DE01 Design Automation Solutions

Track: Design Presenter: Jason Weber Automation Product Manager)

Introduction, Session Agenda

Introduction System Layout Tying HMI and Logix together Security Configuration Management

Objectives
At the end of todays session
have a better understanding of Design Automation solutions see how the Integrated Architecture and FactoryTalk integrates into industrial automation

Design Automation
Design Automation for Manufacturing is an initiative from Rockwell Software to support our customers in meeting their critical time to market needs, improving manufacturing system performance and reducing the costs of design integration..

Customer Value

Facilitate Better Decisions, Sooner & Faster

Reducing costs by Linking the Specification, Creation, Commissioning, and Operation of Automation

Support Re-Use of knowledge and effort

Where is the Value

Project Kick Off

Spec/ Bid

Create

Test/ Validate

Get / Keep Working

Define Standards End-Customer Define Specs Write RFP Create Code Create HMI Create Mechanical Drawings Machine Builder/ System Integrator Generate Design Concept Compile BOM Write a Proposal Create Electrical Drawings Create Cabinets Assemble HW

Prove Concept and System Operation to 3rd Party

Quickly identify root causes as pieces fail

Milestone Acceptance Test Factory Acceptance Test

Quickly integrate and commission system

Key Values
Reduce Commissioning Time Reduce Design Time
Collaborative simultaneous Tooling and Controls Design Digital exchange of mechanical and controls design information to expedite design decisions Design less; reuse more Enter data once Try it before you build it to find problems early Complete logic and operator interface diagnostics available at tryout

Reduce Downtime
Complete diagnostics that reduce time to diagnose faults Standardized fully commented Controls Code that is easy to understand

On average, companies using digital manufacturing can reduce time to market by 30 %, design changes by 65 %, and time spent in manufacturing planning process by 40 % CIMData Study

How Design Automation Provides Value

Project Kick Off

Spec/ Bid

Create

Test/ Validate

Get / Keep Working

Define Standards End-Customer Define Specs Write RFP Create Code Create HMI Create Mechanical Drawings Machine Builder/ System Integrator Generate Design Concept Compile BOM Write a Proposal Create Electrical Drawings Create Cabinets Assemble HW

Prove Concept and System Operation to 3rd Party

Quickly identify root causes as pieces fail

Milestone Acceptance Test Factory Acceptance Test

Quickly integrate and commission system

The Design Automation Suite of Products

Project Kick Off

Spec/ Bid

Create

Test/ Validate

Get / Keep Working

Arena IAB Proposal Builder

IAB/Proposal Builder
Tools to help you specify your system before you purchase it. Part Number Creation Pricing Information

Network layout Hardware wizards BOM creation

Modeling Simulation
Process Design and Simulation begins with Arena: A complete scalable, enterprise wide solution for simulating any aspect of a business. Build an accurate model of your planned or existing operations and simulate to investigate what-if scenarios and select the best manufacturing strategies.

The Design Automation Suite of Products

Project Kick Off

Spec/ Bid

Create
FactoryTalk

Test/ Validate

Get / Keep Working

Arena IAB Proposal Builder

View Studio RSLogix RSNetWorx

Bar Code Config

Vision System Config DriveTools FF Net Config RSBatch MCAD ECAD 3rd Party Network Config

RSLogix
One editor for all forms of the Logix family of hardware Efficient programming tools

Functionality

RSLogix

Distributed

Centralized

RSLogix Architect

Focused at providing system level visualization and configuration

Network view Provides graphical and tree representations of system (multiple networks and controllers) Launch to appropriate tool with Context Augments RSLogix and RSNetWorx to improve system management and maintenance

RSLogix Architect Control Hardware Layout

Simple System Layout (Networks, Controllers, Devices) Drag and drop networks, controllers and communication modules Launch with Context to appropriate tools

Produced/Consumed (P/C) Tag Management

Manage P/C Tags from one location Manages connections count and RPI Matches data types (including UDTs) Tag filtering options available

View Studio
A Unified and Extensible HMI Architecture to Reduce Total Cost of Ownership and Improve Productivity
Leverage All RA HMI Products & Expertise Common Look, Feel & Navigation Scalability Across Platforms Portability of Application

PanelView Plus Multi-Client Multi-Server

MobileView VersaView CE Computer VersaView Win 2000/XP Computer

The Design Automation Suite of Products

Project Kick Off

Spec/ Bid

Create
FactoryTalk

Test/ Validate

Get / Keep Working

Arena IAB Proposal Builder

View Studio RSLogix RSNetWorx

RSLogix Emulate

RSTestStand

Bar Code Config

Vision System Config DriveTools FF Net Config RSBatch MCAD ECAD 3rd Party Network Config

