OEM Application Brochures
Innovative Solutions to Improve Performance for Machine Builders
End users want equipment
delivered quickly and at a
reasonable price. They rely
on their Original Equipment
Manufacturers (OEMs) to
deliver high-performing,
flexible machines that can
easily integrate into a facility
while offering the business
the agility to react to ever
changing market demands.
To respond, OEMs must
evaluate strategic ways to
reduce costs and time to
market while innovating
to stay ahead of the
competition.
Rockwell Automation offers
standardized, scalable control
and information solutions to
allow OEMs to quickly scale
their equipment designs to
meet changing requirements.
These innovative automation
systems are packaged
with design tools, deep
knowledge of industry safety
standards, and security
expertise to help OEMs
navigate their most difficult
design challenges.
Content
Title
Publication
Number
Page
Number
Vertical Form Fill and Seal
Application Solution Brochure
OEM-BR044B-EN-P
4
Horizontal Form Fill and Seal
Application Solution Brochure
OEM-BR047B-EN-P
9
Ampoule and Vial Filling
Machine Brochure
OEM-BR046B-EN-P
14
Automation Control for
Cartoner Machines Brochure
OEM-BR062A-EN-P
19
Automation Control for Blister
Packaging Machines Brochure
OEM-BR020A-EN-P
24
Pasteurizer Solutions Brochure
OEM-BR045A-EN-P
30
Skid Solutions for Mixing and
Batching Brochure
OEM-BR048A-EN-P
35
Water Filtration Skid Solutions
Brochure
OEM-BR051B-EN-P
40
Converting, Print and
Web Handling
Automation Control for
Extruder Machines Brochure
OEM-BR052A-EN-P
46
Manufacturing &
Assembly
Stamping Press Application
Brochure
OEM-BR060C-EN-P
52
Packaging
Process
Packaging
Vertical Form Fill and Seal Application
Solution Brochure
Horizontal Form Fill and Seal Application
Solution Brochure
Ampoule and Vial Filling Machine Brochure
Automation Control for Cartoner Machines
Brochure
Automation Control for Blister Packaging
Machines Brochure
VFFS Application Solution
Vertical Form Fill And Seal Machine
Solutions for Advanced, Customized And Stand-Alone Machines
Machine/OEM Challenges
• Material splice and film roll placement.
• Film tension and gripping control.
• Unique mechanical designs for different products.
• Adjustable sealing pressure for different films and product sizes.
• Grip control / slippage.
• Proper force applied to the seal without energy waste.
Development Tools
• Design productivity tools –Standard and reusable software
modules, AOIs, Motion Analyzer, Safety Automation Builder.
• Modular code and HMI screens compliant with industry
accepted standards.
• Integrated Architecture® offers a scalable, multi-discipline Logix
platform in a single programming environment.
• Standard, off-the-shelf components.
• Engineering expertise and support to help decrease time-tomarket.
Product enters the system
through the forming tube.
Sensor Detects
End of Roll
Detecting Registration Mark to
Synchroniuze Sealing
and Cuting Operations
Edge Detection
(centering of film)
The forming collar shapes the
flat film into a round film tube.
Low friction rollers guide the
film to the forming area.
Vertical sealing bars seal
the edges of the film tube
together.
Detecting Overtravel of
Tension Arm
Film transport belts pull the
film through the forming
area.
Cross sealing jaws create top
and bottom seals in the
pouches, and cut the filled
pouch from the empty pouch.
Detecting
Jam at Outlet
Missing
Lug Check
Advanced Machine
Typical Architecture
• Modern Human Machine Interface – ability to access PDFs
and videos.
• Servo for faster changeover.
• Variable Frequency Drive on integrated architecture with
cost effectiveness.
• Reduction of panel space – I/O outside panel.
Studio 5000 Logix Designer®
Power programming which allows
program designs to be modular for
easier programming and higher
equipment safety. It saves significant
engineering time, enables faster
startup, and commissioning.
PanelView™ Plus 7
Human Machine Interface
Stratix™ Switch
EtherNet/IP
CompactLogix™ L2
Controller
Optimized electronic CAM profiles
motion control systems may ensure
smoother machine operation and
enhance machine mechanical life.
PowerFlex®
Drive
Kinetix®5500
Servo Drives
Studio 5000 Logix Designer®
Unwinder
Film Feed
Sealing Jaw
Packaging Speed
> 80 Packs Per Minute
Network
EtherNet/IP™
Controller
CompactLogix™ L2
Variable Frequency Drive
PowerFlex® 525
Servo Drive
Kinetix® 5500
Synchronous Motion
Up to Four axes
Filler
Jaw Unit
Up/Down
Optimal machine speeds by using
motion sizing tools - Motion Analyzer.
Diagnostic information regarding
Servos available on Human Machine
Interface.
Programmable for constant
seal-time for any machine speed.
Dynamic change of machine
speed and corresponding sections
synchronize with Controller Master
reference.
Application program based on Pack
ML State Model.
Higher machine speeds by
optimization of cycle.
Customised Machine –
Typical Architecture
• Food grade servos and wash-down I/O for better
sanitation.
• Single network based control architecture.
• Motion Analyzer – Advance Motion Design tools
that improve performance.
• Faster development cycle reduces time to market.
Scalable control with a single
programming environment
with integrated motion instructions.
PanelView Plus 7
Human Machine Interface
Higher capability and scalability
with up to 30 I/O modules and 16
motion axes.
Compact logix L3 Controller
Stratix Switch
EtherNet/IP
Integrated recipe management
recipe controls allow companies
to sidestep the repetitive process
of tuning machines during a line
change by saving and managing
multiple settings.
Kinetix 5500
Servo Drives
Common Human Interface
platform and networking services.
Studio 5000 Logix Designer
PowerFlex Drive
Film Feed
Unwinder
Packaging Speed
> 100 Packs Per Minute
Network
EtherNet/IP
Controller
CompactLogix L3
Variable Frequency Drive
PowerFlex 525
Servo Drive
Kinetix 5500
Synchronous Motion
More than 16 axes
Sealing Jaw
Jaw Unit
Up/Down
Rotary Disc Filler
Filler Nozzler
Built-in security capabilities
support security standards,
particularly ISA SP99. Collaborate
with IT security specialist company
such as Cisco to leverage on their
expertise.
Safety enabled throughout.
Stand-Alone Machine
Typical Architecture
Connected Components - proven optimal
configuration. Cost effective solutions.
Reduced panel engineering enables a shorter
time for wiring and thus improves machine
assembly time. Availability of plug-in modules
at the controller allow for expanded machine
features and functions.
Filling of
Materials
1
Material
Feeding
Vertical
Sealing
2
Web
Pulling
3
Sealing
and Cutting
Common programming software
Connected Components Workbench™
software for Micro800®, PowerFlex
(AC Drives), PanelView™ 800.
PanelView™ 800
Human Machine Interface
Film Registration
Sensor
Micro850® Controller
Advanced Motion Control
Supports up to 3 motion axes using
Pulse Train Output.
EtherNet/IP
0
1 2
6 7
8
9
Film Feed
Encoder
IN
POWER
RUN
FAULT
USB
FORCE
COMM
0
1 2
3 4
5
6 7
8
9
10 11 12 13 14 15 16 17 18 19
OUT
Micro850
PTO
Auger Feed
Film Pull
High flexibility
Plug-in and expansion modules
allow you to optimize your machine
cost by choosing performance and
functionality specific to your machine
needs.
Publication OEM-BR044B-EN-P – September 2015
5
20 21 22 23 24 25 26 27
Versatility of interfaces
Up to 6 high speed counter inputs
and up to 3 Pulse Train Outputs
over embedded digital I/O. Up to 5
plug-ins and up to 4 expansion I/O
modules.
Touch probe function
Able to capture accurate registration
position at high speeds with built-in
hardware.
3 4
10 11 12 13 14 15 16 17 18 19
PTO
Connected Components
Workbench Software
PTO
Cross Jaw
Discrete/ Analog
Film Unwind
Packaging Speed
< 80 Packs Per Minute
Network
Modbus / Pulse Train Output
Controller
Micro800® Family
Variable Frequency Drive
PowerFlex® 523
Servo Drive
Kinetix® 3 / Kinetix® 300
Motion
Up to 3 axes
PowerFlex 523 Drive
Copyright ©2015 Rockwell Automation, Inc. All Rights Reserved.
HFFS Application Solutions
Horizontal Form Fill & Seal Machine
Horizontal Flow Wrap Line
Helping You To Design, Develop and Deliver
Machine Basics & Challenges
• Wrapper film feeding in-line to product length.
• Product feeding into wrapper zone and matching the print
mark to align with product length.
• Rotary knife or cross sealer to synchronize with wrapper linear speed and cut length.
• Adjust machine speed without stopping running machine On fly machine change.
• Empty wrapper out leads to wastage.
Pre-tested & Validated Instructions
• Advance registration control with length compensation and position
correction of laminate.
• Advance CAM design with controlled jerk for rotary knife
and film movement.
• Advanced smart belt control algorithm for smooth product
flow in to wrapper.
• Sample code to support `No Product No Bag` feature.
Benefits of Rockwell Solutions
• Reduction of lamination wastage due to “No Product No Bag” feature.
• Improved OEE of line due to auto-recovery of most common
production errors or faults.
• Improved productivity of machine parts as they operate with
controlled jerks with reduced vibration.
• Support of machine code & operator interface in-line to global
standards (PackML, ISA 88 Etc).
