Advantages of Intelligent Motor Control for the Machine Builder

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900D

Advantages of Intelligent Motor Control for the Machine Builder

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. 2

Agenda

Deliver

Develop

Design

Proof points

Intelligent Motor Control – The value proposition

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Motor Control Basics

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A large majority of machines, processes, or systems are driven by motors.

The motor control device used is determined by the required and expected operation of the load, as well as the electrical requirements

Across the line starter- Full Voltage Start- Fixed Speed

Soft starter- Reduced voltage- Fixed Speed

Variable Frequency Drive- Variable Speed

Servo AC Drive- High Accuracy- Multi-Axis coordination


Traditional approach

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Design- Different Software tools for PLC programming

and configuration of Servo Drives- Very limited reutilization of application codeHardware- Digital I/O card for every 16 points- Analog I/O card for every 6/8 variablesInstallation- Wiring and accessories - Installation labor- Commissioning time to verify all connections

Individual I/O connections for motor control devices Basically limited to interlocking, no additional functionality Wiring & installation as significant % of cost per machine


Intermediate approachMaster / Slave I/O networks

Devices communicating to controller through digital networks Master/Slave protocols for I/O devices Lower installation costs than traditional approach Multiple Software tools still required for Controller, Drives and Servo Drives

Application development- Need to handle data tables and/or

create logic to move information- Possibility of address mismatches

during commissioning

Maintenance & troubleshooting- Remote access limited to “master”

devices- Need to transfer information to

“master” for remote diagnostic


Intelligent Motor Control The Current Approach

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Moto

r Co

ntro

l

VisualizationControl

Mach

ine C

ontro

l

CIP

Information

Simultaneous real-time control, configuration and data acquisition ... Integrated Architecture is our differentiator


Intelligent Motor ControlThe Value Proposition for OEMs

Rockwell Automation defines Intelligent Motor Control as a reference architecture for the integration of motor control devices to the controller in the machine.Intelligent Motor Control helps machine builders achieve greater profitability across each stage of the business cycle.

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Commissioning Global Service

& Support

Design Design Productivity Extensible Engineering Global Standards

Develop Deliver Time to Market Simplified Integration Design Optimization


Intelligent Motor ControlDelivering the Value to OEMs

• Acceleration kits• Independence of physical addresses• Optimal integration of Drives & Servos

• Design Productivity• Extensible Engineering

Design

• Automatic mapping of device data• Optimal Integration for position control• Modular designs • Flexible network topology• Safety

• Time to market• Simplified Integration• Design Optimization

Develop

• Configuration Wizards• Unified Software tool• Support Services

• Simplified Commissioning• Global Support

Deliver


Agenda

Deliver

Develop

Design

Proof points



Design Acceleration Toolkits

A

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The DMAT includes automation engineering design tools for the entire machine control application development. - Bill of Material- CAD - Logic- HMI- Quick Start

Bill of Material Files

Wiring Diagrams and Panel Layout Drawings

HMI Screens for status and diagnostics Quick Start for Base

System SetUp

Programming for control and configuration


DesignIndependence of Physical Addresses

Parameters of intelligent motor control devices automatically mapped in the controller memory No “I/O tables” Device parameter immediately identifiable “Tag aliasing” to exactly match Engineering

documentation

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Premier Integration of motor control devices

The Rockwell Automation Integrated Architecture enables best in class integration experience on EtherNet/IP


DesignIndependence of Physical Addresses

Parameters of intelligent motor control devices automatically mapped in the controller memory No “I/O tables” Device parameter immediately identifiable “Tag aliasing” to exactly match Engineering

documentation

12

Premier Integration of motor control devices

The Rockwell Automation Integrated Architecture enables best in class integration experience on EtherNet/IP

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

Design – Drives & Motion IntegrationOptimal Integration for Positioning Control Applications

Applications that use both servos and AC drives Use drives for some axes because they don’t need servo performance Drives and Servos can be configured/programmed in the same way

