM



WATCHTECHNOLOGY

How Solar Trackers Keep on Target

To build effective solar tracker equipment, OEMs need a reliable automation system.

Solar trackers orient photovoltaic panels, refl ectors, lenses or other optical devices toward

the sun. Since the sun’s position in thesky changes with the seasons and the time of day, trackers are used to align the collection system to maximise energy production.

Several factors must be evaluated when determining the use of trackers: the type of solar technology, the amount of direct solar irradiation, feed-in tariffs in the region where the system is deployed, and the cost to install and maintain the trackers. In addition, original equipment manufacturers (OEMs) must consider the automation system that will drive the solar trackers.

Solar Tracker Basics Applications like concentrated

photovoltaic panels (CPV) or concentrated solar power (CSP) require a high degree of accuracy to achieve precise direction of sunlight at the focal point of the refl ector or lens. Non-concentrating applications don’t require tracking, but using a tracker can improve the total power produced by the system.

There are many types of solar trackers, of varying costs, sophistication and performance. The two basic categories of trackers are single-axis and dual-axis.

Single-axis solar trackers can either have a horizontal or a vertical axis. The horizontal type is used in tropical regions where the sun gets very high at noon, but the days are short. The vertical type is used in high latitudes where the sun does not get very high, but summer days can be very long. In concentrated solar power applications, single-axis trackers are used with parabolic and linear Fresnel mirror designs.

Dual-axis solar trackers have both a horizontal and a vertical axis; thus, they

can track the sun’s apparent motion virtually anywhere in the world. CSP applications using dual-axis tracking include solar power towers and dish (Stirling engine) systems. Dual-axis tracking is extremely important in solar tower applications due to the angle errors resulting from longer distances between the mirror and the central receiver located in the tower structure.

Many traditional solar PV applications employ two-axis trackers to position the solar panels perpendicular to the sun’s rays. This maximises the total power output by keeping the panels in direct sunlight for the maximum number of hours per day.

Key ComponentsThe main elements of a tracking

system include:• Sun tracking algorithm: This

calculates the solar azimuth and zenith angles of the sun, which are then used to position the solar panel or refl ector topoint toward the sun. Some algorithms are purely mathematical, based on astronomical references, while others utilise real-time light-intensity readings.

• Control unit: The control unit executes the sun tracking algorithm and coordinates the movement of the positioning system.

• Positioning system: The positioning system moves the panel or refl ector to face the sun at the optimum angles. Some positioning systems are electrical and some are hydraulic. Electrical systems utilise encoders and variable frequency drives or linear actuators to monitor the current position of the panel and move to desired positions.

• Drive mechanism/transmission: The drive mechanisms include linear actuators, linear drives, hydraulic cylinders, swivel drives, worm gears, planetary gears and threaded spindles.

• Sensing devices: For trackers that use light intensity in the tracking algorithm, pyranometers are needed to read the light intensity. Ambient condition monitoring for pressure, temperature and humidity may also be needed to optimise effi ciency and power output.

Tracker Control AlgorithmsTracker control algorithms typically

incorporate a control strategy that is a hybrid between open-loop and closed-loop control. The open-loop component is needed because the sun can be obscured by clouds, eliminating or distorting the feedback signals. The closed-loop component is needed to

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reduce the risk of errors that result from variability in installation, assembly, calibration and encoder mounting.

Closed-loop systems track the sun by relying on a set of lenses or sensors with a limited fi eld of view, directed at the sun, and are fully illuminated by sunlight at all times. As the sun moves, it begins to shade one or more sensor. The system detects this and activates motors or actuators to move the device back into a position where all sensors are once again equally illuminated.

Open-loop systems track the sun without physically following the sun via sensors (although sensors may be used for calibration). These systems typically employ electronic logic, which controls device motors or actuators to follow the sun based on a mathematical formula.

The National Renewable Energy Laboratory (NREL) technicalreport (NREL/TP-560-34302, revised January 2008) provides information and code examples for a solar position algorithm in solar radiation applications. This report is a step-by-step procedure for implementing an algorithm to calculate the solar zenith and azimuth angles. Rockwell Automation® has utilised this report to build a standard logic template that can be implemented by OEMs developing tracker equipment.

Data specifi c to the location must be entered so the mathematical calculations are performed accurately. The values include the time zone, longitude, latitude, pressure, elevation, temperature,surface slope, surface azimuth rotation and delta T (difference between earth rotation time and terrestrial time).

Once the local parameters have been entered, the program will calculate the azimuth angle – used to determine the horizontal rotation – and zenith angles –used to determine the vertical tilt or elevation. OEMs can utilise their desired mechanics to position their trackers based on the calculated angles.

In PositionThe Rockwell Automation control

architecture for solar trackers is based on an Allen-Bradley® MicroLogix™

controller. The controller helps position the solar panels, mirrors, or lenses into the sun in order to capture the sun’s energy.

