The Future of Machine Building is NOW!

The Future of Machine Building is NOW!

Ed Sandlin, Ashish Patwardhan & Alec Grainger
Schneider Electric
Industry NOW Express

Schneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 1

Agenda

1. Simplicity
2. Remote monitoring
3. Energy efficiency
4. MachineStruxure

Schneider Electric - Industry Business – The Future of Machine Building is NOW! –2012

The Mobile Phone Evolution


Machine Control Evolution


The Future of Machines…
Integrated Automation
Now
1900’s


Integrated Automation Defined

●“The convergence of previously distinct automation functions… An
integrated platform uses one programming environment to handle all
required functions”
– Aaron Hand, Control Design and Industrial Networking

●More complete, sophisticated and flexible software environments

●Greater hardware flexibility and integration in machine control

●Simplified and more readily accessible physical machine configuration


Integrated Automation
Then Multiple
Now
software
Single
suites
PLC software
suite

Prop.
Cable
Drive

Motion

I/O HMI

Software

TIA Portal CCW Workbench

CX-One SoMachine
Automation Studio

TwinCat 2 & 3 MELSOFT


One Software: SoMachine

With SoMachine, you can develop and
maintain the complete application in a
single software environment including
control, motion, drives, HMI, sensors,
application libraries and network
automation functions.


Hardware Flexibility
Drive

PLC PLC

HMI Motor Drive
HMI-PLC Integrated
Motor Drive-PLC

“Integrated motor-drives
could overtake standalone “HMI-PLCs will gain in
systems”
Schneider Electric - Industry Business – The Future of Machine Building is NOW! –2012 popularity and drop in price”
10

Architecture Simplification

What is Needed? The Fix
1 Training 1 Training manuals

2 Programming 2 Sample code & templates

3 Wiring 3 Sample architectures

4 3rd party components 4 White papers

5 Testing 5 Simulation mode


Solutions for Machines
Save up to 50% in design time
Ready-to-use architectures for optimum results

Predetermined equipment lists

Tested
● Applications tested by our experts to
ensure that they work in all possible
configurations

Validated
● Fully functional compatibility of devices

Documented
● Full user manual containing all the
required information for installation and
assembly, including CAD and wiring
diagrams


Customizable Machines

Value Innovative Controls
Engineering
●Flexibility

●Scalability

●Repeatability


What Does Simplicity Mean?
With MachineStruxure solutions, you can answer your customers’ challenges
and help them remove complexity from their businesses.

Reduce time to
market

Save 50% in control
design time

100% flexibility &
optimization of your
machines


You remember the Bass Model…

● Ability to forecast future sales and the rate of
adoption
● Bass Model

Frank Bass
1926-2006


Bass Model

f(t) = portion of M
that adopts at time t Total Adoptions
F(t) = portion of M that at Time t
have adopted by time t

M = the potential market
p = the coefficient of innovation
q = the coefficient of imitation


Bass Model Generalization

The “S Curve” of change


Rogers’ Diffusion of Innovation

● Different consumers make it through the steps at different speeds

Everett Rogers
1931-2004

Sales over time

Technology Adoption Curves


Remote Interaction: Internet

● NetMeeting / Skype / Google Hangouts / TeamViewer / Dropbox


Remote Interaction: Machines

● Machine: recipe management, trouble shooting, remote monitoring
● Shop floor to office to service connectivity
● SCADA / Web servers/ Web Gate / FTP servers/ USB keys…

Ethernet Network


Future? The Cloud – Engagement
Engaging with customers, partners, and employees

Microsoft / IBM / Oracle /
Salesforce.com

Ford Focus connecting
onboard WiFi with ATT


The Cloud for Machine Builders: M2M
Engaging with machines and business

● Automation specialists offering dedicated M2M services
● GE: GE Remote Condition Monitoring Center
● HMS: RemoteCom
● ETIC
● Schneider Electric

● Large OEM companies developing their own solution with equivalent
features
● Daikin
● Carrier

● M2M companies offering Cloud-based services
● Ewon: Talk2M
● M2MDatacorp
● Ei3


OptiM2M – How it works
Architectures & infrastructure
Data center Data center
Kelowna - CANADA Les Ulis - France

Web browser
Vpn https
M2M Portal

Web browser
Private APN
The OEM
+ encrypting
services

Vpn

Modbus master

Modem
RS 232
Modbus protocol
Machine
PLC

Stand alone
architecture


Cell Phone Revolution
Connecting with people


Cell Phones for Machine Builders
Connecting with machines / factories

SCADA / PLC / HMI / Software

Example: Aluma Tower


Smartphone – Smart Devices Revolution
Knowledge, empowerment and connectivity

Apple / Samsung / Blackberry / LG / Google / Microsoft / Amazon / …


Smart Devices for Machine Builders
Knowledge, empowerment and connectivity
Selection Apps / Control Apps / HMI Web Gate Apps

Example: Palladium Technologies


The Future? NOW!
Consumer & Machine Building

Completely automated machines and robots

Rodney Brooks

http://www.youtube.com/watch?v=rjPFqkFyrOY

Why Energy Optimization?


