ct233 - intelligent motor control - rockwell automation · automatically build the i/o tree for all...

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900E

CT233 - Intelligent Motor ControlThe Connected Enterprise

John Eddington –

Rockwell Automation

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

The Connected Enterprise

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

$6.62B

Leading global provider of industrial power, control and information solutions

3

Serving Customers for 111 Years

Technology innovation

Domain expertise

Culture of integrity & corporate responsibility

at A GLANCE

22,000EMPLOYEES

80+COUNTRIES Fiscal 2015 Sales

20+INDUSTRIES


EMERGING MARKET CONSUMERISM RESOURCE PRODUCTIVITY INVESTMENT

Increased Demand on Industrial Production

$1T

Source: McKinsey

50%More Energy

More Water

30% 100%More Vehicles

GLOBAL POPULATION TRENDS INCREASE DEMAND FOR

Manufacturing

80%More Steel

Resources

Infrastructure

4

Annually

By 2020 1 billion new middle class consumers will add

$8T to consumer spending

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.COMPANY CONFIDENTIAL - Internal Use Only

$Faster Time

to MarketImproved Asset

UtilizationEnterprise Risk

ManagementLower Total Cost of

Ownership

Connected Enterprise Delivers

Optimized for Rapid Value Creation Supply Chain Integration

Collaborative, Demand Driven

Compliant and Sustainable


Disruptive Technology in Industrial Applications

Scalable Computing/Cloud

Mobility

Data Analytics

Smart ThingsINDUSTRIALInternet of Things

• Machine to machine coordination – high speed

• Mission critical assets – safety

• Integrated Control and Information

Security

Enablers for the Connected Enterprise


<14% PRODUCTIONIn the U.S. have tied their facilities to the enterprise network.

SOURCE: Industry Week


Traditional ApproachHardwired connections to motor control devices

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Individual I/O connections for motor control devices

Basically limited to interlocking, no additional functionality

High costs:

Design, Hardware, Installation in large industrial systems

Wiring & installation as significant % of cost per machine

PLANT WIDE SYSTEMS MACHINE SYSTEMSDesign

- Engineering and documentation costs (very significant in large systems)

- Different Software tools for Controllers and Devices (significant for machine builders)

- Very limited reutilization of application code

Hardware

- Digital I/O card for every 16 points

- Analog I/O card for every 6/8 variables

Installation

- Wiring and accessories

- Installation labor

- Commissioning time to verify all connections


Intermediate approachMaster Slave I/O networks

9

2 layers of digital communication Supervision

I/O control – Master/Slave protocol

Lower installation cost than traditional approach

Costs generated by limitations in the use of information from devices

PLANT WIDE SYSTEMS MACHINE SYSTEMS

Application development

- Need to handle data tables and/or create logic to move information

- Additional engineering labor and documentation costs

- Possibility of address mismatches during commissioning/operation

- Different Software tools for Controllers and Devices (significant for machine builders)

- Very limited reutilization of application code

Maintenance & troubleshooting

- Remote access limited to “master” devices- Need to transfer information to “master” for remote diagnostic

- No access to other “masters” from remote I/O location- Unless Supervision network is extend to I/O locations


Intelligent Motor Control The current approach

10

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


Agenda

Agility

Faster Time to Market

Faster Commissioning and startup Time


Intelligent Motor ControlEnergy information at the device level

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Full Voltage starters

--Fixed speed

- Intelligent overload relays

Soft starters

-Reduced voltage

-Fixed speed

Variable Frequency Drives

- Variable speed

Motor Control Centers

-Single assembly for multiple starters

E300

Overload

Relay

LV


E300 Electronic Overload Relay

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The E300 Electronic Overload Relay is the latest technology for motor protection that will help reduce your motor control investment and keep your plant running

Intelligent Motor Control

Native Ethernet/IP connectivity with easy commissioning, control, and monitoring.

