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Rockwell Automation Fair 2008 Review

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Week of November 17, 2008 Nashville, TN

By Bill Lydon - Contributing Editor

As usual, the Rockwell Automation Fair was an impressive event with over 11,000 attendees and over 90 Encompass partners. This is a very successful show that creates enormous goodwill and is the most successful control show in North America.   Training is becoming a big part of the event and allows users to justify the time and money to attend.  Distributor travel packages also make it much easier for users to attend the event.
 
Encompass Program
The Encompass program has been successful in providing distributors and customers with products to meet field application requirements that Rockwell does not make.  Products referenced in the program must meet the following criteria set by Rockwell Automation:
  • Provide functionality not delivered by Rockwell Automation products.
  • Enhance and Extend the Rockwell Automation Solution through built-in connectivity to a Rockwell Automation architecture or as a critical component to the solution.
  • Support industries or applications associated with Rockwell Automation product solutions.
  • Be provided by reputable, sound companies committed to product and service quality committed to partnering with Rockwell Automation with complementary marketing strategies.
  • Be committed to the mutual success of Rockwell customers.
 
The mix of Encompass partners exhibitiing at Automation Fair illustrates the range of offerings:
Encompass Partners by Technology
  • Software - 14%
  • High Tech Control - 16%
  • Communications  - 19%
  • Wire & Cabinets - 10%
  • Power - 15%
  • Test & Measurement - 15%
  • Other Low Tech - 13%
 
Overall Impression
Rockwell and its distributors are a powerful force in United States and the company is growing in other areas of the world with 50% of its workforce now outside of the USA. The goal is to achieve 60% of revenue outside of USA by 2013.
 
The Rockwell Automation message is simple; buying from Rockwell Automation makes it easier for customers to deploy systems due to an integrated architecture.
 
Comments made by Keith Nosbusch, Rockwell Automation Chairman and Chief Executive Officer at the media day session provide insight into Rockwell Automation’s thinking. The major theme is that manufacturing convergence is central to Rockwell Automation’s strategy. Rockwell views convergence of information from the plant floor to the enterprise as a key need in manufacturing - one that they can address.
 

 
Nosbusch offered advice to manufacturers...
“even as the financial news dominates the headlines it is easy for manufacturers to become preoccupied with things beyond their control, to feel like victims of the economy, and to take their eyes off of things they can control. We strongly advise against that. Productivity is the foundation of every good manufacturing strategy as it has been since the dawn of the industrial revolution.”
 
"...innovation has gone from a luxury to a necessity.”
 
Industrial Networking
Nosbusch made a clear statement about industrial networking,"Open standard, unmodified Ethernet!" This has become the mantra to distinguish EtherNet/IP™ from other protocols that require special hardware and communications stacks. (EtherNet/IP is based on the ODVA CIP model.) Nosbusch punctuated this by stating, “We also understand that the plethora of communications networks in manufacturing will converge to a standard, open, unmodified Ethernet; and information that is highly fragmented today in many custom software applications will converge into a set of software services based on industry standards that we call FactoryTalk”. 
 
Rockwell Automation Investor Meeting
Nosbusch’s answers to analyst’s questions at the Rockwell Automation Investor Meeting held during Automation Fair provided further insight.
Independant Software Opportunity
One analyst asked Nosbusch, “You talk about the information domain being a lot like Logix…are we being led to believe the information opportunity is going to be as important as Logix to Rockwell Automation?”   Nosbusch answered that Rockwell Automation, “...wants to integrate the production disciplines with the FactoryTalk framework.”   Nosbusch went on to describe how FactoryTalk allows multiple applications to play together and provide actionable information for real-time decision making creating greater productivity on the plant floor. “That is the goal we believe we can accomplish with open standards, with a transparent ability to collect information even in a heterogeneous plant environment - where it sits over the top of any automation system but still creates the performance reports.” The analyst followed up by asking, “...are you saying that in fact FactoryTalk could be sold in a competitive environment where it could be sitting on top of an Emerson or Honeywell system?”  Nosbusch replied, “That is exactly what we are saying, our control information technology is control agnostic. Our information strategy is completely independent of what is on the plant floor.”
 
CISCO Joint Venture
When asked how the CISCO joint venture launch was doing, Nosbusch commented, “We started shipping this last summer; the ramp has exceeded our expectations. The real key with what we are doing with CISCO today is the reference architecture which gives the roadmap and the guideline to people about how they should be thinking about architecting their plant information infrastructure for the future.”
 
Note: Reader may want to download the CISCO/Rockwell, Ethernet-to-the-Factory 1.2 Design and Implementation Guide
 
Process Control
Nosbusch noted that process control is long term the single largest growth market for Rockwell Automation.
 
Endress+Hauser Relationship
One analyst questioned, “Can you define your relationship with E&H and what that means as expansion into process industries and establishing your reputation there."  Nosbusch answered that E&H is one of the top two suppliers of end devices in the process industry. “In the process space companies are looking for a complete solution, we work with E&H to give customers interoperable, integrated solutions. Together we can give customers what they are looking for - tighter integration. We appear as one company…” 
 
Logix Architecture vs DCS
Jim Wetzel, Technical Director, Control and Information Systems General Mills was a member of a panel during the media day. Wetzel described how General Mills is in the process of changing all controls, discreet & process, to the Logix architecture. I had the opportunity to ask him how the process DCS engineers are adapting to the new architecture coming from the DCS world.  Wetzel answered,“They love it; they hate it! The people that hate it look at it and say, Finally Logix is going to be a platform like a DCS but it just takes a long time to get there, and they say,  We used to have a DCS and now we will eventually have a DCS. On the positive side they can do a lot of stuff much easier than they could do before. The DCS people are very well grounded in the right thought process and now the tools aren’t in their way. Historically you had to know a whole lot of stuff to be able to get something done; now the tools make that a lot easier. So there are pro’s and con’s on both sides and for us the pros definitely outweighed the cons.”
 

