advance

The Magazine for Totally Integrated Automation

Volume 10, Number 3, 2011

Increased Productivity through Remote Access

Products, systems, and solutions for telecontrol and teleservice

Automation Technology:

Trendsetters in PC-Based Automation

Broad range of applications and high functionality for IPCs Drive Technology:

Ecologically and Economically Smart

Reducing costs with 1LE1 motors and frequency converters Industrial Switching Technology:

Small Technology Making a Big Impact

Sirius modular systems in cooling systems and heat pumps

Contents

In brief

Focus

Automation Technology

News
Focus

Trendsetters in PC-Based Automation

Cutting-edge technologies give IPCs a broad range of applications and high functionality

13

Increased Productivity through Remote Access 5

Products, systems, and solutions for telecontrol and teleservice

Electricity Costs Effectively Trimmed 6

Efcient load management with Simatic WinCC powerrate

16

Efcient Telecontrol

Cost-Effective Plant Monitoring and Maintenance 8 Telecontrol Technology in Wind Power Turbines
Secure data transfer thanks to GPRS
Siemens AG

10

Simatic WinCC powerrate allows power consumption to be monitored in real time

Remote monitoring in wind power turbines is an ideal application for wireless data transfer

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Published by: Siemens Aktiengesellschaft, Gleiwitzer Str. 555, 90475 Nuremberg Drive Technologies Division CEO Ralf-Michael Franke Industry Automation Division CEO Anton S. Huber Editorial Responsibility in Accordance with the German Press Law: Arno Hoier Responsible for Technical Content: Dr. Thomas Rubach (Automation Technology), Oswald Empen (Drive Technology), Bernd Heuchemer (Motion Control), Christoph Hotz (Industrial Controls), Peter Markus (Sensors and Communication) Concept: Christian Leifels Publisher: Publicis Publishing, P.O. Box 32 40, 91050 Erlangen, Tel.: 0 91 31/91 92-5 01, Fax: 0 91 31/91 92-5 94, publishing-magazines@publicis.de Editorial staff: Dr. Beate Bellinghausen (ChR), Gabriele Stadlbauer Layout: Jrgen Streitenberger Cover image: Siemens AG Final editing: Marion Schwab Job number: 002800 34017 DTP: M.T., Nuremberg Printed by: Wnsch, Neumarkt advance appears four times a year Circulation: 20,000 2011 by Siemens Aktiengesellschaft in Munich and Berlin. All rights reserved. This issue was printed on paper manufactured from chlorine-free bleached cellulose. ISSN 1611 101X (Print) The following products are registered trademarks of Siemens AG: ET 200, MOBY, MP270, MP370, S7-300, S7-400, SCALANCE, SIMATIC, SIMATIC Multi Panel, SIMOCODE, SINAMICS, SinaSave, SIRIUS, SITRAIN, STEP, TIA (TOTALLY INTEGRATED AUTOMATION), TIA Portal, WinCC If there is no special mention of trademarks, trade names, technical solutions, or similar items, this does not mean that these items are not protected. The information in this magazine contains only general descriptions and performance features which do not always apply in the described form in the actual application or which may be subject to change in the course of further development of the product. The speci c performance features are only binding if they were agreed expressly in the contract. IWI: TADV Order number: E20001-M2311-B100-X-7600 Cover photo: Siemens AG

Siemens AG

Teleservice and telecontrol modules give workers in plants that are distributed over large distances access to substations from the central control center
Siemens AG

Safety Technology

Industrial Switching Technology

Reaching New Heights in Safety

Safety in heavy-duty building cranes with Simatic WinAC RTX and Sinamics S120
Drive Technology

Perfect Surfaces 19
Optimized paint drying with the Siplus HCS724I heating control system

29

Small Technology Making a Big Impact 21

Sirius modular systems in cooling systems and heat pumps
Industrial Identication

30

High-Tech Organic Potatoes

High-Feature motor starters make conveyor technology reliable

Machines Are Learning to Read

OCR text recognition guarantees the complete traceability of products

32

Modular Handling Solutions

Increased productivity and process safety with the Simotion Handling Toolbox

24

Simatic MV440 reads the lasered serial number within a fraction of a second

A Transparent Cycle
Sachsenmilch relies on RFID in product and pallets handling
Industrial Communication

34

Ecologically and Economically Smart 26

Reducing costs with 1LE1 motors and frequency converters

Communication in Potentially Explosive Areas 36

Industrial Ethernet is suitable for use in potentially explosive environments
Dialogue

High-Performance Gear Units 28

Higher torque and more construction stages with the new Flender SIG

Online Portal/ Sirius 3SB3/3SF5 Library/Dates/Dialogue

38 39

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Siemens AG

ET 200S HF motor starters prevent faults from occurring in the potato sorting plants conveyor technology

Siemens AG

In brief

The Lynas plant in Malaysia is designed to fulll international production and environmental standards

+ Joint venture for magnet production

Strategic Partnership

iemens and Australias Lynas Corporation Limited have signed a joint venture agreement to produce rare earth-based permanent magnets from neodymium. Siemens will use these magnets in energy-efcient drive solutions and in wind turbine generators. Lynas is to supply the joint venture with raw materials, especially metals containing neodymium, via long-term delivery contracts. The company is setting new standards worldwide in terms of both delivery security and environmentally friendly rare-earth extraction. A study by the International Atomic Energy Agency indicated that the plant that Lynas is planning in Malaysia is expected to fulll all international production and environmental standards. The completion of this plant is planned for 2011.

Siemens intends to hold a 55 percent stake in the joint venture, and Lynas a 45 percent stake. The planned joint venture is strategically signicant for us, as it means securing a stable long-term supply of high-performance magnets, explains Ralf-Michael Franke, CEO of the Siemens Drive Technologies Division. We are convinced that in Lynas, we have found the right partner to achieve this. Nicholas Curtis, executive chairman of Lynas, adds: Lynas is delighted that this rst step has enabled us to enter into a long-term partnership with the market leader for large drives. Rare earths have a great deal of potential for growth in these applications. www.lynascorp.com

+ Siemens plant in Amberg wins industry contest

Best Factory 2011

T
The Siemens Equipment Manufacturing Plant in Amberg has already received multiple awards
Siemens AG

he Siemens plant in Amberg (GWA) has been awarded the title National Winner in the industry contest Best Factory/Industrial Excellence Award 2011. The industry contest is held under the aegis of the German Federation of Industries (Bundesverband der Deutschen Industrie e.V., BDI). Competing with its peers, the plant won top marks in the following categories: business model, strategy implementation, value chain, product and process implementation, service and customer integration, and continues improvement.

The Amberg site has been in operation for over 60 years and comprises the EWA, which employs about 1,400 staff, and the GWA, which employs about 2,400 staff, as well as development and services departments, ef cient switching test elds, and test laboratories. Both plants at the site have received awards in the past few years: Best Factory (EWA) and Factory of the Year (GWA) in 2007, and the Bavarian Quality Award and Starpower Operation (both awarded to the GWA) in 2010.

The GWA plant develops and manufactures low-voltage controls for the worldwide market, including the full Sirius product range which is used for switching and protecting loads.

Siemens AG

www.siemens.de/amberg

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Lynas Ltd.

Communication networks

+ UMTS (Universal Mobile Telecommunications System):

A third-generation mobile communication standard that allows data transfer rates of up to 14.4 Mbit/s downlink or up to 5.76 Mbit/s uplink.

+ GPRS (General Packet Radio

Service): A packet-switched mobile data communication service. This allows optimum use of the entire bandwidth available in the mobile network cell.

+ IWLAN (Industrial Wireless Local Area Network):

Local radio network for the industrial sector based on the IEEE-802.11 standard.

+ DSL (Digital Subscriber Line):

Transfer standards for the physical layer in which data can be sent and received at transfer rates of up to 500 Mbit/s.

+ TCP / IP (Transmission Control Protocol / Internet

Protocol): Family of network protocols, also referred to as an Internet protocol family. The computers included are identified using IP addresses.

