Five Technologies That Will Drive The Future Of Industrial Automation

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Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
1
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
2
Copyright © 2006 Rockwell Automation, Inc. All rights reserved.
•Technology and Architecture Trends
•How Will Technology Trends Transform Industrial Automation?
•Q & A
•Manufacturing Trends
•Manufacturing Trends
Outline
3
Copyright © 2006 Rockwell Automation, Inc. All rights reserved.
Technology Predictions:
1954 Popular Mechanics Magazine
Scientists from the
RAND Corp have created
this model to illustrate
how a
“home computer”could
look like in the year 2004.
However the needed
technology will not be
economically feasible for
the average home. With
teletype interface and the
Fortran language, the
computer will be easy to
use.
Scientists from the
RAND Corp have created
this model to illustrate
how a
“home computer”could
look like in the year 2004.
However the needed
technology will not be
economically feasible for
the average home. With
teletype interface and the
Fortran language, the
computer will be easy to
use.
4
Copyright © 2006 Rockwell Automation, Inc. All rights reserved.
Prediction in 1968 of the year 2001
Space travel -common place
Space travel -common place
Computers –Big single computer,
Computers –Big single computer,
Arthur C. Clarke
Stanley Kubrick
possible erratic behavior
5
Copyright © 2006 Rockwell Automation, Inc. All rights reserved.
The Factory
The Factory
Manufacturing Trends
Cost / Energy
Efficiency
Safety/Security
Regulatory
Compliance /
Mandates
Productivity
/ Quality
Supply Chain
Integration
Flexible
Manufacturing
Customer
Demand
Customer
Demand
Supply Chain Integration and Flexible Manufacturing Are Driving
The Integration of Factories With Business Enterprise Systems
Supply Chain Integration and Flexible Manufacturing Are Driving
The Integration of Factories With Business Enterprise Systems
Business Enterprise Systems
Business Enterprise Systems
Suppliers
Suppliers
6
Copyright © 2006 Rockwell Automation, Inc. All rights reserved.
Manufacturing Trends and Drivers
Total “System”Cost
Lowest Procurement Cost
Functional Assets
Physical Assets
Global
Local
Integrated System
Loosely Coupled Design & System
Supply Chain Synchronization
Discrete Supply Chain
Mass Customization
Mass Production
To
From
7
Copyright © 2006 Rockwell Automation, Inc. All rights reserved.
Manufacturing Drivers Today
FLEXIBILITY:
Faster Commissioning,
Reconfiguration
INTEGRATION:
Control, Safety,
Information/IT
GLOBAL
SUPPORT
Services
OPTIMUM
ASSET
UTILIZATION
COST:
Lifecycle Cost
End Users
Optimize the
Operation of the
Production Line
End Users
Optimize the
Operation of the
Production Line
FLEXIBILITY:
Faster Commissioning,
Reconfiguration
INTEGRATION:
Control, Safety,
Information/IT
COST:
Product Cost
& Reusable Components
GLOBAL
SUPPORT
Services
OEMs
Optimize the
Effectiveness
of Machine
Building
OEMs
Optimize the
Effectiveness
of Machine
Building
Many Common Drivers for OEMs and End Users
Many Common Drivers for OEMs and End Users
Solutions
Solutions
PERFORMANCE:
Machine
effectiveness
8
Copyright © 2006 Rockwell Automation, Inc. All rights reserved.
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: Walmartand 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’scompetitors demanding “customized”products
Long-term vision: flexible and integrated manufacturing –
“customized trail mix”for every consumer
Long-term vision: flexible and integrated manufacturing –
“customized trail mix”for every consumer
9
Copyright © 2006 Rockwell Automation, Inc. All rights reserved.
Outline
•Manufacturing Megatrends
•Technology and Architecture Trends
•How Will Technology Trends Transform Industrial Automation?
•Q & A
Technology and Architecture Trends
Technology and Architecture Trends
Technology and Architecture Trends
10
Copyright © 2006 Rockwell Automation, Inc. All rights reserved.