The MicroLogix controller can be equipped with a positioning algorithm to mathematically solve the optimum tracker position for any time of the day. The outputs of the calculation are the zenith angle and the azimuth angle. Depending on the type of tracker being used (single- or dual-axis), one or both of these angles is then used to position the solar collection device.

The position loop can be closed in the controller or in the drive if the axis is so equipped. If the controller is used, the embedded High Speed Counter (HSC) instruction and corresponding inputs on the MicroLogix controller are utilised. Employing a drive that accepts an external encoder allows the position loop to be managed within the drive.

Since concentrated solar applications require more precise positioning to provide maximum and constant power generation, drives with positioning capabilities are often used. Some models in the Allen-Bradley PowerFlex® family of drives offer positioning features that

can be coupled with an appropriate gearbox reduction ratio to manage and hold position.

In applications that require the installation of many trackers in a solar fi eld, a central controller is often required to coordinate and monitor the trackers. Allen-Bradley ControlLogix® or CompactLogix™

programmable automation controllers fi t the bill, opening the door to the capabilities of the Rockwell Automation Integrated Architecture™. The Integrated Architecture system brings together a multi-disciplined control engine, networking, a scalable visualisation platform and information technologies needed to develop effi cient products.

A single or central controller can collect key operating conditions from each tracker in the fi eld. What’s more, data collected can be displayed in a SCADA system like FactoryTalk® View SE. Alarms and status information also can be displayed in a central location or accessed remotely.

Concentrated PowerBy working with a trusted

automation vendor like Rockwell Automation, OEMs can deploy technologies that can capture and convert solar energy effi ciently and cost-effectively. With off-the-shelf components built to globally accepted standards, machine builders can offer end users rugged solutions that are competitively priced. And, OEMs can help end users reduce operating and maintenance costs through secure remote access and monitoring as well as troubleshooting. AT

WATCHTECHNOLOGY

Control System Powers Wind TurbinesThe Rockwell Automation Integrated Architecture system helps manufacturer

simultaneously control multiple turbines.


China’s wind power industry isseeing unprecedented opportunities for development. With strong

government support and abundant wind resources, experts forecast that China’s wind power automation market will increase 30 percent to 50 percent in the next fi ve years.

Shandong Changxing Wind Power Technology Co. Ltd., based in the northern province of Shandong on the country’s eastern coast, is an industry leader in Chinese wind turbine production. This independent producer carries out in-house research and development, production and assembly of turbines as well as after-market support.

As the company began its production plan for building 850 kW wind power turbines, it teamed with system integrator Jinan Wenchuang. The team knew that they needed a control system able to integrate multiple segments including the variable pitch blade, yaw, variable fl ow, synchronisation, protection and monitoring.

An Open PlatformThe rapid pace of development in

China’s wind power industry has given rise to a series of problems, including a dependency on overseas technologies for production. With two key parts – wind power main control systems and variable pitch blade control systems – the adoption of closed systems provided by professional wind power control manufacturers has led to high costs, blockage of key technologies and lack of technical service. These have created a bottleneck for further development in Chinese wind power enterprises.

To address these issues, Changxing needed to integrate a complex control system for both variable pitch blade control and turbine control. The company also needed to be able to service these turbines after they were built.

Changxing needed to turn to an open platform control system that could provide operations at the highest international standards while allowing for local design and development of turbines. With its system integrator, the company built a solution based on the Rockwell Automation Integrated Architecture™ system.

Wind PowerThe Changxing 850 kW

turbines utilise an Allen-Bradley CompactLogix™ programmable automation controller coupled with Allen-Bradley servo drives, IO and human machine interfaces (HMIs). The system communicates over a DeviceNet™ network and includes FactoryTalk® View Supervisory Edition HMI software for real-time information and data collection.

The application of this distributed and scalable architecture allows Changxing to interconnect all 58 of its 850 kW turbines for synchronised control. The ability to simultaneously control all the turbines streamlines operations and greatly improves

the project’s effi ciency. With an open platform, the company also can develop innovative turbine components in-house, meeting government regulations for sourcing and furthering development of the local Chinese wind power market.

This project has become a successful application of Rockwell Automation® solutions in China’s wind power fi eld and has established a fi rm base for the company to further develop in the wind power fi eld. Rockwell Automation has worked with Changxing to realise self-innovation in variable pitch blade and main control systems in wind power generator units; reduce production and maintenance costs with a universal control platform; help ensure further system upgrades with an open system; and improve overall competitive ability. Finally, Rockwell Automation has collaborated with Changxing to obtain international certifi cation and expand overseas business with CE certifi cation for the Rockwell Automation Integrated Architecture products. AT


ENERGYSAVING

Designing Machines That Are Energy-EfficientSeven principles help lead the way to energy-effi cient

machine design that benefi ts OEMs and end users.

Energy-effi cient machine design is increasingly on the minds of original equipment manufacturers

(OEMs). Machines that consume less energy and deliver maximum return on investment are critical to success.