Increased Productivity through Remote Access

To ensure reliable plant monitoring, plant operators require secure and cost-effective access even to machines and plants located far away. Siemens delivers products, systems, and solutions for telecontrol and teleservice for use in the process industry, factory automation, and the public infrastructure sector.

ith Industrial Remote Access, users save time, money, and resources because they can maintain their machines from a central location and can safely monitor and control processes spanning the entire plant from wherever they are. The term telecontrol refers to the control, regulation, or safety-related connection of process stations that are physically distributed over large distances in one or more central control systems. This is done using telecommunication networks based on technologies such as TCP /IP, GPRS, UMTS, IWLAN, and DSL. The exchange of process data via special telecontrol protocols makes it possible for operating personnel to effectively control the overall process. Teleservice is the exchange of data with plants that are physically located at a distance, for the purpose of fault detection, diagnostics, maintenance, or repair; for the optimization of subsystems and control systems through remote programming; and for updating to the newest program modules. For more detailed information about this, see pages 6 to 9.
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Focus

Streitenberger

Focus

Efcient Telecontrol

Mr. Hoock, what does Siemens have to offer users when it comes to telecontrol? Volker Hoock: Telecontrol has a wide and varied range of applications. In building management, in the transportation sector, and in machine control systems, it is often the case that only a small number of stations with a large volume of data need to be monitored. Siemens offers TeleControl Basic for monitoring and controlling systems of this kind via mobile radio communications (GPRS). However, the situation is quite different when it comes to oil and gas pipelines, water supplies, wastewater disposal, and the energy sector, where the remote stations and measuring stations sometimes with large data volumes are often situated more than a thousand kilometers away from the central plant or the control center. These stations also need to be connected using a wide range of telecommunication networks, which means that such cases call for a more complex system such as TeleControl Professional. And what solutions are available for large-scale plants? Volker Hoock: Typical areas of application in large-scale plants include maintenance and control and the optimized operation

Data transfer with components from the Siemens product portfolio guarantees the customer data security and data retention.
Volker Hoock, Marketing Manager for Industrial Communication, Siemens
Hoock

of process-related plants with the aim of saving energy. This spectrum of applications is also covered by TeleControl Basic. The system is capable of more than its name might suggest. It can be used to manage both small plants with a small number of stations and plants with up to 5,000 remote stations. How does that work, from a technical point of view? Volker Hoock: The control center is connected to the Simatic S7 substations via the TeleControl Server Basic software. The connection to the control and monitoring application for example, WinCC exible is made via an OPC interface. The process data are transferred via GPRS, which is particularly convenient and economical for the user, who incurs low investment costs and benets from costeffective tariffs. A teleservice function that allows worldwide access to Simatic controllers is also integrated into the system. This is of particular interest to machine and plant manufacturers who work internationally.

In comparison, what characterizes a complex system such as TeleControl Professional? Volker Hoock: This telecontrol system, constructed using a modular design, is intended for demanding control and monitoring tasks in plants that are distributed over large distances. It allows connections to the Simatic PCS 7, Simatic WinCC, and WinCC OA (Open Architecture) control systems, in addition to control systems from third-party manufacturers. The construction of complex telecommunication networks with point-to-point, line, and node structures is supported, and these can be combined as desired. This makes TeleControl Professional tremendously exible. For data transfer, the user can choose between conventional networks such as dedicated lines or analog telephone networks and communication via IP-based networks. Data security is ensured in all cases, however, because the transfer of data is safeguarded by specic VPN solutions. All systems are additionally equipped with a data buffer,

Industrial Remote Access overview

Telecontrol

+ TeleControl Basic + TeleControl Professional

Teleservice

+ Simatic TeleService + Teleservice Network + IPC Remote Manager + Simatic Remote Services
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Telecontrol in practice

so data will be retained even if the network connection is interrupted.

Siemens AG

You mentioned a connection to the control systems. What does that mean? Volker Hoock: The Simatic PCS 7 and Simatic WinCC control systems combine the automation of centralized plants and the monitoring of distributed remote stations in a single control center. Simatic PCS 7 TeleControl, Simatic WinCC TeleControl, and Sinaut ST7cc allow communication with the remote stations, either via the Sinaut ST7 protocols or the standardized DNP3 protocol. Special communication modules are implemented for communication using telecontrol protocols for example, Telecontrol Interface Modules (TIMs) in the Simatic substations and, if necessary, in node stations. Since TIA components are consistently used for the control center and the modular Simatic substations, the user saves time and reduces costs. Does Siemens offer further telecontrol products? Volker Hoock: In combination with a Simatic controller, substations can be constructed using the Siplus RIC (Remote Interface Control) system to securely transfer process data from remote subunits to a central control center. The addition of a Simatic ET 200S or a Simatic S7-300 / S7-400 allows the integration and management of up to 200 or 5,000 information points, respectively. Siplus RIC can also be used with WinACbased solutions. Data transfer requires little installation work because it is carried out using internationally standardized communication protocols such as IEC 60870-5. Mr. Hoock, many thanks for speaking with us today.

TeleControl Professional in power supply applications

The utility company for the city of Astana, Kazakhstan, placed an order for an automation system to measure and record energy consumption and quality data for the Kazakh railway network. Data recording for the 182 operative measuring points, seven substations, and 10 transformer stations is carried out using Simatic S7-300 and the TeleControl Professional system. Since this automated energy measurement system was introduced, the exibility and reliability of the electrical systems has increased, the control of the electricity supply has improved, and operating costs have been reduced.

Siplus RIC in water supply applications

The water distribution system in Innsbruck, Austria, is an example of Siplus RIC in practice. The water network is monitored here, with data transfer being carried out using an IP-based WAN with a GPRS radio network, allowing maintenance costs and the number of fault-rectifying operations to be signicantly reduced. The new solution means that the entire water network can be monitored, which was not possible using the previous proprietary communication system with a dedicated line.

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Siemens AG / Johansen Krause

Cost-Effective Plant Monitoring and Maintenance

Siemens AG

Focus
8

Even in plants distributed around the world, The new Simatic IPC Remote Manager GPRS, as it allows exible connection fast service must be ensured in order to software package is also available for options that are not possible with convenavoid plant stoppages and increase produc- remote access to industrial PCs. The tional maintenance bound to a xed-line tivity. Teleservice allows plants to be diag- Simatic IPCs with Intel Core i5 and i7 pro- network. This option requires GPRS covnosed and maintained from anywhere in cessors are equipped for this purpose with erage, the appropriate frequency bands, the world. This reduces the number of Intel Active technology (Intel AMT), which and approved devices. The EGPRS (Enhanced GPRS) MD741-1 on-site service visits needed, and thus allows password-protected remote access. saves time and signicantly reduces costs. System or program faults can thus be rec- router, which allows higher data rates Simatic TeleService delivers a range of tied, and BIOS and program updates car- than GPRS, creates a secure data conneccoordinated components to make this pos- ried out, from the control center via a tion between the remote stations and sible. Four different modules are available secure HTTPS or TLS connection. Efcient the service center via GSM. Data transfer energy and service management reduces takes place in a secure virtual tunnel for the new TeleService Adapter IE Basic: power consumption through targeted with IPsec; the security module (e.g., Analog modem shutdown after production is completed Scalance S612) acts as a VPN gateway ISDN modem and reduces downtimes by allowing ser- and terminates the tunnel in the control GSM for mobile radio communication vice work to be carried out outside regular station. If higher data rates need to be RS232 for the connection of external production times via remote access. reached, UMTS can be used via Scalance modems Routing makes access possible beyond M875. network boundaries. A rewall ensures Trend: teleservice via Internet that only Simatic-specic services can be Remote services for monitoring and routed through. Multilevel security mech- IP-based networks are the rst choice maintenance via Internet anisms protect against unauthorized when a higher level of availability is access. From Version 11 and up, the Tele- needed in the remote connection or when To allow cost-effective and exible remote Service software is integrated into Step 7 the data to be transferred require more access to plants, Siemens supplies not Professional that is, it can be used at no bandwidth. The simplest solution for only the appropriate products but also the exible global remote maintenance is corresponding services. The comprehenadditional cost.
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The secure connections in the Customer Web Portal mean that service personnel can access machines and plants, and that external partners can also be integrated

