sf09 - comparison: on-machine vs traditional safety application

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

PUBLIC INFORMATION

Comparison: On-Machine vs. Traditional Safety Applications


Safety System Design Goals and Challenges

Goal:

Providing a machine that is more safe to install / operate / maintain

Comply to appropriate standards (ISO 13849-1:2006, IEC 62061, …)

Challenge:

Deliver a safer, compliant system without compromising the production capability and

flexibility of the overall system

Deliver a system with capability for expansion and upgrading

Deliver a system with global support capability

Deliver a system with adaptability and scalability

Design for Recovery - Minimize MTTR – downtime or service time


Machine & Safety Complexity


How Does The Machine Need to Act?

We write functional safety specifications to determine system needs!

This needs to include all modes of operation (Auto/Manual/Jog/Service/Etc.).

We need to understand the required functions within each mode (reversing rollers for cleaning/slow speed for

feeding/slow speed for adjustments)

We also need to know if the line/system needs to be started and stopped in zones

We need to know how the line/system needs to be stopped and started in a controlled way

(Accel/Decel/Braking)

Is muting needed? (Ignoring safety functions for defined period of time)

Is blanking needed? (Ignoring objects in a controlled area)

Is position control needed? (Identifying where a hazard is)

The biggest reason that safety systems are bypassed or defeated is because all of the system functionality

was not considered and people have to workaround the system to do their job functions


Traditional Contemporary Safety Solutions

Turns machine off

Hardwired Diagnostics

Inter-connect relays for

logic

5

Hardwired

Auxiliary

Inputs

Safety Relay Configurable Safety Relay Standalone Safety PLC

E-stop

#1

E-stop

#5

E-stop

#3

E-stop

#2

E-Stop

#4Out

Feed

Conveyo

r

In Feed

Convey

or

Some zone control

Hardwired Diagnostics

“Programs with a

screwdriver”

Multi-zone control

Comms link for Diagnostics

Programs with separate software


Still Have Challenges…

Additional hardware / programming for Safety System Diagnostics

Additional equipment to specify, purchase, hold as spare parts…

Multiple software programming environments

Extra time to develop

Extra time to troubleshoot

Extra time to maintain

Additional training for maintenance personnel or for end customer

6

What if we used a single PLC for Safe and Standard Control?


• Knowledgeable customers began using two PLCs

• 1oo2 implementation

• From a Safety perspective, this is a good design

• Costly, complex, highly engineering system

• Difficult to design, develop, test, and maintain

• Requires cross-wiring, cross-checking, extensively programmed diagnostics

Chn A

Chn B

Early Safety System Designs


• Functionally Safe!

• Easy to apply

• Safety Rated Products

• Local Diagnostics


• Cumbersome

• Difficult to apply

• Difficult to use

• Often Bypassed

Machine Safety Solutions


• Flexible

• Task Oriented

• Productivity Enhancing!

Machine Safety is also evolving ... from a pure safety approach to a valuable productivity enabler

Past Present Performance


GuardLogix® Key Values

Integrated safety reduces system development costs by 30 ~ 50%

1. Ease of use is the primary factor

Directly correlates to speed, less wasted time and effort

2. Common software helps reduce your costs

One single project per controller: Safety, Motion, Discrete, Process, etc

The more safety is the same as standard, the easier it becomes

How data is used in the system

How I/O is handled

How controller interlocking is performed (tags)

How communications are configured and operate

3. Common Standard Hardware ie: 1756, 1769 and 1734


How can you perform safety and standard together in one

controller at the same time?

GuardLogix® safety system provides complete dual channel

operation, full 1oo2 safety architecture CIP safety I/O devices have full dual channel behavior

Each I/O module has more than 2 independent CPU’s

Both CPU’s read all inputs

And then assemble CIP safety packet and cross compare

Both CPU’s extract and analyze CIP safety Packet

Both cross compare

One writes the outputs, both monitor

Either can set the outputs to safe state

GuardLogix® 1oo2 design provides full independent dual channel behavior

Both disassemble CIP safety input packet

Both independently process safety logic

Both assemble CIP safety Output Packet

Both cross compare safety output packet


1oo2 Safety Made Easy - GuardLogix®

11

GuardLogix Primary Full Standard Logix Functionality (Everything)

Isolated Safety Task (protected memory)

GuardLogix Partner Fully isolated Safety

Redundancy


Benefits of Programmable Safety Systems

Programmable Safety ControllerSafety Relay System

Conversion Highlights:– (60) Safety relays eliminated

– (277) Terminations eliminated

– Panel savings created


What is an On-Machine™ Approach?