Building this equipment requires machine builders to apply seven principles of energy-effi cient machine design. Let’s examine these foundations of leading-edge design.

1. Remove Nonessential Components

Simplifi ed machine designs with fewer components use less energy because they run more effi ciently and are less expensive to build.

Machine builders increasingly rely on sophisticated performance and simulation software to help eliminate many unnecessary components, including line shafts and costly pneumatics and hydraulics. With these mechatronic tools, engineers can analyse energy usage, build virtual prototypes and select the best mechanical design to maximise machine performance, resulting in lower energy consumption and maintenance costs as well as improved uptime and reliability.

2. Minimise Mass Minimising the mass of a machine’s

essential components allows designers to evaluate alternative materials that are lighter and more energy-effi cient than steel. This task is made easier with analytical, modeling and development tools.

3. Use Electric Actuation As users increasingly seek to improve

their plants’ energy effi ciency, new high-performance electric cylinders offer an alternative. An opportunity to deploy

electrical actuation also will help users avoid energy losses associated with pneumatic air leaks.

4. Use Integrated Safety Systems

New safe-speed control solutions provide an example of effective control integration. They help improve fl exibility because operators can perform maintenance and other tasks while a machine is in motion. Safe-speed control helps decrease energy costs and increase uptime because a machine doesn’t need to be completely shut down and then restarted.

5. Get Closer to the Point of Use

While some control components traditionally were located on the machine, technology advancements make it possible to house entire control systems more closely to the application point. For end users, the compact nature of on-machine controls can provide signifi cant plant-fl oor space savings, helping to reduce overhead.

Standard automation components – including controllers, motor starters, drives, sensors, contactors, network media, distribution boxes, I/O and HMI devices – now are designed for on-machine applications. Some machine builders have seen their total machine tear down and reinstallation time decrease more than 50 percent.

6. Use Diagnostics More Effectively

Machines designed with EtherNet/IP™ connectivity allow remote troubleshooting, providing users with improved diagnostics. Remote monitoring helps reduce fuel usage

and related emissions in addition to associated travel time and costs of maintenance personnel who otherwise would go to the machine’s location.

With the ability to embed intelligence-gathering devices into machines without redesign or retooling, machine builders provide customers with self-diagnostic equipment that can predict and guard against failures. This boosts productivity and reduces repair costs. In addition, this technology relays the machine condition information back to the machine builder for value-added monitoring and analysis services without compromising the end user’s existing resources or hindering profi tability.

7. Add IT Connectivity Building information-enabled

machines that can connect to an end user’s IT infrastructure provides users with critical operational insight, including energy effi ciency and overall equipment effectiveness (OEE) calculations. This insight, in turn, helps plant managers reduce waste and optimise productivity.

Applying the Principles Advancements in technology and best

practices can help machine builders design more energy-effi cient machines. By following core design principles and leveraging the best of today’s advanced technologies, machine builders can create more cost-effective equipment with excellent reliability. AT

on the web

For more information on building

energy-effi cient machines, visit: http://www.rockwellautomation.com/solutions/sustainability/energy.html


Evolving automation systems drive advances in manufacturingManufacturing environments are rapidly evolving due to global competition and changing customer

requirements. To maintain competitiveness, intelligent software control programmes are required

to operate at faster speeds; information integration becomes imperative in achieving timely and

accurate data retrieval to support critical business decisions. Paul McRoberts, Industry Solutions

Manager-Initiatives, South Pacifi c Region, Rockwell Automation discusses the importance of

intelligent software for increasing productivity in manufacturing plants.

The notion of intelligent software has existed for a long time, but a paradigm shift is occurring in

how critical and complex automation systems are designed, confi gured, and controlled. To achieve ‘artifi cial intelligence or self healing’ would be the ultimate goal; a system where the intelligence of machines is such that traits like reasoning, knowledge, planning, learning, communication, and perception provide machines with the ability to move and manipulate objects to improve commercial outcomes. While intelligent software still has a long way to go to achieve this, increasing embedded computing in distributed intelligent devices provides improved system operation.

Combining sophisticated software and distributed smart devices produce ‘intelligent software’. These agents often include features such as embedded diagnostics, communications, calibration and control activities that are typically performed in a programmable logic controller (PLC) or other distributed control system. By having the ability to respond to changes in conditions such as unexpected component failure, environment changes, workload changes or system operating objectives, these agents provide superior and reliable performance. Intelligent software devices that can evolve to overcome challenges and self-heal to prevent downtime are being actively developed. This technology has proven to be widely adaptable to a range of complex systems and industrial applications.

Intelligent and integrated manufacturing

The success of a company’s manufacturing capabilities is often measured by their ability to respond to market changes. Traditionally, the production management system used by manufacturers was based on Enterprise Resource Planning (ERP) applications. In this model, a set of separate software applications are used for different parts of planning, scheduling, and execution processes. Signifi cant limitations are entailed with this approach resulting in disconnected planning and execution processes. The move towards an intelligent and integrated environment will bring the fl exibility and effi ciency needed by manufacturing systems.

