Five Technologies That

Will Drive The Future Of

Industrial Automation

Sujeet Chand
Sr. Vice President & Chief Technical Officer
Kenwood Hall
Vice President Architecture and Systems

Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 1

 Outline

•• Manufacturing
Manufacturing Trends
Trends

• Technology and Architecture Trends

• How Will Technology Trends Transform Industrial Automation?

• Q&A

Copyright © 2006 Rockwell Automation, Inc. All rights reserved. 2

Technology Predictions:
1954 Popular Mechanics Magazine

Scientists
Scientistsfrom
fromthethe
RAND
RANDCorp Corphavehavecreated
created
this
thismodel
modelto toillustrate
illustrate
how
howaa
“home
“homecomputer”
computer”couldcould
look
looklike
likein
inthe
theyear
year2004.
2004.
However
Howeverthe theneeded
needed
technology
technologywillwillnot
notbebe
economically
economicallyfeasible
feasiblefor
for
the
theaverage
averagehome.
home.With
With
teletype
teletypeinterface
interfaceand andthe
the
Fortran
Fortranlanguage,
language,the the
computer
computerwillwillbebeeasy
easytoto
use
use..

Copyright © 2006 Rockwell Automation, Inc. All rights reserved. 3

 Prediction in 1968 of the year 2001

Arthur C. Clarke
Stanley Kubrick

Computers
Computers––Big
Bigsingle
singlecomputer,
computer,
Space
Spacetravel
travel--common
commonplace
place possible erratic behavior
Copyright © 2006 Rockwell Automation, Inc. All rights reserved. 4
 Manufacturing Trends

Business
BusinessEnterprise
EnterpriseSystems
Systems

Supply Chain Flexible

Integration Manufacturing Customer
Customer
Suppliers
Suppliers Demand
Demand

The
TheFactory
Factory
Regulatory Productivity
Compliance / / Quality
Mandates

Safety/Security Cost / Energy

Efficiency

Supply
SupplyChain
ChainIntegration
Integrationand
andFlexible
FlexibleManufacturing
ManufacturingAre
AreDriving
Driving
The
TheIntegration
IntegrationofofFactories
FactoriesWith
WithBusiness
BusinessEnterprise
EnterpriseSystems
Systems
Copyright © 2006 Rockwell Automation, Inc. All rights reserved. 5
 Manufacturing Trends and Drivers

From To
Mass Production Mass Customization

Discrete Supply Chain Supply Chain Synchronization

Loosely Coupled Design & System Integrated System

Local Global

Physical Assets Functional Assets

Lowest Procurement Cost Total “System” Cost

Copyright © 2006 Rockwell Automation, Inc. All rights reserved. 6

 Manufacturing Drivers Today

FLEXIBILITY: FLEXIBILITY:
Faster Commissioning, Faster Commissioning,
INTEGRATION: Reconfiguration Reconfiguration
INTEGRATION:
Control, Safety, Control, Safety,
Information/IT Information/IT

End OEMs
OEMs
EndUsers
Users Optimize
OPTIMUM Optimize Optimizethethe PERFORMANCE:
ASSET Optimizethe
the Effectiveness Machine
Operation Effectiveness
UTILIZATION Operationofofthe
the Solutions
Solutions
ofofMachine effectiveness
Production Machine
ProductionLine
Line Building
Building
GLOBAL GLOBAL
SUPPORT SUPPORT
Services Services
COST: COST:
Lifecycle Cost Product Cost
& Reusable Components

Many
ManyCommon
CommonDrivers
Driversfor
forOEMs
OEMsand
andEnd
EndUsers
Users
Copyright © 2006 Rockwell Automation, Inc. All rights reserved. 7
 What Do Manufacturing Companies Want?