• Faster time to build HFFS Line.
• Object oriented combined with common network based architecture to
support modular design.
• Modular program concepts to reuse of code.
• Optimized mechanical components with increased line performance.
HFFS - Intermittent or Continuous Machines
Typical Architecture for Customized Machines
• Advanced Human Machine interface with ability to set machine variabilities
such as wrapper length, laminate slip factor, sealing time, adaptable speeds to
match upstream and so forth.
• Advance Motion control enables machine to
improve with more flexibility.
• Servo motors with food grade and wash down environment,
exclusively required in Food and Life Science Industries.
Studio 5000 Logix Designer™
power programming which allows
program designs to be modular
for easier programming and higher
equipment safety. It saves significant
engineering time, enables faster
CompactLogix
L3
startup, and
commissioning.
PanelView Plus
Human Machine Interface
Stratix Switch
EtherNet/IP
Controller
Compact Logix L2
Controller
Optimized electronic CAM profiles
motion control systems may ensure
smoother machine operation and
enhance machine mechanical life.
PowerFlex Drive
Optimal machine speeds by using
motion sizing tools - Motion Analyzer.
Film Feed
Diagnostic information regarding
Servos available on Human Machine
Interface.
Kinetix 5500
Servo Drives
Studio 5000
Logix Designer
Programmable for constant
seal-time for any machine speed.
In Line Pusher 1
In Line Pusher 2
Packaging Speed Up to 250 Packs per Min.
Network
EtherNet/IP™
Controller
CompactLogix™ L2
Variable
Frequency Drive
PowerFlex® 523
Servo Drive
Kinetix®5500
Synchronous Motion Up to Four Axes
Cross Pusher 1
Cross Pusher 2
Dynamic change of machine
speed and corresponding sections
synchronize with Controller Master
reference.
Application program based on Pack
ML State Model.
Typical Architectures
Various Range of HFFS Machines
Scalable Architectures
with common control
system environment
to address low speed
machines to high
performance lines
by connecting over
Upstream Equipment
to Downstream
packaging lines.
ControlLogix L6
All Servo System
High
Performance
Lines
CompactLogix L3
with Kinetix 350
or Kinetix 5500
& AC Drives
Low Speed
Solution
CompactLogix L2
System with EtherNet/IP
Scalable control with a single
programming environment
with integrated motion instructions.
PanelView Plus
Human Machine Interface
Higher capability and scalability
with up to 30 I/O modules and 16
motion axes.
Compact logix L3 Controller
Stratix Switch
EtherNet/IP
Integrated recipe management
recipe controls allow companies
to sidestep the repetitive process
of tuning machines during a line
change by saving and managing
multiple settings.
Kinetix 5500
Servo Drives
Common Human Interface
platform and networking services.
Studio 5000
Logix Designer
PowerFlex Drive
Smart Belt
Conveyor -1
Smart Belt
Conveyor -2
Film Feed
Packaging Speed
Up to 600 Packs per Min.
Network
EtherNet/IP™
Controller
CompactLogix™ L3
Variable
Frequency Drive
PowerFlex® 525
Servo Drive
Kinetix® 5500
Synchronous Motion
Up to Sixteen Axes
Film Feed Drive
In Feed Belt /
Lug Chain Conveyor
Rotary /
Cross Sealer -1
Rotary /
Cross Sealer -2
Built-in security capabilities
support security standards,
particularly ISA SP99. Collaborate
with IT security specialist company
such as CISCO to leverage on their
expertise.
Safety enabled throughout.
Intermittent Machine -
Typical Architecture for Entry Level
Connected Components - proven optimal configuration.
Cost effective solutions. Reduced panel engineering
enables a shorter time for wiring and thus improves
machine assembly time. Availability of plug-in modules
at the controller allow for expanded machine
features and functions.
Common Programming Software
Connected Components Workbench
for Micro800®, PowerFlex® (AC Drives),
PanelView™ Components.
PanelView™ 800
Human Machine Interface
Micro850® Controller
Advanced Motion Control
supports up to three motion axes
using ‘Pulse Train Output’.
COMO • I-00 • I-01 • I-02 • I-03 • I-04 • I-05 • I-06 • I-07
COM1 • I-08 • I-09 • I-02 • I-10 • I-11 • I-12 • I-13
2080-LC50-24QBB
PWR
MAC ID
00:00:BC:CE:3A:10
1
Stratix™ Switch
Shafted Machine
Master Encoder
MS NS
2
3
Micro850™
4
Versatility of Interfaces up to six
high speed counter inputs and up
to three ‘Pulse Train Output’ over
embedded digital I/O. Up to five
plug-ins and up to four expansion
I/O modules.
High Flexibility plug-in and
expansion modules allow you to
optimize your machine cost by
choosing performance and
functionality specific to your
machine needs.
Touch Probe Function able to
capture accurate registration position
at high speeds with built-in hardware.
Publication OEM-BR047B-EN-P – July 2015
1783-US5T
RUN-REM-PRG
5
+DC
-DC
• 24
24
COM • 0-00 CM1 • 0-01 CM2 • 0-02 • 0-03 • 0-04 • 0-05 CM3 • 0-06 • 0-07 • 0-08 • 0-09
Kinetix Component
Class Servo Drive
Film
Registration
Sensor
PTO
Film Pull Belt
Kinetix Component
Class Servo Drive
Connected Components
Workbench Software
Cross Jaw
PowerFlex Drive
MODBUS RTU
Packaging Speed
<80 Packs Per Min.
Network
Controller
Variable
Frequency Drive
Servo Drive
Motion
MODBUS RTU, Ethernet/IP
Micro800 Family
PowerFlex® 523
Kinetix ® 3 and 300
Up to Three Axes
Film
Unwind
Infeed Conveyor
PowerFlex Drive
Copyright ©2015 Rockwell Automation, Inc. All Rights Reserved.
Ampoule and Vial Filling Machine
Safe, Secure and Sustainable Solution
Challenges
Globalization, pricing pressures, and increasingly stringent environmental
regulations are constant challenges to pharmaceutical companies.
The bottom line is to find a solution that provides better and faster results,
delivers projects faster with better regulatory compliance and a longer
sustained value.
In addition, machine builders specifically expect ampoule filling machines
to be:
• Standard Modular Solution:
Mix and match ampoule filling machine functions specific to products,
customer applications, and local market demands, with pre-developed
Add-on Instructions (AOI) for all potential end user requirements.
• Scalable:
Full range products with the ability to customize features to particular
market and add functionality that are based on customers’ requirements.
• Cost-effective solution that reduces machine integration, mechanical,
electrical optimization and wiring costs while shortening software
development time and maintenance.
• Global support:
Fast response and remote access to decrease end-user downtime.
Recycled water flushing washing
the bottle outside
Bottle infeeding on
mesh belt
Compress air blowdrying the bottle
Ultrasonic tank
removes the particle
inside the bottle
Infeeding with
screw, steady and
smooth
Water-alternatinggas ejection flushing
Hoist wheels put bottle
into fine washing section
Outfeeding on mesh
belt steadily
Faster time to build Ampoule Filling Line
• Flexible common network based architecture.
• Modular program concepts for easy re-use of code.
• Premier Integration capabilities to increase flexibility & performance.
• Global support availability to ensure minimum downtime.
Advanced Machine
Typical Architecture
• Modern Human Machine Interface – ability to access
videos and PDF files.
• Advanced servo system for one button changeover.
• Variable Frequency Drive in the integrated
architecture.
• Customized filling time for filling process optimization.
PanelView™ Plus
Human Machine Interface
Studio 5000 Logix Designer®
Power programming which allows
program designs to be modular
for easier programming and higher
equipment safety. It saves significant
engineering time, enables faster
startup and commissioning.
PanelView Plus 1250
Optimized electronic CAM profiles
on motion control systems may ensure
smoother machine operation and
enhance machine mechanical life.
Stratix™ Switch
Diagnostic information regarding
Servos available on Human Machine
Interface.
ArmorPOINT® 0/1
Faceplate functionality diagnosis
allows easy monitoring and
troubleshooting
Optimized variable frequency
drive commissioning that
improves efficiency, increases
quality and reduces downtime
Programmable filling curves
reduce carbonization rate
Kinetix® Servo Drives
ArmorPower®
Cost savings by using standard
competitive solutions.
Machine Speed
> 40 Cycles Per Minute
Network
EtherNet/IP
Controller
CompactLogix™ L3 OR ControlLogix L7
Human Machine Interface PanelView Plus 6
Variable Frequency Drive
PowerFlex® 525
Servo Drive
Kinetix 5500
Synchronous Motion
More than Sixteen Axes
Advanced Machine
Typical Architecture
• Optimized machine efficiency: online filling volume
adjustment.
• No bottle no filling program: saves product and raw
material and reduce wastage.
• Open interface for online check weight printing etc.
• One single network.
CompactLogix L3 Controller
ControlLogix L7 Controller
ISPE GAMP5 based methodology
To help ensure quality of the
pharmaceutical products.
Capability and experience of the
regulatory compliance with
FDA, EU, and China SFDA GMP.
PowerFlex Drive
PowerFlex Drive
Capability and experience to verify
Equipment Control System, Batch
Control System, Manufacturing
Execution System, and relevant
Interfaces.
PowerFlex Drive
The ampoule filling machine
control system is a 21 CFR Part 11
compliance system to help verify
electronic records and signatures are
trustworthy, reliable, and equivalent to
paper records.
