Just as wireless networking can help users and applications span long distances, virtualized control programming can make it easier to develop, implement and scale up control functions and the processes they manage. For example, to keep simulating and testing its wood processing solutions despite increasing demand and throughput, Comact recently worked with Rockwell Automation to better emulate its controllers, access greater processing power, and test them in a virtual environment.
Typical sawmill projects cover multiple acres, integrate complicated processes and varied equipment, and usually require 15 or more controllers. Because this processing power was often scarce, Comact reports its engineers shared access, and frequently waited until the end of a project to test it. In addition, they had to convert their control programs to run the emulation software, and were losing configurations in the process. Finally, because the final emulated project wasn’t usable in the field, it also had to be reconverted for installation on the actual physical hardware.
“We’ve always simulated and tested our control code before startup,” says Bruno Laplante, SCADA director at Comact. “However, the existing emulation system relied on a limited number of physical PLC processors on racks in our facility. “Plus, the old emulator was no longer up to the task, especially given our increased project volume.”
Because it relies on Rockwell’s ControlLogix 5580 PLCs for its turnkey facilities, Comact gained the increased processing power it needed for simulation and testing by implementing Rockwell’s FactoryTalk Logix Echo software emulates the behavior of the controllers. The company added three sets of 16 emulated processors for a total of 48 usable systems. Laplante estimates this strategy cost about one-tenth as much as physical processors and associated hardware. Using their new emulation software, Comact’s engineers can fully test control code in a virtual environment. The software can emulate machines, production lines, or even an entire plant. These emulated controllers can also be paired with other software for other uses.
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“The process is exactly the same, whether you’re using the virtual processor or the real one,” explains Laplante. “Our team was skeptical at first because when something seems too easy it usually means something is missing in the big picture. However, once they realized it was real and efficient, they embraced the system quickly. Of course, we also worked closely with our IT department to ensure we could allocate the recommended resources to host the virtual machines and support the system. We put everything in place to do it right the first time, and it was a success.”
More capable sawmill workflows
With its increased processor and processing availability, Comact’s engineers can test clients’ projects progressively as they’re built on dedicated systems. There’s no more waiting until the end of a project to test or jockey for access to testing resources. Also, FactoryTalk Logix Echo there is no conversion required between the emulation and the system used in the field.
“Finding and correcting all issues at one time is a large task. It’s much more efficient to test and correct problems on an ongoing basis,” adds Laplante. “You can complete your testing and changes in the virtual environment and simply download the file to the actual system. This was a great improvement for us.”
Plus, with added processing power, Comact can test a complete, integrated, turnkey sawmill end-to-end, which it couldn’t do previously. The company also plans to use FactoryTalk Logix Echo to complement user training at its learning center in South Carolina.
“When we look to the future, we definitely want to expand our use of emulation,” concluded Laplante. “Eventually, we want to host and run virtual sawmills on our system, and simulate and troubleshoot code without impacting real production.”