The integration of a manufacturing system allows functional areas such as design, analysis, planning, purchasing, cost accounting, inventory control and distribution to be linked, providing valuable information about the status of a particular plant. EtherNet/IP remains the industrial network of choice for many manufacturing plants, providing an integrated system with the agility and fl exibility that is essential for competitive manufacturing in today’s global market.

Autonomous Control SystemsIntelligent software has the

potential to create an automated control system that can be applied to a diverse range of industries. There are generally several components to be incorporated into an autonomous control system including variable frequency drives, intelligent software and networked motor condition

monitoring devices. Typically, these systems integrate drives, intelligent relays, motor control centres, sensors and other monitoring devices on a common data-driven Ethernet/IP communications network. This provides precise motor control intelligence as part of a strategic maintenance program.

Technology has allowed for significant advances in generating high level, advanced control software. By increasing productivity on the plant level, the software does not affect the day to day running of the machines eliminating the need for complicated maintenance requirements. These intelligent software applications are aiming to be generic, self-healing type systems for companies that want to take their technology to the next level.

Autonomous control systems must perform well despite significant uncertainties in the plant and the environment for extended periods of time. They must be able to compensate for system failures without external intervention. If a variable on a machine is changed, autonomous control allows the machine to automatically re-configure so that there is no misalignment. The higher the degree of automation, the more critical is the integrity of the data used to control the machines.

Intelligent software and overall equipment effectiveness

Recent advances in integrated manufacturing intelligence systems have expanded the performance

ADVANCESMANUFACTURING


capabilities of overall equipment effectiveness measurements. OEE is established by determining overall capacity and planned production time compared with loss due to downtime, performance or quality limitations. Business enterprise systems are required to collect, organise and report data detailing information about potential ineffi ciencies in a manufacturing plant. Addressing these defi ciencies with integrated manufacturing intelligence systems has expanded the performance capabilities of OEE measurement.

Intelligent manufacturing software allows information to be digitally captured in real-time simplifying interpretation. The challenge for software developers is to overcome the limitations associated with manufacturing plants having to sort through millions of data points to determine how best to interpret the fi ndings. Intelligent software systems need to be adaptable to analyse individual parameters for varying applications.

Integrated safety and motion control

Manufacturing plants are increasingly realising the importance of integrating safety controls to help minimise worker injuries and increase overall cost savings. The safe control of motion has many benefi ts including effi cient maintenance of an application without disrupting power supply to machinery, safe speed control and safe control of potentially hazardous movement. Effi cient translation of data to produce an action, or exact motion to help maximise safety, continues to be the backbone of intelligent software advancement.

Control of intelligent agents that can interact with actuators and sensors

provides the ability to address motion control in large, complex manufacturing s y s t e m s . Relying on

a single, central controller has signifi cant limitations because damage to that controller or to the communication infrastructure used can result in a loss of controllability. Safety hazards are inevitable when motion control is compromised. A distributed, survivable and adaptable architecture can be achieved by distributing the intelligence of the system among multiple controllers. Embedding standalone or multiple intelligent agents inside the controllers, results in an advanced level of motion control.

Distributed Control Agents (DCA) interact with intelligent agents in a manufacturing system to achieve a functional outcome. The use of agents in automation allows for the design of more fl exible and smarter control architectures. By leveraging an agent communication layer (ACL) on top of communication networks such as EtherNet/IP, a manufacturing system is able to achieve coordination of dissimilar systems. Intelligent agents possess the capability to detect equipment failures and to isolate failures from propagating allowing for increased safety and productivity and reduced downtime in a manufacturing plant.

Energy Effi cient SolutionsEnergy management is a complex

but important factor in optimising production processes in manufacturing plants. Globally, manufacturers are putting systems in place to reduce water, air, gas, electricity and steam consumption—resources widely required by processing plants. Recent advances in intelligent motor control, incorporating variable speed drives, intelligent software and networked motor condition monitoring devices allows for a measureable impact on energy use and operational

effi ciency. Intelligent software can offer signifi cant energy savings by improving process diagnosis, stability and consistency in operations and by improving the control response to operating changes.

Manufacturers can use energy consumption data to identify variables in energy costs across all equipment on the plant fl oor collectively and also with individual machines. Energy management can be applied to machine design practices by improving effi ciency of equipment components such as motors and drives or by attaching monitoring devices to assist with data collection. By collecting accurate energy consumption data, manufacturers can modify the OEE calculation to include energy effi ciency, allowing them to achieve higher profi tability while reducing greenhouse emissions.

Intelligent software leads manufacturing into the future

Manufacturing environments arerapidly changing as a result of increased global competition and changing customer needs. Advances in intelligent software technology continue to provide manufacturing enterprises with the capabilities and fl exibility to deal with these changes. By coordinating and integrating production activities within a manufacturing enterprise, intelligent agents provide increased productivity and profi tability.

