Future of Machine Bu..
Contents
1. Schneider Electric Industry Business The Future of Machine Building is NOW 2012 7 THM Software Rockwell SIEMENS Automation TIA Portal CCW Workbench S renes e mem Schneider amp Electric oMachine CX One Automation Studio CX C e MITSUBISHI BECKHOFF ELECTRIC TwinCat 2 amp 3 MELSOFT lt M D lt lt d m Q y 45 Schneider Electric Industry Business The Future of Machine Building is NOW 2012 8 One Software SoMachine With SoMachine you can develop and maintain the complete applicationina single software environment including control motion drives HMI sensors application libraries and network automation functions download connection project file Transfer smire Connect your cabe Create and malta machine program just once and the single project singe step progam i downiogaded to fe entre machine Schneiaer Electric INQUSTTY 51 55 I BUNAING IS IND VV UIZ Hardware Flexibility HMI PLC Y d VV UI LanG QUOI IUCIIWI IG LV Fure oracio Buioingisnow 2012 popularity and drop In Architecture Simplification What is Needed 1 Training 2 Programming 3 Wiring 4 3 party components 5 Testing The Fix 1 Training manuals 2 sample code amp2. 63 Packaging Right Technology for Energy Efficiency e Create the Energy Footprint of your machine simulate and monitor using same software features e Use High efficiency servo motors with Lexium SH e Share DC bus using using PacDrive iSH and Lexium LXM62 ILM62 multiaxis solution a e Save cabinet cooling energy by shifting servo drives to the machine frame integrated servo drives series Lexium ILM e Optimize flexible machines with ATV32 and brushless motors e Design energy efficient motion with ECAM e Design energy efficient path design for robots with PacDrive Robotics library e Use Intelligent Line Shaft and PacDrive libraries to optimize synchronous servo axes consumption e Request Schneider Electric Consulting Engineering fora comprehensive consulting for machine solutions and engineering services support Schneider Electric Industry Business The Future of Machine Building is NOW 2012 64 Hoisting Active Front End Allows Energy Regeneration e 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 e Provides a constant DC voltage supply independent of the load situation e Resistor less technology e Better reliability in harsh environment e Huge energy saving e Compactness of equipments e Reduce
3. templates 3 sample architectures 4 White papers 5 Simulation mode Schneider Electric Industry Business The Future of Machine Building is NOW 2012 Solutions for Machines Save up to 50 in design time Ready to use architectures for optimum results Predetermined equipment lists Tested e Applications tested by our experts to ensure that they work in all possible configurations Validated e Fully functional compatibility of devices Documented e Full user manual containing all the required information for installation and assembly including CAD and wiring diagrams Schneider Electric Industry Business The Future of Machine Building is NOW 2012 Customizable Machines Value Innovative Controls Engineering e Flexibility escalability eRepeatability Schneider Electric Industry Business The Future of Machine Building is NOW 2012 What Does Simplicity Mean With MachineStruxure solutions you can answer your customers challenges and help them remove complexity from their businesses Reduce time to Services amp support lt market Tested validated documented architectures amp function blocks Save 50 in control design time Flexible Machine Control 100 flexibility amp optimization of your machines Schneider Electric Industry Business The Future of Machine Building is NOW 2012 14 You remember the Bass Model e
4. e Automation professionals are now deploying technologies in clever ways to improve the energy efficiency of their automated machinery e Infact 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 Schneider Electric Industry Business The Future of Machine Building is NOW 2012 55 Energy Efficiency as a Source of Energy Fuel w AU X em Consumer 100 units 35 units 33 units 1 unit saved at consumer plug 3 units saved at the energy source eEnergy use split gt 31 gt 2 18 21 28 Industry Data centres amp Buildings Residential Transportation amp Infrastructure networks Schneider Electric Industry Business The Future of Machine Building is NOW 2012 54 The Power of a Combined Solution Greater efficiency smarter grid and cleaner generation e Over 50 of emission abatement will come from end user efficiency World energy related emissions abatement n o Current Policies Abatement Scenario 2020 2030 2035 ki Efficiency Ti 49 485 End use direct 34 24 24 35 End use indirect 33 23 23 E Power plants 3 2 1 30 4 m Renewables 18 21 2 Bio
