june 2013 - rockwell automation · costs, improves customer satisfaction and increases revenue....

AutomationAutomationJune 2013

TODAY ASIA PACIFICAustralia & New Zealand

InsideTunnelling into the future

Virtual Support Engineer

Developing and Managing Process Control Systems Putting More Function into Functional Safety Packaging: Fast and Flexible Micro PLCs ExpandMachine-Building Flexibility

See page 4

Learn how to optimise your assets at the China – Australia Mining Forum

EDITORIAL

Scott Summerville

CONTENTSEDITORIAL

Automation Today is published byROCKWELL AUTOMATION SOUTHEAST ASIA PTE LTD

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Tel: (65) 6622 5188 • Fax: (65) 6622 5100Editor: Steven Goh – [email protected]

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Copyright© 2013 Rockwell Automation Inc. All rights reserved. The contents of this publication may not be reproduced in whole or part without the

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FLEX, Integrated Architecture, Kinetix, MainsFree, Micro830, Micro850, PanelView, PharmaSuite, PlantPAx, PowerFlex, PowerMonitor, Rockwell

Automation, Rockwell Software, RSLogix, Stratix and Studio 5000 are trademarks or registered trademarks of Rockwell Automation, Inc.

Improving Machine Builders’ Performance

Thomas O’Reilly, PresidentRockwell Automation, Asia Pacific Region

2 June 2013 AUTOMATION TODAY ASIA PACIFIC

Features3 News & Events Rockwell Automation® developments

from around the world.

4 Country News News and events from around

Australia and New Zealand.

6 Feature Story – Tunnelling into the future Auckland’s first road tunnel is set to cut commuting times.

8 Feature Story – Virtual Support Engineer Rockwell Automation® Services & Support offers Virtual Support Engineer, enabling OEMs and System Integrators to monitor and manage equipment from anywhere in the world.

10 Technology Watch PlantPAx™ Virtual Image Templates from

Rockwell Automation® reduce validation and engineering costs.

11 Safety Putting more function into Functional

Safety.

12 Value Proposition Rockwell Automation® solution increases

slitter machine speed by 50 percent.

14 Developing better tyre building machines

16 Technology Watch Micro PLCs Expand Machine - Building

Flexibility

17 Product Focus Recent additions to the Rockwell

Automation® product portfolio.

To effectively compete in today’s global marketplace, original

equipment manufacturers (OEMs) need to define value

beyond the cost of machines – and maximize performance,

efficiency and throughput. Rockwell Automation® can help with

solutions and services that lower the total cost to design, develop

and deliver machines.

Maximizing design productivity cuts design labor time and costs, thereby improving manufacturing efficiency. Reducing programming and assembly hours, as well as using off-the-shelf components, helps speed machine development and time to market. Utilizing complementary automation concepts with mechanical optimization such as open EtherNet/IP™and Integrated Architecture™, with all products designed around a common platform and single software environment from a single source supplier leads to “Best-in-Class” designed machinery. Shortening overall commissioning – testing, installation, troubleshooting and start-up time – and having the right level of global service and support minimize delivery lead time. As a strategic partner, Rockwell Automation can help you go beyond a bill-of-material focus to improve your market value, optimize your business costs and improve your customers’ effectiveness.

In this issue of Automation Today Asia Pacific, for example, you’ll learn how Rockwell Automation offers a range of power, control and information services for the Tyre and rubber industry. Our Tyre Building Machine (TBM) solution leverages the Rockwell Automation Integrated Architecture platform, which consists of discrete motion and drive control, input/output, network, visualization and information components including innovative structured programming tools and templates (Power Programming) that enable manufacturers to streamline their TBM operations. From integrated safety functions to distributed control to manufacturing metrics and development tools, our TBM solution gives manufacturers a competitive edge.

With OEMs in mind, Rockwell Automation recently introduced micro programmable logic controllers (PLCs) that optimize stand-alone machine performance and cost. Our Allen-Bradley® Micro850™ and enhanced Micro830™ PLCs feature embedded motion capabilities for up to three axes of motion, allowing them to support a range of applications. The micro PLCs provide options and features that enable machine builders to differentiate their equipment from the competition.

In addition, the expanded Midrange system portfolio includes the Kinetix® 5500 servo drive and VPL low-inertia servo motor with smart-cable technology for an integrated motion solution on EtherNet/IP that is more compact, easier to use and simplifies system wiring. The PowerFlex® 525 AC drive delivers the communications, energy savings and standard safety features you need in a cost-effective compact drive. Built on Cisco® IOS, the Stratix 5700™ switch simplifies the design and development of machine-level networks through configuration and monitoring tools to help enable easy setup and diagnostics of the OEM machine. And, the Studio 5000™ environment provides a framework for engineering collaboration via Logix Designer for programming and configuration that can be leveraged from design to operation to maintenance, lowering the cost of the machine for the machine builder to design, develop and deliver.

In the services realm, Rockwell Automation now offers Virtual Support Engineer for OEMs and system integrators. The service enables users to detect, diagnose and resolve technical issues proactively at customers’ sites; perform scheduled and preventive maintenance remotely; and monitor key tags to ensure optimal performance. It minimizes costs, improves customer satisfaction and increases revenue. This combined with TechConnectSM 24/7 global support and authorized service engineers in over 80 countries.

With the start of a new year, Rockwell Automation wishes you continued business success. From design, to build, to operation and maintenance, you can count on the continuum of Rockwell Automation technology, resources and people to help improve your company performance.

Thomas O’Reilly

Panduit and Rockwell Automation Form Strategic Relationship

Rockwell Automation® and Panduit, a developer and provider of physical infrastructure solutions, have expanded their long-standing Encompass™ product-referencing relationship and have formed a strategic alliance.

The two companies are focused on providing optimised physical network infrastructure solutions, effective collaboration between automation and IT, and integrated solutions and services for customers globally. Panduit and Rockwell Automation also plan to work with companies, like Cisco, to help customers integrate logical architectures to physical deployment from initial design, maintenance and operations throughout the entire enterprise.

Initial emphasis of the collaboration will be placed on integration of physical implementation, employing best practices and industry standards, providing education and services to facilitate manufacturing and IT convergence, and enabling successful architecture deployment.

Chinese Pharmaceutical ManufacturerSelects Rockwell Automation MES Solution

L ivzon Pharmaceutical Group, Zhuhai, China, has selected Rockwell Automation® to provide a manufacturing execution system (MES) for its latest greenfield facility,

which is slated to begin production in May 2013.Livzon researches, develops, manufactures and sells products

to address gastrointestinal, cardiovascular and reproductive issues; anti-infectious and anti-cancer treatments; and active pharmaceutical ingredients (APIs), including antibiotics. The company’s new production line must comply with hardware and software management requirements of the latest edition of the World Health Organization’s good manufacturing practice (GMP).

Rockwell Automation teams partnered with system integrator Austar to provide FactoryTalk® PharmaSuite, pre-validated software comprised of standardised weigh-and-dispense workflows, user interfaces and validation documentation. The solution, based on S88 and S95 standards, will help Livzon control the process of the material movement, monitor the production line, supervise the operation and ensure quality compliance.

Rockwell Automation Awarded US$21.7 Million Contract

R ockwell Automation® announced that the U.S. Navy has awarded the company a US$21.7 million contract for programmable automation controllers, variable frequency drives, software and engineering support

services to operate machinery control systems onboard U.S. Navy and Coast Guard surface ships. The award enables the Navy and other Department of Defense agencies to acquire engineered systems and services from Rockwell Automation vital to daily and strategic shipboard operations, globally and domestically.

“Control systems designed for the marine industry need to meet stringent requirements, especially for the U.S. Navy, which operates world-class fleets 24/7 throughout the world,” says Joe Moffa, Rockwell Automation marine business manager. “We are proud to meet these requirements and provide the machinery control systems, technical support and engineering services, on-site and through our global network of employees and distributors.”

Rockwell Automation products and software have been installed successfully onboard various U.S. Navy and Coast Guard ships since 1997. They are commercially available to navies worldwide in more than 80 countries where Rockwell Automation and its partners conduct business.

NEWS & EVENTS

BRIEFS

O’Reilly Named President,Asia Pacific Region Thomas O’Reilly, Rockwell Automation® regional director, China, has been promoted to president, Asia Pacific Region. O’Reilly has 28 years of service with Rockwell Automation, 16 of which have been in sales and country leadership roles in Japan, Korea and China. He also spent four years in the Customer Support & Maintenance organisation leading Plant Services. O’Reilly succeeds Bob Ruff, who has been named senior vice president, Customer Experience.

Innovation Runs Deep Rockwell Automation® has been included on the Thomson Reuters 2012 Top 100 Global Innovators list. The IP & Sciences business of Thomson Reuters, a leading provider of intelligent information for businesses and professionals, honored 100 corporations and institutions around the world that are at the heart of innovation. The companies are selected by Thomson Reuters using a series of patent-related metrics that get to the essence of what it means to be truly innovative.