A design philosophy that moves

industrial controls and hardware

closer to the application or on the

machine

Reduces the size of panels and MCC

Reduces wiring time

Increases uptime at a lower total cost

13

Reduce costs, accelerate start-up and boost reliability

On-Machine™ products are characterized by:

Enhanced environmental ratings

On board diagnostics

Plug-and-play electronics

Modular wiring connections


A Wide Range of Benefits

14

“By developing an alternative to our traditional, chassis-based I/O, we have been able to reduce the installation time of our conveying systems by more than 50 percent,” said Ron Newlum, engineering manager for AEC.

On-Machine™ solutions offer:

Optimized floor/cabinet space

Quicker installation with fewer

mistakes

Re-usable solutions

Ease of design

Simplified testing

Faster maintenance/repair

Re-configurability

Reliability

Nick Mercorella, plant engineer at Continental P.E.T. Technologies Inc., states: “We were able to install our entire system without ever screwing a wire down, thus eliminating any potential miss-wiring and the system debugging cost associated with such problems. It’s true plug-and-play, which is exactly what we needed.”

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED1

5

Not an All-or-Nothing Proposition

On-Machine™ solutions are scalable

Varying degrees of On-Machine™ connectivity

can be used to suit the application needs:

Mix of hardwiring and components with

connectors

System with complete set of connectors

Various networks


OEMs can improve productivity, lead times, commissioning time, testing and delivery

Time to market

Improved quote-to-cash

Build more machines and impact top line

End users improve OEE Reduced downtime

Simplified troubleshooting and easy replacement

Scalability, modularity, expandability

Increased Overall Equipment Efficiency (OEE) for a competitive edge

A consortium of European manufacturers and machine tool technology groups concluded that On-Machine™ assembly costs are up to 30% less than conventional methods.

On-Machine™ Solutions: Addressing Your Top Priorities

16

Through On-Machine™ solutions…

The larger and more complex the machine, the greater the potential savings.

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED 17

A Real-Life Example…

• A coil handling and press feeding automation systems OEM was able to significantly reduce the number of potential failure points attributed to connection errors by using On-Machine™ products.

• For a single proximity switch connection:

Before On-Machine™

productsAfter On-Machine™ products

8 connections (with 19

potential failure points)

before the device was

seen by the controller

2 connections (with only

6 potential failure points)

before the device was

seen by the controller


Results using On-Machine™ Solution

Controls Advancements Gains Achieved

Junction boxes 97% reduction (30 boxes down to 1)

Feet of cable (comms & power) 70% reduction (from 10K ft to 3K ft)

Hard-wire termination points 87% reduction (from 348 to 45 points)

In-house network comms setup 93% reduction (from 72 to 5 hours)

In-field network comms setup 86% reduction (from 8 to 1 hours)

In-house wiring time (man-hrs) 50% reduction (from 1800 to 900 hrs)

No. of control enclosures 16% reduction (from 6-door to 5-door)

Control hardware component cost 25% reduction

Potential failure points per switch 68% reduction (from 19 to 6 points)

By applying On-Machine™ products, the same OEM made substantial gains in a variety of areas:


Wrapping up the On-Machine™ Approach

Centralized power distribution panel

Many manual connections

Long conduit and cable runs

Long commission time

Limited status & diagnostic help

Harder to troubleshoot

Longer repair or replacement time

Limited scalability of design

On-Machine™ motor control solutions

Plug and play connections

Scalable, modular & expandability

Faster installation

Reduced engineering time

Optimized production floor space

Simplified troubleshooting

Reduced downtime

Quicker component replacement

Lower total installation cost

Traditional

More than

8 days


A complete On-Machine™ solution

Programmable Controllers

Ethernet Switches

Connection Systems and Network Media

Distributed I/O

Sensors, Switches, Push Buttons and Signaling

Power Supplies

Distributed Motor Control

Motion

Safety

20

Rockwell Automation® offers a complete portfolio of Allen-Bradley® On-Machine™ products


On-Machine Safety Solutions

Eliminate need for I/O panels

Many devices directly connect to IP67 ArmorBlock® Guard I/O™

Simplify designs and reduce installation timeGate Switch

Safety

Valves

Safety

Mat

Safety Motor

Starters

Benefits: Reduce Cost, add Flexibility


Today’s On-Machine™ Offering from Rockwell Automation® for EtherNet/IP

* Junction box required for termination of tether


Armor™ GuardLogix® and Armor™ ControlLogix®

5570

On-Machine™ standard and safety controllers help reduce downtime and costs, simplify

troubleshooting and improve time to market by moving the controller closer to the application or on the

machine. Armor™ GuardLogix® offers the full benefits of the GuardLogix® controller with SIL 3, PLe,

CAT 4 integrated safety. Both controllers are in an IP67-rated housing for dust and wash-down

protection in harsher environments. Dual independent Ethernet ports support the Device Level Ring

(DLR) network topology, simplifying integration of components in the control system.