The Five “Key Technologies”
For Industrial Automation
Machine
(Factory)
Line
(Manufacturing
Solutions)
Plant
(Enterprise)
Electronics
Electronics
Electronics
Materials
Materials
Materials
Software
Software
Software
Commercial
Electronics
On-Machine
Commercial
Electronics
On-Machine
Alternate
Materials
Nanocoatings
Alternate
Materials
Nanocoatings
Software
Integration /
Web Services
High
Reliability
Software
Software
Integration /
Web Services
High
Reliability
Software
√√

Control /
Diagnostics
Control /
Control /
Diagnostics
Diagnostics
Advanced
Control
Prognostics
Autonomous
Systems
Advanced
Control
Prognostics
Autonomous
Systems
Communications
Communications
Communications
Wireless
RFID
Wireless
RFID
11
Copyright © 2006 Rockwell Automation, Inc. All rights reserved.
Technology Evolution
Nano
& Virtual
2010
to ….
Nano
& Virtual
2010
to ….
Information
Technology
1960
to 2010
Information
Technology
1960
to 2010
Industrial
1800
to 1960
Industrial
1800
to 1960
Agriculture
10K BC
to 1800 AD
Agriculture
10K BC
to 1800 AD
Hunting/
Survival
Million BC
to 10 BC
Hunting/
Survival
Million BC
to 10 BC
12
Copyright © 2006 Rockwell Automation, Inc. All rights reserved.
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
13
Copyright © 2006 Rockwell Automation, Inc. All rights reserved.
Outline
•Manufacturing Megatrends
•Technology and Architecture Trends
•How Will Technology Trends Transform Industrial Automation?
•Q & A
How Will Technology Trends Transform Industrial Automation?
How Will Technology Trends Transform Industrial Automation?
How Will Technology Trends Transform Industrial Automation?
14
Copyright © 2006 Rockwell Automation, Inc. All rights reserved.
The Five “Key Technologies”
For Industrial Automation
Machine
(Factory)
Line
(Manufacturing
Solutions)
Plant
(Enterprise)
Electronics
Electronics
Electronics
Materials
Materials
Materials
Software
Software
Software
Commercial
Electronics
On-Machine
Commercial
Electronics
On-Machine
Alternate
Materials
Nanocoatings
Alternate
Materials
Nanocoatings
Software
Integration /
Web Services
High
Reliability
Software
Software
Integration /
Web Services
High
Reliability
Software

Control /
Diagnostics
Control /
Control /
Diagnostics
Diagnostics
Advanced
Control
Prognostics
Autonomous
Systems
Advanced
Control
Prognostics
Autonomous
Systems
Communications
Communications
Communications
Wireless
RFID
Wireless
RFID
Copyright © 2006 Rockwell Automation, Inc. All rights reserved.
Advanced Control
Trend toward application-specific
advanced control methods that optimize
performance and energy efficiency
Trend toward application-specific
advanced control methods that optimize
performance and energy efficiency
Simulator
Cheese Cook
Cycle Control
•Increased production-
shortened average cook cycle
duration by 10%
•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.
16
Copyright © 2006 Rockwell Automation, Inc. All rights reserved.
Prognostics Application At A Food
Manufacturer
Remote Analysis of Pump Operation
Remote Analysis of Pump Operation
Remote Analysis of Pump Operation
•Discharge Pressure
•Suction Pressure
•Bearing Temperature
•Fluid Temperature
•Vibration
•Barometric Pressure
•Current (future)
•Discharge Pressure
•Suction Pressure
•Bearing Temperature
•Fluid Temperature
•Vibration
•Barometric Pressure
•Current (future)
Monitoring
Monitoring
Monitoring
Customer’s Problem:
Pump Life Unloading Rail Cars
Customer’s Problem:
Customer’s Problem:
Pump Life Unloading Rail Cars
Pump Life Unloading Rail Cars
•Bearings, pump cavitation, vibration monitoring
•Spectral signature analysis, Neural Networks
•Motor condition monitoring
•Bearings, pump cavitation, vibration monitoring
•Spectral signature analysis, Neural Networks
•Motor condition monitoring
Pump diagnostics & prognostics
Pump diagnostics & prognostics
Pump diagnostics & prognostics
Growing trend towards prognostics and remote monitoring of machinery, e.g., nonstop,
operator-free operation
Growing trend towards prognostics and remote monitoring of machinery, e.g., nonstop,
operator-free operation
17
Copyright © 2006 Rockwell Automation, Inc. All rights reserved.
Next Generation Control Systems Architecture:

Autonomous Control Systems
Autonomous Systems
(Modular, Adaptive Systems)
Today Future
•Difficult to expand
•Faults Stop Operation
•Manual Recovery
•Minimal Redundancy
•Hierarchical
•Easy to expand
•Fault-Tolerant
•Self Recovery
•High Redundancy
•Distributed
Competitive Differentiation
Competitive Differentiation
Flexible Automation
Flexible Automation
Flexible Automation
Fixed Automation
Fixed Automation
Fixed Automation
18
Copyright © 2006 Rockwell Automation, Inc. All rights reserved.
