t61 leveraging integrated architecture - rockwell … –leveraging integrated architecture using...

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900E

PUBLIC INFORMATION

T61 – Leveraging Integrated ArchitectureUsing Kinetix and PowerFlex Drives

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION

Integrated Architecture® System

SUPPLIER CUSTOMER

MATERIAL HANDLING

OEM OTHER PLANT

PROCESSING

BATCHING / BLENDING

RECEIVING

PACKAGING SHIPPING

CONTROL ROOM

Integrated Architecture

CORPORATE HEADQUARTERS

UTILITIES

The Factory

Business Enterprise Systems• Improves productivity

& reduces costs

• Integrates control,

networking, visualization

& information technologies

• Addresses full range of

control & information

needs

• Extends performance

gains across your

enterprise

• Provides unparalleled

functionality, flexibility

& scalability

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.COMPANY INTERNAL - Internal Use Only

EtherNet/IP - Enabling/DrivingConvergence of Control and Information

3

Industrial Network Convergence

Converged Plantwide EtherNet/IP

Industrial Network Model

Corporate Network

Sensors and otherInput/Output Devices

Motors, DrivesActuators

SupervisoryControl

Robotics

Back-Office Mainframes andServers (ERP, MES, etc.)

OfficeApplications,Internetworking,Data Servers,Storage

Human MachineInterface (HMI)

SafetyController

Traditional – 3 Tier

Industrial Network Model

Corporate Network

Sensors and otherInput/Output Devices

Controller

Motors, DrivesActuators

Robotics

Back-Office Mainframes andServers (ERP, MES, etc.)

OfficeApplications,Internetworking,Data Servers,Storage

Control NetworkGateway

Human MachineInterface (HMI)

SupervisoryControl

Camera

Phone

Industrial NetworkIndustrial Networks

SafetyI/O

I/O

Controller


Complete Machine Control on EtherNet/IP


Classic Drives vs. Motion

6

When do you choose an A/C drive and when do you choose a servo?

Traditionally, an A/C drive was chosen for velocity applications

And servos were chosen for position (and torque) applications

Most machines contained a mix of A/C drives and servos

Each are programmed with their own tool set

Not many look and feel the same

What about applications where the lead drive is an A/C drive?

How would you gear or cam the servos to this lead drive?

How much cost is added by adding an encoder to the drive?

How do relate positions for servos to speed/time of the drive?

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION 7

Drives and Motion Product PortfolioLeveraging EtherNet/IP

Stratix 5700 Stratix 8000

ControlLogix

GuardLogix

Ethernet

CompactLogix

Distributed I/O

PowerFlex 755PowerFlex 527

Kinetix 6500

Kinetix 5500

Encoder

Kinetix 350

Chassis I/O

1783-ETAP


Customer application Lets take a look !

9


Agenda

Examples of Applied CIP Motion

CIP Motion Products

How Does CIP Motion Work?

Terminology

What is Integrated Motion?


Agenda


CIP Motion Products


Terminology



Integrated Motion on EtherNet/IP

Single network solution:

No dedicated motion network required

Flexible network layout

Utilize existing Ethernet infrastructure

CIP Motion & CIP Sync:

CIP Sync distributes time on wire

Enables event time stamping

Enables scheduled outputs

Increased diagnostics

Covers both Kinetix and PowerFlex

products


Studio 5000Configuration, Programming, Commissioning, Diagnostics, Maintenance

Instruction based programming

Graphical motion profile editor

Axis/Drive management

Drive status and diagnostics

Kinetix, PowerFlex, and I/O via EtherNet/IP


Studio 5000Motion Configuration

Add up to 100 axes

Position Loop configured drive

Vhz configured drive

Drive/Axis configuration

Application type and loop response for optimizing out of box defaults

EtherNet/IP drives


Studio 5000Motion Commissioning

Application settings customize out-of-box defaults…no need to tune for most applications

Integrated Auto tune

Integrated Manual tune


Studio 5000Motion Diagnostics

Drive/Axis status and diagnostics

Network connection diagnostics

Drive/Axis Motion and I/O status

Time stamped faults and alarms log


Automatic Device ConfigurationBuilt Right In

Natively part of Integrated Motion:

Configuration stored in controller

No additional steps required

All parameters sent to drive at power up

Even IP addresses can be automatically

obtained via BOOT/DHCP:

Managed switch

DHCP persistence ports

Firmware Supervisor supported, not

required


Agenda


CIP Motion Products


Terminology



Terminology

21

CIP Motion™ is and open standard administered by ODVA™

Integrated Motion on EtherNet/IP™ is a Rockwell Automation concept

Rockwell Automation is the only vendor using CIP Motion today

For today’s talk:

CIP Motion = Integrated Motion on EtherNet/IP = Integrated Motion

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

Built on Open & Global Standards from ODVA

Taking the advantage of the EtherNet/IP knowledge and mastering. Over the

last several years, Rockwell Automation has been developing Integrated

Motion on EtherNet/IP™ (CIP Motion) products that integrate with Logix

control system.