RS TestStand
A modeling tool to validate your logic and alarm conditions to drastically reduce your start-up time and help train operators

Control

Model

Key Features Extensive Model Library of common control devices Flowchart Editor and other tools to build new models 3D graphics capability to enhance visualization
Connect to PLC

Integrated linkage to PLCs and Emulators

TestStand Capabilities

PLC
O P C

TestStand
The 3D Model Solenoid

Roller Bed

O P C

Drive & Motor

Clamp

RSTestand/RSEmulate
A modeling tool to validate your logic and alarm conditions to drastically reduce your start-up time and help train operators
RSTestStand Simulation

PLC Logic Verification

RSEmulate

Operator Training

RSView HMI System

Optimization
RSLogix

The TestStand Value Curve

Value

Cell Level System Level Modeling System Level Modeling Modeling

Optimization Tools Connectivity

Cell Level Modeling

RSTestStand Enterprise

RSTestStand

Complexity

Key Benefits
Reduced Start-Up Time Testing of subroutines, modules and functions within the PLC. E.g: Safety Circuits, Homing Conditions, etc I/O and Tag check-Out HMI Configuration Check-Out Training Tool System Visualization for the operator The Process Sequence Analysis System reaction and diagnostics could also be explained and studied

OEM Coordination OEM Code Validation by running it against a test criteria developed in TestStand Multiple levels of validation Level 1 is validation of OEM code Level 2 is the integration of OEM code with the base application

Optimization High Speed Data Acquisition and learning tools allows for detecting timing slack between key sequence events System level integration such as integration with Robotic Controls and Line feed models allows for line level cycle time optimization

Why RSTestand?
Typical reduction in start-up times: 30 40% Go beyond Emulate Test your complete process or application Completely portable testing environment No Hardware Comprehensive Visualization for Training; Also Electronic logging of Operator Actions and Results Introduce New Code Modules with confidence Validation of Panel View applications without connecting to the Process

Testimonial
Business OEM for Hydro Electric Generating Systems End Customer NY Power Authority, St. Lawrence-Franklin D. Roosevelt Project Details Power Project , 16 hydroelectric generators using ControlLogix controllers RSTestStand Role Unit Testing of software for each of these Generators

Results and comments about RSTestStand by

Darryl Stevenson, Project Leader 1. 2. 3. RSTestStand saved us 40 to 50% of the time we would normally spend testing basic stuff like testing I/O. It saved us 25 to 30% of the time we would normally spend doing sequential testing. It took quite a few weeks off our schedule We were able to test faster; set up was easier. We didnt have to rewire when we ran out of lights and switches. We also found problems that we normally wouldnt have found until we go out to the field. Its much easier to fix a problem in the shop than out in the field!

Testimonial
Business RSTestStand Role Large Material Handling OEM Modeling and Simulation of Entire MH Lines

Results and comments about RSTestStand by

Curtis Doane, Controls Tech Manager
1. 2. We were very impressed that it took us only two weeks to develop the SRM emulation, especially since none of us were formally trained on RSTestStand With its first RSTestStand test on a retrofit project, HK Systems reduced onsite startup and debug time by three daysa 40 percent savings in installation time

The Design Automation Suite of Products

Project Kick Off

Spec/ Bid

Create
FactoryTalk

Test/ Validate

Get / Keep Working

Arena IAB Proposal Builder

View Studio RSLogix RSNetWorx

RSLogix Emulate

View Studio RSLogix

RSTestStand

RSNetWorx

Bar Code Config

Vision System Config DriveTools FF Net Config RSBatch MCAD ECAD 3rd Party Network Config

The Design Automation Suite of Products

Project Kick Off

Spec/ Bid

Create
FactoryTalk

Test/ Validate

Get / Keep Working

Arena IAB Proposal Builder

View Studio RSLogix RSNetWorx

RSLogix Emulate

View Studio RSLogix

RSTestStand

RSNetWorx

Bar Code Config Automation Desktop Vision System Config DriveTools FF Net Config RSBatch MCAD ECAD 3rd Party Network Config

Centralized Project Organization

The center of the RSAutomation Desktop Project System Equipment Features
Design equipment layout model for a plant. Lines, Stations, Machines can be stored and reused. Simple means for storage of all system files. Controls system navigation

FactoryTalk Directory is at the root of all projects

Multi-User Support and Versioning

Only one users edits at a time All Objects are versioned with history

Changes are published to FactoryTalk Audit

Other Features Project Archiving To not have to look for old projects Project Labeling To recreate projects as-built later

Multi-User support for less conflict and greater project management.

Templates
Simple Objects System and Subsystems Motors
HMI Graphics Files Word Documents

Conveyors My Plant Etc.

