2002 Conference & 8th Annual General Meeting Maintenance System with DeviceNet Presented by Tai Tateishi for OMRON Maintenance System with DeviceNet Masaru Imoto OMRON Corporation Presenter: Tai Tateishi OMRON Electronics LLC October 1, 2002

2002 Conference & 8th Annual General Meeting Maintenance System with DeviceNet Presented by Tai Tateishi for OMRON Agenda 1.Expectation for Field Networks 2.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 functions 5.Access of smart information 4.Conclusion

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

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

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

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

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

2002 Conference & 8th Annual General Meeting Maintenance System with DeviceNet Presented by Tai Tateishi for OMRON Smart Technology Enables preventive maintenance easier, more efficient, and more economic by having value added information in slave.

2002 Conference & 8th Annual General Meeting Maintenance System with DeviceNet Presented by Tai Tateishi for OMRON Control system Maintenance system Maintenance System and Procedure with DeviceNet Smart Technology DeviceNet IN OU T Information for Maintenance Control information IN Time to Operate Monitor Cycle Counter Network Power Monitor I/O Power Monitor Total Working Time Monitor The cylinder's speed is incorrect! It might be time to check the switch! IN 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-series Smart Slave Value-added information with machine control Ethernet ： Connection to Information layer Information for preventive maintenance and real-time error status Communication Error History Monitor

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

2002 Conference & 8th Annual General Meeting Maintenance System with DeviceNet Presented by Tai Tateishi for OMRON 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 slave Node 00 INOUT Output slave Motor A output ON Sensor input did not turn ON within setting time! Machine system DOWN! Input slave Output slave Node 01 IN OUT Motor A Input B

2002 Conference & 8th Annual General Meeting Maintenance System with DeviceNet Presented by Tai Tateishi for OMRON 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 O UT IN O UT Explicit message

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