Innovation Center

Send Data between Controllers with Handshake in Studio 5000 The Send Data between Controllers with Handshake Sequence is defined shows how to send one packet of buffered data using a Produce / Consume (Class 1) connection over Ethernet/IP.

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What is this for?

Sometimes there is a need to send data from one controller to another and be confident the data being sent/ received is accurate and not a combination of old and new data. This application note shows how to send one (500byte) packet of buffered data using a Produce / Consume (Class 1) connection over Ethernet/IP.

 

General Features

• Data Buffer
• Handshake

 

Advantages: This sequence facilitates the implementation and quick configuration when is need it to send one packet of buffered data using a Produce / Consume (Class 1) connection over Ethernet/IP, without any other hardware.

Limitations/Disadvantages: This sequence is available for CompactLogix / ControlLogix Controllers.

Is this helpful?
This code is defined for applications when it is needed to send one packet of buffered data over Ethernet/IP.

Application areas: Food, Manufacturing, Beverage

 

How can I get this working?

• Hardware
  • Personal computer with an available USB port
  • CompactLogix, ControlLogix Controller 
• Software
  • Studio 5000, version 21 or later
• Previous knowledge:
  • Intermediate knowledge of programming and configuration in Studio 5000 software: Ladder language (LD)

Implementation Guide 

Step 01

Next steps offer an explication on the code and how buffer of data before sending it to another controller and using handshaking numbers (#’s) to indicate when a new packet of data has arrived.

Buffering of data: One reason for buffering data would be to keep a running list of data before transferring in case there is a communication failure. Another reason would be to make sure the data packet you are creating is complete. In this example I am buffering 10 (492byte) packets in a first in / first out fashion. If this is too much data buffering, this can be customized to your application.

Handshaking is used to indicate when there is a new packet of data being sent/ received. Some applications use what is called a footer # at the end of the packet, other applications use a header # at the beginning of the packet. In this example, I am using both a header and footer #. The basic operation of this is as follows; every time a new packet of data is ready to be sent, the incremented header and footer #’s are attached to the beginning and end of the (492byte) packet of data, making it a full (500byte) produce/ consume packet, when the other controller sees there is a difference between the old header/ footer # and the new header/ footer # it knows this is a new packet of data and buffers it in its memory. This new header / footer # is stored to be checked later when a new packet is sent again. This is taken one step further by introducing a bidirectional handshaking method. This means I am sending either the header or footer # back to the producer of the data as a trigger to send another packet.

send-data-between-controllers-with-handshake-in-studio-5000_Step 1-Image1

There are two Control Logix programs, one program produces data, and the other program consumes data. The program that is producing data is called CLX1_producing_ data_with_handshaking_ and_Buffering1. The program that consumes data is called CLX2_consuming_data_with_handshaking. They will be referenced as program CLX1_Produce and CLX2_Consume.

 

Data must be collected and buffered before sending it to the produced tag.

 

Refer to CLX1_produced program Rungs 7, 8, and 9.

 

Rung 7. Data is collected and buffered in a First in First out manner. In this example I am buffering 10 (123dint) data chunks (1 – 10). If there is no data in the 10th buffered data chunk, add 123 to the Buffered data pointer, if there is data there, stop filling the Buffered register.

 

Rung 8. When data appears in the 10th (123dint data chunk buffered register, The buffered register area is full and will set the Buffer full output.

 

Rung 9. If Buffer full output is set, shift Buffered data chunks 2 – 10 up by (123dints). Then fill the 10th buffered data chunk with zeros.

Step 02

Now that we have data buffered, start producing this data on the Ethernet network. Refer to CLX1_produced program Rungs 10, 11. 

Rung 10. Will copy the first chunk of data from the Buffer to the produced tag.

 

Rung 11. Will assign a Header and Footer ID #. These numbers will range from (0 – 100). These ID’s will also be used as the handshaking numbers between the two CLX processors. The next scan through the ID’s will be increased by 1.

 

At this point the packet is formed and looks like this:

 

• Producing_data_to_CLX1
  • [0] = Header ID#
  • [1] - [123] = Data
  • [124] = Footer ID#

send-data-between-controllers-with-handshake-in-studio-5000_Step2-Image1

Step 03

The data is being consumed by another CLX2 processor over Ethernet. The consumed tag looks like this:

• Consumed_data_from_CLX1
  • [0] = Header ID#
  • [1] - [123] = Data
  • [124] = Footer ID#

 

Refer to CLX2_consumed program Rung 1.

 

Rung 1. Compares the New ID’s assigned in Step 2 Rung 11 to the old ID’s Buffered in Step 6 Rung6. If the ID’s are different, it knows it is reading a new packet of data.

send-data-between-controllers-with-handshake-in-studio-5000_Step3-Image1

Step 04

If the communications stop, the control needs to be aware of this, refer to CLX2_consumed program Rung 2, 3, and 4.

 

Rung2. Every time there is a different in ID’s seen the counter counts +1

 

Rung3. If the counter doesn’t get done within 5 sec. the retentive timer times out.

 

Rung4. If the retentive timer gets done, there have not been comms for over 5 sec and the no comms. between clx1 and clx2 output is set. This can be used as an alarm bit.

send-data-between-controllers-with-handshake-in-studio-5000_Step4-Image1

Step 05

Double checking that the Header and Footer ID’s did not change. Refer to CLX2_consumed program Rung 5.

send-data-between-controllers-with-handshake-in-studio-5000_Step5-Image1

Step 06

Now it's time to copy data from the consume tag to a different register in the CLX2, to be used in its program.

 

Next move the present header and footer ID #’s into the Old ID register to be compared later when the next packet of new data is sent over. Now for the handshaking portion of the program.

 

The Footer ID # is sent back to the CLX1, in a Produced tag, to act as the handshaking piece of data, which will be compared in the CLX1 as you will see in Step8. Refer to CLX2_consumed program Rung 6 to 8.

send-data-between-controllers-with-handshake-in-studio-5000_Step6-Image1

Step 07

Once again if communications stop, the control needs to be aware of this. Refer to CLX1_produced program Rung 2, 3, and 4.

 

Rung2. Every time there is a different in ID’s seen the counter counts +1

 

Rung3. If the counter doesn’t get done within 5 sec. the retentive timer times out.

 

Rung4. If the retentive timer gets done, there have not been comms for over 5 sec and the no comms. between clx1 and clx2 output is set. This can be used as an alarm bit.

send-data-between-controllers-with-handshake-in-studio-5000_Step7-Image1

Step 08

Referring to Step6, the footer ID # is being produced by CLX2 and will now be consumed by CLX1, if the initial produced ID # matches the now consumed ID #, there is still communications, the handshaking is complete, and CLX1 is now ready produce a new packet of data.

 

But before producing a new packet of data, we must examine if our ID # has reached 100, if so, reset back to 0, and start counting up to 100 again. Refer to CLX1_produced program Rung 5 and 6.

send-data-between-controllers-with-handshake-in-studio-5000_Step8-Image1

send-data-between-controllers-with-handshake-in-studio-5000_Step 1-Image1

send-data-between-controllers-with-handshake-in-studio-5000_Step2-Image1

send-data-between-controllers-with-handshake-in-studio-5000_Step3-Image1

send-data-between-controllers-with-handshake-in-studio-5000_Step3-Image1

send-data-between-controllers-with-handshake-in-studio-5000_Step5-Image1

send-data-between-controllers-with-handshake-in-studio-5000_Step6-Image1

send-data-between-controllers-with-handshake-in-studio-5000_Step7-Image1

send-data-between-controllers-with-handshake-in-studio-5000_Step8-Image1

Send Data between Controllers with Handshake in Studio 5000

Version 1.0 - November 2024

Application and Configuration of a Torque Follower System with PowerFlex 755T- and the use of the TLink Module (FO Module) Configuration of a Power Flex 755T using a TLink module for load distribution, using a torque follower configuration.

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What is this for?

The purpose of this document is to provide guidelines how to setup a load sharing application using a torque follower setup.

Load sharing is a term used to describe a system where multiple drives and motors are coupled and used to run one mechanical load.

The following assumptions are made:

• Drives and motors are properly sized for the application
• The drives are at factory default settings
• The motors are equipped with rugged feedback devices
• Drives are equipped with TLink option module and feedback cards

The example is based on a large diameter bull gear with two motors. The motors are coupled via tooth sprockets and gearboxes.

This creates a rigid connection between the motors, ideal for a torque follower setup.

The torque follower (also known as master-slave) is a type of load sharing setup when we use one master drive in speed regulation and one follower drive in torque regulation.

The torque command generated by the master’s speed loop is transmitted to the follower drive to be used as torque reference.

A torque follower setup makes two or more motors act as 1 big motor. See below torque follower block diagram.

In this example the torque reference is transferred from the master drive to the follower drive via TLink option module.

Is this helpful?
If you are working with systems involving multiple motors coupled to a single load, this document will be very useful to you in setting up an efficient and effective control strategy.

 

How can I get this working?

• Hardware
  • Logix 5580-1756-L8SE Control
  • PowerFlex 755T Flux Vector Tuning
  • TLink (FO Module) - 20-750-TLINK-FOC-5
  • Incremental Encoder Board 20-750-ENC-1
• Software
  • Studio5000 (V36)
• Previous knowledge:
  • Basic knowledge of Studio5000
  • Basic knowledge of PowerFlex 755T.

 

References documents

• PowerFlex Drives with TotalFORCE control Quick Start, Rockwell Automation Publication 750-QS100D-EN-P - January 2023.
• PowerFlex Drives with TotalFORCE control Programming Manual, Rockwell Automation Publication 750-RM100C-EN-P - August 2022.
• PowerFlex 755T Flux Vector Tuning Application Technique, Rockwell Automation Publication 750-AT006D-EN-P - January 2022.
• TLink Option Module User Manual Original Instructions, Rockwell Automation Publication 750COM-UM100A-EN-P - June 2021.

Installation Guide 

Step 01

Pasos de configuración VDF

1. General Settings

In this example both drives are equipped with a 20-750-TLINK-FOC-5 (Fiber 5 m) Module located in the Port 4, and a 20-750- ENC-1 Incremental Encoder card in the Port 5.

The following settings apply to both drives.

- 0:65 [Pri Mtr Ctrl Mode] = 4 “Induction FV”. This selects motor control mode as Induction Flux Vector.
- Enter motor data parameters in 10:400 - 10:407.
- 10:1000 [Pri Vel Fb Sel] = 5:4 [Encoder Feeback]. This selects incremental encoder as motor feedback source.
- Enter encoder resolution in 5:2 [Encoder PPR].

2. Master Drive setup

• 10:30 [PsnVelTrq Mode A] = 1 “Velocity Reg”. This selects control mode for velocity regulation.
• Select speed reference source in 10:1800 [Vel Ref A Sel]
• Set the speed limits and ramp rates according to the application.
  • 10:1392 [Max Speed Fwd] 
  • 10:1393 [Max Speed Rev] 
  • 10:1915 [VRef Accel Time 1]
  • 10:1917 [Vref Decel Time 1]
• 10:930 [Direction Mode] = 1 “Bipolar”.This selects the Velocity reference can be positive and negative.
• 10:2020 [LdObs Mode] = 1 “LdObs Only”.
• This is the recommended Load Observer setting for velocity mode applications. For more information about Load Observer feature see PowerFlex 755T Flux Vector Tuning, publicación 750-AT006.
• Set output torque limits according to machine design, drive and motor sizing. In this example +/-150%.
• 10:2083 [Torque Limit Pos] = 150%
• 10:2084 [Torque Limit Neg] = -150%

3. TLink Option Module Master Drive setup

 

• 4:1 [TLink Mode] = 1 “Mode A”. Master sends 2 words synchronized 50 mµ updates.
• 4:2 [TLink Role] = 0 “Master”. Sets TLink role for the drive, Master sources data to nodes.
• 4:201 [TLink Out Sel 1] = 0 “Trq Ref Out”. Selects the torque reference output.
• 4:202 [TLink Out Sel 2] = 3 “VRef Ramped”. Selects the ramped velocity reference output.
  

4. Slave Drive setup

• 110:30 [PsnVelTrq Mode A] = 2 “Torque Reg”.  This selects control mode for torque regulation.
• 10:2000 [Trq Ref A Sel] = 4:203 [TLink In 1]. This gets Torque Ref from master.
• 10:1800 [VRef A Sel] = 4:206 [TLink In 2]. This gets ramped velocity reference from master.
• 10:2020 [LdObs Mode] = 0 “Disabled”. This is the recommended Load Observer setting for torque mode applications.
• Set output torque limits according to machine design, drive and motor sizing. The slave drive values are set slightly higher as the command values are clamped by the master drive.
• 10:2083 [Torque Limit Pos] = 155
• 10:2084 [Torque Limit Neg] = -155%

 

5. TLink Option Module Slave Drive setup 

• 4:1 [TLink Mode] = 1 “Mode A”. slave receive 2 words synchronized 50 mµ updates.
• 4:2 [TLink Role] = 0 “Slave”. Sets TLink role for the drive, Slave consumes data from the master.
• 4:3 [TLink Status] = 1 “Tx Active”. Verify transmission of data by master (TLink option module in master drive)
• 4:3 [TLink Status] = 3 “In Sync”. Verify that slave drive is synchronized to the master drive in slave (TLink option module in slave drive)
  

Step 02

Tuning Steps

Tuning is critical working in Flux Vector control mode. We will use the Autotune function to measure motor characteristics. Autotune is composed of several individual tests, each of which is intended to identify one or more motor parameters. These tests require motor nameplate information to be entered into the drive parameters. We can run all the tests in the parameter 10:910 [Autotune].

These are the recommended steps:

1- Enter motor data parameters in 10:400 – 10:407.

2 - Run 10:910 [Autotune] = 1 “Direction”. This allows you to determine if the motor rotates in the desired direction. Also allows you to check if encoder feedback count increases in value for a forward velocity command.

3 - Measure the motor electrical parameters:

• Set 10:510[MtrParam C/U Sel] = 1 “User Entered”
• Run 10:910 [Autotune] = 3 “Rotate MtrID” to measure the motor electrical parameters. It initiates motion and rotates the load. To obtain the most accurate measure of motor flux current, disconnect the load for this test.
• If you cannot initiate motion to rotate the load, then run 10:910 [Autotune] = 2 “Static MtrID” to measure the motor electrical parameters.

 

4 - Set the current regulator bandwidth 10:445 [VCL CReg BW]

• 125 when 10:425 [PWM Frequency] = 1.33 kHz
• 250 when 10:425 [PWM Frequency] = 2 kHz
• 375 when 10:425 [PWM Frequency] = 4 kHz

 

5 - Run 10:910 [Autotune] = 4 “InertiaMotor” to measure the motor inertia. This test initiates momentary motor rotation to measure and update 10:900 [Motor Inertia].

 

This test is only an option if the load can be disconnected to run the test. If the load cannot be disconnected, you should enter the value manually in 10:900 [Motor Inertia].

 

6 - In the master drive, run 10:910 [Autotune] = 5 “Inertia Total”. This test initiates momentary rotation of the motor and load to measure total inertia and calculate 10:901 [Load Ratio]. After selecting this value, you must issue a start command to begin the test. Perform this test with the load connected to the motor.

 

10:900 [Motor Inertia] and 10:901 [Load Ratio] are used to calculate the torque scaler Kj, an internal parameter that compensates for the effects of inertia and affects overall tuning. Load Ratio is also used to calculate controller gains.

Since the application will be controlled by 2 load sharing motors, the Load Ratio of the Master drive measured during the test can be divided by 2.

 

7 - In the master drive, run 10:910 [Autotune] = 6 “BW Calc”. The bandwidth calculation test calculates control loop gains and dynamic limits.

8 - Run the master drive and adjust system bandwidth in 10:906 [System BW] if necessary. Decreasing system bandwidth stabilizes the system and increasing it improves performance. Typically, high gain results in a quicker response time, but excessive gain causes system instability.

 

For more information about tuning see PowerFlex 755T Flux Vector Tuning, publication 750-AT006.

Step 03

Signal Checks and Operation Steps

1. Signals Checks

Run the master motor (only) up to nominal speed. Master Drive: Check 10:2087 [Trq Ref Limited] during acceleration.