Kinetix Servo Drive
Support of Flexible Mass
Serialization. Industry Regulation is
becoming stringent. With Adaptable
and Modular solutions from RA
combine Serial Data Engagement with
High speed device management.
Kinetix Servo Drive
Master
Infeed Screw
Stack Screw
Outfeed Screw
Pump Valve
4-16 Filling Motors
Stand-Alone Machine
Typical Architecture
Connected Components - proven optimal configuration.
Cost effective solutions. Reduced panel engineering enables
a shorter time for wiring and thus improves machine assembly
time. Availability of plug-in modules at the controller allow for
expanded machine features and functions.
Common Programming Software
Connected Components Workbench
for Micro800®, PowerFlex (AC Drives),
PanelView™ 800.
PanelView 800
Human Machine Interface
Micro800® Controller
EtherNet/IP
Kinetix 3/300 servo drives with
embedded indexing simplifies motion
control.
0
1 2
3 4
Embedded communications:
USB for configuration and monitoring,
Ethernet for HMI, Serial Port for simple
device connectivity.
Publication OEM-BR046B-EN-P - September 2015
6 7
8
9
10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
IN
POWER
RUN
USB
FAULT
FORCE
COMM
0
1 2
3 4
5
6 7
8
9
10 11 12 13 14 15 16 17 18 19
OUT
Micro850
Versatility of Interfaces up to six
high speed counter inputs and up
to three ‘Pulse Train Output’ over
embedded digital I/O. Up to five
plug-ins and up to four expansion
I/O modules.
High Flexibility plug-in and
expansion modules allow you to
optimize your machine cost by
choosing performance and
functionality specific to your
machine needs.
5
Digital I/O
Nozzle Up/Down
Control (Index)
Discrete/ Analog
Connected Components
Workbench Software
Main Drive
Discrete/ Analog
In-feed Conveyor
Machine Speed
<40 Cycles Per Minute
Network
EtherNet/IP, USB
Controller
Micro800 Family
Variable Frequency Drive
PowerFlex 523
Servo Drive
Kinetix 3 and 300
Motion
1 Indexed servo axes
Discrete/ Analog
Bottle Rotation
for Heating
Copyright ©2015 Rockwell Automation, Inc. All Rights Reserved.
Automation Control for Cartoner Machines
Solutions for Advanced, Customized and Stand-Alone Machines
image courtesy of ADCO Manufacturing
Machine Builder Efficiency
• Flexible, modular machine and code design for maximum
reuse potential.
• Creating differentiation in a competitive / global market.
• Partnership association with key suppliers.
Machine Optimization
• Smoother and faster machines that need to adopt quick changes.
• Increased machine flexibility to overcome product variability.
• Information enabled machine designs.
• Functional machine safety to compete in global market.
End User
• Ease of use and maintenance, graphical diagnostics,
and OEE capabilities.
• Secured remote access for online information including parts
ordering and maintenance schedules.
• Seamless integration and support with rest of production line.
• Optimal power consumption and reduce product wastage.
Erecting
Carton erected into
flight chain
Loading
of line
To endipment
equ
r
e minoin
d
i
s
d
a
Non LoFlaps tucked
inor
de m in
i
s
g
d
in
Load ps tucke
fla
Carton Handling
(outfeed)
Product insertion
section
feed
uct In veyor
d
o
r
P
con
Loading side flaps
prepared to load
Extended machine lifecycle and noise reduction
• Flexible control architectures can effectively manage the various methods
of product handling.
• Reduced manufacturing time and cost.
• Global availability of replacement parts and remote diagnostics capability.
Advanced Machine
Typical Architecture
• Advanced Human Machine Interface with ability to set the machine
variability which includes pick up delay, carton drop angle, product
infeed slip factor, and adaptable speeds to match upstream.
• Advanced motion control improves machine flexibility.
• Servo motors with food grade and wash down environment,
required in consumer packaged goods industries.
• Leverage NPNC (No Product, No Carton) feature.
• Secured Remote Access providing real-time
data collection, alarming, analytics,
and troubleshooting.
Secured
Remote Access
PanelView™ Plus 7
Human Machine Interface
Studio 5000 Logix Designer®
power programming which allows
program designs to be modular
for easier programming, saving
significant engineering time with faster
startup and commissioning.
Controller L3
Guardmaster®
Safety Relay
Stratix™ 5700
Optimized electronic CAM profiles
motion control systems can help
ensure smoother machine operation
and improved machine mechanical
life.
Studio 5000 Logix Designer
PowerFlex 525
Kinetix® 5500 Servo Drive
5700
5700
5700
5700
Optimal machine speeds by using
motion sizing tools -Motion Analyzer.
5700
5700
527
527
Case Conveyor
In-Feed
Conveyor
Smart Belt
Conveyor 1
Product
Transfer
Smart Belt
Conveyor 2
Blank Carton
Transport
Cartoner Speed
Up to 300 Cartons Per Minute
Network
EtherNet/IP™
Variable AC Drive
PowerFlex® 527
Servo Drives
Kinetix 5500
Synchronized Motion
Up to Sixteen Axes
Loaded Carton
Transport
Carton Guide
Adjustment
Human Machine Interface includes
servo diagnostic information.
Dynamic change of machine
speed and corresponding sections
synchronize with Controller Master
reference.
Application program based on Pack
ML State Model.
Custom Machine
Typical Architecture
• Continuous operation, fully automatic with higher
throughput, capable handling many carton variations.
• Manage critical sections with advanced motion and
sophisticated actuators.
• Tightly integrated to upstream line with adaptable speeds.
• Improved machine productivity and reduced
maintenance.
• Leverage NPNC (No Product, No Carton) feature.
• Secured Remote Access providing real-time data
collection, alarming, analytics, and troubleshooting.
Secured
Remote Access
Scalable control with a single
programming environment
with integrated motion instructions.
GuardLogix® Safety Controller
EtherNet/IP™
Logix5573S™
Logix55L7SP™
EtherNet/IP™
Logix5573™
PanelView Plus 7
Human Machine Interface
Stratix 5700
Higher capability and scalability
with up to 30 I/O modules and 100
motion axes.
PowerFlex 527 Drive
9 9 9
1734-AENTR Series-B
MS
24VDC
Safety Sink
Input
Network
Activity
IO Modules
Machine and Safety
Link 1
Activity
Status
Network
Status
Point Bus
Status
System
Power
Field
Power
IP ADDRESS
Studio 5000 Logix Designer
Integrated recipe management
simplifies line changing process by
managing multiple settings.
NS
LK
Module
Status
P
W
R
1734-IB8S
Common Human Interface
platform and networking services.
Link 2
Activity
Status
PowerFlex 525
Kinetix 5700 Servo Drive
Mod
Net
Mod
Net
5700
5700
Risk of electric shock.
Power off and wait 5 min.
2
Risk of electric shock.
Power off and wait 5 min.
1
1
1
4
5700
Mod
Net
11
I/O
6
1
6 1
I/O-B
1
1
4
10
5
10 5
UFB-A
10
UFB-b
5700
Risk of electric shock.
Power off and wait 5 min.
11
I/O
6
1
10
5
I/O-A
6 1
I/O-B
6
4
I/O
UFB
Mod
Net
5700
22
11
1
1
Mod
Net
Risk of electric shock.
Power off and wait 5 min.
22
6
I/O
5
Risk of electric shock.
Power off and wait 5 min.
2
1
I/O-A
5700
Risk of electric shock.
Power off and wait 5 min.
2
4
I/O
Mod
Net
5700
Risk of electric shock.
Power off and wait 5 min.
22
11
1
1
Mod
Net
5700
Risk of electric shock.
Power off and wait 5 min.
22
2
Mod
Net
I/O
527
5
UFB
10 5
UFB-A
10
UFB-b
Infeed/Outfeed
Conveyor
Smart In-feed
Solution - Robotics
Packaging Speed
400 -600 Cartons Per Minute
Network
EtherNet/IP
Controllers
ControlLogix® 5570
Servo Drives
Kinetix 5700
Synchronized Motion
As high as 90 Axes
Blank Carton
Transport
Carton
Loader
Flap
Closer
Loader Carton
Transport
Built-in security capabilities
support security standards,
particularly ISA SP99. Collaborate
with IT security specialist company
such as CISCO to leverage on their
expertise.
Safety enabled throughout
under unsafe condition of “Machine”,
“Safe shut down” will be performed
by integrating safety signals (safe
torque off in drives and motion) to
control system.
- This enables faster recovery of
machine thus improves
productivity.
Stand-Alone Machine
Typical Architecture
• Leverage Connected Components for optimized
configuration using a common software.
• Simplified motion using indexing drives.
• Controller plug-in modules allow for cost effective
expansion of machine features and functions.
Common Programming Software
Connected Components Workbench®
software for Micro800®, PowerFlex (AC
Drives), PanelView™ 800.
PanelView™ 800
Human Machine Interface
Registration Sensor
Micro850® Controller
EtherNet/IP
Kinetix 3/300 servo drives with
embedded indexing simplifies motion
control.