Major Food Company

• (INTEGRATION) IT and factory control becoming integrated
– Rolling out ERP (focus on supply chain integration)
– Regulatory Mandates: Walmart and FDA

• (COST) Into “second wave” of driving productivity of manufacturing plants

– Looking to save about $750M / year
– Plants are efficient today; however, significant annual waste still exists

• (FLEXIBILITY) Moving to new, “healthier” products will require new

processes and smaller batches
– Rapid re-configuration of automation equipment
– Walmart’s competitors demanding “customized” products

Long-term
Long-termvision:
vision:flexible
flexibleand
andintegrated
integratedmanufacturing
manufacturing––
“customized
“customizedtrail
trailmix”
mix”for
forevery
everyconsumer
consumer
Copyright © 2006 Rockwell Automation, Inc. All rights reserved. 8
 Outline

• Manufacturing Megatrends

• Technology
Technology andand
Technology and Architecture
TrendsTrends
Architecture
Architecture Trends

• How Will Technology Trends Transform Industrial Automation?

• Q&A

Copyright © 2006 Rockwell Automation, Inc. All rights reserved. 9

 The Five “Key Technologies”
For Industrial Automation

√ Software
Software
Plant
(Enterprise)

√ √ Software
Integration /
Web Services
Line
(Manufacturing
Control
Control/ / Electronics Materials Solutions)
Diagnostics Communications
Communications Electronics Materials
Diagnostics

Advanced High
Control Commercial Alternate Reliability
Wireless
Electronics Materials Software
Prognostics
Machine
Autonomous (Factory)
Systems RFID On-Machine Nanocoatings

Copyright © 2006 Rockwell Automation, Inc. All rights reserved. 10

 Technology Evolution

Nano
Nano
&& Virtual
Virtual

Information
Information
Technology
Technology

Industrial
Industrial 2010
2010
to
to ….
….

Agriculture
Agriculture 1960
1960
to
to2010
2010

Hunting/
Hunting/ 1800
1800
Survival
Survival to
to 1960
1960

10K
10K BC
BC
to
to 1800
1800 AD
AD

Million
Million BC
BC
to 10 BC
to 10 BC

Copyright © 2006 Rockwell Automation, Inc. All rights reserved. 11

Trends Impacted By Information Technology
Evolution

• Integrated Control, Safety, Security, and

Information
– Information-Enabled Control Platforms with Integrated
Safety and Security

• Ethernet
– Industrial Ethernet Becomes the Dominant Network

• Adoption of World-Wide Web Software

Standards
– WWW Data Exchange and Software Integration
Standards for Industrial Automation

Copyright © 2006 Rockwell Automation, Inc. All rights reserved. 12

 Outline

• Manufacturing Megatrends

• Technology and Architecture Trends

How
• HowWill
How Will Technology
Will Technology
Technology Trends
Trends
Trends Transform
Transform
Transform Industrial
Industrial
Industrial Automation?
Automation?
Automation?

• Q&A

Copyright © 2006 Rockwell Automation, Inc. All rights reserved. 13

 The Five “Key Technologies”
For Industrial Automation
Software
Software
Plant
(Enterprise)

√ Software
Integration /
Web Services
Line
(Manufacturing
Control
Control/ / Electronics Materials Solutions)
Diagnostics Communications
Communications Electronics Materials
Diagnostics

Advanced High
Control Commercial Alternate Reliability
Wireless
Electronics Materials Software
Prognostics
Machine
Autonomous (Factory)
Systems RFID On-Machine Nanocoatings

Copyright © 2006 Rockwell Automation, Inc. All rights reserved. 14

 Advanced Control

• Increased production - Cheese Cook

shortened average cook cycle
duration by 10% Cycle Control
Simulator
• Increased efficiency –
New control algorithm
enabled stabilizing water
content in the cheese to
the maximum allowed.
The manufacturer produces
more cheese for the same
cost.

Trend
Trendtoward
towardapplication-specific
application-specific
advanced
advancedcontrol
controlmethods
methodsthat
thatoptimize
optimize
performance
performanceand
andenergy
energyefficiency
efficiency
Copyright © 2006 Rockwell Automation, Inc. All rights reserved.
 Prognostics Application At A Food
Manufacturer
Pump Customer’s
Customer’sProblem:
Problem:
Pumpdiagnostics
diagnostics&&prognostics
prognostics Pump
Pump Life UnloadingRail
Life Unloading RailCars
Cars

•• Bearings,
Bearings, pump
pump cavitation,
cavitation, vibration
vibration monitoring
monitoring

•• Spectral
Spectral signature
signature analysis,
analysis, Neural
Neural Networks
Networks