Intelligent agents are increasingly able to incorporate logic and collaborative reasoning parameters to detect faulty components, process problems and ineffi ciencies in a manufacturing plant. By eliminating the need for centralised control, autonomous intelligent agents display the capabilities for predictive reconfi guration of production processes, thereby reducing downtime and increasing productivity.

With the manufacturing environmentconstantly evolving—the ultimate goal is to develop adaptive, self-healing systems that can react to their environment and modify their behaviour accordingly to maximise production effi ciencies. AT


WATCHTECHNOLOGY

Machine builders and their customers want to simplify their automation systems and avoid

risk. Many are accomplishing these goals by moving to a network infrastructure based on EtherNet/IP™.

EtherNet/IP’s genius and simplicity rest on its ability to deliver the real-time performance, resiliency and security of a traditional fi eldbus solution, along with the bandwidth, open connectivity and global acceptance of standard Ethernet.

Converging to EtherNet/IP helps eliminate the need for machine builders to design, integrate and maintain multiple networks – a move that reduces the Total Cost to Design, Develop and DeliverSM machines – while bringing new performance-boosting capabilities to their customers.

One Standard NetworkTraditionally, machine builders

have used a dedicated network for each application. By replacing this multi-tier networking strategy with one standard network, machine builders can reduce their engineering time and integration risks.

Rockwell Automation® supports EtherNet/IP for network convergence. It is the only industrial protocol that is established enough to provide connection from the instrumentation level all the way up to the customer’s IT infrastructure -- and across applications, including discrete, process, safety, motion and drive control.

Also, EtherNet/IP is the only industrial network built on standard TCP/IP technology – the same Ethernet standard as e-mail, the Internet and other commercial applications. Other industrial Ethernet protocols require proprietary chipsets and hardware, which can hinder innovation and system longevity.

The Value of EtherNet/IPWith EtherNet/IP, machine builders can

simplify their network architecture while eliminating the risks and boundaries associated with proprietary and dedicated networks. Therefore, EtherNet/IP brings value at various phases in the process:

• Design Phase: Removes separate motion, human-machine interface (HMI), sensor and safety network requirements.

• Develop Phase: Provides a single approach to confi guring devices with reduced debugging and interlocking code to write.

• Deliver Phase: Makes it easier to integrate a machine into the customer’s environment since an Ethernet protocol natively conforms to the customer’s standard factory and enterprise network infrastructure.

After the machine is running, EtherNet/IP continues to bring value. For example, technicians can directly connect to the machine from a remote locationand conduct a detailed diagnosis using video, voice and other technologies enabled by Ethernet. The same capabilities can be used to order replacement parts or OEM-supplied raw materials.

Also, machine builders can leverage EtherNet/IP to help their customers effectively converge machine-level data with business-level data for improved management and decision-making. For example, Edson Packaging is a machine builder that has traditionally used a SERCOS interface® for its high-speed motion. It chose to use EtherNet/IP so its customers could converge to a single network for both machine and motion control. Its latest case packer uses EtherNet/IP and Stratix 8000™ managed switches from Rockwell Automation to effectively manage real-time control and information fl ow from the machine to the customer’s

manufacturing and IT enterprise (http://ab.rockwellautomation.com/networks-and-communications/stratix-8000-ethernet-switches).

For Askim Mek Verksted (AMV), a Norway-based manufacturer of cold-end glass wool production machinery, EtherNet/IP opened up some exciting new capabilities. Now, every aspect of AMV’s packaging system can be monitored for effective maintenance and rapid fault diagnosis, from pneumatic valve operation to motor temperatures. EtherNet/IP also allows comprehensive remote diagnostics and machine management over the Internet through a secure Virtual Private Network (VPN).

With shrinking corporate engineering staffs and more pressure to bring systems online quickly, manufacturers are relying on their machine builders to deliver machines that integrate seamlessly with their existing systems.

Using standard Ethernet and IP network technology, EtherNet/IP is the best pathway to a converged network architecture. It helps simplify control and information fl ow from the machine to the customer’s IT enterprise. AT

Convergence with EtherNet/IP helps simplify control and information fl ow

from the machine to the customer’s IT enterprise.

Leverage EtherNet/IP to Reduce Network Integration Risks

on the web

For more information on Rockwell

Automation machine builder solutions,

visit http://www.rockwellautomation.com/solutions/oem/

FOCUSPRODUCT


Rockwell Automation extends PlantPAx

process automation systemPlantPAx process automation system optimises user

uptime and improves profi tability by integrating motor control devices into a plant-wide control system

Rockwell Automation has extended the reach of its PlantPAx process automation system to integrate critical rotating assets, such as compressors, pumps, turbines and fans, giving users the ability to manage plant-wide operations with a single platform. The PlantPAx system combines the company’s core process automation capabilities and technologies with those of partners and acquisitions to deliver an integrated control and information solution for customers.

