using cip safety over wireless for material handling
TRANSCRIPT
Using CIP safety over wireless for material
handling applications with ProSoft Technology
Krzysztof Hajzyk & Romain Timmer
ProSoft Technology – Who We Are
Application Experts
• ProSoft really knows industrial communications applications
• COMM - Connect, Optimize, Modernize, and Migrate
Customer Oriented
• We are relentless in solving our customers’ challenges
• Industrial customers trust ProSoft
Great Partner
• Partnerships are integral to our business
• We make our partners more successful
ProSoft Technology, with our partners,
optimize industrial productivity
with innovative communication solutions
Close to your customers
Global HQ:
ProSoft Technology, Inc.
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ProSoft Technology SAS
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Technical support included - 3 years warranty - 400+ partners worldwide
Madison
Wireless
RLX2-IHNF-W
Where Automation Connects.
MVI56-DNP
RLX2-IHNF
RLX2-IHNF
RLX2-IHNF
Automated Material Handling
Automated Guided Vehicles (AGV)
Electrified Monorail Systems (EMS)
Skillet Conveyors
Automatic Storage and Retrieval Systems (AS/RS)
Cranes
Why customers use Automated Material Handling?
Value compared to Manual Material Handling Reduced Labor Costs – 72% of TCO for manual forklift
Improved Safety – Hundreds of injuries from forklift operations
Improved Operational Efficiency - Lower WIP, faster turnaround
Access to Hostile Environments – Cold storage, clean rooms, etc.
Reduce Product Damage and Inventory Errors
Challenges for Industrial Wireless
Lots of RF / EM Noise
Constantly Moving Parts
Enclosed Spaces
Unusual Work Paths
Control Network Timeouts
Extreme Conditions
System Maintenance
Local certifications
Reliable communication for IO’s and
safety equipment
Industry Challenge – Robust Wireless Network
Advanced machines need reliable, high speed wireless
communications
Each end user environment has unique RF characteristics
Enterprise products fail to meet the specific needs of
industrial applications
Machine OEMs and System Integrators do not have the time
to become wireless experts
Robust wireless products designed for industrial applications increase OEM/ SI success
ProSoft wireless advantagesMAXIMIZE SYSTEM RELIABILITY
Ultra Fast Roaming – avoids communication loss faults that stop the machines and require end user intervention to restart. Critical for I/O traffic.
Client Repeater Mode – Each mobile unit can act as an access point, making the entire system far more reliable. System keeps running even if an AP fails.
Manufacturers are seeking to reduce their costs through automated
material handling, so reliability is critical. Systems depend on wireless
communications to keep running. ProSoft RLX2 radios address system
reliability in these applications in a few key ways:
ProSoft wireless advantagesMINIMIZE PROJECT RISK
Application Expertise – ProSoft’s Field Application Engineers work with OEMs, integrators, and end users to plan out the wireless system
Control System Diagnostics – RLX2 radios deliver status and diagnostic data via EtherNet/IP, Modbus TCP or OPC directly to control system, where operators and see and act on it.
ProSoft wireless advantages
HANDLE DIFFICULT PATHS, NOISY ENVIRONMENTS
Radiating Cable Solutions – Many
material handling systems are well
suited for radiating cable, which reduces
the potential for poor radio frequency
connections and dead spots. ProSoft
are experts at applying radiating cable.