Offering Solutions to Asia’s Oil and Gas Market Rockwell Automation® and strategic alliance partner Endress+Hauser recently showcased the PlantPAx™ process automation system in Singapore at OSEA 2012, the 19th International Oil & Gas Industry Exhibition & Conference. The PlantPAx system integrates information, control, power and safety to help redefine operational excellence and reduce risks for maximised productivity, reduced total cost of ownership, minimised lifecycle costs, increased safety and high levels of control and flexibility.

AUTOMATION TODAY ASIA PACIFIC June 2013 3


NEWSCOUNTRY

Optimising pit to port operations and strengthening mining collaborations between China and Australia.

As global economic uncertainty continues and commodity prices decline, the mining industry is facing many new challenges. Leading companies are investing in technology to “sweat their assets” or get more from the existing operations rather than invest in new greenfields projects.

Building on the success of the China- Australia mining forum held in 2011, Rockwell Automation® will host a not to be missed one-day event on 15th July, 2013 at the Brisbane Convention Centre.

According to Geoff Irvine, Mining Industry Manager, South Pacific, “This year’s event will focus on streamlining the supply chain from pit to port together with exploring options for smart, safe and sustainable mining. The focus is on getting more out of what you have. The case for

implementing autonomous mining and remote operations is even more compelling now as miners have seen significant cost reductions via these technologies.”

Attendees will hear about the latest advances in autonomous mining, remote operations, automation, networks, power and safety. Industry experts will also discuss how companies can reduce inefficiencies and energy costs in mining operations. Chinese Mining End Users and OEM’s have much to offer the Australian Mining Industry to assist in reduce the operating costs of their plants.

The Integrated Architecture™ platform from Rockwell Automation enables optimised pit to port operations. The platform promotes agility through mine-wide optimisation; productivity through improved machine builder performance and sustainable production for mining applications.

Collaborating with industry peers to

cut costs through shared infrastructure and supply chain can help mining companies address the challenges associated with rising operational and capital costs.

As both nations work to increase productivity and reduce environmental impact, there are opportunities for the supply of more efficient mining equipment and processing technologies. The Forum will also provide the opportunity to expand the already strong business relationships between mining companies in China and Australia.

The China – Australia mining forum will offer an invaluable networking opportunity to discuss applications with leading End Users, EPC’s, Consultants, System Integrators and OEM’s involved within the mining industry in China and Australia. This event will be followed by the Safety Symposium the next day which will focus on safety automation solutions. AT

Rockwell Automation to host China – Australia Mining Forum in July

Rockwell Automation appoints new Sales Operations & Industry Manager for South Pacific

AUSTRALIA & NEW ZEALAND


Rockwell Automation® is pleased to announce the appointment of Paul Ponticello to the role of Sales Operations & Industry Manager, South Pacific. “The main objective of the role is to drive continuous improvement throughout our sales processes. This is closely aligned to our Strategic Framework with the ultimate goal of improving customer experience and loyalty and hence growing market share,” said Ponticello. “We operate within a complex model in which selling resources need to juggle numerous demands of both internal business units and our channel partners and I would like improve consistency on how sales activities are carried out across the South Pacific region. I’ll be working towards breaking down barriers and promoting effective teaming across the various internal and distributor channel selling groups,” he continued.

In this role, Paul will both drive and support the sales organisation in the areas of planning and execution, productivity and overall effectiveness. He will also have direct line responsibility for the South Pacific Industry teams that are not specifically aligned to a product or solutions business unit. “I would like to congratulate Paul on his new appointment and look forward to his partnership in this role. Paul is a very well respected leader in the region. His strong business and financial background will enable us to accelerate our focus on disciplined selling processes, sales forecasting and other growth initiatives,” said David Hegarty, Regional Director South Pacific, Rockwell Automation. Paul has been working at Rockwell Automation for more than 20 years, in various operational functions. He brings

deep knowledge and experience to his new role, displaying sound business acumen, as well as organisational, mentoring and coaching skills. The challenging global environment continues to drive industrial efficiency which in turn increases the demand for organisational information flow. At present companies are exercising a degree of belt tightening and are placing the breaks on significant capital expenditure in favour of optimising existing assets. “Rockwell Automation is well placed to serve current and future market needs as it offers exceptional value to customers with its highly integrated products and solutions portfolio,” said Ponticello. AT

RSTechED Provides Innovative Solutions to Application Challenges

The annual Rockwell Automation® Software Technical Education (RSTechED™) conference was held in Melbourne. In its thirteenth year, the popular event was sold out weeks in advance with more than 150 end-users, system integrators, partners and OEMs attending the three day event. According to Dean Tresidder, Solutions Architect, Rockwell Automation, “The lab sessions were an opportunity to provide hands-on product demonstrations which allowed customers to use the technology and see what it can do for them within their specific applications.” Incorporating advances in software technology is increasingly becoming an important means for companies to increase productivity, reduce operating costs and improve quality. “RSTechED provided the venue to share ideas, educate people about the core technology and open their eyes to new technologies,” explained Tresidder. As demands on resources,

infrastructure and manufacturing continue to increase so does the need for innovative solutions to deliver improved productivity. Innovation was a key theme in this year’s event as Rockwell Automation continues to release and integrate more products to meet customers changing requirements. “The need for increased productivity is driving the quest for innovation and our products provide a platform for our customers to add their specific components and deliver their own innovative solution to their individual applications,” said Scott Miller, Business Manager, Visualization Software at Rockwell Automation. Visualisation technology is moving towards integrating HMI software functionalities to controllers. The latest version of FactoryTalk® View provides the scalability and usability to meet customer requirements together with a common look, feel, and navigation to help speed HMI application development and training

time. Companies around the globe are investing in innovative ways to defer the cost of installing and maintaining server and application infrastructure. According to Rachel Shi, Marketing Project Manager Rockwell Software, Asia Pacific, “We have established a strategic alliance with Microsoft to develop Cloud based technologies that meet our customers’ changing requirements. “The Cloud presents an attractive alternative to move traditional infrastructure from on-premise to the virtual environment—allowing manufacturers to focus on manufacturing and not infrastructure,” continued Shi. By investing in innovation, Rockwell Automation continues to develop strategies to help companies optimise their automation and control systems to meet the changing requirements of today’s competitive marketplace. AT

Paul Ponticello


Tunnelling into the FutureAuckland’s first urban road tunnel is set to cut commuting times from the Auckland Harbour Bridge across to the central business district. Its innovative design melds old and new, partly housing an advanced monitoring and control system from Rockwell Automation in a restored heritage building.

In 2009, the New Zealand government announced the Roads of National Significance project, an ambitious undertaking to build or upgrade seven essential state highway links to support national economic prosperity. The first of these projects, the Victoria Park Tunnel, completed in March 2012, paved the way for a new era in Auckland’s intra-city commuting.

A government-funded upgrade to State Highway 1, the Victoria Park Tunnel provides increased safety and reliability for trips on Auckland’s central motorway system for 150,000 vehicles each day. Designed and constructed as a 450 metre cut-and-cover tunnel, it lies adjacent to the existing Victoria Park Viaduct and carries all northbound traffic formerly flowing over the viaduct. The viaduct has been reconfigured to carry four southbound lanes. This is Auckland’s first major urban road tunnel. The decision to go underground stemmed from the need to protect the character of Victoria Park, the sensitive and historically significant inner-city green space which it runs through.

According to Helen Cook, Communications Manager with the Victoria Park Alliance, the northbound peak-time trip between Greenlane and the Auckland Harbour Bridge reduced by approximately 10 minutes when the full capacity of the tunnel became available in late March. “It is still early days but indications are that the Victoria Park tunnel project has achieved its main objective, to remove the last major traffic bottleneck

on Auckland’s central motorway network.” The opening of the tunnel’s third lane was the final stage of project delivery, following the opening of two northbound lanes in November 2011. This staged completion was necessary due to the project’s complexity, which involved major traffic and service diversions.

The project was delivered by the Victoria Park Alliance, comprised of the New Zealand Transport Agency (NZTA), Fletcher Construction, Beca Infrastructure, Higgins Contractors and Parsons Brinckerhoff. Designed and commissioned by Rockwell Automation®, the tunnel’s plant is monitored and controlled by a dual Allen-Bradley® ControlLogix® system to provide redundancy in the event of system failure.

Auckland’s First TunnelAs the city’s first urban road tunnel,

built through reclaimed land in a busy and heritage-rich area, Victoria Park Tunnel presented some unique challenges. It involved the diversion and upgrade of major services, including New Zealand’s largest sewer; the International Telecommunications Cable which links New Zealand to the rest of the world, and water supply pipelines for Auckland’s North Shore. Contamination from previous land usage needed to be contended with, as did frequent encounters with unrecorded pipelines, power cables and drainage.

Traffic diversions were necessary during tunnel construction and associated motorway widening. “There

The kindergarten was restored to its original state and is now dual purpose.


were definitely challenges around traffic management—keeping traffic flowing while digging a huge hole in the ground.” says Wernher Roding, Mechanical and Electrical Design Leader with the Victoria Park Alliance. According to Roding, diversions were managed through good planning: traffic was diverted to local roads overnight and on weekends, minimising disruptions during the working week.