0
1 2
3 4
5
6 7
8
20 21 22 23 24 25 26 27
IN
2080-OF2
POWER
1
RUN
FORCE
1 2
2080-OF2
3
4
A COM COM COM COM
COMM
0
2
B VO-0 CO-0 VO-1 CO-1
FAULT
USB
Master Encoder on
Upstream Conveyor
9
10 11 12 13 14 15 16 17 18 19
3 4
5
6 7
8
1
2
3
4
B VO-0 CO-0 VO-1 CO-1
A COM COM COM COM
9
10 11 12 13 14 15 16 17 18 19
OUT
Micro850
Versatility of Interfaces up to six
high speed counter inputs and up
to three ‘Pulse Train Output’ over
embedded digital I/O. Up to five
plug-ins and up to four expansion
I/O modules.
High Flexibility plug-in and
expansion modules allow you to
optimize your machine cost by
choosing performance and
functionality specific to your
machine needs.
Digital I/O
Carton Pick Up & Erection
(Index)
Digital I/O
2
Connected Components
Workbench Software
Feeder (Index)
Discrete/Analog/Modbus
Touch Probe Function in
2080-MOT-HSC plug-in captures
accurate registration position.
Serial Port in 2080-SERIALISOL
plug-in adds isolation for
Modbus RTU.
Publication OEM-BR062A-EN-P – August 2015
In-feed Conveyor
Discrete/Analog/Modbus
Packaging Speed
< 180 Cartons Per Minute
Network
EtherNet/IP, USB, Modbus RTU
Controller
Micro800 Family
Variable Frequency Drive
PowerFlex 523
Servo Drives
Kinetix 3 / Kinetix 300
Motion
2 Indexed servo axes, master encoder feedback axis
Upstream Conveyor
Copyright ©2015 Rockwell Automation, Inc. All Rights Reserved.
Automation Control for Blister Packaging Machines
Solutions to Help You to Design, Develop, and Deliver Innovative Machines
Blister Packing Machine Basics and Challenges
• Formation of uniform blisters on aluminum or plastic sheet through
thermal forming process.
• On-the-fly feeding of product (capsule or tablet) into blisters.
• Print mark registration control for accurate sealing of blisters, at
desired length.
• Adjust machine speed without interrupting running machine on-the-fly machine change.
• Reduce wastage due to unfilled blisters or improper sealing.
Machine Builder Efficiency
• Flexible, modular machine, and code design for maximum reuse
potential.
• Creating differentiation in a competitive and global market.
• Partnership association with key suppliers.
Machine Optimization
• Smoother and faster machines that need to adopt changes quickly.
• Increased machine flexibility to overcome product variability.
• Information enabled machine designs.
• Functional machine safety to compete in global market.
End User Challenges
• Ease-of-use and maintenance, graphical diagnostics, and OEE
capabilities.
• Secured remote access for online information including parts ordering
and maintenance schedules.
• Seamless integration and support with rest of production line.
• Optimal power consumption and reduce product wastage.
Automatic feeding system
(option)
PanelView™ Plus
HMI
Aluminum foil feeding
5
4
era
Cam
Sealing
station
Perforation
10
Product
8
6
9
Trimming
7
Coding &
embossing
1
2
Forming film reels
Forming film
preheating
3
Pocket forming
Extended machine lifecycle and reduced noise
• Flexible control architectures can effectively manage the various methods of product handling.
• Reduced manufacturing time and cost.
• Global availability of replacement parts and remote diagnostics capability.
Advanced Machines
Typical Architecture
• Advanced human machine interface (HMI) with ability to set machine variabilities
such as wrapper length, laminate slip factor, sealing time, and
adaptable speeds to match upstream.
• Advance motion control enables machine to improve
with more flexibility.
• Servo motors with food grade and wash down
ratings designed to meet requirements in food and life
sciences industries.
• Secured remote access provides real-time data collection,
alarming, analytics, and troubleshooting.
PanelView Plus HMI
Secured
Remote Access
CompactLogix™ L2
Controller
Stratix 8000™
Ethernet Switch
EtherNet/IP Network
LK
9 9 9
1734-AENTR Series-B
MS
Network
Activity
Link 1
Activity
Status
NS
24VDC
Safety Sink
Input
Module
Status
Network
Status
Point Bus
Status
System
Power
IP ADDRESS
Field
Power
P
W
R
1734-IB8S
I/O Modules
Link 2
Activity
Status
Optimized
electronic
CompactLogix
L3 CAM profiles
can help Controller
ensure smoother machine
operation and improve machine
mechanical life.
Optimal machine speeds by
using Motion Analyzer Software, a
comprehensive motion-application sizing
tool.
PowerFlex® 525
AC Drive
Studio 5000 Logix
Designer® Software
Studio 5000 Logix Designer®
Power programming offers modular
program designs for easier programming,
saving significant engineering time, faster
startup, and commissioning.
Human Machine Interface includes servo
diagnostic information.
Kinetix® 5500
Servo Drives
Film Unwinder
Dynamic change of machine speed
and corresponding sections synchronize
with Controller Master reference.
Application program based on Pack ML
State Model.
Sealing & Cutting
Packaging Speed Up to 250 Packs per Min.
Network
EtherNet/IP™
Controller
CompactLogix™ L2
Variable
Frequency Drive
PowerFlex® 525
Servo Drive
Kinetix®5500
Synchronous Motion Up to Four Axes
Product Feeding
Thermo Forming
Custom Machines
Typical Architecture
• Continuous operation, fully automatic with higher
throughput, capable to handle many carton variations.
• Manage critical sections with advanced motion and
sophisticated actuators.
• Tightly integrated to upstream line with adaptable
speeds.
• Improved machine productivity and reduced
maintenance.
• Secured remote access providing real-time data
collection, alarming, analytics, and troubleshooting.
PanelView Plus HMI
Secured
Remote Access
1oo2 Architecture
PLe (ISO13849)
Compact GuardLogix®
Compact Guard Logix
SAFETY CPU
SFTY RUN
SFTY TASK
SFTY LOCK
SFTY OK
E4:90:69:A1:1A:EE
Stratix Managed
Ethernet Switch
EtherNet/IP Network
9 9 9
1734-AENTR Series-B
MS
24VDC
Safety Sink
Input
Network
Activity
Network
Status
Point Bus
Status
System
Power
Field
Power
IP ADDRESS
Kinetix 5500/5700 Servo Drives
NS
LK
Module
Status
Link 1
Activity
Status
ISPE GAMP5 based methodology
To help ensure quality of the
pharmaceutical products. Capability
and experience of regulatory
compliance with FDA, EU, and China
SFDA GMP. Capability and experience
to verify Equipment Control System,
Batch Control System, Manufacturing
Execution System, and relevant
Interfaces.
P
W
R
1734-IB8S
Link 2
Activity
Status
PowerFlex 525 AC Drives
I/O Modules Standard & Safety
21 CFR Part 11 compliant control
system to help verify electronic
records and signatures are trustworthy,
reliable, and equivalent to paper
records.
Built-in security capabilities
support security standards, particularly
ISA SP99. Collaborate with IT security
specialist companies such as CISCO® to
leverage on their expertise.
Robotics
Integration
Conveyor Control
Packaging Speed
Up to 600 Packs per Min.
Network
EtherNet/IP
Controller
CompactLogix L3
Variable
Frequency Drive
PowerFlex 525
Servo Drive
Kinetix 5500/5700
Synchronous Motion
Up to Sixteen Axes
Motion Control
Various Section of
Blister Packaging Machine
Integrated safety assists with
“safe shut down” of machine. Safety
functions including Safe Torque-off
and Safe Speed Monitor in the drives,
enable faster machine recovery for
improved productivity.
Stand-Alone Machine
Typical Architecture
• Leverage Connected Component solutions for simple
blister packaging solutions using one common
configuration software with broad portfolio of safety
components in the industry.
• Simplified motion using PLC Open instructions.
• Controller plug-in modules offer cost-effective
expansion of machine features and functions.
Common Programming Software
Connected Components Workbench™
software for Micro800® controller,
PowerFlex AC drives, PanelView 800 HMI,
and Guardmaster® 440C-CR30 safety relay.
PanelView 800
Human Machine Interface
Micro850® Controller
COMO • I-00 • I-01 • I-02 • I-03 • I-04 • I-05 • I-06 • I-07
COM1 • I-08 • I-09 • I-02 • I-10 • I-11 • I-12 • I-13
Shafted Machine
Master Encoder
2080-LC50-24QBB
MAC ID
Advanced Motion PTO
supports up to three motion axes using
‘Pulse Train Output’.
00:00:BC:CE:3A:10
A B
Z O
PWR
MS NS
2080-MOT-HSC
1
B 0+ A+ B+ Z+
A 0- A- B- Z-
Stratix Switch
2
Micro850™
3
RUN-REM-PRG
Versatility of Interfaces up to six high
speed counter inputs and up to three
‘Pulse Train Output’ over embedded digital
I/O. Up to five plug-ins and up to four
expansion I/O modules.
5
+DC
-DC
• 24
24
COM • 0-00 CM1 • 0-01 CM2 • 0-02 • 0-03 • 0-04 • 0-05 CM3 • 0-06 • 0-07 • 0-08 • 0-09
Kinetix Component
Class Servo Drive
1783-US5T
4
PTO
High Flexibility plug-in and expansion
modules allow you to optimize your
machine cost by choosing performance
and functionality specific to your machine
needs.
Touch Probe Function to capture
accurate registration position at high
speeds with built-in hardware.
High Speed Counter module supports
up to 4 feedback axes. Position feedback
from encoders or servo drives.