 

2. Operation

To start the torque follower application

• Start the follower drive first. Since the master drive is not running the follower drive is not receiving any torque reference. At this stage the motor is fluxed and ready to go.
• When the slave drive is running start the master drive. The speed regulator of the master drive generates a torque command which is used in the master drive and transferred to the follower drive. Both drives and motor will take an equal share of the load and act as 1 big one.

 

To stop the torque follower crusher application

• Stop the master drive first. The master drive will ramp down its speed and send out a negative torque command to the slave drive to assist. The torque command values can be clamped by the bus regulator reducing the amount of regenerative energy.
• Stop the follower drive once the master drive is not active anymore. See Drive status word via the communication interface or via 10:354 [Motor Side Sts 1] bit 1 [Active].

 

When a drive is faulted

• If the master drive is faulted the follower won’t receive any torque reference. In this condition the slave drive would almost coast to a rest. At this stage there are two options:
• The fault can be cleared, and the master drive can be restarted, the speed will be picked up immediately by the motor encoder (no need for flying start activation).
• The slave drive can be stopped. To make sure the slave drive stops with a controlled deceleration ramp verify that bit 1 [Torq Mode stop] of 10:40 [Motor Cfg Options] is set.
• - If the slave drive is faulted the master drive is taking the full load. It may reach current limit and potentially stall. The drive could then trip on motor overload. The master drive can be stopped.

 

Step 04

Load Logix program into the controller Steps

1 - On the Studio 5000 development software we open the program “Torque_Follower_with_TLink”, the following image is then displayed, where the controller, an analog and a digital card, as well as the Ethernet card where the PowerFlex 755TS Drives will be part of the network are already added.

2 - On the menu bar, click on “communication” and choose “download” from the options that appear, then click again on the button in the window that opens, as shown in the following image.

3 - We wait for the program to download to the controller

4 - Finally we click on the Yes button on the window that appears after the program is loaded into the controller, this, to change the controller mode to “Remote Run”

Application and Configuration of a Torque Follower System with PowerFlex 755T- and the use of the TLink Module (FO Module)

Version 1.0 - December 2024

Programmable Numerical Solution Controller and HMI program solution which provides midrange computer numeric control (CNC) functionality in the Logix architecture which is capable of executing RS274D tool path programs.

What is this for?

PNC stands for Programmable Numerical Control and it is a paired Logix Controller and HMI program solution which provides midrange computer numeric control (CNC) functionality in the Logix architecture which is capable of executing RS274D tool path programs. These programs are often referred to as CNC part program, or M&G code files. The M&G codes are provided by the PNC, that start with the letter ‘M’ and ‘G’, and provide instructions for the machine.

General Features

• Executes RS274D based Part Files
  • Core set of M&G codes supported
  • Codes may be modified or added by machine builder
• Executes on Compact or ControlLogix controllers, PanelView Plus or PV5xx0 HMI, any CIP Motion standard drives or servo drives
• Support for up to 6 axis of coordinated motion and 2.5D contouring
• Supports a wide variety of machine types (X Y Z table, gantry, mill, lathe, grinder)
• Provided as sample code at no-charge to customers
• Provides a good value for medium axis count coordinated motion applications, which use RS274D
• Cutter or Tool compensation

Advantages:

Modular and Flexible Equipment

• Adaptable/customizable for new or rebuild machines
  • Wide variety of machines supported
• Scalable standard control and safety solutions to meet application specific requirements

Compatible with Industry Standard RS274D CNC Programs

• Broad compatibility across design tools and utilities
• Expandable to meet application requirements

Design Flexibility and Productivity

• Standards conformity and modular programming
• Faceplates, code libraries, Add-On Instruction, Integrated Architecture system, EtherNet/IP offers a pre-engineered solution

Lower-cost solution

• Can provide a lower-cost TCD3 than traditional or PC-based CNC solutions
• Right sized solutions for medium axis count machines

Limitations/Disadvantages

• Offers a subset of features to those found in a CNC controller
• Max. 6 axis of coordinated motion
• Automatic Tool changer (ATC) not included on sample code
• Works with ControlLogix (L8) or CompactLogix (5380) controllers only

 

Is this useful for me?

In general, PNC solution can be recommended to OEM manufacturers of following machine types:

• Boring machines
• Broaching machines
• Drilling machines
• Grinding machines
• Honing machines, vertical spindle
• Lapping machines
• Laser cutting or drilling systems
• Laser marking systems
• Laser welding and cladding machines
• Lathes
• Machining Centers
• Milling machines
• Pipe and tube bending machines
• Plasma cutting machines
• Plastic cutting and slitting
• Riveting machines
• Roll finishing machines
• Roll forming and bending machines
• Sawing machines
• Thread cutting and Thread rolling machines
• Threading and cutoff machines, pipe and bar
• Turn/mill machines, CNC
• Turning centers
• Ultrasonic machining equipment
• Water jet cutting machines
• Welding machines
• Woodworking equipment

Application areas:

Automotive, Manufacturing, Metals, Plastics, Wood, Glass

Benefits of applications with PNC solution:

• Allows the use of same control platform as used on other machine type 
• Customizable solution (open-source application sample code), improves machine flexibility
• Easy of integration with other devices

 

How can I make it work?

Hardware

• Kinetix 5300, Kinetix 5500, Kinetix 5700 with CIP Motion and CIP Sync
• PowerFlex 755 with CIP Motion
• CompactLogix L340ERM, ControlLogix L82E or higher
• Firmware revision 33 or higher
• PanelView Plus / PanelView 5000

Software

• Studio 5000 Logix Designer
• FactoryTalk View Machine Edition / Studio 5000 View Designer
• PNC_202111291223.ACD / PNC_202111291223_CompactLogix.ACD
• PNC_202110261632.mer / PNC_202112011432.vpd

Required Knowledge

Intermediate knowledge of Motion control, programming and configuration using Studio 5000 Logix Designer. Basic knowledge of HMI programming using FactoryTalk View ME or Studio 5000 View Designer. Familiarity with CNC programming (Part program, G-Code). Training on PNC Solution.

Downloads

Please note: You will need to agree to the Terms & Conditions for each download.

Need Help?

If you need help with an application or have feedback from the Innovation Center, please contact us.

Installation guide 

To implement, check the steps below.

Step 1

Open the file PNC_202111291223_CompactLogix.ACD (for a CompactLogix 5380 controller) or PNC_202111291223.ACD (for a ControlLogix L8 controller)

Step 2

Motion Configuration

1. Configure the Axis Properties of both virtual (Ax.._Path) and physical (Ax.._Physical) axis for all applicable axes, according to application requirements
2. Move unused axes to Ungrouped Axes folder
3. Replace and configure the Drive Modules according to the application
4. Either inhibit or delete unused Drive Modules
5. If a Drive module is deleted, the corresponding Program module must be deleted as well

Step 3

Download the ACD file to the Controller

Step 4

HMI – FactoryTalk View ME application (for PanelView Plus only)

1. Open the ME Transfer Utility
2. Select the file PNC_202110261632.mer and download to the terminal
3. Configure the Application Settings > Device Shortcuts in order to connect to the right Controller
4. Run the Application
5. Access Machine Parameters through the Menu: Machine Setup > Machine Params
6. Configure the Machine Parameters according to the application requirements 

Step 5

HMI – Studio 5000 View Designer (for PanelView 5000 only)

1. Open the file PNC_202112011432.vpd
2. Configure the Project Properties to match your application
3. Download the Runtime Application to the terminal
4. Run the application
5. Access Machine Parameters through the Menu: Machine Setup > Machine Params
6. Configure the Machine Parameters according to the application requirements

Using the MQTT protocol with FactoryTalk Optix and Studio 5000 Application of the MQTT protocol with FT-Optix and Studio 5000

WHAT IS THIS FOR?

The MQTT (Message Queuing Telemetry Transport) protocol allows the transport and sending of messages via Publisher/subscription, it is based on the client/server model, extremely light, ideal for remote connectivity, sending data to the cloud with little code and minimal bandwidth. These principles make this protocol ideal for "Machine-to-Machine" (M2M) communications and for IoT (Internet of Things) and IIoT (Industrial Internet of Things) applications in order to facilitate the connection of devices, such as sensors, meters, industrial controllers, directly to the cloud.

Factory Talk Optix allows the implementation of applications using MQTT with the advantage of having a communication driver for Ethernet/IP network (among others) as a connection to industrial controllers.

In this note, we present the ways and demonstrate how easy it is to implement MQTT in FactoryTalk Optix, connecting with a CompactLogix automation controller (1769-L36ERM) and sending data via MQTT to a broker, allowing devices and controllers on the factory floor (machines and processes) to send data directly to the cloud.

Downloads

Please note: You will need to agree to the Terms & Conditions for each download.

Need Help?

If you need help with an application or have feedback from the Innovation Center, please contact us.

Useful links

• MQTT: https://mqtt.org/
• MQTT Software (Servers, Brokers, others): https://mqtt.org/software/
• FactoryTalk Optix: https://www.rockwellautomation.com/pt-br/products/software/factorytalk/optix/try-it-now.html
• FactoryTalk Hub: https://home.cloud.rockwellautomation.com

GENERAL CHARACTERISTICS

MQTT is a publish/subscribe protocol designed to connect IoT devices. Unlike the HTTP request/response paradigm, MQTT operates in an event-driven manner, allowing messages to be sent to clients. This architectural approach enables highly scalable solutions, decoupling data producers and consumers, eliminating dependencies between them. Two main components for establishing the MQTT connection for publishing and subscribing to messages are the MQTT Clients and the MQTT Broker.

More information about the MQTT protocol: https://www.hivemq.com/blog/mqtt-essentials-part-1-introducing-mqtt

FactoryTalk® Optix™ enables system developers to improve their processes, efficiency, and deliverables with a modern, cloud-enabled HMI platform that allows you to design, test, and deploy applications directly from a web browser – anytime, anywhere. This new open platform offers:

• Design options: Create and test your designs in a modern, object-oriented programming environment.
• Deployment options: Create your application program once and deploy it to any device.
• Graphics options: Style your graphics to cater to a global audience and deliver a responsive experience.
• Extensible options: Openness and interoperability through machine-to-machine and machine-to-cloud communications enabled by native OPC UA, MQTT, and IOT connectivity, with an open C# interface.

ADVANTAGES

• Lightweight and efficient - MQTT clients are very small, require minimal resources, so they can be used in small microcontrollers. MQTT message headers are small to optimize network bandwidth.
• Two-way communications - MQTT enables device-to-cloud and cloud-to-device messaging. This makes it easier to transmit messages to groups of things.
• Reliable message delivery - Message delivery reliability is important for many IoT use cases. That's why MQTT has 3 defined quality of service levels: 0 - at most once, 1- at least once, 2 - exactly once.
• Support for untrusted networks - Many IoT devices connect over untrusted cellular networks. MQTT support for persistent sessions reduces the time to reconnect the client with the broker
• Safety Enabled - MQTT makes it easy to encrypt messages using TLS and authenticate clients using modern authentication protocols such as OAuth.

 

LIMITATIONS AND DISADVANTAGES

• One of the disadvantages of using the MQTT protocol is that messages are not stored in the Broker.
• Network dependency. It needs stable and constant connection for proper operation.

 
KNOWLEDGE

• THEN Windows
• MQTT – Concepts and fundamentals
• FT-Optix – Basic Knowledge
• Studio 5000 – Basic knowledge
• Visual Studio C# - Basic Knowledge

IS THIS USEFUL TO ME?

• Easy to implement
• Easy to add new devices/clients in the architecture
• Has security and encryption features (SSL/TLS)
• Currently one of the easiest protocols to implement to transport IoT and IIoT telemetry data to the cloud

 

HOW CAN I MAKE IT WORK?
You will need the following software:

1 - FactoryTalk Optix Studio Free/Pro – latest version available - Download: https://www.rockwellautomation.com/pt-br/products/software/factorytalk/optix/try-it-now.html

Important: FactoryTalk Optix Studio uses C# as the backend language – NetLogic. We recommend installing Microsoft Visual Studio 2022 Community (after installing FT-Optix).

No FT-Optix menu, Options>>Optix Studio>>Preferred Code Editor (select Visual Studio) https://visualstudio.microsoft.com/pt-br/vs/community/

2 - MQTT.fx Broker - Download Option: https://mqttfx.jensd.de

Note: There are other sources to download this program

3 - FactoryTalk Studio 5000 Design Studio V30 or higher

Installation Guide

To implement, check the following steps.

Step 01 - Loading the base application (sample) from FactoryTalk Optix Help.

Step 02 - Configuring FT-Optix Application for Communication with Studio 5000.

Step 03 - Configuring FT-Optix Application for Publish/Subscribe.

Step 04 - Setting up MQTT.fx Broker and testing the applications.

Using the MQTT protocol with FactoryTalk Optix, and Studio 5000

Version 1.0 - July 2024

Home to Torque Limit Sequence in Studio 5000 The Home to Torque Limit Sequence is defined for applications to monitoring torque while driving an axis into a mechanical hard-stop

What is this for?

This application explains how to use the Home to Torque-level sequence in Studio 5000 software, and the considerations required when using this homing method. This document provides an example for a typical homing program routine.

Home to torque-level homing is a process that references a known position by monitoring torque while driving an axis into a mechanical hard-stop. Once the actual torque level reaches or exceeds a specified torque level for a set time of 500 ms, a status flag is set in the controller.

General Features

• Home to Torque-level sequence
• Home tab Axis Configuration
• Limits tab Axis Configuration

Advantages:

This sequence facilitates the implementation and quick configuration for Homing an Axis when is required monitor the torque.

 

Limitations/Disadvantages:
This sequence is available for CompactLogix / ControlLogix Controllers.

This code is defined for applications to monitoring torque while driving an axis into a mechanical hard-stop.

 

• Application areas: 
  • Food, Manufacturing, Beverage

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• Hardware
  • Personal computer with an available USB port
  • CompactLogix, ControlLogix Controller

• Software
  • Studio 5000, version 21 or later

• Knowledge
  • Intermediate knowledge of programming and configuration in Studio 5000 software: Ladder language (LD)

Installation Guide

Step 01 - Configure the Axis Homing Tab

Because the process of home to torque-level requires axis motion, the axis homing mode must be configured as Active.

 

1- Open the Axis Properties tab. And complete the next configuration. The Torque level option sets the Home Position after the output torque reaches the Torque Level value, reverses direction, and moves until the Homing Torque Above Threshold bit is low and the status bit sets. The Torque Level – Marker sets the Home Position after the output torque reaches the Torque Level value, reverses direction, and encounters an encoder marker.

When either the Torque Level or Torque Level - Marker homing option is selected on the Homing tab, the Torque Level field is activated in the Active Home Sequence Group. The units for this field are a percentage of the continuous torque of the motor (% Continuous Torque) limited by the drive-rated current/motor-rated current ratio. This number is interpreted in the drive as an absolute value and the range is 0...TorqueLimitPositive value.

 

Forward Bi-directional and Reverse Bi-directional are the only options for the Direction field when Torque Level or Torque Level - Marker homing sequence is selected. Uni-directional homing is not possible, because the Home to Torque-level sequence relies on a mechanical hard-stop.

Step 02 - Drive Bipolar Torque Limit Adjustment

When homing an axis to a mechanical hard-stop, set the Home Torque-level value above the torque value required to move the system, but low enough not to cause problems with the system mechanics.

As part of the process of homing to a torque limit, limit the Peak Torque value to a level 10% above the Home Torque value to reduce the stresses on the mechanics and to eliminate the chance of an over-current fault.

The 10% value is an estimated starting point. This value may need adjustment based on the application requirements. Limit the Peak Torque value before issuing the homing instruction (MAH) and reset the Peak Torque field to the original value after homing completes.

Step 03 - Disable Soft Overtravel Limit

If the application requires the use of soft-overtravel limits (Limits tab) to safeguard the system mechanics, the Soft Travel Limits must be disabled for the axis to home.

The Soft Travel Limits must be disabled through programming to prevent a fault from occurring during the homing operation, but re-enabled after homing completes.

