Vous êtes sur la page 1sur 24

October 2017 Issue 52

ASIA PACIFIC
Australia & New Zealand

Migrate for Optimal Solutions Optimise Asset Performance


Inside Seamless for Motor Control: throughout Oil & Gas
Integration Drives Success Production Lifecycle

Less is More:
Premier
Integration
EXECUTIVE MESSAGE
Contents
04 News & Events
Highlights on the journey toward
The Connected Enterprise
Ready to Leverage
All the Key Aspects of
06 Cover Story
Less is More: Premier Integration Premier Integration?
10 Case Study
Migrate for Seamless Integration
System integration is driving todays manufacturing industry and can be a key
12 Technology Watch catalyst for its growth. The time and effort needed to design, configure and
Optimal Solutions for Motor Control: maintain assets are coming under greater scrutiny, especially as systems
Drives Success become more connected and complex. If systems are not integrated, there will be
significant increases in cost and resource consumption, which are the least wanted
14 Case Study outcomes for all manufacturers.
Tissue Machine Upgrade
Therefore, todays best-in-class organisations are seeking ways to comprehensively
16 Application Profile integrate different platforms, as well as components, to bridge the gap between
Optimise Asset Performance throughout
multiple business functions, from the plant floor to top floor.
Oil & Gas Production Lifecycle

Rockwell Automation has an extensive product portfolio, as well as services


18 Local Capability and support capabilities that are designed to improve our original equipment
Medium Voltage Drive Services
manufacturers (OEMs) processes through every stage of the manufacturing cycle.
And we are working at our best to advance our strategies for creating seamless
19 Product & Solution Integration. For instance, we have introduced The Premier Integration a better
Focus integration between the automation controller and system devices - to provide new
Solution offerings for experiencing the time and cost saving opportunities and give end-users greater access to production
power of Premier Integration
intelligence. Now you can expect to use a single control platform with a common
control engine and development environment designed to simplify system designs,
Automation Today Asia Pacific
cut development time and costs, and support faster deployments while delivering
October 2017, Issue 52
industry leading capabilities for any automation discipline.
This magazine is published 4 times a year by
ROCKWELL AUTOMATION Inc. for Asia Pacific
Early this year, we were honored with a number of Best-in-Control by Process
Automation Discipline wins, voted by global end-user readers of the Control
Executive Publisher: magazine. Also in late July, Rockwell Automation Southeast Asia was named the
John Watts jwatts@ra.rockwell.com
Best Internet of Things (IoT) Provider in Asia, by Contineo Media, the organiser of
Managing Publisher:
Sandra Lay Yan Sim ssim@ra.rockwell.com the Asian Manufacturing Awards 2017. Not only do these recognitions reinforce
This magazine is produced and printed by
the value of our process automation systems, but also encourage us to continue
dedicating new advanced solutions to our OEMs, providing control, automation, and
ROCKWELL AUTOMATION AUSTRALIA LTD
Tel: +61 3 9757 1111 Fax: +61 3 9729 1418 information technologies for integrated manufacturing and industrial processes.
Contact: award@ra.rockwell.com

This time, we are focusing on integration and highlighting our fleet of intelligent
To subscribe or unsubscribe, solutions for process control and power control. I invite you to review this issue
visit : of Automation Today Asia Pacific to discover the true value of integration. Most
www.rockwellautomation.com/en_AU/go/ATAP importantly, we will show you how you can satisfy your end-users and stay ahead
of the competition with an experience of Premier Integration, helping to make your
investment, time and effort pay off.

Copyright 2017 Rockwell Automation Inc. All rights reserved. The contents of this
publication may not be reproduced in whole or part without the consent of the
copyright owner.

Allen-Bradley, Automation Today Asia Pacific, Connected Components Workbench,


ControlLogix, E300, Encompass, FactoryTalk, FORCE, Integrated Architecture,
IntelliCENTER, PartnerNetwork, PlantPAx, PowerFlex, ProductionCentre, Rockwell
Automation, Rockwell Automation On The Move, Rockwell Software, SequenceManager,
Stratix, Studio 5000 Logix Designer, ThinManager, TotalFORCE, VisiSight are trademarks of
Rockwell Automation, Inc.
Joseph Sousa, President
PLANTSCAPE is a trademark of Honeywell, Inc.
Asia Pacific Region, Rockwell Automation
EtherNet/IP is a trademark of ODVA, Inc.
All other trademarks are the property of their respective owners.

ASIA PACIFIC 3
NEWS & EVENTS

Rockwell Automation TechED revealed the latest


technologies in automation, information and analytics
Using connected technologies to gain business value. abnormalities requires a real time
The recent Rockwell Automation TechED event in Melbourne response and should be handled
attracted record numbers and revealed the latest techniques and onsite.
technologies to help maximise manufacturing and production operations. The companys new analytics solutions have the capability to scale from
With a focus on advancing industrial automation and solving business device through to enterprise. The devices that are in machines, lines and
challenges, the event brought together the best in the industry including applications produce data. To run a connected enterprise, this data must
end users, system integrators, distributors, partners and machine builders. be extracted and sent up to plant-wide and enterprise-wide information
TechED has established a reputation as the industrys only multi-day, systems.
hands-on event focusing on the latest technologies to help maximise The new FactoryTalk Analytics for Devices provides information about
assets and information across operations. The number of people attending the diagnostic health of devices, at the source. With plug-in appliances that
TechED is growing year upon year because it not only focuses on the automatically detect, digitise, analyse, and act on device data, real-time
latest technologies to enable a Connected Enterprise, but demonstrates alerts on critical device and machine health are delivered at the device
first-hand how companies can connect silos of information to extract level.
real business value, explained Matthew Treeby, commercial marketing Revealing insights into new and future products, Pantaleano explained
manager, Rockwell Automation. that the focus of product development is on simplicity and experience so
The event began with an informative keynote presentation by John that devices are easier to use and deploy. In addition, collaboration and
Watts, marketing director, Rockwell Automation that highlighted the mobility requirements are met through the new FactoryTalk TeamONE app,
importance of investing in smart manufacturing and production to remain helping to make customers more productive.
competitive on a global scale. Another welcome addition to the companys offering, Rockwell
The growing middle class in emerging countries together with an aging Automation ThinManager helps manage information and streamline
workforce are key market drivers for smart manufacturing and production. workflows for a more connected production environment. ThinManager
As the consumer market grows and demands more choice, manufacturers software allows centralised configuration and management of deliverable
need to embrace new technologies to address these changing content to any combination of user, device or location.
requirements. Similarly, Studio 5000 Logix Designer has added new features to help
In light of these macro-trends, the Industrial IoT is estimated to have improve productivity. It is clear that the companys focus is on providing
an economic impact of 4.6 trillion dollars by 2025 as new technologies appliances that can begin delivering results quickly products that already
including analytics, mobility, app platforms and the cloud, help securely have analytics, are easy to use and deploy, readily integrated and scalable
connect plant information with enterprise systems. for future needs.
In closing, Watts explained the importance of firstly understanding why With more than 60 sessions on offer, attendees were able to experience
you are taking the journey to smart manufacturing. As a manufacturer, the latest trends and technologies in the areas of scalable industrial
its important to have a clear understanding of the productivity and analytics, operational data infrastructure and management, digital
manufacturing issues you are working to solve. It is not all about the transformation, remote access and monitoring, and connected services
technology, think about the people and processes involved. Make sure and solutions.
you understand the business outcomes and why you are heading towards The Process Solutions Users Group (PSUG) provided a unique
smart manufacturing. perspective on how to optimise process applications and the opportunity
To help customers work towards increased productivity and profitability, to interact directly with the Rockwell Automation global process team. For
he also shared a five-step guide to the Connected Enterprise; the first step process industries, PlantPAx embraces the cloud, mobility and virtualisation,
being to identify desired business outcomes, then sourcing an outside providing an easy information flow and the flexibility to adapt to new
perspective, assembling the team, starting small by implementing a technology.
pilot program and finally scaling for expansion to eventually enable The Another area where Rockwell Automation has made significant
Connected Enterprise. advances is security. As manufacturing and production facilities connect
Michael Pantaleano, global business manager for analytics and cloud, the plant floor with business systems, a comprehensive approach to
Rockwell Automation, delivered the second keynote presentation focusing industrial security is required.
on how the companys latest tools and technologies focus on scalable Securing the Connected Enterprise requires a holistic defense-in-depth
analytics to help customers meet production and operational goals. approach. TechED provided the forum to learn about developing standards
Manufacturers rely on production data to solve challenges on the plant and regulations around security and the Rockwell Automation approach
floor and across the enterprise. Scalable analytics, performed at the device, for building security into their products.
system or enterprise level, provide actionable information to the people TechED demonstrated the importance of investing in smart
who need it and a pathway to move data into higher-level systems. manufacturing and production; and the costly danger of missed
Pantaleano emphasised the importance of running analytics where opportunities. The industrial automation market in Australia and New
it makes sense, based on the real time nature and power required. For Zealand is expected to grow consistently over the coming years, making
example, analysis of historical data and trends for future optimisation now the right time to reap the rewards of using analytics to transform data
could and should take place in the cloud, whereas detection of device from smart, connected industrial assets into meaningful insights.