•• Motor
Motor condition
condition monitoring
monitoring

Monitoring
Monitoring Remote
RemoteAnalysis
AnalysisofofPump
PumpOperation
Operation

•• Discharge
Discharge Pressure
Pressure
•• Suction
Suction Pressure
Pressure
•• Bearing
Bearing Temperature
Temperature
•• Fluid
Fluid Temperature
Temperature
•• Vibration
Vibration
•• Barometric
Barometric Pressure
Pressure
•• Current
Current (future)
(future)

Growing
Growingtrend
trendtowards
towardsprognostics
prognosticsand
andremote
remotemonitoring
monitoringofofmachinery,
machinery,e.g.,
e.g., nonstop,
nonstop,
operator-free
operator-freeoperation
operation
Copyright © 2006 Rockwell Automation, Inc. All rights reserved. 16
 Next Generation Control Systems Architecture:
Autonomous Control Systems

Autonomous Systems
(Modular, Adaptive Systems)

Flexible
FlexibleAutomation
Automation
Competitive Differentiation

• Easy to expand
• Fault-Tolerant
• Self Recovery
• High Redundancy
Fixed • Distributed
FixedAutomation
Automation
• Difficult to expand
• Faults Stop Operation
• Manual Recovery
• Minimal Redundancy
• Hierarchical

Today Future
Copyright © 2006 Rockwell Automation, Inc. All rights reserved. 17
 Looking at the Evolution of Agent Technology
Commercial
Highly distributed
Development Deployment
& heterogeneous environment and
optimized firmware
(Future)
Agent firmware Intra & Inter
integrated with Autonomous Control
Logix OS (2000-2006) (WWW)

Heterogeneous Water / Waste Water

systems with
Initial proof-
proof-of-
of- diverse complexity
concept and (1998-2000) nodes
conceptualization
Large systems with
low- complexity
nodes
(1995-1998)

Small applications
with high-
complexity nodes • Survivability • Multi component multi
• Reduced manning objective control
• Process optimization

• Jam prevention
• Dynamic rerouting of packages
• Optimum configurations
• Considerable reduction
of scrap material

Agent population size

Copyright © 2006 Rockwell Automation, Inc. All rights reserved. 18

 Autonomous Control Systems Application:
Shipboard Automation
Agent Navy
NavyRequires
Requires
AgentBased
BasedSolution
SolutionDeveloped
Developed Highly
Highly SurvivableSystem
Survivable System
LPAC
V003
AN/SPY1-D
V002 DHYR 2 PORT ARRAY
V103
V121
IC/ CHW CIC
CIC AN/SPY1-D 400 HZ
GYRO 2 PLANT 1 EQPT 2
EQPT 2 CIC
STBD ARRAY EQPT 1 CNVTR 2
HVAC SONAR SLQ-32
CLS 2 400 HZ
SONAR V127 EQPT EQPT
EQPT STBD
CNVTR 1
V601 ARRAY
V122

SLQ-32
400 HZ
CNVTR 1
V603
PORT
ARRAY
C&D ELEC V231
EQPT V004
CIC
EQPT 2
V001 LPAC LPAC
HVAC
HVAC (NV) DHYR 1 CHW CHW
CLS 1 IC/GYRO 1 DHYR 2 IC/GYRO 2
CHW
CLS 1 C&D PLANT 1 HVAC (NV) PLANT 2
PLANT 2
IC/ LPAC 400 HZ EQPT CLS 2
GYRO 1 DHYR 1 CNVTR 2
V230

Combat Chilled Water

V234
V204
400 Hz Electrical Power Low Pressure Air

Interior Communication HVAC

V006 V005

Agent Demonstrate
Demonstrate
Agentbased
basedprototype
prototypedeveloped
developed on
onthe
theNavy’s
Navy’sLand
Landbased
basedSimulator
Simulator

• Test and debug automatically generated agents • Test Reconfigurable Shipboard

• Test Agent Behavior for different configurations Automation Architecture

Potential
Potentialfuture
futureapplications:
applications:Automated,
Automated,self-adjusting
self-adjustingmanufacturing
manufacturinglines
linestotooptimize
optimize
throughput
throughput
Copyright © 2006 Rockwell Automation, Inc. All rights reserved. 19
 The Five “Key Technologies”
For Industrial Automation
Software
Software
Plant
(Enterprise)

