Optimising Your
Machine for
Differentiated Value
Rev 5058-CO900C
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Why We Are Here Today
 We want to show you how you can design a high performance system at a
cost effective price
Design Optimisation
 We want to show you how you can reduce the time and cost it takes to
integrate your equipment into the end user environment
Simplified Integration
 We want to show you how you can do the above while also delivering
equipment that provides differentiated value to your end users
Differentiated Value
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
2
Manufacturing Drivers Today
Flexibility
Flexibility
Integration &
Simplification
Faster Commissioning,
Reconfiguration
Faster Commissioning,
Reconfiguration
Control, Safety,
Information/IT
Control, Safety,
Information/IT
Optimum
Asset
Utilisation
Global
Support
Services
Integration &
Simplification
End Users
Optimise the
Operation of
Production
Line
Cost
Total Lifecycle
Cost
OEMs
Solutions
Optimise the
Effectiveness
of Equipment
Building
Cost
Performance
Equipment
Effectiveness
Global
Support
Services
Total Cost to
Design, Develop,
& Deliver
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
3
Response:
Machine and Equipment Builder Performance
Machine Builders today are challenged to
differentiate themselves amidst global competition
and rapidly evolving technology.
To achieve greater profitability, Machine Builders
must improve their overall operational performance.
Design
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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 Optimisation
Deliver
 Commissioning
 Global Service &
Support
 Reliability & Quality
 Machine Performance
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
4
Design, Develop & Deliver Examples
 Maximise design productivity with
extensible engineering

Use scalable control architectures

Provide extensive industry & application expertise
 Optimise Your Machine Design
Leverage product selection & configuration tools
 Easily select hardware & generate bills of material
 Size & select an optimal motion system
 Use scalable technology

 Meet global safety & environmental standards

Meet functional safety standards with
integrated safety solutions

Harness the inherent value of intelligent safety solutions
with a Safety Lifecycle Approach
 Avoid redesign changes – Perform risk
assessments up front
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
5
Design, Develop & Deliver Examples
 Optimise & reuse your machine design
Improve machine flexibility with
modular programming techniques
 Develop reusable equipment modules with Modular
Programming
 Retrieve code to use as a foundation

 Simplify Integration
Integrated Architecture solutions with a single network
 Scalable control solutions reduce
engineering time & eliminate risks
 Reduce number of programming and configuring
software packages

 Supply Chain Efficiency
Local sales & support
 “Preferred parts” availability consultation
 Reduce time & costs using a single supplier
 Reduce BOM

Improve time to market to meet customer delivery commitments
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
6
Design, Develop & Deliver Examples
 Reduce Overall Installation & Commissioning
Easily integrate with your customer’s information systems
 Link real-time reporting from machine-level to IT infrastructure with standard EtherNet/IP
 Provide an accurate view of plant operations

 Improve Reliability & Quality
Remotely monitor machine system status & perform authorised program changes
 Achieve higher levels of business performance with Network & Security Services

 Provide Global Service & Support
24 x 7 multi-lingual support
 Connect to your machines globally with remote managed services
 Start up, warranty, emergency and more via Field Support Options