Customer

DMZ1)
Customer Web Portal Web Portal

Siemens Service

Business Partner

DMZ cRSP 2)

Access Server

Web Portal

Internet (VPN)3) Customer Site

Access Gateway

IT-System
Administration
1)

Demilitarized Zone

2)

common Remote Service Platform

3)

Virtual Private Network

The Siemens Remote Service platform

sive service range from Simatic Remote Advantages at a glance Support Services covers the monitoring, maintenance, and repair of machines and Simatic Remote Support Services plants via remote access. The various ser+ Graded security and access concept vices are graded modularly and are available in three packages that can be adapted + Collaboration & Customer Web Portal to suit any users requirements. The Starter + Central monitoring, logging and reporting Package is the solution for fast and eco+ Transparent accessing through e-mail notication nomical reactive fault rectication. The + Reaction-free thanks to isolation of networks Enhanced Package uses special diagnostic tools to remotely ensure the problem-free + State-of-the-art security concept operation of the plant. With this option, + ISO/IEC 27001 certication the user has a xed contact person who + Compatible with plant IT security concepts is familiar with the features of the individual plant. The top-level Comprehensive Package additionally includes preventive inspection services according to DIN 31051. This range of services is based on the Siemens Remote Service (SRS) platform, a Users also have the option of being able MORE ON THIS TOPIC: particularly secure and high-performance to view and monitor all changes made by + www.siemens.com/ remote connection that is certied the service personnel in real time via a industrial-remote-access + www.siemens.com /siplus-ric according to ISO /IEC 27001. The system dedicated Customer Web Portal (CWP). + www.siemens.com/ not only gives Siemens personnel remote The system keeps a log of who has accessed simatic-pcs-7-telecontrol access to the plants, but the companys the individual plants and at what time, thus + www.siemens.com/industrialsecurity own specialists also have the same access. making changes reproducible later on. +
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Telecontrol Technology in Wind Power Turbines

Wind power turbines are among the applications in which remote monitoring is particularly critical. At the same time, these applications also have particularly high requirements when it comes to data transmission. Wireless communication via the mobile phone network not only fullls the requirement for high data transfer rates and high levels of data security, but its low installation costs mean nancial benets at the same time. For precisely these reasons, the EGPRS MD741-1 router was chosen for a wind power turbine near Hannover, Germany.

Focus

f all the renewable energy sources, vidual wind power turbines and small wind wind power is the one being devel- farms, the number of available communioped fastest around the world. Not cation connections is frequently insuf even the recession of 2009 could halt its cient. This means that the telephone lines progress. But wind power turbines are not installed by Deutsche Telekom do not only becoming more and more efcient; reach the gondolas of the wind turbines, they are also becoming larger and more and the requirement for wireless commutechnically complex. The consequence: nication here is consequently especially monitoring the operation and condition of high. important components is essential in order to guarantee a high level of plant avail- The economical solution: ability. GPRS routers In large wind farms today, Internet access is largely ensured via telephone Package-oriented transmission services lines. However, many wind power turbines such as GPRS can be implemented here. in lower output classes are not retrotted Long gone are the days when these serwith condition monitoring systems such vices were only to be found in cell phones as Siplus CMS when the service contracts with mobile Internet access. This radio with the manufacturer expire and the communication service, which is based on operator takes responsibility for main- the GSM network, has another important taining the turbines. In the case of indi- function in telecontrol technology.

Service International
Service International is a service provider within the Mechanical Drives business unit of Siemens Industry Drives, which provides services for components used in mechanical and electrical drive technology primarily maintenance and repair work on and problem analyses of gears, for example, in wind power turbines. The range of services provided includes both on-site measuring operations and telediagnostic services for vibration-based condition monitoring of gears and so-called troubleshooting visits for problem analyses with mobile measuring systems.

A particularly economical solution is on offer from Service International. The GPRS MD741-1 router gives the Siemens service provider a wireless Internet connection that is independent of the respective plant operator and allows unambiguous allocation of costs for that communication channel. The communication system and the VPN are very easy to install, making parameterization via the Scalance S security network component possible without specialist IT personnel. In this way, condition-based maintenance becomes possible permanently and economically despite some locations being dif cult to reach via condition monitoring. The use of EDGE technology, which is supported by the MD741-1, means that data transfer rates can be achieved that are more than sufcient for the application. Another crucial factor for Service International is the high level of data security in the VPN, which in the case of the MD741-1 is ensured by the IPsec security protocol.

Online monitoring is possible

In the spring of 2008, the experts from Service International tested the application over a period of three weeks in a wind power turbine situated near Hannover. The main components to be implemented were the GPRS MD741-1 router and the Scalance S612 security module. The creation of a VPN tunnel between the station and the control center was relatively easy, thanks to the presence of a common conguration

10

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Siemens AG

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11

Focus
tool. Online access was ensured throughout the entire test period, and no loss of data was detected. The MD741-1 router is currently being implemented in a temporary Siplus condition monitoring system in a plastic extruder. This monitoring system is beneficial wherever and whenever an Internet connection cannot be made via telephone lines. However, the advantages of this type of system are also clear when it comes to troubleshooting operations where continuous online moni-

Installation in the gondola of a wind power turbine

toring is not necessary in other words, operations that require a diagnostic system to be created only temporarily (for a period of up to 12 weeks), for example,

if it is suspected that mechanical problems are occurring in a plant.

Fast and secure

Using the MD741-1 means that Service International is not dependent on telephone lines being available. Thanks to the ease of installation and the combination with Scalance S, the application is ready for operation in a very short span of time, while the IPsec security protocol integrated into the MD741-1 also ensures data security. Since the integrated IPsec function frees the user from dependence on a small number of mobile telecommunication providers, there are additional financial benefits to be reaped through flexible selection of the GPRS providers and tariffs available both nationally and internationally. The national approvals that the MD741-1 has received in many countries are another decisive factor in making this monitoring system a viable + solution around the world.

Conguration example for using the GPRS MD741-1 router in a wind power turbine Siemens MD Service International Condition Monitoring Center Database Server Windows 2003 Mail server

Industrial Ethernet

Scalance S612 DSL modem

Internet Customer

VPN tunnel

MD741-1 GPRS modem

LAN Industrial Ethernet

Siplus CMS4000 IFN VIB-A Condition Monitoring System

Opt. data server

Operations

Advantages of GPRS

+ Low costs thanks to volume-based billing and specic M2M

(machine-to-machine) tariffs

MORE ON THIS TOPIC:

+ VPN security without additional costs thanks to the GPRS MD741-1

router, which allows bidirectional communication between two stations without additional charges

+ www.siemens.com/telecontrol
CONTACT:

+ Higher data transfer rates: GPRS achieves a data transfer rate of

107 kbit/s, compared to 9.6 kbit/s in GSM networks

+ Contact person: +

+ High level of data security through the use of the IPsec protocol
to protect process data exchanges in automation applications

Dr. Jrg Deckers, Diagnostics Expert, Mechanical Drives E-mail: joerg.deckers@siemens.com

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Siemens AG

Trendsetters in PC-Based Automation

The demand for industrial PCs (IPCs) is constantly on the rise in part because more and more data must be processed in machine-oriented applications. Siemens focuses on easy scalability, high reliability, operating safety, and ease of maintenance in its IPCs.

Siemens AG

The right hardware for every application: the Simatic IPC family

iemens has been an expert in indus- Uniform product line trial control technology for many years. Simatic programmable control Siemens provides a comprehensive line of systems have been around for 50 years PC-based automation products to suit this now, and the rst IPCs appeared on the diverse range of applications. These prodmarket 20 years ago. These have been ucts include IPCs in various versions, as under continuous development and also well as software controllers and visualizapresent a functional alternative to tradi- tion software. True to the Totally Integrated tional hard PLCs. Today, modern IPC tech- Automation motto, the utmost importance nology is not only found in production and is attached to the compatibility of Simatic process technology; it can also be found devices with one another and with other in the warehouse management, building devices from the automation product portmanagement, and energy management folio. Users can also use their existing prosectors in other words, wherever large grams with different hardware, as Step 7 quantities of data need to be processed. is used for programming both the convenIts also no longer possible to imagine re- tional Simatic S7 and the PC-based controlnewable power generation without indus- ler Simatic WinAC. Eisenbeiss continues: trial PCs, emphasizes Heinz Eisenbeiss, Our WinAC software PLC is compatible marketing director for the Simatic product with Simatic S7. A Step 7 program runs on line at Siemens. both control systems, irrespective of the

physical implementation and the version. In this way, we provide the user with outstanding exibility in addition to a high level of investment security.

