2002 Conference & 8th Annual General Meeting Maintenance System with DeviceNet Presented by Tai Tateishi for OMRON Maintenance System with DeviceNet Masaru

2002 Conference & 8th Annual General Meeting

Maintenance System with DeviceNet

Presented by Tai Tateishi for OMRON


Masaru ImotoOMRON CorporationPresenter: Tai TateishiOMRON Electronics LLCOctober 1, 2002




Agenda

1. Expectation for Field Networks2. Maintenance System with DeviceNet

• How to get trouble information• Preventive maintenance• Maintenance procedure by DeviceNet

3. Smart Technology and challenges (Value-added Information with machine control capability)

4. Overview of smart functions5. Access of smart information

4. Conclusion




Expectation for Field Network

Market Trend

Corporate reorganization

Oversea production

Cost to raise ROI

High Productivity

Free Competition

Global Standard(Machine, equipment and operations)

Optimization of production system

(Simple rule & skill)

c) Device Profile

a) Open

d) Value-added Information with machine control

e) Interconnection to Information layer

b) International Standard

Expectation to NetworkKey Issues




Requirements for Maintenance

<Purpose of the above requirements>Increase Productivity

“I do not want to stop production line!!”>> Preventive Maintenance

“Even if the line stops, I want to recover the line as quick as possible!!”

>> Maintenance (when a trouble occurs) Troubleshooting




Current Situation:Maintenance System without DeviceNet

How to get trouble information?

• Communication gap, knowledge gap, skill gap and information gap• Support staff does not have enough information about what is happening on the shop floor. (Sometimes, even wrong information!!)

A Machine got trouble.COM ERROR LED is lit. Something is wrong!!

???

Support staff Staff on the shop floor




Current Situation:Maintenance System without DeviceNet

Preventive maintenance In many cases for preventive maintenance, components are replaced periodically -- before failure.

Some components still have enough life time remain.Some components life already expired.

We do not have a clue to identify the end of product life. So we replace all devices for preventive maintenance ...

Because ...• There are too many components on the entire shop floor.• Information for the preventive maintenance is not enough.




Current Situation:Maintenance System with PLC

Preventive maintenance Program for preventive maintenance• Increases total program size.• Requires more speed, memory ( costs more )

Smart Technology

Program for machine control

Program for maintenance

CAN BE REPLACED BY




Smart Technology

Enables preventive maintenance easier, Enables preventive maintenance easier, more efficient, and more economic by more efficient, and more economic by

having value added information in having value added information in slave.slave.




Control system Maintenance system

Maintenance System and Procedure with DeviceNet Smart Technology

DeviceNet

IN OUT

Information for Maintenance

Control information

ININ

Time to Operate Monitor

Cycle Counter

Network Power Monitor

I/O Power Monitor

Total Working Time Monitor

The cylinder'sspeed is incorrect!

It might be time

to check the switch!

IN

ININ

Is the I/O power

supply turned ON?

What was the cause

of the error?

It's time for motor maintenance

What is the current

Network voltage?

DRT2-seriesSmart Slave

Value-added information with machine control

Ethernet：Connection to Information layer

Information for preventive maintenanceand real-time error status

Communication Error History Monitor




Smart Technology• Failure recovery information

– Device Description – I/O Power Monitor– Communication Error History Monitor– Sensor Disconnected Detection– Short Circuit Detection

• Preventive maintenance– Cycle Counter– Total Working Time Monitor– Network Power Monitor– Conduction Time Monitor




Smart Technology and challenges Overview of smart function - Example

Monitor ON Timing

A slave module with smart technology measures time duration from one input being ON to one output being ON.It is possible to estimate a failed device (point) in a machine.

Node 00 (Robot) operation is abnormal!It did not move within limited time.

Input slaveNode 00

IN OUT

Output slave

Motor A output ON

Sensor input did not turn ON within setting time!

Machine system DOWN!

Input slave Output slaveNode 01

IN OUT

Motor A

Input B




Access of smart information

• Smart information is accessed by Explicit Message– To give priority on machine I/O control– To separate control system and information system

IN OUT

IN OUT

Explicit message




Conclusion • Smart Technology bridges the gap between shop floor and

office floor.• Smart Technology provides a lot more detail information from

the components on the shop floor. And this enables the preventive maintenance and the quick failure recovery possible without huge investment.

• Smart Technology is best suited to DeviceNet protocol.With this profile of multi-vendor environments, Omron believes that this technology is very useful for any users, and also can be a big advantage against other networks and hard-wired systems.

Documents

2002 Conference & 8th Annual General Meeting Maintenance System with DeviceNet Presented by Tai Tateishi for OMRON Maintenance System with DeviceNet Masaru