√
Software
Integration /
Web Services
Line
(Manufacturing
Control
Control/ / Electronics Materials Solutions)
Diagnostics Communications
Communications Electronics Materials
Diagnostics

Advanced High
Control Commercial Alternate Reliability
Wireless
Electronics Materials Software
Prognostics
Machine
Autonomous (Factory)
Systems RFID On-Machine Nanocoatings

Copyright © 2006 Rockwell Automation, Inc. All rights reserved. 20

 Wireless Industrial Applications

Wireless
WirelessEthernet,
Ethernet,Self -Powered
Self-Powered RFID
Wireless Sensors
Wireless Sensors RFID

Source: Milwaukee Journal Sentinel 2/8/03

Copyright © 2006 Rockwell Automation, Inc. All rights reserved. 21

 Future Of Wireless:
Self-powered Wireless Sensors
• Low-power radio Wireless
WirelessNetwork
Network
• Energy harvesting technology
– Energy harvesting from machine
vibration and other “parasitic”
means
– Efficient and reliable generation and
supply of energy to power nodes http://www.millennial.net

Self-Powered Mode
Mode(no
(nobatteries)
Self-powered,
Self-powered, wireless
wireless Self-Powered batteries)
sensors
sensors and
and sensor
sensor
networks
networks for
for production
• Vibration
production • Power Gen.
• Power SOC.
metrics,
metrics, machine
machine health
health
monitoring
monitoring and
and remote
remote Processor / radio modules Energy Harvesting device with
asset
asset monitoring
monitoring
with sensors and signal
conditioning
piezo generator, power conversion
electronics, & power storage module

Copyright © 2006 Rockwell Automation, Inc. All rights reserved. 22

 Key Considerations for Deploying Wireless
in Industrial Automation
• Potential interference
– Existing wireless, legacy radios, microwave
ovens, cordless phones, emerging radios, Customer
Customer Value
Value Propositions
Propositions
process, fusion lighting Example:
Example: Rotating
Rotating Machinery
Machinery
• Achieving proper coverage Monitoring
Monitoring
– Antenna placement, reliable bandwidth, -Lower cost
-Lower cost (wiring)
(wiring)
minimize radios, channel usage (3D), -Ease of
-Ease of expansion
expansion
redundancy -Mobility
-Mobility
• Environmental compatibility
– Indoor/outdoor, temperature, contaminants,
wash-down
• Guaranteeing security
– IEEE 802.11i, 802.1x, TKIP, AES, RADIUS
• Minimizing cost
– Installation, power, communication,
enclosures

Copyright © 2006 Rockwell Automation, Inc. All rights reserved. 23

 Is RFID Revolutionary?

Bar
BarCode
CodeTechnology
Technology RFID
RFIDTechnology
Technology
“Static” •• Dynamic
Dynamic ---- information
information can
can bebe added
added or
or
deleted
deleted at
at every
every step
step in
in the
the supply
supply chain
chain
•• Can
Can store
store significantly
significantly more
more information
information

+
Fixed amount of information

Process Transformation

Deeply embedded in =
Revolutionary
existing processes

Copyright © 2006 Rockwell Automation, Inc. All rights reserved. 24

 RFID For Track/Trace, Genealogy

Phase
Phase22
Product
Product/ /Parts
PartsTagging
Tagging
•• Read
Read Tags
Tags
•• Program
Program // Print
Print Tags
Tags
•• Apply
Apply real-time
real-time control
control
•• Production
Production interlocking
interlocking
Phase •• Integration
Integration with
with MES
MES // ERP
ERP
Phase11
Case
Caseand
andPallet
PalletTagging
Tagging
• Read tags
• Program / Print Tags on
cases/pallets
• Provide traceability in supply
chain
• Integration with MES / ERP

Provide
ProvideTraceability
TraceabilityInInSupply
SupplyChain
ChainWith
WithRFID
RFIDEmbedded
EmbeddedInInPacka ging Material
Packaging MaterialSuch
SuchAs
As
Cardboard, Plastic Caps, Cartons
Cardboard, Plastic Caps, Cartons
Copyright © 2006 Rockwell Automation, Inc. All rights reserved. 25
 The Five “Key Technologies”
For Industrial Automation