Step 04 - Ladder Code Sequence

This sequence shows how to adjust the peak torque limit and disable the soft-overtravel limit checking when homing to a torque limit. The code uses a state model methodology in which each rung of code needs to complete successfully before moving to the next rung.

Rung 11 of the ladder code checks to make sure that the axis position, after homing, is within the Soft Travel Limits before re-enabling soft-overtravel limit checking. In this code a 1.15 cm Offset move is configured in the Homing tab and that is the final home position. The 0.5 cm is within the Soft Travel Limits set on the Limits tab.

List of Tags Used

Axis Properties - Homing Tab

Axis Properties - Limits Tab

Ladder Code Example

Potential for Position Error Fault

When executing a torque limit homing procedure there is potential for a Position Error fault. As mentioned earlier, for the home to torque limit to complete, the output torque to the motor must reach (or exceed) the specified torque level for a set time of 500 ms. During this time the axis is against the mechanical hard-stop, and following error is increasing in the position loop. If the Position Error Tolerance value is exceeded before completion of the homing instruction, a Position Error fault (E19) will result.

 

There are two ways to limit the occurrence of an E19.

- Set the Position Error Tolerance value on the Limits tab of the Axis Properties to a value high enough to eliminate a fault from occurring.

- Modify the Position Error Tolerance value via an SSV instruction similar to the method used in code above to change the Bipolar Torque Limit.

 

Rung 6 of the ladder code opens the Position Error window. This allows the Homing to complete without causing a Position Error fault. The original value is reset after Homing completes.

Home to Torque Limit Sequence in Studio 5000

Version 1.0 - August 2024

Local Control System in a pumping station with PlantPAx v5.20 Pump station monitoring and control with PlantPAx, using ViewDesigner, process and power objects

What is this for?

The objective of this development is to show the ease of implementation of the control system in water pumping stations, using predefined objects of process control and motor control strategies in local graphical interfaces: Panel View 5000 family with process control objects library.

The pumping of water in stations is a recurring operation in various types of industry with water treatment plants, or particularly, in mining, where it is a key resource in different process stages and optimizing its use is vital. This liquid is driven from or to a storage network or distribution network, making the assurance of resource availability, maintaining the operation, and equipment condition crucial tasks.

Implementing this type of system is relatively straightforward, as the operation of a pumping station is comparatively simple. These are areas with low signal density where controllers can be used to guarantee good performance at an optimized cost. Depending on the type of water moved throughout the process, there will be more or fewer elements with specific functionalities requiring particular adjustments. However, using previously tested objects developed by Rockwell Automation to integrate local monitoring and control into centralized system allows:

• Optimize development time for control strategies and operation screens
• Ensure approval and repeatability at a graphical level from a local interface
• Facilitate the familiarization and adoption of an operating environment based on the ISA 101 standard at the local level
• Facilitate connectivity to a centralized system, completely compatible with other plant areas
• Use more recent hardware and software components

 

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• Use of the Engineering Station template with the following applications:
  • FactoryTalk Services platform software, version 6.31.00
  • FactoryTalk Linx software, version 6.31.00
  • FactoryTalk View Site Edition Server software, version 13.00.00
  • FactoryTalk View Studio Enterprise software, version 13.00.00
  • Studio 5000 Logix Designer ® application, version 36
  • Logix View Designer version 9.02
  • FactoryTalk Logix Echo, version 3.00.00
• Power Device library version 3.02
• Process library version 5.10.01
• Panelview 5510 15”
• CompactLogix 5069-L320EP
• 5069-IF4H Analog Input Modules
• Endress+Hauser HART Instrumentation
• PowerFlex 755

The physical components, as well as the configuration of the control strategies may vary in a real implementation but can be taken as a basis for development. For testing purposes, all hardware components are configured as inhibited so that they do not generate alarms due to lack of hardware.

Links of interest

• PlantPAx Distributed Control System
• PlantPAx Distributed Control System Configuration and Implementation
• Compatibility & Downloads
• ISA101, Human-Machine Interfaces
• ISA95, Enterprise-Control System Integration

Installation Guide

The station where the application is developed must contain all the aforementioned applications.

One option to guarantee software compatibility is the use of Rockwell templates; the image of a PASSC (Process Automation System Server Consolidated) can be used. 

Step 01

• Restore the application backup by opening the PumpingStation.ACD file

You will notice that it has been used:

- CompactLogix process in v36
- I/O Modules with HART
- Endress+ Hauser Instrumentation
- PowerFlex 755 Drives
- Stratix 5200 Switch
- 15” PaneView 5510
- Process control strategies in v5.10

• Create an emulated controller in FactoryTalk Logix Echo to test, add, modify, or remove control strategies

• Download the project to the controller and select RUN mode

Fig. 1. Project in Logix Designer

Step 02

• Open the Pumping station.vpd project in View Designer

• Explore the project to get familiar, the main screens are:
  - Overview
  - Pumping station
  - Temperatures
  - Vibrations
  - Energy consumption
  
  

Fig. 2. Project in View Designer

Note: The project was initiated using the template developed in View Designer for control system applications that use process objects in versions 5.10 and later. There are components not used in the application but left for future use, which when emulating the project will show alerts that do not impact the performance of this application.

• Ensure to link the project to the emulated or physical controller if you have one:

1 - Select Project in the Main Menu
2 - Select Project Properties
3 - Set the controller path in the HMI and Emulator Controller path fields

Fig. 3. Project properties in View Designer

• Emulate the project and navigate the screens. The developed screens allow navigation through a general view with access to screens that enable deeper detail, as established by the ISA 101 standard.

Fig. 4. Project Overview

Fig. 5. Pumping station view

Fig. 6. Temperature summary 

Fig. 7. Vibration Summary 

Fig. 8. Current summary/Device Faceplate

Fig. 4. Project Overview

Fig. 5. Pumping station view

Fig. 6. Temperature summary 

Fig. 7. Vibration Summary 

Fig. 8. Current summary/Device Faceplate

As the data has been collected in the project, as many screens as necessary can be generated to show generalities or details of the Pumping Station status without compromising the performance of the controller and panel. In the following images, you can see the conditions in which this implemented application is left.

Fig. 9. Current Controller capacity

Fig. 10. Instruction usage summary

Fig. 11. Current Panel Capacity

Fig. 9. Current Controller capacity

Fig. 10. Instruction usage summary

Fig. 11. Current Panel Capacity

Local Control System in a pumping station with PlantPAx v5.20

Version 1.0 - August 2024

Ethyl Acetate and Ethanol Reaction under an Adiabatic model This application use a reaction model of second order to represent the Ethyl Acetate reaction using Ethanol and producing Ethyl Acetate and water, under an Adiabatic model.

What is this for?

Context

Esterification reactions are very important in the process industry, generally esters are used in the chemical industry and in the food industry, these reactions are characterized by a reaction model.

 

Objective

Use the ethyl acetate reaction as an example to verify that the reaction model represents the reaction model in Logix.

How to use

Assumed items:

Limitations

In the current configuration, the chosen reactor is an ideal perfect mixture reactor (ideal CSTR) so that in the liquid inside, it is assumed that:

1. There are no gradients in any of its properties and, therefore, the conditions of the output streams are the same as those of the fluid within it, this to simplify the implementation of the configuration.
2. In the reactor there is no evaporation of any of the components and, additionally, the adiabatic process is considered.
3. Mixture properties are not considered, that is, the properties of the mixture will be the weighted sum of the properties of each of the species.
4. The properties of substances are all independent of composition and, therefore, invariant over time.
5. Although the reaction is reversible, the reverse reaction can be considered negligible.

 

Problem to be addressed

The idea is to have an initial configuration element, to be able to start the configuration of a reaction model.

The reaction model is useful because it could be used for other developers to represent Fischer–Speier esterification reaction model, between carboxylic acid and alcohol.

 

How can I make it work?

Products	Studio5000 34.11.00 FactoryTalk Logix Echo V3.00.00
Knowledge	Reaction Model

 

External Links

https://www.sciencedirect.com/science/article/abs/pii/S0926860X0300694X?via%3Dihub

Downloads

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Need Help?

If you need help with an application or have feedback from the Innovation Center, please contact us.

Installation Guide

To implement, check the steps below.

Step 1

Open FactoryTalk Logix Echo, add a new controller (ControlLogix5580) and connect it.

Step 2

Download the configuration .ACD in your laptop and run it in Studio 5000, observe reactants and products:

Step 3

After the reaction starts, the formation of products such as ethyl acetate uses the interaction between reactor volume, activation energy, ethanol and acetic acid compositions and follows this mathematical model.

Step 4

After the reaction starts, the formation of products such as water uses the interaction between reactor volume, activation energy, compositions of ethanol and acetic acid and follows this mathematical model.

Ease of integrating a MT IND360 weight indicators via Ethernet/IP Ease of integrating a Mettler Toledo IND360 weight indicators via Ethernet/IP using Application Code Manager

What is this for?

The Mettler Toledo IND360 product is a product for accurate weight measurement (load cell) and allows excellent integration with our controllers (ControlLogix, CompactLogix) via Ethernet/IP. The partnership between Mettler Toledo and Rockwell Automation has allowed the development of libraries such as Add-on, Faceplates (HMI), sample codes, to make integration easy and fast. With the Application Code Manager feature (code generator and screens) it is possible to integrate, generate controller application code (Studio 5000), generate HMI screens and network configurations, reducing setup time and startup of production lines and industrial machines.

https://www.mt.com/us/en/home/library/case-studies/industrial-scales/Encompass.html

 

General Features

Our Device Object Libraries allow you to easily interact with Rockwell Automation® Intelligent devices, as drives, motion, network switches, sensors, IoT, and more. The libraries contain tests, documented, and lifecycle. Managed objects that can be used with the manufacturer of machines, processes, and libraries packaged or as stand-alone components. Device Objects Include HMI Faceplates para FactoryTalk® View ME/SE e Studio 5000 View Designer® software and provide a user interface that integrates seamlessly with the goods.

HMI faceplates are standard display files that provide the average user with Interface. These are HMI pop-up screens used to display detailed information related to a specific instruction or device. On systems that follow ISA 101.1 According to design guidelines, front-facing displays are often referred to as Level 4 monitors.

Preconfigured device objects include a supplemental instruction line and a HMI front panel that offers the following benefits:

• Collect, process, and deliver data between smart devices and Application Logic
• Detailed collection and delivery of device data
• Improved device status and diagnostics
• Common control interfaces that maximize device automation flexibility Selection and reuse of application code

Device objects use cases:

• Basic device maintenance and diagnostics
• Virtual device operations for start-up and commissioning
• Operator and program control for machines and processes Applications

 

Advantages

Integration via Ethernet/IP allows for excellent ease of integration, reducing time and line start-up process. Use of Application Code Manager to generate controller code (Add-on) and general configurations and construction of HMI faceplates for integration.

 

Application Code Manager

Studio 5000® Application Code Manager is a tool that can be used with Device Object libraries to speed up the development of projects and machines. This volume Coding tool allows you to easily design and standardize functionalities with Reusable application code. Enable more efficient project development with reusable code libraries:

• Quickly create and deploy projects through our app content

 

Libraries

• Import Rockwell-sourced application content libraries for agility system development.

 

Limitations and drawbacks

Number of IND-360 devices, integrated via Ethernet/IP, depends on the limitation of CIP connections of each controller used.

 

Is this helpful for me?

Integration via Ethernet/IP allows excellent ease of integration, reducing time and start-up of lines, process and industrial machines.

 

How can I make it work?

Hardware

• PanelView™ 5500 with v8 or later firmware
• PanelView™ Plus with v10 or later firmware
• ControlLogix® 5570/5580 controller or CompactLogix™ 5370/5380
• Controller with v3.01 or later firmware

Software

• Studio 5000 Logix Designer® v31.02 or later for PAC Application Development
• Studio 5000® Application Code Manager v4.01 and later for bulk code configuration
• Studio 5000 View Designer® v8.00 and later for PanelView™ 5000 Application Development
• FactoryTalk® View Studio v10 and later for PanelView™ Plus or
• FactoryTalk® View SE Application Development

Required knowledge

• SO Windows
  
• Studio 5000 Design Studio and View Design
• FactoryTalk View Studio ME
• FactoryTalk View Studio SE
• Application Code Manager - Basic

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Installation Guide

To implement, check the steps below.

Step 1

Manual de Referência: DEVICE-RM905A-EN-P.pdf

 

Localizado em General_Files.zip, no caminho:

MettlerToledoDeviceLibrary_v1.00.00\Reference Manual\DEVICE-RM905A-EN-P.pdf

 

Como importar e configurar objetos de dispositivo Metter Toledo no ACM – Application Code Manager.

Step 2

How to Import and Configure Metter Toledo Device Objects in Studio 5000 Logix Design.

Step 3

How to Import and Configure Metter Toledo Device Objects in FactoryTalk View ME and SE.

Step 4

How to Import and Configure Metter Toledo Device Objects in Studio 5000 View Design.

Step 5

MT-IND360 Visualization & Operational Data - Faceplates.

Torque Calculator for Servo Motors This will help you convert motor torque feedback from percent to torque units and also calculate the Peak Torque/Force Lim parameter.

What is this for?

Simplify the calculation of the motor feedback torque in torque units for servo motors, as well as the conversion of the maximum torque from a given value in torque units to percent.

General Features

The use of the block or AOI (for Add-On Instruction) is extremely simple, just open the attached file labeled “AOI_TorqueCalculator_ForServoMotor - Application Code.ACD” and copy to your project file.

Add-On Instruction should look like this:

Limitations/Disadvantages

It can be used only with Servodrives with SERCOS network.

How can I make it work?

The AOI_TorqueCalculator_ForServoMotor automatically calculates the motor Torque Feedback in torque units. This AOI can also calculate the Peak Torque/Force Lim in percent from a desired maximum motor torque limit given in torque units.

This AOI is constituted by three sets of parameters: one set for configuration of the AOI, one set to convert Torque Feedback from % to torque units, and a set to convert the Peak Torque/Force Lim from torque units to %.

The user needs to enter only two motor parameters in the AOI: Continuous Stall Torque and Peak Stall Torque found in datasheets. All the other parameters needed in this AOI are automatically read from the drive when this AOI is enabled. This AOI continuously converts the Torque Feedback from percent to a given toque unit while enabled. The result is placed in the parameter Out_Torque_Nm. The torque unit is the same of the parameters Inp_ContStallTorque_Nm and Inp_PeakStallTorque_Nm. Meanwhile, this AOI can be used to calculate the parameter Peak Torque/Force Lim from the torque entered in the parameter Inp_DesiredTorqueLim_Nm, which corresponds to the maximum peak torque required for a particular application. The parameter Inp_DesiredTorqueLim_Nm is entered in torque units and the result for the Peak Torque/Force Lim stored in the parameter Out_ForceTorqueLim_Perc is given in percent.

This AOI must remain enabled to calculate Torque Feedback in a given torque unit.

AOI Control

Typically, the AOI_TorqueCalculator_ForServoMotor instruction can be executed when torque feedback needs to be read in torque units or when the Peak Torque/Force Lim needs to be calculated for specific torque limit as shown below.

Appendix: Parameter Definitions

Inp_Axis:
Axis (Servo_Axis_Drive data structure) that will have torque converted torque units.

Ref_MotorContStallCur:
This is a Message data type tag. This parameter is used to read the Motor Continuous Stall Current from the drive. The Motor Continuous Stall Current is parameter 111 (S:0:111) in a Kinetix drive. The Ref_MotorContStallCur tag is configured in the AOI as shown below. The Destination is the tag MTC.Inp_DriveContCur_mA.

Ref_MotorPeakStallCur:

This is a Message data type tag. This parameter is used to read the Motor Peak Stall Current from the drive. The Motor Continuous Peak Current is parameter 109 (S:0:109) in a Kinetix drive. The Ref_MotorPeakStallCur tag is configured in the AOI as shown below. The Destination is the tag MTC.Inp_MotorPeakStallCur_mA.

Ref_DriveContCur:

This is a Message data type tag. This parameter is used to read the Drive Continuous Current from the drive. The Drive Continuous Current is parameter 112 (S:0:112) in a Kinetix drive. The Ref_DriveContCur tag is configured in the AOI as shown below. The Destination is the tag MTC.Inp_DriveContCur_mA.