Publication OEM-BR020A-EN-P – March 2016
Film
Registration
Sensor
Aluminium foil index
Kinetix Component
Class Servo Drive
Connected Components
Workbench Software
PTO
MODBUS
RTU
MODBUS
RTU
Thermo
Forming
PowerFlex Drive
Unwinder
Packaging Speed
<80 Packs Per Min.
Network
Controller
Variable
Frequency Drive
Servo Drive
Motion
MODBUS RTU, Ethernet/IP
Micro800 Family
PowerFlex 523
Kinetix 3 and 300
Up to Three PTO Axes
Outfeed
Conveyor
PowerFlex Drive
Copyright ©2016 Rockwell Automation, Inc. All Rights Reserved.
Process
Pasteurizer Solutions Brochure
Skid Solutions for Mixing and Batching Brochure
Water Filtration Skid Solutions Brochure
Pasteurizer Solutions
Automation Control Solutions for Pasteurization
Rockwell Automation Solution
Rockwell Automation Solution
The Rockwell Automation emphasis of “COLLABORATING
WITH YOU”, allows Machine and Equipment Builders
to effectively compete in this global market place by
differentiating itself. Machine and Equipment Builders
need to define value beyond the cost of machines
and maximize company’s performance.
Whether measured from a business, commercial or
technical perspective, Rockwell Automation can help
improve Machine and Equipment Builders’ performance
with services and solutions to lower the Total Cost of
DESIGN, DEVELOP and DELIVERSM machines and meet
customers’ requirements.
Design
Maximize design productivity, reducing design
labor time and cost and also creating consistent,
modularized designs help improve manufacturing
efficiency to meet delivery needs.
Scalable Control Solutions
Process Objects Libraries
Functional Safety
Standards Compliance
Develop
“Faster Time to Market” to meet customer delivery
commitments is important to be competitive in
today’s economy.
Engineering Workstation
Modular Programming
EtherNet/IP Network
On Machine Solutions
Hardware Integration
Scalable Data Collection and Decision
Support Tools
Deliver
Delivery lead time is often a considerable factor
important for Machine and Equipment Builders to help
communicate effectively to the extent to which
machines can be delivered in a shorter time period.
Information Enabled Solutions
Remote Monitoring
Network and Security Services
Global Service and Support
DESIGN
Design Productivity
Extensible Engineering
Scalability
Global Standards
Risk Assessment
Design for Sustainability
DEVELOP
Time to Market
Supply Chain Efficiency
Flexible Equipment Models
Simplified Integration
Design Optimization
DELIVER
Commissioning
Global Service & Support
Reliability & Quality
Machine Performance
Core Process Control Solution
Typical Architecture for High Temperature Short Time (HTST)
or Ultra High Temperature (UHT) Pasteurizer Skid
Pasteurizers are being used increasingly in food & beverage production worldwide. The ability to offer ‘right
sized’ efficient equipment is essential to remain competitive. Rockwell Automation solutions can give Machine
and Equipment Builders a competitive advantage by optimizing energy usage, maximizing throughput and
reducing waste. Our scalable solutions using standardized objects can deliver a competitive advantage and
reduce time to market to food & beverage equipment builders.
PanelView™ Plus
Human Machine Interface
CompactLogix™ L3
Controller
Supervisory Connection Stratix™ Switch E/IP
Raw Supply
ArmorPOINT® I/O
Hot Water
Supply
LC
Chilled Water
Supply
ArmorPOINT® I/O
LSH
Hart
TIC
Hart
TIC
LSL
PT
PIC
Supply
Tank
I
TT
PIC
SC
PT
TT
AB or E+H Temp
Sensor
SC
Product to Form & Fill
Heater
FT
FIQ
Chiller
Hot Water
Return
Booster Pump
Supply Pump
PowerFlex® Drive
Chiller Water
Return
PowerFlex® Drive
Pressure/Flow Meter
Benefits of Integrated Architecture
Scalable solution
EtherNet/IP e.g. premier integration that allows savings
On commissioning costs
Real-time information
Pre validated process library
Seamless integration with analytical instruments
Plate or Tube Heat
Exchanger
Network
EtherNet/IP
HART and Profibus
where applicable for
instrumentation
Controller
CompactLogix™ L1 / L2 / L3
Variable Frequency Drive
PowerFlex® 525
Instrumentation
I/O
Allen-Bradley 4-20mA
Temperature Sensors,
E+H (Endress + Hauser)
EtherNet/IP and flow
instrumentation
Point / Compact /
ArmorPOINT® I/O.
All options can be used
Core Process Control Solution
Typical Architecture for High Temperature Short Time (HTST)
or Ultra High Temperature (UHT) Pasteurizer Skid
Rockwell Automation Core Solution Offering
Rockwell Automation delivers the tools and expertise to help OEMs build equipment control solutions
that are more scalable, highly reusable, and plug-and-play enabled.
System Architecture
Integrated Architecture® provides scalable solutions to
meet specific requirements through a wide range of
controllers, I/O, HMI, and power control devices
EtherNet/IP network offers scalable, high bandwidth,
fast and ‘future ready’ control network architecture,
compatible with the enterprise’s IT network
– Incorporates enabling technologies including cloud,
mobile and personal devices
– Simplifies remote monitoring and support utilizing
unmodified Ethernet
Developed based on design-for-security philosophy to
facilitate physical and logical access control, IP preservation
and protection against external threats
Provides integration to process control networks
including seamless EtherNet/IP, HART, FOUNDATION
Fieldbus, and Profibus-PA
Power Integration
Premier integration of power control devices, such as
variable frequency drives and motor control centers, saves
time and energy
Provides real-time diagnostics for asset management
Programming Software
Engineering and Configuration Software
Integrated design and configuration environment shorten
debugging time and minimize human errors
Faster software development cycle
Reduced equipment cost
Drives consistent specifications
Helps preserve OEM’s Intellectual Property
Modular programming
Easier to expand the program with the copy function
Smoother and more consistent data flow
(Unit
EM
CM)
Easy for recipe management
Programming standardization
Reusable code
S88 Compliant Running States Management
Compliance to standards for batch control and definition
of the physical model
Design running states flow to ensure equipment can
work safely. Specially designed for pasteurizer/UHT/HTST
Logix Batch & Sequence Manager delivers cost-effective
recipe management for a single unit – ideal for “clean-inplace” and “steam-in-place”
Information Management
Easily integrates to MES and ERP systems for real-time
information and better decision making
Population of Historian and audit data, supporting cGMP
and compliance in regulated industries
Immediate diagnostic information enables quick
troubleshooting and intervention
Drives continuous improvement using trends, dashboards
and reports
Process Libraries
PIDE Autotune function on Human Machine Interface
Standard faceplates for common devices such as pump,
valve, PID, instruments, switches
Quickly assemble applications utilizing Add-On
Instructions, Global Objects and Faceplates
Reduce engineering time with pre-defined objects for
common functions
Rapidly develop information-rich operator displays
Simply configure a device from I/O to operator interface
Advanced Process Control Instructions
Coordinated control function block can be utilized
in processes where several control variables can be
manipulated to control one process variable
Internal Model Control (IMC) helps regulate temperature
control to prevent overheating
Reduce temperature variation
Minimize energy usage
Typical Architecture for
Small Controller Solution
PanelView™
Component Human
Machine Interface
High Performance Networks and Standardized
Communication Protocols
Use open communication standards and leverage on
ethernet as it’s backbone to make real-time information
available.
Connected Components Workbench
Software
Modular Devices
Availability of plug-in modules, expandable I/O, flexible safety
functions. Modular AC drive designs and an array of Human
Machine Interface panel sizes.
Micro850®
Controller
RTD
Sensor
Instrumentation
Pressure
Sensor
PowerFlex®
Drive
Defined objects and standardized connectivity providing for
instrumentation management, instrumentation calibration,
the ability to get information from the instrumentation to
display the key KPIs.
Touch Probe Function
Able to capture accurate registration position at high speeds
with built-in hardware.
Cost Effective Solution
Rockwell Automation offers scalable options for your
discrete control applications. Machine specific sample code,
pre-configured drive parameters, sample Human Machine
Interface screens make development and commissioning
easier with online software acquisition, multiple site
installations and application IP protection.
Rockwell Automation solution provides faster time to market
and lower total cost of ownership.
Publication OEM-BR045A-EN-P
PID Process Loop
Able to help control physical properties such as Temperature,
Pressure, Liquid level & Flow rate.
Recipe Management
Up to 10 recipe sets each containing up to 128 variables per
recipe to support manufacturing needs.
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Skid Solutions for Mixing and Batching
Our goal is to use a mixing and blending process template to demonstrate
the solution for simple to medium complexity batch application.
The technology leverages off the Logix Batch and Sequence Manager (LBSM)
along with Rockwell Automation Process Library.
This offers the added benefit of ISA88 standardization that not only
reduces both engineering and commissioning cost but also improves time
to market.
Rockwell Automation Solution
Rockwell Automation Solution
The Rockwell Automation emphasis of “COLLABORATING
WITH YOU”, allows Machine and Equipment Builders
to effectively compete in this global market place by
differentiating itself. Machine and Equipment Builders
need to define value beyond the cost of machines and
maximize company’s performance. Whether measured
from a business, commercial or technical perspective,
Rockwell Automation can help improve Machine and
Equipment Builders’ performance with services and
solutions to lower the Total Cost of DESIGN, DEVELOP
and DELIVERSM machines and meet customers’
requirements.
Design
Maximize design productivity, reducing design
labor time and cost and also creating consistent,
modularized designs help improve manufacturing
efficiency to meet delivery needs.
