Motion control used to require users and OEMs to connect a dedicated controller for logic and I/O control, and another controller for motion control, each of which needed its own software package, hardwiring, communications, and synchronization logic for integration. The connection was complex and time consuming. Today, some motion manufacturers are integrating the two controllers in one control architecture, resulting in higher speeds, increased product throughput, faster application development, easier maintenance, and lower system costs.
With the Allen-Bradley ControlLogix™ controller with integrated motion control, users receive complete motion configuration and programming within a single automation control programming package using RSLogix 5000 software. This eliminates the need to purchase and maintain separate motion, sequential, and drive programming tools. Built-in motion instructions eliminate the need to wire and coordinate two separate programs on different controllers, simplifying application programming and enhancing system performance.
Embedded directly into the ControlLogix system, the integrated motion control platform helps eliminate multiple programs and other redundancies found in traditional approaches, providing a single integrated system that streamlines the development process and reduces operating costs.
Contrast this with traditional systems, which require two separate controllers: one dedicated for logic and I/O, and another for motion. Each of those controllers requires its own software package, hardwiring, communications, and synchronization logic to integrate together. To synchronize the two, as much as 25% of program logic in a dedicated controller and 25% of program logic in the motion controller is used.
OEMs can use the integrated motion and sequential control platform and eliminate those redundancies. Programmers use central, built-in motion instructions to simplify motion and sequential programming, instead of the traditional two-controller approach that required writing and coordinating two separate programs on two different controllers. Motion and sequential elements are automatically synchronized with direct in-line execution of motion commands, decreasing modification programming and making troubleshooting easier.
Building in Modularity and Flexibility
Integrated motion control helps ensure flexibility, accuracy, speed, ease of use and, increasingly important, machine modularity -- the major challenges facing motion users.
Packaging OEMs, for example, can use integrated motion control to create modular machinery that meets the flexibility needs of its customers. Machines can be built in function models where machinery modules can be coupled together to create a variety of different machines. This flexible design scheme allows designers and operators to disconnect the machine in the center and add a new complete function module, as needed. The packaging OEM simply splits the machine, splits the electrical wiring at the interface points, adds the additional function modules required, programs the code into ControlLogix with integrated motion control, and gives the end user a reconfigured machine that now can run a different package.
Kinetix -- The New Science of Integrated Motion Control
The seamless integration of the Allen-Bradley ControlLogix™ controller, SERCOS Interface™, Allen-Bradley servo drives and motors and applied application knowledge, and Rockwell Automation Encompass™ partner actuators -- is called Kinetix, Rockwell Automation''s new standard for integrated motion control.
Kinetix involves fewer components, which means smaller panel enclosures, saving money on control cabinets and floor space. Plus, the Kinetix solution is scalable, offering expansion flexibility as needed. For example, modular memory, networking, and a multiprocessor architecture allow users to size the controller to meet changing application requirements.
Kinetix also decreases installation time. Unlike an analog terminal block, Kinetix uses a fiber optic SERCOS interface connection between drives and controllers. This results in fewer axis module cards and no external breakout boards to mount: two fiber optic connections can replace 18 discrete wires per drive, eliminating 36 terminations per axis. The result is a system that is less expensive and easier to wire. And by using the ControlLogix M08SE SERCOS Interface Motion Module, users can control eight axes at the same cost as a two-axis motion module, providing six additional axes of control at no additional cost.
Troubleshooting also is easier with Kinetix because of its improved diagnostics. For example, detailed drive and motor status information is available in RSLogix 5000 and the ControlLogix application program. Graphical trending allows users to collect and view important motion parameters. And with remote diagnostic capability, detailed drive status information can be sent from drive to controller and from controller to drive, allowing users to manage applications remotely from one central location.
A high-resolution feedback option in the controller improves positioning accuracy and reduces motion cycle time. And an absolute feedback option eliminates time-consuming homing cycles. Digital commands replace range-limited analog signals, while the integrated controller design eliminates both network delays and synchronization logic, greatly enhancing performance.