Ref_DrivePeakCur:

This is a Message data type tag. This parameter is used to read the Drive Peak Current from the drive. The Drive Peak Current is parameter 110 (S:0:110) in a Kinetix drive. The Ref_DrivePeakCur tag is set in the AOI as shown below. The Destination is the tag MTC.Inp_DrivePeakCur_mA.

Inp_ContStallTorque_Nm:

This is a REAL data type tag. The user uses this parameter to enter the Motor Continuous Stall Torque, which is found in the motor nameplate or in the Motion Selection Guide. This parameter is shown to be given in Nm. However, any other torque unit can be used if the Inp_PeakStallTorque_Nm be also set in the same toque unit. Thus, the torque feedback given in the Out_Torque_Nm will also be given in this same torque unit.

Inp_PeakStallTorque_Nm:

This is a REAL data type tag. The user uses this parameter to enter the Motor Peak Stall Torque, which is found in the Motion Selection Guide.

Out_Torque_Nm:

This is a REAL data type tag. This parameter shows the Torque Feedback converted from percent to the torque unit given by the parameters Inp_ContStallTorque_Nm and Inp_PeakStallTorque_Nm.

Inp_DesiredTorqueLim_Nm:

This is a REAL data type tag. This parameter is used to enter in torque units the torque limit for a particular application. The AOI converts this torque from torque units to percentage. This torque in percent is the Peak Torque/Force Lim to be manually entered in the Limits tab of the Axis Properties. The torque entered in this parameter must be in the same unit as the parameters Inp_ContStallTorque_Nm and Inp_PeakStallTorque_Nm.

Out_TorqueForceLim_Perc:

This is a REAL data type tag. This parameter returns the Peak Torque/Force Lim necessary to limit the motor torque to the value entered in the parameter Inp_DesiredTorqueLim_Nm. This parameter is given in percentage.

Sts_EN:

The Enable bit is set while the rung is on.

Sts_TLim:

This Torque Limit bit is set when the value entered in the Inp_DesiredTorqueLim_Nm parameter is higher than the torque that the motor-drive system can deliver.

Sts_ER:

The Error bit is set if same of the message instructions used to read parameters from the drive fail to communicate with the drive. This bit is reset when the AOI is enabled. When an error occurs, the error message can be read in the Message Configuration window which can be accessed by hitting the box beside the tag name as shown below.

Inp_MotorContStallCur_mA:

This is a DINT data type tag. This parameter is the Destination in the Ref_MotorContStallCur message. This parameter contains the Motor Continuous Stall Current in mA read from the drive by the Ref_MotorContStallCur message.

Inp_MotorPeakStallCur_mA:

This is a DINT data type tag. This parameter is the Destination in the Ref_MotorPeakStallCur message. This parameter contains the Motor Peak Stall Current in mA read from the drive by the Ref_MotorPeakStallCur message.

Inp_DriveContCur_mA:

This is a DINT data type tag. This parameter is the Destination in the Ref_DriveContCur message. This parameter contains the Drive Continuous Current in mA read from the drive by the Ref_DriveContCur message.

Inp_DrivePeakCur_mA:

This is a DINT data type tag. This parameter is the Destination in the Ref_DrivePeakCur message. This parameter contains the Drive Peak Current in mA read from the drive by the Ref_DrivePeakCur message.

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MQTT Data Exchange: Real-Time Dashboard & Historical Data Guide on MQTT for data exchange between applications, focusing on real-time visualization and historical data, with setup steps for deployment.

What is this for?

Demo MQTT is an example consisting of two projects: Field Application and Data Aggregator Application. The objective of this demo is to simply show an example of communication via MQTT protocol between a hypothetical application running on a machine/plant (Field Application) and an application that collects the data sent by the machine, showing them in the form of a dashboard (Data Aggregator Application). Usually, it would be done only with the visualization of historical data (cold data) but in this project, we also wanted to show an example of receiving live data.

Use MQTT for real-time data visualization and communication between applications, emphasizing safety and practical implementation using FT Optix.

General Features

MQTT for real-time communication between field and data aggregator applications, with a focus on practical setup and safety. 

Limitations/Disadvantages

The example is provided as-is and can be a useful reference for building your application. The example as its cannot be used on a real machine but must be adapted for the purpose, respecting the highest safety standards required. A public and open source MQTT broker is used in the project for demonstration purposes only, it is not secured, and its uptime can’t be guaranteed. We strongly encourage you to change the topic and server names using your provider before deploying the final application.

How to start the project?

To setup the Field Application and/or to solve compiling issues/missed references please read the MQTT_Field documentation.

Please note:

This application works paired with the Field Application, showing data received via MQTT protocol in form of a control dashboard. This app you can find in the Innovation Center under the following tittle: Real-Time Data Implementation and Visualization with MQTT in Optix.

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Guía de implementación

Paso 1

Start the Field Application.

Paso 2:

After that, open this project on another FT Optix window and run the application with FT Optix Emulator.

Paso 3:

If the connection with the Field Application is working, the “Live Data” LED will be green.

Detailed information

The data exchange is based on a Runtime Netlogic which can be found in the Netlogic folder. The Netlogic MQTTBrokerLogic is present on both applications but is configured differently.

Field application

Here the Runtime Netlogic acts as Publisher, in this way it publishes data on certain topics, addressed to an MQTT broker.

Data aggregator application

Here the Runtime Netlogic works as Subscriber: subscribing to the topics on which the Field Application publishes, it shows all data in the form of a dashboard.

MQTT BrokerLogic

Server MQTT

Debe activarse (TRUE) solo si desea utilizar su aplicación Uniqo como Broker (por lo tanto, no usar un broker MQTT existente, en este ejemplo test.mosquitto.org).

Parameters:

• IPAddress: IP address where the Broker will be instantiated.
• Port: number of the port on which the broker is listening
• UseSSL: enables the use of certificates.
• Certificate
• CertificatePassword
• AutoStart LEAVE TRUE
• UserAuthentication: if true only the specified users can access
• AuthorizedUsers
• IsRunning: Server status
• IsDebuggingMode NOT USED
• MaxNumberOfConnections: maximum number of clients that can connect to the Broker
• NumberOfConnections: number of active connections

MQTT Client

It must always be active (TRUE) because it is the connection with the Broker to which you publish or to which you subscribe. If you want to connect two applications, you need to set the same broker and the same port on both projects. Instead, the ClientID parameter must be different (unique) on each application.

Parameters:

• IPAddress: broker address (test.mosquitto.org) could be external like in this case, or internal if the application work as a broker (e.g., MQTTBrokerLogic.MQTTServer.IPAddress)
• Port: broker port (1883 for test.mosquitto.org)
• UseSSL: Switch to TRUE if the broker requires certificates
  • CaCertificate
  • ClientCertificate
  • ClientCertificatePassword
  • AllowUntrustedCertificates
• UserAuthentication: Switch to TRUE if the broker requires authorized users.
  • AuthorizedUsers: String array which contains Uniqo users (User1; User2; User […]);
• IsRunning NOT USED
• IsDebuggingMode NOT USED
• ClientId: this is the unique Id, different for each application that wants to participate in the data sharing/exchange
• Connected: connection status to the broker
• SentPackages STATS
• ReceivedPackages STATS

Subscriber

It must be active (TRUE) if your application needs to receive data published on the broker.

Parameters:

• LiveTags: TRUE = receive LIVE DATA
  • LiveTagsFolder: this folder/Node contains a copy of the Publisher LiveTagsFolder parameter, on which the Netlogic will copy the values read from the broker.
  • LiveTagsTopic: on this parameter needs to be specified the topic on which you are subscribed, and you want to receive live variables/tags values.
  • LastPackageTimestamp: Timestamp of the last published packet
• StoreTables: TRUE = receive HISTORICAL DATA
  • Store: DataStore on which we are saving received data. The store’s tables must be renamed with the “TablesPrefix” parameter, plus the name of the publisher application tables. Below is an example:
    • Publisher application DataStore table names: Datalogger, AlarmsEventLogger
    • Publisher “TablesPrefix” parameter: Station1
    • Subscriber application DataStore table names: Station1_DataLogger, Station1_EventLogger Verify to have the same columns you have on the Publisher application.
  • StoreTablesTopic: on this parameter needs to be specified the topic on which you are subscribed, and you want to receive historical variables/tags values.
• CustomPayload: Custom message without pre-defined format
  • CustomPayloadMessage: Custom text message from the CustomPayloadTopic
  • CustomPayloadTopic: On this parameter the topic on which you are subscribed, and you want to receive custom messages needs to be specified.

Publisher

It must be active (TRUE) if your application needs to publish data to the broker.

Parameters:

• LiveTags: TRUE = publish LIVE DATA
  • LiveTagsPeriod: Sending frequency (if 0000:00:00.000 send data on value change).
  • LiveTagsFolder: folder (or node) that contains data to be sended
  • LiveTagsTopic: /UniqoFieldHmiLiveTopic is the topic on which we are sending/publishing data
  • QoS: MQTT Quality of Service (0,1,2)
  • Retain: Retain message on the topic even after read
• StoreTables: TRUE = publish HISTORICAL DATA
  • Store: DataStore on which we are saving our data
  • TableNames: Store tables to be sended
    • Table1: Datalogger
    • Table2: AlarmsEventLogger
    • Table (…) could be added or removed
  • PreserveData NOT USED
  • MaximumItemsPerPacket: define how many rows per packet to send
  • MaximumPublishTime: Maximum waiting time before publishing data even if it does not reach the MaximumItemsPerPacket value.
  • MinimumPublishTime: Minimum waiting time before publishing data when the MaximumItemsPerPacket value is reached.
  • StoreTablesTopic : /UniqoFieldHmiDataLoggerTopic is the topic on which we are sending/publishing data
  • QoS: MQTT Quality of Service (0,1,2)
  • Retain: Retain message on the topic even after read
  • TablesPrefix: A model variable containing the hypothetical name of different production sites, in this case, will be “Station1”. Into the sent packet will appear the table sent with the unique prefix corresponding to the right machine/site from which the packet arrives (Station1_AlarmsEventLogger). This is useful when we have more than one of the same machine models/more than one of the same plant configurations and we need to distinguish from which machine/plant data arrives.
• AllRows: When it is TRUE, publish all the data already present in the Store Tables. Set on FALSE to publish only the data stored after the implementation of the MQTTBrokerLogic.
• CustomPayload: Custom message without pre-defined format
  • CustomPayloadMessage: Custom text message published to the CustomPayloadTopic
  • CustomPayloadTopic: The topic on which the message will be published.
  • CustomPayloadPeriod: Sending frequency of the custom message (if 0000:00:00.000 send data on value change)
  • QoS: MQTT Quality of Service (0,1,2)
  • Retain: Retain message on the topic even after read

Master-Slave application using PowerFlex 755TS Master-follower system with fast parameter setup for precise and efficient synchronization in industrial applications.

What is this for?

The master-slave application using frequency drives with load variations on the motor shaft demonstrates the PowerFlex 755TS frequency drive's ability to respond to these changes with rapid response and precise speed control, as well as the adaptive control operation in response to load variations.

This system enables the synchronization of two AC motors with PowerFlex 755TS frequency drives using a master-slave scheme, along with the use of DC motors as loads. 

This demonstration includes operating in both automatic and manual modes. It offers a comprehensive solution that combines visualization tools, integration with the Logix platform, and operation to visualize the response of the frequency drives. 

General Features

The master-slave application with load variations offers the following features:

• Operating modes: Automatic and manual.
• Adjustable speed reference.
• Simulation of load variations with DC motors.
• Flexibility and adaptability to a variety of industrial applications.

Advantages

• Demonstrates the integration of monitoring and operation tools.
• Streamlines the programming time of frequency drives.
• Exhibits scalability and repeatability to adapt to various industrial environments.
• Allows agile and precise modifications according to changing needs.
• Provides versatile control that adjusts to different application scenarios.
• Optimizes performance in terms of efficiency and productivity.

Is this useful for me?

Frequency drives with Total Force technology represent an effective solution because the adaptive control of the PowerFlex 755TS can adapt to changes in motor load, fluctuations in supply voltage, and other variable operating conditions. This ensures an optimal response of the frequency drive to different operating scenarios, enhancing system stability and reducing the possibility of failures or performance issues.

This improvement in energy efficiency brings significant benefits, including reduced carbon emissions and compliance with increasingly stringent environmental regulations in the industry. Additionally, by smoothly controlling the speed and torque of the motors, mechanical wear on the equipment is reduced, extending its lifespan and lowering maintenance costs.

The master-slave application minimizes the time required to configure slave parameters, reducing the total system startup time, allowing for quicker and more efficient implementation in the workplace.

How can I make it work?

Hardware

• 2 AC Motors IDVSNM3581T-5.
• 2 DC Motors Bulletin 1325R.
• 2 PowerFlex 755TS Frequency Drives.
• 2 PowerFlex DC Frequency Drives.
• PanelView Plus 7.
• ControlLogix 5573. 

Software

• Studio5000(V35)
• FactoryTalk View(V12)
• Connected Components Workbench(CCW - V21)

Required knowledge

Knowledge of CCW, AC and DC motors, and Studio 5000.

Links of Interest:

https://www.rockwellautomation.com/es-mx/support/product/product-downloads/innovation-center/potenciometro-dancer-para-powerflex-755T.html 

https://www.rockwellautomation.com/es-mx/products/hardware/allen-bradley/new/powerflex-755ts.html

Downloads

Please note: You will need to agree to the Terms & Conditions for each download.

Need Help?

If you need help with an application or have feedback from the Innovation Center, please contact us.

Installation Guide

Step 1

Identify the applications used for implementation: CCW, Studio 5000, and FactoryTalk View.

Step 2:

Open the CCW application, click on File, Import Project, and import the .ccwarc files.

Step 3:

Access the device parameters and modify the IP to place it on the same network mask as your computer, controller, and PanelView.

Step 4:

Open the Studio 5000 application and run the project: Master_Slave.ACD, configure the assigned IP addresses, leaving the device names the same.

Step 5:

Validate the connection of each part of the system through pings in Command Prompt.

Step 6:

Open FactoryTalk View with the RA_Master_Slave.apa file, within FactoryTalk ensure that the server points to the project controller.

Step 7:

Create the runtime application of the HMI and upload it to the PanelView for project visualization.

Step 8:

The master motor's speed reference, in Hz, entered analogically, is reflected in the numeric indicator. The "START" and "STOP" buttons on the HMI serve to start and stop the rotation of the motors.

Step 9:

When pressing the "Master Trend" button, a pop-up screen allows us to monitor the current and torque variables of the master motor.

Step 10:

When pressing the "Slave Trend" button, a pop-up screen allows us to monitor the current and torque variables of the slave motor.

Application deployment with FactoryTalk Optix and FactoryTalk Remote Access The combined solution between FT-Optix and FT-Remote Access allows you to send your application remotely, through a secure VPN connection.

The Solution combined between FactoryTalk Optix and FactoryTalk Remote Access allows you to remote deploy your FT-Optix Application and allows to remote connect the Studio 5000 directly controllers and network, through a secure VPN. This Solution save cost and allows assistance, installation, programming, troubleshooting, and maintenance of any automation system that can be used by end users, machine builders.

The FactoryTalk Optix portfolio is a cutting-edge cloud-enabled industrial platform. It transforms raw manufacturing data into actionable insights, providing real-time visibility into production processes with built-in interoperability, flexibility, modularity, and edge connectivity. FactoryTalk Optix enhances operational efficiency, reduces downtime, and improves overall productivity for smarter manufacturing.

Note:

For a good understanding of this application note, we strongly recommend reading our application note: Remote Access using Factory Talk Remote Access Runtime, it presents basic concepts for understanding this application note.

General Features

Factory Talk Hub is a cloud-based SaaS Solution, enabling project development from anywhere with multi-teams. FactoryTalk Optix has two basic types for developing your project: Local Desktop or Cloud. Both, combined with the FactoryTalk Remote Access solution, allow the user to deploy an application remotely, without the need to travel to an organization or customer.