Innovations open new areas of application

Customer demands relating to IPCs show two clear trends: on the one hand, customers are consistently requiring increased computing power, and on the other hand, the demand for compact designs is on the rise. Siemens has therefore made corresponding innovations in its range of IPCs. To ensure maximum performance, the 19 PCs now come equipped with highperformance multicore processors such as the latest-generation Intel Core i7 quadcore processor. The rack PCs high comadvance | 3-2011 13

Automation Technology

Automation Technology

John Doyle, Group Product Manager, Microsoft Windows Embedded

We want to provide outstanding exibility for our customers in the machine and plant engineering industries through our range of products. We achieve this through easy scalability of the automation solution with uniformity between Simatic S7 and the PCbased control, and with TIA Portal the efcient, common engineering tool for the entire controller family. As the hardware basis, we supply a line of IPCs that covers the entire performance range. Our aim is also to reduce hardware and engineering costs through a reduction in the complexity of the automation solution by Siemens for example, through the implementation of fail-safe applications in IPCs without any special additional components and with only one network.
Heinz Eisenbeiss, Head of Marketing and Promotion, Industrial Automation Systems, Siemens

puting power and high system and graph- with the latest generation of process-opics performance makes it particularly timized Intel Atom processors, which rewell suited to the fast processing of large quire next to no electric power. The comquantities of data for example, in indus- pact PCs are also available in a Nanopanel trial image processing and in process PC Simatic IPC277D version, with a highvisualization. resolution industrial touch display in For applications in which size is a deci- widescreen format (7 size and upward). sive factor, Siemens has developed the These robust devices are used in the Nanobox PC Simatic IPC227D, which is machine building, building management, about the size of a milk carton and works and transportation sectors.
14 advance | 3-2011

Kradisch

The new developments arent conned solely to the hardware, however. The software too has been developed further. Siemens is the rst and only supplier to set trends in the implementation of fail-safe applications with PCs. In the Simatic WinAC RTX F real-time software controller, the safety functions are completely integrated, and the user does not require a further controller for control intelligence. TIA

Schwaderer

As a leading automation supplier to the manufacturing and process industries, Siemens is a highly valuable Windows Embedded partner. The Windows Embedded Standard 7 platform is designed for developers and device makers to quickly create innovative user experiences and reliable devices that provide high performance, and smooth connectivity to other Windows devices, PCs and servers through Windows 7 technologies, said John Doyle, Group Product Manager, Windows Embedded. As a participant in Microsofts early technology adopter programs, Siemens provided valuable feedback from manufacturing system end users that helped us provide precisely the features that machine and plant engineers need.

The close collaboration between Siemens and Intel means that we can take the specic requirements of industrial customers into account during product development. This is especially important in industrial automation, because customers needs here differ greatly from those in other industries. The result is Intel processor platforms that are optimally suited for use in PC-based automation.

Hannes Schwaderer, Managing Director, Intel GmbH

SIEMENS

4 2

SIMATIC BOX PC

SIMATIC BOX PC

SIEMENS

SIEMENS

SIMATIC BOX PC

SIEMENS

SIMATIC BOX PC

The Nanobox PC has all its interfaces on one side, simplifying installation and reducing space requirements in the control cabinet

Portal is another leap forward. In addition to the Simatic S7 controller family, Siemens will also integrate the PC-based control systems into the new engineering framework. IPC Remote Manager software package means that remote maintenance is also possible for IPCs (see Focus article on pages 89).

with Intel in turn allows us to make the most up-to-date processor technology in IPCs available to users at an early stage for example, in the new IPC547D rack PC with the latest-generation multicore processor. The development and production of all IPCs, including the mainboards, takes place in Siemens own plant in Karlsruhe, where the staff have made it their mission to fulll the customers need for long service life Investment security and minimal and exibility. The developers rely on a installation work platform concept in order to achieve this Investment security is an important issue for that is, various design types such as rack IPC users. We are very targeted in the way PCs, box PCs, and panel PCs are developed we innovate, our purpose being to give the on the basis of a common mainboard. The customer a competitive advantage through evaluation work required is reduced bethe use of new technologies and, at the same cause all the devices of one generation use time, allow investment security through the same processors, chip sets, and drivers. long-term availability and compatibility, To reduce installation work, users have Heinz Eisenbeiss explains. In this way, we embedded PC bundles at their disposal, guarantee that our IPCs are available for up which have HMI software and/or a software to ve years and provide repairs and service controller installed and ready to use. work for a further ve years. The development partnership with Intel and Microsoft, Efcient service and support which allows Siemens to react quickly to and to implement innovations, plays an IPC users receive the customary Simatic important role in this context. Our close service, with the addition of certain speMicrosoft makes it possible for us to supply cial offers. Thirty-three authorized repair operating systems with our IPCs for the long centers in 27 countries are on hand to take term. Users thus need to carry out less adap- care of repairs to defective Simatic IPCs tation work, and sometimes they can even and PDs. Customers can obtain a 36skip a generation in terms of the operating month service option for their Simatic IPCs system, adds Eisenbeiss. The partnership and PDs, which entitles them to repairs

SIMATIC BOX PC

SIEMENS

SIMATIC BOX PC

SIEMENS

2 2

Mounting type
1 Standard

Advantage Mounting without tools by snapping onto standard mounting rail Flexible choice of mounting position (e.g., horizontal, vertical) Easy access to operator controls and narrow footprint Minimal footprint in the control cabinet with simple cable routing

mounting rail
2 Wall 3 1

mounting
3 Portrait

mounting
4 Side

mounting

free of charge for 36 months and is valid in any repair center in the world. Today, the first port of call for technical problems with automation is usually the Internet. Online support provides users with around-the-clock expert advice in several languages, including Chinese. The Online Service Tool at www.siemens.com/ ped provides product equipment data on the relevant devices and the Simatic IPC/ + PG spare parts available.

MORE ON THIS TOPIC:

+www.siemens.com/pc-based-automation
CONTACT:

+ Contact person:

Elske Meyer, Head of Marketing and Promotion, Simatic PC-Based Automation E-mail: elske.meyer@siemens.com

advance | 3-2011

15

Electricity Costs Effectively Trimmed

Automation Technology

S
High peak loads are expensive. To eliminate violations and adhere to the limit set by the utility company, Gardena Manufacturing has installed a solution for efcient load management in its production facilities. Simatic WinCC powerrate monitors power consumption in real time and automates reductions at peak power.

ince its founding in 1961, Gardena has evolved from a gardening tool retailer to a global manufacturer of products and systems for garden maintenance. The company was acquired by Swedens Husqvarna Group in 2007. Subsidiaries of Gardena GmbH, headquartered in Ulm, Germany, include Gardena Manufacturing GmbH in Heuchlingen, Germany, which produces plastic products for garden tools, cleaning equipment, and irrigation technology, in addition to various storage and transportation containers for a range of applications. In addition, the company also develops and manufactures OEM products. Every year, the 260 employees at the plant in Heuchlingen process 11,000 t of plastic granulate on 100 injection molding machines to produce around 500 million parts. Production runs 7 days a week, 330 to 335 days per year. Our goal was to nd a solution that would quickly provide a precise overview of the consumption values and cover cost-intensive peak loads at an early stage, explains Harald Whrle, who

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advance | 3-2011

Gardena

Gardena relies on efciency both in nished products and in production

WinCC powerrate all the functions at a glance

+ Sensing, monitoring, evaluation, and display of energy ows + Trend calculation and comparison with a predened limit + Alarm signal when a limit is about to be exceeded + Enable/disable signal generated according to priority list + Predened faceplates for displaying the current status + Precise knowledge of the consumption prole at all times + Increased energy efciency + Optimized energy-purchasing contracts + Adherence to the utility companys contractual conditions + Energy cost assignment to individual cost centers

is in charge of the Maintenance Building and Equipment sector at Gardena Manufacturing GmbH in Heuchlingen. We work with a three-shift system from Monday to Friday, with an average consumption of 2 to 2.3 MW per day. On weekends, power consumption drops to between 1 and 2 MW, depending on how much of our capacity is being utilized. Requirements increase again on Monday morning an ideal consumption pattern for any utility company, Whrle continues.