Monitoring and ControlIntegrated monitoring and control of

the tunnel’s mechanical and electrical systems was also a challenge. According to Roding, the project required a plant monitoring and control system (PMCS) which had no single point of failure and a could achieve a hot-changeover—where control is handed over seamlessly from the main controller to the backup controller, so the plant doesn’t experience any glitches or interruptions. The Alliance selected the Allen-Bradley Control Logix system supplied by Rockwell Automation as it met these criteria, and because of their previous experience in road tunnel projects.

“The PMCS is responsible for controlling drainage, ventilation, lighting and low voltage areas of the plant,” says Sean McGinity, Bid and Proposals Manager, South Pacific with Rockwell Automation. “It acts as the critical interface between fire systems, plant and NZTA’s traffic management system.” The PMCS is hardwired to 10 remote I/O locations inside and above the tunnel, comprising a mix of sensing switches, fans and pumps.

The PMCS interfaces with a number of third party products, including drives, power monitors and the NZTA’s Transdyn Traffic Management System, at the Auckland Motorway Control Centre in Takapuna, approximately six kilometres away. McGinity says that the key to making the project work was drafting an interface specification document to define each interface fully at the design stage. “Rockwell Automation authored the specification which included our requirements for integration. Each third party supplier added to the specification, outlining their requirements and answering our needs.”

According to Prasad Nory, Industry Manager, Rockwell Automation “ControlLogix is becoming a standard Programmable Automation Controller

for tunnels in New Zealand due to its excellent reliability and performance, ease of use and local service and support.”

The specification then went through a three-way approval process: Rockwell Automation, third party suppliers and the Victoria Park Alliance before the code was developed, prototyped and tested, and finally deployed. The design and testing of the PMCS was completed in just 15 weeks. “Given the short project timeframe and high public profile, we needed to deliver on time and to requirement,” McGinity says.

Old and NewFinding a place to house the PMCS

and other tunnel equipment was also an interesting process. According to Roding, the equipment needed to be located as close to the middle of the tunnel as possible to minimise the cabling required. Because the tunnel went under Victoria Park, a sensitive area reserved for community green-space, building a new equipment room there was not possible. An underground space was prohibitively expensive. Fortunately, another option presented itself in the form of Auckland’s (and New Zealand’s) first kindergarten building, which had lapsed into disrepair.

“We identified the Campbell Free Kindergarten as a potential building. We did an analysis and found equipment would fit, and we found that it would be economic as well,” says Roding. Following approval from the local council, the kindergarten was restored to its original state and is now dual purpose: tunnel equipment is housed partly on the ground floor and top storey, while the remainder of the building is for community use.

Some issues of safety, both for the public and the tunnel equipment arose from this arrangement, particularly that of fire protection. Although not required under New Zealand legislation, the Alliance chose to install fire doors and gas suppression systems in the rooms containing tunnel equipment to help protect the public from equipment fires, and help protect the equipment from fires in the public areas. “If one of the public areas became a coffee shop, for instance, we wanted to make sure that if there was a fire it didn’t affect tunnel equipment,” says Roding. Security systems and locked doors

further protect the equipment from public access.

Sharing the WealthThe New Zealand government’s

Roads of National Significance projects, including the Victoria Park Tunnel, have been classified as ‘lead infrastructure projects’, specifically designed to inject money into the local economy. “The government wanted the project to be split up in to smaller pieces—a philosophy of sharing the wealth, so to speak. We had to make sure we were up-skilling smaller organisations and also those that weren’t used to doing this kind of work. It wasn’t just about the money,” says Roding.

Tunnel work was new to many of the project’s suppliers and providers, and so design specifications had to be especially clear to keep things on track. This, along with careful monitoring and management of suppliers by the Alliance, lead to a successful outcome in this unusual project environment.

As part of the project evaluation, scores were given to project suppliers, and one of those receiving a high score was Rockwell Automation, who has also been working with the Victoria Park Alliance to make changes and improvements to the tunnel following its commissioning. “From a technical perspective they were easy to work with, professional, and did what they said they would without any fuss. It seemed that there was a genuine drive to get the job done.” says Roding.

The Alliance has received positive comments about the urban design initiatives included as part of the project, including the tunnel egress structures which incorporate artistic references to the importance of the area as a Maori fishery before European settlement. Early feedback from commuters on how the tunnel is working to improve their trip is that traffic through St Marys Bay is free-flowing for the first time in many years.

The Victoria Park Tunnel has been a complex, multistage project successfully completed on schedule. With its state of the art control and integration system, focus on protecting community assets and assistance to small local suppliers as well as experienced collaborators, it has set the benchmark for road projects of the future. AT


Original equipment manufacturers (OEMs) and System Integrators (SIs) everywhere face increasing

pressure — to reduce costs, increase their customers’ up time, provide performance guarantees and to generate revenue.

In recent survey results conducted by U.S.-based industry analyst Aberdeen Group, 50 percent of the responding OEMs reported significant customer demand to provide faster, lower-cost, post-sale service. In response to this demand, OEMs and SIs are developing strategies to drive revenue from post-sale support offerings.

In developing these strategies, savvy OEMs recognize that, because 50 to 70 percent of all support calls result from configuration changes involving equipment or settings, troubleshooting calls should begin there rather than with trying to diagnose product issues. To perform this troubleshooting effectively, OEMs need to collect all log files, run all traces and diagnostic commands, and parse key information from this data.

But customers often don’t collect all of the necessary data, or they don’t know what they need to collect. How helpful would it be to automate this data collection to assist less experienced personnel with execution of all of the complex but required steps, and

deliver clear, readable analyses in their local language?

Improvement through Automation

To address these needs, Rockwell Automation® has developed the Virtual Support Engineer. Virtual Support Engineer is an innovative service through which OEMs and SIs can detect, diagnose and resolve technical issues proactively at their customers’ sites; perform scheduled and preventive maintenance remotely; and monitor key tags to ensure optimal performance.

As a result, OEMs and SIs enjoy lower support costs due to fewer calls and field dispatches, shorter resolution times and more frequent first-call resolution. They also realise higher support revenue based on increased renewal rates, premium service contracts, up-sell opportunities and the ability to offer new products and services. Additionally, they can increase asset up time with improved Service Level Agreement compliance and increased customer satisfaction.

Using Virtual Support Engineer, OEMs and SIs can discover technical issues at customer sites before their customers do. They can predict technical issues at customer sites to enable prevention, automate routine

manual support tasks to decrease Mean Time to Repair and collect required data for reporting automatically, enabling them to sell premium services.

Reaping the BenefitsVirtual Support Engineer runs on

the Allen-Bradley® 200R industrial non-display computers. These computers combine today’s latest technology and ruggedness in a compact form factor to meet specific industrial needs. The flexible form factor lets users Vesa-mount the computer to the back of an industrial monitor, integrate the computer into an existing panel using a DIN rail or machine-mount the computer. Custom installations are available, and customers need only a single part number for the computer, software, set-up and configuration assistance, as well as first-year maintenance.

There are several advantages to this virtual solution:

Simple and Secure Connectivity: Using IT-approved, outbound-only communication, Virtual Support Engineer provides safe access to assets and valuable information about machinery without sacrificing the security of transferred data.

Real-Time Alarming: Virtual Support Engineer alerts OEMs and SIs to issues

VIRTUAL SUPPORT ENGINEERRockwell Automation Services & Support offers Virtual Support Engineer, enabling OEMs and System Integrators to monitor and manage equipment from anywhere in the world.


with their machinery through real-time alarms that can be delivered via e-mail and text message.

Data Collection and Analytics: With Virtual Support Engineer, OEMs and SIs gain access to a wealth of alarm data and analytics for their machinery.

Scalable, Cost-Effective Solution: Rockwell Automation has developed Virtual Support Engineer as an easy, cost-effective solution for remote support. With a small, DIN-rail mounted footprint and remotely configurable interface, getting started is easy.

Behind the Technology Virtual Support Engineer is a software

client that is bundled on a Rockwell Automation industrial PC. OEMs and SIs can connect Virtual Support Engineer to anything with an IP address, for example, a ControlLogix® controller, a FactoryTalk® View SE terminal or server, FactoryTalk Historian or perhaps a Cisco switch.

With this connection, an OEM or SI can connect to these assets securely and remotely. Virtual Support Engineer also includes monitoring capabilities so that OEMs and SIs can set up alarms on any of these devices and software. With these alarms, OEMs and SIs receive immediate notification when a motor fails, a CPU crashes or an interlock is tripped

OEMs and SIs can set proactive alarms as well. They can track consumables on end customer machines and send an alarm when it’s time to reorder. They can monitor cycle counts on an end customer machine and determine when to schedule preventive maintenance. They can also set alarms for notification when temperatures range outside of certain bandwidths and when a computer’s memory is 80 percent full.