Online & Phone Support | Training | OnSite Support | Repair Services | MRO Asset Management | Safety | Energy | Network & Security | Managed Services
80 Countries I 20 Languages I 6 Remote Support Centers I 10 Remanufacturing Depots I 9 Exchange Hubs I Average 13+ Years Experience
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
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Continuing to Enhance Our Capabilities
 Rockwell Automation recently released a number of new products designed to help
OEM’s increase their business performance
L1
Motion Analyzer 6
PanelView Plus 6
Terminals
Kinetix 350
LDAT Linear Thruster
PowerFlex 525
Stratix 5700
L2
L3
CompactLogix 5370
Controllers
Kinetix 5500 and VPL Motors
*coming soon
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
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Equipment Builder Performance
L1
Motion Analyzer 6
PanelView Plus 6
Terminals
Design
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Design Productivity
Extensible Engineering
Scalability
Global Standards
Risk Assessment
Design for Sustainability
PowerFlex 525
Kinetix 350
LDAT Linear Thruster
Stratix 5700
Develop
 Time to Market
 Supply Chain Efficiency
 Flexible Equipment Models
 Simplified Integration
 Design Optimisation
L2
L3
CompactLogix 5370
Controllers
Kinetix 5500 and VPL Motors
*coming soon
Deliver
 Commissioning
 Global Service &
Support
 Reliability & Quality
 Machine Performance
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
9
Mechatronics and Machine Design
Control Design
Motion
System
Design
Mechanical
Design
“synergy of several engineering disciplines…”
Mechatronic design is a collaborative venture between mechanical, electrical, and control design
engineers – the outcome is a machine design optimised for high performance controls.
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
10
Time to Market Improvements –
Motion Analyzer
 Tuning Simulation
 Decrease / eliminate Prototype builds
by testing scenarios in Solidworks and
Motion Analyzer
 Code Generation
 Motion Analyzer can both export and
import project as .L5X
 Enables fast and reliable exchange of
data with RSLogix5000
 Partially supports Product Lifecycle
Management
Download Motion Analyzer Here
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
11
Time to Market Improvements –
Drives and Motion Accelerator Toolkit
 Drives and Motion Accelerator Toolkit (DMAT) design wizard can automate file selections
and importation.
 To speed development, the wizard asks questions about your application and produces
the tools to start YOUR application WITHIN MINUTES.
 Tell the Wizard which controller, drives, HMI and I/O your application will use.
 The Wizard then runs and generates.
 A Bill of Materials of the products you specified
 A Folder of Wiring Diagrams and Panel Layout footprints ready your CAD
program
 A Logix program with the configuration and basic control needs for your products
 A starting HMI application with adaptation instructions for your application
Download DMAT Here
How much faster can you bring your machine to market with
the DMAT Wizard to help start your design?
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
12
Time to Market Improvements –
Drives and Motion Accelerator Toolkit
The DMAT includes automation engineering design tools
for the entire machine control application development.
Bill of Material, CAD, Logic, HMI, Quick Start
The DMAT allows Machine Builders to significantly
reduce design time and cost; allowing them to
concentrate on the intellectual property that produces
compelling and differentiating machine features.
Programming for control
and configuration
Bill of Material Files
Wiring Diagrams and Panel
Layout Drawings
HMI Screens for status and diagnostics
Quick Start for Base
System Setup
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
13
Time to Market Improvements –
Drives and Motion Accelerator Toolkit
 The DMAT Wizard was used to develop the base
application files for a 4 axis example.
 The Designer Wizard produced files ready for the
application details after
16 minutes of work
425 Lines of Code
6 Products configured
5500+ Program &
Diagnostic Tags
65 catalogue numbers
15 Wiring Diagrams
7 pages of panels / product
lines Models
22 HMI Screens Covering
4 Drives, Alarming /Machine Control
Quick Start for Base
System Setup
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
14
Time to Market Improvements –
Drives and Motion Accelerator Toolkit
 Advantages


Designers can spend their time optimising their machine operations for better
performance and higher profits
Initial Project setup Time needed for an example 4 axis system
Time w/o DMAT
Accelerator
Time Using
DMAT Wizard
Turning specifications into catalog numbers and
accessories
4 Hours
5 Minutes
Produce initial base set of CAD drawings
80 Hours
5 Minutes
Produce initial base program
40 Hours
3 Minutes
Produce initial base HMI set
80 Hours
3 Minutes
Task
From 204 hours to 16 minutes !!!!!
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
15
Simplifying Your Design –
Single Network, Global Standards
 Standard Unmodified Ethernet
 Lower wiring costs
 Simplified Integration of the entire control solution on one network. including HMI, PAC,
I/O and motion.
 Safe Torque Off standard
 Scalable Platform to meet global machine standards
 120V, 240V - single and 3 phase
 460V – 3 phase
 Designed as a System
 Controller, Motion, HMI
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
16
Simplifying Your Design –
Motion Simplification
 50% reduction in size
 Efficient motors reduce size and cost
 Up to 2 Sizes Smaller Drive
 Single Cable Design reduces installation (60%) & procurement costs (27%)
 Induction Motor support reduces inventory, and simplifies design
 Energy efficient drive/motor match and green shunt
 Zero stacking, no backplane
 Two EtherNet/IP ports to support Device Level Ring (DLR)
 Designed as a System
 Controller, Motion, HMI
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
17
Simplifying Your Design –
Linear Thruster
 Replace complex transmissions with linear
actuators.
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Eliminates weeks of engineering, design and
documentation time per custom designed
actuator axis.
Vastly reduces the amount of components that
need to be purchased from multiple vendors
for custom actuators.
Eliminates the time needed to assemble a
custom actuator into a machine.
Reduces Engineering, Purchasing
and Assembly Efforts!
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
18
CompactLogix 5370
Programmable Automation Controllers (PACs)
Expanding on the scalability of the Logix family of controllers
The CompactLogix 5370 PACs offer:

A wider variety of options to provide best-fit alternatives for specific application requirements

A strong motion solution when combined with Kinetix® servo drive for customers requiring high
performance in a compact and affordable package