5. Ability to forecast future sales and the rate of adoption e Bass Model Frank Bass 1926 2006 Schneider Electric Industry Business The Future of Machine Building is NOW 2012 15 Bass Model f t portion of M that adopts at time t Fle at Time t M the potential market p the coefficient of innovation q the coefficient of imitation F t portion of M that have adopted by time t Schneider Electric Industry Business The Future of Machine Building is NOW 2012 Bass Model Generalization d 000 Pot aren 505 000 w 68 A 5 amp amp ub a j The S Curve of change Schneider Electric Industry Business The Future of Machine Building is NOW 2012 Rogers Diffusion of Innovation e Different consumers make through the steps at different soeeds 96 1a Je N Everett Rogers 1931 2004 Innovators Early Early Late Laggards 2 5 Adopters Majority Majority 16 13 5 34 34 Sales over time Schneider Electric Industry Business The Future of Machine Building is NOW 2012 Technology Adoption Curves E mu om ae m A mue 1 aE Schneider Electric Industry Business The Future of Machine Building is NOW 2012 19 Remote Interaction Internet e NetMeeting Skype Google Hangouts TeamViewe
6. The Future Machine Building is NOW Ed Sandlin Ashish Patwardhan amp Alec Grainger Schneider Electric Industry NOW Express Schneider GF Electric 1 Simplicity 2 Remote monitoring 3 Energy efficiency 4 MachineStruxure Schneider Electric The Mobile Phone Evolution Schneider Electric Industry Business The Future of Machine Building is NOW 2012 5 Machine Control Evolution ERLA oW Aas E W Eli B E E Br E N HASCE B a cATTERU cau sra apr m map Schneider Electric Industry Business The Future of Machine Building is NOW 2012 4 The Future of Machines Integrated Automation Schneider Electric Industry Business The Future of Machine Building is NOW 2012 5 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 complete sophisticated and flexible software environments eGreater hardware flexibility and integration in machine control eSimplified and more readily accessible physical machine configuration Schneider Electric Industry Business The Future of Machine Building is NOW 2012 Integrated Automation Then Now Single software suite Prop Cable Drive
7. anagement ISO 14001 environmental management ISO 22000 food safety ISO IEC 27001 information security e Follows the Plan Do Check Act process for continual improvement of the energy management system e 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 consumption Measure the results Review the effectiveness of the policy lt Continually improve energy management e ISO 50001 can be implemented individually or integrated with other management system standards Schneider Electric Industry Business The Future of Machine Building is NOW 2012 61 Motor Consumption in the World Motor s energy bill motor cost x 100 e in Industry 60 of electricity gt e in Building 30 o electricity Motor 1 Month Energy Motor Cost Installation amp Maintenance 2 EEA Investment 196 Global costs during motor life average 15 years Schneider Electric Industry Business The Future of Machine Building is NOW 2012 Optimizing Energy Efficiency of Conveyors Optimising energy efficiency conveyors January 2010 White paper By Daniel Make the most of your energy Schneider Electric Industry Business The Future of Machine Building is NOW 2012
8. and support at every step of your machine life cycle Improve your end user customers satisfaction by maximizing their investments Further develop your sales in a profitable way 58 Solutions for Machines Machine ftruxure With MachineStruxure solutions you can answer your customers challenges and help them remove complexity from their businesses Added value throughout the M Services amp support entire of your machine cad Tested validated documented architectures amp function blocks Build a strong automation platform through the use of our proven ready to use automation architectures and application function Flexible Machine libraries Control SoMachine is a single software suite that runs on multiple hardware control platforms to achieve flexible machine control HMI motion drive and logic controllers Schneider Electric Industry Business The Future of Machine Building is NOW 2012 Reduce time to market Save 50 in control design time 100 flexibility amp optimization of your machines 59 Schneider Electric Industry Business The Future of Machine Building is NOW 2012 60 ISO 50001 Standard Published in June 2011 e ISO 50001 is based on the ISO management system model familiar to more than a million organizations worldwide who implement standards such as e 5 9001 quality m