23

Addressing

the needs of On-

Machine™

control…

Addressing

the needs of

standard and safety

control…


5570 On-Machine™ Control Features

5570 Armor™ ControlLogix® and Armor™ GuardLogix® Controllers

Offer quick-connect cabling that streamlines system wiring

Require no specialized personnel to replace system components

Are easy to install and maintain

Simplify troubleshooting, which reduces labor and maintenance

costs

Improve time to market, testing and commissioning for machine

and equipment builders

24


5570 On-Machine™ Control Benefits

Simplified network architecture Allows unparalleled access to machine data

Enables faster decision making

Dual, independent Ethernet ports simplify component integration

Common programming and configuration tools Studio 5000® Design and Configuration Software and

Integrated Architecture® Builder

Simplifies design and maintenance

Speeds time to market

Reduces time for troubleshooting and maintenance

Enables easy application code migration

Studio 5000® Design and

Configuration Software


5570 On-Machine™ Control Benefits

Single Network Architecture

Embedded Ethernet switches support Device Level Ring (DLR)

Includes 2 separate, full-featured EtherNet/IP DLR-capable network channels

Allows user to connect the Ethernet network in a ring topology

Provides resiliency from loss of one network connection

Reduces the number of Ethernet switches in the system that reduces cost


Armor™ GuardLogix® and

Armor™ ControlLogix® 5570 Differentiators

5570 Armor™ ControlLogix® and Armor™ GuardLogix® Controllers

Standard and safety On-Machine™ control up to SIL 3, PLe, CAT 4

in an IP67-rated housing for dust and wash-down protection in

harsher environments

Status indicators

Four indicators provide immediate

status about the controller’s health

Power Supply

Enables power for each

device

Embedded 24V DC power

with pass-through to power

other On-Machine™

products

Networks

Two independent

Ethernet network

connectors provide

network flexibility

Dual ports allow

Device Level Ring

topology

USB Port

High performance and speed for

easier programming and firmware

updates

Secure Digital (SD) card

1 GB/2 GB nonvolatile

memory permanently stores

user programs and tag data

Faster reads and writes

compared to CompactFlash

Offers configurable

parameters to enable

automatic program load from

SD card on power-up

Mount

Flexible options including

On-Machine™

Battery-less Storage

No maintenance, transportation

and environmental issues

associated with lithium batteries


ArmorTM GuardLogix® Series C

Enhancements to Armor Guardlogix Series B

Armor™ GuardLogix® Series B – AFC Dec 2013

Series change will include:

Upgrading of 1756- EN2TR to EN3TR Series B

Providing support for increased number motion

axis

Overlay improvements to assist with wiring

Display changes to improve LED readability

Addition of NEMA 4

Marine certifications


Armor™ ControlLogix® Technical Features

29

(1) ControlLogix® 1756-L72EROM controller

(2) 1756-EN3TR series B

Same dimensions and standard certifications as ArmorTM

GuardLogix® series C

Ingress Protection (IP67 and NEMA 4) provides environmental protection from the effects of:

Dust Immersion between 15 cm and 1 m

Extending ControlLogix® to the On-Machine™ space

Create a complete IP67 system architecture with ArmorTM Stratix™, ArmorTMBlock and ArmorTMPOINT I/O


1732ES ArmorBlock® Guard I/O™ on EtherNet/IP

Module I/O mix, 2 separate catalogs: 12 single channel input (6 dual)+ 2 dual channel bipolar output

12 single channel input (6 dual)+ 2 dual channel sourcing output

Feature Overview EtherNet/IP, supporting unicast and multicast

Dual port: embedded switch for DLR & liner topologies

Rotary switches to set last octet of IP address

Standardized M12 input and output connectors (same as 1732DS)

Separate input and output Power via mini-connector, with pass through

IP67 rated package for use on machine

Release with CE, C-Tick and TUV

Add KCC Korea markings (date TBD)

TUV certified up to Category 4, SIL 3, PLe

Configure with RSLogix 5000


Rockwell Automation® ArmorBlock® Dimensions

31

258 mm

70 mm

1732ES (2 models)16pt Combined Input + Output

EtherNet/IP Safety

1732DS (2 models)