4 ASIA PACIFIC
NEWS & EVENTS

Winner of Best Internet it seamlessly to decision-makers companywide. As a result, smart


of Things Provider manufacturers can help to shorten time to market, lower total cost
of ownership, enhance asset utilisation, minimise enterprise risks,
Against intense competition in the and advance workforce efficiency.
manufacturing industry, Rockwell The Asian Manufacturing Awards 2017 has been recognising and
Automation Southeast Asia has honoring companies from the industrial automation sector that
won the Best Internet of Things (IoT ) Provider at the Asian provide cutting-edge industrial automation technology and value-
Manufacturing Awards 2017 award ceremony, which was held on added solutions to help enable manufacturers to achieve increased
July 27 in Singapore. performance.
As an IoT pioneer, Rockwell Automation has been focused for We are pleased to be recognised for the third time as the
several years on understanding the evolving industrial automation Best IoT Provider in Asia, said Tang Poi Toong, Market Access and
requirements and combining technology innovation and expertise Marketing Director, Rockwell Automation Southeast Asia. It is a
to simplify those factories business experiences. The award testament to our strong commitment to continuous innovation
recognises The Connected Enterprise and the companys work empowering our customers to experience quantifiable operational
to integrate data from self-aware and system-aware intelligent breakthroughs as they become Connected Enterprises.
sensors, convert it into contextualised knowledge, and distribute

Partnership with Foxconn Achieves companies are confident the collaboration will further demonstrate
the power and broad applicability of The Connected Enterprise.
Visions of Smart Manufacturing They also agree that together they will help increase operational
efficiencies in electronics manufacturing to new levels, achieving
Rockwell Automation has confirmed collaboration with Hon the vision of Smart Manufacturing and Made in China 2025.
Hai Precision Industry Co., Ltd, also known as Foxconn, to Foxconn is a Taiwanese multinational electronic contract
implement Connected Enterprise and Industrial Internet of manufacturer and has its corporate headquarters in Taiwan. It has
Things (IIoT) concepts for smart manufacturing. The announcement been increasing its employee base in the United States and has
was made in late July 2017 at Foxconns Consumer Electronics committed to take part in programs to upskill military veterans
Assembly Operations. and create a pool of certified talent for in-demand advanced
The two companies will collaborate to develop and apply manufacturing roles across the U.S.
Smart Manufacturing solutions at Foxconns new United States The Taiwanese manufacturer shares Rockwell Automations
facilities. Their technological expertise will be combined to deliver commitment to expanding the upskilling of the U.S. workforce to
a state of the art manufacturing system with unparalleled levels provide the necessary talent for advanced manufacturing roles.
of operational efficiency. The Chairmen of the global leading

of technology-related roles. These


Welcoming New Member to positions include vice president and

Board of Directors global chief information officer for The


Brinks Company, and senior technology
executive for Bank of Americas treasury,
Rockwell Automation announced that Patricia Watson has payments and credit functions. She
been elected to the companys board of directors effective currently serves as a board director for
July 1, 2017. Now, Watson starts helping the company Texas Capital Bancshares.
assess new technologies, business models, and talent to create Patty is a leader in her industry, with
meaningful business outcomes for customers with her expertise. proven business and technical skills, and
Watson joined Total System Services (TSYS) with 17 years were pleased to welcome her to our board of directors, said Keith
of financial services industry experience, serving in a variety Nosbusch, chairman of Rockwell Automation.

ASIA PACIFIC 5
COVER STORY

Less is More:
Premier Integrati
As i n d u s t r i a l a u to m a te d p ro d u c t i o n a n d
infor mation systems continue to grow in
complexity, productivity is becoming increasingly
important in all aspects of manufacturing operations
including the machine design and configuration
stages. The traditional, labor-intensive approach of
manually integrating and configuring devices and
systems is doubtlessly time-consuming, costly and
counterintuitive to the needs of todays
manufacturers.
Achieving faster time-to-market is a
key to get ahead and stay ahead of
the competition. There is no time
to build a system from scratch,
nor deal with the compatibility
risks that come with off-the-shelf
components. When companies are
using devices from multiple vendors,
they often encounter difficulties in
getting the devices to communicate and
operate in concert with each other efficiently. Such
problematic issues can result in extended engineering
time and increased costs. Besides, an array of devices in
the control system can create maintenance challenges in
the future.

To perform efficient engineering as well as greater synchronization in operations,


a better integration between controller and devices is particularly essential for
designing and building products.

Next Level Integration


Throughout the supply chain, from manufacturers to end-users, all are striving
to boost efficiency and effectiveness. In order to optimise performance, both the
architecture and each component within must be designed appropriately, and the
resource allocation must be efficiently performed.

A simpler, holistic integration can help machine builders consolidate high levels
of complexity and connectivity while having development time and costs on the
watch. Rockwell Automation has introduced The Premier Integration experience
to represent the next level of controller and device integration. More than just

6 ASIA PACIFIC
An effective level of integration mitigates

on
redundant programming while establishing
functional connectivity within
the controller-device network.

connecting process, power, information, and safety into one control architecture,
Premier Integration performs a seamless integration that simplifies and streamlines
system design, maintenance, and operation for any networked automation systems,
thus addressing common yet vital operational challenges.

With a foundation constructed by a Logix-based control architecture and


intelligent Allen-Bradley devices, Premier Integration is unique to a wide range of
specific control-system elements from Rockwell Automation, such as controllers,
devices, motor control centers (MCC) and soft starter.

Executing controllers programming, devices configuration and maintenance


management processes all within one single software environment can be said
as another defining characteristic of Premier Integration. With these capabilities,
manufacturers and engineers can ease integration, cut development time, improve
information visibility and productivity in manufacturing operations since all they
need now is a centralised intelligent platform for leveraging many different
devices.

Rockwell Automation understands that, to meet challenges in


this world of smart manufacturing and to establish The Connected
Enterprise, flexibility and responsiveness are as important as
effectiveness. Acquiring a fleet of Smart tools and software,
Rockwell Automation brings OEMs the opportunity to
gain a Premier Integration experience and the ability to
respond more quickly to changing market and business
needs, while helping to reduce total costs of ownership,
including maintenance and training.