Small applications
with high-
complexity nodes
Looking at the Evolution of Agent Technology
(1995-1998)
(1998-2000)
(2000-2006)
Large systems with
low-complexity
nodes
Agent population size
Highly distributed
& heterogeneous
Heterogeneous
systems with
diverse complexity
nodes
(Future)
Intra & Inter
Autonomous Control
(WWW)
Initial proof
Initial proof
-
-
of
of
-
-
concept and
concept and
conceptualization
conceptualization
•Jam prevention
•Dynamic rerouting of packages
Agent firmware
Agent firmware
integrated with
integrated with
Logix
Logix
OS
OS
Development
Development
environment and
environment and
optimized firmware
optimized firmware
Commercial
Commercial
Deployment
Deployment
•Survivability
•Reduced manning
Water / Waste Water
•Optimum configurations
•Considerable reduction
of scrap material
•Multi component multi
objective control
•Process optimization
19
Copyright © 2006 Rockwell Automation, Inc. All rights reserved.
Autonomous Control Systems Application:
Shipboard Automation
CHW
PLANT 2
CHW
PLANT 1
C&D
EQPT
AN/SPY1-D
PORT ARRAY
AN/SPY1-D
STBD ARRAY
SLQ-32
EQPT
400 HZ
CNVTR 2
IC/GYRO 2
400 HZ
CNVTR 1
IC/GYRO 1
LPAC
DHYR 1
SONAR
EQPT
HVAC (NV)
CLS 1
HVAC (NV)
CLS 2
LPAC
DHYR 2
CIC
EQPT 2
CIC
EQPT 1
Combat
400 Hz Electrical Power
Interior Communication
Chilled Water
Low Pressure Air
HVAC
•Test Reconfigurable Shipboard
Automation Architecture
V001
V004
V234
HVAC
CLS 1
V230
V122
V006
V002
PORT
ARRAY
STBD
ARRAY
V603
V127
IC/
GYRO 1
400 HZ
CNVTR 2
LPAC
DHYR 1
HVAC
CLS 2
V121
CIC
EQPT 2
CIC
EQPT 2
LPAC
DHYR 2
SLQ-32
V601
V231
V204
CHW
PLANT 2
V103
CHW
PLANT 1
V003
IC/
GYRO 2
SONAR
EQPT
400 HZ
CNVTR 1
C&D ELEC
EQPT
V005
•Test and debug automatically generated agents
•Test Agent Behavior for different configurations
Agent Based Solution Developed
Agent Based Solution Developed
Agent Based Solution Developed
Navy Requires
Highly Survivable System
Navy Requires
Navy Requires
Highly Survivable System
Highly Survivable System
Agent based prototype developed
Agent based prototype developed
Agent based prototype developed
Demonstrate
on the Navy’s Land based Simulator
Demonstrate
Demonstrate
on the Navy’s Land based Simulator
on the Navy’s Land based Simulator
Potential future applications: Automated, self-adjusting manufacturing lines to optimize
throughput
Potential future applications: Automated, self-adjusting manufacturing lines to optimize
throughput
20
Copyright © 2006 Rockwell Automation, Inc. All rights reserved.
The Five “Key Technologies”
For Industrial Automation
Machine
(Factory)
Line
(Manufacturing
Solutions)
Plant
(Enterprise)
Electronics
Electronics
Electronics
Materials
Materials
Materials
Software
Software
Software
Commercial
Electronics
On-Machine
Commercial
Electronics
On-Machine
Alternate
Materials
Nanocoatings
Alternate
Materials
Nanocoatings
Software
Integration /
Web Services
High
Reliability
Software
Software
Integration /
Web Services
High
Reliability
Software

Control /
Diagnostics
Control /
Control /
Diagnostics
Diagnostics
Advanced
Control
Prognostics
Autonomous
Systems
Advanced
Control
Prognostics
Autonomous
Systems
Communications
Communications
Communications
Wireless
RFID
Wireless
RFID
21
Copyright © 2006 Rockwell Automation, Inc. All rights reserved.