Secure OperationsThe computer installed with Virtual

Support Engineer deployed at an OEM’s or SI’s site connects through the customer’s firewall using an outbound-only connection. OEMs and SIs need to open only a single port, and they retain the ability to prevent access to their machine from all incoming traffic. The outbound connection passes through the OEM’s or SI’s Internet service provider to the Internet, so that the

OEM or SI can control and monitor his machines from any location.

Each TCP port has two distinct connections, inbound and outbound. A firewall can be configured to permit or deny access on any TCP port for either inbound or outbound connections. Virtual Support Engineer requires only that TCP port 443 be configured to permit outbound and acknowledgement packets. In this way, an end customer can set up his firewall to block all inbound or outbound traffic to his network. Expensive VPN access is not required.

Virtual Support Engineer uses 1024-bit encryption, certificate-verified, outbound-only communication with customer-authorised remote access. Virtual Support Engineer uses customer-standard firewalls to protect devices from public access. End customers can specify levels of access to specific devices and information and also limit the information that users can transmit out of their facility. Remote sessions are logged, and data is encrypted using Secure Socket Layer protocol to prevent interception.

Each engineer is assigned a unique login to access the Rockwell Automation Service Center, and Rockwell Automation manages all user accounts. Rockwell Automation recommends that all process networks are managed and secured correctly using managed switches with VLANs to ensure security and high availability; it also recommends that routers/firewalls are used to control access to corporate networks and the Internet. Furthermore, Rockwell Automation recommends Windows Active Directory security to control access to all Windows servers, workstations and clients.

Finally, at the end customer’s site,

Rockwell Automation ControlLogix controllers can be secured at multiple levels by limiting physical access to the controllers, setting key switches to Run, and securing them to permit authorised access only. End customers can use Logix controller security and control access to workstations running RSLogix™ 5000 programming software with FactoryTalk Security and Windows Active Directory security.

Unique Among the Competition

Rockwell Automation is not the only company to offer a remote access and monitoring solution. Virtual Support Engineer is, however, unique. It offers outbound-only communication through customer-standard firewalls. There is no need for customers to permit inbound access, no need for VPN access and end customers control access to their equipment and information.

Virtual Support Engineer also allows OEMs and SIs to access and edit their programs remotely with no additional Rockwell Software® packages required on their machines. Most other solutions cannot provide this ability, and those which can require the use of a VPN.

In addition, Rockwell Automation monitors the health of each Virtual Support Engineer system and notifies the OEM or SI if the connection is lost. Rockwell Automation proactively pushes updates and patches as available and backs up OEM and SI configurations for quick and easy replacement.

If you’re an OEM or SI, you may want to consider the Virtual Support Engineer remote access and monitoring solution. It minimises costs, improves customer satisfaction and increases revenue. AT

The Virtual Support Engineer enables OEMs to detect, diagnose and resolve technical issues proactively at their customers’ sites.

Simplify the Deployment and Management of Process Control Systems

WATCHTECHNOLOGY


PlantPAx Virtual Image Templates from Rockwell Automation reduce validation and engineering costs.

Manufacturers in a range of industries can more easily deploy, operate and maintain

operations using the PlantPAx™ process automation system from Rockwell Automation®. With its latest release, Rockwell Automation delivers new tools for engineers to streamline project implementation.

The PlantPAx Virtual Image Templates are among these tools. The preconfigured, drop-in templates – delivered as images on a USB hard drive – help reduce validation costs and initial engineering time. That’s because installing a complete process automation system traditionally takes several days. A virtual image of each component, however, can be deployed in a few hours. Once deployed, the components can be duplicated in minutes.

The templates operate in an open virtual-format file, officially supported by VMWare vSphere. There are three templates:

• Engineering Workstation (EWS): Contains the necessary software to fully configure the control and visualisation components of the PlantPAx process automation system.

• Operator Workstation (OWS): Consists of the software needed for visualising and controlling the process.

• Process Automation System Server (PASS): Provides central name resolution and look-up services across multiple computers for central administration of data throughout the PlantPAx process automation system. The PASS also provides data, human-machine interface (HMI) and alarm server capability.

A virtual environment, which the PlantPAx Virtual Image Templates help create, offers several advantages to end users. For example, it extends the hardware life cycle, resulting in reduced IT administration and support. It allows multiple applications and operating systems to run on one hardware platform. Legacy software can run on newer hardware, and/or older hardware can run newer software.

In addition, a virtual environment enables control system independence from hardware, improving total cost of ownership and enhancing high availability. Separating software from hardware extends the life cycle of the control system and reduces risk associated with hardware, operating systems and applications.

Also, a virtual environment enables users to standardise on customised process control strategies, resulting in easy distribution of best practices. Once a process control strategy is designed, it can be reproduced throughout the plant or in multiple plants around the world.

Virtual machines structured on end-user roles enhance security and increase flexibility. Operators and engineers are able to access their workstations through any number of “thin clients,” traditional desktops or tablets transparently and seamlessly. This feature allows an EWS to be converted to an OWS based on the log-in.

Furthermore, dynamic movement of virtual machines minimises lost

revenue from planned or unplanned downtime. Virtual machines can be migrated between servers while the system is still running. Administrators can shift workloads with no impact to the system during scheduled outages, and machines can automatically recover if a server fails.

Finally, a virtual environment helps eliminate underutilised servers, improving operational efficiency. Traditionally, IT isolates servers based on tasks, which mean many servers aren’t used to capacity. Independence from hardware prevents under-utilisation in a virtual environment.

“Whether you’re operating one plant or many, virtual image templates significantly simplify the deployment and management of process control systems,” says Steve Pulsifer, director of Process Market Development, Rockwell Automation. “Plus, users benefit from immediate access to simplified upgrade and patch management typical within a virtualised architecture.” AT

F unctional safety covers a broad range of devices that are used to create safety systems. Devices

like interlocks, light curtains, safety relays, safety programmable logic controllers (PLCs), safety contactors and safety drives are interconnected to form a safety system, which performs a specific safety-related function.

Two types of requirements are necessary to achieve functional safety: the safety function and the safety integrity. A safety function is implemented by the safety-related parts of the machine control system to achieve or maintain the equipment under control in a safe state with respect to a specific hazard. The safety system must be designed with a level of integrity that is commensurate with

the risks of the machine.The required performance level

(PL) is the result of a risk assessment and refers to the amount of the risk reduction to be carried out by the safety-related parts of the control system. Part of the risk reduction process is to determine the safety functions of the machine.

The International Standards Organization (ISO) in its ISO 12100:2010 standard specifies basic terminology, principles and a methodology for achieving safety in the design of machinery. Rockwell Automation has considered this standard in the development of its documents.

DEFINING FUNCTIONAL SAFETY

Documentation for safety functions helps designers build a complete safety system.

Putting More Function into Functional Safety

SAFETY


1

2

3

From: Risk Assessment (ISO 12100)

To: Realisation and PL Evaluation

Identification of safety functions

Specification of characteristics of each safety function

Determination of required PL (PLr) for each safety function

In today’s manufacturing environment, good implementation of safe machine systems serves two purposes: it

minimises workplace incidents and enhances productivity.

That is why it is important for manufacturers and original equipment manufacturers (OEMs) to focus on automation safety in their operations. Doing so enables them to better meet long-term business goals of greater efficiency and optimised assets while protecting human and manufacturing capital.

A Pre-Engineered Safety Solution

To help customers focus on functional safety, Rockwell Automation® has introduced a series of specifications for various safety functions. According to Chia Chang Kin, Rockwell Automation product manager, the documents will enable customers to set up control systems quickly and easily.

The documents address questions

customers may have such as: What type of safety functions should be implemented on my machines? What are the right safety components? How can the safety solutions be integrated into the machines? What’s more, the documents explain how to ensure that the safety solution meets a required safety performance level (PL) and how to maintain and improve the safety solution over time.

Documents are available in two versions. The short version is geared for those with an existing understanding of safety system development. A longer version provides more detailed description including general safety information, functional safety descriptions, setup and wiring notes, and configuration information. It also includes verification and validation plans.

In October 2012, Rockwell Automation released the first six sets of safety functions: Emergency Stop, Light Curtains, Two-Hand Controls,

Enabling Switch, Guard-Locking Switches and Door Interlocks. These are the most common safety functions employed in machines. Eighteen more safety functions/documents will be released in 2013.

What’s more, the company has compiled suites of safety functions commonly used in different industries. Metal stamping; material handling; automotive; Tyre and rubber; and appliances are among the industries as well as paper, pulp, and lumber; food and beverage; packaging; and palletisers/de-palletisers.

on the web

These free materials are downloadable from the Rockwell Automation Safety Resource Centre:http://discover.rockwellautomation.com/SFTY_EN_Machine_safety_functions.aspx#page=page-3

PROPOSITIONVALUE

Packaging: Fast and Flexible


Rockwell Automation solution increases slitter machine speed by 50 percent.