A One-stop Solution
Specifically designed to deliver an intuitive and user-
friendly experience for designing and configuring systems
and devices, The Rockwell Software Studio 5000 attains
Premier Integration by combining engineering and design
elements into one standard framework that enables optimised
productivity and reduced commissioning time. It provides a standardised way to
share data, tags, and alarms across multiple design applications so that engineers
are allowed to configure information once and use it across the entire automation
system. Likewise, they can configure all elements of the automation system in one
place, rather than using multiple tools for control and visualisation.

ASIA PACIFIC 7
COVER STORY

There is 64 percent of surveyed


industrial manufacturers have reduced
engineering time with Rockwell
Automations integrated programming
experience; 63 percent successfully
achieve improved diagnostics.

When a system is operational, operators engineering time and associated costs in the Studio 5000 software can help reduce
and maintenance technicians can view all numerous ways, including the following: the time needed to integrate additional,
system components from a central location similar devices once they are configured. If
so that they can easily reconfigure devices, Device Mapping and duplicate devices are needed for the same
troubleshoot and access information. Configuration project, the engineer could simply copy the
The Logix-based controller can recognise original to create additional device nodes.
Common Industrial Protocol (CIP) is specific Allen-Bradley components and The Studio 5000 software automatically
an application-layer protocol that delivers automatically import their device profiles. transfers the descriptive tag names and
plantwide communication for control, When integrating an Allen-Bradle y configuration settings used in the original
device configuration and data collection. PowerFlex AC drive, the engineer can drive to the new drives through the copy-
Based on the CIP, EtherNet/IP enables simply select the specific module and the and-paste process.
real-time, deterministic control for both Studio 5000 software will then automatically
drives and servo drives. Multiple motors pull in all drive parameters. Mapping devices Tag-Aliasing
can be accurately coordinated through the will become easier since the engineer no Within a Logix-based architecture,
combination of synchronization capabilities longer has to manually associate parameter engineers can write an entire program with
in Logix-based controllers. These exclusive numbers with descriptions or enter the meaningful tag names before the physical
application resources are available for AC drives details, such as power and voltage. hardware is ready, and then assign the
and servo drives that present the specific, physical module and terminal information
device-independent profile supporting Also, using a single software environment at a later time. Such tag-aliasing capability
synchronization over the network. Works and configuring the controller and drive is commonly used to develop programs
for engineers can be done more easily since network connections from a single location before wiring diagrams are available. It
they will not need to do programming nor can reduce costly development errors and allows concurrent development, and
make changes every time over again. eliminate input/output (I/O) mismatch programmers need not wait for the design-
errors. engineering group to complete its electrical
Beyond reducing integration complexity, layout; thus it speeds the time for product
industrial manufacturers will find Premier Duplicating Devices designs to get to market.
Integration is capable of shortening their The copy-and-paste capabilities within
Library Management
As an essential element of Premier
Integration, library management enables
engineers to store, manage and reuse code
from their programs efficiently. It saves
development time while also building on
the outcomes of successful projects. Project
code can be exported to the code library
for use again in future projects or even
to establish a new company standard for
similar applications. Engineers can simply
drag and drop the code from the library
into the new project whenever they wish to
reuse the content.

8 ASIA PACIFIC
The Evolution of Integration
Since industrial automation devices have become more dependent on digital communication, the success of a project will highly
depend on how easily devices and components are configured to exchange data across digital networks. Perhaps OEMs have already
noticed that such advancement needs have accelerated the development of more comprehensive and flexible integration solutions for
enterprises.
In todays world of smart manufacturing, Premier Integration can offer OEMs a business-enhancing alternative to the traditional
integration approach. Learn about how the integration of technologies evolves over time, and then rethink how important it is for
machine builders to adopt modernised and advanced integration technologies.

1 Original Hardwired System 2 Early Networks 3 Typical Single Network 4 Integrated Software Today
I/O & Programming
Non networked I/O network network
Controller Drive Controller Drive Controller & Supervisory /
Drive Controller with fully integrated
Drive
I/O-only networks
Programming network software

Controller Drive Controller Drive Controller


Software Software Software Software Software Drive System
Software Software

Enhancing Smart by achieving effective connectivity. Premier running more productively and profitably.
Manufacturing Integration gives engineers an exclusive Therefore, every piece of information can
Improvements in controller-device integration and configuration experience then be used to make better decisions
integration help OEMs move one step and assures operators and technicians that from the machine up to the enterprise
closer to smart manufacturing and design they will have the secure and accurate level.
smart machines and automation systems information needed to keep machines

Our partners, your success.


Personal contact is more than phone calls and e-mail. Its people working
together to develop unique solutions.
Take the guesswork and risk out of choosing your extended automation team. Selecting a qualified Rockwell Automation
Authorised Distributor brings you resources closely matched to your industry or application need.

For more information, go to:


www.rockwellautomation.com/distributor
Copyright 2017 Rockwell Automation, Inc. All Rights Reserved.

ASIA PACIFIC 9
CASE STUDY

Migrate for Seamless Integration


Asias top hygiene product manufacturer enjoyed beneficial outcomes from
a successful conversion of a legacy control system to modern DCS

Perhaps it is more economical to venture between Yuhan-YangHang and the legacy control system, Honeywells
keep legacy control systems running American company Kimberly-Clark, has Pl a n t S c a p e , a n d m o d e r n i z i n g t h e
than to upgrade to new ones. successfully overcome such challenges. architecture, once they recognised the old
However, finding replacement parts and They have proved to worldwide system that they were running in the plant
getting support for maintaining its useful manufacturers that their decision of could not answer the challenges brought
life were certainly some tough challenges. migrating outdated DCS to an integrated up by the new manufacturing plan nor
Even some professionals claimed that it was modern one is far more cost-efficient. fulfill their new targets on productivity and
almost impossible to obtain the updated safety.
functions needed to improve efficiency. Yuhan-Kimberly has been engaging
in manufacturing and distribution of A Unified Process Solution
But if the Distributed Control System sanitary products for many years, and their Yuhan-Kimberly was determined to
(DCS) reaches the end of its useful life, personal care products have now become convert their legacy system, which includes
or more commonly, hits the bottleneck an important part of everyday life in South controller, human-machine inter face
of productivity, system migration will be Korea. (HMI) and machine safety. They adopted
necessary. Apparently, system migration PlantPAx, a modern process DCS based
will need to be completed quickly yet safely Realised that importing raw materials on the Rockwell Automation Integrated
and securely, with no downtime or risk to from the U.S. for processing and packaging Architecture system, to provide full
meeting production targets. These are the hous e ho ld supp lies w as no lo nger production line and recipe capabilities,
inevitable challenges, but resolvable if the efficient or effective, Yuhan-Kimberly had solving quality and consistency issues.
right tool is used. decided to move their machine in the U.S.
facility to Kimcheon, their hygiene paper The new process control system centers
Time to Migrate: manufacturing plant in South Korea, to on the Allen-Bradley ControlLogix
From Legacy to Modern handle a rapidly increased demand for programmable automation controller (PAC).
One of Rockwell Automations clients, paper towels. One of the differentiating capabilities of
Asias top leader in the Home and Personal the ControlLogix PACs is that they build
Care Industry Yuhan-Kimberly, a joint They began working toward replacing the tools, protocol, and architecture into

10 ASIA PACIFIC
expertise of the Rockwell Automation Global Process Technical
Consultant (GPTC) team provided technical supports and coaching
sections to Chumdan FA, Rockwell Automation Process Solution
Integrators (SI) engineers and the Korean manufacturers operators.
The engineers and operators received training on acclimating to
the new system and leveraging the features. The GPTC led Yuhan-
Kimberly through its well-defined and strategic technology
migration path.