9. business e Automation specialists offering dedicated M2M services e GE GE Remote Condition Monitoring Center e HMS RemoteCom e e Schneider Electric e arge OEM companies developing their own solution with equivalent features e Daikin e Carrier e M2M companies offering Cloud based services e Ewon 2 e M2MDatacorp Schneider Electric Industry Business The Future of Machine Building is NOW 2012 23 OptiM2M How it works gt Architectures amp infrastructure Data center Data center Kelowna CANADA LesUlis France Schneider she diu speci Electric lt ewegy GSM network k s GPRS rqe Terea isat Dei leat Dmm ede Ot r browser W Qu GPRS M2M Portal Aes Private The OEM encrypting services eb Web browser Vpn h Modbus master RS 232 Modbus protocol Cell Phone Revolution Connecting with people Technology Adoption 100 90 80 70 60 30 2 40 Cell TH Jo Electricity P Telephone e 2 82 p p a 30 kA 7 f Airplane 20 J F E 10 r j 4 i UP F Q 10 70 30 40 50 8 70 80 8980 100 110 Number years year 1 year invented st Mobile Source Forbes Magazine Schneider Electric Indu
10. chine Energy Ricetta Attuale Zona di Incremento 96 Velocit Variazione massima Velocut da Trave Parametri Trave Pendolamento Velocita Zona Riduzione Velocita 0 Punto di Inizio Riduzione 96 Velocita Punto di Inizio Incremento 96 Velocita FEP PREV PAGE NEXT PAGE EXIT Schneider Electric Industry Business The Future of Machine Building is NOW 2012 Instant Real Power Energy per Unit Last reset 82 05 2811 14 15 66 Total Real Energy Last reset 62 65 2611 14 15 66 208 8 wh RUH Real Energy Last reset 02 85 2811 14 15 66 221 0 wh IDL Real Energy Last reset 82 85 2811 14 15 09 06 wh 50 Italy Packaging Machine Energy Instant Real Power ENERGY COUNTERS CURRENT VOLTAGE POWER FACTOR 3 phase 11 50 230 0 990 11 00 228 12 00 229 11 50 231 FREQUENCY ENERGY TOTAL REACTIVE 123442 00 wh REAL 102234 00 wh REAL 234 00 wh REACTIVE 49 95 POWER 23455 10200 13455 TOTAL RESET Trend Schneider Electric Industry Business The Future of Machine Building is NOW 2012 Hz Last reset 82 05 2011 14 15 66 2580 0 wh 14 15 00 221 0 wh IDL Real Energy EXIT 29 0 wh 51 Machinefftruxure Schneider Electric Comprehensive Automation Solution for Industrial Machines gt MachineStruxure solutions help machine builders design machines that are optimized
11. ctric Industry Business The Future of Machine Building is NOW 2012 36 Easily Identifiable Energy Efficiency Opportunities j 4 T F E 47 U JE Industrial companies dont sufficient information to know where to look beyond the easily identifiable energy efficiency opportunities Less obvious higher impact energy efficiencythrough process and machine efficiency mri Com reduce the energy consumed per unit of output solving the Energy Equation with a focus on energy efficiency Q ria out what the challenge is T metering amp ISO 50001 Active energy efficiency e optimize through Monitor automation maintain amp regulation improve Low consumption devices Variable speeddrives Metersinstallation 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 Schneider Electric Industry Business The Future of Machine Building is NOW 2012 38 Why Improve Energy Efficiency Machines e Energy efficiency is an increasing concern the global strategy of your customers By offering them machines that save energy you will have a definite advantage over the competition eMachineStruxure solutions help you desig