Wireless Industrial Applications
Wireless Ethernet, Self-Powered
Wireless Sensors
Wireless Ethernet, Self
Wireless Ethernet, Self
-
-
Powered
Powered
Wireless Sensors
Wireless Sensors
Source: Milwaukee Journal Sentinel 2/8/03
RFID
RFID
RFID
22
Copyright © 2006 Rockwell Automation, Inc. All rights reserved.
Self-Powered Mode (no batteries)
Self
Self
-
-
Powered Mode (no batteries)
Powered Mode (no batteries)
Wireless Network
Wireless Network
Wireless Network
Future Of Wireless:
Self-powered Wireless Sensors
•Low-power radio
•Energy harvesting technology
–Energy harvesting from machine
vibration and other “parasitic”
means
–Efficient and reliable generation and
supply of energy to power nodes
Energy Harvesting device with
piezogenerator, power conversion
electronics, & power storage module
•Vibration
•Power Gen.
•Power SOC.
Processor / radio modules
with sensors and signal
conditioning
Self-powered, wireless
sensors and sensor
networks for production
metrics, machine health
monitoring and remote
asset monitoring
Self-powered, wireless
sensors and sensor
networks for production
metrics, machine health
monitoring and remote
asset monitoring
http://www.millennial.net
23
Copyright © 2006 Rockwell Automation, Inc. All rights reserved.
Key Considerations for Deploying Wireless
in Industrial Automation
•Potential interference
–Existing wireless, legacy radios, microwave
ovens, cordless phones, emerging radios,
process, fusion lighting
•Achieving proper coverage
–Antenna placement, reliable bandwidth,
minimize radios, channel usage (3D),
redundancy
•Environmental compatibility
–Indoor/outdoor, temperature, contaminants,
wash-down
•Guaranteeing security
–IEEE 802.11i, 802.1x, TKIP, AES, RADIUS
•Minimizing cost
–Installation, power, communication,
enclosures
Customer Value Propositions
Example: Rotating Machinery
Monitoring
-Lower cost (wiring)
-Ease of expansion
-Mobility
Customer Value Propositions
Example: Rotating Machinery
Monitoring
-Lower cost (wiring)
-Ease of expansion
-Mobility
24
Copyright © 2006 Rockwell Automation, Inc. All rights reserved.
Is RFID Revolutionary?
•Dynamic --information can be added or
deleted at every step in the supply chain
•Can store significantly more information
•Dynamic --information can be added or
deleted at every step in the supply chain
•Can store significantly more information
Process Transformation
Process Transformation
Revolutionary
Revolutionary
=
=
=
+
+
+
“Static”
“Static”
Fixed amount of information
Fixed amount of information
Deeply embedded in
existing processes
Deeply embedded in
existing processes
Bar Code Technology
Bar Code Technology
Bar Code Technology
RFID Technology
RFID Technology
RFID Technology
25
Copyright © 2006 Rockwell Automation, Inc. All rights reserved.
RFID For Track/Trace, Genealogy
•Read tags
•Program / Print Tags on
cases/pallets
•Provide traceability in supply
chain
•Integration with MES / ERP
•Read Tags
•Program / Print Tags
•Apply real-time control
•Production interlocking
•Integration with MES / ERP
•Read Tags
•Program / Print Tags
•Apply real-time control
•Production interlocking
•Integration with MES / ERP
Phase 1
Case and Pallet Tagging
Phase 1
Phase 1
Case and Pallet Tagging
Case and Pallet Tagging
Phase 2
Product / Parts Tagging
Phase 2
Phase 2
Product / Parts Tagging
Product / Parts Tagging
Provide Traceability In Supply Chain With RFID Embedded In Packaging Material Such As
Cardboard, Plastic Caps, Cartons
Provide Traceability In Supply Chain With RFID Embedded In Packa
Provide Traceability In Supply Chain With RFID Embedded In Packa
ging Material Such As
ging Material Such As
Cardboard, Plastic Caps, Cartons
Cardboard, Plastic Caps, Cartons
26
Copyright © 2006 Rockwell Automation, Inc. All rights reserved.