Great Savings
We could also conduct an independent test and a simulation
test effectively before the Site Acceptance Test, which allowed us
reliable and fast system startup, said Se-Yong Jang, Project Lead, SI
partner Chumdan FA.
The PlantPAx platform based on the Rockwell Automation Integrated
Architecture system in Kimcheon Factory floor-delivering a unified process
and discrete solution Yuhan-Kimberly partners with Rockwell Automation for ongoing
support and training, reducing their operational costs. With the
one fully integrated, scalable control platform that can be used smooth migration completed on an integrated platform, they
throughout the manufacturers plant. have improved knowledge transfer and minimised the cost for the
PlantPAx provides a broad range of architecture options for spare parts and training remarkably with the one common plant-
increased flexibility. The same platform can be utilised for single wide platform. Additionally, PlantPAx has reduced their Total Cost
stations or large distributed architectures. For the project, the of Ownership (TCO) while satisfying the customers request for
modern DCS consolidates control technology, offering scalable improved machine safety.
system capabilities HMI, batch management and data collection
that do not require a server or workstation, which is perfect for
process skid equipment and rapid integration. Based on open
communication standards leveraging EtherNet/IP as its backbone,
PlantPAx makes real-time information readily available throughout
the enterprise for better business or operational decisions.

Moreover, PlantPAx Library of Process Objects contributed to


accelerating the migration process, maintaining consistency and
reducing installation time. As system operators and engineers were
able to minimise system deployment and test time, production
efficiency and time-to-market were improved.

Significant Optimisation Improvements


It was not an easy project. We thought we would need various
network interfaces with many products from different makers,Jong-
Kyu Lee, Project Leader, Yuhan-Kimberly Project Leader expressed.
But we were able to deploy PlantPAx DCS and GuardLogix Safety
on a single hardware/ software through Rockwell Automation
Integrated Architecture products and solutions, which allowed us
to implement a reliable, robust system.

PlantPAx Library of Process Objects saved two months from the


total implementation time; the stable and successful conversion
from PlantScape legacy DCS to PlantPAx process automation
system was completed ahead of scheduled time. Because the
Library is simple and convenient to use, the overall migration
procedures have become easier. Unlike that with the legacy system,
operators can skip checking the Logic programs one-by-one;
instead, they check and make changes to the operating condition
of the machine and view the interlock status via a single faceplate.

Other than supporting on hardware and software, the domain

ASIA PACIFIC 11
TECHNOLOGY WATCH

Optimal Solutions for Motor Control:


Drives Success
Achieve operational excellence and application flexibility with
the latest control technologies

Motors cannot alter their speed, regenerative drive, and PowerFlex 755TM with the requirement of the application.
even for fixed speed systems, it is common DC bus drive system: Predesigned modules are available with a
certainly difficult to find a motor that power range from 160 to 2,000 kW.
rotates at the right speed for its designated PowerFlex 755TL D rive: Provides
application. Therefore, variable speed drives low AC input harmonics through the The highly differentiated control
are required to provide solutions that use of ac tive front- end technology technology in the PowerFlex 755T products
effec tively manipulate voltage and and an internal harmonic filter keeps equipment running through most
frequency, with a wide range of power to reduce harmonic distortion. power quality disturbances with active front
ratings for a diversity of applications. The drive is available from 160 to 1250 kW. end ride-through control that regulates
the DC bus voltage independently of the
Aiming to offer the best-in-class power PowerFlex 755TR Drive: Provides an incoming AC voltage.
and process control solutions, Rockwell energy efficient solution that uses
Automation has introduced the latest and regenerative active front end technology to The high bandwidth motor control
upgraded suite of drive solutions - Allen- deliver energy back to the incoming supply. has a significant disturbance rejection
Bradley PowerFlex 755T drives. The new It also provides low AC input harmonics. and low tracking error while the excellent
additions to the PowerFlex family help users This drive delivers power from 160 to 2,000 kW. torque accuracy is responsive to torque
reduce energy costs and increase machine disturbances and can function smoothly
uptime for assets running in high-demand PowerFlex 755TM Drive System: Allows throughout operating range.
applications. All compliant to the IEEE 519 engineers to build the system that
specification, and built with the patented best fits their needs for regeneration Besides, operators can estimate and gain
TotalFORCE technology, the expanded and coordination of multiple motors in knowledge of the remaining life span of
drive portfolio includes the PowerFlex common bus configurations, so that energy drive components, such as fans, blower,
755TL low-harmonic drive, PowerFlex 755TR consumption remains strictly matched relay contacts and power semiconductors;

12 ASIA PACIFIC
parameters like temperature and runtime of
the motors and drives can be monitored to Maintains operation through Machine
most line disturbances with
allow for preventive action if necessary. AFE ride-through control

How it Works Supports multiple combinations


With the next generation of Force of inverters to the limit
established by the capacity of AC Drives /
Technology - TotalFORCE technology, the regenerative bus supply
Inverter
PowerFlex 755T drives deliver superior PowerFlex 755 TM
Bus Supply
electric motor control through precise
Eases maintenance and
adaptive control of velocity, torque reduces installation time,
labor and cabling costs with
Engineers
and position. The drives respond to its modular design

production demands by comparing current


per formance to application settings, Example of a start-up project to upgrade power drives on machine
and making any necessary adjustments
automatically. They communicate their Designed and built using a modular Likewise, for the drives, there is a Safe
performance data through the control to approach, the PowerFlex 755T drives offer Speed Monitor option is certified at SIL 3,
operation in real-time. the added advantage of fast and easy PLe, Cat 4. This option allows access to parts
PowerFlex 755T drives continuously installation and maintenance with simplified of the application while there is limited
monitor their internal components and management of spare parts. The new motion. In another words, operators can
own activities. During operation, the load drives design allows complete removal of perform process or maintenance work
observer and the adaptive tuning are without stopping the machine.
responsible for monitoring the variables Without shutting
that can change over time, they will Powerful Performance.
then automatically make adjustments to the machine Flexible Control
compensate for the mechanical changes as Ask any heavy industry manufacturer
they occur, keeping the system performing down to make about the top challenges they face, more

adjustments,
as efficiently as possible. Most importantly, than likely the answer will be reducing
the drives notify operators immediately energy consumption, minimizing
about issues that might compromise drive
or motor health. This level of self-awareness users will downtime and optimizing productivity. And
they need to resolve these challenges while
helps to significantly reduce unplanned
downtime. experience reduced increasing profitability and protecting their
investment.

Premier Integration and commissioning AC drive technology is an important


Installation
The new PowerFlex drives are able to
and downtime. investment for our customers, and they
want their application up and running every
achieve an exceptional level of integration a module from the cabinet, creating ample possible minute, said Brad Arenz, product
when the drives are used on an EtherNet/ space for wire installation and allowing the manager, Rockwell Automation. The
IP network. Configuring PowerFlex 755T power wiring to stay connected while the PowerFlex 755T drives have been designed
drives with dynamic Human Interface module is rolled out. Hence installation and to provide savings from installation, through
Module (HIM), Studio 5000 Logix Designer maintenance are further simplified with an operation and maintenance with advanced
application or Connected Components accessory cart that allows one person to features that allow you to optimise use of
Wor k bench sof t ware allows users easily insert or remove a module without your assets.
consolidate controller programming and the need for a ramp or hoist.
drive system configuration, operation, The PowerFlex 755T drive solutions are
and maintenance into a single software Safety Options Available developed to provide the benefits that
environment, reducing programming The Safe Torque Off option of the matter most to the manufacturers. The
time, simplifying startup and streamlining PowerFlex 755T drives, certified at SIL 3, powerful new additions offer motor control
diagnostics. In addition, their expanded uses PLe, Cat 3, removes rotational power to the along with cost-effective solutions for
of motion instruction within Studio 5000 motor without removing power from the regeneration, low harmonics and common
environment allow device I/O capabilities drive for faster start-up after a demand on bus system configurations.
to be assessed through the Logix controller. the safety system. It makes integration of
Such availability of general-purpose analog safety functions over EtherNet/IP possible. Find PowerFlex 755T Drives product details in
and digital I/O helps to reduce complexity Such ability provides opportunities to Product & Solution Focus
and save engineering time. reduce hardware and installation costs
while improving productivity.