Founded in 1964, Taiwan’s Dah Bah Machinery Industrial Inc. designs products for use in the

packaging industry. The company manufactures and supplies machines for the full range of converting applications in compliance with the ISO 9001:2008 and CE standards, and has earned the prestigious Symbol of Excellence award.

As an original equipment manufacturer (OEM), Dah Bah is challenged to differentiate itself amidst global competition and rapidly evolving technology. Within today’s dynamic marketplace, end users demand innovative solutions that increase business agility, optimise productivity and achieve sustainability objectives, all while lowering their total cost of ownership.

Dah Bah’s quality policies are an integral part of its core values. This OEM believes strongly in persistent investigation, constant improvement, effective efficiency and customer satisfaction – living these values allows the company to consistently provide quality products and services to customers worldwide.

Teaming for SuccessTo compete in this global marketplace,

Dah Bah defines value beyond the cost of machines. Three years ago, Dah Bah started collaborating with Rockwell Automation® to improve each stage of a customised, high-end, bag-making machine for a French end user.

From design through development, to customer delivery and beyond, Dah

Bah was so satisfied with the services and global technical support received from Rockwell Automation that it gave Rockwell Automation the opportunity to be the control system provider for its slitting machine/ULTIMA series, a computerised, touch-screen control, high-speed slitting machine.

In the past, Dah Bah used control systems from competitors to meet the needs of different end users in Europe, the Americas and Asia. Those competitors, however, did not freely share technical knowledge and know-how with Dah Bah, pushing the OEM into a corner when it came time to develop new machines or offer service for machines.

With the slitting machine, Dah Bah’s goal was to enhance the machine’s accuracy to achieve a faster, smoother slitting operation. Using a single provider for the slitter machine simplified development and design time, provided Dah Bah engineers with easy-to-use programming and gave Dah Bah engineers the knowledge they needed to move forward on other slitter machine projects.

Of critical importance to Dah Bah was improved performance. The Rockwell Automation team was particularly challenged by the tension control of the machine. Because of the variety of materials the machine must handle – precision-cutting of OPP, PET, CPP, PVC (soft base), PVC shrinkable film, PE, paper and plating paper –


the change of tension can be rapid and dramatic. To address this, the Rockwell Automation solution delivers steady tension control. Now, the slitter can run smoothly up to 400-500 metres per minute – a 50 percent improvement over the machine’s previous speed.

A Solution for Seamless Integration

The ULTIMA series is designed for easy loading and unloading of the material while maintaining the true roundness of the paper core and rewinding roll as well as homogeneous hardness. It also allows the operator to select the desired tool type according to the material characteristics and to use the programmable metre counter to calculate the winding length.

The slitter machine utilises CompactLogix™ L27 controllers, PowerFlex® 755 drives, PanelView™Plus 1000 human-machine interfaces (HMIs), 1734 POINT I/O™, and Stratix 2000™ Ethernet unmanaged switches.

With PowerFlex drives and integrated motion control, the

ULTIMA machine can achieve multiple functionalities simultaneously. The CompactLogix L27 controller with CIP networking capability controls the operation sequence of the slitting machine and seamlessly integrates the drives and multi-axis tension control.

With the integration of motion control capability, the PowerFlex drive supports EtherNet/IP™ networking and links to other automation equipment. In addition, the CompactLogix controller can be configured with the multi-axis motion control module and be expanded up to 16 axes of synchronous motion control, controlling the position and speed of these axes while monitoring the status of the drive and providing a time stamp for diagnostics.

This control solution delivers the performance and cost saving Dah Bah expected while meeting industry standards. While the standard modules and user-defined function blocks are available for various application programs, the standard HMI helps to reduce the maintenance and stock costs. In addition, IT professionals

can use the familiar tools to provide more networking capabilities for information exchange. This helps new adopters simplify the integration of the fundamental structures.

Expanding Markets GloballyThe slitting machine is an important

product for Dah Bah; its goal is to sell the machine worldwide, making the Rockwell Automation global support and PartnerNetwork™ critical to success.

“This OEM values our global resources, co-marketing opportunities and instant technical support and service,” says Tim Hsieh, OEM account manager, Rockwell Automation Taiwan. “With strong name recognition throughout Europe and the Americas, the Rockwell Automation brand has put Dah Bah in a better position for gaining market share. In addition, the support team and supply chain established by Rockwell Automation will allow Dah Bah to market this machine globally.” AT


In today’s highly competitive Tyre and rubber manufacturing industry, businesses across the globe face

unprecedented and volatile changes. Manufacturers, material suppliers and original equipment manufacturers (OEMs) are affected by shifting customer demands, globalisation, industry consolidation, technology innovations, safety requirements, government regulations and the demand for lower customer prices.

In particular, Tyre manufacturing demands machines that combine high production output, consistent reliability and product quality with low manpower requirements and low maintenance costs. Alongside high-speed production, flawless product quality is also a priority. The machines also need to be flexible enough to adapt to trends like larger Tyre dimensions and more sophisticated designs.

Implementing automation and information solutions for Tyre and rubber manufacturing can lower the total cost to design, develop and deliver equipment such as Tyre building machines (TBMs), widely used to produce green Tyres.

The TBM ProcessThe TBM assembles all semi-

manufactured goods such as tread, sidewall, inner liner, body ply, bead and cord body to build green Tyres according to industry standards. The machine cycle is programmed to carry out the various operations automatically and simultaneously, to give a balanced and single operator building cycle. Sequences are controlled by a programmable logic controller.

The process is complex, as multiple machine parts need to be coordinated from and to drums, conveyors, rollers, jointless belt arrays and unwinding operations as well as the cutter system, laser mark, correction system and pneumatic valves.

Complicated sequencing and logic linking are coordinated via motion control, drive control and safety interlocks.

In addition, human-machine interface requirements include recipe, alarm, diagnostics and operation. Communication takes place with multiple third-party devices.

Challenges abound in the process, depending on the type of vehicle, Tyre size, Tyre structure (bias/radial)

and building methods. For the Tyre manufacturer, the goal is to leverage a TBM that is:

• Productive: Optimise period per phase as short as possible; shorten changeover time by complex recipe management; shorten recovery time; and maximise throughput with highest quality.

• Safe: Meet safety compliance standards to ensure the safety of staff and equipment.

• Flexible: Match different Tyre types and building processes, including the size of the green Tyre and different types of components.

• Easytouse: Easy maintenance despite complexity of the machine.

• IT-integrated: Provide enterprise-level connectivity with standard Ethernet access, MES platform and ERP support.

From the perspective of the machine builder, the TBM should be:

• Modular: Mix and match Tyre machine functions that are suited for specific customer applications; customise functions to develop a new machine that is localised to market demands.

• Standard: Develop and document mechanisms common to complex Tyre machines that can be easily redeployed with minimum modifications, despite different machine sections/conditions that result in more complicated sequencing and interlocking.

• Cost-effective: Machine integration, mechanical and electrical optimisation and wiring start-up time and costs are reduced.

Rockwell Automation®, with more than 100 years of close partnerships with Tyre and rubber manufacturers and OEMs, offers a range of power, control and information services designed to give manufacturers a competitive advantage.

By integrating control and information along with finite-capacity scheduling, manufacturers can streamline their Tyre building machine operations.

DEVELOPING BETTER TYRE BUILDING MACHINES

A Focus on Safety FunctionsThe Rockwell Automation

Integrated Architecture™ consists of discrete motion and drive control, input/output, network, visualisation and information components. It enables the real-time, enterprise-wide information exchange required to move decision-making to a higher level – where decisions can improve responsiveness and quality, increase productivity and reduce costs.

One of the TBM solutions Rockwell Automation offers features integrated safety functions. When safety protection is applied in the machine, hazards are removed, resulting in manufacturers achieving EN/ISO 13849-1.

Accelerating value with integrated safety increases productivity, efficiency levels, intelligence and overall competitiveness. Optimising functional safety beyond compliance improves the functional operation of the machine while reducing waste. In addition, designing integrated solutions increases competitiveness to capture global opportunity, reduce risk, improve service and improve mean time to repair (MTTR) and diagnostics.

The Rockwell Automation integrated safety solution maximises results while keeping machine downtime to a minimum. It also reduces acquisition costs by using a common platform and programming tools for safety and standard control and visualisation, as well as reducing switches (safety relays) and cabinet space. What’s more, safety programming provides open and integrated control that will help to ensure machine safety and protect the current control investments.

Distributed ControlWhen there is a need to have one

controller to achieve distributed control, Rockwell Automation offers a solution that includes open networks, integrated motion and a range of safety components. The result is one set of spare parts, one maintenance department and one system to manage.

The solution is based on the Allen-Bradley® CompactLogix™ programmable automation controller, which uses a common control engine with a common development environment to provide mid-range

application control. It combines safety, motion, discrete and drives capabilities in a single controller.

Other elements of this solution include: Allen-Bradley Kinetix® 350 and 6500 servo drives with MP-Series Low Inertia (MPL) servo motors, providing smooth acceleration and deceleration, fewer wiring connections and a common software platform; EtherNet/ IP™, which leverages CIP Motion, CIP Safety, CIP Sync, and device-level ring (DLR) technology so that the TBM can integrate with the IT environment; Allen-Bradley PanelView™ Plus human-machine interface (HMI), which shows the machine status and alerts operators to faults; and a range of Allen-Bradley safety components to add safety controls.

