Client Goal

Technical Goals:
• Establish a standard for plant data aggregation
• Build a network, hardware and software infrastructure for plant data collection

Project Overview

With each machine configured as an island, the task of gathering and analyzing machine efficiency and production rates was formidable. Management andtechnical staff realized that an automated and intelligent data collection system was  the answer.  This system would aggregate raw machine performance data into vivid, actionable information.

Because of the distributed nature of the data collection task, Rockwell Automation’s NetLinx architecture (Ethernet, ControlNet, DeviceNet) was chosen as the communications backbone of the system. At the device level, the array of machines was divided into four separate DeviceNet networks serving 1734 Point I/O and Panelview 300 displays.

The Point I/O satisfied the need for a low cost highly  distributed I/O system with the flexibility for future discrete and analog expansion options. The price, performance, and graphical capabilities of the Panelview 300 proved unbeatable for a device-level operator interface.

Minimize installation cost and maximize communication bandwidth…

Each DeviceNet network was bridged to the supervisory ControlNet network through 1788 CN2DN bridging modules. The bandwidth and range of ControlNet allowed the aggregation of data into a single PC executing a softcontrol engine. SoftLogix 5 and a 1784-KTCS ControlNet scanner card proved to be the best choice in support of the architecture. The performance of SoftLogix 5 allowed a single routine to rapidly service the entire array, calculating and
analyzing machine performance.

A separate server housing RSSQL, RSHistorian Server and Microsoft SQL Server functioned as the transaction concentrator for all plant data. This transaction server taps into the SoftLogix 5 box over a dedicated Ethernet segment separate from the existing company-wide network. The RSSQL transaction manager server routes filtered and conditioned data to an Oracle 8i database. A local Microsoft SQL Server works in conjunction with the RSHistorian Server to store and serve time series data.

Build it and they will come…

The existence of single plant data transaction server has accelerated efforts in other areas of the plant. With the network, hardware, and software infrastructure already in place, data collection is now simply a matter of dropping cabling and installing a communications or bridge module to interface with processors and devices propelling the plant floor. For production areas without intelligent devices, the successful NetLinx architecture is being considered for deployment.

Having established and implemented a standard for plant data aggregation, the manufacturer is now concentrating on its primary task – production. By visualizing and analyzing the gathered data, the manufacturer is beginning to identify and prioritize opportunities in machine maintenance, hardware and software upgrades, and production scheduling.

Automated, available, and relevant…

now that’s information that drives results.

Scope of Supply

• New Technology Evaluation
• Scope Development
• Technology Comparison
• CAD Documentation
• Commissioning & Start-up
• Control Panel Fabrication
• Electrical Construction Management
• Electrical Control Design
• Electrical Power Distribution Design
• Human Machine Interface Development
• PC Software Development
• PLC Software Development
• System Training
• Emergency Support
• Support Agreements
• Engineering & Technical Staff Augmentation
• Remote Monitoring & Support

The Outcome

Production Benefits

• Identify complex machine behaviors realtime
• Visualize information beyond tabular data
• Identify inefficient machines and apply corrective measures within minutes
• Archive data to drive simulation models, reducing variability out of the “what if” scenarios