ASIA PACIFIC 13
CASE STUDY

Asaleo Cares tissue machine upgrade


future-proofs production
Tissue machine upgrade leverages control, drives and safety features of the Integrated
Architecture platform and the application knowledge of the Global Solutions team at
Rockwell Automation

Asaleo Care is a leading personal


care and hygiene company that
manufactures, markets, distributes
and sells essential ever yday
consumer products across the Feminine
Care, Incontinence Care, Baby Care,
Consumer Tissue and Professional Hygiene
product categories.

The companys products include Purex,


Sorbent, Handee and Tork and are used
daily in households and businesses across
Australia, New Zealand, Fiji and a number
of countries in the Pacific. Asaleo Care has
eleven manufacturing and distribution
facilities throughout Australia, New Zealand
and Fiji.

Asaleo Care is committed to introducing the


latest technologies to their manufacturing
plants to continue to produce quality
The New Zealand plant produces 50,000 tonnes of various tissue related products.
produc ts and meet evolving safet y
standards.
of intense competitive pressure from a renewable energy source at Kawerau, for
The manufacturing plant in Kawerau, imported products, the company decided drying the tissue.
New Zealand was established in 1955 to upgrade the control and drive system
and to this day is still the only tissue base of their tissue machine to incorporate the Driving production
paper manufacturer in New Zealand. To latest technologies while continuing to Drive technology has advanced in leaps
address obsolescence issues, Asaleo Care meet current safety standards. and bounds providing greater flexibility,
called on Rockwell Automation to design, productivity and ease of use. The existing
manufacture and commission a control According to Paul Stevenson, electrical drive system at the Kawerau plant was an
and drive upgrade to their tissue machine engineer at Asaleo Care, We must stay analogue, direct current system, requiring
that would also incorporate the latest safety competitive in order to remain in business periodic maintenance and being 30 years
technologies. over the long term and thats a key reason old, was also facing obsolescence.
for the upgrade.
Tissue making perfection Over the years we became familiar with the
Asaleo Care has been manufacturing The tissue paper making process at Asaleo processes required to maintain the system
tissue related products since 1952 and is Care starts with responsibly sourced but we had to replace the brushes quite
committed to meeting customers needs. pulp. The pulp entering the Kawerau a lot. One of the things to bear in mind is
The manufacturing plant in New Zealand site carries a Forest Stewardship Council the risk profile, if it gets to the point that
produces 50,000 tonnes of tissue related (FSC) certification. This pulp is blended to its breaking down every week we couldnt
products annually. slurry, formed pressed, creped and dried. afford the risk of the machine being down
The company is the only known tissue for weeks while we are waiting on parts,
To maintain their niche in the midst manufacturer that uses geothermal steam, said Stevenson.

14 ASIA PACIFIC
B y m ov i n g to a n AC d r i ve s y s te m , reduce risk by providing the capability for Future-proofing production
maintenance requirements were reduced. these machines to be configured correctly As a result of the upgrade diagnostic
The system was designed to take into the first time. information is more readily available and
account various factors relating to AC drives the level of support to be able to access,
system such as excessive electrical noise To keep downtime to a minimum during repair and maintain the system is improved.
and motor circulating current. The new commissioning, a full Factory Acceptance The machine is more reliable and has
system was also designed for integrated Test (FAT ) was conducted at Lane Cove, advanced capabilities for guarding and
safety control using Allen-Bradley which allowed us to test the equipment productivity gains.
GuardLogix with safe speed monitoring prior to installation. The FAT provided the
and safety gates. opportunity to get a lot of the leg work Kirsopp explained that Global Solutions
done, with the exception of the encoders, was more than just a drive system specialist,
The upgrade included new motors and so we were confident that commissioning with specific experience in tissue machines
eight new Allen-Bradley PowerFlex drives would be hassle free, said Project Manager and paper machines they have an in depth
for the tissue machine line. The Active Front Paul Kirsopp. understanding of the entire machine and
End (AFE) capability provided regenerative how to engineer the drives to meet the
braking for energy savings as well providing These machines are not designed to specific application requirements.
Harmonic mitigation for all the common stop and the process does not allow
bus line drives. By placing two AFEs in for it in terms of our supply channel so The system does not require an
parallel, the DC bus capacity reached 2470 time is always a limitation. We had to enormous amount of technical input and
Amps, providing power for all the tissue keep downtime to a minimum and took with improved reliability as the primary
machines common bus drive system. advantage of the two week shutdown to outcome, the productivity will start coming
complete some additional work at the site, when we start increasing the speed. In
According to Liam Hayes, project manager he said. addition, the machine is so much quieter
at Rockwell Automation, We leveraged that we had to check that it was still
our application knowledge to engineer Kirsopp added that, the cooperative running at times. We are extremely happy
a solution that incorporates the latest approach by everyone involved in the with the outcome and the relationship
technologies. The drives also included Safe project allowed for ahead of schedule established with the Global Solutions team,
Speed Monitoring allowing the operators delivery despite the challenges of working he said.
safe access to the machine for maintenance alongside two other major upgrades at the
purposes. plant.

High Speed trending provides accurate


information about the drive system and
to assist with fault finding by picking up
any process changes that may require
resolution. PanelView Graphic Terminals
display application status information
graphically for the drive and control
systems.

We are positioning ourselves with this


upgrade so we can improve speed and
increase productivity. The drives have
always posed a limitation. We were looking
to future proof the drives and sizing was
an important aspect, said Roy Ormiston,
Paper Machine Operations Manager at
AsaleoCare.

Hassle-free commissioning
The entire solution was engineered,
manufactured and delivered from the Lane
Cove Assembly Centre in Sydney, Australia.
The Rockwell Automation Global Solutions
team have numerous software standards The upgrade included new motors and eight new Allen-Bradley PowerFlex drives for the
that have been developed over the years to tissue machine line.

ASIA PACIFIC 15
APPLICATION PROFILE

Optimise Asset Performance throughout


Oil & Gas Production Lifecycle
Intelligence and integrated solution enhance visibility, scalability and reliability
of information for energy production operators

World energy demand is set to grow Rockwell Automation Integrated Power protective measures. As one of the benefits
by 48 percent by 2040 according to and Automation integrates Intelligent of Premier Integration, plant owners and
the International Energy Agencys Packaged Power (IPP) and Intelligent Motor operators that are coupled to IMC can
World Economic Outlook 2016. Although Control (IMC) to achieve Premier Integration exploit operational data from motors
nowadays energy companies are and putting digital technology to work to and motor-driven equipment to assess
implementing process instrumentation simplify the supply chain and unify systems. parameters such as energy consumption,
systems to increase uptime and optimise speed, torque, and temperature while
production, the energy industr y has It all starts with a control tower - a measuring vital signals relating to bearing
historically lagged behind other industries modern Distributed Control System failures or winding efficiencies. Such open,
in the area of asset performance, often (DCS). For instance, Rockwell Automation networked architecture enhances motor
referred to in manufacturing as operational PlantPAx uses scalable, multi-disciplined protection, shares diagnostic information
equipment effectiveness (OEE). control technology to provide a common and speeds troubleshooting for a more
a u t o m a t i o n p l a t fo r m fo r s e a m l e s s productive, intelligent process.
The traditional approach of designing, integration between plant processes
building and upgrading oil and gas plants and power systems, establishing a new Cost plays a huge role; with motors
was making it too time-consuming and workflow. Because of its plant-wide control typically consuming ten times their initial
expensive to meet global demand. It also capabilities, the modern DCS can easily purchase price and from an operational
put a burden on workers to learn how
to operate a wide variety of equipment. INTEGRATED POWER & AUTOMATION
Multiple vendor relationships, complex
Design Software Controllers HMI
interfaces between systems and limited
access to data for real-time control are SINGLE NETWORK
blocking oil and gas processing from Unmodified Ethernet
accelerating. Besides, energy usage is one
of the most difficult costs to manage in a
production environment. On the plant floor,
motors typically consume over 60 percent
of the energy in any industrial facility; lack Motor Starters Drives IntelliCENTER MCC Intelligent Switchgear Intelligent eHouse
of control of the devices will only result in INTELLIGENT PACKAGED POWER
INTELLIGENT MOTOR CONTROL INTELLIGENT PACKAGED POWER
lower energy efficiency and higher total
cost of ownership. PUBLIC Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 27