Users now can tie intelligent motor devices into this unifi ed-control architecture, making an immediate and measurable impact on asset availability, operational effi ciency and energy management. The tight integration between process automation and motor control is especially benefi cial in heavy industrial applications with considerable mechanical investments, such as metals, mining, cement, power, oil and gas, water/wastewater, and pulp and paper applications.

PlantPAx system users will have access to diagnostic information on any device in the system from any location – including motor control centers, drives, compressors, pumps, fans and instrumentation. Leveraging the EtherNet/IP network, engineers can monitor process conditions such as electric motor current, vibration signatures of key rotating assets and torque signatures of variable speed drives. This allows plant engineers to predict potential problems and help

avoid equipment downtime – resulting in improved productivity and reduced maintenance costs.

“To improve plant performance, our customers prevent unplanned shutdowns while protecting expensive machinery,” said Andrew Sia, Process Solutions Manager, Rockwell Automation. “Leveraging a single-network architecture to bring operational information from motor control devices into the control system helps engineers extend the life of their mechanical assets and improve their overall confi guration, operation and maintenance experience.”

Unlike other distributed control systems that require users to manually map data from motor control devices to the control system, the PlantPAx system mirrors the device memory, making data automatically available within the control system. Users can also setup applications in the PlantPAx system to collect and archive performance data from motor control devices into databases for analysis.

This convenient data acquisition provides cost savings throughout the lifecycle of the equipment. For example, bringing intelligent motor control devices into the PlantPAx system is useful in managing the performance of energy-intensive assets. Furthermore, since EtherNet/IP is the delivery mechanism for the PlantPAx system, users can avoid electrical hazards by accessing information remotely, helping personnel safely monitor, troubleshoot and diagnose motor control centers and other equipment. This saves time associated with suiting up with personal protective equipment and helps protect personnel from

exposure to hazardous conditions. According to the ARC Advisory Group, “The PlantPAx

system helps lead the trend in the convergence of power and process automation systems, which will result in improved productivity and energy effi ciency for end users in metals, mining, cement, power, oil and gas, and pulp and paper industries.”

In addition to integrating motor control devices into the control system, other key features with the PlantPAx system include:

EtherNet/IP network support for redundant systems and Device Level Ring network topology that provides a highly available EtherNet/IP network without any additional infrastructure costs.

Improved device integration and asset management as drives, for example, are now exposed via icons and faceplates in the visualisation layer, and managed in the asset management layer to provide disaster recovery, automatic backup and restore of drive confi guration, and change auditing.

Accelerated design engineering with initial sizing and architecture design, the creation of reusable engineering and template objects, and engineering and deployment tools for objects and diagnostics in the PlantPAx library.

For more information, visit:

PlantPAx Process Automation System http://www.rockwellautomation.com/solutions/process/systems


FOCUSPRODUCT

Cost-Effective Coordinated

Motion SystemThe Allen-Bradley Kinetix® 350 single-axis servo drive provides motion scalability.

It connects and operates with the new family of CompactLogix™ controllers, supporting Integrated Motion on EtherNet/IP™.

CIP Sync and CIP motion technologies provide real-time, closed-loop motion control on standard Ethernet. This topology-independent network provides a simplifi ed integration of the entire control solution on one network, including programmable automation controllers (PACs), human-machine interface, I/O and motion.

With its compact design, the Kinetix 350 requires less panel space and can be connected easily. In addition, users can reduce design, installation and commissioning time by reusing code across the Logix control platforms.

Programmed with RSLogix™ 5000 software, the servo drive provides a scalable motion system to be used with ControlLogix® and CompactLogix PACs. What’s more, it is equipped with embedded safe torque off.

Its scalable platform is optimised for lower axis count systems. The Kinetix 350 supports 100V and 200V single phase and 200V and 400V 3-phase class voltage models. Power ranges from 400W to 3kW. Users can reduce commissioning time with the automatic drive identifi cation of the MP-Series™ and TL-Series™ motors and actuators.


http://ab.rockwellautomation.com/Motion-Control/Servo-Drives

Delivering New

Dimensions

of Scalability

with Integrated

ArchitectureThe new CompactLogix™ programmable

automation controllers (PACs) are designed to meet the growing need for a higher performance controller in a compact and affordable package. As part of the Rockwell Automation Integrated Architecture™ system, the controllers use the same programming software, network protocol and information capabilities as all Logix controllers, providing a common development environment for control disciplines.

Cost-saving features of these controllers include support for Integrated Motion on EtherNet/IP™; Device Level Ring network topologies; built-in energy storage that removes the need for lithium batteries; reuse of existing 1769 I/O; and kinematics that removes the need for additional robot controllers and software.

