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Smart Devices
  • Smart Sensors
  • Smart Safety
  • Smart Motor Control
  • Smart Motor Control

    Get more from your application investment

    Icon collage containing a motor and a user at a computer with alerts on the computer screen
  • Industrial Smart Devices

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    Allen-Bradley Smart Devices are an integrated, scalable solution, offering new efficiencies and reduced total cost of ownership. 

     

    Smart Devices improve product quality, reduce downtime, and future-proof your investment in smarter machines to allow smarter manufacturing.

  • Efficient motors drive industrial performance

    photo of a motor

    Across multiple applications, the electric motor keeps industry running, from motion systems, ventilators and conveyors to pumps and compressors. Central as they are to manufacturing and industrial performance, the impact of motor failure can be significant, costing thousands or even hundreds of thousands per hour of lost production. The most expensive motor isn’t necessarily the most critical: a failure on a small, single mixer motor can be enough to cause a major disruption to plant productivity.

  • How much do unforeseen motor failures cost you?

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    Motor costs

    • Motors are the largest consumers of energy in industry
    • Responsible for over 50% of the total energy used by industry
    • Running a motor can cost 10 times its initial purchase price each year
    • Reducing the speed of a motor by 20% can save up to 50% energy
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    Why motors fail

    The most common causes of motor failure are:

    • Thermal overloads
    • Single phasing
    • Bearing failure
    • Rotor failure
    • Stator failure
    • Contaminants
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    Cost of downtime

    • Loss of production
    • Manufacturing scrappage
    • Establishing cause of failure (mechanical/electrical)
    • Motor and system repair costs
    • Safety issues
    • Impact on other equipment
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    Maintenance options

    • Advanced diagnostic information
    • Preventative not reactive maintenance
    • Planned downtime possible
    • Be in control of your plant
    • Reduced maintenance costs
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    Increased productivity

    • Reducing unplanned downtime improves productivity
    • Be in control of your production process
    • Reduce energy costs
    • Make fact-based decisions with advanced diagnostic information
  • Smart Motor Control at work

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    Motors are used in many industrial applications and these are critical to the productivity of the enterprise.

     

    With Smart Motor Control solutions it is possible to monitor the health and performance of each motor to help identify, in advance, potential issues that could lead to unwanted downtime or reduced productivity levels.

  • Smart Motor Control devices

    Diagram illustrating the benefits of Smart Motor Control devices within The Connected Enterprise and how they all connect

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    Smart Motor Control provides a continuous flow of valuable process and diagnostic data to your design environment, visualization system, information software and Logix Programmable Automation Controller – facilitating smart manufacturing and helping to increase productivity and minimize downtime while reducing total cost of ownership.

  • Smart Motor Control enables Smart Machines for Smart Manufacturing

    diagram of motor with callouts illustrating specific benefits of smart motor control

    The integration of Allen-Bradley Smart Motor Control solutions help reduce programming time, ease startup and commissioning, and streamline diagnostics. By providing consolidated programming, device and system configuration, operation and maintenance within the Studio 5000 engineering environment, complexity and potential errors are minimized.

     

    Smart Motor Control provides key diagnostic information that enables you to optimize performance with real-time access to operation and performance trends.

  • Today's smart approach

    diagram of motor with callouts illustrating specific benefits of smart motor control

    •  Seamless communication and system visibility for increased performance and flexibility

    •  Control & maintain motor performance through smart equipment and networks

    •  Reduce unplanned downtime with alarms and advanced diagnostic information

    •  Monitor energy consumption

    •  Simplify troubleshooting and reduce startup times

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    Smart Motor Control solutions are programmed using Studio 5000® software

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    Just one development environment for configuring and programming

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    Add-On Profiles for simplified machine development, operation and maintenance

  • Application Scenario 1 of 14

    Motor underload

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    Helps detect and inform of mechanical failures



    Reduces costs associated with production loss



    Can help minimize repair costs due to controlled shutdown



    Time to repair and restart process reduced



    Allows maximum efficiency to be benchmarked and monitored

  • Application Scenario 2 of 14

    Process optimization

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    Can help increase production throughput



    Reduces unnecessary wait times
     



    Helps increase product quality



    Optimizes efficient use of energy

  • Application Scenario 3 of 14

    Motor overload

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    Early warning and diagnostic functions provided



    Minimizes production downtime
     



    Helps protect your critical assets from costly failure
     



    Fact-based decision making using real time diagnostic information



    Opportunity for predictive, rather than reactive maintenance

  • Application Scenario 4 of 14

    Ground fault current detection

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    Predictive monitoring of motor health



    Proactive maintenance can be achieved
     



    Reduced downtime of critical equipment

  • Application Scenario 5 of 14

    Network issue

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    Local management of process in event of network communication issue



    DeviceLogix™ allows for decentralized intelligence and reduces unnecessary network traffic



    Critical asset health can be maintained



    Batch production can be completed reducing clearing and cleaning issues

  • Application Scenario 6 of 14

    Energy waste detection

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    Automatically identifies possible issue



    Helps reduce the cost of energy consumption
     



    Minimizes stress on motor and mechanical equipment
     



    Reduces maintenance time and cost

  • Application Scenario 7 of 14

    Device health and diagnostics

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    Aggregate, analyze and present data from your devices, no matter where you are



