Industrial Smart Devices
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
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?
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
Why motors fail
The most common causes of motor failure are:
- Thermal overloads
- Single phasing
- Bearing failure
- Rotor failure
- Stator failure
- Contaminants
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
Maintenance options
- Advanced diagnostic information
- Preventative not reactive maintenance
- Planned downtime possible
- Be in control of your plant
- Reduced maintenance costs
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
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
Click image to enlarge
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
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
• 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
Smart Motor Control solutions are programmed using Studio 5000® software
Just one development environment for configuring and programming
Add-On Profiles for simplified machine development, operation and maintenance
Application Scenario 1 of 14
Motor underload
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 monitoredApplication Scenario 2 of 14
Process optimization
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
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
Predictive monitoring of motor health
Proactive maintenance can be achieved
Reduced downtime of critical equipment
Application Scenario 5 of 14
Network issue
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
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
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
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
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
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
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
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
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
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.Adopt a Smart Motor Control solution today
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