1) 16pt Combined Input + Output

2) 8pt Input only

Both on DeviceNet Safety

179

mm

70 mm

179

mm

65 mm

1732EStandard


Other On-Machine™ Distributed I/O Hardware

32

CatalogArmorBlock® & Armor™ WeldBlock

1732

ArmorPOINT

1738

I/O Type 24V DC, digital, analog, RTD, Thermocouple24V DC, 120/230V AC, relay, analog, specialty,

temperature, serial

Density Points 4, 8 or 16 points 2-16 points

Communication Options EtherNet/IP, DeviceNet, 3rd Party ,EtherNet/IP, DeviceNet, ControlNet, 3rd party

Removable Terminal Blocks -8 mm, 12 mm, 23 mm, & D-shell quick

disconnect

Mounting OptionsOn-Machine™ (IP67/69K), horizontal, vertical On-Machine™ (IP69K), panel, horizontal,

vertical

Protected Outputs Yes

Distinctions

Self-configuring I/O for any combination of inputs/outputs, Armor™ WeldBlock resists effects of

weld slag and magnetic fields, CIP Sync SOE & Scheduled Output blocks, High Accuracy and

conversion rate Analog blocks

Direct connect to ArmorStart®, bus expansion cables to extend I/O up to 12

meters, power supplies, configures just like POINT I/O™


1732ES Target Applications

33

Automotive Industry - Body shop, paint shop, final

assembly, power train assembly

Consumer goods

Packaging equipment

Material handling


Guardmaster® 440G-LZ

Safety certified to PLe and Cat 4 EN/ISO 13849-1

EN/ISO 14119:2013

Solid-state design and monitored outputs

Scalable protection with Unique or Standard coded RFID actuators

High holding force of 1300N (Fzh)

Energy Efficient Green Device: only uses 2.5W

IP69k and hygienic design

Power to Release and Power to Lock versions

Compact design optimized for ease of mounting

Diagnostic info provided with 2 bright 270° LEDs

Bar code with URL link

Metal holding bolt (inserts into the metal

bracket and sensor assembly)

Actuator

Global approvals

LEDs (both sides)

Slim, clean-design, sealed body

(IP69k)


Guardshield Safety Light Curtain 450L POC

35

Innovative Platform for Simple and Complex Applications

Modern Compact Design IP65, 30mm x 30mm / (1.2” x 1.2”) profile

Available in lengths of 150mm (5.9”) increments up to 1.95m (6.4’)

Patented universal stick design Reduces Inventory

Ease of Use with cutting edge Plug-in System

Plug-in module provides applications specific functionality

Transmitter, EMD, Cascading, Muting, Blanking

No dead zones allows for Flexible Mounting

Top, bottom or side mount with no loss of resolution

Ease of Installation with patented integrated laser alignment

Single laser projects an array of points for easy alignment


Products that offer: Technology that offers:

Layer 2 and Layer 3 switching for simple

to complex networks applications

Advanced switching, routing and security

features

Advanced security services Common tools for Controls & IT

Plant floor and Enterprise integration Improved Maintainability

“On-Machine™” Connectivity Flexible design

Wireless integration in hard-to-wire and

remote areas Customization based on your plant’s needs

The Stratix™ Portfolio

Integrating Industrial and Enterprise Environments


Stratix™

8000/8300Layer 2, Layer 3

ArmorStratix™

5700

…as well as

Operations and

IT

Addressing

the needs of

Automation…

Stratix 5900™

Services RouterStratix 2000™

Unmanaged Stratix™ 5100 Wireless

Access Point/Workgroup

Bridge

Stratix 5700™Layer 2

Stratix 6000™Layer 2

Stratix™ ETAPs

The Stratix™ Portfolio

Integrating Industrial and Enterprise Environments


The ArmorStratix™ 5700 Offering

38

Part of an “On-Machine™” system moving the industrial controls

and hardware closer to the application, or onto the machine

Rugged, IP67-rated design for ideal integration into widely distributed applications

with extreme environment conditions

Enables integration with enterprise network using

Cisco Internet Operating System (IOS)

Provides Premier Integration

(CIP-enabled) to the Rockwell Automation®

Integrated Architecture® system

Costs can be reduced due to minimized cabinet components and wiring time


ArmorStratix™ 5700 LineOverview

Features: Layer 2 managed switch Panel/machine mount design M12 Ethernet connectors

Stratix 5700™ FW (full version)

Base offering:

8-,16- and 24-port versions- 10/100 ports

Expanded offering:

10 and 18 port versions with: 2 additional Gigabit ports PoE ports (4 PoE ports with 10-port

version and 8 with 18-port version) IEEE 1588 support HW alarms

Five new catalog numbers offer 8 to 24 ports for optimized

industrial automation applications

39


8-port 16-port

24-port

ArmorStratix™ 5700 Line Base Offering

40

IP67-rated for dust and washdown protection

8-,16- and 24-port versions with rugged M12 (D-coded) Ethernet Connectors

Panel/machine mount design for on-machine connectivity outside of the cabinet

Dual Power InputConsole portSD card for simplified

device replacement


Built on Stratix 5700™ firmware with “full” feature set and uses the same configuration and support tools

Includes IP67-rating for protection in extreme conditions

Minimizes hardware in the control cabinet for compact solution

Simplifies device replacement via SD card storing entire configuration

Provides advanced features including Power over Ethernet (PoE), gigabit ports and IEEE 1588 support

Enables integration with enterprise network using Cisco Internet Operating System (IOS)

Provides Premier Integration (CIP-enabled) to the Rockwell Automation® Integrated Architecture® system

Predefined Logix tags to retrieve diagnostics

FactoryTalk® View faceplates for status monitoring and alarming

Studio 5000® Automation Engineering and Design Environment™ Add-on Profiles for configuration and monitoring

ArmorStratix™ 5700In Summary


Overview of On-Machine™ Distributed Motor Control

Robust, hardened enclosure for harsh environments

Provide local disconnecting means

Variable frequency, solid-state, or direct on line motor control

Intelligent with networking capabilities

Embedded inputs, outputs, analog

Machine safety functionality

Easily installed at or near the motor application

44

Pre-engineered motor starting solutions


ArmorStart® Portfolio

Eth

erN

et/

P

De

vic

e L

eve

l R

ing (

DL

R)

Functionality

Co

st

L

T

L

T

• Compact

• Full Voltage/Reversing

• Embedded I/O

• Local Disconnect

• 0.37KW (1/2HP) to 4KW(5HP)

• VFD,SVC

• Embedded I/O

• Local Disconnect, High SCCR

• 037KW(1/2HP) to 4KW(5HP)

• Full Voltage/Reversing

• Embedded I/O

• Local Disconnect, High SCCR

• 0.37KW(1/2HP) to 7.5KW (10HP)

• VFD, V/Hz

• Embedded I/O

• Local Disconnect

• 0.37KW(1/2HP) to

1.5KW(2HP)

DeviceNet Safety PLe Category 4

DeviceNet Safety PLe Category 4

Use With:

• Armor Connect®

• Round 3-Phase

and

• Control Media

• (UL2237, UL2238)

De

vic

eLo

gix

™

De

vic

eN

et


ArmorStart® LT

CONTROL ENGINEERING2013 Engineers' Choice Awards: Spotlight on InnovationArmorStart® LT recognized in the “Best automation, control, and instrumentation products” category

• Compact Size

• Low Cost

• Logix Premiere Integration


ArmorStart® LT: AnatomyVariable Frequency Drive

At-Motor

Disconnect Switch

Wiring Access

Power and Motor

Connection

6 User Configurable

I/O Points

Network

Connection

Status & Diagnostics

with Reset

Device Address

Hand-Off-Auto

Option

381mm(15in)

206m

m(8

.1in

) 202mm(8in)


Customer Value:

Logix Premiere Integration with EtherNet/IP

49

Only 1 software for programming

EtherNet/IP Embedded switch technology

Plant-wide network using industry-standard technology

Easier connectivity to the enterprise

Enables real-time control and information

Studio 5000® Add-on Profile

Built-in web server capability


Virtual Brochure

http://www.ab.com/armorstart/virtual-demo

C:/Program Files (x86)/Mozilla Firefox/firefox.exe

C:/Program Files (x86)/Mozilla Firefox/firefox.exe


ArmorStart® Applications

51

Automotive:

Paint, Body, and Assembly lines

Engine and Power Train lines

Rotary tables

Overhead conveyors

Vertical position (lift) table

Finish (board) conveyor

Transportation:

Passenger baggage handling

Circular storage

EDS (Explosive Detection Systems) lines

Baggage claim

Tilt truck

Tray trolley

Material Handling:

Warehouse distribution and sorting conveyors

Assembly and process lines

Gapping

Palletizing

Solar panel assembly

Palletizing machines

Food, Beverage, and Tobacco:

Processing and fill line

Palletizing

Pack and Unpack

PET Air transportation

Packaging:

Case and Packing

Packaging

Rotary tables

Freezer

Other potential Application

Pumps

Fans

Compressors

HVAC

Mixer

Storage and retrieval

Postal & Parcel Delivery

Filling, Sealing, Punching

Process Skids

Marine

sf09 - comparison: on-machine vs traditional safety application

Technology

rockwell automation

safety functions

system needs

safety systems

overall system

compliant system

system functionality

hardwired diagnostics