Peak power means signicant additional costs

Power supply contracts have two components: the price of the supplied power in kilowatt-hours and the price per kilowatt of the peak connected power. While no credit is given when peak power consumption is undershot, excess consumption is always charged at the end of the relevant settlement period. A power peak of as little as 15 minutes already brings signicant

additional costs. This cost increase can be The range of necessary applications is eliminated with a load management sys- covered by nine Sentron PAC power montem that measures the load prole, evalu- itoring devices corresponding to the ates energy pulses and time signals, and number of transformers. These monitor creates a projected calculation for the end voltage, current, and power, and forward of the quarter-hour measuring cycle. If the corresponding data to Simatic WinCC there is danger of exceeding the consump- powerrate. The software compares the tion limit, the system automatically shuts measured values with the data from the down individual loads according to a pri- energy supplier and, based on this information, creates a projected calculation for ority list. The load management system, which the end of the quarter-hour measuring was installed at Gardena in spring 2010 cycle. If the power supply reaches a critiduring renovation work on a transformer cal level, Simatic WinCC transmits a comstation, includes a PC workstation with mand to the higher-level Simatic S7 conSimatic WinCC powerrate software for troller via the building management monitoring, visualizing, and controlling system to shed the load in stages of 20 or the load management processes. The 25 kW according to the priority list until Gardena employees customized the the increase has stopped. When the limit powerrate faceplates themselves. Whrle is undershot again, Simatic WinCC reenexplains: Real-time monitoring and eval- ables the loads. uation of measured values was very imporThe nine transformers are designed in tant for us, as was automatic load shed- such a way that they run at 50 to 65 perding. Since we started using this system, cent of their rated output, which accordwe have been able to precisely measure ing to Whrle is the perfect operating range. At a higher load, the power loss and log the consumption values.
advance | 3-2011 17

Automation Technology

Siemens AG

Simatic WinCC powerrate monitors power consumption in real time and displays the performance values. Analog displays and curve charts provide a fast and precise overview of current consumption (Note: The screens are in German only)

Simatic WinCC powerrate makes the power consumption of all transformers transparent. When the power limits agreed with the utility company are exceeded, the software automatically shuts down predened loads to prevent load peaks from occurring

would increase disproportionately. We have congured our system so that the transformers have sufcient reserves to deal with power peaks that might occur. Even a short-term increase to 100 percent output can be handled without problems. If we were to operate at full power from the outset, however, then a critical situation could arise, continues Whrle. He stresses that at high loads and high external temperatures, cooling requirements increase signicantly, which in turn also means an increase in power consumption.

Optimized power costs

The drying processes used by the company provided the initial incentive to optimize power costs. To be able to process the plastic granulate in the injection molding ma- Transparency in power consumption chines precisely, the remaining moisture is rst removed from it using an energy- Before the load management system was intensive hot air treatment process. At the implemented, the employees had only the end of the drying process, the raw mate- gures provided by the utility company to rial retains only 0.02 to 0.05 percent mois- help them trace the plants power conture. This additional drying is necessary, as sumption. Today, Simatic WinCC provides a higher water content could cause entrap- ongoing energy and performance values ment and surface streaks could form in the and monitors the limits according to specinjection molding process. Since the gran- ied parameters. Curve charts make power ulate is cast at a temperature of 200C to consumption transparent and display the 300C in the machines, the moisture that relevant load prole. The faceplates that remains in the material evaporates and can are supplied allow data to be transferred burn the plastic. to the SAP system in Excel format. The data
18 advance | 3-2011

Gardenas employees use the load management software to determine when it is best to initiate energy-intensive processes such as that used to dry the plastic granulate. The drying system extracts the remaining moisture from the granulate and binds it in the drying agent. During the regeneration phase, the water is then reevaporated by heating. Admittedly, the regeneration process occurs during periods of reduced load, but should shortfalls arise, the software also provides a multistage load shedding function for drying. Gardena now has the capability of shedding total loads of up to 300 kW for 30 to 60 minutes during times of peak demand. That is equivalent to around 10 percent of the power drawn by the plant.

can then be used by controlling for usagebased allocation of energy costs and for load and consumption prognoses, which means that planning becomes more reliable. This optimized energy utilization helps Gardena avoid expensive consumption peaks and take better advantage of unused reserves. Consequently, the company plans to take the next step and use the management system to optimize its gas and water consumption in addition to + its power consumption.

MORE ON THIS TOPIC:

+ www.siemens.com/wincc
CONTACT:

+ Contact person: +

Carsten Schmidt, Marketing Management HMI E-mail: carsten.schmidt@siemens.com

Siemens AG

Reaching New Heights in Safety

Crane specialist Wilbert relies on IPC-controlled safety technology to ensure the productivity and reliability of its building cranes. A tower crane with a nominal lifting capacity of 128 t was designed and realized efciently using a combination of Simatic WinAC RTX-F and Sinamics S120.

igh-performance construction site logistics are essential if the ambitious deadlines and budgets common to construction projects are to be met. In this context, tower cranes which quickly and reliably deliver construction materials to the exact spot where they are needed play a key role in building construction. Wilbert, based in Waldlaubersheim in Germany, specializes in the design, construction, and rental of this type of crane. The companys wide range of lufng jib and boom cranes also includes its Heavy Lifter series: the WT 2405L e.tronic model, which is used in power plant construction, has a tower height of 120 m, a nominal lifting capacity of up to 128 t, and a maximum load torque of 2,400 mt gures that can only be achieved with high-performance drive technology and comprehensive safety equipment. This allows the hoist gears drive to be monitored for deviations in the speed and direction of rotation and safely shut down in the event of a fault, before the load is dropped and causes damage.
advance | 3-2011 19

all pictures: W. Geyer

Safety Technology

Safety Technology

The crane is controlled by the fail-safe Soft SPS WinAC RTX-F (left), and the drives are regulated by the Sinamics S120 CU320 control units (right)

A complete overview at all times

The crane operator is constantly kept up to date by a Simatic MP277 multipanel that continually supplies the required data, so he or she can always maintain an overview from the high cabin and deliver materials safely and precisely to where they are needed. Wilbert relies on Simatic S7 for safe crane control. The central component here is the IPC-based WinAC RTX-F safety control system, which, together with an additional ET 200 IM151-8F safety control system (in distributed operation), records and processes the entire range of safetyrelevant signals. In this way, the rotary movements of the motors and the load torques, as well as the distance limit switches and operation area limits, are all

reliably monitored. This combination of safety components and the remaining control functions in a common PLC reduces both hardware and engineering costs. Even the transfer of the safety-relevant signals and data together with the standard signals using Pronet as a common bus contributes to the cost savings: the amount of cabling work required remains small, wiring errors are avoided, and commissioning times shortened.

Collaboration with the systems integrator

Automation technology also has a role to play in shortening on-site installation and commissioning times for Wilbert. The implementation took place in close collaboration with HW-Elektrotechnik, based in Laudert, Germany, which allowed the initial commissioning of the new Heavy Lifter to be carried out quickly; the systems integrator also took over service and maintenance for the cranes automation solution. Remote diagnostics and maintenance via GPRS data transfer, which is possible anywhere in the world, means that faults can be responded to immediately and ensures a high level of availability for the crane. The automation concept meets all requirements regarding reliability, safety, and efciency based on the fail-safe SoftSPS WinAC RTX-F and the Sinamics S120 modular drive system. It also allows safetyrelevant signals and other data to be transferred using a common medium Pronet as well as enabling easy remote maintenance. A range of high-performance engineering tools are available to assist users in programming the PLC, integrating the components, and commissioning the drives. +
MORE ON THIS TOPIC:

Reliable and efcient

Wilbert uses motor modules from the Sinamics S120 multiple-axis drive system with outputs of 75 to 250 kW to carry out all moving functions lifting and lowering of loads, rotating the crane, and luffing the cranes boom. To raise and lower the cranes hook with no load or with only a minimal load, the motors are operated in a delta connection and with the converter in eld-weakening operation. This leads to higher rotational speeds, which in turn means shorter lifting/lowering cycles and thus increased productivity. Innovative Safety Integrated products are used to implement the overall crane safety concept. Drive-integrated safety functions such as Safe Torque Off (STO) are also included in addition to the fail-safe control components. The Sinamics S120 drive system is supplied with power via a central Active Line Module (ALM), which corrects mains uctuations and thus allows the motor modules to be reliably supplied via a DC link. Even on construction sites with unstable power supplies, Sinamics S120 guarantees a high level of safeguarding against crane failures. Another positive feature of Sinamics ALM: energy that is freed up in generator operation is fed synchronously back into the grid.

