Controller MIgration & Connectivity 11.10.09

© 2009 Online Development Inc. All Rights Reserved.

Controller Migration & Connectivity

Mark Knebusch, Business Development,

Laurie Wilson, Product Manager, Online Development Inc. (OLDI)

November 11-12, 2009


Online Development Inc. (OLDI)

• Headquartered in Knoxville, TN with North American and European locations.

• Develop and produce integrated factory automation hardware and software: OLDI, Rockwell Automation and ProSoft Technology brands

• Core Competence: Computing and communications platforms


You May Know Us For:

• cATM™ controller-to-controller modules that

connect ControlLogix PACs with over 100

brands and types of controllers without

programming

• eATM® xCoupler® modules that connect

ControlLogix® PACs with IBM®, Microsoft® and

Oracle® databases without programming

• SAM, Special Application Modules, for custom

application development in a ControlLogix

environment


Our Customers:

• Wide use by Fortune® 100 customers around the globe:


Topics

• What is an Automation Appliance?

• Latest Developments

• cATM

• eATM

• eATM tManager

• Connectivity

• Configuration/Operation

• Applications

• Takeaways


Appliance: What is it?

• An Automation Appliance does just one

thing and does it well…transfer data to

and from one Application/System to

another Application/ System


Appliance: Operation

• Configure and go –

• No….

…..code to write

…...command prompt

…...installable or updateable code – updates as

full firmware images only

……installation services

Reduces installation and maintenance costs


Appliance Transaction Modules

• OLDI’s Appliance Transaction Modules…ATMs

• Controller to Controller…cATM

• Controller to Enterprise…eATM®

• Typically mount in ControlLogix® chassis

• Communicate

• Via CLX backplane to controller

• Via Ethernet externally

• Designed and tested to PAC/PLC environmental

specifications and certifications

Tightly integrated and physically robust


Controller-to-Controller &

Enterprise-to-Controller Connections

General Purpose Computing

Enterprise/Division IT Plant Floor Systems

Controllers Controllers

Controllers

cATM

eATM


Business Planning &

LogisticsPlant Production Scheduling,

Operational Management, etc.

Manufacturing Operations

ManagementDispatching Production, Detailed

Production Scheduling,

Reliability Assurance

Discrete

Control

Batch

Control

Continuous

Control

Level 4

Level 1

Level 3

Level 2

Sensing; manipulating production process

Monitoring, supervisory control and automated control

of production process

Time frame: Hours, minutes, seconds, subseconds

Workflow/recipe control; Maintaining records;

Optimizing production process

Time frame: Days, shifts, hours, minutes, seconds

Plant schedule: production, material use, delivery

shipping; Determining inventory levels

Time frame: Months, weeks, days

eAT

McATM

eAT

M

Relationships to

Enterprise/Plant Systems


Topics



• cATM

• eATM

• eATM tManager

• Connectivity

• Applications


• Takeaways


Controller-to-Controller: cATM Bailey

• Migrate ABB Bailey Infi 90 or Network 90

Legacy DCS to ControlLogix PACs

• Flexible Data Handling

– Supports DCS Block functions:

– System status monitoring

– No hard tag limits

• ABB Bailey Database Conversion Tool

– Available from Rockwell Automation.

– Converts Bailey tag database into CSV for import

into the cATM-BLY90 appliance and RSLogix 5000

programming software.

Once configured, use with applications such as

FactoryTalk View® SE for visualization, alarming, etc.

cATM


Controller-to-Controller:

cATM Universal Gateway

A “Swiss Army Knife” module with all drivers included

cATM

Connect ControlLogix to over 50 brands;

100s of controllers devices…including…

– AutomationDirect

– BACnet

– Cutler-Hammer

– Fuji

– GE Fanuc

– Honeywell

– Koyo

– SIXNET

– SquareD

– Stanley

– Telemecanique

– Thermo Westronics

– TIWAY

– Torque Tool

– Krauss-Maffei

– Mitsubishi

– Omron

– Optimation

– Opto 22

– Philips– Siemens

– Toshiba – Toyopuc– Wago– Yaskawa– Yokogawa


Topics



• cATM

• eATM

• eATM tManager

• Connectivity


• Applications

• Takeaways


Appliance Transaction Modules

• eATM Enterprise Appliance

Transaction Modules…

• Typically mount in ControlLogix

chassis

• Communicate

• Via CLX backplane to controller

• Via Ethernet externally

• Designed and tested to

PAC/PLC environmental

specifications and certifications

Tightly integrated and physically robust

Ethernet

Computer

System

Backplane

DataControlLogix PAC

with eATM


New eATM tManager ®

• Enterprise-to-controller

applications

• Enables Workflow, SOA,

ERP and MES

applications

• Data transfer configured –

not programmed


New eATM tManager ®

Simplifies Transaction Handling between

Business/Plant Applications and Controllers

• Supports…

– Message based data

exchange (e.g. JMS)

– Databases

– Controller Protocols

– TCP/IP, UDP, email, FTP

– Excel, Access


eATM tManager Module

eATM tManager Adapter Overview

Computer

Adapters:

Connect to

Enterprise &

Plant-wide

Applications

Automation

Adapters:

Connect to

PAC/PLCs

Mapping

&

Triggers


eATM tManager Computer Adapters:

Messaging

Messaging Adapters

• IBM® WAS JMS

• Red Hat® JBoss JMS

• JBoss Community JMS

• IBM WMQ


eATM tManager Computer Adapters:

Database Adapters

• MS SQL

• Oracle

• MY SQL

• IBM DB2

• AS400

• System i

• z/OS


eATM tManager Automation Adapters:

Rockwell Automation PAC/PLCs

SLC™

PLC-5®

ControlLogix

MicroLogix™

CompactLogix™

FlexLogix™

Local Rack

ControlNet

Ethernet/IP

ControlNet

Ethernet/IP

DH485

DH+

Ethernet/IP

DH485

Ethernet/IP

ControlNet

Ethernet/IP

DH+

Ethernet/IP

Rockwell Automation CIP:

– Via ControlLogix backplane

– Through RA bridge modules

– Via EtherNet/IP

– Enables communications for:

• ControlLogix

• CompactLogix

• FlexLogix

• MicroLogix

• SLC500

• PLC-5


• Siemens S7

TCP/IP

• Schneider Modbus

TCP

Via front port Ethernet

eATM tManager Automation Adapters:

Siemens & Schneider PAC/PLCs

Schneider/

Modbus TCP

Siemens S7


eATM tManager: Organization

Transaction Configuration Options

• Store & Forward - if the incoming message cannot be

processed immediately, it can optionally be stored in an

onboard store and forward queue

• Transaction Log - optionally all transactions to/from IT logged

to later prove receipt or absence of successful receipt

• Failover - two or more redundant adapters can be specified. If

the currently active one does not respond, the next one in the

chain is tried. Reset of the failover sequence is manual.


Feedback/Handshaking to Controller

• ControlLogix profile support

• Control

• Status

• Automation Flow Control

• Handshaking

• When data acquired from Input

• When placed in queue for Endpoint

• When message accepted by Endpoint


Status Reporting & Logging

• Status Reporting

– CLX profile bits

– Status tags

– Module front panel display

– Email

– FTP log export

• Logging

– Error logging

– Transaction logging


Automotive Assembly Line Using IBM JMS WAS

Enterprise System – Connected to Rockwell

Automation FactoryTalk ProductionCentre

Application Solution


• Problem: Transfer complex build instructions from

plant-wide MES (FactoryTalk ProductionCentre) to

assembly line with highly distributed, installed,

PAC/PLCs based on tag/VIN




Solution:

• Data transfer via

eATM module

– Reads messages

in queue

– Maps data to

ControlLogix tags

– ControlLogix

transfer to PLC-5s

• Assembly

information via

FactoryTalk

ProductionCentre

eATM Modules

Enterprise/

Plant System

• FactoryTalk

Production-

Centre

• IBM WAS

JMS

ControlLogix

PLC-5s

JMS

Message

Queue


eATM tManager Solution & Results:

– FactoryTalk ProductionCentre writes 500+ byte packet to

message queue

– eATMs pull messages from the queue and map data to

multiple ControlLogix PACs

– ControlLogix PACs connect to many PLCs to initiate

production activity

– Includes failover capability...can switch to another

messaging queue if primary unavailable



PCC Air Foils

– Gas Turbine Blade

Manufacturer

Application Solution –


Problem:

• Upgrade manufacturing download and production

reporting from a Visual Basic system to reduce

programming time

• Use existing equipment that includes:

– Allen-Bradley ControlLogix, PLC-5 and SLC 500

PACs/PLCs

– Microsoft SQL database

– Rockwell Automation RSView32 visualization

Application Solution – PCC Air Foils


Furnace B, PLC-5Furnace A, PLC-5

Cleaning Machine

CompactLogixRobotic Cell #2

SLC

Robotic Cell #1

ControlLogix

Application Solution – PPC Air Foils

Solution:

• Data transfer via eATM

tManager module

– Download recipes

– Upload process data

• Log operations

• Operation monitored

via RSView32

eATM Module

Server

Room

Microsoft®

SQL Server

ENBT Module

ControlLogix

• Cleans up molds

• Weighs and logs values via stored procedure

• Sign-off certified operation in MS SQL


Results:

• Enables faster data exchange between MS SQL

database, ControlLogix, and legacy PLC-5 and SLC 500

PLCs

• Reduced time to configure data exchange by 75%

• Adds ability to execute stored procedures

• Includes failover capability…can switch to another

database if primary unavailable

Application Solution – PPC Air Foils


Takeaways

• OLDI Appliance Transaction Module line-up is

expanding

• cATMs line-up expanding with Bailey and Universal Gateway

• eATMs extend upward to message oriented adapters e.g.

JMS and downward with MS Office & TCP/IP versions

• Connectivity includes all major Rockwell

Automation controllers plus Siemens S7 and

Modicon Modbus TCP

• Configuration is drag and drop

• Operation is secure

Controller MIgration & Connectivity 11.10.09

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