The Energy Dilemma
The facts The need

vs
Energy demand CO2 emissions to
by 2050 avoid dramatic climate
Electricity by 2030 changes by 2050
Source: IEA 2007 vs. 1990 level

Energy management is the key
to address the dilemma


Recent Articles
The push to achieve reductions in energy consumption is a significant
global trend

● MGM Resorts Hits the Energy Efficiency Jackpot
● Design World, SEP 2012

● Energy Management Strategy, Roadmap Needed?
● Automation World, SEP 2012

● Don’t Leave Energy Projects ROIs on the shelf
● ControlDesign, MAY 2012

● Energy Efficiency: The Secret to Sustainable Machines
● Automation World, MAR 2011


Trends
● The focus for machine design is no longer simply
maintaining acceptable production rates at an
appropriate level of quality.

● Automation professionals are now deploying
technologies in clever ways to improve the energy
efficiency of their automated machinery.

● In fact, companies that endorse energy efficiency
and sustainability in their thinking experience
stronger loyalty from their customers, produce
better quality machines with improved machine
performance, and find more opportunities for new
business even in a tough economic environment.

Source: Automation World

Energy Efficiency as a Source of Energy

Fuel Consumer
100 units 35 units 33 units

3 units saved at the 1 unit saved at
energy source consumer plug


The Power of a Combined Solution
Greater efficiency, smarter grid, and cleaner generation

● Over 50% of CO2 emission abatement will come from end user efficiency
World energy-related CO2 emissions abatement

Source: World Energy Outlook 2010, OECD / IEA

Energy Efficiency for Industry
Has Already Started Consumer Packaged
Retail Goods

• 3% year-over-year reduction in energy, water, and
waste. We are committed to reducing our waste and
use of non-sustainable energy and water.
• Sustainable in a generation. We are committed to a
zero carbon footprint, zero impact in the use of water
and zero waste to landfill at our sites by 2040.
y
bilit
aina
Material Handling S ust
Buildings
Going Green

MGM Resorts Hits the Energy Efficiency
UPS has become the first major package delivery Jackpot: In Las Vegas, one of the leading
and logistics company to earn Gold Status corporations in the “entertainment capital of the
certification from the Leadership in Energy and world” is staying true to the city’s visionary
Environmental Design (LEED) along with an history by anticipating the need for sustainable
Energy Star certification for its corporate and energy-efficient structures well ahead of
headquarters complex many of its competitors.


Easily Identifiable Energy Efficiency Opportunities

Industrial companies don’t have sufficient information to know
where to look beyond the easily identifiable energy efficiency
opportunities

Less obvious, higher impact:
energy efficiency through
process and machine efficiency…
…to reduce the energy consumed
per unit of output!

Solving the Energy Equation
with a focus on energy efficiency
1 Energy audit
Find out what the challenge is… & metering

Model fully compliant with
EN 16001 & ISO 50001

Passive energy efficiency Active energy efficiency

2 3 Optimize through 4 Monitor,
Fix the basics automation maintain,
& regulation improve

Low consumption devices, Variable speed drives, Meters installation
insulation material, power HVAC control, and integration,
factor correction machine controllers for supervisory services,
production optimization EE analysis software
Passive + Active EE solutions = Sustained Energy Savings

Why Improve Energy Efficiency in
Machines?

● Energy efficiency is an increasing concern “Together with Schneider
Electric we realized the
in the global strategy of your new SP2 NG – an energy
customers. By offering them machines that efficient machine, bringing
tangible improvements
save energy you will have a definite to the end user in energy
advantage over the competition. usage, in terms of consumed
watts per manufactured unit,
enabling up to 30% energy
savings compared to
●MachineStruxureTM solutions help you traditional machines.”
design more energy efficient machines
ACMA
while increasing: Flowpack Division
●Machine performance
●Machine attractiveness for end users