Manufacturing Metrics and Development Tools

Performance metrics, like equipment/material use and overall equipment effectiveness (OEE), can provide critical insight into how well a TBM production operation is being managed. Rockwell Software® FactoryTalk® Metrics monitors plant-floor equipment and provides timely, granular and specific information both on current machine performance as well as historical data for long-term analysis. The data empowers plant personnel to make informed decisions on optimising assets within a production facility or across a manufacturing enterprise.

For example, a Tyre manufacturer may want to create a reporting system that collects data such as downtime, quality and material waste. Key data collection and reporting could include production counts, scrap production, material consumption, downtime events and key performance indicators.

Power programming is suitable for any Logix controller. Modular programming techniques – with predefined templates and faceplates that are reusable – result in shorter engineering time across the machine portfolio. In addition, flexible production allows existing assets to be adapted to new product requirements with minimal time and capital investment. Ease of modular implementations to test software

objects reduces development time by up to 50 percent.

Rockwell Automation also offers mechatronics tools and electronic cams to optimise servo-system hardware and motion cam profiles. For example, the Motion Analyzer Virtual Design Tool links mechanics with controls, enabling users to analyse, optimise, simulate and select options in a virtual environment before committing to a final machine design. Motion Axis Complex Move generates absolute or incremental complex motion profiles from a given move distance and move time. Multi Servo-Loop Configuration provides position, velocity and torque servo as well as dual feedback, auxfeedback and dual-command servo.

By integrating control and information along with finite-capacity scheduling, manufacturers can streamline their operations. What’s more, significant financial savings can be realised, including achieving increased manufacturing throughput as well as benefits from greater visibility, tracking and control of operations.

As solution experts in Tyre manufacturing, Rockwell Automation can help manufacturers succeed and grow with power, control and information services that provide a competitive advantage. The company’s in-depth understanding of the policies and requirements affecting business can help manufacturers reduce risk, improve operational efficiency and achieve faster time to market. AT



WATCHTECHNOLOGY

To meet machine builders’ needs for flexible micro programmable logic controllers (PLCs) that

optimise stand-alone machine performance and cost, Rockwell Automation® announces the new Allen-Bradley® Micro850™ and enhanced Micro830™ PLCs. Both feature embedded motion capabilities for up to three axes of motion, allowing them to support a range of applications.

The Micro850 micro PLC is equipped with the same form factor, plug-in support, instruction data size and motion capabilities as the 24-pt and 48-pt Micro830 controllers but with the added capabilities of Ethernet and expansion I/O. The Micro850 controller targets the needs of original equipment manufacturers (OEMs) and excels at stand-alone machine applications.

The Micro850 controller has an embedded Ethernet port for higher performance connectivity to human-machine interfaces (HMIs). The EtherNet/IP™ protocol with CIP Symbolic support is used for simplified Allen-Bradley PanelView™ Component HMI connectivity. Tags created while configuring the HMI screens can easily reference the variable names in the Allen-Bradley Micro800™ program.

IO flexibility in the Micro850 PLC is one of the keys to successfully minimise the cost of a machine. With support for up to five plug-ins, OEMs can customise the functionality of the controller with

additional IO, special functions and serial ports without increasing the size of the controller. If more I/O or higher performance analogue I/O is required, the Micro850 controller supports up to four 2085 expansion I/O modules, including high-density digital I/O and high-accuracy analogue I/O, for a total of 132 digital I/O points (with 48-pt model).

The enhanced Micro830 (via a firmware and software upgrade) and Micro850 controllers support up to three motion axes using pulse output to stepper or servo drives. OEMs can use intuitive motion function blocks – including Home, Move Velocity, Move Absolute and Move Relative – to make single-axis moves easily. For applications where precise positioning is required at high speeds, the Touch Probe function block has special hardware to achieve exact-position registration.

A single programming software called Connected Components Workbench™ simplifies the installation, configuration, connectivity and maintenance of machine devices, including the series of Micro800 controllers, Allen-Bradley PowerFlex® drives and PanelView Component graphic terminals. The single connected Components Workbench software saves OEMs time and associated costs compared with using a different programming tool for each device.

Connected Components Workbench software comes in two versions, Standard and Developer. Standard can be downloaded for free at h t tp : / / ab . r o ckwe l l au tomat ion .com/Programmable-Controllers/Connected-Components-Workbench-Software. Developer, which features run-time download, user-defined function blocks and controller simulation, is available for order through local Allen-Bradley distributors around the world.

Co Gia Nguyen, vice president and general manager, Rockwell Automation Asia Pacific Business Center, says, “To be profitable, machine builders around the globe demand world-class micro PLCs. But these controllers must meet machine builders’ requirements for economical, just-enough control while providing additional options and features that enable machine builders to differentiate their machines from the competition. The new Micro850 and enhanced Micro830 controllers balance those needs and help machine builders compete more profitably.”

Rockwell Automation launched the Micro800 controllers in May 2011. AT

on the web

For more information on the Micro850 and enhanced Micro830 micro PLCs, visit:http://ab.rockwellautomation.com/Programmable-Controllers/Micro-and-Nano

Micro PLCs Expand Machine-Building FlexibilityRockwell Automation micro PLCs help machine builders compete more profitably.

FOCUSPRODUCT


Personal contact is more than phone calls and e-mail. It’s people working together to develop unique solutions.

Take the guesswork and risk out of choosing your extended automation team. Selecting a

qualifi ed Rockwell Automation Authorised Distributor brings you resources closely matched

to your industy or application need.

Go to http://www.rockwellautomation.com/distributor/

RA-Partner-Advert_Half-page_pace.indd 1 2/02/2011 11:49:59 AM

A new publication from Rockwell Automation® looks at the principles and standards relating to safety in process applications and discusses how to implement effective solutions.

‘Process Safebook 1 – Functional Safety in the Process Industry’ has been published by Rockwell Automation to provide its customers with an overview to functional safety and guidance in the application of IEC61511, the process industry specific implementation of IEC61508.

IEC61508 has already been hugely influential and will continue to be the basis of modern safety standards and legal frameworks, so it is essential that personnel with responsibilities at any stage of the life of a safety-related system should make the effort to understand it. It covers the safety management of electrical, electronic and programmable electronic systems throughout their lives, from concept to decommissioning and brings safety principles to the management of systems, and safety engineering to their development.

At its core is the principle that, in safety planning, safety goals based on risk assessment should be set, and then that the rigour of management and processes should be appropriate to meeting them. This makes the standard goal-based rather than prescriptive, and means that compliance with the standard does not exonerate users of any blame in the event of a safety problem.

According to Keith J Kirkcaldy, author of ‘Process Safebook 1’: “The book was originally aimed at sales engineers and designers within Rockwell Automation, to help them understand some of the basic concepts that customers typically ask for; the objective being the provision of cost-effective solutions to their requirements.”

The publication evolved from a local, internal publication to one that spread throughout the global organisation. It has now become available as a published book to customers and System Integrators. “It has been written in such a way that it clarifies the terminology and jargon and uses simple language illustrated with examples taken from our own experience,” Kirkcaldy explains. “It shows that compliance with the standards is not just about calculation and analysis and meeting quantitative targets, but also stresses and shows the importance of competent management and

implementation. It shows compliance is not a paperwork exercise with the objective of producing documents but, instead, it is about making sure that adequate information is available.”

The book gives an overview of many facets of process safety including, but not limited to:

• Safety Lifecycle• Hazards and Hazard

Identification• Risk and Risk Reduction• Determining SIL Targets• Allocation of Safety Functions• Reliability Techniques• SIL Verification• Functional Safety, Assessment and Auditing‘Process Safebook 1’ is just part of the total safety offering from Rockwell

Automation, which also includes a comprehensive portfolio of process safety solutions and services. The company also offers similar guidance, products, solutions and services for machine safety. ‘Safebook 4 - Principles of Machine Safety: Legislation, Theory and Practice’ is another book available to order or download. It covers the principles, legislation, standards and application of machine safety.

Recognising the impact that safety has across many industries, as well as the challenges and opportunities its customers face, Rockwell Automation has put significant budget and resources behind a strategy aimed at assisting companies to address safety legislation. From white papers and videos through technical publications to machine-level software and library files, Rockwell Automation is your one-stop choice for all things relating to safety – especially if you want it to work for you rather than against you.Download Process Safebook 1 here: http://literature.rockwellautomation.com/idc/groups/literature/documents/rm/safebk-rm003_-en-p.pdf

Process Safebook 1: Functional Safety in the Process Industry

FOCUSPRODUCT


Safety Automation BuilderThe Safety Automation Builder † (SAB) tool facilitates planning of

safety systems, helps you select products to achieve the required safety performance level (PL) according to EN ISO 13849-1, and creates SISTEMA projects for analysis of all Safety Functions. Use SAB to:

• Layout machine hazards and access points. • Define safety functions and select safety products for each. • Export data to SISTEMA for analysis.* • Direct integration to ProposalWorks for complete BOMs SAB leverages the industry’s most complete offering of safety products,

utilizing widely accepted best practices to build a complete safety solution. Outputs of the tool include:

• Bills of Material • Conceptual Safety Layout Drawings • SISTEMA project files*

†Patent pending.*SAB and SISTEMA tools must be used in conjunction with each other

to provide this output.