Scalable Solutions

Modularity in the design provides the right solution for your specific needs

Diagnostic Information

Motor diagnostics to reduce unplanned downtime



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The E300 is fully integrated into the Integrated Architecture

Network connectivity - Native Ethernet/IP reduces hardware and engineering cost

Integrated into Logix – Device profiles and faceplates reduce engineering time and

project development

Automatic Device Configuration – Reduces time to repair

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VisualizationControl

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CIP

Information

EtherNet/IP

Simultaneous real-time control, configuration, and data acquisition


Easy Integration into Logix

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The E300 has an Add On Profile for RSLogix

5000 and Studio 5000 software.

Creates meaningful tag names

Configures the E300 (supports ADC)

Tested to v17 of RSLogix 5000


Network Connectivity – E300

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Two Ethernet ports that operate as an Ethernet switch Star Topology

Linear Topology

Ring Topology (DLR)

Embedded web server

Supports SMTP messaging


PowerFlex 520-Series AC Drives

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Simplified Programming

Dynamic Human Interface Module (HIM)

LCD

QuickView™ Scrolling Text

Multiple Languages

Connected Components Workbench™ Software

Free software

Application Programming Groups: AppView™

& CustomView™ configuration

Studio 5000 Logix Designer™ Application

Premier Integration

Automatic Device Configuration (ADC)

Integrated motion instructions

PF523

PF525

PF527



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Communications

PowerFlex 523 AC drives Standard Serial (DSI) port

Optional dual port EtherNet/IP card

Additional network options

PowerFlex 525 AC drives Standard Serial (DSI) port

Built-in EtherNet/IP single port

Optional dual port EtherNet/IP card

Additional network options

PowerFlex 527 AC drives Built-in EtherNet/IP dual port

Dual port EtherNet/IP supports DLR topology

Adding option cards to the

PowerFlex 520-Series does not

affect the foot print of the drive

Device Level Ring topology

helps increase system resiliency

in the case of the loss of one

network connection.

Communication is rerouted to

help continue operations


All PowerFlex 750-Series drives can be configured using:

Drive HIM module

DriveTools SP, DriveExplorer

RSLogix 5000 Add-On Profiles —Premier Integration

PowerFlex 755 drives additionally can be configured using:

RSLogix 5000 embedded instructions (CIP Motion)

PowerFlex 755 native to RSLogix 5000

Program with motion control instructions

CIP Motion technology from 1 to 2000 HP

Seamless integration with Logix platform

Automatic device Configuration (ADC) for PF755

Reduced Engineering and commissioning time

PowerFlex 750-Series Drive Configuration

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Provides valuable integration features

1. Automatically build the I/O tree for all Intelligent Motor Control devices in the MCC

2. Auto-generate the device tags using Device AOPs

Full integration between power and control for Rockwell Automation products

Exclusive integration capabilities

IntelliCENTER TechnologyIntelliCENTER Software – Integration Assistant


IA Productivity ToolsAdd-On Instructions (AOIs)

Save time by creating sets of commonly used

custom instructions

Promote consistency between projects – no need to

constantly re-invent commonly used control

algorithms

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Example AOI to scale drive engineering units to units operators can

understand


IA Productivity ToolsFactoryTalk® View Faceplates

Available Faceplates from Rockwell Automation Sample Code Web Site:

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Preconfigured

Go to Display Buttons

Status and Operator Control

Device Configuration Device Diagnostics Operator Help


Agenda

Productivity

Downtime Mitigation

Preventative Maintenance


E300 Motor Diagnostics

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The E300 provides a wide variety of diagnostic information to monitor motor performance and proactively alert users to possible motor issues

This information can trigger either manual or automatic intervention before the occurrence of an unplanned shutdown