Ladder Logic

Reuse Your Work with Templates

Store reusable pieces that you have created and tested in the past Use them efficiently reuse that work in future Update tags and values automatically Build entire subsystems quickly Enter custom control logic using the traditional editors Provide tools standardization

Conveyor
Tags Logic Faceplates/HMI Field Devices Documentation Files

Improved automation system quality

Control Hardware Layout and I/O Configuration

Multiple Processor and Network Support Configure I/O Card Ownership Configure Produced/Consumed Tags Synchronize with existing RSLogix 5000 Projects Generate I/O Lists and BOMs automatically

The Design Automation Suite of Products

Project Kick Off

Spec/ Bid

Create
FactoryTalk

Test/ Validate

Get / Keep Working

Arena IAB Proposal Builder

View Studio RSLogix RSNetWorx

RSLogix Emulate

View Studio RSLogix

RSTestStand

RSNetWorx

Bar Code Config Automation Desktop

RSAsset Security

What Is Security?
Security means different things to different people
Our Definition: Security applies to any action that can disrupt normal business activity Loss of assets including product, plant, production, IP, life, etc Damage to environment, company reputation, etc. Actions can be either internal or external Disruptions can be either malicious or accidental

RAs Goal:
Help our customers safeguard the Reliability and Cyber Security of the critical assets embodied within their industrial automation systems.

RSAssetSecurity Key Features

Allows central administration of corporate security policies
User Authentication and Authorization managing access to Rockwell Software tools Who can carry out what operations, on which automation resources, and from where Tool Level Security (outer ring)

Provides single security solution across all products Part of FactoryTalk Architecture and works in concert with Directory, Live Data, Diagnostics (audit)..
Requires Factory Talk Directory Server (network scope) Logs automation access information Authorized and unauthorized access to automation system Actions attempted, performed, etc.

RSAssetSecurity Key Features (continued)

Compatible with Windows 2000, 2003, XP Professional Caches security credentials to support disconnected operation (similar to Windows) Supports both Windows user accounts (support single sign on) and RSAssetSecurity user accounts (any combination) Allows for administration of users and privileges (securable actions) without requiring IT intervention

RSAssetSecurity Users and Users Groups

RSAssetSecurity Windows Linked User

User Group

RSAssetSecurity Computers and Computer Groups

RSAssetSecurity Product Policies

Establish general corporate guidelines for usage of the software

Networks and Devices

20,PLC-5/46B,6COATER

The Design Automation Suite of Products

Project Kick Off

Spec/ Bid

Create
FactoryTalk

Test/ Validate

Get / Keep Working

Arena IAB Proposal Builder

View Studio RSLogix RSNetWorx

RSLogix Emulate

View Studio RSLogix

RSTestStand

RSNetWorx

Automation Desktop

RSI Products offer greater productivity throughout the Design Cycle due to integration across products

Changes Cause Problems When

They are not documented The old configuration cant be recovered The changes are not accessible to all who need them Access to configurations is not controlled Multiple versions exist without accurate identification Multiple people are making independent changes

Managing Your Manufacturing Configuration

Source code control of your approved manufacturing configuration CAD drawings Operating procedures PLC programs Network configuration EOI projects Perform periodic device configuration comparison with master files

PLC programs EOI programs Operating procedures

Flexible notification options when differences detected

Email Printer

Managing Device Configuration Changes

User logs into the System: A license for a device editor is User checks out the Master Information can checked out. application for the device frombe viewed in I.E. the Authentication System Determines what Activity and Archive. activities that user can perform. records details of use. 5 Browser User saves the changes to the RSMACC changes are logged application and disconnects from Controls Access RSMACC by RSMACC the device. Audit The configuration and license are returned to RSMACC. RSMACC Increments the Revision number and marks the new file as the master. Audit Archive Archive Later that night the RSMACC Event Verification Module, uploads all applications and verifies their RSMACC reports confirmation of a correctness. properly handled change, and Recovery quickly exposes rogue operations. Report

User connects to a control device and performs tasks online. All activity and changes are captured by RSMACC

Documenting Configuration Changes

Supports self-documenting Change Management procedure
Ability to prove scope of change is limited to approved change Contains information necessary to enable FDA 21 CFR Part 11 compliance Date/Time of audit event Source (Application) Location (Workstation) Username (Domain ID, and Full Name from Domain Id) Automatically generated description of change with old and new value

RSI Design Solutions

RSAutomation Desktop collaborative, multi user design framework that provides
archive and version control of RA and 3rd party design data.

Arena A complete scalable, enterprise wide solution for simulating

any aspect of a business.
Design Collaboration Planning

Design Automation
Controls Validation & Test Development

Logix 5/500/5000 Development and deployment of

controls standards including control code, HMI, network configuration, diagnostics and ECAD.

RSEmulate and RSTestStand Complete Manufacturing system

validation - "try it before you build it".

simulation and

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