12. e results e Make your machine an enabler for end user compliance to EN 16001 amp 150 50001 standards Up to 8 per year is lost without monitoring and 100 70 Up to 12 per year is lost IET without regulation and 5 35 ps control systems 52 05 Z E me lt Operate n Schneider Electric Industry Business The Future of Machine Building is NOW 2012 42 Machine Energy Optimization In Four Sustainability Steps em S m E E ER I gt 1 Audit your machine energy 4 Monitor Identify energy waste in your machine and recommend optimization solutions nsumpgption consumptio gt 2 Fix your machine basics Select relevant motor optimizer motor control A gt Use variable speed drives Use Servo drives and synchronous motors ENS i distantes IP67 variation __ l iici 3 Optimize your machine I Energy operating modes high value mechanism 4 with no additional hardware cost gt Energy management functions T ES controllers and N d gt Energy optimization guidelines for machines in targeted applications HVAC amp R packaging conveying hoisting etc Schneider Electric Industry Business The F
13. for cost energy efficiency and performance Reduce Complexity With One single Unique T VDA End to end Simple and easy software value service support to use environment proposition gt Integrated software SoMachine Simplify machine programming amp commissioning Logic 4 hardware control platforms Embedded Intelligence where it is needed gt gt 6 targeted applications vawd om Hoisting Textile Packaging Conveying HVAC amp R Elevators amp Escalators Motion centric Drive centric Speed up conceptto design Optimize machine production flow and capacity Optimize on site intervention costs Schneider Electric Industry Business The Future of Machine Building is NOW 2012 54 TVD Architectures Machine ftruxure e Tested e Tested in laboratory by experts e Ensuring the right functional performance in all possible configurations e Validated Fully functional compatibility of the devices e Documented e Complete user guide giving all the details required for installing and building your application with confidence e Ready to use with e plan predefined CAD panel designs amp wiring diagrams e Up to 50 control system design time savings e Installation time reduction Schneider Electric Industry Business The Future of Machine Building is NOW 2012 55 Inno
14. fuels 1 25 3 75 Nuclear 90 8 450 Scenario B CCS 7 173 19 2008 2015 2020 2025 2030 2035 Source World Energy Outlook 2010 OECD IEA Schneider Electric Industry Business The Future of Machine Building is NOW 2012 35 Energy Efficiency for Industry Has Already Started Pack Retail Consumer Packaged Goods Wa rt Sustainability at our sites I ROV star 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 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 100 zero Extra whiskas Material Handling G R MGM Resorts Hits the Energy Efficiency Jackpot In Las Vegas the leading corporations in the entertainment capital of the world is staying true to the city s visionary history by anticipating the need for sustainable and energy efficient structures well ahead many of its competitors UPS has become the first major package delivery and logistics company to earn Gold Status certification from the Leadership in Energy and Environmental Design LEED along with an Energy Star certification for its corporate headquarters complex Schneider Ele
15. ladium Technologies Schneider Electric Industry Business The Future of Machine Building is NOW 2012 28 The Future NOW Consumer amp Machine Building Completely automated machines and robots Rodney Brooks irtobotE rethink robotics http www youtube com watch vzrj PFakFyrO Y Schneider Electric Industry The Future of Machine Building is NOW 2012 29 Why Energy Optimization The Energy Dilemma The facts The need x2 Energy demand emissions 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 Schneider Electric Industry Business The Future of Machine Building is NOW 2012 51 Recent Articles The push to achieve reductions in energy consumption 15 a significant global trend e MGM Resorts Hits the Energy Efficiency Jackpot e Design World SEP 2012 e Energy Management Strategy Roadmap Needed e Automation World SEP 2012 Don t Leave Energy Projects ROIs on the shelf e ControlDesign MAY 2012 e Energy Efficiency The Secret to Sustainable Machines e Automation World MAR 2011 Schneider Electric Industry Business The Future of Machine Building is NOW 2012 52 Trends e The focus for machine design is no longer simply maintaining acceptable production rates at an appropriate level of quality