Scalable Control Solutions
Mechatronics
Functional Safety
Standards Compliance
Develop
“Faster Time to Market” to meet customer delivery
commitments is important to be competitive in
today’s economy.
Modular Programming
EtherNet/IP Network
On Machine Solutions
Hardware Integration
Supply Chain Integration
Deliver
Delivery lead time is often a considerable factor
important for Machine and Equipment Builders to help
communicate effectively to the extent to which
machines can be delivered in a shorter time period.
Information Enabled Solutions
Remote Monitoring
Network and Security Services
Global Service and Support
DESIGN
Design Productivity
Extensible Engineering
Scalability
Global Standards
Risk Assessment
Design for Sustainability
DEVELOP
Time to Market
Supply Chain Efficiency
Flexible Equipment Models
Simplified Integration
Design Optimization
DELIVER
Commissioning
Global Service & Support
Reliability & Quality
Machine Performance
Typical Architecture
for Standard Equipment
OEM, SI and End User
Challenges
The need for configurable
equipment definitions without
changing controller code
High development, commissioning
and validation cost due to non
standardized programming
Industry calls for ISA88 compliant
code structure
Market trend for integration to
plantwide system
Panel View™ Plus
Stratix™ Switch
CompactLogix™ L1
Controller
I/O
PowerFlex® Drive
Control System Architecture
High scalability due to an already
ISA88 compliant code structure
and Logix platform
ISA88 compliant code structure
with equipment module, control
module allocation and phase
configuration reduce engineering
time and makes the system easily
expandable
Process library used on control
module layer to drive standardization
and replication
HOT PRODUCT WATER
FT100
FT
Liquid Ingredient 1
Liquid Ingredient 2
FT
Phases:
• Add Milk
• Add Water
• Stir
• Heat
• Add Liquid Sugar
• Add Cocoa
• Discharge
• CIP cleaning
V100
FT101 V101
V102
MANUAL
M100
ADDITIONS
M
XS100
XS
Steam
VS100
V104
DOSING ALARM (R) YS
MAN. DOSING (Y) YS
AUTO DOSING (G) YS
MT100
WT
TT100
TT
LSL100
V103
TO PASTEURISER
LS
FT
M101
P
I
Typical Architecture
with Enhanced Features
Network
EtherNet/IP
Controller
CompactLogix™
L1 OR L3
Human Machine
Interface
PanelView™ Plus 6
Variable
Frequency Drive
PowerFlex® 525
Panel View™ Plus
Stratix™ Switch
CompactLogix™ L3
Controller
Batch Application Features
Controller based online equipment/recipe
configuration
Value-added, zero charge, un-licensed LBSM as batch
manager to manage recipe without code change
increase efficiency and reduce programming time
when a change of recipe is required
Intuitive operator runtime for recipe, equipment
module and control module visualization
Faster time to market
Reduce engineering cost
Reduce maintenance and modification effort
Standardized ISA88 compliant code structure
On line recipe management
Integration with plant wide control including information
availability
Easy scale up
Remote control and diagnostic capability
I/O
PowerFlex® Drive
Typical Architecture
for Simple Equipment
Common programming software
Connected Components Workbench™ software
for Micro800®, PowerFlex® (AC Drives), PanelView™
Network
EtherNet/IP
Modbus
Controller
Micro800® series
Component.
Human Machine
Interface
PanelView™
Component
Flexibility
Variable
Frequency Drive
PowerFlex® 523
PanelView™
Component Human
Machine Interface
High uses of open communication standards as it
backbone to make real-time information available.
Touch Probe Function
Able to capture a more accurate registration
position at high speeds with built-in hardware.
Connected Components Workbench
Software
PID Process Loop
Able to help control physical properties such as
Temperature, Pressure, Liquid level & Flow rate.
Micro850®
Controller
RTD
Sensor
Recipe Management
Up to 10 recipe sets each containing up to 128
variables per recipe to support manufacturing
needs.
Pressure
Sensor
PowerFlex®
Drive
Publication OEM-BR048A-EN-P
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Water Filtration Skid Solutions
Helping You To Design, Develop and Deliver
• Modular Program Design
• Process library blocks
• Reusable code
• Standardized programming
• Program templates
• Scalable architecture
• Flexible network design
• EtherNet/IP integration
• Reduce build time & engineering effort
• Information enabled system
• Remote monitoring & diagnostics
• Faster time to market
Rockwell Software® Platform
• Easier to expand the program
with the copy function
• Smoother and more consistent
data flow
• Standardized programming
• Reuseable code
PowerFlex 525
Armor POINT I/O
ArmorPower
Library: Process Automation
System is Normally HMI
Rich Application.
• Add-On Instructions for Logix
• Graphic Symbols and Faceplate
• Displays for FTView (SE or ME)
- For a variety of valves, motors,
pumps, drives, inputs, outputs, and other devices
- Supporting instructions for modes, alarms, permissives,
interlocks, statistics
• Reference Manuals
• Supported by Tech Support
Connectivity
for all non
EtherNet/IP™
Instruments
& sensors
Raw Water
Pump (p )
Air
PowerFlex 525
Back Wash
Pump
PowerFlex 525
Stratix 2000
Level
Capturing Operator
Knowledge Through
Automated Sequencer
• New sequencer object
• Easily configurable to
capture critical sequences
• Handles exceptions
• Rich visualization
provided to the operator
Pre-Filter
Flow
Turbidity
H
P
P
FAULT
Running States Management
• For safe running, the running states flow is
designed to manage equipment running states
• The states include: Startup, Standby, Filtration,
Draindown, Backwash, Pressure Test, CIP,
Maintenance Wash and Fault
STOP
START UP
CIP
DRAIN
Recirculation Pump
FILL IN
FILTRATION
BACKWASH
PRESSURE TEST
UF Module
IntraNet to
Plant Network,
VPN or Email
Pop Server
Wired or Cell
Connection
Use the Rockwell Automation Cloud
infrastructure to monitor all machines
Managed
Switch
RA Cloud Agent
PVP 1000
Equipment #1
Firewall
A Cloud Agent enabled hardware
is deployed at the remote site
Rockwell Automation Cloud
Permeate Tank
RA Cloud Agent
Firewall
BIG DATA
Equipment #2
L18ERM
0
DC
INPUT
1
0
24VDC
SINK
DC
OUTPUT
24VDC
SOURCE
9
2
10
3
11
4
12
5
13
6
14
7
1
2
3
4
5
6
7
9
10
11
12
13
14
15
RA Cloud Agent
Equipment #3
00:00:BC:66:0E:29
EtherNet/IP
Email
Notifications
15
0
0
Firewall
WARNING
EXPLOSION HAZARDDo Not Disconnect
While Cirecuit Is Live
Unless Area Is
Known To Be
Non-Hazardous
DC
INPUT
DC
OUTPUT
0
8
0
8
1
9
1
9
2 10
VDC
+
VDC
CG
FP+
FP-
3 11
4 12
5 13
6 14
2 10
3 11
4 12
5 13
6 14
7 15
7 15
V V
C C
V V
C C
24VDC
SINK
24VDC
SOURCE
Dashboards & Reports
Reusable for each equipment
1 (Front)
2 (Rear)
1769-L1 Controller
Temperature
SCADA Computer
Remote Access and Data Publish
Skid 1
Skid 3
Skid 2
Add-On System for
Central Monitoring,
Data Archiving
and Reporting
• Central Control
• Data Collection
• Alarm Log-in
• Trending
• Reports
Aggregate Equipment
Data Benefits
• Performance Dashboards
• Alarm Diagnostics
• Alarm Notification
• Current Equipment Status
• Historical Trends
Data Accessibility Benefits
• Secure Internet Access
• Mobile Devices
Remote Services/Support
Benefits
• Application Support
• Remote Monitoring Services
Typical Architecture for Entry Level Equipment
Connected Components Workbench™ software - proven optimal configuration. Cost effective solutions.
Reduced engineering and reduced wiring time & materials reduce commissioning time.
Availability of plug in modules at the Controller allows for expanded features and functions.
Connected Components
Workbench Software
Common Programming Software
Connected Component Workbench
Software for Micro800®, PowerFlex®
(AC Drives), PanelView™ Components.
High Performance Networks and
Standardized Communication
Protocols
Use of open communication standards
and leveraging of Ethernet/IP as the
backbone gives real time information
availability.
High Flexibility
Plug-in and expansion modules
allow you to optimize your machine
cost by choosing performance and
functionality specific to your
machine needs.
Micro850
Controller
PanelView Plus 1250
PowerFlex Drive
PanelView Component
Human Machine Interface
Instrumentation
Defined objects and standardized
connectivity providing for
instrumentation management
and calibration, and the ability to
take information from the
instruments to display process KPIs.
Publication OEM-BR051B-EN-P – March 2016
RTD Sensor
Network
EtherNet/Serial
Controller
Variable
Frequency Drive
HMI
Micro800 Family
PowerFlex® 523
PowerFlex Drive
Pressure Sensor
PanelView™ Series
Copyright ©2015 Rockwell Automation, Inc. All Rights Reserved.
Converting, Print,
Web Handling
Automation Control for Extruder Machines
Solutions for Advanced, Customized and Stand-Alone Machines
Challenges for Plastic Extruders
• Maximize profit margins and reduce the amount of raw
resin material usage
• Energy consumption management
• Increase machine throughput rates without sacrificing product
quality; repeatability even with variations in material characteristics
• Increase market share in niche applications including wood plastic
composites, encapsulation of active ingredients in pharmaceuticals, and fuel cell manufacturing.