The cloud-based FT-Optix has connection portability to Git-based application repositories (Github), where you can store your application, upload it directly to FT-Optix Studio (cloud) and send it directly to the End Point (IPC or Optix Panel) through FT-Remote Access.

With the use of Factory Talk Remote Access, it is also possible to remotely connect to the controllers and networks connected to the End Point (IPC or Optix Panel), allowing access to the control program.

In this application note, we'll walk you through the key steps on how you can configure and enable this solution.

Advantages

FactoryTalk® Optix Studio Pro

Integrated Design environment for creating FactoryTalk® Optix projects

Design & test your HMI projects directly from a web browser or desktop editor

Standard capabilities plus

• Web-based FactoryTalk® Optix Studio™
• Multi-user collaboration
• Save applications to a remote or local repository
• Project and library version control
• Deploy applications from the cloud

FactoryTalk® Optix Application

Application built by FactoryTalk® Optix Studio

Runtime – runtime modules strictly necessary to run a specific application

Project – application logic, objects, communication parameters.

Application is deployed to devices

Rockwell Automation devices – open and closed 

Third-party PCs and devices

Rockwell Automation & third-party communications

Limitations / Disadvantages

FactoryTalk® Optix Studio Basic only allows local application development. Doesn't allow remote deployment.

Is this helpful to me?

• Cost reduction with travel to the organization/customer for deployment and startup
• Changes and changes to your project quickly
• Versioning
• User Management

How can I make it work?

RA Credentials

FactoryTalk Remote Access Manager - Entitlements

Install FactoryTalk Optix Studio Pro – Entitlements to Hub Operations

Install FactoryTalk Optix Studio – Last Version

GitHub Credentials – Free 

Required Knowledge

SO Windows

FT-Optix – Basic KNOWLEDGE

FT-Remote Access – Basic KNOWLEDGE

Need Help?

If you need help with an application or have feedback from the Innovation Center, please contact us.

Installation Guide 

To implement, follow the next steps.

Step 1

Open FactoryTalk Hub.

Step 2

Deploy the application from Local Desktop/Laptop to Remote IPC.

Motor Starting Sequence with SQL Recipe Parameters The SQL Motor Starting Sequence features the use of FactoryTalk Transaction Manager (FTTM) to bind the communication between an SQL database and Studio5000.

What is this for?

The SQL motor startup sequence introduces the use of FactoryTalk Transaction Manager (FTTM) to link communication between an SQL database and Studio 5000. FTTM reads values from different recipes for flexible and reconfigurable manufacturing and applies these values to tags in sequence programs to start the corresponding process once the current routine is completed. This way, an information exchange is implemented between production floor control and commercial databases.

The current model performs bidirectional information transactions between FTTM and Studio 5000. These are carried out once the control system indicates it and proceeds to take information from the database for application in the system. All transactions made are stored for the necessary traceability of production operations. With applications in consumption, automotive, packaging, and other industries, this project serves as a template for commissioning motors with parameters in databases.

General characteristics

The motor startup sequence with an SQL database offers the following features:

• Information exchange between plant floor and commercial databases
• Connectivity between backed-up information for processes
• Remote commissioning of motors
• Parameterization of processes controllable in the database prior to implementation.
• Structured organization of productive process information

Advantages

• Organized production parameter changes
• Secure and backed-up procedural information
• Centralized or distributed architecture according to scalability requirements
• Traceability of historical operations with transaction records
• Process quality traceability
• Download of recipes and configuration information to the control system
• Collection of information and automated storage
• Production performance monitoring

Is it useful for me?

The demand for multiple SKUs (Stock Keeping Unit) on production lines requires quick transitions between manufacturing setups. This project serves as a fundamental basis for connecting a Studio 5000 program and an SQL database with all necessary production parameters. Through flexible technology, manufacturers will be able to improve equipment performance and overall efficiency (OEE), while digitizing operations to provide real-time process control and production support.

Customer demand will continue to increase and present different scenarios on production lines. Manufacturers will need to implement flexible and reconfigurable manufacturing to address these challenges. Through this project, a Studio 5000 program commissions motors according to the selected recipe number and provides an integrated database solution for production companies.

Implementations of this project can vary from serving as a demonstration for companies facing these challenges to being used as a template for configuring production parameters from an SQL instruction database.

How can I make it work?

Hardware:

• Motor stations (Motor, VFD’s Power Flex,PAC).

Software:

• Studio 5000 (v33-35)
• FactoryTalk Transaction Manager v13
• FactoryTalk Live Data source (Logix Echo, Logix Emulate, or Logix controller)
• FactoryTalk Administration Console
• Microsoft SQL Server 2016 w/SQL Server Management Studio

Knowledge:

Familiarity with the use of SQL databases, motor commissioning through frequency inverters and PAC controllers, knowledge of network configuration for motor stations. 

Links of interest:

FactoryTalk Transaction Manager Basic Configuration Lab.

Downloads

Please note: You will need to agree to the Terms & Conditions for each download.

Need Help?

If you need help with an application or have feedback from the Innovation Center, please contact us.

Installation Guide

Step 1

Identify the applications used for this implementation: Studio 5000, SQL Server Management Studio, FactoryTalk Transaction Manager, and FactoryTalk Administration Console.

Step 2

In the FactoryTalk Administration Console application, create a shortcut to the motor system controller named "Mach1_Ent".

Step 3

3.1 Enter the Studio 5000 program attached with the motor startup sequence. Go to the Object_Assignments routine. Adjust the variables of the motor commands towards the used PowerFlex VFDs.

3.2. If you wish to create different variables for your VFDs, do so in Controller Tags.

3.3. If you need to change or improve the routine, you can activate or deactivate them with the Jump to Sub Routine (JSR) instruction found in the Servos routine.

Step 4

Access the routines of each station (in this case there are five stations) and assign values to the variables using the MOV command. For example, if you want to change the "PRESET" time of a timer, in our case the S1M1_TimeOn1, or if you want to change the RPM value of the motor, you can also do it with this instruction. In the attached program, there are examples for assigning time intervals and changing speeds.

Step 5

Access FTTM and add the created variables as Data Points in the Checklist. Then click on Save Edits and subsequently Assemble Edits.

Step 6

Access the SQL queries in the MotorStationCommands Excel file and modify the database using the columns as the variables used in Studio5000 to commission the motors. Add as many recipes as desired.

Step 7

Access Programmability: Stored Procedures: dbo.Recipe_sp. Modify the SQL query procedure to get the values of the columns and assign them as data points in FTTM.

Step 8

In step 4 of the FTTM checklist, add the parameters of the revised procedure in the previous step of the SQL database.

Step 9

Separate the input and output parameters of the variables in step 5 of the FTTM configuration. Assign null values to all input variables for motor control. Apply and save all changes and start the FTTM configuration.

Step 10

Enter the Studio5000 program and test all changes by selecting different recipes. To do this, enter the recipe number in the RecipeReq tag in the S01_TransactionManager program. Then toggle the Recipe_On_Off bit. Validate the process operation by checking the recipe values once the current cycle is completed.

Center driven Winder and Unwinder application Sample code for variable diameter spindle based on tension feedback from a load cell, uses Torque Regulator to control web tension of material in center driven.

What is this for?

A winder and unwinder machine are essential in various industries, particularly in the manufacturing and processing of web materials such as paper, film, textiles, rubber, wire, tape, etc.

These machines are used to wind and unwind continuous rolls of material, facilitating efficient production, storage, and transportation.

Winder is designed to wind the web material onto a core or a spool, creating a tightly wound roll.

Unwinder on the other hand, is used to unroll or unwind the material from a roll, feeding it into the downstream processes or applications.

This sample code shows us how to use it in applications with variable diameter spindle based on tension feedback from a load cell, uses Torque Regulator to control web tension of material in center driven.

General Features:

• Center Driven application.
• Torque control for Winder, Unwinder drives.
• Speed Limited Adjustable Torque
• Speed control for the puller drive.
• Speed follows a virtual axis.
• Tension control at line speed.
• Full tension control when accelerate and decelerate.
• Flexible parameters
  • Reference speed of machine.
  • Acceleration time.
  • Deceleration time.
  • Roll Unwind tension control.
  • Roll Wind tension control.
  • Roll length control.
  • Roll diameter control.
• Drive status, Alarms and Faults.

Advantages:

The Winders controlling web tension in a center driven has excellent accuracy of torque control for web material.

• Flexible, Predictive Diagnostics, Integrated Safety.• Automatic Device Configuration.
• Integrated Architecture.
• Speed Limited Adjustable Torque.

Limitations / Disadvantages

• Drive for Unwinder and Winder must have torque control.
• Controller must at least 1769-L19 or above.
• Must adapt the application if use Surface Driven.

Is this useful for me?

In general, systems can be recommended to customers, OEM manufacturers,

Use when: 

• Controlling web tension in a center driven (un)winder.
• Torque Control to control web tension.
• Tension feedback device is a load cell or a dancer.

Do NOT use when:

• Speed Trim Regulator to control web tension is preferable is over Torque control.
• Drive has no torque control feature.
• Surface driven for Winder or Unwinder. Must adapt the application to calculate it.

 

Application areas

Web Material, CPW, Converter, Printer, Metals, Plastics

Benefits of application:

• Center driven winders have the benefit of controlling tension via directly controlling the torque of the wound product.
• Tension taper can be applied as the diameter increases.
• Flexible control and production gain and speed.
• Increased dynamism in production.
• Full tension control when accelerate and decelerate machine.
• Automatic Device Configuration, if have any problem with devices. This feature reduces downtime of process.
• Control length of product by tracking material.
• Control Diameter of product if include sensor diameter.

 

How can I make it work? 

Hardware:

• CompactLogix 1769-L19ER, 5069-L310ER or high
• PowerFlex 753 or PowerFlex 755.
• PowerFlex 525.
• PanelView 800.
• CR30.• Firmware revision 30 or high

Software:

• Logix Design Studio 5000 version 30 or higher.
• Connected Component Workbench, version 21 or higher. 
• Winder_Unwinder.ACD.
• WinderUnwinder.ccwarc.

 

Previous Knowledge 

Basic knowledge of programming and configuration in Logix Design Studio 5000 software:

Basic knowledge of programing and configuration in Connected Component Workbench software:

• PowerFlex 525 configuration.
• PowerFlex 753 and PowerFlex755 configuration.
• PanelView 800 configuration.
• CR30 configuration.
• Ladder language (LD), Function Block Diagram (FBD)

Knowledge about Drive System, Speed, Torque, Position Control.

Downloads

Please note: You will need to agree to the Terms & Conditions for each download.

Need help?

If you need help with an application or have feedback from the Innovation Center, please contact us.

Installation Guide

Step 1

1. Open program Winder_Unwinder.ACD – This file is located on Generalfiles.

Step 2

Assign static IP address and last firmware version for all components of the architecture.

PowerFlex 525

https://literature.rockwellautomation.com/idc/groups/literature/documents/um/520com-um001_-en-e.pdf#page=29
https://rockwellautomation.custhelp.com/app/answers/answer_view/a_id/546043/loc/en_US

PowerFlex 75x

https://literature.rockwellautomation.com/idc/groups/literature/documents/qs/750-qs001_-en-p.pdf#page52

CR30

https://rockwellautomation.custhelp.com/app/answers/answer_view/a_id/702836/loc/en_US
https://literature.rockwellautomation.com/idc/groups/literature/documents/um/440c-um001_-en-p.pdf#page=106

PanelView 800

1.1 Communication Settings, Configure PanelView 800: Go to the main configuration screen.

1.2 Press terminal settings.

1.3 Press Communication.

https://literature.rockwellautomation.com/idc/groups/literature/documents/um/2711r-um001_-en-e.pdf#page=28

Step 3

Download application for controller.

• From the Communications menu, choose Who Active to open the Who Active dialog box.
• From the navigation pane, find the path between your Workstation and the target Logix controller for this project.
• Click Download to open the Download dialog box.

Step 4

Repeat this step, for another PowerFlex 75x drives.

Step 5

Download application for CR30

https://literature.rockwellautomation.com/idc/groups/literature/documents/um/440c-um001_-en-p.pdf#page=115

 After the download is complete, the I/O Not Responding indicator flashes.

A warning icon appears on the CR30 safety relay in the I/O Configuration tree.

The module fault is Code 16#0106 as the configuration in the Logix controller for the safety relay CR30 does not match what is in the physical device.

• Double-click the safety relay profile. 

• Click the Logic Configuration tab. The Project Mismatch dialog box opens. Click Download the current project to the safety relay.
• The Change to Program Mode dialog box appears. Click Yes
• The Download Success dialog box appears. Click Yes.
• Once the download is complete, the I/O connection between the Logix controller and the I/Os is successful.

Step 6

Open and Download for PanelView 800 the HMI application.

• Open program Connect Components Workbench - CCW 
• Open program WinderUnwinder.ccwarc – This file is located on Generalfiles.zip.

• Download the application to the PanelView 800 and execute it.

Step 7

Configure the application according to your respective project.

For all drives, you must configure:

• Motor Speed (rpm).
• Motor Frequency (Hz).
• Roll Diameter (mm).
• Gear ratio

When the PanelView 800 is running you have this screen to configure all these parameters:

MagneMover Lite and Cobot UR5 Digital Twin Implementation Digital Twin creation through Emulate3D with ICT and robotics collaboration.

What is this for?

The Digital Twin interaction between a cobot and a 1-meter MagneMover LITE (MML) system is the foundation for the development of both technologies through Emulate3D. This project can be used to demonstrate MML technologies and robots working together, or as a template for developing digital twin models of these technologies. Using the Studio5000 program, MML vehicles can be commissioned, and a routine can be created.

The implementation of the digital twin model demonstrates the capabilities that enable its use throughout the industry. The model allows for performance tracking of multiple systems on a manufacturing floor. It also provides the opportunity to optimize production processes through digital emulation without the need to shut down production. Additionally, it is possible to ensure higher quality, train operators, and make configuration changes in a secure virtual environment with immersive reach into cyberspace.

General Characteristics

The integration of a MagneMover LITE system and a cobot via a digital twin offers the following features:

• Two-way communication.
• Precise and efficient coordination of tasks.
• Expedited implementation of technology through an efficient and agile programming process.
• Synchronous integration of movements between the movers and cobot.
• Efficient configuration and adjustment of position and time parameters in the motion sequence.

Advantages

• Demonstration of Emulate3D's capability.
• Understanding the underlying logic in the physical movement of the MML system.
• Displaying the physical and digital integration of MML and cobot.
• Interoperability with control systems.
• Real-time performance monitoring of systems.
• Flexible reconfiguration for quick response.
• Adaptability to variations in different processes.
• Energy efficiency of the system.
• Scalability for expansion.
• Safety and quality standards.

Is it useful for me?

Digital Twins are a game-changer for manufacturers looking to optimize their production processes and stay ahead of the competition. By creating a virtual environment to model and analyze their operations, manufacturers can identify inefficiencies and areas for improvement, leading to increased productivity and cost reduction. With Digital Twins, manufacturers can design an efficient layout and allocate equipment accordingly, eliminating the need for hardware testing and saving valuable time and money.

No longer do you have to wait for a machine to be built to test controls and confirm that mechanics and logic are working correctly. This saves valuable time and resources and reduces the costs spent on correcting errors found during the physical implementation stage. By working together, you can visualize an efficient transition for implementing the digital twin in your production lines and understand the benefits it brings.

Once your system is up and running, a digital twin records data on behavioral trends and performance history. This creates a reference for improvements and operational training methods throughout the system's life cycle. With this valuable information at your fingertips, you can optimize your processes, increase efficiency and productivity, and take your manufacturing to the next level.

How can I make it work?

Hardware:

• Cobot UR5
• MML 1m Motor
• 2 MML Movers
• MML Node Controller with Power Supply
• Compact GuardLogix 5380
• Stratix Switch
• 24V Power Supply

Software:

• Studio 5000 (V35)
• Emulate3D

Expertise:

• Knowledge of Motion, ICT, and Emulate3D

Downloads

Please note: You will need to agree to the Terms & Conditions for each download.

Need Help?

If you need help with an application or have feedback from the Innovation Center, please contact us.

Installation Guide

Step 1:

Identify the applications used for implementation: Studio 5000 and Emulate3D.