Voltage, Current, & Energy

CIP Energy Enabled

Trip / Warning Histories

% Thermal Capacity Utilization

Motor Winding Temperature

Trip Snap Shot

Time to Trip

Time to Reset

Operational Hours

Number of Starts


Automatic Device Configuration

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Firmware

IP Address

Configuration


Automatic Device Configuration (ADC)

A v20 Logix-based feature that allows a user to configure their Logix system to automatically download a “large” device’s configuration - typically after it has been replaced

Configuration data for “large” devices resides in the ACD file and

the Logix controller, but the download was a manual process in v16-v19

Also compliments:

Stratix 6000 & 8000 switches

Automatically assigns IP Address (if desired for the application)

Firmware Supervisor

Flash the drive and/or peripherals (if desired for the application)

Downloadbutton

Add-On Profile (AOP)of desired drive inRSLogix 5000

v20 released

January ‘12

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PowerFlex 755 is native to data structure in RSLogix 5000 Configuration Motion instruction-based programming Commissioning Diagnostics and drive maintenance

Position, velocity, or torque control

Motion instruction programming Positioning, gearing, camming, interpolation

Synchronized drive control Simple and complex profile for

1 drive to 100+ drives Velocity Position with phase control

Safety options SIL 3, Cat 4, PLe Safe Torque Off SIL 3, Cat 4, PLe Safe Speed

PowerFlex 755 with CIP Motion

Power range and voltage 0.75…1500 kW / 1…2000 Hp

400/480V, 600/690V

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With Intelligent Motor Control – Remote Connectivity & Mobility

• Remotely connect to any part

of the system including

- Drives

- Electronic overloads

- Intelligent MCCs

• Improved remote diagnostics

on your smart device

• Machine builders suggest

ways of solving the problem

Full access at device level

Rockwell AutomationCloud Platform


Smart Diagnostics


Devices on the EtherNet/IP

network


Critical motor experiences overload condition


Thermal capacity utilisation of relay rises, motor still operates


When warning level is reached:

Controller uses EtherNet/IP delivers warning

message to HMI stations (PC)

Mobility-ready

solutions allows to share

alarm to electrician


Electrician unavailable, alarm escalated to foreman


Foreman checks motor, removes cause of overload


• Electric motor current indicating loading conditions

• Vibration signature indicating mechanical unbalance

• Torque signature indicating process anomalies

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Intelligent Motor ControlEmbedded Diagnostics

• Embedded diagnostics

• Remote Monitoring

• Automatic device configuration

• Troubleshooting wizards

• Reduce unplanned downtime

• Reduce time to repair

• Centralized maintenance staff

Improve AssetUtilization

Diagnostic data from intelligent

motor control devices can trigger

either manual or automatic

intervention before occurrence of

unplanned shutdown.


Agenda

Sustainability

$Reduced Industrial

FootprintSafety, Reliability &Risk Management



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Safety

Safe Torque-off can help increase safety and machine

uptime

PowerFlex 525 AC drives: Built-in hardwired safety

Certified to SIL2 / PLd

Requires the use of any external safety relay to meet ISO 13849-1

PowerFlex 527 AC drives: Choice of safety options

Built-in Hardwired Safe Torque-off SIL3/PLe, Cat 3

Built-in Network Safe Torque-off SIL3/PLe, Cat 3

Help protect your personnel and assets with standard built-in

Safe Torque-off

Helps with faster start ups and reduces wear on motor assets

Reduce wiring and installation space with built in safety or integrated safety-- safety over the network


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Safety solutions to meet your needs

Network

PowerFlex 527SIL 3 / PLe (Network)

Hardwired

PowerFlex 525SIL 2 / PLd

PowerFlex 527SIL 3 / PLe

External

PowerFlex 523

PowerFlex 520-Series AC Drives Safety Solutions


CB,

filters, ect VFDCB,

filters, ectMCC Main VFD VFDCB,

filters, ect VFDCB,

filters, ect

Total panel width of 5.8 meters

MCC

feeder

section 2

MCC

feeder

section1 MCC mainVFD

panel

CB,

filters, ect

Drive Panel 1

VFD

panel

CB,

filters, ect

Drive Panel 2

VFD

panel

CB,

filters, ect

Drive Panel 3

VFD

panel

CB,

filters, ect

Drive Panel 4

Total panel width of 7.4 meters plus spacing between panels

Power Cabling

Footprint reduction approximately 30%. Eliminate expensive and time consuming power wiring between panels