The Five “Key Technologies”
For Industrial Automation
Machine
(Factory)
Line
(Manufacturing
Solutions)
Plant
(Enterprise)
Software
Software
Software
Software
Integration /
Web Services
High
Reliability
Software
Software
Integration /
Web Services
High
Reliability
Software

Electronics
Electronics
Electronics
Materials
Materials
Materials
Commercial
Electronics
On-Machine
Commercial
Electronics
On-Machine
Commercial
Electronics
On-Machine
Commercial
Electronics
On-Machine
Alternate
Materials
Nanocoatings
Alternate
Materials
Nanocoatings
Alternate
Materials
Nanocoatings
Alternate
Materials
Nanocoatings
Control /
Diagnostics
Control /
Control /
Diagnostics
Diagnostics
Advanced
Control
Prognostics
Autonomous
Systems
Advanced
Control
Prognostics
Autonomous
Systems
Advanced
Control
Prognostics
Autonomous
Systems
Advanced
Control
Prognostics
Autonomous
Systems
Communications
Communications
Communications
Wireless
RFID
Wireless
RFID
Wireless
RFID
Wireless
RFID
27
Copyright © 2006 Rockwell Automation, Inc. All rights reserved.
Customers
Customers
Support
Support
Enterprise
Enterprise
Suppliers
Suppliers
Design
Design
Factory
Factory
Impact of Software/IT on Manufacturing
Supply Chain Integration
Supply Chain Integration
Supply Chain Integration
Batch Size of One
Batch Size of One
Batch Size of One
CAD-To-Part
CAD
CAD
-
-
To
To
-
-
Part
Part
Warranty Cost Reduction
Warranty Cost Reduction
Warranty Cost Reduction
Opt. Asset Management
Opt. Asset Management
Opt. Asset Management
Data-Information Integration
Data
Data
-
-
Information Integration
Information Integration
The Value Chain
The Value Chain
The Value Chain
The Product Lifecycle
The Product Lifecycle
The Product Lifecycle
The Enterprise
The Enterprise
The Enterprise
28
Copyright © 2006 Rockwell Automation, Inc. All rights reserved.
Plant Floor
Control Functions
Enterprise Level
Business Functions
Software –
Customer Problems Today with Information Architecture
Customer Problems Today
(Information Architecture):
•High cost
•Too many servers
•Custom code
•Upgrades difficult
•Multiple copies
of data
•Difficult to Operate
& Maintain
(training, personnel)
•Too many custom interfaces
•Lack of standards
•Lack of Integrated
Security
•Distributed (decoupled)
security
•No device level security
Customer Problems Today
(Information Architecture):
•High cost
•Too many servers
•Custom code
•Upgrades difficult
•Multiple copies
of data
•Difficult to Operate
& Maintain
(training, personnel)
•Too many custom interfaces
•Lack of standards
•Lack of Integrated
Security
•Distributed (decoupled)
security
•No device level security
Business Processes
Resources
Marketing
Sales
Costing
Compliance
Data
Data
MES Gateway
Production Functions
Information
Information
Common
Database
Control
Data
Integration
Costs
Engineering
Time
Maintenance
Costs
Integration
Costs
Engineering
Time
Maintenance
Costs
29
Copyright © 2006 Rockwell Automation, Inc. All rights reserved.
Summary:
Impact of The Five Key Technologies On Manufacturing
•Flexible Automation
–Reconfigurable Control Systems
–Agent-Based, Autonomous Cooperative Systems
–Wireless Systems
•Integration
–Information-enabled automation
–Adoption of WWW standards
•Optimum Asset Utilization And Lowest Cost
–Advanced Control
–Self-Diagnostics and Maintenance
–Health, Safety, and Environmentally Responsible
Systems
Modern Manufacturing Systems Will Be
Modular, Adaptable, Smart, and Efficient
Modern Manufacturing Systems Will Be
Modern Manufacturing Systems Will Be
Modular, Adaptable, Smart, and Efficient
Modular, Adaptable, Smart, and Efficient
FLEXIBILITY:
Faster Commissioning,
Reconfiguration
INTEGRATION:
Control, Safety,
Information/IT
GLOBAL
SUPPORT
Services
OPTIMUM
ASSET
UTILIZATION
COST:
Lifecycle Cost
End Users
Optimize the
Operation of the
Production Line
End UsersOptimize the
Operation of the
Production Line
FLEXIBILITY:
Faster Commissioning,
Reconfiguration
INTEGRATION:
Control, Safety,
Information/IT
COST:
Product Cost
& Reusable Components
GLOBAL
SUPPORT
Services
OEMs
Optimize the
Effectiveness
of Machine
Building
OEMs
Optimize the
Effectiveness
of Machine
Building
Solutions
Solutions
PERFORMANCE:
Machine
effectiveness
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
30
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