Step 2

Change the IP address of the components used to place them in the same network mask:

• 2.1 MML system node controller 
• 2.2 Computer 
• 2.3 Cobot 
• 2.4 PLC Controller
  

Paso 3:

Replace the physical devices in the Studio 5000 configuration and configure the assigned IP addresses while keeping the same device names.

Step 4

Replace the controller in the Studio 5000 configuration for program download.

Step 5

Validate the connection of each part of the system through pings in Command Prompt. After that, change the IP address of the components in Emulate3D.

5.1 Click on Global Settings of the MML controller and change the PLC's IP address.

5.2 Click on Node Settings of the MML controller and change the node controller's IP address.

5.3 Change the HLC address in the NCHost tab to the node controller's IP address.

Step 6

Click on IO Browser and import the tag configuration from the shared Excel file.

Step 7

Open the attached Studio 5000 project and locate the "R02_StartupSequence" program with the path: ms0016p10: P01_MM_Management. 

Change the IP address of the node controller in line 2.

Step 8

Download the Studio 5000 project to the PLC controller and select Run Mode.

Step 9

In the same program, apply a Toggle Bit to Cmd_Startup to initialize the MML motor and wait for the nStartSeq value to be 999 to validate the initialization process.

Step 10

Enter the "R05_MotionPositionMove Program" program in the same path and apply a Toggle Bit to "AutoCycle." This will start the MML system's motion program. In this program, the vehicular motion sequence can be edited.

Step 11

11.1 Open the Emulate3D model and verify that the connection type in the NC Host tab is Status. 

11.2 Select Connect under the HLC Address section. 

11.3 Select the MML controller and in the NC Host tab, select Connect Movers and Connect Paths. 

11.4 Change the Mover Polling Rate for smoother movements by decreasing its value.

Step 12

12.1 On the Home Tab, select the play icon. 

12.2 Verify that the components move correctly. If the cobot is in a different static position, repeat Step 7 and check the PLC connection in IO Browser to the digital model.

Energy saving monitoring system with FactoryTalk Optix FactoryTalk Optix and variable speed drives for process control and efficiency in the soft drink industry​.

What is this for?

The "Energy Saving Monitoring System with FactoryTalk Optix" developed in FactoryTalk Optix aims to provide a clear and understandable visualization of energy efficiencies by allowing operators to monitor tank levels, flow rates in pipes, and other critical parameters in the extraction and pumping process in a beverage industry; thus, facilitating faster decision-making and problem resolution.

Additionally, integration with FactoryTalk Optix enables effective alarm management. Operators can configure alerts for critical events, such as tank level deviations or equipment failures, ensuring timely intervention and minimizing downtime. This way, we can ensure:

• Reducing losses
• Increasing asset utilization
• Maintaining optimal quality levels
• Real-time data collection
• Improving the use of energy resources (WAGES: water, air, gas, electricity, and steam)

Characteristics

“Energy Saving Monitoring System with FactoryTalk Optix" offers the following features:

• Connectivity between information stored in the controllers for processes
• Remote activation and control of motors
• Collection and analysis of data, providing information on process performance and efficiency
• Efficient alarm management

Advantages

• Enhanced decision-making: by visually presenting real-time data and information through FactoryTalk Optix, the demonstration enables users to make informed decisions regarding process optimization, resource allocation, and equipment maintenance.
• Cost-saving visualization: the “savings” screen, powered by the VFD PowerFlex 520 series, demonstrates potential cost savings associated with the implementation of these technologies. Users can see tangible evidence of how investing in automation can generate financial benefits over time.
• Safety and reliability: the “Alarms” screen highlights the importance of proactive monitoring for safety and reliability in the extraction process. Users can appreciate the value of early detection and response to potential issues, minimizing downtime and ensuring consistent product quality.

Is it useful for me?

The growing demand to achieve "net zero” carbon emissions require technologies that allow us to monitor the energy consumption of motors in plants and; if it is an application where torque is variable, as it is the case with pumps, take small actions that allow consume less water and energy. Thus, through the PowerFlex 520 family, manufacturers will be able to improve the performance and overall efficiency of the equipment (OEE).

Customer demand is versatile and presents different scenarios in production lines. Manufacturers will have to implement flexible and reconfigurable automation to address energy consumption challenges. Through this project, a Studio 5000 program simulates the water demand required by the industry, and Optix allows users to become aware of the savings that the drive provides.

How can I make it work?

Hardware:

• PowerFlex 525

Software:

• Studio 5000 (v33-35)
• FactoryTalk Optix (v1.2.0.272)
• CompactLogix 5370

Knowledge required:

Familiarity with modifying parameters of frequency drives of the 520 family A-B and knowledge of the CompactLogix 5370 family.

Downloads

Please note: You will need to agree to the Terms & Conditions for each download.

Need help?

If you need help with an application or have feedback from the Innovation Center, please contact us.

Installation Guide

Step 1:

Familiarization with the Program.

Note that in the left panel "Controller Organizer," there are 4 routines. In BATCH_CONTROLS, can be found the control of system power on/off and motors power on/off. In the "FILLING ROUTINE", the filling process of a tank is simulated, while in the "EXTRACTING ROUTINE," the tank extraction is simulated. The "FLOW_METERS" routine simulates how the water flow increases as more time is spent pumping.

Step 2

Verify that the SoftDrinkProduction program has been downloaded into the controller and is already online.

Step 3:

Familiarize yourself with the PowerFlex 525, that is, which parameter it starts, stops, and which one changes the speed. Note that the PowerFlex is active and running.

Step 4

Open the Factory Talk Optix program.

Step 5

Verify that the controller is already on the correct BackPlane on FactoryTalk Optix.

Step 6

Run the program from the main toolbar located at the top of the interface.

Step 7

7.1 Once the program is running, the main screen will be displayed where you can observe:

• The tank level.
• If there is a flow difference (you can simulate a flow difference by pressing the "Resolved Difference" button).
• The buttons that start and stop the extraction process.
• And the alarms that notify if there is a flow difference in the pumping process compared to the suction process (at the top of the "Extraction" screen).

The navigation bar is located at the bottom.

Extraction Screen: Allows monitoring the extraction process from a well to notify the operator if a pipe leak occurs.

7.2. Process Control Screen: Here, the extraction process from a tank can be visualized.

At the beginning, a warning screen will appear informing us that the production for the beverage industry in this example ranges from 200 bottles per minute (BPM) to 480 BPM.

7.3. On this screen, on the left, you can reset the parameters of the "Extraction" and "Process Control" screens (parameters such as tank level, pumping and extraction flows, the number of bottles entered, etc.). In the textbox on the right, you can enter the number of bottles required for production and observe how the revolutions per minute (RPMs) change on the motor's faceplate.

• To access the faceplate of the motor on the right, click on the motor.
• To start or stop the motor, simply click on START and STOP respectively.
• If you want to close the faceplate, click on the X in the bottom left corner.
• It is worth noting that if you do not enter a number of bottles per minute [BPM], i.e., 0 or less than 200 BPM, you will see that the extraction process is carried out in "active saving" mode (automatic), meaning the motor speed is self-negotiated between the pumping flow and what is extracted to satisfy a tank level greater than 50%, i.e., to prevent the pump from running out of water.
• If you enter a BPM number, the motor speed will vary; and in the process simulation, developed in Studio 5000, it was done in such a way that if you enter a number higher than 350 BPM, the pump will extract more liters than the liters that are being filled. However, if the tank level drops below 20%, the motor will automatically shut off.
  

7.4. Alarm Screen: This screen allows monitoring all system alarms, as well as important trends such as tank level, pump speed, and pumping flow in gallons per minute [GPM].

7.5. Data Screen: Allows recording tank level data, as well as detecting leaks in the water extraction process from the well into the tank.

7.6. Savings Screen: In this screen, you can observe how by varying the motor intensity, based on the affinity laws of centrifugal pumps, greater energy savings are achieved compared to controlling the flow with a throttling valve.

AC Motor AOI Simulator for E300 An AOI to simulate the motor with a E300 to use it in applications where they have to see their behavior and show the visualization applications with data.

What is this for?

An AOI to simulate the motor with a E300 to use it in applications where they have to see their behavior and show the visualization applications with data.

Is this useful for me?

Better simulate my operation and motivate the HMI application in a more realistic way.

How can I make it work?

Using Studio 5000 library import tools (Devices, UDT, AOI).

Downloads

Please note: You will need to agree to the Terms & Conditions for each download.

Need help?

If you need help with an application or have feedback from the Innovation Center, please contact us.

Installation Guide

Step 1

Create a Studio 5000 Logix Controller File

Step 2

Add Etherent Card In the ControlLogix Project

Step 3

Import E300 in the Ethernet Channel created in Step 2

Step 4

Import UDT for E300

Step 5

Import AOI for E300

Step 6

Use the AOI in your program

Step 7

Download the program to the controller

Step 8

Test the program

RMCT - Remote monitoring center with ThinManager The Remote Monitoring Center application with ThinManager allows you to monitor OT applications remotely from a centralized monitoring center.

What is this for?

The Remote Monitoring Center application with ThinManager allows you to monitor OT applications remotely from a centralized monitoring center in a secure environment, managing devices and deploying content (applications, Web content, IP cameras, VNC Server, HMI, etc.) by devices, users/roles, locations, and events. 

Is this helpful?

This version is a basis to accelerate the development of remote monitoring, allowing to improve productivity, security and visualization of information from anywhere in the plant. You have the possibility to display content from different manufacturers on terminals such as Desktops, Laptops, Tablets, mobile devices and thin clients.

This first version is focused on deploying OT content that can be viewed in IT, following good information security practices.

Success stories:

• Remote operation and monitoring of cement plant (Supervision and operation of cement plant 200 kilometers away due to collapse events on the road to the plant).
• Remote support of the cement plant, reducing the cost of transfer and stopped machinery. 

Functionality includes:

• Monitoring of critical variables locally or remotely, deploying existing and future software tools, using ThinManager terminals (WinTMC, aTMC or iTMC) to make real-time decisions and improve productivity.
• Possibility to display 4 contents (applications) at the same time on a Thin client (ASEM 6300) or an ASEM 6300 terminal via WinTMC.
• Provide support from anywhere in the plant.
• Mitigation of the risks present in a connected industrial environment.
• Deploy OT-to-IT content securely.
• Option to deploy preconfigured content such as Factorytalk View SE, FactoryTalk Optix, and Studio 5000.

 

How can I make it work?

Download the "RMCT_backup and VTC1_TEST" files and restore the RMCT_backup file to ThinManager Server and configure the applications you want to deploy to the terminals. To begin with, use the application VTC1_TEST as a Virtual ThinClient to test the content you want to deploy. 

Follow the reference architecture for secure connectivity between OT and IT and keep in mind the ports to be used, which will depend on the functionalities that need to be enabled.   

Ports with º are  optional and are not required for core functionality, and ports with ͨ  are configurable in the solution.

Port	Protocol	Description
UDP 67	DHCP	Used by the PXE server (if using PXE initialization hardware).
UDP 69	TFTP	It is used to run TFTP from firmware and modules to thin clients that support ThinManager.
TCP 443º	HTTPS	It is used to establish HTTPS SSL tunnels to the RD gateway.
TCP 1494º	ICA	Used by the ICA protocol (if using Citrix ICA instead of RDP).
UDP 1758 ͨ	TFTP Multicast	Used if ThinManager enables multicasting.
TCP 2031	Property	It is used to pass configuration from the ThinManager server to the terminal and is used for automatic synchronization between ThinManager servers.
TCP 3268	LDAP	It is used for domain authentication using the Lightweight Directory Access Protocol.
TCP 3389 ͨ	RDP	Used by the RDP protocol. The thin client initiates the connection to the RD server
UDP 3391º	Datagram	Allows the transport to create a connection to the RD gateway (only required if RDP over UDP is enabled; otherwise, it defaults back to TCP 443).
UDP 4011	DHCP	Used by the ThinManager PXE Service when a standard DHCP server is installed on the same computer as ThinManager. This port is used when initializing ThinManager-compatible PXE initialization thin clients using the UEFI (Unified Extensible Firmware Interface) BIOS. (ThinManager 11)
UDP 4900	TFTP	Used to run firmware TFTP to ThinManager ready thin clients
TCP 5900 ͨ	Property, VNC	Propriety Shadow Protocol, VNC initialized by the thin client to the VNC server.

System requirements for the application.

Item	Requirement	Version
1	ThinManager/Primary RDS Server – Windows Server	2019
2	ThinManager Server	13.2
3	FactoryTalk View Site Edition	14
4	Studio 5000	36
5	FactoryTalk Optix	1.3

Required Knowledge

Knowledge in ThinManager software, networking and configuration of solutions with RDS.

Downloads

Please note: You will need to agree to the Terms & Conditions for each download.

Need help?

If you need help with an application or have feedback from the Innovation Center, please contact us.

Installation Guide

Step 1

Refer to the reference architecture for secure connectivity between OT and IT and Refer to the ThinManager-v132-UserGuide_TM-UM001I-EN-P.pdf Manual.

Step 2

Download the "RMCT_backup and VTC1_TEST" files and restore the RMCT_backup file to ThinManager Server and configure the applications you want to deploy to the terminals. You can use the VTC1_TEST application as a Virtual ThinClient to test the content you want to deploy.

Step 3

Configure PEX Server and VMware Player 17 and run VTC1_TEST.

Step 4

Boiler Efficiency Library A library to measure the efficiency of a boiler in real time using existing instrumentation in an Allen Bradley control system.

What is this for?

The objective of creating a standard Boiler Efficiency library is to gather knowledge from experience and applications utilizing the best approaches to provide features that will be selected based on the detailed requirements of the project scope.  Control, process design, and the configuration approach will utilize a PlantPAx based control system that will be used with standard Boiler Efficiency applications.  It is also desired for the controller to be flexible and allow integration of custom requirements and expansion as future technological developments are realized through industries.

The vision is to allow the user to select specific requirements and procedures, including and configuration capabilities, to meet the needs of the required mixing application. 

Is this useful for me?

Currently, there is no way to calculate Boiler Efficiency in a standardized way. A standard library with flexibility allows for the same basic building blocks to be utilized.

By standardizing the Boiler Efficiency library, it may be used for multiple industries (F&B, Chem, Life Science, Home & Personal Care) across the globe.  This standard will also be able to assist in cost benefit to the organization by lowering the engineer labor to create basic functionality.

Capturing of industry specific knowledge. Future go-to-market features for sales of Plant Pax application. Financial and labor savings are unknown currently.  However, reduced development time is expected due to the ability of tool to create basic functionality.

How can I make it work?

User will enter Boiler system inputs based on standard instrumentation typically used in Boilers.

This first version allows you to have real time efficiency in a Rockwell Automation control system, just import and configure the AOI and the Display, add it in your application and that's it.

System requirements of app:

Item	Requirement	Version
1	Tool will be built using Steam properties libraries of PlantPAx	4.x – 5.x
2	FactoryTalk View SE/ME	12.00
3	Studio 5000	21 and above

Process variables will need to be able to be configured including input signal, scaling, and units.

Item	Instrumentation
Temperature (Steam and Water)	Type: Resistance - RTD with common ranges configurable (PT100, PT1000, etc.) with configurable units: degK, degC, degF mV - Thermocouple with all types for temperature ranges (Type J, Type K, etc.) with configurable and units: degK, degC, degF Analog - analog input signal, with scalable engineering units, with configurable units: degK, degC, degF Digital - networked device, ethernet I/P, profibus, ASi, etc. with configurable units: degK, degC, degFTool will be built using Steam properties libraries of PlantPAx
Flow (Steam, Water, Fuel)	Type: Analog - analog input signal, with scalable engineering units, with configurable units: gpm, gpm, lpm, lph, m3h, kgh, etc. Digital - networked device, ethernet I/P, profibus, ASi, etc. with configurable units: gpm, gpm, lpm, lph, m3h, kgh, etc.
Pressure (Steam, Water)	Type: Analog - analog input signal, with scalable engineering units, with configurable units PSI, MPa, etc. Digital - networked device, Ethernet I/P, Profibus, ASi, etc with configurable units: PSI, MPa, etc.