Benefits of Rockwell Automation Solutions
• Global supplier of industrial automation solutions, providing
local service and support
• Integrated Architecture® solution offers system configuration
ease and flexibility
• Controller-based architecture with integrated drive and temperature
control to help improve overall machine performance
• Modular programming techniques based on proven code
• Domain expertise support for extruder machine development
Com
IN2
Ref
IN1
Feeder
Output Shaft
Gearbox
Barrel
Heating
Screw
Die
Motor
Input Shaft
Flow
Faster time to build Extrusion Machine or Line
• Object oriented common network based architecture
• Modular program concepts to re-use of code
• Premier Integration capabilities to increase flexibility & performance
Cooling
Advanced Machine
Typical Architecture
The CompactLogix™ PAC offers a smaller form factor
and cost-effective package which provides you
a wider variety of options from which
to choose. It also provides a best-fit
alternative for extruder
application requirements.
Stratix Switch
Studio 5000 Logix Designer™
Power programming modular
program design, based on PackML
state model, eases programming and
helps improve equipment safety.
Saves significant engineering time,
L3
reduces CompactLogix
start-up, and
commissioning
Controller
time.
L18ERM
DC
INPUT
24VDC
SINK
DC
OUTPUT
24VDC
SOURCE
0
1
2
3
4
5
6
7
0
9
10
11
12
13
14
15
0
1
2
3
4
5
6
7
0
9
10
11
12
13
14
15
00:00:BC:66:0E:29
WARNING
EXPLOSION HAZARDDo Not Disconnect
While Cirecuit Is Live
Unless Area Is
Known To Be
Non-Hazardous
DC
INPUT
VDC
+
VDC
CG
FP+
FP-
DC
OUTPUT
0
8
0
8
1
9
1
9
2 10
2 10
3 11
3 11
4 12
4 12
5 13
5 13
6 14
6 14
7 15
7 15
V V
C C
V V
C C
24VDC
SINK
24VDC
SOURCE
1 (Front)
2 (Rear)
CompactLogix L1 Controller
9 9 9
PanelView Plus 7
Human Machine Interface
Diagnostic information of drives
and motors available on HMI.
1734-AENTR Series-B
Module
Status
Network
Activity
Link 1
Activity
Status
Network
Status
Point Bus
Status
System
Power
IP ADDRESS
Field
Power
Integrated temperature control
eliminates speciality modules and
simplifies control.
Link 2
Activity
Status
PowerFlex
520 AC Drive
1734 POINT I/O™
EtherNet/IP
Feeder Motor
Studio 5000 Logix Designer
Main Motor
Asynchronous
Motor No Encoder
Network
Controller
Main Screw Drive
Temperature Control
Temperature Zone
EtherNet/IP
CompactLogix™ L1 PAC
PowerFlex® 750 AC Drive
By PAC
Up to twenty four
Extrusion Motor
(High Performance Asynchronous Motor)
PowerFlex
750 AC Drive
PowerFlex Series AC drives
combine powerful performance,
ease of use, and ultimate
flexibility. Connect the drive to a
synchronous motor to save more
energy and panel space. The AppView
and CustomView tools support faster
and customized configurations.
Custom Machine
Typical Architecture
Reduce development time and improve time to market with a Logix-based
platform on EtherNet/IP™. Integrate a modern HMI to access PDFs and videos
for operator training and machine maintenance.
Reduce panel space with distributed I/O
and optimize power ratings for extruder
machine main motor using the
Motion Analyzer tool.
Stratix Switch
Scalable control and single
programming environment
with integrated motion instructions.
Higher capability and scalability
with up to 30 I/O modules and 16
motion axes.
CompactLogix L3Y Controller
PanelView Plus 7
Human Machine Interface
Main motor selection flexibility
PowerFlex755 drive provides
additional flexibility to connect
asynchronous or synchronous
type motor.
PowerFlex
520 AC Drive
EtherNet/IP
Temperature control over
distributed I/O
Feeder Motor
PowerFlex
520 AC Drive
Traction Motor
Studio 5000 Logix Designer
Main Motor
Asynchronous
Motor No Encoder
Network
Controller
Main Screw Drive
Temperature Control
Temperature Zone
EtherNet/IP
CompactLogix™ L3 PAC
PowerFlex® 750 AC Drive
By PAC
Up to eighty
Main Extrusion Motor
(High Performance Asynchronous Motor)
PowerFlex
750 AC Drive
Integrated recipe management
Save and manage multiple recipe
control settings to eliminate the
repetitive process of running
machines during a line change.
Common HMI
platform and networking services.
Built-in security capabilities
support security standards,
particularly ISA SP99. Collaborate
with an IT security specialist
company such as Cisco and leverage
on their expertise.
Integrated safety
Stand-Alone Machine
Typical Architecture
Connected Components are cost-effective solutions with
proven optimized configurations. You can reduce panel
engineering and decrease wiring and machine assembly
time. Plug-in modules are available for the
controller to expand machine features
and functions.
Common Programming Software
Connected Components Workbench™
software for Micro800 controller,
PowerFlex (AC Drives), and
PanelView™ 800 HMI.
PanelView 800
Human Machine Interface
High Flexibility plug-in and
expansion modules allow you to
optimize your machine cost. Up to five
plug-ins and up to four expansion
I/O modules are also allowed.
Choose the performance and
functionality specific to your
machine needs.
COMO • I-00 • I-01 • I-02 • I-03 • I-04 • I-05 • I-06 • I-07
COM1 • I-08 • I-09 • I-02 • I-10 • I-11 • I-12 • I-13
2080-LC50-24QBB
MAC ID
00:00:BC:CE:3A:10
Micro850 Controller
with Series Port plug-ins
MS NS
Micro850™
RUN-REM-PRG
+DC
-DC
• 24
24
COM • 0-00 CM1 • 0-01 CM2 • 0-02 • 0-03 • 0-04 • 0-05 CM3 • 0-06 • 0-07 • 0-08 • 0-09
Bulletin 900
Temperature Controllers
MODBUS RTU
MODBUS RTU
Maximum of six serial ports for
communications to temperature
controllers, bar code readers and
other devices.
PowerFlex 523
Drive
Main Heater
Connected Components
Workbench Software
Feed Heater
Publication OEM-BR052A-EN-P – July 2015
Main Motor
Asynchronous
Motor No Encoder
Network
Controller
Drives
Main Screw
Temperature Control
Temperature Zone
Modbus RTU, EtherNet/IP
Micro850, Serial Port Plug-ins
PowerFlex 523 AC Drive
Asynchronous Motor, No Encoder
Bulletin 900-TC
Up to sixteen
Cooler
Feeder Motor
Main Extruder Motor
Copyright ©2015 Rockwell Automation, Inc. All Rights Reserved.
Manufacturing &
Assembly
Stamping Press Application
Press solutions for multiple sizes and types of metal forming equipment
Photo courtesy of Simpac
Machine Builder Challenges
• Deliver safe, efficient, and reliable press automation solutions.
• Build equipment to accepted industry standards that easily
integrate with other equipment.
• Reduce setup and changeover times with standardized
solutions.
• Drive sustainable production to reduce downtime, line
inefficiencies, and energy consumption.
• Balance machine performance, safety requirements, and
machine costs.
End User Challenges
• Reduce setup and changeover times.
• Develop solutions that reduce downtime and improve
diagnostics to reduce repair times.
• Enhance repeatability and reduce material variations to
minimize scrap.
• Provide connectivity for real-time data collection and
analytics to drive continuous improvement.
• Provide secure remote access for remote troubleshooting.
• Implement off-the-shelf solutions with standardized products
that can be supported globally.
Helping You Differentiate Your Machines
• Broad range of control, safety, and information disciplines with one single,
fully-integrated platform that provides actionable, real-time data
- Integrated Architecture offers single-source buying to ease design, development,
and maintenance
- Connected Component solutions for simple press solutions
- Meet your customer demands for secure and information-enabled machines
- Safety expertise and off-the-shelf integrated safety solutions
- Low risk deployments with standard off-the-shelf solutions
• Global services and support and locally available spare parts
• Our end user relationships and dedicated OEM experts help extend your market reach
Metal Forming and Stamping Line Layout
Straightener
Sizer
Flattener
Coil Handling
Area
Mechanical Press
Servo Press
Hydraulic Press
Feeder Area
Typical Architecture
Un-coiler to Press Feeder to Stamping Press
PanelView™ Plus 7
Human Machine Interface
Studio 5000 Logix Designer®
Compact Guard Logix®
Compact Guard Logix
SAFETY CPU
SFTY RUN
SFTY TASK
SFTY LOCK
SFTY OK
E4:90:69:A1:1A:EE
Press Angle Encoder
Stratix™ 5700
EtherNet/IP
9 9 9
MS
1734-AENTR Series-B
24VDC
Safety Sink
Input
Network
Activity
Network
Status
Point Bus
Status
System
Power
Field
Power
IP ADDRESS
Mod
Net
Mod
Net
5700
5700
Mod
Net
Mod
Net
5700
5700
Mod
Net
Mod
Net
5700
5700
Mod
Net
Mod
Net
5700
5700
Two Hand Control
NS
LK
Module
Status
Link 1
Activity
Status
P
W
R
1734-IB8S
light
curtain
Link 2
Activity
Status
Risk of electric shock.