HW-Elektrotechnik e.K.
HW-Elektrotechnik is a high-performance, globally active partner for manufacturers of controls and switchgear, automation technology, and energy systems. The company is a qualied Solution Partner for the Simatic automation system, the Simatic HMI human machine interface, industrial communication with Simatic NET, and Safety Integrated for factory automation. Head ofce: Rhein-Mosel-Strae 37, D-56291 Laudert, Germany Founded: 1992 Employees: 60 Contact: Harald Wendling Tel./fax: +49 6746/9411-90/-925 E-mail: mail@hw-elektrotechnik.de

+ www.siemens.com/sinamics-s120 + www.siemens.com/safety-integrated
CONTACT:

+ Contact person: +

Sigmund Frstl, Marketing Manager, Motion Control Systems E-mail: sigmund.foerstl@siemens.com

20

advance | 3-2011

High-Tech Organic Potatoes

A company in the food industry is constructing a fully independent production plant for its organic products. For the conveyor technology to work as reliably as possible, the decision makers chose High-Feature motor starters, which deliver a range of diagnostic capabilities and are extremely easy to maintain.

grata Agrarhandel GmbH & Co KG, rungstechnik. This is because the devices particularly beneficial in the case of based in Beelen, near Mnster in deliver a range of diagnostic information plants that span large distances and Germany, processes around 600 t of to which the user can respond in a targeted whose construction includes bends and potatoes of up to 100 different types manner, thus reducing costs. Faults always corners. every day. Approximately 100 t of these occur, especially during the commissionare organic potatoes, which come from ing of new conveyor technology systems; Easy to parameterize, with ecological cultivation. Agrata installed a one reason can be that the mechanical ad- signicant additional benets fully independent conveyor and storage justment of the belts is not yet exact. system specically for these potatoes. Then there are the occasional overload The design of the distributed I/O devices When it came to choosing what drive tech- trips, which are immediately signaled to is simple and clear. The ET 200S head nology to use for sorting, washing, and the technician, says Steinkamp. The tech- modules are connected to the control syspackaging the organic potatoes in the plant, nician then immediately knows which tem a Simatic S7-400 in this case via the decision makers opted for a combina- drive is affected. Probus. The starters in their side-by-side tion of distributed I/O devices with HighUp to 16 of these High-Feature starters arrangement provide standard motor paFeature motor starters. These motor start- can be mounted side by side on a Simatic rameterization, which in many cases can ers were subsequently installed in around ET 200S distributed I/O head module. This be retained. Individual characteristic means a maximum current load of 50 A values can be entered via the Hardware 120 electric drives. Thanks to the High-Feature motor for the subordinate I/O devices. Impor- Cong module in the Step 7 PLC programstarters, we know immediately if a motor tant parameters such as current flow, ming environment. The drives used in the isnt running properly, explains Klaus voltage, and symmetry can be monitored, organic potato conveyor system, with outSteinkamp, proprietor of the Gevelsberg- which makes the conveyor technology puts between 0.75 and 3 kW, must meet based CS Ingenieur-Bro fr Automatisie- system very transparent. This feature is similar requirements. Time can be saved
advance | 3-2011 21

Drive Technology

Drive Technology

Agratas new plant for sorting, washing, and packaging organic potatoes employs around 120 drives all of which are started using Simatic ET 200S High-Feature motor starters

during parameterization, as the operating data can be copied as lists from one drive to the next in Hardware Cong. After this routine task, it is relatively easy to individually adjust the specic characteristic values. In addition, the starters can also be parameterized on-site using the Motor Starter ES software. The same software gives the technician further information about the number of operating hours of each drive, the on-time, the number of switching cycles, currents such as the highest tripping current, and the exact cause of fault indications. This method is ideal for allowing us to perform a detailed analysis of dif culties that occur, emphasizes Steinkamp. If intolerable overloads should occur on the conveyors in particular starting situations, the causes can be determined quickly via Motor Starter ES. It is then usually helpful to set individual start-up ramps on the starters, a task that can be performed using the rotary switches located on the front of the devices. Drives can also be shut down directly with High-Feature starters. The front of the device features an interface for this purpose, into which an auxiliary contact block with two sensor inputs can be inserted. If a conveyor belt reaches a nal position while lling the silos, for instance, the position switch shuts down the relevant drive independently of the control system. Of course, the drive is also simultaneously shut down by the control system. Direct shutdown, however, provides additional safety and means that the con22 advance | 3-2011

Advantages of Simatic ET 200S High-Feature motor starters

Easy parameterization, diagnostics, and monitoring

+ Parameterization via bus using Step 7 or another Probus tool + Selective protection concept + Remote reset of the electronic overload protection and
emergency start function in the event of an overload

+ Acyclic services, current value transmission via Probus DP,

and current limit value analysis Clear product range to suit every application + Extension of power rating to 16 A / 7.5 kW

+ Only two versions span the entire

performance range

+ Available as direct, reversing, and soft starters + Increased short-circuit strength

Proven basic functions of the ET 200S + Bit modular

+ Fixed wiring + Hot swapping: replacement during operation while power is on + Self-structuring power bus
Efcient energy management + Targeted stoppage of individual loads or system components during production pauses

+ Load peaks are avoided and electricity costs allocated directly

to the relevant loads

all pictures: Siemens AG

 The High-Feature motor starters with their diagnostic capabilities signicantly increase the plants availability.
Klaus Steinkamp, Managing Director, CS Ingenieur-Bro fr Automatisierungstechnik

trol system is relieved during time-critical control processes. The organic potato conveyor system also includes conveyor belts that need to be operated in a controlled manner and this is another area in which the modularity of the ET 200S is a great benet, as frequency converters for outputs of up to 4 kW are available for the distributed I/O devices. Direct starters, reversing starters, and frequency converters can be arranged side by side on a head module up to a length of 2 m.

Device replacement during operation

The ET 200S High-Feature starters are not only available with contactors; they are also available as soft starters with electronic overload tripping. This is especially advantageous in dusty environments. Steinkamp speaks from experience: In contactor-only control systems, environmental inuences can cause contacts to become stuck or to not connect through at all. Though there have been no failures in the ET 200S to date, the automation expert appreciates how valuable the ease of maintenance provided by distributed I/O devices is. This is because the devices can be replaced while the plant is still in operation, by simply withdrawing the enclosure toward the front and inserting a new starter. The control system then automatically transfers the necessary data to the new device via Probus. This is something that every technician can do on-site, adds

Steinkamp. This feature, combined with the diagnostic capability of the devices, allows technicians to easily carry out remote maintenance on the plant. An additional service for the operator: if a motor starter is tripped, the maintenance personnel can immediately view the corresponding circuit diagram. This involves interaction between the CAE system and an industrial PC workstation with a CAE viewer. Visualization takes place in the same way as the normal operating display on the WinCC visualization platform. If the maintenance engineer presses the Help key, the corresponding circuit diagram sheet, which is saved on the workstation, is automatically displayed. This solution, which we developed ourselves, is ideal for users, says Steinkamp, because the red border allows the technician on-site to immediately see which sector or which starter is affected by a fault, and to view the corresponding circuit diagram.

maximum runtimes for conveyor belts to be calculated. This meant that we didnt need any additional measuring technology, explains Steinkamp. If a potato is blocking one of the drive wheels, the control system detects this and shuts down the affected drive. Until that has been carried out, the starters protect the motor against overloading. The distributed I/O devices are also economical to install. The control cabinets for the 120 drives were completely wired in the factory, so all the operator had to do on-site was install the bus cables and connect the motors to the starters. This produces signicant savings in terms of time and most importantly costs, comments Steinkamp, because whatever work is involved, its always a lot easier to carry + out in the factory than it is on-site.