Drives applications that could benefit from more powerful (i.e. motion) instructions High-end users that write complex programs for their drives Don’t need servo performance, but would like to take advantage of the

motion instruction set to save time

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Agenda

Deliver

Develop

Design

Proof points



Develop - Premier IntegrationAutomatic Mapping of Device Data

Automatic generation of descriptive Logix tag names with proper data types respective of each parameter Can have a mixture of data types

Saves development time Descriptive tag names eliminate

need to manually add descriptions

Tags are the actual network I/O as set up in the Module Definition window

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Develop - Premier IntegrationAutomatic Mapping of Device Data

Auto-generated tags are operational network I/O Could go online and control

drive directly from here with no Logix program present

No additional programming required to move from a ‘blob’ of I/O to descriptive tag names from a User-Defined Data Type

No additional programming required to convert data formats

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Just add your application program here using the above tags


Develop – Drives & Motion IntegrationOptimal Integration for Positioning Control Applications

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SoftStarters

EtherNet/IP™

Logix Controller

Kinetix® 6500 Servo DrivePowerFlex® 755 Drives

Overloads

Rockwell Software Studio 5000 - the optimal environment for the integration of Drives and Servo Drives

PowerFlex® 525DrivesKinetix® 5500 Servo Drive


Develop – Drives & Motion IntegrationOptimal Integration for Positioning Control applications

Common user experience for Kinetix 350, 5500 & 6500 servos and PowerFlex 755 drives Common configuration experience Common programming experience

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Develop – Drives & Motion IntegrationOptimal Integration for Positioning Control Applications

Utilizes same set of instructions

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Application code independent of motor control device


DevelopFlexible Network Topology

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ArmorStart

PV+ EOI

Plant Network

PowerFlex 520

Stratix 5700Kinetix 5500

Compact Logix

Cisco 3750

Electronicoverload relay

STAR

ArmorStart

EtherNet/IP

Kinetix 5500 PowerFlex 520

Electronicoverload relay PanelView +

CompactLogix

RING


DevelopModular Design

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Compact Drives Power module can be detached from control module Drive installation independent of control configuration Installation and configuration can happen concurrently

Option cards in PowerFlex 750-Series Communications, I/O, Feedback and Safety options Rationalization of inventory Add just the functionality required by the application


DevelopSafety

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Helps to increase productivity and protect personnel with standard safety and safety options

Saves space, and helps reduce system wiring and complexity

Safe Torque-Off Prevents drive restarts after safety circuit is tripped Use of any external safety relay

Safe Speed Monitor Reduce and safely monitor the speed of an application Helps personnel perform some maintenance work without

stopping the machine completely Input devices can be connected directly to the PowerFlex drive


Agenda

Deliver

Develop

Design

Proof points



DeliverUnified Software tool

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Single software tool Development of control application Configuration of motor control devices Troubleshooting Simplified learning curve Device parameters immediately available in

controller memory No address mismatches No logic required to move data into the

control system Fully featured configuration interface

Powerful resources for easy commissioning and long term maintenance.

Linear ListEditor

Wizards

Diagrams

Programming


DeliverStart-up & Application Wizards

• Simplified Configuration withStartup and Application Wizards

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Linear List

Step-by-Step,Graphical

vs.


Virtual Support Engineer – OEMs

Simple and Secure Connectivity Real-time Alarming Data Collection & Reporting Scalable, Cost Effective Solution

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Secure Remote Access for OEM’s via Rockwell Hosted VPN

Email or text message alarm annunciation delivered to OEM

Alarm and Data Reporting

TechConnect 24x7 Monitoring and Support

Virtual Support Engineer

Allowed: Connection initiated by Remote Support Solutions Virtual Support Engineer

Blocked: Connection initiated by inbound attempts.

Rockwell Service Center

Help OEMs Drive Cost Down - Revenue and Asset Availability Up


Questions?


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Advantages of Intelligent Motor Control for the Machine Builder

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