ProSoft Wireless Advantages
WITHSTAND FACTORY CONDITIONS
Industrial Rated Products Extended Operating Temperature
– - 40C to + 70 C
Hazardous Location Certified– Class 1, Division 2
– ATEX Zone 2
Industrial Power Options– 12/24 VDC
– Power over Ethernet (PoE)
DIN Rail Mountable
High Shock/Vibration Tested– Shock IEC 60068 2-6 (20g, 3-Axis)
– Vibration IEC 60068 2-27 (5g, 10-150 Hz)
Local country certifications and approvals
Customer Success Story – Automotive AGV OEM
Problem Automaker needs to reconfigure several plants to manufacture new models
These lines require highly reliable I/O communications between the moving AGV or skillets and the master control system
Automotive plants present many issues for wireless applications including interference with existing WLAN, reflections from metal parts moving around the plant and unusual paths of moving vehicles
Approach
AGV OEM worked with ProSoft wireless field application engineer to analyze the requirements and propose a WLAN architecture to meet the application needs
ProSoft recommended a system using radiating cables and ultra-fast roaming WLAN radios
AGV OEM constructed a proof-of-concept system at its facility and demonstrated that performance of the system exceeds the requirements for the project
Customer Success Story – Automotive AGV OEM
ProSoft Solution
ProSoft RLX2-IHNF WLAN radios were selected due to the ultra-fast roaming capability
– Ultra-fast roaming is critical to prevent production outages from communications loss as carts move
from one segment to the next
– During POC testing, OEM’s engineers “could not detect” when roaming took place because it
happened so quickly
Radiating Cable system selected due to several advantages
– Radiating Cable provides consistent signal strength between moving carts and master radios
throughout plant
– Leaky feeder follows the track of the conveyors and AGVs through plant, minimizing blocked signals
ProSoft experience applying leaky feeder solutions in other automotive plants reduces the
project risk
Access to expert wireless application engineers for pre- and post-sale support is a key
value for OEM
Problem Replace slip ring which requires
frequent maintenance
Build system that will allow CIP Safety communication
Solution and customer benefits Allow communication between moving
Safety devices
Data transfer improved
Increasing reliability
Secure and stable communication
Customer replaced slip ring
Wireless does not need maintenance
Amusement ride
Amusement ride – Radiating Cable installation
Packaging Machine Application description Customer machines can perform every type of sleeve
application required by the client, at different production speed. The production includes linear and rotary machines.
Customer need: Replace the Slip Ring communication with a new more
secure and robust one
Reduce maintenance cost and time
Radios are used to manage the rounding tables
The Master Radio is able to received data from two rounding tables at the same time, thanks to the installation of two radiating cables and two repeaters
Packaging Machine
Our solution
Wireless architecture solution
RLX2-IHNF, Radiating cable
Customer benefits
Benefits in terms of ease of
operation and/or maintenance:
• Improve the Data Transfer
speed time and strength
communication with
EtherNet/IP protocol.
Lower maintenance cost because
the slip ring contact are subject to
wear.
Customer: Hong Kong International
Terminals Ltd.(HIT) HIT is a major container terminal operator in one of the
world’s busiest ports – Hong Kong Kwai Tsing Port
Application description A project to install remote-control operations for the 29
Rubber-Tired Gantry Cranes (RTGC)
The project is the first time that this innovative technology
is being implemented for RTGCs outside of Japan
Customer needs Increase operational efficiency
Enhance industrial safety
Improve the working environment for
crane operators
Hong Kong International Terminals
Hong Kong International TerminalsCustomer problem Poor performance from the competitor wireless products
Support from competitor was poor
System needs to work before the end of the year
Customer was looking for alternative wireless products on their own. Motorola, Huawei, Conductix was not satisfactory
Our Approach Our Sales team in China set up a Proof-of-Concept (PoC) test. Developed a Proposal quickly
Distributor in China, HiTE, supplied all the testing equipment within a week
Sales and Engineering team actively involved in the PoC test and had on-site visits to support testing
Testbed was set up in Fremont lab in order to troubleshoot issues and optimize performance
Worked closely with system integrator, Sumitomo Heavy Industries
Our solution
Replaced all (~90) competitor wireless access points by ProSoft RLX2-IHNF
radios
Two parallel wireless networks are deployed to provide redundancy
Fast-roaming ensures seamless connectivity during roams
Video streaming from the cranes are not interrupted at all
Existing radiating cable infrastructure can be reused with only minor adjustments
Customer saved substantial investment (both material and deployment cost)
Where Automation Connects.
Application design example
Possible InstallationsAluminum Smelting
Steel Production
Material Handling
Vehicle Manufacturing
Station 1 Station 2 Station 3
Crane 1 Crane 2
Pallet 1 Pallet 2
5GHz – Wireless network
Crane Automation - Architecture
Controller Messaging
I/O (Implicit) Messaging is frequently used to transfer tags
between PLCs and HMI such as PanelView.
Understanding messaging has a big impact on project success.
Safety
Integral part of any crane application.
Light curtains and gates limiting access to areas where load enters.
