Automation Today South East Asia - June 2019
An overview of Rockwell Automation's technologies and industry insights.
Executive Message: Simplify Systems with Premier Integration
As systems become more connected and complex, integration between automation controllers and devices offers new time and cost-saving opportunities. Premier Integration simplifies system designs, cuts development time, and provides better access to production intelligence. A survey indicated that 64% of manufacturers reduced engineering time and 63% achieved improved diagnostics with integrated programming.
This issue explores Premier Integration, Modern DCS, Digital Twins for Manufacturing Efficiency, and TotalFORCE Technology for Smart Motor Control.
- Joseph Sousa, President, Asia Pacific Region, Rockwell Automation
News & Events
Rockwell Automation Earns Top Marks in 2019 Corporate Equality Index
Rockwell Automation received a perfect score on the Human Rights Campaign Foundation's 17th Annual Scorecard on LGBTQ Workplace Equality, highlighting its inclusive culture.
Rockwell Automation TechEd is Back!
Upcoming events in Mumbai, India (August 6-7, 2019) and Gold Coast, Australia (September 3-5, 2019) offer opportunities to learn about operational excellence, digital transformation, and the latest technologies.
RAOTM Season Wraps Up in Asia Pacific
Rockwell Automation on the Move (RAOTM) events across Asia Pacific connected with nearly 10,000 guests, showcasing automation expertise, smart practices, and the Connected Enterprise through seminars and hands-on labs.
AP Customer Events Calendar
| Event | City/Country | Date |
|---|---|---|
| Oil & Gas Asia 2019 | Kuala Lumper, Malaysia | 18-20 June |
| AMTS 2019 | Shanghai, China | 3-6 July |
| Industry of World Things Asia | Singapore | 10-12 July |
| TechED India | Mumbai, India | 6-7 August |
| TechED Australia | Gold Coast, Australia | 3-5 September |
| RubberTech China | Shanghai, China | 18-20 September |
For more details, visit: www.rockwellautomation.com/global/events/events.page
Cover Story: The Premier Integration Experience
Achieving faster time to market is crucial. Premier Integration simplifies machine design and configuration by providing a unified platform for controllers and devices. It addresses challenges like multi-vendor integration, extended engineering time, and maintenance complexities.
Key features include:
- A single software environment for programming, configuration, and maintenance.
- Centralized platform for leveraging multiple devices.
- Device mapping and configuration with automatic profile import.
- Duplicating devices via copy-paste functionality.
- Tag-aliasing for concurrent development.
- Library management for reusable code.
- Self and system-aware smart devices for enhanced visibility and decision-making.
A survey indicated that 64% of respondents saw reduced engineering time and 63% achieved improved diagnostics with integrated programming.
Case Study: City of Lima Wastewater Treatment Plant's Operations Flow Smoothly After DCS Migration
The City of Lima upgraded its outdated control system to a PlantPAx distributed control system (DCS) from Rockwell Automation. This migration addressed issues like limited river overflows, increased capacity needs (53 to 70 MGD), and system knowledge loss.
The new DCS provides a unified plantwide solution, streamlining control and information flow. Benefits include reduced downtime, improved troubleshooting via remote access, better performance management, and automated reporting. The city reported saving approximately 50 hours of overtime and $2,000 in the first three months of operation.
Case Study: How Cargill Achieves Sustainable Process Optimization
Cargill implemented a global continuous improvement initiative focused on process control. To sustain optimization gains, they adopted PlantESP from Control Station for control loop performance monitoring and advanced diagnostics across over 70 manufacturing sites.
The solution addresses issues like PID controllers reverting to manual mode and complex manual analysis. PlantESP provides standardized performance metrics, automated reports, and forensic capabilities, leading to improved yield, efficiencies, and throughput. It also helps detect programming anomalies and human errors.
Case Study: Sleeman Breweries Increases Production Capacity
Sleeman Breweries modernized its production with a Rockwell Automation system, including PlantPAx DCS and FactoryTalk Brew software, implemented by McRae Integration. This addressed challenges with an antiquated system and manual recipe changes.
The new system standardized operations across facilities, providing real-time production data and enabling quicker recipe configuration. Within two weeks, Sleeman increased production by 50%, achieving a 2-hour brew cycle with improved consistency.