integrate with motor control devices. perspective, simply reducing the speed of
The Right Moreover, the level of integration achieved a motor by 20 percent saves 50 percent
Optimization Method between a modern DCS and the motor in running costs. Allen-Bradley E300
Coping with the demands, oil and gas control devices results in information Electronic Overload Relay one of the
producers take steps toward connected that drive improved plant availability by most capable relays in terms of intelligence
production to break down geographical reducing unplanned downtime as it can and connectivity, sits at the heart of any
barriers and improve business value, trigger manual or automatic intervention IMC fixed-speed application. Important
including production throughput, process before an occurrence predictive and operational information of integrated
quality, asset health, and energy efficiency. preventative measures. software and hardware can be extracted
However, before they can capitalise on from a variety of production equipment
significant opportunities, they need to Make Smart Energy and and applications; operating parameters
understand that the key component Production Decisions can also be recorded, such as voltage,
in successfully fostering a culture of In fact, 75 percent of motor failures can current and energy, trip/warning histories,
optimization is Premier Integration. be prevented by deploying appropriate percentage thermal capacity utilization,

16 ASIA PACIFIC
time to trip/reset, operational hours
and number of starts. Its flexible design,
simplified wiring, and seamless Logix
integration enable the transformation
of actionable information from real-
time diagnostics; these capabilities allow
engineers to conduct preventive measures
for protecting assets and maximizing oil
and gas production uptime.

As part of an IMC architecture, low-


voltage PowerFlex drives enjoy Premier
Integrated Power & Automation solution provides the unified visualization experience:
Integration within the Studio 5000 All IED information is presented in pre-built faceplates.
environment and automatic device
configuration when integrated into a i n d e p e n d e n t e S C A DA a n d p ro c e s s offering to enhance safety and emissions
Logix-based control system. Productivity control systems with a unified, fully digital monitoring by limiting exposure with
is enhanced thanks to Safe Torque-Off and system based on unmodified Ethernet. remote control and anticipating air gap
Safe Speed Monitoring capabilities and In the open automation architecture, breakdown.
their ability to share safety information and substation data is mapped directly to the
signals over EtherNet/IP. control environment to enable seamless In addition, Rockwell Automation has
communication between the IEDs and the a comprehensive portfolio of solutions,
For oil and gas production process, all control platform. Time-stamped, sequential products, tools and support services that
motor control needs can be addressed by data generated by the IEDs can be easily tightly integrate safety functionality and
a high performance packaged solution accessed and used within the production features to help oil and gas producers
- Low Voltage and Medium Voltage process. This ability to correlate power deploy safety across their facilities. Process
Motor Control Centers (MCCs). Designs of distribution events to motor and power safety solutions including Emergency
IntelliCENTER are factory validated and control events can significantly speed Shut Down systems (ESD) and Safety
pre-configured to integrate seamlessly into troubleshooting for any power-related Instrumented Systems (SIS) at all Safety
the site control system for faster start-ups issue. Integrity Levels (SIL) meet stringent design
and higher visibility of device operations. requirements. These reliable controller
The MCCs also illustrate Premier Integration Furthermore, the correlated information based products increase safety and
approach to equipment and personnel provides operators a more comprehensive productivity while reducing downtime,
protection, by allowing operators to picture of the asset performance across nuisance trips and lifecycle costs.
remotely monitor their equipment. the oil and gas life cycle, allowing them to
Without physically coming into contact better anticipate power-related process Manufacturing Intelligence
with the electrical equipment, they can still conditions in real-time and make better for Success
stay abreast of machine performance while energy and production decisions. It is estimated that the industry needs
keeping themselves out of harms way. to invest over a trillion a year in oil and gas
An e-house solution is another development by the 2030s for meeting
Optimise turnkey offering from Integrated Power the forecast demand. On top of that,
Resource Management and and Automation that provides project companies will have to brace for the
System Resiliency management, integration engineering, and impact of low oil price.
In a conventional design approach of documentation control. Intelligent eHouse Challenged with market volatility
power distribution, manufacturing plants supplies tested and certified equipment and a variety of other issues, oil and gas
maintain substation automation systems for the complete system, hence can producers are constantly looking for
with intelligent electrical devices (IEDs) simplify installation and commission while ways to improve competitiveness by
operating on a variety of networks. The providing a streamlined process control containing costs that help lead to bigger
electrical supervisory control and data and power management system for the bottom lines. But thanks to the new
acquisition (eSCADA) system has limited industrial projects. level of manufacturing intelligence and
visibility to the process control system. But integration, plant owners and operators
now, integrating the power distribution Another Important Aspect can now leverage Integrated Power &
system and process control system within Safety is just as important to customers Automation to reap the benefits of digital
the same infrastructure allows a new level as asset performance. Each device and technology and Ethernet connectivity
of intelligence and information awareness component of the Integrated Power and ex tend information transparenc y,
across the oil and gas facility. Automation meets safety and reliability integrated user experience and the value
expec tation. The solutions provide of investments across process, power
The packaged power solution replaces improved safety features as a standard control, and electrical systems.

ASIA PACIFIC 17
LOCAL CAPABILITY

Medium Voltage Drives Services


Rockwell Automation Australia and New Zealand region

Features and Benefits

Provide localised support for customers


who have invested in Rockwell
Automation medium voltage products.

Start-up & Commissioning


Trained field service engineers
based in Australia
Local support and service

Installed Base
Extensive experience in local
market
160+ drives installed and
commissioned

Spares
Local holding to support installed PowerFlex Medium Voltage Variable Speed Drives
base
Parts Management Agreement I nvesting in medium voltage factories in Canada, Brazil, China and Poland.
(PMA) service available products is a significant commercial
and business investment and you Installed Base
Preventive Maintenance need to be comfortable that the vendor We have installed more than 170+
Protect your assets and prolong can support your investment. Rockwell PowerFlex 7000 / PowerFlex 6000 variable
their longevity by using Automation has the service capability in speed drives in Australia/New Zealand
Rockwell Automation field Australia to support our customers installed and hundreds more globally over the last
service professionals for planned base. Following are the services we can 15 years. These drives are installed across
maintenance provide to support our Customers and diverse industries on applications such as
PartnerNetwork groups, post-purchase of conveyors, pumps, compressors and fans.
Remote Support Rockwell Automation medium voltage
Remote Monitoring and Analytics products. Spares
To support our installed base of medium
Remanufacturing Start-up & Commissioning voltage drives throughout Australia, our
Repair service available Use our extensive product knowledge main spare parts holding is located in
and industry experience to help you Victoria at our Melbourne facility. Other
commission and start-up your new Medium options are available to suit specific
Voltage equipment, and in turn, reduce the customer needs. For example, customised
time between integration and production. Parts Management Agreements (PMAs)
are an option that enable critical spares to
We have Field Support Professionals located be held on a customers site if they arent
in Sydney, Melbourne, Brisbane, Adelaide purchased outright.
and Perth with over a century of combined
experience with servicing and supporting Preventative Maintenance
PowerFlex AC Drives. Our professionals are Medium Voltage drives require special
supported by technical and field support k n ow l e d g e to k e e p t h e m i n p r i m e
teams located in our four Medium Voltage operating condition. Your Rock well