MORE ON THIS TOPIC:

+ www.siemens.com/et200s
Protection against unnecessary no-load operation
CONTACT:

Around 100 t of organic potatoes are stored, transported, washed, and packaged in small quantities every day using this plant. To guarantee that this throughput is maintained, operation must be as efcient as possible. Here, too, the ET 200S High-Feature motor starters proved to be an excellent solution, as the signal exchange of the starters via Probus, together with the time stamp from the WinCC visualization software, allows the

+ Contact person: +

Heinz Czichy, Promoter, Decentralized I/O Devices E-mail: heinz.czichy@siemens.com Arno Theunissen, Sales Coordinator E-mail: arno.theunissen @siemens.com

+ Contact person: +

advance | 3-2011

23

Drive Technology

Modular Handling Solutions

In innovative handling applications, high productivity and process safety are musts. Highly dynamic motion control requires coordinated interaction between mechanisms and drives, as well as path control that automatically generates optimized motion proles based on a small number of parameters.

hether in packaging, forming, or solar technology, handling is implemented wherever the variety of products and processes makes exible motion design necessary. The handling function allows machines to be interconnected and products to be transported from one machine to another. In addition to performing the task of movement, there are also other factors to be considered, such as product-friendly transportation and short cycle times.

A compact, reduced-mass lifting/rotating system with a pickup paddle for processing at piece goods

Optimized mechanism in a modular design

Delta pickers are fast and are intended for highly dynamic handling processes. Short Bahr Modultechnik GmbH supplies a wide cycle times and thus high productivity can range of spindle and belt-driven positionbe achieved even with gantry systems, ing systems. Horizontal gantry systems though. The advantage of these modular with a circumferential belt (so-called roller positioning systems is that the mechani- pickers) can be operated in a very dynamic cal quantities are known and the compo- manner, as the motors are xed mounted. nents are optimized in terms of their mass The ELZU and ELZI gantry systems can run and rigidity. This makes it possible to de- at speeds of up to 7 m/s, which means that sign each system to precisely match the lighter components such as wafers, DVDs, individual positioning task. Additionally, and electronic components can be sorted modular positioning systems are easier to and positioned particularly fast. adapt to the design of the machine than Roller pickers are usually plane kinematprefabricated robotic solutions are. The ics. If 3D motion and additional orientaworking space for gantry systems can also tions are required, the horizontal gantry be exibly extended using a modular sys- can be expanded with the addition of further axes. When using a lifting/rotating tem of mechanical components.
24 advance | 3-2011

Fast acceleration for high productivity

In Simotion, the handling function for standard kinematics is already integrated

Siemens AG

Advantages at a glance

+ Kinematics that are system-integrated and can be dened as

desired via the free transformation interface allow almost any application to be realized.

+ Workroom monitoring uses exclusion, signaling, and product

zones.

+ Synchronization on up to 10 moving conveyor belts, standardized

system, for example, very long cycle times can be achieved through signicant weight reductions in the masses being moved. The small masses being moved prevent almost all vibrations in the machine frames. This increases productivity and saves energy at the same time. connection of camera systems, and optimized path dynamics form a high-performance bundle for high-end pick-and-place applications.

+ 3D visualizations provide support during commissioning.

This type of modular machine concept naturally requires a exible automation solution. Handling functionality with path interpolation and kinematic transformation for standard kinematics is already integrated into the Simotion family of control systems. Customer-specic kinematics can also be integrated via the free transformation interface. The control system is capable of carrying out synchronization with a moving reference system in addition to linear, circular, and polynomial interpolation systems. In this way, pick-and-place applications on moving belts (conveyor tracking) become easily programmable. The Simotion Handling Toolbox, a software library that provides standard modules for the automation of handling applications, can be used to calculate an optimized motion prole for each path, which allows that path to be run as fast as possible without any dynamic limit values of the system being violated. For example, it is thus possible to set limits for speed, acceleration, and jerk for the machine axes at the Tool Center Point, as well as moving axes connected to the path, which must be adhered to while the system is in motion. The free design of the path also allows the dynamic behavior of the system to be inuenced in order to reduce vibrations or to allow a higher running speed to be achieved, for example. When vision systems are used to recognize products, the product positions are automatically managed in a product register by the Handling Toolbox. The Handling Toolbox is topped of with software that provides support during commissioning and allows 3D visualization of the han-

Simotion Handling Toolbox

Basic libraries
Simotion Handling Basic Simotion TopLoading Function block for basic handling Standard library for high-end handling

Extension libraries
Transformation Interface Product Register Message Handling OMAC 3.0 Integration of customer-speci c kinematics Management of products in pick-and-place applications Management of control system and drive messages Operating mode manager

3D visualization
Kinematics Simulation Center 3D Trace Tool Display of space curves 3D visualization of kinematics

dling process. The handling functionality is available on all Simotion platforms. Since the performance of the system is scalable, multiple kinematics can be operated with one control system, which means that less engineering and fewer interfaces are required.

thanks to motion optimization in the control system. This guarantees high produc+ tivity.

MORE ON THIS TOPIC:

Conclusion
Optimized mechanism components in a modular system allow the implementation of high-performance, modularly extendable, and cost-effective gantry systems. Coordination of the mechanism and the drive components creates an optimized mechatronic system that runs in a timeoptimized way along its dynamic limits,

+ www.siemens.com/simotion
CONTACT:

+ Contact person: +

Holger Schrmann, Motion Control Systems E-mail: holger.schuermann@ siemens.com

Siemens AG

Optimum adaptation of control and drive

advance | 3-2011

25

Drive Technology

Ecologically and Economically Smart

Knolls KTS series of high-pressure pumps for internal coolant supply is equipped with IE1 motors, and in the future will be expanded to include 1LE1 high-efciency IE2 motors

According to legislation that came into effect on June 16, 2011, all 3-phase asynchronous motors brought into circulation within the European Union must meet the requirements of at least efciency class IE2. This modernization measure affects the bulk of electric motors. Ecological thinking is also economically smart as one manufacturer of chip conveyors, lters, and pumps is demonstrating.

ince 1970, Knoll Maschinenbau GmbH, Increased efciency based in Bad Saulgau, in Germanys Upper Swabia region, has manufac- After years of using 1LA7-series 3-phase tured chip conveyors and ltration systems asynchronous motors, Knoll Maschinenfor processing coolants in the machine tool bau GmbH has now taken its KTS pumps industry. Today, the family-run company into the new era by switching to motors has a staff of over 700 employees and de- of efciency class IE2. Forstenhusler emlivers its solutions to customers around the phasizes, In using the 1LE1 series of IE2 world. For more than 20 years, the com- motors, we expect to improve efciency pany has also been developing and manu- levels by an average of 3 percent. Dependfacturing its own screw spindle pumps for ing on the size, switching from IE1 to IE2 internal cooling lubricant supply, with max- can mean an efciency increase of up to imum pressure levels ranging from 15 to 7 percent. One reason for the higher 120 bar. The experts at Knoll are always efciency of the 1LE1 motors compared to working intensively to make these systems IE1-class motors with standard efciency even more efcient. Our systems are often is that copper is used in the rotor. operated according to a three-shift model, which means that availability is an ex- Efciency increased in tremely important factor when it comes to dened stages competitiveness, explains Peter Ludewig, purchasing manager at Knoll. Anton Forsten- The systematic switch to IE2 motors that husler, head of Knolls electrical engineer- has taken place at Knoll is a result of EU ing section, adds, Saving energy is another directive 640/2009, which puts new regimportant aspect involved in reducing pro- ulations in place regarding the energy consumption and energy efficiency of duction costs for machine tool users.