• Time synchronization on EtherNet/IP

o +/- 100ns precision,

o IEEE 1588 technology

• Motion synchronization and time dependent services

support

• Profile support for drives control and peer-peer

motion synchronization services

o AC and SERVO drives

o Position, velocity, torque, Vhz

• Peer-peer motion synchronization


TerminologyI/O Mode or CIP Motion?

Premier Integration(I/O Mode)

Integrated Motion on EtherNet/IP(CIP Motion)

PowerFlex 755

PowerFlex 523 with Card

PowerFlex 525

PowerFlex 7-Class with Card (Legacy)

Kinetix 300

PowerFlex 753 with Card

Kinetix 350

Kinetix 5500

Kinetix 6500

PowerFlex 527 (Future)

Kinetix 5700 (Future)


Agenda


CIP Motion Products


Terminology



How Does CIP Motion Work?Here’s a Simple Analogy

CIP Motion coordinates devices in a manner that’s similar to our own methods for coordinating meetings and events

All members (devices) have clocks to compare time to an absolute base and scale

A destination (position) is targeted for the event

A time (timestamp) is set for when the event shall occur

A message is sent to each member (device) to meet at a given place at the pre-determined time

Not all messages will arrive at precisely the same time…

MeetingConf Rm2:00 pm


How Does CIP Motion Work?Here’s a Simple Analogy

CIP Motion coordinates devices in a manner that’s similar to our own methods for coordinating meetings and events

All members (devices) have clocks to compare time to an absolute base and scale

A destination (position) is targeted for the event

A time (timestamp) is set for when the event shall occur

A message is sent to each member (device) to meet at a given place at the pre-determined time

Not all messages will arrive at precisely the same time……but all members arrive in the proper destination at the proper time for the meeting to take place.

Conf Rm


Synchronized Time Example

27

PowerFlex 755

Kinetix 6500

ControlLogix(Grandmaster Clock)

ArmorBlock I/O

DataTimestamp

PositionTimestamp

PositionTimestamp

FdbkTimestamp

FdbkTimestamp

Each device has a clockThe clocks are all synchronizedTime stamped inputsCommand data to drivesFeedback data from drives


Agenda


CIP Motion Products


Terminology



Controllers

5370 CompactLogix (ERM)

Support for up to 16 axes of

Coordinated Motion

Embedded Dual-Port Ethernet

ControlLogix/GuardLogix

Up to 100 Axes/Controller

1756-EN2Tx (8 Axis)

1756-EN3Tx (Up to 128 Axis)

RSLogix/Studio 5000


Kinetix 350

Multiple Voltages

Up to 3 kW

Indexing Drive

EtherNet/IP

Safe Torque-Off

CIP Motion

RSLogix 5000


Kinetix 5500

Universal Power

Bus Connection Options

Up to 15 kW

CIP Motion

Compact Size


Kinetix 6500

Modular Multi-Axis Structure

460V Power

Up to 22 kW

CIP Motion

Enhanced Hardwire Safety

Options STO, SSM


PowerFlex 755 AC Drive

Most Flexible Offering (CIP Motion,

Premier Integration, Discrete, Multiple

Comms)

Up to 2000 HP

Multiple Control Modes

Multiple Enclosure Offerings

Enhanced Safety Options (STO, SSM)

Induction Motor or PM Motor Control


Introducing the PowerFlex 527 Drive

Expanding your system solutions to include the PowerFlex 527 gives you:

A low-cost integrated motion drive

Synchronization over the network

Induction motor support

Configuration, control and monitoring with the same

motion instruction sets as Kinetix drives!

Time stamping capabilities

PLe/SIL3 integrated safety in two formats:

Hardwired safe torque-off

Network-based safe torque-off


EtherNet IP Switches

Stratix Managed/Unmanaged

IEEE-1588 Support

QOS Support

ETAP

Consult your Motion/Automation

Specialist


842E-CM CIP Motion Encoder

Single-Turn / Multi-Turn

No Discrete Wiring

Diagnostics

18 bit single-turn, 30 bit multi-

turn (262,144 cts/rev x 4096

revs)

Dual Port. Multiple Topologies

Ideal for Feedback-Only Axis

for Kinetix 350 and 5500


1732E CIP Sync / CIP Motion ArmorBlock Modules

1732E-IB8M8SOER

8 CIP Sync Sequence-of-Events input module

Inputs are time-stamped

2048 buffer memories per block

1732E-OB8M8SR

8 CIP Sync Scheduled Output sourcing module

Outputs are updated at a specific schedule time

High accuracy scheduling increments of 1 microseconds

Ability to fire multiple outputs at high speed interval of 100 microseconds

Support 16 schedules per coarse update period


CIP Motion Drive PortfolioScaled for the Application Requirements

Kinetix 5500PowerFlex 527

Focus Control Type Speed Torque, Speed Position, Torque, Speed Position, Torque, Speed