18 ASIA PACIFIC
Automation factory-trained Field Service assets are working and alert you when and lost revenue when your automation
Professional is armed with the test performance falls outside of acceptable assets malfunction or fail. To minimise
instrumentation, special tools, performance performance standards. Our platform downtime and keep production running,
data and experience needed for optimum uses IT-approved and outbound-only Rockwell Automation can provide quality
suppor t of your equipment. We can communication to protect access to your repairs when you need them. Ever y
provide you with this service on an as assets and any transferred information. Allen-Bradley remanufactured product
required basis or at fixed intervals as per undergoes our comprehensive proprietary
manufacturers requirements. You can view production data, asset and remanufacturing process.
system health, and other information.
Remote monitoring & Support You can then use this information to help Rockwell Automation Australia has an ISO
(previously VSE) workers make better decisions in each of 9001 certified Remanufacturing centre
Remote Monitoring and Analytics provides their unique roles. located in Melbourne, in full collaboration
a simple and secure approach to help with our global factories located in Canada,
monitor equipment and collect valuable Remanufacturing Brazil, China and Poland.
performance analytics. It can give you Reductions in maintenance staff and
valuable insights into how well your spare parts often lead to longer downtime

Rockwell Automation Australia Ltd


Melbourne 841 Mountain Highway, Bayswater Vic 3153 Tel: +61 3 9757 1111
Sydney 32 Sirius Road, Lane Cove NSW 2066 Tel: +61 2 9428 7222
Brisbane Unit 4 / 8 Metroplex Avenue, Murarrie Qld 4172 Tel: +61 7 3399 0100
Adelaide Wellington Centre, 2 Portrush Road, Payneham SA 5070 Tel: +61 8 8165 4000
Perth 38 Belmont Avenue, Rivervale WA 6103 Tel: +61 8 9333 5800

Rockwell Automation (NZ) Ltd


Auckland 2B Pacific Rise, Mt Wellington, Auckland Tel: +64 9 276 3070

PRODUCT & SOLUTION FOCUS

New Power Ranges and Motor Control Capabilities Available


for PowerFlex 6000 Drives
Allen-Bradley PowerFlex 6000 with the PowerFlex 7000 drive, users can
medium-voltage AC drives offer now select the right feature set for their
expanded, user-friendly control for application requirements.
variable and constant torque applications.
The latest release delivers a wider voltage With an extended power range, the
range (2.4 to 11 kV) and provides 100 drive can be used for applications with
percent starting torque, leveraging output-voltage ratings up to 11 kV
sensorless vector control. and motor current ratings up to 680 A,
while remaining an air-cooled design.
The PowerFlex 6000 drive is easy to With eco-designed main cooling fans, New output-voltage ratings are available
commission, use and maintain, with users in IEC-based markets can meet EC 11 kV for Australia. The full range of
standard faceplates and EtherNet/IP regulation 327 and ErP directive 2009, ratings includes 3.3, 6.6 and 11 kV. With
connectivity. The drive is a cost-effective and avoid the larger footprint of a liquid- optional, automatic cell bypass up to
solution for heavy industries with higher cooled drive. Internally powered cooling 680 A, users can keep their operations
power needs for their applications. fans reduce customer-supplied control running in case of a power cell failure
power requirements, and equipment and and reduce unplanned downtime. In
Our scalable portfolio of medium-voltage installation costs. A tertiary winding on addition, an uninterruptible power supply
drives offers a breadth of functionalities the isolation transformer provides internal helps increase system reliability, minimise
to best fit application needs, said Marjan power for the fans. downtime and mitigate potential
Sprajc, Rockwell Automation. Together machine damage.

ASIA PACIFIC 19
PRODUCT & SOLUTION FOCUS

PowerFlex 755TL Drive for Mitigate Harmonics


The PowerFlex 755TL drive provides a complete solution that includes a line side converter,
harmonic filter, and inverter to help reduce the adverse effects of harmonic distortion on
adjacent electrical equipment and control system instrumentation.
Mitigates harmonics with active front end technology combined with active converter and LCL filter
Lower harmonics reduces the need to oversize electrical power equipment
Eliminates the need for external multi-phase transformers or filters along with the associated wiring,
labour, installation and maintenance costs.

Power Ratings:
400 / 480V: 160 to 1250 kW
600 / 690V: 200 to 1400 kW

PowerFlex 755TR Drive for Regeneration


With built-in regeneration, the PowerFlex 755TR drive provides regenerative and low harmonic
capability to help reduce energy consumption by delivering energy back to the incoming
supply rather than wasting it as heat. The line regeneration reduces the need for braking
resistors and associated cooling equipment and helps avoid wasteful dissipation of energy.
Minimises the need for braking resistors and cooling equipment along with associated wiring, labor,
installation and maintenance costs
Recovers dissipated energy and re-use that energy for other applications, creating energy savings that
increase the return on investment made in the drive
Active front end technology with regeneration and lower harmonics provides means for regeneration
Power Ratings:
400 / 480V: 160 to 2000 kW
600 / 690V: 200 to 2300 kW

PowerFlex 755TM Drive System for Flexible Configurations


The PowerFlex 755TM drive system is a world-class coordinated multi-motor
common bus system with best-in-class system footprint, usability and motor control
performance. It is designed to enable coordination of multiple motors based on two
main building blocks: regenerative common bus supplies and common bus inverters. The
common DC bus optimises the sizing of the bus supply so that energy consumption remains
strictly matched with the requirement of the application.
Flexibility to combine inverter and bus supplier into different arrangements and ratings to
create a high power dense system with a small footprint
Integrated control bus in each unit for efficient distribution of auxiliary 24V, 240V, and an
optional 120V throughout a cabinet line up
Optimises floor space, installation, and hardware with drives connected via common bus Power Ratings:
(Common Bus Inverters)
Reduces costs associated with additional hardware, wiring, installation when using common 400 / 480V: 160 to 2000 kW
bus system 600 / 690V: 200 to 2300 kW
(Regenerative Bus Suppliers)
Uses one interface to configure and program the converter and inverter 400 / 480V: 188 to 2204 kW
600 / 690V: 221 to 2379 kW

The PowerFlex 755T Drive uses a modular design with roll-in units. The units only need to be wired once; power wiring
stays connected while units are rolled out. The drives are highly serviceable with easy access to service areas and
simplified removal of parts. To meet environmental requirements, the enclosure types include IP21 (UL Type 1) and IP54
(UL Type 12). There are common spares between the drives which help reduce spare part inventory.
They are all designed to meet the IEEE 519 standard, and their safety options help protect users personnel and assets
while enabling increase machine uptime.

