Automation Fair 2009

November 11-12, 2009

Integrated Architecture In Action Top Floor to Shop Floor Control A Case Study: Aircraft Paint Hangar Integration
Ed Diehl Concept Systems Inc

Copyright 2009 Concept Systems Inc. All rights reserved.

Agenda
Concept Systems Introduction Paint Hangar Overview Upgrade Objectives Design Approach System Design Network Architecture Visualization Top Floor Connection Solution Benefits

Who is Concept Systems?

Full-Service Multi-Industry Automation Solution Provider Regional Offices
Albany, Oregon Seattle, Washington Denver, Colorado

Control Engineering 2007 System Integrator of the Year Certified Member Control Systems Integrator Association (CSIA) UL-508A, UL-698A, CSA, CE & UL-NNNY Manufacturer
Our designs comply with NFPA79 standards Our designs comply with NEC standards We will support customer-specific requirements and standards

Most importantly our people and our processes

Case Study Aircraft Paint Hangar

Boeing Everett Facility Commercial Airplane Group 45-03 Building Paint Hangar Outdated controls and equipment Did not meet production requirements Tooling/process equipment not acceptable for 787 Dreamliner

The Boeing Company

Two ways to paint airplanes

Manual Process

Integrated Controls

Upgrade Objectives
New 787 Dreamliner Increase production rates for 777 Eliminate accidental contact with aircraft Improve curing process Improve water treatment, air filtration and solvent processing Tight control over all process variables (except spraying paint) Provide integrated control of all hangar systems
Stacker Cranes Wing/Tail Stands Process Air Water Treatment Over Wing Safety Hoists Solvent Still Paint Mix Room Waste Disposal Lighting
The Boeing Company

Critical to Success: Stacker Cranes & Collision Avoidance Intelligence

Design and Construction Teams

Project Implemented in two main phases Design
Harris Group Facility engineering FSi Consulting Process air, HVAC EISI Stacker Crane and Wing Stand mechanical Casper, Philips Process Air Concept Systems Integrated controls

Construction
Dahlgren Industrial General Oregon Iron Works Stacker Cranes American Boiler Works Wing Stands University Mechanical Mechanical Electrix Facility Electrical Dunston Bradley Equipment Electrical Johnson Controls Instrumentation Concept Systems Integrated controls

Control System Design Approach

Rockwell Automation Integrated Architecture
Hybrid application (process and discrete control) Customer experience and familiarity (evolution from PLC5) Scalable network architecture Client-server HMI

Specific Technologies
ControlLogix L63 processors PowerFlex 70 and 700 FlexEx distributed IO (Hazardous) FlexIO distributed IO (Safe) Entek (Vibration monitoring) AMCI 7264 (Logix SSI interface module) IntelliCenter MCCs Ethernet/ControlNet EX/DeviceNet Redundant FactoryTalk View SE (primary visualization/control) PanelView Plus (local visualization/control) Specter Win-911 (messaging) RSLinx Gateway (PLC5/RSView32 comm) Custom C++ application (Collision Avoidance)

Vital Statistics
12 Processors 56 Variable Frequency Drives 2,517 IO points 90,000 sqft facility

Overall System design

Collision Avoidance

Supervisory Control & Visualization

Floor Control

Wing/Tail OWSH

Misc Bldg

Stacker Crane (typical)

Process Air

Network Architecture
Corporate
FactoryTalk View SE Redundant Servers View SE Clients Collision Avoidance Workstation Collision Avoidance Computers (1 per Stacker)

Collision Avoidance
(typical)

Peer-to-Peer
Misc Bldg Process Air Stacker Crane (typical)

12 PACs total

System Ethernet
FlexIO Intellicenter MCC PV+ VFD FlexIO Intellicenter MCC VFD

VFD

VFD

VFD

VFD

System ControlNet EX
FlexEX FlexEX FlexEX FlexEX FlexEX FlexEX

System DeviceNet
Entek Entek

Visualization - Overview

Visualization Stacker Cranes

Visualization Wing & Tail Stands

Visualization Process Air

Visualization Process Air

Visualization Solvent Still

Collision Avoidance

Logic Best of Both

Used combination of Ladder and Function Block programming Function Block programming used for Process Air PID control Ladder Logic used everywhere else

Top Floor Connection

Logging of all Paint Cure data (DataLog) used by Engineering NEHSHAP data
National Emissions Standards for Hazardous Air Pollutants Filter box exhaust data stored on ODBC database on server Measured once a day Accessible from any computer on Corporate network using MS Access

Tracking of Login/Logout Tracking of all control operations and alarm acknowledgements by user HMI access from any Corporate network with a View Client In Process ViewPoint web server (remote HMI access via browser)

Solution Benefits
Tight control over all process variables Reduced cycle time No collisions! Plus . . . . Common control hardware platform Common control software platform Common visualization platform Integrated manufacturing solution Network capabilities and flexibility Easy, secure access from corporate network System customer can maintain and support Provided a control framework and common look and feel standard for use throughout the Everett facility

Questions?

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Thank You!
Learn more about Integrated Architecture in Action
Discrete Process

Please visit our booth #315

Numerical Control (PNC)

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