16. losses and disturbances inthe mains with a THDI lt 4 gt More on AFE Schneider Electric Industry Business The Future of Machine Building is NOW 2012 65 PowerLogic System Panorama Advanced energy metering Perfect for Machines leren Energy Monitoring PM 1200 PM 800 IONBSO0 10 8650 aC 31xxv Panelinstruments ro 1 i mum mm j CHEI Current Transformers Schneider Electric Industry Business The Future of Machine Building is NOW 2012 66 Tnank You Schneider
17. n more energy efficient machines while increasing eMachine performance eMachine attractiveness for end users Schneider Electric Industry Business The Future of Machine Building is NOW 2012 77 Together with Schneider Electric we realized the new 5 2 NG an energy efficient machine bringing tangible improvements to the end user in energy usage in terms of consumed watts per manufactured unit enabling up to 30 energy Savings compared to traditional machines ACMA Flowpack Division End users Have Already Shifted to Green e Energy savings in 2007 in 2011 is now the Price 1 Price second of operators 2 Saving use of consumables 03 Saving use consumables criteria Packing material reduction 4 of operators considered when Energy savings 5 Packing material reduction choosing a machine How is your ein 2011 of investment In end users sustainable increased or development maintained their evolving investment towards Green Europack Euromanut 300 enterprises Packaging Consumers Industry Summer 201 1 Schneider Electric Industry The Future of Machine Building is NOW 2012 40 How to Boost Energy Efficiency in Machines Machine Energy Optimization In Four Sustainability Steps ISO 50001 e Follow the 4 energy efficient principles adapted to the machine life cycle to Support energy savings and obtain immediat
18. ntroller s Servo Drive Prevents Safety Module E Drive ir Safety Module um E x AHivar Akivar Tess E Lexiurn D 187 Variable Variable kc Kotor Starter Servo Drive Tesys Speed Drive Speed Drive I Tesys Motor P Medicon TM Fin Wan Circuit Breaker E ata L Distributed 8 m a Lexium i Lexium Servo Drive Modicon Modicon OTB Integrated Modicon TM Integrated Distributed A Distributed 42 Drive Distribuled Ir Serve Drive Smart instrumentatian Machine Process Schneider Electric Industry Business The Future of Machine Building is NOW 2012 57 Solutions for Machines Services amp support Throughout the complete machine life cycle gt Innovation and competitiveness right from the start gt Speed up concept to design Conception amp Design gt Optimize machine production flow and Capacity _ Operation amp Maintenance Assembly gt Maximize machine continuity of operation gt Optimize on site intervention costs gt Generate profit while gt Expand business by addressing new keeping end user markets customer satisfied gt Access international markets while minimizing associated risks Schneider Electric Industry Business The Future of Machine Building is NOW 2012 gt gt MachinedZtruxure OEM specific services
19. r Dropbox Schneider Electric Industry Business The Future of Machine Building is NOW 2012 Remote Interaction Machines e Machine recipe management trouble shooting remote monitoring Shop floor to office to service connectivity e SCADA Web servers Web Gate servers USB keys Web Gate T m A Ul The SCADA system reads the measured Montonng flow and level sends the setpoints to the PLCs 327 pr 47 Eos wawan 1100 naqpa Category 12 7 compares the measured flow to the setpoint controls the pump speed as required to match flow to setpoint PLC2 compares the level to the setpoint controls the flow through the valve to match level to setpoint Schneider Electric Industry Business The Future of Machine Building is NOW 2012 21 Future The Cloud Engagement Engaging with customers partners and employees Microsoft IBM Oracle Salesforce com Microsoft ORACLE i 1i ll 1 Blue insight analy cs anm Ford Focus connecting onboard WiFi with ATT Schneider Electric Industry Business The Future of Machine Building is NOW 2012 The Cloud for Machine Builders M2M Engaging with machines and
