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Reduce Cost, Size, and Weight

Programmable Automation Controllers (PAC). Reduce Cost, Size, and Weight. July 21, 2005. Product Development. Engineering Services. About Fairmount Automation. Founded in 1996 Located in Suburban Philadelphia, PA OEM of Programmable Automation Controllers

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Reduce Cost, Size, and Weight

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  1. Programmable Automation Controllers (PAC) Reduce Cost, Size, and Weight July 21, 2005 © 2005 Fairmount Automation, Inc. All Rights Reserved.

  2. Product Development Engineering Services About Fairmount Automation • Founded in 1996 • Located in Suburban Philadelphia, PA • OEM of Programmable Automation Controllers • Products Installed on Over 30% of U.S. Navy Fleet • Leadership Role in Design and Development of Automated Damage Control Systems for DD(X)

  3. DD(X) AFSS • Designed and implemented leading-edge Autonomic Fire Suppression System (AFSS) • Based on embedded smart-valve technology • Distributed device-level control (LonTalk protocol) • Successful Weapon Effect Test (WET) on ex-USS Peterson (first ever) • Successful live-fire tests on ex-USS Shadwell • Anticipate central role in DD(x) Flight I ADCS design • Process improvement initiative underway to achieve CMMi Level 3 assessment (sponsored by Raytheon)

  4. First Generation FAC-2000 • MIL-SPEC Grade A Shock, MIL-SPEC Vibration • Programmable Digital Multi-Loop Controller • User-Friendly, Hardened Integral Operator Interface • Initially Installed in 1997 to Overhaul Legacy Controls • Reactor Secondary Steam Plant Controls • Catapult Accumulators • Primary Boiler Controls • Main Feed Pumps • Distilling Plants • Evaporators USS John F Kennedy

  5. Current Installed Base Over 1500 Loops of Control • Aircraft Carriers • Amphibious Assault • Amphibious Transport • Destroyers • Cruisers • Frigates • Combat Support Ships • Submarine Supply Ships USS Boone

  6. Propulsion Boilers Feed Pumps Distilling Plants Waste Heat Boilers Condensers Evaporators Oil and Fuel Heaters Steam Turbine Aux. Diesel Generator Aux. Force Draft Blowers Deaereating Feed Tanks Chilled Water Plants Catapult Accumulators Compressors Purifiers Compressors Shaft Speed Indication Installed Applications USS Ticonderoga

  7. Chameleon: New Controller Platform

  8. Key Characteristics MIL-SPEC qualified “out-of-the-box” Eliminates need for costly, bulky, and heavy enclosures Distributed processor architecture enhances survivability Open connectivity to industry standard protocols and networks Flexible and modular architecture with versatile I/O suite Easy to assemble, install, and maintain Integrated user-interface with prominent displays and buttons Wireless device configuration and data retrieval

  9. Chameleon PAC Installations • 350+ Chameleon Modules In Service (U.S. Navy) • Currently Installed on 20 U.S. Navy Ships: USS IWO JIMA USS VANDERGRIFT USS DUBUQUE USS BOONE USS JOHN HALL USS WASP USS DOYLE USS UNDERWOOD USS PONCE USS DEWERT USS KAUFFMAN USS FORD USS GARY USS ESSEX USS SIMPSON USS BRADLEY USS CLEVELAND USS PELELIU USS NASHVILLE USS MCINERNY

  10. FFG-7 Class SSDG Aux. Control • Decentralized Control Architecture • 5 Networked Chameleon Nodes • 9 PCM-1, 6 NIM-1, 5 ACP-1 • Installed on 10 Ships; Approved for Entire Class • Control Loops Include • Fuel Oil Transfer and Service Heaters • Main Engine Lube Oil Purifier Heater, Start Air Cooler • Main Engine Lube Oil Cooler, Lube Oil Pressure • Hot Water Tank • SSDG Waste Heat Temperature • SSDG Jacket Water Temperature • Networked to flat screen to provide plant-wide information and remote control USS Doyle