For more information, visit:http://discover.rockwellautomation.com/SFTY_EN_safety_automa-tion_builder.aspx

New Industrial Ethernet Switch simplifies line integration of OEM machines

The integration of machines onto a plant’s network architecture can prove difficult as OEM IP-address assignments rarely match those of the end-user network IP-address requirements. This is challenging for the machine builder and end user as IP addresses are generally unknown until the machine is being installed, which can add cost and time to the commissioning of the equipment, and delay moving that equipment into production. Rockwell Automation® has addressed this challenge with the Allen-Bradley® Stratix 5700™ managed industrial Ethernet switch, which now includes an optional integrated Network Address Translation (NAT) feature.

The hardware-based NAT feature allows for high performance and simplified integration of IP-address mapping from a set of local, machine-level IP addresses to the end user’s broader plant-process network. This can greatly benefit manufacturers that are integrating identical machines into a production line, especially when multiple equipment builders are being integrated into a common production line. The Stratix 5700 switch NAT feature allows OEMs to deliver their standard machines to customers without having to program unique IP addresses into them. The end user can then use the NAT feature to more simply integrate the machines into the larger network. Because the machines are identical to their standards, they are easier to maintain.

“In addition to integrating NAT into the Stratix 5700 switch, we are able to offer customers an optimized solution by eliminating the need for additional components that require extra cabinet space, extra wiring, and additional configuration and management support. Additionally, the NAT setup is part of the overall switch configuration environment, making it easier to maintain,” said Gavin Black, Business Manager Components – South Pacific, Rockwell Automation

The Stratix 5700 switch with NAT technology also allows users to have the flexibility to segment or isolate network traffic by determining which devices are exposed to the larger network. By limiting access to certain devices, they can be isolated from broader network traffic, which can help optimize the network performance at the local level.

The Stratix 5700 line of switches is currently available with six, 10 and 20 fixed-port configurations. The product includes features, such as IEEE-1588 time synchronization, QoS (prioritisation) and Resilient Ethernet Protocol (REP). Additional features also allow for increased network availability, and help improve network performance and troubleshooting-enhanced security. Each Stratix 5700 switch includes: dual-power inputs, input and output alarms, console port, fiber-ready SFP slots, DIN rail mount, and operating temperature range of minus 40 C to 60 C. Model options include: NAT, two gig ports, SD flash card, conformal coating, and two different software configurations for a total of 20 different models to best match machine and end-user applications.

For more information, visit:http://literature.rockwellautomation.com/idc/groups/literature/documents/pp/enet-pp005_-en-e.pdf

Guardmaster GLP Safety Relay

Rockwell Automation® has expanded its family of Allen-Bradley® Guardmaster® GSR safety relays with the new GLP module. Developed specifically for guard locking applications, the GLP helps OEMs reduce design and installation time for standstill or slowspeed guard locking applications. It uses two proximity sensors inputs to monitor motion and unlock a gate when equipment reaches a safe speed. Designed to meet international safety standards, such as EN ISO 13849-1 and EN 62061, the entire GSR relay line – including the GLP – features a patented, single-wire communication capability that helps eliminate the need for dual-channel connection between relays. Users can expand and cascade safety functions up to a safety integrity level (SIL) 3 rating using a single wire to connect between relays thus reducing installation time.

For more information, visit:http://ab.rockwellautomation.com/Relays-and-Timers/Safety-Relays/Single-Function/Guardmaster-GLP

FOCUSPRODUCT


Gain Energy IntelligenceEnergy Intelligence solutions from Rockwell Automation® help our customers get more value from

their energy data. You can take your energy data and now give it context in organisational or production models, making it more valuable, more relevant to the decisions manufacturers need to make.

FactoryTalk® EnergyMetrix™ provides insight across processes, across facilities or across countries. It is a scalable solution that helps to drive smart energy decisions. Gathering data from Allen-Bradley® power monitors, programmable automation controllers and other energy-aware devices, FactoryTalk EnergyMetrix software provides essential information for monitoring and managing energy use. Combining FactoryTalk EnergyMetrix with FactoryTalk VantagePoint enables users to visualise energy in context of the process/equipment/material or other such production or environmental data, to drive productivity programs to proactively control energy utilisation.

For more information, visit:http://discover.rockwellautomation.com/IS_EN_Intelligence_Energy_Intelligence.aspx

Jump Start Your Energy Reduction Initiative

The Energy Management Accelerator Toolkit helps users quickly develop and deploy an energy monitoring and control system with easy-to-use system design, programming and analysis tools.

The toolkit walks users through the fundamentals of creating an energy management plan including business goal development, plant walk-through, energy assessment and monitoring method techniques. PowerMonitor™ and other energy data collector panel layout and wiring drawings – prepared in DWG, DXF and PDF file formats – help to save preparation and installation time.

Utilise detailed configuration instructions for energy data collecting devices and FactoryTalk® EnergyMetrix™ software for energy monitoring, analysis and reporting needs. Pre-configured logic and human-machine interface (HMI) faceplates for “Time of Day” and “Demand Control” provide a starting point in saving energy consumption and demand charges.

To obtain this free toolkit, ask your local Rockwell Automation Distributor or Sales Office for the Energy Management Accelerator DVD, publication IASIMP-SP014.

For more information, visit:www.rockwellautomation.com/rockwellautomation/products-technologies/ integrated-architecture/tools/overview.page?#tab5

Improve Design and Productivity of Automation Systems

Rockwell Software® Studio 5000™ Automation Engineering and Design Environment allows engineers to enter configuration and programming information only once, then leverage it across their entire control system architecture – from design to operation to maintenance.

Based on the familiar interface of the RSLogix™ 5000 design tool, the Studio 5000 environment is intended to be the one place for design engineers to develop the elements of their control system. Version 21 includes the Logix Designer application, which is the progression of RSLogix 5000 software. Future versions will integrate additional elements into the design environment to accomplish typical engineering and design tasks such as human-machine interface (HMI) development, library management for reusable components, information integration and more.

Studio 5000 Logix Designer enables a new level of integration within the Integrated Architecture™ system. It enables the use of one design and configuration package; simplifies development of complex control solutions; provides access to real-time information; and helps to develop localised applications in a single control platform and in a collaborative engineering environment.

In addition, this engineering and design environment will have the ability to communicate and perform at higher speeds, resulting in improved productivity, shorter design cycles and a faster time-to-market.

For more information, visit:www.rockwellautomation.com/rockwellautomation/news/news-detail.page?reqid=1755581


FOCUSPRODUCT

Dual-Port EtherNet/IP I/O Adapter

The Allen-Bradley® FLEX™ I/O dual-port EtherNet/IP adapters from Rockwell Automation® help OEMs connect machines to their customers’ IT infrastructures using a single network. With dual ports, users can also leverage the adapter to display diagnostics via a simple web browser, helping reduce troubleshooting and downtime.

The new EtherNet/IP adapters support a device-level ring (DLR) topology, which provides robust network infrastructure and fast recovery time while keeping implementation costs down. DLR infrastructures are connected at the end device versus the switch. With no need for unnecessary switches and cabling, users can reduce design time and simplify implementation and maintenance.

A DLR topology also adds a measure of redundancy that ensures a single network failure, such as a cable break, won’t lead to failure of other devices in the ring. Recovery time is less than 3 ms for a 50-node system, and the connection between the programmable automation controller and the I/O device is not interrupted. Adapters also support the daisy-chain topology for applications that involve devices located long distances from CPU subsystems. The adapters – 1794-AENTR and 1794-AENTRXT for extreme environments – are compatible with Rockwell Software® RSLogix™ 5000 programming software V16 and higher.

For more information, visit:http://www.ab.com/en/epub/catalogs/12762/2181376/104830/2416241/1168992/ I-O-Communication-Adapters.html

842E-CM Integrated Motion on Ethernet/IP Absolute Encoder

To continue to drive machine scalability, Rockwell Automation® developed the Integrated Motion on EtherNet/IP Encoder as part of the Midrange System with its CompactLogix™ 5370 controllers.

The size of a machine’s footprint is becoming very important today. With the introduction of the the Kinetix® 5500, Rockwell Automation has greatly reduced the footprint required for the control panel. By utilizing a single network, the 842E-CM contributes to this footprint reduction by placing aux feedback requirements out of the panel and right on the machine.