Power off and wait 5 min.
2
Risk of electric shock.
Power off and wait 5 min.
1
1
1
4
Risk of electric shock.
Power off and wait 5 min.
Risk of electric shock.
Power off and wait 5 min.
22
11
1
1
Risk of electric shock.
Power off and wait 5 min.
22
2
2
11
I/O
6
1
10
5
1
I/O-A
6 1
1
4
10 5
UFB-A
11
I/O
6
1
10
5
I/O-A
6 1
I/O-B
6
4
I/O
UFB
Risk of electric shock.
Power off and wait 5 min.
22
11
1
6
I/O
5
Risk of electric shock.
Power off and wait 5 min.
22
1
1
I/O-B
4
I/O
Risk of electric shock.
Power off and wait 5 min.
2
I/O
10
5
UFB
UFB-b
10 5
UFB-A
10
Safety I/O
UFB-b
9 9 9
MS
1734-AENTR Series-B
Emergency
Stop
NS
LK
24VDC
Safety Sink
Input
Module
Status
Network
Activity
Network
Status
Link 1
Activity
Status
Point Bus
Status
System
Power
IP ADDRESS
Field
Power
P
W
R
1734-IB8S
Link 2
Activity
Status
Interlocking Switch
Un Coiler
AC Motor
Straightener
AC Motor
Feeder Servo
Motor
Type:
Mechanical
Type:
Servo
Mod
Net
2
1
Mod
Net
5700
Risk of electric shock.
Power off and wait 5 min.
5700
Risk of electric shock.
Power off and wait 5 min.
22
11
1
1
1
4
Mod
Net
5700
Risk of electric shock.
Power off and wait 5 min.
22
2
1
Control Option for
Main Motor
Mod
Net
5700
Risk of electric shock.
Power off and wait 5 min.
11
I/O
6
1
10
5
I/O-A
6 1
I/O-B
6
4
I/O
I/O
5
UFB
10 5
UFB-A
10
UFB-b
Servo Drive - Kinetix® 5700
PowerFlex®
AC Drive
Scalable Press Solutions with Integrated Safety Architecture
Compact Guard Logix
SAFETY CPU
SFTY RUN
SFTY TASK
SFTY LOCK
SFTY OK
PanelView™
Human Machine
Interface
Compact
GuardLogix™ PAC
E4:90:69:A1:1A:EE
Left Front Upright
Right Front Upright
Slide Angle Single Turn
Die Block, E-Stop, Run Bar
Die Block, E-Stop, Run Bar
Left Rear Upright
Right Rear Upright
PowerFlex® Drive
Flywheel Motor Drive
Die Block, E-Stop, Run Bar
Die Block, E-Stop, Run Bar
Final Output
Basement
Magnetics Enclosure
CES Interface (optional)
ROSS Valve Interface
Clutch Valve Reset
Reset OK
Mod Switch, Inch P/B
Clutch Control Reset
Control Reset
Clutch Valve Reset
Faster Machine Start-up
Power programming template in
Studio 5000 Logix Designer™ offers
modular program code to reduce
engineering and commissioning time.
Standard, reusable software modules
and Add-on-Instructions (AOIs) also
reduce development time.
Modular Wiring
Ethernet solutions for drives, servos
and I/O reduce wiring and start up
times with modular building blocks.
Energy Management
Motion Analyzer sizing tool helps
identify the right drives products to
optimize power usage.
Motor Starter Outputs
Aux Contact Inputs
Slide Angle Single Turn
Non Safety PB/SS/LT
• BGIA certified instruction suite for
§ BGIA certified instruction suite for metal§
metal forming industry
forming industry
– EN692, ANSI B 11.1 & CSA Z142.02
§ EN692, ANSI B 11.1 & CSA Z142.02
– Two hand Control station
§ Two hand Control station
– Crank Shaft Position monitor
§
§ Crank Shaft Position monitor
– Main valve control
§ Main valve control
– Position mode selector
§ Position mode selector
Pre-engineered Solutions
Proven, off-the-shelf solutions
include PressGuard™ and Compact
PressMaster™ pre-engineered press
control systems.
§
§
§
§
§
EN692, ANSI B 11.1 & CSA Z142.02
Two hand Control station
Crank Shaft Position monitor
Main valve control
Position mode selector
Pre Configured Engineered solution for
Press Control system – Press Guard
§ Pre Configured Engineered solution for
Presson
Control
system
– Press
Guard system complexity
Press and safety control
a single
platform
to reduce
Safety and Productivity
Innovative safety solutions improve
press machine functional operation
and help to increase personnel safety,
efficiency, and productivity.
Real-time Information
Information-enabled machines that
use Rockwell Automation Integrated
Architecture with EtherNet/IP easily
integrate into production lines and
provide actionable production
information for improved decision
making (e.g. OEE).
BGIA certified instruction suite for metal
forming industry
Compact Guard Logix
SAFETY CPU
0 1 2 3 4
5 6 7 8 9
SFTY RUN
SFTY TASK
SFTY LOCK
SFTY OK
0 1 2
3 4 5
440C-CR30
2080-1040
1
B VO
2
3
2080-1040
4
CO CO1 V1
5
6
01 CO1
A COM COM COM COM V-5 C1-1
1
B VO
2
3
4
CO CO1 V1
5
6
01 CO1
A COM COM COM COM V-5 C1-1
E4:90:69:A1:1A:EE
Compact Guard Logix
Safety Relays
Guardmaster®
440C-CR30
E-Stops and
Signaling
Laser Scanner
Safety Contactors
Gate Switches
(For presses with physical guards)
Safety Mats
Light Curtains
Safety Drives
Stand-Alone Machine
• Scaled solutions to match press functionality needs.
• Leverage Connected Component solutions for simple press
solutions using one common configuration software with
broad portfolio of safety components in the industry.
• Software configurable safety relay with SIL 3/PLE
certification.
• Controller plug-in modules offer cost-effective expansion of
machine features and functions.
Common Programming Software
Connected Components Workbench™
software for Micro800® controller,
PowerFlex AC drives, PanelView 800
HMI, and Guardmaster® 440C-CR30
safety relay.
Typical Architecture
for Micro-Solutions
PanelView 800
Human Machine Interface
Safety Functions and I/O provided
by Guardmaster® 440C-CR30.
Encoder
Line
Encoder
Micro850 A
4 Position Mode
Select Switch
Micro850 B
EtherNet/IP
Heavy duty performance and high
torque at low frequencies for fly wheel
with PowerFlex 753 drive.
Versatility of controller interfaces
up to six high speed counter inputs
and up to three ‘Pulse Train Output’
over embedded digital I/O. Up to five
plug-ins and up to four expansion
I/O modules also allowed.
Controller expansion I/O and plugin for Die Protector, Tonnage Monitor
and CAM output.
Relays
2 Hand Control
Stratix
2000
Reset
Guardmaster®
440C-CR30
0 1 2 3 4
5 6 7 8 9
0 1 2
3 4 5
440C-CR30
2080-1040
1
B VO
2
3
2080-1040
4
CO CO1 V1
5
6
01 CO1
A COM COM COM COM V-5 C1-1
1
B VO
2
3
4
CO CO1 V1
5
6
01 CO1
A COM COM COM COM V-5 C1-1
Light Curtain
Relays
& SSRs
PowerFlex Drive
Flywheel Motor Drive
E-stop
Interlocking Switch
Clutch Brake
Valve
Neutral
Connected Components
Workbench™ software
Component Safety Solution
Publication OEM-BR060C-EN-P – July 2016
Network
EtherNet/IP, Modbus RTU
Controller
Dual Micro850 controllers
Variable Frequency Drive
PowerFlex 753 for fly wheel
Safety Devices
Guardmaster®440C-CR30 and Guardmaster® GuardShield
Motion
Dual encoder feedback from flywheeel
Copyright ©2015 Rockwell Automation, Inc. All Rights Reserved.
Supporting Your Business Every Step of the Way
At every stage in the life cycle of your machines, Rockwell
Automation is your collaboration partner. From design to build
to operation and maintenance, you can count on the continuum
of Rockwell Automation resources to deliver safe automation
solutions for press applications.
change, increasing profits and attracting new customers with high
performance and innovative machines. Whether providing you with
single components, entire systems or specialized consultation or
trying to achieve sustainable production initiatives, our goal is to offer
solutions on a personalized level.
By taking advantage of our products and services, you can lower
your Total Cost To Design, Develop and Deliver®, while improving
your time to market. You will be better equipped to react quickly to
For More Information:
Call a Rockwell Automation sales office or an authorized distributor
today or visit us online at www.rockwellautomation.com
For more information about our OEM Solutions, please visit:
http://www.rockwellautomation.com/go/lit/oem
Allen-Bradley, Connected Components Workbench, CompactLogix, Integrated Architecture, Guardmaster, Kinetix, LISTEN. THINK. SOLVE., Micro800, Micro850, PanelView, PowerFlex, Rockwell Automation, Rockwell Software,
Stratix, Studio5000 Logix Designer, and Total Cost to Design, Develop and Deliver are trademarks of Rockwell Automation, Inc. EtherNet/IP is a trademark of the ODVA. All other trademarks and registered trademarks are
property of their respective companies.
Publication OEM-CL002B-EN-P - August 2016
Copyright ©2016 Rockwell Automation, Inc. All Rights Reserved.