  11. FFG-28 Installation Pictures

  12. LHA-1 / LHD-1 Class SSTG Aux. Control • Decentralized Control Architecture • 3 Networked Chameleon Nodes • 5 PCM-1, 3 NIM-1, 3 ACP-1 • Installed on 4 Ships; 2 more to begin in October • Control Loops Include • SSTG Hotwell Level • SSTG Recirc Temperature • SSTG Gland Seal Pressure Control • Fully networked • Plant-wide information accessible at any node via wireless infrared interface USS Peleliu

  13. LHD-1 Installation Pictures

  14. LPD-4 Class Chilled Water Control • Decentralized Control Architecture • 5 Networked Chameleon Nodes • 9 PCM-1, 5 NIM-1, 5 ACP-1, 2 UCM-2AMI • Installed on 3 Ships • Expanded system to be installed on LPD-9 in Q4 • Control Loops Include • Flow rate thru chiller pump with local A/M control • Cooling water for condenser • Monitor expansion tank level and pressure • Monitor condenser outlet pressures • Networked to flat screen to provide plant-wide information and remote control USS Cleveland

  15. Automatic Burner Ignition System • Two Nodes (4 DAM-2, 2 PCM-1, 2 NIM-1, 2 ACP-1) • Installed on USS IWO JIMA (LHD-7); LHD-2 next • Burner light-off system for main propulsion boiler • Monitors atomization pressure, windbox pressure, fuel-oil pressure, and port-use fan speed • Controls burner fuel flow, ignition arm position, and ignition spark • Coordinated control from burner front, EOS, or both • Future expansion to include • Full burner management system • Integration with FAC2000-based Automatic Boiler Controls • Fully automated throttle control from the bridge USS Iwo Jima

  16. Manual Boiler Light-Off

  17. Shaft-Speed Indication System • Two Nodes • 2 PCM-1, 2 NIM-1, 6 ACP-1, 4 UCM-1, 2 NBM-1 • Installed on USS PONCE (LPD-15); LCC-19 next • Port and starboard shaft quadrature encoders inputs • Calculates RPM and maintains shaft revolution count • Provides redundant power supplies for remote RPM displays • Interfaces with external display using NMEA protocol • Implemented with our user-defined ASCII messaging • Applicable to every ship in the Fleet USS Ponce

  18. LPD-15 Installation Picture

  19. Key Characteristics: Packaging • MIL-SPEC qualified “out-of-the-box” • High Impact Shock: MIL-STD-901D (Grade A, Class I) • Mechanical Vibration: MIL-STD-167B • Electro-Magnetic Interference: MIL-STD-461E (Pending) • Power Spikes: MIL-STD-1399 • Designed for shipboard environments • Operating Ambient Temperature Range: -40°C to 65°C • Keypad & Housing: NEMA 4X, 6, and 13 • Eliminates need for costly, bulky, and heavy enclosures • Easy to assemble, install, and maintain • Integrated user-interface with prominent displays and buttons

  20. Key Characteristics: Packaging

  21. Key Characteristics: Modular Design • Multi-Processor architecture enhances survivability • Each module is self-contained controller • Deterministic performance (sub 10ms) • Facilitates future technology insertion • Open connectivity to standard protocols and networks • Versatile I/O suite • All modules are hot-swappable • Highly granular redundancy • I/O connections • Control execution • Power sources • Network connections

  22. Key Characteristics: Modular Design

  23. Key Characteristics: Design Flexibility • Local controller for OEM equipment • Strainers • Chillers • Pumps • Generators • Valves • Remote I/O drop • Connectivity to central PLC • Potential integration with Smart Carrier program • Decentralized and highly-survivable ship-wide machinery control and monitoring system

  24. MCMS Conventional I/O Drop • Enclosure to House • PLC or VME-based control hardware • Din-rail mounted terminal points • Power supplies / conditioners • Network media converters • Assume 24” x 24” x 8.5” • Require shock mounts • Coily mounts • C-Worthy mounts (adds 5.5” to depth) • Angle spot weld studs mount to ship (adds 2” to depth) • Signal densities • 50-100 I/O points typical, approximately 160 maximum • Assume 100 points per enclosure for this example • Total weight • 140 lbs typical (including mounts) • Assume 90 lbs per enclosure is achieved for this example