The Allen-Bradley® 842E-CM encoder is a creative solution for these applications that complements the new Kinetix 5500 architecture. By providing auxiliary feedback directly through the EtherNet/IP network, the 842E-CM eliminates the need for point-to-point wiring while allowing customers to use the encoder in a variety of network topologies. What also makes this product truly unique is that it takes advantage of CIP Sync and CIP Motion Technology, a time synchronisation extension for the Common Industrial Protocol (fully compliant with IEEE-1588). Using CIP Sync and CIP Motion Technology, the encoder provides a timestamp associated with all data delivered to and from the controller to allow it and the entire system to be synchronised with the master clock reference on sub-microsecond levels. Thanks to Premier Integration between the 842E-CM and Allen-Bradley Logix controllers provides a seamless user experience. A user can add and configure the encoder into their Studio 5000™ Logix Designer (formerly

RSLogix5000®) software project thereby allowing it to function as a feedback-only CIP axis in the Logix controller.

For more information, visit:http://ab.rockwellautomation.com/Motion-Control/Integrated-Motion-on-EtherNet-IP-Abso-lute-Encoder

Compact AC DriveThe new Allen-Bradley® PowerFlex® 525

AC drive from Rockwell Automation® is the next-generation compact drive designed to provide stand-alone applications and basic machines with programming flexibility and simplified commissioning.

Offering a variety of motor control options and available in power ranges from 0.5-30 hp or 0.4-22 kW at 100-600V input, the PowerFlex 525 drive offers a hardware design with a removable control module for MainsFree™ programming. The drive can be configured through its human-machine interface (HMI) module, Allen-Bradley Connected Components Workbench™ software or Rockwell Software® Studio 5000™ unified engineering and design environment.

Using the AppView™ tool, users can take advantage of predefined application sets for common applications. Configurations can be downloaded quickly to drives using a PC and standard USB cable. The drive comes standard with an embedded port for EtherNet/IP, Safe Torque-Off and energy-saving features. The drive is rated up to 50°C (140°F) and with an optional control module fan kit rated up to 70°C (158°F) with current derating.

For more information, visit:http://phx.corporate-ir.net/phoe-nix.zhtml?c=196186&p=irol-newsArticle&ID=1753026&highlight=

Virtual Support EngineerRockwell Automation® has developed the Virtual Support

Engineer. Virtual Support Engineer is an innovative service through which OEMs and SIs can detect, diagnose and resolve technical issues proactively at their customers’ sites; perform scheduled and preventive maintenance remotely; and monitor key tags to ensure optimal performance.

The service enables OEMs and SIs to realise lower support costs due to fewer calls and field dispatches, shorter resolution times and more frequent first-call resolution. They also realise higher support revenue based on increased renewal rates, premium service contracts, up-sell opportunities and the ability to offer new products and services. Additionally, they can increase asset up time with improved Service Level Agreement compliance and increased customer satisfaction.

For more information, visit:www.rockwellautomation.com/services/online-phone/ virtual-support-engineer.page

CompactLogix 5370 Controllers

Bulletin 1769 CompactLogix™ 5370 Controllers are ideal for small to mid-size machines and provide the benefits of Integrated Architecture™ for lower-cost machines. When combined with Kinetix® 350 servo drives, these controllers provide a strong motion solution for customers who require high performance in a compact and affordable package. These controllers expand on the scalability of the Logix family and share common features across all three platforms, including support for Integrated Motion on EtherNet/IP and Device Level Ring (DLR) for enhanced network resiliency.

For more information, visit:http://ab.rockwellautomation.com/Programmable-Controllers/CompactLogix-5370-Controllers

Life Cycle ServiceRockwell Automation® has developed a support offering to minimise

the risk associated with using older or discontinued Rockwell Automation products. The Lifecycle Service Agreement consists of three unique services: Reserved Repair and Parts, Remote Support for Discontinued Product and OnSite Service for Discontinued Product.

Reserved Repair and Parts provides manufacturers a “reservation” that assures access to Rockwell Automation product replacement, remediation or repair for Rockwell Automation products included in the agreement – even when maintenance resources or spare parts are constrained or are unavailable to the general public. Remote Support for Discontinued Product provides unlimited web support for obsolete or discontinued Rockwell Automation products included in the agreement. OnSite Service for Discontinued Product provides annual preventive maintenance services, migration and conversion-planning support on Rockwell Automation discontinued products included in the agreement.

For more information, visit:www.rockwellautomation.com/rockwellautomation/solutions-services/capabilities/migration-solutions/lifestyle-extensions.page

At last, there’s a purely electronicsolution to position sensors. Ournew 955 eBrik uses magneto -strictive technology so there’s no contact, no moving parts, and

nothing to wear out. No erraticposition signals. Available in1" to 72" stroke lengths, it’seconomical and versatileenough for many applica-tions, field-programmable,

and the perfect replacementfor old-style potentiometers.

Learn more at our website.

Price and performance so well balanced, it just might displace

potentiometers.

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AMETEKAPT10017-R_eBrick-4x5_RAOTM_Layout 1 09/11/12 10:41 AM Page 1

FOCUSPRODUCT


CALENDAREVENTS

VISIT ROCKWELL AUTOMATION AT THESE EVENTS: JULY - SEPTEMBER 2013

DATE EVENT LOCATION3-4 July

15 July

16 July

18 July

23 July

8 August

13 August

14-15 August

15 August

20-23 August

22 August

August - September

4-5 September

New Zealand Safety Show

Executive China - Australia Mining Forum

Safety Automation Symposium

ECANZ

EtherNet/IP Seminar

Consultant Evening

Process Forum

Electrotech

CPG Value Forum

AIMEX

Consultant Seminar Series (Network Security & Wireless Comms + CISCO)

Technology Roadmap

WIOA Bendigo

Auckland, New Zealand

Brisbane, QLD, Australia


Christchurch, New Zealand

Perth, WA, Australia

Richmond, VIC, Australia


Hamilton, New Zealand

Sydney, NSW, Australia

Homebush, NSW, Australia

Auckland Region, New Zealand

New Zealand: Whangarei, Tauranga, Hamilton, New Plymouth, Palmerston North, Napier,Wellington, Christchurch,Timaru, Invercargill

Bendigo, VIC, Australia

Machinery Automation and Robotics (MAR) were awarded the Best New Product award at the APPMA Awards of Excellence at Auspack 2013 Sydney Olympic Park. The award was presented by Sam Kekovich and received by Machinery Automation & Robotics General Manager Troy Krogh.

When accepting the award Troy thanked the entire MAR team for their commitment and perseverance in developing the Singulator system into a product that we can take to market. ‘MAR are honoured APPMA recognised the innovation and advances we have made with the High Speed Singulaton; the win reinforces the confidence we have in the product,’ comments Troy Krogh.

Often products need to be singulated in order to facilitate picking ‘n’ place automation or horizontal flow wrapping. Machinery Automation and Robotics’ High-Speed Singulator is designed for hygienic high-speed primary processing and packing where gentle product handling is paramount to maintain quality. The singulation is done through a series of 90 degree turns using standard food-grade belt conveyors. The Singulator is highly efficient no matter the source of the chosen product, whether it be a baked goods, biscuit or frozen beef burger. The Singulator’s control system uses Rockwell Automation® components including an Allen-Bradley® CompactLogix™ PLC, PowerFlex® 40P drive and PanelView™ Plus 700 graphics terminal. They provide the comprehensive monitoring and control needed to complete the singulation process. The HMI provides an instant visual overview of the complex sequencing and activities that occur. ‘By incorporating Rockwell Automation technology into the process we’ve managed to deliver a reliable, visual, integrated automation and control solution to unscramble and singulate product ready for picking and packing,’ states Troy Krogh.

The High Speed Singulator has been under development for several years, initially with Applied Robotics and JLS. MAR have further developed the idea and identified numerous primary processing applications across the food and packaging industries, fulfilling a strong need for a robust yet compact singulation solution. The key benefit of the Singulator is increased operational gain whilst maintaining the food quality that is necessary. MAR are keen to explore similar applications throughout Australia and New Zealand.

Best new product at the APPMA Awards of Excellence - MAR High Speed Singulator

Troy Krogh, Sam Kekovich, Malcolm McIntosh, Adam Saint & Jamie Bailey


Integrated Architecture Tools: System Level Quick Starts The System Level Quick Start Manuals can teach you how to connect CompactLogix™ controllers to I/O, variable frequency drives and graphical displays. These manuals guide you through every step of the process to get your controller communicating. If this is your first time commissioning a CompactLogix controller or you simply need a little help, download these manuals for assistance.

Available from the Integrated Architecture™ website at www.ab.com/go/iatools

Copyright © 2012 Rockwell Automation, Inc. All Rights Reserved. AD RS2391-R1P

Integrated Architecture Tools:System Level Quick StartsThe System Level Quick Start Manuals can teach you how to connect CompactLogix™

controllers to I/O, variable frequency drives and graphical displays. These manuals

guide you through every step of the process to get your controller communicating.

If this is your first time commissioning a CompactLogix controller or you simply need

a little help, download these manuals for assistance.

Available from the Integrated Architecture™ website at www.ab.com/go/iatools

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

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