A new version of ProcessLogix, the scaleable, open control system for batch and process applications from Rockwell Automation, extends a system's capabilities to provide increased functionality while further lowering its system cost.
With release 320, new functionality has been added for batch processing, while the system architecture has been expanded to accommodate larger projects, distributed control and a further increase in system robustness. New features in the engineering environment of ProcessLogix have been added to make the tasks of project implementation and documentation easier.
The new batch functionality in release 320 provides an operator with a tool to immediately detect the reasons why a batch is blocked, allowing actions to be taken to continue the production and thus increase the utilisation of the equipment. An operator sees conditions in a descriptive way, rather than using the classical cryptic tag name approach, which reduces the chance of making errors. The support of common phases helps to reduce engineering cost during batch implementation by allowing an operator to create one phase against many equipment units. Further improvements have been made in logging the operator and engineering activities, an important factor in complying with international standard requirements like FDA for the food and pharmaceutical sector.
"In the last year we have achieved our goal of providing the best-in-class and the most comprehensive process solution available on the market. With our existing product portfolio and the recent acquisitions of the Sequencia batch automation business and Systems Modeling (a US-based developer of shop floor scheduling, simulation and modelling software), Rockwell Automation is able to offer the most comprehensive process solution from shop floor to integration with existing ERP systems," said Jordi Andreu, President, Rockwell Automation EMEA region.
Laszlo Varga, European Process Marketing Manager, Rockwell Automation, added, "We believe a batch solution is much more than just a system to run batches. Besides the process control it has to include scheduling of the equipment and batch campaigns, material handling and tracking, integration with customers' business systems, asset management and implementation know how - all integrated to deliver the highest ROI for customers. And this is exactly what Rockwell Automation can offer today."
I/O and network benefits
The architecture of ProcessLogix has been expanded with the integration of Allen-Bradley Flex I/O, a modular I/O that provides all the functionality of larger, rack-based I/O, but without the costly hardware, installation and space requirements. System design, installation and cabling cost can be significantly reduced by placing Flex I/O and Flex Ex I/O, the intrinsically safe variety of Flex, on the open and deterministic ControlNet network close to the transmitters and actuators in normal or hazardous areas of a plant.
Human-machine interface benefits
The integration of Allen-Bradley PanelView operator interface solutions with ProcessLogix allows local panels to be located near the equipment being controlled. This is especially important for batches heavy in manual operations. With PanelView, operators can quickly acknowledge the action they have performed letting the batch run further, and thus reducing execution time. Added robustness is achieved with PanelView and ControlNet since the connection is maintained even if a server fails.
Reducing cost and time
Release 320 has significantly increased the system size by allowing for more controllers and operator stations. For lower cost solutions an Ethernet network can be used to connect the stations and servers with the controllers. Further enhancements have been made in the area of self-documenting the configuration and printing it out, reducing the time required for the engineer and making the configuration easier to understand for a person who makes changes.
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