End-users Have Already Shifted to “Green”
● Energy savings in 2007 in 2011
is now the 1. Price 1. Price

second 2. # of operators 2. Energy savings
3. Saving use of consumables 3. Saving use of consumables
criteria 4. Packing material reduction 4. # of operators
considered when 5. Energy savings 5. Packing material reduction
choosing a
machine
How is your
● In 2011, 77% investment in
of end users sustainable
increased or development
maintained their evolving?
investment
towards “Green”
Europack-Euromanut (+300 enterprises in Packaging-Consumers Industry) Summer 2011


How to Boost Energy
Efficiency in Machines


Machine Energy Optimization 1

In Four Sustainability Steps ISO 50001
2 3 4

● Follow the 4 energy efficient principles adapted to the machine
life cycle to support energy savings and obtain immediate results
● Make your machine an enabler for end user compliance to
EN 16001 & ISO 50001 standards

10 to
15%
Up to 8% per year is lost
5 to
15%

10 to
without monitoring and
2 to
8%
15%
5 to
maintenance program
15%
2 to
8% Up to 12% per year is lost
without regulation and
control systems


Machine Energy Optimization
In Four Sustainability Steps
1- Audit your machine energy 4- Monitor
Identify energy waste in your machine and energy
recommend optimization solutions
consumption

2- Fix your machine basics
Select relevant motor optimizer motor control
 Use variable speed drives
 Use Servo-drives and synchronous motors

3- Optimize your machine
Energy operating modes: high value mechanism
with no additional hardware cost
 Energy management functions in
controllers and HMI
 Energy optimization guidelines for
machines in targeted applications
(HVAC&R, packaging, conveying,
hoisting, etc.)


Focus on Energy Monitoring
Libraries for Machines


How does it work?
Libraries interactions:

SoMachine HMIs
Machine Energy Dashboard

MED Graphical Objects
(Vijeo Designer Tool chest)

Data Processing Machine
FBs production
data
EE Toolbox library

Accumulator Controllers
FB

Devices Generic Energy Meter
Communication FBs FB

In the Field Supported field-buses:

Power meters Circuit breaker Motor control Other equipment
(based on rated power)


Machine Energy Dashboard - Overview

● Simple indicators for operator
● Real power: Color ranges for quick
detection of any deviation
● Real energy:
● Split by operating mode
● Spent per unit produced
● Peak alert
● Trend indicator
● Ready-to-use and fully customizable (units,
thresholds, reset control, etc.)


Machine Energy Dashboard - Overview

● Trend Information
● Energy per unit
1. Energy calculated per unit produced
2. Average energy for total amount of units
3. Energy per unit target (constant value)
4. Energy per unit high limit - generates an alarm
when reached

● Power and unit
1. Average power per sampling time (hours,
minutes, etc.)
2. Amount of units produced per sampling time


EE Monitoring: Improve Predictive
Maintenance
 Deviation to target often indicates equipment “pre-failure“
Energy per unit
Dec, 21st, 2010 – 18:05:02

Instant
Power Last reset
20/12/2010
10:00:00
230 AVERAGE

2.89
Wh
Energy per unit
172
Deviation
+ 0.57 Wh
AVERAGE

2.89 Wh
115
200 kW
1 - Analyze over-consumption
58 • Worn mechanical bearings
• Motor failure
• Electrical issue (insulation, power
0 quality, etc.)
• Lack of lubricant
• Unexpected temperature increase
• Raw material properties change
• Dirty filters
•…
2 - Fix problem before serious issue
occurs – limit impact on performance

EE Monitoring: Distributed Architectures
Machine (Zone 1)
PM800

 Example of distributed monitoring architecture Zone 2

Zone 2.1
Modbus / CANopen with M258 ATV32 1

ATV32 2

Zone 2.2

 ATV71 1
ATV71 2
Zone 3

LXM 32 1
  LXM 32 2
PM1200

 Zone 4

TESYSU 1

PM1200
Zone 5
On/Off Eqt


Italy - Packaging Machine: “Energy Bar”


A Comprehensive Automation
Solution for Industrial Machines

MachineStruxure solutions help
machine builders design machines
that are optimized for cost, energy
efficiency and performance


Reduce Complexity With
One single Unique TVDA* End-to-end Simple and easy
software value service support to use
environment proposition

Integrated software SoMachine:
Motion
Simplify machine programming & centric
commissioning
Drive
centric Speed up
Logic
“concept to
centric
design”
4 hardware control platforms Optimize
Embedded Intelligence machine
production, flow
where it is needed and capacity
Optimize on-
site intervention
costs
6 targeted applications
HMI
centric
Hoisting, Textile, Packaging, Conveying, HVAC&R, Elevators & Escalators