√ Software
Software
Plant
(Enterprise)

Software
Control Integration /
Control/ / Communications Electronics
Electronics Materials
Materials Web Services
Line
Diagnostics
Diagnostics Communications (Manufacturing
Solutions)
Advanced
Control Wireless Commercial Alternate
Electronics Materials High
Prognostics Reliability
Software
Autonomous
Systems RFID On-Machine Nanocoatings Machine
(Factory)

Copyright © 2006 Rockwell Automation, Inc. All rights reserved. 26

Impact of Software/IT on Manufacturing

Supply
SupplyChain
ChainIntegration
Integration Batch
BatchSize
SizeofofOne
One

Suppliers
Suppliers Customers
Customers
The
TheValue
ValueChain
Chain

CAD-To-Part
CAD-To-Part Warranty
WarrantyCost
CostReduction
Reduction

Design
Design Support
Support
The
TheProduct
ProductLifecycle
Lifecycle

Opt.
Opt.Asset
AssetManagement
Management Data -Information Integration
Data-Information Integration

Factory
Factory Enterprise
Enterprise
The
TheEnterprise
Enterprise

Copyright © 2006 Rockwell Automation, Inc. All rights reserved. 27

 Software –
Customer Problems Today with Information Architecture

Business Processes Customer

CustomerProblems
ProblemsToday
Today
Resources Marketing (Information
(InformationArchitecture):
Architecture):
Enterprise Level •• High
Costing Sales
Business Functions Highcost
cost
Compliance ••Too
Toomany
manyservers
servers Integration
Integration

Information ••Custom
Customcode
code Costs
Costs
Engineering
Common Control ••Upgrades
Upgradesdifficult
difficult
Engineering
Time
Time
Database Data MES Gateway ••Multiple
Multiplecopies
copies Maintenance
Maintenance
Costs
Production Functions ofofdata
data
Costs

Data
Plant Floor •• Difficult
Difficultto
toOperate
Operate
Control Functions &&Maintain
Maintain
(training,
(training,personnel)
personnel)
••Too
Toomany
manycustom
custominterfaces
interfaces
••Lack
Lackofofstandards
standards

•• Lack
Lackof
ofIntegrated
Integrated
Security
Security
••Distributed
Distributed(decoupled)
(decoupled)
security
security
••No
Nodevice
devicelevel
levelsecurity
security

Copyright © 2006 Rockwell Automation, Inc. All rights reserved. 28

 Summary:
Impact of The Five Key Technologies On Manufacturing

• Flexible Automation
– Reconfigurable Control Systems
– Agent-Based, Autonomous Cooperative Systems
– Wireless Systems FLEXIBILITY:
Faster Commissioning,
FLEXIBILITY:
Faster Commissioning,
INTEGRATION: Reconfiguration Reconfiguration
INTEGRATION:
Control, Safety, Control, Safety,
Information/IT Information/IT

• Integration End
End Users
Users
OEMs
OEMs
Optimize
Optimizethe
– Information-enabled automation
OPTIMUM Optimize the PERFORMANCE:
ASSET Optimizethe
the Effectiveness Machine
Operation Effectiveness
UTILIZATION Operationofofthe
the Solutions
Solutions
ofofMachine effectiveness
Production Machine
ProductionLine
– Adoption of WWW standards
Line Building
Building
GLOBAL GLOBAL
SUPPORT SUPPORT
Services Services
COST: COST:

• Optimum Asset Utilization And Lowest Cost

Lifecycle Cost Product Cost
& Reusable Components

– Advanced Control
– Self-Diagnostics and Maintenance
– Health, Safety, and Environmentally Responsible
Systems

Modern
ModernManufacturing
ManufacturingSystems
SystemsWill
WillBeBe
Modular, Adaptable, Smart, and Efficient
Modular, Adaptable, Smart, and Efficient

Copyright © 2006 Rockwell Automation, Inc. All rights reserved. 29

 Five Technologies That
Will Drive The Future Of
Industrial Automation

Questions

Sujeet Chand
Sr. Vice President & Chief Technical Officer
Kenwood Hall
Vice President Architecture and Systems

Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 30