In addition, the new family features a removable 1 GB secure digital card that improves data integrity and fl exible memory options up to 3 MB. The No Stored Energy (NSE) version of the family offers additional features for hazardous environments found in industries such as mining and oil and gas. What’s more, an open socket capability allows support for Modbus TCP as well as devices such as printers, barcode readers and servers.

The PACs deliver affordable control suited for applications ranging from small, stand-alone equipment to high-performance indexing tables, process skids, case packers and erectors, and packaging.


http://ab.rockwellautomation.com/Programmable-Controllers/CompactLogix

Rockwell Automation

RSLogix 5000 Software for

New Scalable ControllersRockwell Software RSLogix™ 5000 software provides a single development

environment for design, confi guration and maintenance for the Allen-Bradley ControlLogix®

and CompactLogix™ programmable automation controllers (PACs) and the Kinetix® 350 servo drive on EtherNet/IP™.

Using RSLogix 5000 V20 in combination with scalable, right-sized control system components allows machine builders and end users to scale from 48 to 10,000 I/O using a single control platform and common user experience. It brings integrated motion on EtherNet/IP to the CompactLogix controller family for a high performance yet compact and affordable packaged solution.


www.rockwellautomation.com/rockwellsoftware/design/rslogix5000/index.html

FOCUSPRODUCT


Portable Data

Collector for Predictive

Maintenance and

DiagnosticsThe real-time, multi-channel, Fast-Fourier

Transformer (FFT) signal analyser and data collector is used for predictive maintenance and machinery vibration diagnostics. It measures, processes, displays and stores a range of analysis functions.

The data collector includes:• A high-performance computing platform running Windows CE 6.0• A sunlight-visible color LCD• Suitability for harsh environments with a Mil 810 spec drop rating, IP65

sealing and an operating temperature range from -10C to +50CThe combination of the Dynamix™ 2500 data collector with Emonitor® software

provides users with tools for predictive maintenance using noise and vibration analysis. The data collector can also be used in other applications such as balancing or bearing analysis.


http://www.rockwellautomation.com/solutions/conditionmonitoring/portable.html

Redundant I/O Increases

Availability of Critical ApplicationsThe 1715 Redundant I/O platform requires no user programming code or

add-on instructions, special wiring or additional hardware to operate. It supports multiple confi gurations and applications, in standard and extreme environments, with a single product.

Unlike other I/O platforms, 1715 I/O lets users put redundancy where they need it. It offers the fl exibility of simplex (non-redundant) or duplex (redundant) module operations.

Modules offer native device intelligence in that they can monitor their own health with internal diagnostics. The modules perform multiple samples of a single signal using different criteria to alert users to issues such as open and short circuits, unexpected rate of change and thresholds. In addition, the 1715 platform includes redundant Ethernet adapters for greater fault-tolerant capabilities.


http://literature.rockwellautomation.com/idc/groups/literature/documents/pp/1715-pp001_-en-e.pdf

Connect the Allen-Bradley

PowerFlex 750 Drives

to the Profi bus NetworkThe PowerFlex® 750-Series Profi bus DPV1 module enables

users to integrate the Allen-Bradley PowerFlex 750-Series AC drives with the Profi bus network.

The optional module mounts inside the PowerFlex 753 and 755 AC drives to save panel space and offers V1 services beyond the standard VO services. Various tools can be used to confi gure the module and connected drive(s) including the Enhanced PowerFlex 7-Class HIM or drive confi guration software such as DriveExplorer and DriveExecutive.

Features of the module include:• I/O Messaging: Used to transfer time-critical information,

including data that controls the drive. The module can send and receive logic command/reference, logic status/feedback and datalinks (read and write up to 32 parameters simultaneously).

• Explicit Messaging: Involves non-time critical information that is typically triggered by the application (for example, ladder program in the controller). The module supports reading/writing of drive parameters, reading the drive fault queue, and reading/writing of option or other peripheral parameters.

• Confi guration Switches: The module has a binary-coded decimal switch for setting the node address (01-126). Alternatively, the switch can be disabled (00 – all off), allowing the node address to be set using a confi guration parameter. There is a dedicated switch setting that allows for byte swapping on the network depending on the controller that is selected to communicate with the module.

• Network Operating Mode Jumper: Allows users to set the operating mode of the module from either standard Profi bus or Profi Drive, providing network fl exibility and convenience.

• Standard D89 Connector: Connects to a Profi bus network, greatly simplifying the connection point and increasing longevity of the wiring system by providing strain relief.