    Automatic discovery of EtherNet/IP connected devices 



    Automatically generated dashboards monitor the control system and perform analytics



    Action cards delivered when a situation occurs that needs attention


     

    Voice activated function to request and interact with networked devices



    No cloud connection and no dashboard development required

  • Application Scenario 8 of 14

    Automatic device configuration

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    Set-up automatically downloaded from controller



    Minimizes downtime and simplifies maintenance



    Minimal specialist knowledge needed, allowing quick device replacement



    Reduces risk of incorrect configuration


     

    Device configuration stored locally in controller

  • Application Scenario 9 of 14

    Single programming environment

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    Single programming environment helps minimize programming errors



    Easy to access and edit information



    Diagnostic, fault, alarm and event information are integral to Studio 5000®



    Helps reduce development time by up to 70%

  • Application Scenario 10 of 14

    Predictive maintenance

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    Predictive maintenance features predict when to replace critical drive components



    Prediction based on real time operating conditions



    A variety of functions are available to monitor



    Can configure and retrieve data via HIM, software tools and Studio 5000® engineering environment

  • Application Scenario 11 of 14

    Energy management

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    Use network access to configure and troubleshoot devices without opening MCC enclosure doors



    Smart motor control technology within the MCC can warn of failures before they occur
     



    Network devices are pre-configured with node addresses so you can configure device parameters via the network
     



    IntelliCENTER Software includes electronic versions of manuals, wiring diagrams and spare parts

  • Application Scenario 12 of 14

    Application Code Manager

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    Leverage Rockwell Automation provided libraries



    Flexible library authoring, structuring reusable content the way you want



    Easily generate your standardized application code in bulk to configure projects



    Users don’t need to understand the library object dependency structure; the tool manages the dependencies per the librarian’s rules



    Out of the box integration enables simple and fast bulk deployment of the Library of Process Objects and Machine Builder Library

     



    Facilitates continuous reuse of IP and aids to enforce standards

  • Application Scenario 13 of 14

    Automotive - Adaptive Tuning

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    Load Observer - Helps reduce startup time by reducing the effort needed for tuning

    Automatically monitors and compensates for changes in inertia and for motor‑to‑load compliance by anticipating need for torque

     



    Compensates for normal machine wear



    Provides consistent dynamic behavior

    Adaptive Tuning - Helps increase machine reliability and performance

    Monitors drive performance characteristics and adapts if necessary

     



    Tracking notch filters automatically suppress potentially harmful resonance and vibration conditions. With four tracking notch filters, the PowerFlex 755T drives can identify up to four resonances



    Can be used to indicate machine wear out over time

  • Application Scenario 14 of 14

    Automotive - Predictive Maintenance

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    Predictive Maintenance parameters are customizable enough to fit a multitude of machine applications



    Track maintenance items such as motor bearings, motor lubrication, machine bearings and machine lubrication



    Configure system components and determine when periodic maintenance may be required



    A variety of functions are available to monitor

     



    Can configure and retrieve data via Human Interface Module (HIM), software tools and Studio 5000 engineering environment

  • Efficient motors drive industrial performance

    From fixed and variable speed control to precise torque and position control, Rockwell Automation supports you with application knowledge,
    industry experience and a complete portfolio of Smart Motor Control solutions, helping you achieve the control you need.

    photo collage of Allen-Bradley fixed speed control products
    Fixed Speed Control

    Motor Starters and Protection

    For fixed speed control of your application, the comprehensive portfolio of direct online starters, electronic overloads and soft starters with embedded protection capabilities allows you to achieve the control, protection and integration you need. 

    With electronic overload protection and communication capabilities networked into your Integrated Architecture®, you can achieve system visibility, protection and diagnostics that conventional solutions simply cannot offer.

    photo collage of Allen-Bradley variable speed control products
    Variable Speed Control

    PowerFlex® AC Drives

    A comprehensive portfolio from low to medium voltage drives, including options of configured versions to your specific needs are available. 

    With built-in specific features to benefit many applications and seamless integration into the Rockwell Automation Integrated Architecture, the PowerFlex family of AC Drives offer you powerful performance and flexible control whatever your needs.

    photo collage of Allen-Bradley motion control products
    Motion Control

    Kinetix® Integrated Motion

    Kinetix provides you with the hardware, software and application knowledge to achieve full integration of logic and motion control within the Rockwell Automation Integrated Architecture.

    With a comprehensive portfolio of motion drives matched to servo motors, integration of Kinetix can simplify your application without compromising the control you need.

    photo collage of Allen-Bradley condition monitoring products
    Condition Monitoring

    Detect and Protect Solutions

    Condition monitoring products help you keep your plant floor running productively by detecting potential equipment failures. 

    Smart Condition Monitoring solutions include real time protection modules, sensors, portable instruments and surveillance software.

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    Adopt a Smart Motor Control solution today

    LEARN MORE

    Efficient motors drive performance and the impact of motor failure can be significant. With smart motor control devices, you can improve productivity and help avoid motor failures with an integrated, data-driven approach.

     

    Our smart products include:

    •  Fixed Speed Control

    •  Variable Speed Control

    •  Motion Control

    •  Condition Monitoring