  25. MCMS Chameleon I/O Drop • Integrated Package • All power supply, media converters, terminal points, etc. • Sample I/O drop configuration • 2 power modules, 2 network modules, 8 I/O modules • Dimensions: 24” x 24” x 6.5” • Chameleon node • 3-row mounting bars • Angle or studs connect bars to ship • Signal density • 96 to 144 I/O points with currently available modules • Assume 100 points on average for this example • Total weight: 40.5 lbs • Chameleon nodes 20 lbs, Mounting bars 10.5 lbs, Other 10 lbs

  26. MCMS Chameleon Mini-I/O Drop • Integrated Package • All power supply, media converters, terminal points, etc. • Sample mini-I/O drop configuration • 1 power module, 1 network module, 2 I/O modules • Dimensions: 16.5” x 11.5” x 6.5” • Chameleon node • 2-row mounting bars • Angle or studs connect bars to ship • Signal density • 24, 30, or 36 I/O points with currently available modules • Assume 25 points on average for this example • Total weight: 16 lbs • Chameleon node 7.5 lbs, Mounting bars 3.5 lbs, Other 5 lbs

  27. CVN-21 MCMS I/O Drop Comparison • Assume example platform has 20,000 I/O points • Conventional I/O Drop • 200 drops required • Volume: 5.33 ft3 per drop, 1,067 ft3 total • Weight: 90 lbs per drop, 18,000 lbs total • Cost Estimate (Avg.): $25,000 per drop, $5.0MM total • Chameleon I/O Drop • 200 drops required • Volume: 2.17 ft3 per drop, 433 ft3 total • Weight: 40 lbs per drop, 8,100 lbs total • Cost Estimate (Avg.): $15,500 per drop, $3.1MM total • Chameleon mini-I/O Drop • 800 drops required • Volume: 0.71 ft3 per drop, 571 ft3 total • Weight: 16 lbs per drop, 12,800 lbs total • Estimated Cost: $4,500 per drop, $3.6MM total

  28. CVN-21 MCMS Example Plant • Example plant layout for I/O drop • 100 points of I/O • Ten pieces of machinery • 100ft x 100ft plant • All cabling runs to I/O drop • Mix of analog and digital cables • Assumed cable weights of 0.075lbs/ft and 0.1lbs/ft • Estimated cable weight: 269lbs

  29. CVN-21 MCMS Example Plant • Example plant layout for Mini I/O drop • 100 points of I/O (4 mini drops) • Ten pieces of machinery • 100ft x 100ft plant • Network cable runs to Mini I/O drops • Assumed average power source within 25ft • Assumed average I/O length is 28ft • Assumed CAT5e network cable weight 0.065lbs/ft (LSC5OSW-4) • Assumed I/O and power wire weights of between 0.075lbs/ft and 0.1lbs/ft • Estimated cable weight: 85lbs

  30. CVN-21 MCMS Mini I/O Benefits • Assume example platform has 200 plants similar to example plant (i.e. 20,000 points of I/O on platform) • Total Weight Comparison • I/O drop weight • Cable: 53,800 lbs • I/O Drops: 18,000 lbs • Total: 71,800 lbs • Mini I/O drop weight • Cable: 17,000 lbs • Mini I/O Drops: 12,800 lbs • Total: 29,800 lbs • Weight Savings: 42,000 lbs (over 18 tons or the 1.4 times the weight of one empty F/A-18F jet fighter!)

