Intelligent Motor Controll Increases productivity across the

automation lifecyclel Increases intelligence for better

decision makingl Ensures your operations are safel Secures your environment

2Intelligent Motor Control Solution

Efficient motors drive industrial performance

Why motors fail• The most common

causes of motor failure are

- Thermal overloads

- Single phasing

- Bearing failure

- Rotor failure

- Stator failure

- Contaminants

Motors costs• Motors are the largest

consumer of energy in industry

• Motors consume in excess of 50% of energy in industrial applications

• A motor costs 10 times its initial purchase price each year

• Reducing the speed of a motor by 20% saves 50% in running costs

Maintenance options• Advanced diagnostic

information

• Preventative not reactive maintenance

• Planned downtime possible

• Be in control of your plant

• Reduced maintenance costs

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

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

Across multiple applications, the electric motor keeps industry running, used everywhere 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. And 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.

of motor failures can be prevented by appropriateprotection measuresSource: IEEE Petro-Chemical Paper PCIC-94-01

75%

What is your cost of unplanned motor down time? > Read the Blog

2 3Intelligent Motor Control Solution

Causes of motor failuresn Overloading

n Unbalanced power or single phasing

n Over- or undervoltage

n High ambient temperature

n Too many frequent starts

n Rotor failure

n Damaged bearings

… and many more

Impact of motor failuren Equipment downtime

n Loss of production

n Collateral equipment damage

n Equipment replacement

n Work in progress scrappage

n Overtime for repair crews

n Safety hazard for personnel

In a 10-year period, the energy costs of a motor could be 100 times the purchase value. Reliable and efficient motor performance is a business priority.

Imagine if you could predict your motors life... > Read the Blog

Mechanical 44%

CAUSES OF MOTOR FAILURE

Overcurrent 30%

Single Phasing

14%Others

12%

Visualization

Fixed Speed Variable Speed

EtherNet/IP EtherNet/IP

Design Environment

InformationSoftware

Logix Programmable Automation Controller

Safety Energy Security

Soft Starters

ArmorStart Low Voltage Drives

Intelligent Motor Control Centers

Medium Voltage Drives

Motion Control

Integrated Condition Monitoring

Electronic Overload Relays

Motion Control Condition Monitoring

Electronic Overload Relays

The Connected Enterprise/Industry 4.0

4Intelligent Motor Control Solution

Intelligent Motor Control

4 5Intelligent Motor Control Solution

Improve productivity and avoid motor failures with an integrated, data-driven approachThe integration of Allen-Bradley motor control devices into the Logix control platform helps reduce your programming time, ease startup and commissioning, and streamline diagnostics. By providing consolidated controller programming and device system configuration, operation and maintenance in a single software environment – Studio 5000 Logix Designer® – Premier Integration helps reduce complication and errors.

When functioning as part of the Rockwell Automation Integrated Architecture, Motor Control devices can do much more than just respond to start and stop commands.

eg. Predict mechanical problems and help improve performance with diagnostics and real-time data.

eg. Monitor performance either locally or remotely to make informed decisions about your assets.

One single development environment to configure and program your entire Logix/motor control system.

Add-on Profiles and motion instructions for simplified machine development, use and maintenance.

Integrated diagnostic, fault, alarm and event information into the Studio 5000 environment.

Automatic Device Configuration (ADC) allows Logix controllers to detect a replaced motor control device and download all configuration parameters automatically.

Motor control configurations are saved as part of the Studio 5000 Logix Designer project file. No need to store and maintain multiple files. You only need one file for the controller and motor control configurations.

Studio 5000® helps reduce programming time by automatically populating motor control parameters in the controller memory.

6Intelligent Motor Control Solution

Scalable performanceFrom simple fixed speed control to demanding variable speed control, precise multi-axes motion control to a specific engineered solution, Intelligent Motor Control helps to achieve higher levels of performance.

ProtectionIntelligent Motor Control products constantly monitor operations and can reduce unwanted downtime while increasing production efficiency, also enhancing safety and predictive maintenance.

InformationAn open, networked architecture enhances motor protection, shares diagnostic information and speeds troubleshooting for a more productive, intelligent process.

The Benefits of Intelligent Motor Control

6 7Intelligent Motor Control Solution

The conventional approachMany devices are still hard wired and unable to communicate with higher level control systems and are therefore unable to provide access to real-time data.n No access to real-time datan ON, OFF and Tripped - no pre-warnings possiblen User manual fault finding process - no diagnostic datan Unnecessary downtime periodsn Higher maintenance costs possiblen Changing parameters requires a specialist engineern Hard to track and record energy costs

Intelligent Motor Control provides key diagnostic information that enables you to optimize performance with real-time access to operation and performance trends.