20. rgy per unit target constant value 4 Energy per unit high limit generates an alarm when reached e Power and unit 1 Average power per sampling time hours minutes etc 2 Amount of units produced per sampling time Schneider Electric Industry Business The Future of Machine Building is NOW 2012 Energy per unit Last reset 2012 88 24 dad 25 Average Power and unit Sampling time 15 a 24202201 9 1288 kW 47 EE Monitoring Improve Predictive Maintenance gt Deviation to target often indicates equipment pre failure Energy per unit Dec 21st 2010 18 05 02 Instant Last reset 20 12 2010 E 10 00 00 2 89 Wh Energy per unit Deviation iB 0 57 Wh 2 89 wn 200 kW 1 Analyze over consumption e Worn mechanical bearings Motor failure Electrical issue insulation power quality etc Lack of lubricant Unexpected temperature increase e Haw material properties change e Dirty filters 2 Fix problem before serious issue occurs limit impacton performance Schneider Electric Industry Business The Future of Machine Building is NOW 2012 48 EE Monitoring Distributed Architectures Machine Zone 1 gt Example of distributed monitoring architecture Modbus CANopen with M258 Schneider Electric Industry Business The Future of Machine Building is NOW 2012 Italy Packaging Ma
21. stry Business The Future of Machine Building is NOW 2012 25 Cell Phones for Machine Builders Connecting with machines factories gt Performance gt Compact SCADA HMI Software HMI controllers E The SCADA system reads the measured flow and level and sends the setpoints to the PLCs 42 fiil valve control 7 1 compares the measured flow to the setpoint controls the pump speed as required to match flow to setpoint V 2 PLC2 compares the measured level to the setpoint controls the flow through the valve to match level to setpoint Drives controllers Logic controllers gt Efficient gt Flexibility Example Aluma Tower he L tl Pad iT am m 010 TL Schneider Electric Industry Business The Future of Machine Building is NOW 2012 26 Smartphone Smart Devices Revolution Knowledge empowerment and connectivity Apple Samsung Blackberry LG Google Microsoft Amazon Schneider Electric Industry Business The Future of Machine Building is NOW 2012 27 Smart Devices for Machine Builders Knowledge empowerment and connectivity selection Apps Control Apps HMI Web Gate Apps kuwa 123 Schneider 2 Electric Control amp et Une View In iTunes Example Pal
22. uture of Machine Building is NOW 2012 43 Focus Energy Monitoring Libraries for Machines How does it work Libraries interactions SoMachine Machine Energy Dashboard MED Graphical Objects Vijeo Designer Tool chest Data Processing FBs Machine production data EE Toolbox library Accumulator Controllers FB B EFF Devices Generic Energy Meter Communication FBs FB a In the Field Supported field buses CANopen MODBUS Power meters Circuitbreaker Motor control Other equipment based on rated power Schneider Electric Industry Business The Future of Machine Building is NOW 2012 45 Machine Energy Dashboard Overview Energy per unit Number of units em Average e Simple indicators for operator 8 576 Wh 57 128 e Real power Color ranges for quick Power Total Energy detection of any deviation e Real energy m uu e oplitby operating mode AM Run Energy e Spent per unit produced Time e Peak alert e Trend indicator e Ready to use and fully customizable units mn thresholds reset control etc TE 3 9 7 Idle Energy Schneider Electric Industry Business The Future of Machine Building is NOW 2012 46 Machine Energy Dashboard Overview e Trend Information e Energy per unit 1 Energy calculated per unit produced 2 Average energy for total amount of units 3 Ene
23. vation for Simplicity Simplified offers Simplified maintenance Modiconcontrollers Altivar 32 and Lexium 32 drives HMI controllers Motion controllers gt Compac 1 formance MMS e mail Wap Internet Drives controllers Logic controllers J ficient gt Flexibility oend receive configuration everywhere amp any time Upload download configuration with drive Monitor control drive Getting closer and being more responsive to local needs Adapting our offer to meet customer needs Self powered wireless push button and Magelis STU Hardwareflexibility ZigBee Ensure permanent availability battery less Robustness for harsh environment Mobile control 22mm mounting system Ethernet embedded Powered by Vijeo Designer Simplified integration Simplified assembly Helos you manage your process more efficiently Ethernet C H Process u igh Machinegftruxure Availability Safety Madicon Modicon 258 CANopen Quantum SILI Logie Gentraller ms som Drive eun PROFIBUS asian Controller uj Machine Heal un Controller SERCOS III Madison Integrated Safety LMG CANopen Remote O Madican wu Tesys aj T Altiva Mule E Sate Logic Contactor Bs 19 Variable Circuit Breaker Fi s Du Preventa l Controller Lexium Speed Drive Safety gt Proventa al Lexium Co
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