Line Up vs Traditional Packaging

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Frame 9600…1350 Hp

Frame 101100…2000 Hp

Frame 8350…700 Hp

PF 755 Floor Mounted: Basic Architecture

44


PowerFlex 750-Series AC Drives Conformal Coating Standard

Standard on all PowerFlex 750-Series drives

In harsh environments increases drive reliability

Protects components with micro lead spacings which are otherwise vulnerable to dust and moisture build up

Without coating, unintentional conductive paths can be formed, leading to circuit failure

Enclosures must still be considered in the

overall application of a drive

See Conformal Coating for Variable Speed Drives white paper for more information

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PowerFlex 750-Series AC DrivesPredictive Diagnostics

The PowerFlex 750-Series can be programmed to keep track

of information that affects the life of its cooling fans and relay

outputs, as well as customer motor and system bearings

Provides data on estimated life expectancy for fans and relays

Provides configuration for customer motor and system bearing data for drive monitoring

Provide advanced notification to help prevent unplanned downtime

Real time data provides actual time stamping from the real-time clock

Can configure and retrieve data via HIM, software tools, and

RSLogix 5000

Information can be transferred to the controller as I/O tags

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Heatsink Fan Example

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PowerFlex 750-Series AC Drives - Reliability

Thermal management algorithm

Increasing Drive Reliability

Lowers IGBT Junction Temperature Peaks during High Load Conditions

PF700 & PF70 Thermal Regulator Improvements

• IGBT junction temperature peak has been lowered during High Load Conditions.

• The Screen shot below was taken with a drive starting into a 150% load and the PWM set to

10kHz. IGBT Temp was measured at 91C versus prior readings at 129C

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IntelliCENTER Energy is a premier software package with all the features of

IntelliCENTER PLUS additional Energy Management benefits powered by

FactoryTalk® EnergyMetrix™:

Real-time energy consumption and historical

trending down to the device level, all across the

network!

Ability to monitor and manage energy usage for

substantial cost savings

IntelliCENTER TechnologyIntelliCENTER Software – Energy



Collect data for any time period (hourly, daily, weekly, monthly, etc.)

Trend key parameters simultaneously

Export data for recordkeeping or further analysis.



View all key energy values for a

particular device on a single screen


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Dev

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VisualizationControl

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EtherNet/IP

Net

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Tech

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Information

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


The Stratix Family Today

A unique line of industrial Ethernet switches –from plant floor to enterprise level applications

Applications with small, isolated networks

Monitor and control distributed devices

Plant floor and enterprise integration

Stratix 6000 Fixed Managed• Port Configurations:

• 4 copper ports, • 8 copper ports plus 1 fiber

Stratix 2000 Unmanaged• Port Configurations:

• 4, 5, 7, & 8 port versions

• Single fiber options

Stratix 8000/8300 Mod. Managed• Port Configurations: • 6 to 26 ports• 6 & 10 ports base units with 2 port fiber

option• 8 port copper & fiber expansion options• Up to 10 fiber ports• 2 gig ports• Layer 3 VLAN and subnet routing (8300)

Stratix 5700

Stratix 5700 Managed• Port Configurations: • Three port configurations (6, 10 and 20 )• 2 to 4 fiber port options• Up to 2 gig ports

Stratix 5100 Wireless

Stratix Armor

Stratix Nat

Stratix 5900

Stratix 8000 / 8300

ct233 - intelligent motor control - rockwell automation · automatically build the i/o tree for all...

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