How are process DCS engineers adapting to the new architecture coming from the DCS world?
"They love it; they hate it!”
 "So there are pro’s and con’s on both sides and for us the pro’s definitely outweighed the con’s.”
 Jim Wetzel, Technical Director, Control and Information Systems General Mills
PlantPAx
Rockwell Automation introduced PlantPAx systems and solutions to take another step in becoming more effective in process control. “This roadmap represents a culmination of the investments we’ve made to extend and enhance our process technologies, systems, solutions and services,” said Steve Eisenbrown, senior vice president, Automation and Software, Rockwell Automation. “It also reflects tremendous progress in integrating our organic investments with our partner and acquisition investments. The PlantPAx portfolio is the next step in our commitment to help customers achieve process automation excellence. It unifies our core capabilities and technologies with those of our market leading partners, like OSIsoft and Endress+Hauser, and acquisitions, like Incuity, Pavilion Technologies, ICS Triplex and ProsCon, under a common systems and solutions umbrella to provide even greater market innovation and value to process industry customers. The PlantPAx portfolio also exemplifies the Rockwell Automation leadership position in plant-wide automation and information systems and solutions.”  See PlantPAx Announcement.
 
Rockwell appears getting more skilled at successfully acquiring and integrating software companies.
 
Expand ControlLogix® and CompactLogix® Systems with
Opto 22 SNAP I/O™
 
Opto 22 is promoting the use of their SNAP I/O as a way to add field I/O points and functions to ControlLogix® and CompactLogix® systems over EtherNet/IP™.
This is accomplished with a free firmware upgrade to SNAP-PAC-EB1 and -EB2 Ethernet I/O that adds support for the EtherNet/IP™.  SNAP I/O integrates into these Logix platforms natively with no additional programming.
 
The company promotes the idea that SNAP I/O can perform a variety of advanced control functions independent of the programmable controller. Functions include PID loop control, high-speed counting,  thermocouple linearization, analog ramping, scaling, engineering unit conversion, temperature conversion, and time-proportional output.
 
SNAP I/O has been conformance-tested by ODVA’s Test Service Providers®, to be compatible with EtherNet/IP.
 
For more information, contact Opto 22 at +1-951-695-3000 or visit www.opto22.com or www.io4ab.com.
Rockwell Controllers
Rockwell has a wide range of controllers including the older SLC 500 and PLC-5 lines.  This is how Rockwell breaks out the product lines:
 
Programmable Automation Controllers (PAC)
  • CompactLogix System
  • ControlLogix System
  • FlexLogix System
  • SoftLogix5800
  • DriveLogix System
 
Programmable Logic Controllers (PLC)
  • Pico Controllers
  • MicroLogix 1000
  • MicroLogix 1100
  • MicroLogix 1200
  • MicroLogix 1400
  • MicroLogix 1500
  • SLC 500 System
 
SLC 500 Support Commitment
Rockwell has a published statement committing to selling & supporting SLCs into the next decade.
 
Management Statement
Dear Customer,

Rockwell Automation appreciates your investment in the Allen-Bradley SLC 500, and we will continue to protect that investment. We offer a complete range of SLC 500 products for sale to service a wide variety of applications. And we continue to invest in the SLC 500 architecture. Our most recent additions include an Enhanced 5/05 CPU with 10/100 Mbps, increase connections, and embedded web server capability. Other additions include DF1 Radio Modem Compatibility for SLC 5/03, 5/04 and 5/05, the 1747-DPS1 Port Splitter, and the 1747-UIC Universal Serial Port (USB) to DH-485 Interface Converter.

We plan to actively market and manufacture the SLC 500 product line well into the next decade. This line will continue to service those small to mid-range PLC applications where high performance and a wide variety of communication networks and I/O structures are important.

Allen-Bradley plans to continue to offer hardware/firmware upgrades and repair of SLC 500 Family products. Protecting our customers’ investment is a significant reason we have an installed base over 1.6 million CPU and over 12 million 1746 I/O installations world-wide. Furthermore, it is our practice to support products for seven years from the date they are removed from general sale, pending availability of components.

To give you some idea of our commitment to our customers, the 1772 Series PLC-2 family, which was introduced in 1979, was removed from sale in 2002. That is a product life in excess of twenty years. While we cannot predict component availability and market forces for the SLC 500 that would allow us to do the same, we are committed to the sale and support of the SLC 500 family for the foreseeable future.

I hope that this brief correspondence will give you some idea of Allen-Bradley’s commitment to providing a quality automation product and commitment to the SLC 500 product line.

Paul Kohntopp
Control Platforms (SLC/PLC) Business Manager
Automation Control and Information Group
Rockwell Automation / Allen-Bradley
 
PLC Migration Program - STEPFORWARD™
Rockwell has created the STEPFORWARD™ migration program.  The StepForward program offers promotional incentives for companies wanting to upgrade/migrate Rockwell Automation equipment.
 
Program Overview
  • Product trade-ins (both hardware and software) must be same product type as new product replacement (i.e., Controller for a Controller).
  • Product trade-ins must be in working condition.
  • StepForward credits cannot be combined with any other promotion, credit or special discount.
  • Local distributor participation is optional.
  • The StepForward program is available in the USA. If outside of the USA, please check with your local Rockwell Automation office for participation.
  • Customers have 90 days from the shipment date of new product to request Return Authorization.
  • New product received will have a full-factory warranty.
  • The StepForward program will be reviewed quarterly and is subject to change without notice.
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