  31. CVN-21 MCMS Mini I/O Benefits • Significant cabling reduction • Cable cost savings • Installation labor cost savings • Design engineering cost savings (simplified drawings) • Weight savings: 42,000 lbs • Simplified troubleshooting • Easier to isolate wiring problems • Can operate systems in isolation • Don’t need to bring up all systems at once • Improved survivability • Move towards decentralizing control • Heartbeat control • Mode shedding

  32. Chameleon Modules • AC Power Module (ACP-1, ACP-1PA) • DC Power Module (DCP-1) • Process Control Module (PCM-1) • Discrete Automation Module (DAM-1, DAM-2) • Network Interface Modules (NIM-1, NIM-3, NIM-4, NIM-6) • RS-485, RS-422, RS-232 • Modbus • LonTalk • FairNET • User-defined ASCII / Binary messaging • User Configurable Modules (UCM-1, UCM-2, UCM-2NB, UCM-2AMI)

  33. AC/DC Power Modules • Single or Multi Power Source • Redundant Power with Automatic Switch-over • Rugged packaging • Spike Tolerance per MIL-STD 1399 • Over-current Shut-off • Input Circuit Fused • ACP-1PA Standalone Power Source

  34. Process Control Module (PCM-1) • Process and Motion Control • Four Analog Inputs • Current, Voltage, Resistance, RTD • Four Analog Outputs • Current, Voltage • Two Digital Inputs • On/Off, pulse counting • Frequency meter, event timing • Pulse width, quadrature decoding • Two Digital Outputs • On/Off, PWM, square-wave generator • Four 4-digit numeric displays • Eight 3-color LED indicators

  35. Discrete Automation Module (DAM-2) • Discrete logic, sequence, batch • Ten Digital Inputs • Broad range of AC or DC signals • Configured in software • Eight Digital Outputs • AC or DC Individually Soft-Configured • Hybrid Mechanical / Solid-State Relays • Dramatically improved endurance • Drastically reduce conducted and radiated EMI produced when switching inductive loads by maintaining zero voltage crossing turn on and zero current crossing turn off • Four Push-Buttons • Eight 3-color LED indicators

  36. Network Interface Modules • Network Media Available Today: • NIM-1: RS-485, NIM-3: RS-422 • NIM-4: RS-232, NIM-6: TP/FT10 • Network Protocols Available Today: • Modbus (Master/Slave, RTU/ASCII) • LonTalk • FairNET (FAC2000 Integration) • OPC Server (ICAS Integration) • Custom ASCII / Binary Protocols • NMEA Implementation • Adaptable to custom TCP/IP messaging • Currently In Development • NIM-2: Ethernet w/ 6-Port Switch • NIM-5: Ethernet (TCP/IP, Ethernet/IP) • NIM-7: ProfiBUS DP (Master/Slave)

  37. User-Configurable Modules (UCM-X) • Custom modules with buttons, displays, etc. • Use as junction box • Available in full or half size

  38. Development Roadmap • Networking Modules in Development: • NIM-2: Ethernet with built-in 6-Port Switch • NIM-5: Ethernet (support TCP/IP, Ethernet/IP, ProfiNET) • NIM-7: ProfiBUS DP (Master/Slave) • NRM-1: Multi-port RS-485 Repeater Module • Wireless Access Point Module • Joint Development Program with 3e Technologies (SBIR) • FIPS 140.2 Certified Wireless Security • 802.11 a/b/g, Zigbee • Continue to Expand I/O Module Offering • Touch-Screen Interface Module • Motor Drive Module • Battery Backup Module • Direct connectivity to TSCE (DDS Protocol) • Integrate C/C++ Programming with Function Blocks • Plant-wide Configuration Management

  39. PAC Programming: Design Pad G3 • Easy to Use Graphical Programming • Intuitive Function Block Diagrams • Requires Little or No Training • State-Transition Diagrams • Clear and Concise Method of Programming • Reduced Program Size and Complexity • Organizes Complex Control into Easy to Program Nuggets • Eliminates Multiple Use of Interlocks and Transition Logic Typical Using Ladder Logic • Integrated Simulation Platform • All signal values continuously displayed during simulation run • Simplifies Diagnostics and Check-out by Highlighting Active States • Wireless Device Configuration

  40. Design Pad G3 Demonstration

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