Common and consistent features across all three platforms (L1, L2 and L3); scalability between
the Logix families (CompactLogix and ControlLogix)
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
19
5370 CompactLogix Summary
Battery-less
Operation
2x Scan Time
Performance Increase
Integrated Motion in L1,L2
and L3 “M” controllers
(CIP Motion / CIP Synch)
All models
(L3, L2, L1)
L1
SD Flash for Program
and Data Storage
L2
USB port
for programming
Embedded DLR
EtherNet/IP Switch
Local Expansion with
up to 6 or 8 POINT I/O
Modules
>25% improvement in network
Packets Per Second (PPS)
Universal Analog Input
(C, V, Thermocouple, RTD),
14 bit resolution
Sockets
communication
Much smaller
form factor for
L2 Controllers
Local Expansion
with up to
4 1769 Modules
Integrated Motion, 2x performance increase, >25% improvement in network and many more…
…in a compact form factor provides a right size control for your application needs
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
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The Power of Logix
AOI
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
21
Simplified and Scaled Architectures
CompactLogix chassis
Stratix
PanelView Plus
EtherNet/IP
SERCOS
DeviceNet
POINT I/O
ArmorBlock I/O
Kinetix 6200
PowerFlex
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
22
Simplified and Scaled Architectures
CompactLogix chassis
Stratix 5700
PanelView Plus 6
EtherNet/IP
POINT I/O
ArmorBlock I/O
Kinetix 5500
PowerFlex
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
23
Simplified and Scaled Architectures
CompactLogix chassis
Stratix 5700
PanelView Plus 6
EtherNet/IP
POINT I/O
ArmorBlock I/O
Kinetix 5500
PowerFlex
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
24
Kinetix 5500 Servo Drive
50% smaller
Supports 195 – 528
VAC input,
reducing inventory
Innovative Common
AC/DC bus
eliminates hardware,
reduces installation time
and lowers costs
Single cable eliminates
Hardware and wire
terminations
Induction motor (V/Hz)
support simplifies inventory
and maintenance
Clamp design prevents
installation mistakes
and enforces 360° bonding
for noise immunity
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
25
PowerFlex 525 AC Drives
Modular Design
Offers ease of installation
and programming
USB
Connectivity for
Faster Configuration
Power Range
115V to 600V
0.37 to 22kW
HIM
The LCD Human Interface Module supports
multiple Languages and feature scroling text
Embedded Ethernet Port
Provides Premier Integration into
the Logix environment
Safe Torque-Off
A standard feature of the
PowerFlex 525 Drives
Simplified Programming
Easy to use Software and MainsFree
programming via USB
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
26
Stratix 8000 & 5700 Family
Layer 2 & 3 Managed Switches w/ Cisco Technology Inside
A unique product family in the market….
Best of Rockwell Automation
 Premier (CIP) interface to Integrated Architecture
– Studio 5000 for configuration (AOP)
– Predefined Logic tags for diagnostics
– FactoryTalk View Faceplates
Stratix 8000/8300
Best of Cisco
 Secure integration with plantwide network
– Cisco internetworking operating system (IOSTM)
– Cisco CatalystTM switch architecture and feature set
– Familiar tools for IT professionals: command line interface (CLI),
Cisco Network Assistant (CNA) and Device Manager
Stratix 5700
Best for the Plant Floor Environment
 Easy to Integrate and Maintain
– Default configurations for Industrial Automation
– Removable storage cards for one step device replacement
… integrating the IT and Industrial Environments
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
27
Switch Tools and Integration
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
28
Equipment Integration
How do you overcome the challenges?
• Simplified architectures
• Standard unmodified Ethernet
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
29
Differentiation – Smart Machines
contact a remote service engineer?
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
30
Differentiation – Smart Line
Lowers Lifecycle TCO
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
31
Summary
 You design a machine with less parts, and lower inertia, which leads to lower cost motors
and drives
 Less parts and smaller motors and drives means a smaller footprint
 Increased scalability of controllers allows you to only pay for the control and features you
need
 Simplified equipment allows you to turn over jobs faster, meaning getting paid faster
Design Optimisation
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
32
Summary
 Using standard, unmodified Ethernet allows you to easily integrate into an end user
environment
 Cisco enabled switches promotes easy adoption by end user IT departments
 Fast integration means less time at end user site
Simplified Integration
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
33
Summary
 Because back in design you optimised, you deliver a machine with less parts, requiring
less spares, less maintenance, less energy usage and longer uptime
 Providing a smart machine gives a competitive advantage to your end users and
differentiates your equipment in the market
 Providing information enabled equipment allows the customer to get the information they
need to optimise operations and meet their efficiency goals
Differentiated Value
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
34
More Information
 If you would like more information on our midrange platform, you can visit
www.scalabletechnology.eu
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
35
Questions?
Follow ROKAutomation on Facebook & Twitter.
Connect with us on LinkedIn.
www.rockwellautomation.com
Rev 5058-CO900C
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.