Knowledge required

Basic knowledge of programming and configuration in Studio 5000 Logix Designer® software and FactoryTalk® View Site Edition Studio.

Downloads

Please note: You will need to agree to the Terms & Conditions for each download.

Need Help?

If you need help with an application or have feedback from the Innovation Center, please contact us.

Installation Guide 

Step 1:

1. Import file L5X for routine according with the programing language to use:

• Calc_Boiler_Efficiency_FB_Routine_FBD. L5X for Function Block.
• Calc_Boiler_Efficiency_LD_Routine_RLL.L5X for Ladder.

Note: Please read the instructions in the program comments

Step 2

Import the Global Object in FTView SE Application.

• Boiler efficiency.ggfx.

Flying Shear Application Their unique design allows product to be cut on the fly as it moves past the shear. Productivity is optimal because the belt never stops during the cut.

What is this for?

Flying shears are used in a variety of industries like Glass, Plastic & Rubber, fiber, etc to cut product to specified lengths. Their unique design allows product to be cut on the fly as it moves past the shear Productivity is optimal because the belt never stops during the cut.

Is this useful for me?

The Master Axis (conveyor) may be servo driven, to synchronize speed and position with the slave Axis, an encoder is mounted on one of the Master axis’ (conveyor) drive rolls. This encoder becomes a feedback only axis in the Motion controller.

The Slave Axis is typically servo driven. Its speed and position are synchronized with the Master Axis (conveyor) during the cut.

The Shear Axis (perpendicular with conveyor) may be servo driven. Less costly system may use open loop pneumatic or hydraulic cylinders to traverse the Shear across the cut zone. In these open loop applications, programmers use on delay timers to allow enough time for the cut.

The entire slave/shear assembly is typically raised during the retract move to prevent the knife from cutting the belt. Accuracy for raising and lowering the assembly isn’t critical; therefore servos aren’t used for this operation.

How can I make it work?

• Studio 5000 (V30 – V35) 
• Kinetix Over Ethernet 
• Knowledge of Motion Control.

Downloads

Please note: You will need to agree to the Terms & Conditions for each download.

Need help?

If you need help with an application or have feedback from the Innovation Center, please contact us.

Installation Guide

Step 1

Open the Studio 5000 project that you downloaded from the Downloads section of this page.

Step 2

Replace the Physical Drives in the configuration and keep the actual Names.

Step 3

Rung (2) in the Web Control Routine is used to detect the product registration mark. Its .PC bit advanced the State Machine after the event is captured.

Step 4

Rung (3) isn’t required. It’s included to count registration events for diagnostics.

Step 5

Rung (4) isn’t used in this lab. It can be employed on an actual machine to compensate for mechanical inaccuracies or for product slippage (i.e. registration mark doesn’t occur at the axis rollover point).

Step 6

Rung (5) starts the flying shear. It consists of (2) MAPC instructions. Let’s examine each MAPC in detail.

Step 7

The first MAPC executes the Acceleration Cam Profile. It executes once, every time a product registration occurs.

Step 8

Click on the Cam Profile configure button.

Step 9

Update the Cam Profile according the values of your application. Click Apply and OK.

Step 10

Download and test the application.

Custom Numeric Input for PanelView 5000 This is an alternative to use a different size and typography vs the standard Numeric Input Keypad for PanelView 5000.

What is this for?

This is an alternative to use a different size and typography vs the standard Numeric Input Keypad for PanelView 5000.

Is this useful for me?

If for some reason you need to comply with a certain font or if you want to customize the size of the numeric input keyboard for PanelView 5000, this application is an excellent alternative.

How can I make it work?

• Studio 5000
• Logix Designer
• View Designer
• PanelView 5000

Downloads

Please note: You will need to agree to the Terms & Conditions for each download.

Need help?

If you need help with an application or have feedback from the Innovation Center, please contact us.

Installation Guide

Follow the next steps and modify the HMI/Controller files as needed.

Step 1:

Import the desired number images.

Step 2

Create an Add On Graphic using the imported images.

Step 3:

On the Add On Graphic you need to assign visible animation to each number picture. All number pictures from “0” to “9” should be overlapping each other. Use the number of digits as you need.

Step 4

Open the Add On Instruction on Logix Designer. In this particular application we are working with three digit numbers.

Step 5

The rest of the code on main routine is to manage the custom keyboard.

Step 6

To run the application, check that the references to the controller and HMI are correct.

Step 7

The app should look like this.

Smartbelt System Smartbelt is a conveyor system that uses smart belts. Its objective is to organize a queue of products that arrive haphazardly in an orderly position.

What is this for?

Smartbelt is a conveyor system using intelligent belts. It seeks to organize a queue of products coming in a disordered manner into an orderly position. The system is commonly used to control the positioning of flight conveyors. Correction can be made by one or more conveyors, depending on the dynamics required.

The application uses AOI resources that perform the correction based on the size of the conveyor, registration sensors to check the current position of the Servodrive movement, the size of the product on the conveyor, and the correction distance to the target. In this way, each conveyor performs independent movement control.

The Smartbelt feature is recommended for OEM manufacturers who use movement mechanisms to deliver loads using flighted conveyors with product separation:

• Boxing machines
• Packaging machines
• Special machines

General Features

Flexible system that can change between different product sizes using just a few parameters:

• Add-on instruction for calculating position correction error.
• Follower x master working regime for target position from 0 to 360 degrees.
• Use of the Virtual Axis as the main axis for the follower axes.
• Use of the Machine Builder Library as a reference for motion control via Axis Handler.

Limitations/Disadvantages

• For positioning on perpendicular belts, the correction of each belt must not be greater than the gap between products, to avoid product collisions.
• High speeds depend on the mechanics available for correct movement.
• Tight product delivery window.

How can I make it work?

The architecture involves the use of Compactlogix or Contrologix hardware with CIP Motion and CIP Sync capabilities, as well as the use of ServoDrives from the Kinetix 5300, 5500 or 5700 families. In this program, the K5500 is being used.

And that's the software you need:

• Logix Design Studio 5000.
• Firmware Revision 33 or higher.
• Program SmartBelt.ACD
• User-defined function blocks:
  • AOI_CalcCorrectionDistance
• FactoryTalk View Studio V13.0
• Program SmartBelt.MER

Knowledge required:

We recommend having an intermediate understanding of programming ladder logic in Logix Design Studio 5000 software and configuring the Motion Control system. As well as basic knowledge of the FactoryTalk View ME application in order to set up the HMI application to restore and run it.

Downloads

Please note: You will need to agree to the Terms & Conditions for each download.

Need help?

If you need help with an application or have feedback from the Innovation Center, please, contact us.

Installation Guide

Step 1

1. Open the SmartBelt.ACD program - The file is located in the Generalfiles.zip folder in the Download area.
2. Download in a virtual environment (Logix Echo - optional) or physically on a Logix controller.
3. Restore the HMI file for use in simulation mode or physically as a runtime.
4. Initially, you can use the program with Virtual Axis, enabling this option for existing Kinetix Drives via the HMI faceplate.

Step 2

Check the physical configurations of the axes, changing them as required by the project:

1. EM00 - Virtual Master Axis
2. EM01PHY - First conveyor belt axis
3. EM02PHY - Second conveyor belt Axis
4. EM03PHY - Third conveyor belt Axis

Step 3

In the EM01 to EM03 programs, in the CM08_Correction routines, adjust the respective measurements in the AOI as required by the project:

1. Inp_Unwind - One-turn cycle in degrees of the EM00 Master - Default 360.
2. Inp_Unwind_mm - Belt length in millimeters.
3. Inp_ProductSize_mm - Product length in millimeters to be corrected on the belt.
4. Inp_MaxPositiveCorrection_mm - Maximum positive correction value for each belt.
5. Inp_MaxNegativeCorrection_mm - Maximum negative correction value for each belt.

Step 4

1. Start the Factory Talk View application to begin the motion tests. You can change the speed of products per minute. Always respect the frequency at which the products are released, which must be lower than the frequency of packages per minute requested. This avoids overloading the conveyor belt and congesting products for correction.
2. The system should be able to hold a maximum of one product per conveyor belt, thus avoiding correction errors. Check the project presentation in the support material.
3. The position set point is the desired flight conveyor target in degrees (Example 115 degrees).
4. To use Emulate 3D to simulate the application, Class 1 MSG must be enabled for the Point IO to operate as a remote and Emulate 3D test sensors.

Multibelt Transport System Designed to transport industry specially food and beverage, multibelt system is a storage/transport system used in many aplications where it requires movement of multiple products simultaneously from one point to another

What is this for?

The Multibelt system is a storage/transport system and consists of two or more independently driven belts. Each belt contains two or more trains (collators) that are built to carry a tray or built for a variable number of pockets. Trains vary in mechanical design. In the case of using a tray, the tray is placed inside the train in the loading position by any loading module. Products are fed from an infeed conveyor to the train at the filling position. If the feed train is full, it moves to the unloading position. If this is done, the train moves in positive rotation (recovery motion) behind the next train. This sequence guarantees a continuous flow of product in the filling area, while the other trains can be loaded with a tray and unloaded passing through the unloading position. The Multibelt equipment module can be configured with a large number of parameters, which are described in other chapters. A standardized interface for the load, supply and output module allows flexible adaptation. 

General Features

The  Multibelt System module concludes the following features:

• Multibelt storage sequence procedure for 2 axes (production mode)

• Automatic homing / reference move procedure

• Automatic synchronize move procedure

• Variable speed override adaption while production

• Jog function for each axis separately (service mode)

• Handling of multiple trains per belt

• Interface data handling to any other loading, infeed and outfeed module device

• Wide range of parameters to configure the module

Advantages:

The Mutibelt system has the advantage of being flexible and with the possibility of adaptation according to the application needs - number of collators (train).

From a software point of view, the system is relatively easy to implement using specific AddOn and Data DataTypes: Multibelt_AOI and Q_MAM_P (developed for this application, in order to reduce configuration, commissioning and startup time.

Limitations/Disadvantages

• Speed – Depends on the Drag Mechanism

• Number of mechanical elements - gears, belts

• Fixed space between cleats, if need change, mechanical change neededc

Is this useful for me?

In general, multibelt systems can be recommended to OEM manufacturers such as:

• Conveyor belt manufacturers
• Special machine manufacturers
• Palletizers manufacturers
• Packing machines manufacturers

Application areas:

Food, Manufacturing, Beverage

Benefits of applications with multibelt systems:

• Production gain and speed

• Increased dynamism in production

• 60% reduction in commissioning and startup time

• Easy of integration with devices: Robot, transfer devices

 

How can I make it work?

Requirements: Products, Tools, Previous Knowledge.

Hardware

• Kinetix 5300, Kinetix 5500, Kinetix 5700 with CIP Motion and CIP Sync
• PowerFlex 755 with Position control/ CIP Motion
• CompactLogix L18ERM or high
• Firmware revision 30 or high

Software

• Logix Design Studio 5000
• Program Multibelt_2Collators.ACD
• AddOn instructions: Multibelt_AOI, Q_MAP_P

Knowledge

Intermediate knowledge of programming and configuration in Logix Design Studio 5000 software:

• Ladder language (LD)
• Motion configuration.

Downloads

Please note: You will need to agree to the Terms & Conditions for each download.

Need Help?

If you need help with an application or have feedback from the Innovation Center, please contact us.

Installation Guide 

Additional information is in the "Multibelt.pdf" document in Downloads >> GeneralFiles.zip

Step 1:

Instructions:

1. Open program Multibelt_2Collators.ACD – This file is located inside the Generalfiles.zip package in the Downloads section.
2. Initially you can use this program with Virtual Axis for tests. After that you can couple the virtual axis with physical axis using Motion Axis Gear (MAG).

Step 2

Motion Configuration:

1. Configure the Axes Parameters Virtual (Collator_X_AV) and Physical (Collator_X_AP) . For Physical: Model of operation: Position Loop.
2. Configure the virtual axes.
3. Couple virtual axis with real – This function is already in the program example (Multibelt_2Collators.ACD) .

Step 3:

Configure Add-ons Data parameters:

1. MainTask > MainProgram > _01_Multibelt, Configure Add-on MultiBelt_AOI.

• Axis
• Axis Preceding
• Wagon Size
• Number of Wagons
• Loading Station Position
• Waiting Station Position
• Unloading Station Positions

2. MotionEventTask > Main_Motion_Rtn, configure Add-ON Q_MAM_P parameters (Setup and configure Train Data).

• Axis
• Axis Preceding
• Command Position
• Velocity
• Acceleration
• Deceleration 
• Acceleration Jerk 
• Decceleration Jerk

Step 4:

Download and commissioning

1. You can use the Emulator (Factory Talk Logix Echo)
2. For simulation, use MainTask > MainProgram > _02_Simulation program

MicroLink Remote Control, MicroLink MQTT Remote Control Streamline IoT in industrial environments. Unlock MQTT capabilities effortlessly through Micro800 controllers.

MicroLink MQTT is a transformative suite of User-Defined Function Blocks (UDFBs) for Micro800 controllers, enabling seamless MQTT communication with any MQTT broker. This package includes three function blocks: one for establishing connections, one for subscribing to specific topics, and one for publishing data. It offers high customizability with settings for unique MQTT IDs, broker/server IP addresses, usernames, passwords, and your chosen Quality of Service (QoS).

Target to use with PowerFlex 523 and 525 component drives from Rockwell Automation.

This code can be used with the following equipment:

• PowerFlex 523
• PowerFlex 525
• Micro850
• Micro870
• PanelView 800d

 

What is this for?

MicroLink MQTT is a UDFBs suite designed for seamless integration with Micro800 controllers from Rockwell Automation. It's meant to enhance the capabilities of these controllers by enabling MQTT communication with any MQTT broker.

This solution is especially useful for remote control use cases and in the industrial field where data exchange and communication efficiency are critical. MicroLink MQTT provides three function blocks for establishing connections, subscribing to specific topics, and publishing data.

With MicroLink MQTT, users can easily establish a connection to an MQTT broker, subscribe to the data they need, and publish data back to the broker. It offers high customization options for MQTT IDs, broker/server IP addresses, usernames, passwords, and your chosen Quality of Service (QoS), ensuring efficient and secure data communication.

Therefore, whether you're an industrial operator looking to optimize data communication or a developer who needs to integrate efficient data exchange in your applications, MicroLink MQTT can be the perfect solution.

General Features

Our package provides three core User-Defined Function Blocks:

• RA_MQTT_CONNECT_v2: Step into the future with our connection function block. It lets your Micro800 controller establish a connection with an MQTT broker, setting the stage for robust data interchange.
• RA_MQTT_SUBSCRIBE_v2: Leverage our subscription function block to stay connected with the data you need. Tailor your subscriptions to specific topics from the MQTT broker and always keep your operations data-rich and up-to-date.
• RA_MQTT_PUBLISH_v2: Take control with our publish function block. Transmit data with precision by publishing topics to the MQTT broker, making your data-driven operations a benchmark for others to follow.

Each function block is highly customizable, allowing you to specify unique MQTT IDs, broker/server IP addresses, usernames, passwords, and your preferred Quality of Service (QoS). With RA_MQTT v2, every aspect of your MQTT communications is in your hands.

Limitations / Disadvantages

• Limited to Micro820, Micro850 and Micro870
• Third-party MQTT broker dependent

 

How can I make it work?

The architecture implies using Micro820, Micro850, Micro870 hardware. And this is the required software:

• Connected Component Workbench, version 21 or higher.
• The firmware of the equipment used must be compatible with the version of Connected Component Workbench.
• User-defined Function Blocks:
  • RA_MQTT_CONNECT_v2
  • RA_MQTT_SUBSCRIBE_v2
  • RA_MQTT_PUBLISH_v2

Knowledge

A foundational understanding of ladder programming and system configuration using the Connected Components Workbench software is highly recommended. Additionally, familiarity with MQTT protocols would be beneficial.

Downloads

Please note: You will need to agree to the Terms & Conditions for each download.

Need Help?

If you need help with an application or have feedback from the Innovation Center, please contact us.