20 ASIA PACIFIC
PRODUCT & SOLUTION FOCUS

Comprehensive Solution for An Enhanced Sensing Solution for


Measuring Temperature Packaging Industry
As part of the Solid-State Condition Sensors portfolio, The Allen-Bradley 42JT VisiSight
Allen-Bradley 837T Temperature Sensor is built with family offers a broad range of sensing
high-accuracy and new technology, providing users with a modes, and a teach push button that
comprehensive solution for measuring temperatures in liquids, simplifies sensitivity adjustment and provides
gases, and vapors. light versus dark operate output selection. It
comes in a small rectangular package with
The flexible 837T display model is embedded with IO-Link 1.1 class 1 Eye Safe red laser and visible red LED
communications protocol, which allows sensors to integrate into beam for ease of alignment and industry
The Connected Enterprise, delivering data from the sensor directly standard mounting hole spacing of 25.4 mm.
into a control system in a very cost-efficient and easy-to-use The unique Auto PNP/NPN output
manner via an IO-Link master and EtherNet/IP. continuously monitors how the load is
connected and automatically configures the output for proper
It has temperature ranges from -20 to 80C (-4 to 178F) and operation. When connected to an IO-Link master, the 42JT can
features a compact, rotatable house (320) and head (330) to take advantage of advanced functionality including real-time
accommodate any complicated applications. These sensors have diagnostics, automatic device configuration (ADC) and multiple
2 x PNP and 1 PNP + 4 to 20 mA analog output configurations, job-specific profiles. These features make the 42JT VisiSight easy to
probe lengths from 25 to 350 mm and an IP67 enclosure rating. apply in challenging packaging and assembly applications; hence
optimizing the supply chain by reducing the number of models to
Other options available from 837T Temperature Sensors: be stocked by 50%.
Embedded with IO-Link functionality which helps minimise
837T Non-Display downtime and increase productivity, the 42JT VisiSight
photoelectric sensors can be integrated into The Connected
Temperature range: -50 to 250C (-58 to 482F) Enterprise easily.
Analog Outputs: 4 to 20 mA (25 to 400 mm probe lengths)
Enclosure Rating: IP67

837RTD (Resistance Temperature Detector) Ethernet Switches for Rugged


Temperature range: -50 to 200C (-58 to 392F)
Environment
Enclosure Rating: IP67
Pt1000 measuring element The series B of Allen-Bradley Stratix 2000 Industrial
Unmanaged Switches with compact design maximise
837T Solid-State Temperature Sensors are accessible in various users cabinet space. An industrial-grade enclosure with
process connections to fit users application needs. For easy- IP20 to IP30 rating provides upgraded environmental protection
on-machine programming, the temperature sensors can be thats ideal for small control networks requiring reliable network
configured manually; or users can experience Premier Integration connectivity and extended temperature range (-40 to 75 C). Users
by completing the settings through the Studio 5000 Logix can enjoy:
Designer software.
100 MB or 1 Gb speeds for increased network flexibility and
performance
Broadcast storm protection against unwanted network traffic
D ual power inputs to help maximise uptime in harsh
environments

In addition to
these benefits,
users can
enjoy easier
installation and
integration with
the Plug-and-
Play operation.

ASIA PACIFIC 21
PRODUCT & SOLUTION FOCUS

Out-of-box Integration Tools Ease Entry to Smart Manufacturing


Rockwell Automation has expanded its scalable manufacturing execution system (MES) to allow operations to configure their
environment without programming, add more applications, increase DCS process system integration, and expand
deployment options. Comparing to traditional MES, the new modular MES applications can be easily deployed and used, with
instructive and more graphical configuration.

A new suite of capabilities improves functionality across its portfolio of scalable MES applications based on the FactoryTalk
ProductionCentre R10 platform. With the increased integration of process applications, manufacturers can address specific
manufacturing challenges, like quality, machine performance, track/trace, and genealogy. Solutions can start at the machine or work-
area level with a single application and with minimal infrastructure requirements, and scale to an integrated MES solution as ROI is
realised.

Process manufacturers can seamlessly connect FactoryTalk MES applications, including their DCS, LIMS, QMS, PLM or CMMS
systems and other databases by using Enterprise Integration Hub (EIHub) An application that streamlines data translation across
The Connected Enterprise. Through this vendor-agnostic integration, operators can transport batch-reporting parameters, GMP
critical alarms for review by exception, and consumption, production and order-completion data. There are pre-configured value
packs in EIHub software that offer increased productivity for the discrete, automotive and pharmaceutical industries.

In addition to the introduction of FactoryTalk Warehouse, there are recent updates to FactoryTalk Production, FactoryTalk
Performance, and FactoryTalk Quality applications which provide a simplified, visual drag-and-drop tool to build out new workflows
with no coding needed. Therefore product changeovers can happen more quickly and more flexibility is allowed for new product
introductions.

New
FactoryTalk Warehouse Application
Plant-floor operations are tasked with fast and accurate tracking of material movement and stock information. The latest MES
application, FactoryTalk Warehouse, streamlines warehouse logistics to allow fast, precise inventory management and tracking
capabilities from goods receipt through stock records and goods issuing. Improved insight and control benefit manufacturers
looking to better manage raw-material lots, palette load tracking and work-in-progress (WIP) inventory while accessing sublot-level
details all synchronised with the company ERP system. With this information at their fingertips, personnel can manage material
levels in near real time, including forward and backward product genealogy. The FactoryTalk Warehouse application is scalable to fit
individual deployment needs.

22 ASIA PACIFIC
PRODUCT & SOLUTION FOCUS

FactoryTalk Production Application


Manufacturers are challenged to optimise production processes, lower structured costs, improve productivity and achieve a near
zero-inventory system. The FactoryTalk Production application is a scalable MES solution that addresses the challenges associated
with enforcing processes in manufacturing. This application integrates with ERP and tracks the order and recipe parameters necessary
for production. The Production application supports end-to-end production management within a facility, offering a vital platform for
continuous improvement.
Synchronises production activities
Improves work-instruction delivery to personnel
Better manages material flow from warehouses and suppliers
Sustains continuous improvement with manufacturing context for operational procedures
Integrates genealogy reporting

FactoryTalk Quality Application


Facilities relying on disparate systems and antiquated paper processes cannot guarantee consistent production quality. The newly
expanded Quality application allows manufacturers to effectively model and enforce their plants in-process quality regimens at
a scalable rate. The application supports a facilitys efforts to deliver a timely, quality product and react quickly to quality issues.
Manufacturers can use the Quality application on a project basis and scale up when value is proven. The application can be expanded
to include other functionality within the FactoryTalk ProductionCentre MES system or run as a standalone. Including user-friendly
intuitive widgets, the application recommends pre-configured visual widgets, such as gauges or historical data charts, speeding time-
to-value and reducing the cost of quality-management efforts based on choices that manufacturers made in setup.
Reduces cost of compliance (trading partner & regulatory)
Eliminates plant floor quality paperwork
Increases first time yield and first time through
Dynamically changes quality testing regimens based on test results
Reduces IT infrastructure costs

FactoryTalk Performance Application


Manufacturing companies today lack visibility into real-time production performance and productivity data. Performance is a
modular application that assists manufacturing companies with factory efficiency and production improvement. By providing
visibility into the operations performance, this application allows for lean and continuous improvement, preventive manufacturing,
improved asset utilization and operational intelligence.
Increases capacity with higher production from existing equipment and deferred capital expenditures
Decreases manufacturing costs with lower overtime and reduced labor costs
Lowers material costs through improved quality and reduced scrap
Reduces overhead costs by saving time collecting data and preparing reports and real-time availability of efficiency information

Each expanded MES application is implemented on thin clients for a modern user experience and reduced, IT infrastructure
cost. Users can add on each application to their current framework, helping protect their current investments while realizing
these additional benefits. Moreover, the scalable MES applications are cloud-enabled, supporting centralised deployments
in private, public and hybrid configurations.
Today, Rockwell Automation provides infrastructure-as-a-service offerings via pre-configured and managed industrial
data centers. Yet, investment in new delivery options never stops. Manufacturers will soon be able to purchase and enjoy
Software as a Service (SaaS) offerings and cloud-based versions of the FactoryTalk MES applications.

ASIA PACIFIC 23

Vous aimerez peut-être aussi