Technology Watch: TotalFORCE Technology Drives Smart Motor Control
TotalFORCE Technology for Allen-Bradley PowerFlex 755T AC drives enhances smart motor control. It offers predictive analytics, adaptive control capabilities, and real-time health monitoring to reduce downtime and optimize operations.
Features include self-awareness for predictive maintenance (e.g., fan life modeling), adaptive tuning to block resonance, and monitoring of temperature, voltage, and current. Active Front End (AFE) drives also contribute to energy savings by mitigating harmonic distortion.
Application Profile: Digital Twins Deliver Greater Manufacturing Efficiency
Digital twins, virtual replicas of physical assets, offer significant advantages for manufacturing efficiency and predictive maintenance. They allow for simulation of designs and processes before physical implementation.
Key benefits include experimenting with equipment configurations, optimizing production scheduling, and diagnosing/solving problems virtually. Gartner predicts widespread adoption of digital twins, leading to significant improvements in effectiveness.
Rockwell Automation partners like Maplesoft provide tools like MapleSim software, which integrates with Studio5000 Simulation Interface to develop digital twins for conceptual design and virtual commissioning.
Product & Solution Focus
Latest Kinetix 5700 Servo Drive Delivers Energy Savings
The Kinetix 5700 Regenerative Bus Supply leverages EtherNet/IP for energy monitoring, providing cost savings through energy regeneration. It offers CIP security, an integrated LC filter, a smaller footprint, and stabilizes DC bus voltage. Designed for high axis counts and power requirements, it integrates with Studio 5000 for streamlined design and control.
Micro800 Controllers Deliver Flexible and Scalable Solutions
The Micro800 controller family provides flexible micro control solutions for standalone machines. The Micro870 controller offers enhanced scalability and customization. Connected Components Workbench software supports configuration, programming, and visualization. Applications include packaging, material handling, and heavy industry.
Nano Signal Conditioners for Precise Process Measurement and Control
Allen-Bradley 931 Nano Signal Conditioners offer optimal signal isolation, conversion, and amplification, saving space, time, and cost. They protect critical process measurements from noise and integrate with PlantPAx DCS for various industries including food and beverage, and pharmaceuticals.
Life Sciences Facility of the Future
The future of life sciences facilities involves digital technologies for personalized medicine and faster drug development. Modern DCS, single-use technology, and modular design enable greater efficiency, lower capital costs, and improved compliance.
Rockwell Automation Strengthens Industrial Control System Security
New products offer built-in security to protect industrial control systems. The Allen-Bradley ControlLogix EtherNet/IP module uses CIP Security, and the ControlLogix 5580 controller is certified to IEC 62443-4-2, enhancing system integrity and device-to-device communication security.
Stratus ztC Edge Computing System
The Stratus ztC Edge is a self-protecting Edge Computing system designed to increase efficiency, reduce IT burden, and lower downtime risk for resource-constrained operators. It offers virtualization, automated recovery, and cloud-based health management for industrial IoT and control applications.
Enhanced Connectivity with new ArmorBlock IO-Link Hub
The ArmorBlock I/O family provides hardened, water-resistant I/O solutions for on-machine use. The new ArmorBlock EtherNet/IP Modules and IO-Link Hubs enhance connectivity for The Connected Enterprise, supporting harsh applications and offering flexible I/O configurations.
Rockwell Automation Releases AI Module to Improve Industrial Production
The FactoryTalk Analytics LogixAI module provides predictive analytics without requiring a data scientist. It detects production anomalies and alerts workers, helping to improve product quality and process integrity. It integrates with the FactoryTalk Analytics platform for broader insights.
Bulletin 800G Hazardous Location Push Buttons
Rockwell Automation has expanded its Bulletin 800G portfolio with products certified for hazardous locations (ATEX/IECEx). These components are designed for field installation and offer various operator styles and configurations for safety in hazardous environments.
Rockwell Automation TechEd - Australia
The ultimate training event will be held in Gold Coast, Australia from September 3-5, 2019. It offers 6 streams of learning, from beginner overviews to advanced labs, focusing on improving machine performance, plant optimization, and empowering a Connected Enterprise. Highlights include keynotes, AR/VR demos, and a Women in Automation session.
For more information and to register, visit: www.rockwellautomation.com/en_AU