The module can be fl ash-updated in the fi eld using Drive Explore, DriveExecutive and ControlFLASH.


http://literature.rockwellautomation.com/idc/groups/literature/documents/pp/750com-pp001_-en-p.pdf

eeeeeeeee

CALENDAREVENTS

VISIT ROCKWELL AUTOMATION AT THESE EVENTS: JANUARY - JUNE 2012

DATE EVENT LOCATION21-23 February21 February22-24 Februrary6-7 March15-18 March2-3 May22-23 May22-23 May6-7 June

RSTechED 2012Manufacturing Operation Management in CPGAOG 2012RAOTMAPPITA 2012RAOTMRAOTMResources & Energy SymposiumRAOTM

Auckland, New ZealandAuckland, New ZealandPerth WA, AustraliaMelbourne VIC, AustraliaMelbourne VIC, AustraliaSydney NSW, AustraliaBrisbane QLD, AustraliaBroken Hill SA, AustraliaPerth WA, Australia

Guard I/OGuard I/O provides all the advantages of traditional

distributed I/O for safety systems.It reduces wiring costs and start up time for

machines and cells, as compared to in-chassis I/O. You can use Guard I/O with any safety controller that communicates on DeviceNet or EtherNet/IP networks. Several Guard I/O blocks variants are available, with a variety of features for both in-cabinet and

on-machine mounting. Rockwell Automation has a well-established

reputation for helping manufacturers improve productivity. We’re also one of world’s largest safety system providers. By understanding global safety standards and practices as well as your manufacturing applications, we can help you achieve both operational excellence and a safe working environment.


http://ab.rockwellautomation.com/safety/io

FOCUSPRODUCT

Allen-Bradley PowerFlex 755 AC Drives Power Range

Extended

New high-power drives provide users with expanded application flexibility, additional voltages and common DC bus option for energy savings Building on the foundation of the Allen-Bradley PowerFlex 755 high-power models, Rockwell Automation has extended the power range of its PowerFlex 755 AC drives to 900 kW and added 690 volt ratings. The new drives, well-suited for a variety of heavy industrial applications, provide users with increased application flexibility, advanced diagnostics and a common DC bus option. “We’ve expanded the horsepower range and added new features to bring the benefits of the PowerFlex 755 family – advanced diagnostics, a convenient roll-out design and control options – to a broader range of motor control applications,” said Andrew Hoch, Solution Architect Power Control, Rockwell Automation. “This helps heavy industrial users reduce costs through enhanced flexibility, reduced downtime and low meantime to repair.”The common DC bus option allows users to connect the PowerFlex 755 AC drive to a common DC bus

configuration, which takes advantage of different drive cycles to share energy. In this configuration, a DC bus acts as a common energy source that feeds energy from a generating load to a motoring load. Managing energy from a shared source increases overall system performance and reduces losses – ultimately improving the application’s energy efficiency. Like all PowerFlex 755 drives, this latest frame size includes an embedded Ethernet port and five option slots, so users can tailor it to their application. Option modules include I/O, feedback, safety, additional communications and an auxiliary power supply. A convenient roll-out design allows easy access to the drive for fast installation and maintenance. The drive’s converter and control pod can remain in the unit while the inverter is rolled out, so control wiring can remain connected.In addition to the extended power range, a firmware upgrade for all PowerFlex 755 drives will contain the following new features and benefits: Interior Permanent Magnet Motor Control – Delivers increased application flexibility and high energy

efficiency. “Stop Dwell” feature – Helps prevent a motor from coasting to a stop. Ideal for converting applications, it allows users to preconfigure the motor to perform a controlled stop to protect valuable motor investments. The next version of Rockwell Software RSLogix 5000 software, planned for later this year, will include an automatic device configuration feature. Rather than manually configuring a replacement drive, this feature allows Logix controllers to automatically configure the drive upon installation. Users can quickly and easily replace drives without programming – ultimately improving uptime while reducing time and money spent on installation.


http://www.ab.com/drives/powerfl ex/755


Accelerator Toolkits are available at our website:

ab.com/go/iatools

You can also contact your distributor for a free copy of any of these DVDs.

Accelerator

Toolkits Off ered:

(Drives, I/O)

Dynamix™ Surveillance

Integrated Architecture™ Tools

Accelerator Toolkits

Publication 0000-XX000X-EN-P – January 2011 Copyright © 2011 Rockwell Automation, Inc. All Rights Reserved. Printed in XXX.

Accelerator Toolkit DVDs help you get your

Rockwell Automation® projects started.

Where Automation Connects™ www.prosoft-technology.com/fi eldserver-slotserver

(AP Rep) Offi ce – MalaysiaTel: +603.7724.2080

Email: [email protected]

Building Automation In-Rack Communication Modules…

The new FieldServer Gateways off er even more connectivity for Building Automation Systems:• LonWorks• EtherNet/IP• DF1 to BAS and Modbus Serial• TCP to BAS

…and Gateways

ProSoft Technology is now the exclusive provider of the SlotServer product line, manufactured by FieldServer. The SlotServer products provide in-rack connectivity between the Rockwell Automation® ControlLogix® control platform and an array of Building Automation Systems and Fire Alarm Control Panel protocols including:

• Metasys N2• BACnet• LonWorks

• Fire Alarm• Building Automation

Systems (BAS)

Contact your ProSoft Technology

representative for pricing and

availability.

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