Motor TypesInduction

Open & Closed Loop

Induction

Open & Closed Loop

sPM Open & Closed Loop

iPM Open & Closed Loop

Induction Open Loop

sPM Closed LoopsPM Closed Loop

Focus ArchitectureCIP Motion for

Single Axis Control

CIP Motion for

Single Axis Control

CIP Motion for

Multi Axis Count

CIP Motion for

High Axis Count

Focus ApplicationsMedium Performance

Feeder Conveyors,

Pumps, Fans

High Performance

Web, ASRS, Roll Forming,

Chain Conveyors

Highest Performance

Packaging, Printing,

Winder, Filler, Carton

Forming

Highest Performance

Packaging, Printing,

Winder, Filler, Carton

Forming

SafetyHardwired STO, CIP

Safety

Hardwired STO & Safe

Speed(Future CIP Safety)

Hardwired STO or CIP

SafetyHardwired STO

Kinetix 6500PowerFlex 755


Product Summary

39

PowerFlex® 527 focuses on applications that require only speed control,

i.e. pumps, fans, conveyors

PowerFlex® 755 targets applications that require speed and torque

control, i.e. web, ASRS, roll forming

Kinetix® 5500 is best used on applications that require speed, torque and

position control, i.e. winders, filler, carton forming


Agenda


CIP Motion Products


Terminology



Smart BeltApplication Overview

In-feed conveyor Out-feed conveyor

Gapping belts


Smart BeltApplication Discussion

How would you solve this with an (any) AC drive?

In-feed conveyor Out-feed conveyor

Gapping belts


Smart BeltApplication Discussion


Lots of sensors

Lots of math

Complex logic

What if the drives didn’t use Premier Integration?

Lots of extra communication logic

Multiple configuration tools and software platforms

Diagnostics are difficult to get

What if the drives aren’t on EtherNet/IP?

Lots of additional wiring

No diagnostics


Smart BeltHow Can You Solve This Using CIP Motion?

Kinetix

5500

Kinetix

5500

Kinetix

5500

PowerFlex

527

PowerFlex 527 controls

induction motor on in-

feed conveyor

Kinetix 5500 controls

conveyors for precise

movement to evenly

space packages

CIP Motion and CIP Sync

provide common

instruction set and

coordinated motion for all

drives in system

CompactLogix

Controller



Velocity

Time

Corrective or Offset Moves are easy with incremental move instructions


Smart BeltBenefits of the CIP Motion Solution

Easy programming in Logix:

All of the motors are

commanded at the same

speed

Correction moves (forward or

reverse) are added to the

gapping conveyors

Reduced wiring

Any registration sensor can be

used globally by all drives

Common instructions and

minimized product cost

In Feed and Out Feed Conveyors:

PowerFlex 527

Gapping Conveyors:

Kinetix 5500

Sensors:

Sequence of Events Inputs


Pump and FanApplication Overview

Pumps Fans


Pump and FanApplication Discussion


Pumps Fans


Pump and FanApplication Discussion

Typical approach:

Dedicated stand-alone drive

Start/Stop interlock

Preset speed(s)

Pros:

Cheap and simple

Works great

Cons:

Hundreds of parameters to sort through for any changes (on HIM)

Drive replacement takes a skilled technician

Is there a better way?


Pump and FanHow Can You Solve This Using CIP Motion?

Pumps Fans

PowerFlex

527

CompactLogix

Controller

PowerFlex

755

PanelView

Plus


Pump and FanBenefits of the CIP Motion Solution

CIP Motion approach:

Component drive

Start/Stop interlock from

controller

Preset speed(s) from controller

Easy programming in Logix

Simplified drive replacement

There is a better way

Pump:

PowerFlex 527

Fan:

PowerFlex 755


ExtruderApplication Overview

Cutting(Tread skiver)

Cooling Line

Warm Up MillsWinding(Side-walls)

Extruder

•Simplex

•Duplex

•Triplex

•Quadraplex

Extruding(Tread or Side-wall extruder)

Product transfer

conveyorCut-off wheel


ExtruderApplication Discussion



Cooling Line


Extruder

•Simplex

•Duplex

•Triplex

•Quadraplex


Product transfer

conveyorCut-off wheel


ExtruderHow Can You Solve This Using CIP Motion?


Cooling Line


Extruder

•Simplex

•Duplex

•Triplex

•Quadraplex


PowerFlex

527

CompactLogixController

Kinetix

5500

PowerFlex 527 controls

induction motor on the

conveyor for product

transfer

CIP Motion and CIP

Sync provide common

instruction set and

coordinated motion for

all drives in system

Kinetix 5500 controls

cut-off wheel with

precise motion


ExtruderBenefits of the CIP Motion Solution

Easy programming in Logix:

Product conveyor is commanded

at desired line speed

Cut-off wheel can be cammed to

line speed

Common instructions and minimized

product cost

One location for all troubleshooting

and monitoring

Product Transfer Conveyor:

PowerFlex 527

Cut-off Wheel:

Kinetix 5500

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

To take away…

Support for High performance Servo and AC drives

Complete machine on a single and flexible network

Studio 5000 provides complete system support for industry leading Easy-Of-Use

EtherNet/IP & CIP Motion are open and broadly adopted

High system performance using standard EtherNet/IP

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

www.rockwellautomation.com

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Rev 5058-CO900F

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