Guard I/O & light curtain communicating over EtherNet/IP to
GuardLogix.
HMI in a safe area for system control.
Central Control Crane
Crane automation - Components
Safe Area
Safe Area
Safe Area
Central Control
Hazard AreaHazard
Area
Crane
Crane Automation Safety in Industrial Wireless
Number of EIP packets 3 x ( 1 + 1 ) = 6
RPI 20 ms
Packet rate per connection 50pps
System Packet Rate 6 x 50pps = 300pps
Traffic LevelSystem
1 central ControlLogix
2 remote ControlLogix
1 Panel View
1 EtherNet/IP Connection to each
2 Packets per connection per RPI
Allowable rates
802.11a/g: ~1,000pps max
802.11n: ~4,000pps max
2.4GHz (3 non overlapping channels) & 5GHz Band (23
channels)
Short to Medium Range
Low packet latency: ~5ms
1 6 11
24
00
24
83
24
12
24
37
24
62
20dBmMAX
802.11n
ProSoft FAST ROAM Technology
Fast Roam between Access Points
Less than 10 ms roam time
Bridging – multiple Ethernet devices on machines/carriers
No Wireless Controller required
Overhead Cranes
Automotive Assembly
Automatic Guided Vehicles
Fast Roam – How it is implemented
802.11abgn Fast Industrial Hotspot Diagrams
~ 600’
Radiating cable in the trench
Radiating cable in the trench
Skillets
Master:B2-16 (Ch.
165) T4B_South, IP
.23
Master: B2-18 (Ch.
165) T4B_NORTH, IP
.53
, T4B_NORTH
Master: 6B (Ch. 48)
T4A_NORTH, IP .43
Master: 6C (Ch. 48)
_T4A_South, IP .13
63 Skillets
Automotive Skillet Application
30
~180m
Stacker/Reclaimer – Cement Plant Architecture
HighlightsLonger range
Obstacles
High vibration
Antennas Focus Energy
Like the beam of light from a flashlight
Types
Omni – Narrows energy vertically
Yagi – Often a tube or series of vertical bars
Parabolic – Dish type antenna
Patch / Panel – Flat surface
ParabolicYagi
Omni
Panel
Equipment used
Control Room to Stacker Link
Distance – 550 meters
Antennas – 6dB Omni
RSSI of -62dBm (Good for 802.11)
Antenna Angle
StackerControl Room
Stacker/Reclaimer – Cement Plant
Installation ConsiderationSystem Design with ProSoft Wireless Designer
1. Wizard guided defaults
2. Add Sites with defaults
3. Evaluate Link
4. Modify if desired
5. Review Choices
6. Create Materials
List
Limitation of the wireless systems
Wireless cannot compete with wired solutions in
terms of performances.
Motion Control – CIP Motion can work with slower
refresh time.
Time Synchronization – CIP Sync protocol must be
filtered by radios to not overload the network.
EtherNet/IP CIP Safety – programming advicesParameter Value
CRTL 4xRPI, >=60ms
RPI >= 15ms
System Reaction Time – worst case no fault >= 200ms
(may vary depending system size and RPIs)
System Reaction Time – worst case single fault >=360ms
(may vary depending system size and RPIs)
36
Things to consider:
Use unicast connections.
Adjust cycle time for Safety Task.
Adjust RPI time for I/O’s.
Try to limit number of connections on wireless.
Implement a way to get and log communication diagnostic.
Wireless advices - environment
Use right type of antenna to each application
Limit interferences with other systems
Radiating Cable can help to bypass environment
challenges.
Wireless environment can change over time. Monitor
it by using diagnostic tools provided with Radios
(AOI, OPC, Modbus)
Calculate system needs
Do site survey at installation location
Questions?
38
Thank you
Sales Contact:
Krzysztof Hajzyk
Regional Director Sales & Marketing – EMEA
Phone: +33-5-3436-8720
Email: [email protected]
Technical Contact:
Romain Timmer
Technical Support Engineer - Europe Middle-East Africa
Phone: +33-5-3436-8952
Email: [email protected]
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Copyright © 2018 Rockwell Automation, Inc. All Rights Reserved. 41
Krzysztof Hajzyk & Romain TimmerThank you