TVD Architectures
● Tested
● Tested in laboratory by experts
● Ensuring the right functional
performance in all possible
configurations
● Validated
• Fully functional compatibility of the
devices
● Documented
● Complete user guide giving all the
details required for installing and building
your application with confidence
• Ready to use with e-plan: predefined
CAD panel designs & wiring diagrams

● Up to 50% control system design time savings
● Installation time reduction


Innovation for Simplicity
Simplified offers Simplified maintenance

Modicon controllers Altivar 32 and Lexium 32 drives

 MMS
 e-mail
 Wap
 Internet

Send-receive configuration everywhere & any time
Getting closer and being more responsive to local needs Upload-download configuration with drive
Adapting our offer to meet customer needs Monitor-control drive
Simplified
Self powered wireless push button and Hardware flexibility
Magelis STU

Ensure permanent
availability – battery-less
22mm mounting system
Robustness for harsh
Ethernet embedded
environment
Powered by Vijeo Designer Mobile control

Simplified assembly Simplified integration

Helps you manage your
process more efficiently
while using less energy


Services & support
Throughout the complete machine life cycle

> Innovation and competitiveness right OEM-specific
from the start services and
> Speed up « concept to design » support at every
step of your
machine life cycle

Improve your end
user customers’
> Optimize machine
satisfaction by
production flow and maximizing their
capacity investments

Further develop
your sales in a
> Maximize machine profitable way
continuity of operation
> Optimize on-site
intervention costs
> Generate profit while > Expand business by addressing new
keeping end user markets
customer satisfied > Access international markets while
minimizing associated risks


With MachineStruxure solutions you can answer your customers’ challenges
and help them remove complexity from their businesses

Reduce time to
Added value throughout the market
entire life of your machine

Build a strong automation
platform through Save 50%
the use of our proven and in control design
ready-to-use automation
architectures and
time
application function
libraries

SoMachine is a single
software suite that runs on 100% flexibility &
multiple hardware control optimization of your
platforms to achieve flexible machines
machine control: HMI,
motion, drive and logic
controllers


Annex


ISO 50001 Standard
Published in June 2011
● ISO 50001 is based on the ISO management system model familiar to
more than a million organizations worldwide who implement standards such as:
● ISO 9001 (quality management), ISO 14001 (environmental management), ISO
22000 (food safety), ISO/IEC 27001 (information security)
● Follows the Plan-Do-Check-Act process for continual improvement of the
energy management system
● Provides a framework of requirements enabling organizations to:
• Develop a policy for more efficient use of energy
• Fix targets and objectives to meet the policy
• Use data to better understand and make decisions concerning energy use and
consumption
• Measure the results
• Review the effectiveness of the policy
• Continually improve energy management

● ISO 50001 can be implemented individually or integrated with other
management system standards


Motor Consumption in the World
Motor’s energy bill = motor cost x 100

● in Industry 60% of electricity
● in Building, 30% of electricity Big Motor:
1 Month
Energy Bill
= Motor Cost

Energy
97%
Installation & Maintenance: 2%
Investment: 1%
Global costs during motor life (average 15 years)

Optimizing Energy Efficiency
of Conveyors


Packaging: The Right Technology for
Energy Efficiency
● Create the Energy Footprint of your machine - simulate and
monitor using same software features
● Use High-efficiency servo motors with Lexium SH
● Share DC-bus using using PacDrive iSH and Lexium LXM62 / ILM62
multiaxis solution
● Save cabinet cooling energy by shifting servo drives to the machine
frame - integrated servo drives series Lexium ILM
● Optimize flexible machines with ATV32 and brushless motors
● Design energy efficient motion with ECAM
● Design energy efficient path design for robots with PacDrive Robotics
library
● Use Intelligent Line Shaft and PacDrive libraries to optimize
synchronous servo axes consumption
● Request Schneider Electric Consulting/Engineering for a
comprehensive consulting for machine solutions and engineering
services support


Hoisting: Active Front End Allows
Energy Regeneration

● Active Front End is an option for the frequency inverter to return
energy to the mains. It provides 4-quadrant operation and thus it
is well qualified for hoisting applications which then generate
energy during descent (braking) stages
● Provides a constant DC voltage supply independent of the load
situation.
● Resistor-less technology
● Better reliability in harsh environment
● Huge energy saving
● Compactness of equipments

● Reduce losses and disturbances in the mains with a THDI < 4%

> More on AFE


PowerLogic System Panorama

Perfect for
Machines
Energy « PowerLogic » Power Meters
Monitoring
PM 9C PM 1200 PM 32xx PM 800

« Acti9 » Energy Meters

iEM 31xxv iEM 32xx

Current Transformers


Thank You!


The Future of Machine Building is NOW!

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