Access to production and machine data helps you to make informed decisions that improve production and mitigate downtime, increase productivity and boost profitability, offering substantial benefits over conventional approaches.

Today’s intelligent approachn Seamless communication and system visibility for increased

performance and flexibilityn Operate and maintain motor performance through

intelligent equipment and networksn Reduce unplanned downtime with alarms and

advanced diagnostic informationn Monitor energy consumptionn Remote monitoring helps keep personnel away

from potential hazardsn Simplified troubleshooting and reduced start-up times

Providing the information you needCurrent

% Thermal Capacity Utilization

Trip / Warning Histories

Time to Trip

Time to Reset

Operational Hours

Number of Starts

Voltage

Energy & Power

3

2 3

1

E300 Electronic Overload has detected an overload condition on bottling conveyor – Line 2 – Motor 5MAINTENANCE ALERT. ? !

8Intelligent Motor Control Solution

2./3. Motor Control device detects an issue on a specific motor. Within seconds an alert is sent to the control room identifying the fault and specific motor.

Conventional technology vs Intelligent Motor Control SolutionIntelligent Motor Control technology diagnoses problems early and identifies where they are, reducing production losses significantly. Unplanned downtime is reduced to a minimum and proactive maintenance can be scheduled to avoid further issues.

• Early warning and diagnostic functions

• Production loss can be zero

• Opportunity for predictive maintenance rather than reactive

Cost of downtime • Loss of production

• Manufacturing scrappage

• Establishing cause of failure (Mechanical/ Electrical?)

• Time to troubleshoot and understand issue diagnosis

• Safety issues

• Impact on other equipment

1. Conveyor operates normally.

Scenarios

To see how Intelligent Motor Control makes the difference, CLICK HERE

764 5

E300 Electronic Overload has detected an overload condition on bottling conveyor – Line 2 – Motor 5MAINTENANCE REQUIRED.? !

8 9Intelligent Motor Control Solution

6. The problem is resolved and process returns to normal with minimal or no loss of production.

With Intelligent Motor Control Devices energy consumption can be monitored on each motor individually at any point in time. This not only helps control energy costs but can also show changes in trends that allow action to be taken accordingly.

4. Maintenance engineers are advised of an ongoing issue and are able to plan required action.

5. A maintenance engineer now has the opportunity to quickly resolve the issue before production stops or perform a controlled shut down.

Additional benefit - Real-time Energy Management

10Intelligent Motor Control Solution

Solutions that make more intelligent use of assetsFor simple fixed and variable speed control to precise torque and position control, we offer a complete portfolio of Intelligent Motor Control solutions that help customers to achieve the right levels of control, whatever the application.

Condition Based Maintenance Solution Reduces Downtime

Read the Customer Case Study

Eco Drives and The Connected Enterprise

Read the Customer Case Study

10 11Intelligent Motor Control Solution

Consider Intelligent Motor Control solutions for new projects and existing application upgrades

Use Intelligent Motor Control as part of your drive towards a Connected Enterprise / Industry 4.0The information unlocked with Intelligent Motor Control can be a significant step towards maximizing today’s technologies. The Connected Enterprise brings IT and OT together to optimize productivity and competitiveness.

• Transforms data into actionable, real-time information

• Smart manufacturing employing standardized, secure networks

• Connected, efficient and safe equipment

• Work smarter and increase asset utilisation

• Increase workforce efficiency and lower total costs of ownership

Upgrade existing applications• Upgrade existing installations and enhance

OPEX investments

• Upgrades possible at evenings, weekends or shutdown periods, minimising disruption

• Immediate Energy savings can be achieved by modifying control options and accessing real-time data

• Diagnostic information gives immediate return on investment in terms of improved productivity

For new applications• Implement as part of a CAPEX-funded solution

for new projects and greenfield sites

• Investment in modern technology soon recovered in productivity and uptime gains, operational efficiencies and energy savings

• Specifying the right Intelligent Motor Control solution for any new project helps to future-proof designs and protect your investment

Find out more about The Connected Enterprise

For help with updating your applications please contact Rockwell Automation.

Working together with Rockwell Automation

Make more of your Connected Enterprise by connecting with Rockwell Automation and our partners.

Get answers to your questions on sales, products, services and technical support. Find out more

Access help to design, build and maintain your system solution through the Rockwell Automation PartnerNetwork™ of leading distributors, system integrators and others. Find out more

Allen-Bradley, LISTEN. THINK. SOLVE., Rockwell Software, Studio 5000 and Studio 5000 Logix Designer are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.

Rockwell Automation, Inc. (NYSE:ROK), the world’s largest company dedicated to industrial automation, makes its customers more productive and the world more sustainable. Throughout the world, our flagship Allen-Bradley® and Rockwell Software® product brands are recognized for innovation and excellence.

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Publication IMC-BR004A-EN-E December 2015 Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.