26

advance | 3-2011

all pictures: Knoll

 We dont need energy-efcient drive solutions only for the sake of the environment they will also be a key factor for maintaining our competitiveness in the future.
Peter Ludewig (left) and Anton Forstenhusler, Knoll Maschinenbau

asynchronous motors. Since June 16, denitely exist that greatly benet from 1LE1 series of IE2 motors, solutions of this 2011, asynchronous motors in the perfor- the use of a frequency converter solution. kind are already optimally prepared to mance range of 0.75 kW to 375 kW that An example tested by Knoll in which the meet the next legally required efciency are brought into circulation on the Euro- potential savings were obvious was pres- increase set to come into effect in 2015. pean market must meet the requirements sure regulation when processing a transof at least energy efficiency class IE2. This mission enclosure: The initial system (100 New motors reduce costs applies with several exceptions in the percent) has a constant pressure of 90 bar, new IEC 60034-30 efficiency standard which is set via an uncontrolled pressure- Because 1LE1-series motors have the same to motors of up to 1,000 V at 50/60 Hz, limiting valve. This has an energy con- ange connection as the previously used with operating mode S1, and for all de- sumption of 0.55 kW per enclosure, which 1LA7 3-phase asynchronous motors, Knoll signs. The next stage in the efficiency im- means energy costs of 2,970 euros per experienced no problems in making the provement process will begin on January year. When variable pressure generation transition to using the new motors with 1, 2015. From this date onward, 3-phase is combined with pressure-limited ow, the companys innovative rotor technolasynchronous motors that are operated only 64 percent of these energy costs are ogy. For customers, however, the most dedirectly from the power grid in Europe incurred. The best results were obtained cisive factor is the high efciency of the must meet the minimum efficiency re- by adapting the speed with frequency con- drives. For Forstenhusler and Ludewig, quirements of the IE3 rating (Premium verters in combination with variable pres- one thing is for certain: Electric motors Efficiency). sure generation. This reduced the energy with improved efciency according to the consumption values to around 29 percent IE2 standard, such as the Siemens 1LE1 of those under the initial conditions de- series, provide an effective solution for It pays to use frequency converters scribed above, which translates into en- saving energy and therefore reducing A possible alternative to this is to use an ergy costs of only 864 euros per year. The costs. Experts believe that the extra costs IE2 motor in combination with a frequency company therefore also offers frequency of the high-pressure pump systems with converter. Forstenhusler explains: While converter solutions that are specially op- IE2 motors will be amortized within one carrying out our energy evaluation, it timized for use with pump systems, such year if they are operated according to a became clear to us that system variants as the Sinamics G120P. Combined with the three-shift model. +

It pays to use frequency converters

MORE ON THIS TOPIC:

+ www.siemens.com/
Constant pressure via an uncontrolled pressure-limiting valve Variable pressure with pressure-limited ow Variable pressure via frequency converters 29% 100%

Electricity costs per year: 2,970

64%

+ www.siemens.com/1LE1-motors
CONTACT:

international-efciency

1,901

+ Contact person: +

864

Ernst Prill, Sales Coordinator for Machine Building E-mail: ernst.prill@siemens.com

advance | 3-2011

27

Drive Technology

High-Performance Gear Units

Siemens has further developed its range of gear units with the new Flender SIG line. These new units feature higher torque than their predecessors, and the size grading has now been harmonized.

The right solution for every application

Flender SIG units can be used universally in many sectors for example, as drives for conveyor belts in the materials handling and building materials industry or as drive components in the environmental technology and steel industries. In the rst stage of the introductory phase, Flender SIG gear units are available as 2- to 4-stage helical as well as 3- or 4-stage bevel-helical gear units with torques ranging from 7,000 to 125,000 Nm. In further development stages, the range will be expanded to include a total of 20 sizes (503522) with a torque range of up to 500,000 Nm. The new series will thus gradually replace ries. This means that the same tasks can the existing modular system. Existing now be carried out with smaller gear units. Flender gear units in sizes 23 to 28 can be The revised logistics concept also allows connected seamlessly, with torques of up greater availability in comparison to the to 1.4 million Nm. The range of features previous series. The customer therefore described above makes Flender gear units benets from shorter delivery times for and the SIG line the largest standard range both new gear units and spare parts. of gear units on the market. + In response to the increasing demand for integrated systems, the new line of gear units features an optimized casing MORE ON THIS TOPIC: design that provides exible installation + www.siemens.com/gearunits and mounting options. Flender SIG units can be mounted in both horizontal and vertical mounting positions and on the CONTACT: front of the device. The gear units are pre+ Contact person: pared as standard for the connection of Steffen Rintsch, Head of Sales, Siemens Industriegetriebe systems for temperature control, oil supGmbH ply, condition monitoring, and so on. This + E-mail: makes system planning and design more steffen.rintsch@siemens.com exible.

Siemens AG

The new gear units offer exceptionally high performance

sers today want to be able to employ standard gear units for applicationspecic drive tasks instead of being restricted to custom-made designs. Standard gear units must also be constructed in such a way that they can be adapted exibly to the application. Siemens has made provision for these requirements with its newly developed Flender SIG gear units.

Finely graded modular system with high torque

Because the size grading has been harmonized, drive tasks can now be performed with precisely the right gear unit, which saves weight and reduces costs. Furthermore, the torque has been increased by up to 15 percent compared to the previous se28 advance | 3-2011

To help achieve a rapid shine and maximum color consistency in high-quality car paints, the Opel plant in Eisenach, Germany, is perfecting its drying technology. The control of radiant heaters is particularly important in this process, and the Siplus HCS724I heating control system proved its worth when it came to nding the right solution for this technologically and economically challenging task.
Opel AG

Infrared heating elements ensure surface perfection in automobile painting

n terms of environmental sustainability, manufacturing technology, and production systems, Opel Eisenach, a wholly owned subsidiary of Adam Opel AG, is one of the worlds most modern car manufacturing plants. The Eisenach plant is currently producing the Opel Corsa model using a three-shift system. The production capacity stands at approximately 180,000 vehicles per year. The Siplus HCS724I heating control system ensures that the plants drying tunnels are able to dry the cars paint perfectly. In just one week, the painting and drying experts from Blumenbecker IPS Polska Sp. z o.o. were able to completely convert the production line to use the new system.

cisely control 920 infrared heating elements. Siplus HCS724I communicates with the higher-level Simatic S7-400 via Probus, with a transfer rate of 12 Mbit/s. Control of the outputs, fuse protection of each individual channel, and the integration of various diagnostic functions directly into the heating control system mean that 30 percent less space is required in the control cabinet, compared to the previous solution. Since the application of energy in drying processes must be limited and controlled very precisely, the system operates in an extremely energy-ef cient manner.

tivation of a drying cycle with a defective heater can be safely prevented. During commissioning, the extended diagnostics function helps detect possible wiring errors in the radiant heaters.

Perfect service and availability

Developers, commissioning engineers, and end users can obtain qualified support via the Siplus hotline. Both Blumenbecker IPS Polska and Opel Eisenach were impressed by the simple engineering, low space requirements, and good diagnostic and service features of the flexibly con+ figurable Siplus HCS724I.

Versatile diagnostics ensure process safety

Although the radiant heaters are controlled in pairs, Siplus HCS724I can detect and localize a defective heater, thanks to its integrated current diagnostics function. During operation, Siplus HCS724I also detects internal module faults and external faults such as fuse failures, cable breaks, and the failure of heaters not connected in parallel using the standard voltage diagnostics and signals these via the Simatic control system to the WinCC process visualization system and thus to the operator. In this way, the ac-

Precise, space-saving, and efcient heating control

The most inuential factors in car painting are the drying process, the cycle times, and the space requirements and energy consumption of the plant and these parameters naturally affect the quality of the nished paint job. The target temperature must be precisely maintained, but at the same time the application of energy needs to be economical and efcient. In the drying tunnel, the heating control system uses three central interface modules to pre-

MORE ON THIS TOPIC:

+ www.siemens.com/siplus
CONTACT:

+ Contact person: +

Christian Helmrich, Sales Coordinator, Siplus HCS E-mail: christian.helmrich@ siemens.com

advance | 3-2011

Industrial Switching Technology

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Perfect Surfaces

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