Installation Guide 

Step 1:

Establishing Connection Settings to Connect to or Disconnect from a MQTT Broker

An MQTT broker essentially serves as a server to manage MQTT messages. To connect to an MQTT broker, we must input the broker's IP address and port number into the RA_MQTT_CONNECT_v2 UDFB. The broker could be housed on your computer (in which case you would need to install and operate an MQTT broker compatible with your OS), or it could be a remote server, such as the ones previously mentioned.

1.1 Assign the IP address and port number of the MQTT broker to your RA_MQTT_CONNECT_v2 UDFB

This example is for connecting to the test.mosquitto.org broker in the cloud.  An alternative to entering the IP address directly is to enable Domain Name Service (set ‘EnableDNS’ TRUE) after entering in the MQTT broker URL into ‘MQTTBrokerName’ and the local DNS server IP address into ‘DNSIPaddr’ in rung 2.

1.2 Enter a unique ‘clientName’, as well as a ‘userID’ and ‘userPass’ if your MQTT broker requires it. (Many public MQTT brokers do not require a username and password, so these fields are optional and can be left blank if not required.)

1.3 Set ‘EnableMQTT’ to TRUE to connect to the MQTT broker.

Note:

There are a few things to keep in mind to ensure a successful connection. The MQTTsocketSts should eventually display a 9. If it shows a 7 and then reverts back to 0, it could imply that your broker is either not running or doesn't exist.

The data in resultData_Out is helpful for diagnostic troubleshooting. Typically, when you send a connect command to the server, the server responds with an acknowledgement. The acknowledgement is indicated by the 1st byte, which in this instance, is '32'.

Another frequent response you'll receive is a ping acknowledgement, denoted by '208' in the 1st byte of the returned data. The ping command is sent to the remote broker at 50-second intervals. This interval is hardcoded in the UDFB but can be modified if needed.

If the return data is something other than 32 or 208 upon connection, it could suggest that the client has subscribed to a topic that was broadcasted while it was offline. The message is retained and sent to the client when it comes back online. If you encounter this, process the message and then reinitialize the connection.

1.4 If you want to configure for LWT, you need to access these parameters in the UDFB:

322| willTopic := willTopic_In;
323| willData := willData_In;

‘willTopic_In’ is where you enter the Last Will topic for the connection.

‘willData_In’ is where you enter the testament for the connection.

The MQTT broker will publish the testament to all clients that subscribe to the Last Will topic when the client is disconnected abruptly.

1.5 If you want to disconnect gracefully from the server (without triggering LWT), set ‘disconnect_Cmd’ to TRUE.

This is a rising edge triggered bit, so you can reset it immediately.

Step 2

Subscribing to or Unsubscribing from a Topic

The MQTT protocol exchanges data through subscribe and publish methods. Clients communicate directly only with the MQTT broker. Clients subscribing to a topic will receive a message from the broker when another client publishes to that topic. Clients can be of any form as long as they have a running MQTT client application. For example, it could be software on a PC, a connector or API for the software, an app on a phone, or application code on a PLC.

2.1. Enter the name of the topic (‘topicName_input’) to subscribe to or unsubscribe from.

2.2. Set the quality of service (‘subQoS’) for the subscription. By default, use ‘0’ as it consumes the least bandwidth.

2.3. Set ‘subscribe’ or ‘unsubscribe’ to TRUE to subscribe to or unsubscribe from the topic.

2.4. These bits detect for rising edge, so you can reset them immediately.

2.5 Notice that the resultData_Out from RA_MQTT_CONNECT_v2 is also copied to respondData_In.

Note:

It is recommended to use only 1 instance of each UDFB.

Step 3:

Publishing a Topic

When a topic with data is published to an MQTT broker, the broker then forwards this topic data to all the clients subscribed to it. The client that publishes the message does not know if any remote nodes receive the topic, as that responsibility lies with the broker, depending on the QoS level. Topics can be published or subscribed to at any QoS level, but they will only be delivered at the lowest QoS level.

3.1. Enter the topic to publish into ‘pubTopic_In’.

3.2. Enter the data for the topic into ‘pubData_In’.

3.3. Set the quality of service into ‘pubQoS’. By default, use ‘0’ as it consumes the least bandwidth.

3.4. Set ‘publish’ to TRUE to publish the topic with its data. It will automatically will be set back to FALSE when ‘publishDN’ becomes TRUE.

3.5. Notice that the resultData_Out from RA_MQTT_CONNECT_v2 is also copied to respondData_In.

Step 4

Getting Messages from Subscribe Topics

The MQTT broker handles all topic subscriptions. It sends the data of any published topic to the clients that are subscribed to it. When a topic is received by the Micro800 MQTT client, it populates the 'TopicName' and 'TopicData' array variables in the RA_MQTT_CONNECT_v2 UDFB. The data is stored in a First In/First Out order, so it is crucial to process the data before it gets overwritten.

Step 5

Subscribing to an Array of Topics

MQTT_Subscriptions is an optional Structured Text program that works in conjunction with the MQTT_Client program. It enables you to subscribe to a 'Subscriptions' array of preconfigured topics. Adjust the array dimension of the global variable 'Subscriptions' to the desired size and modify the initial value of the local variable 'maxSubscriptions' to match the array size (default=10). 'Subscriptions' is a User-Defined Data Type (UDT) array that comprises the MQTT topic 'Name', the latest topic 'Data', a timestamp based on the RTC value when the latest topic 'Data' was received, and a 'Subscribed' indicator. Enter the desired topic names to subscribe to as initial values for Subscriptions[i].Name before downloading the project to the controller.

Local variable 'enableSubcriptions' must be TRUE in order to enable this functionality.

Step 6

Automatically Publishing an Array of Topics

MQTT_Publications is an optional Structured Text program that works in conjunction with the MQTT_Client program. It allows you to publish an entire 'Publications' array of preconfigured topics. Adjust the array dimension of the global variable 'Publications' to the desired size and modify the initial value of the local variable 'maxPublications' to match the size of the array (default=10). 'Publications' is a User-Defined Data Type (UDT) array that comprises the MQTT topic 'Name', the latest topic 'Value', the previous topic value 'Valueprev', and a timestamp based on the RTC value when the latest topic 'Value' was published. Enter the desired topic names to publish as initial values for Publications[i].Name before downloading the project to the controller.

Set the local variable 'ChangeOfState' to TRUE to publish any value that changes on an exception basis. Set the local variable 'Interval' to TRUE and 'intervalTime' to a non-zero value to publish all of the current values that aren't null ('') on a timed interval basis. Typically, one would choose either 'ChangeOfState' or 'Interval' as the method for publishing topic updates. For a one-time update, set the local variable 'OnDemand' to TRUE to publish all current values that aren't null (''). 'OnDemand' is set to FALSE once the entire 'Publications' array has been published. The local variable 'enablePublications' must be set to TRUE to enable this program functionality.

Easy Dashboards and Control for a Powerflex 520 This is a Connected Component Workbench development that provides basic parameters monitoring and control, either from a PanelView 800 or remotely (through VNC)

Easy Dashboards and Control for a Powerflex 520 enables you to have a ready to use code and HMI screens to apply them with PowerFlex 523 and PowerFlex 525 drives. This is a Connected Component Workbench development that provides basic parameters monitoring and control, either from a PanelView 800 or remotely (through VNC).

Target to use with PowerFlex 523 and 525 component drives from Rockwell Automation.

This code can be used with the following equipment:

• PowerFlex 523 
• PowerFlex 525
• Micro850
• Micro870
• PanelView 800

What is this for?

The main purpose is to provide visualization and basic control through principal parameters as a ready-to-use development for basic drive control. In addition, it will be possible to access the information contained in the dashboards remotely (Internet).

This can be applied to control systems that include Micro-controllers and Powerflex 520 component drives. Implicit and explicit messaging are used (the most important parameters are handled by implicit messaging).

General Features

• Basic Control parameters modification:
  • Reference Speed
  • Acceleration Time
  • Deacceleration Time
  • Position Reference

• Drives faults reset

• Visualization of the following parameters:
  • Ready
  • Active
  • Command Speed
  • Actual Speed
  • Drives fault
  • Output current
  • Output voltage
  • DC Bus voltage
  • Drive temperature
  • Consumed energy
  • Elapsed power
  • Accumulated cost savings

• Remote access to the PanelView 800 screens through FTP functionalities

 

Limitations/Disadvantages

• Limited to PowerFlex 523 and 525
  
• Limited to Micro800 and PanelView 800
• Parameters selected are fixed

 

How can I make it work?

The architecture implies the following hardware:

• PowerFlex 523, PowerFlex 525
• Micro 850, Micro 870
  
• PanelView 800

And this is the required software:

1. Connected Component Workbench, version 21 or higher.
2. The firmware of the equipment used must be compatible with the version of Connected Component Workbench.
3. User-defined Function Blocks:

• RA_PF523_VEL
• RA_PF525_VEL
• RA_PF525_POS
• RA_PFx_ENET_PAR_READ
• RA_PFx_ENET_PAR_WRITE

Knowledge

Basic knowledge of programing and configuration in Connected Component Workbench software:

• PowerFlex 523/525 and PanelView 800 configuration
• Ladder Language

Downloads

Please note: You will need to agree to the Terms & Conditions for each download.

Need Help?

If you need help with an application or have feedback from the Innovation Center, please contact us.

Installation Guide 

Step 1: Communication Settings

1.1 Configure VNC settings in PanelView 800: Go to the main configuration screen.

1.2 Press terminal settings.

1.3 Press Communication.

1.4 Press VNC Settings.

Step 2: Parameters import

2.1 Import “Parameters_52X”.

Step 3: PanelView800 configuration

3.1 Verify that all FTP Accessibility Settings are enable.

3.2 Configuration of email server and account setting to send email on PV800 (optional).

Step 4: Configuration of the PowerFlex 523/525

4.1 Create the PowerFlex as Ethernet modules (this enables implicit messaging)

4.2 PowerFlex523 communicated with EIP card (2 ports) and speed control mode.

4.3 PowerFlex525 communicated with EIP card (2 ports) and speed control mode.

4.4 PowerFlex525 communicated by ethernet Embedded IP and position control mode.

4.5 Configuration of parameters for Ethernet communication. For communication by 25-COMM-E2P card.

4.6 Configuration of parameters for Ethernet communication. For the communication of the PF525 through the embedded EIP port.

4.7 Parameter setting for control mode: Speed.

4.8 Parameter setting for control mode: Position.

Step 5: Program download and commissioning

5.1 Compile the Micro800 program.

5.2 Validate PV800 application.

5.3 Verify the right connection and IP assignment of the equipment in the Ethernet IP network.

5.4 Download program (without errors) to Micro800 controller and leave in run mode.

5.5 Download the HMI application to the PV800 and execute it.

LOTO - LockOut and TagOut How to make an efficient and safe digital electrical lock on electrical panels?

What is this for?

LOTO consists of a functionality available in Factory Talk View Studio SE and Studio 5000 that allows the safe, direct and indirect digital blocking of equipment in electrical panels, drawers and CMM, controlled by duly accredited users, increasing safety for operators and maintenance people. 

General Features

The electrical lock consists of the shutdown of the component responsible for energizing a circuit (usually a circuit breaker) and inserting a padlock into this disconnected circuit breaker, so that it cannot be reconnected by another person during the entire maintenance.

In this way, the electrical block prevents anyone from being able to access and/or maneuver this component and from energizing a certain circuit, where workers are intervening in maintenance.

Locks can be used individually or collectively, through multiplier devices, in situations where multiple teams are working on the same equipment, but on different service fronts. This way, the machine will only be energized when all team locks are removed.

After all, it is important to emphasize that the blockage in the electrical circuits must be carried out mainly in the power circuits and can be complemented with the shutdown of the control circuit. 

Next to the locking device, a signaling card is also inserted, usually containing the photo of the person responsible for the lock, its function and allocation sector, in addition to the name of the circuit or equipment that was blocked by it.

Therefore, the purpose of the signal card is to visually alert people not involved in the process that the equipment is blocked for some reason and cannot under any circumstances be energized.

Advantages:

LOTO with Factory Talk View Studio and Studio 5000 make it simple and safe to lock panels, CMM drawers, specific equipment such as valves, motors and instruments in the field.

• Time for configuration
• Request
• Authorization by the area owner
• Indication of padlock placement
• Indication of zero energy test by the area owner
• Removal of the blockade by the owner of the area
• Block outputs
• Label placement
• Label withdrawal
• Authorization by the General Manager
• Break by the maintainer
• More protection for operators and maintenance people

 

Is this useful for me?

In general, LOTO is recommended specially for automation process control where it requires the need to block equipments for maintenance and repairs.

• Cement process
• Food and Beverage process
• Chemical process
• Steel industry
• Mining Companies

Application areas:

Cement, Food and Beverage, Chemical, Steel, Mining.

Benefits of applications with LOTO systems:

• Secure digital lock management
• Treacebility
• Lock by area and equipment
• SQL Server database for record datas

 

How can I make it work?

Hardware

• Logix Controllers (ControlLogix / CompactLogix)

Software

• Factorytalk View SE Enterprise v13 or higher
• Studio 5000 Logix Desing v35 or higher
• SQL express (ou SQL Server para  FTAlarm&Event)
• FactoryTalk Logix Echo V2 (or Physical Controller)P

Knowledge

Intermediate knowledge of programming and configuration in Logix Design Studio 5000 software:

• Studio 5000 - Ladder language (LD)
• Studio 5000 - Function Block Diagram (FBD)
• Factory Talk View Studio
• Factory Talk Echo

Downloads

Please note: You will need to agree to the Terms & Conditions for each download.

Need Help?

If you need help with an application or have feedback from the Innovation Center, please contact us.

Installation Guide 

Step 1:

Studio 5000 Logix Design:

1. Download files documentation available
2. Open FILES> LOTO_Aplication Referency_en_EN.docx – Use this document as referency
3. Studio 5000 Logix Desing, Open program PController_FTEcho.ACD in Files/CS – Control Strategie
4. Import the 32Dis Card (to exemplify using the "Connection" where we can modify with the controller running without stopping)
5. Slow/Slow Program, import routine MTR_Lock_Routine_FBD.L5X.

Step 2

Factory Talk Logix Echo:

1. Open FactoryTalk Logix Echo - ControlLogix 5580 Emulator V35
2. Add the controller (ACD) PController_FTEcho.ACD
3. In Studio 5000, Who Active, Select Emulate 5580 Controller and Download the program and Run Mode.

Step 3:

Factory Talk SE:

1. Open FactoryTalk View SE Application Manager
2. Restore an Archive (menu), FILES\Backup .Apb – Distribuited Application, Select LOTO_2023_01.apb application. Check the name of your machine (Primary Host)
3. Open Application in FT View Studio (Network Distributed)
4. Import alarm configuration from Excel file. FILES\Alarms Exported > LOTO_2023_01_FTAE_AlarmExport.xls
5. Configure the communication setup
6. Add Database in System\Connections\Databases.

Step 4:

Factory Talk SE – Application:

1. Where we have a folder called LOTO, the sample screens "001_Coluna 1-8" for use in the application
2. With the "001_Coluna 1-8" screen open, see that each column contains its devices in each drawer, thus setting up according to your CCM
3. Add Engine lock MTR001 in Column 3 (ra-blk) equip lock and hold and drag the "GO_EqpLockLOTO" object to Column 3.

Step 5:

Factory Talk SE – Client Application:

1. Click on the FactoryTalk View Client file in the folder (if I need to edit to work, please click with the right and Edit). We have in the Example of the PlantPAx DCS template where it can be used.
2. Column 1-8" button opens the screen with the CCM
3. See that automatically the column we set up appears already configured
4. Type as example "RAZAO 01" and click ENTER to start Digital Lock  
5. "Request", check to follow the next step
6. Follow the steps and see that there is the possibility of checking STATUS (reason) for the following items (Autoruzar and Zero Energia)
7. In the Etiquete we have as shown the option below and in the lock /padlock icon for the execution of the job or the break of the same all recorded in the events). In the Advanced icon, check the other available settings. For modification of descriptions, it can be done via faceplate or via controller in aoi MTR001_lock 
8. After performing the job, click "Unlock" the faceplate will return to normal mode (all clean action)
9. To Check all the steps taken for blocking, users, comments, click "Events" and navigate each line for detailing