Four Ways to Turn a Basic Controller into an Automation Dynamo

Transcription

1 Four Ways to Turn a Basic Controller into an Automation Dynamo Unrestricted Siemens Industry, Inc usa.siemens.com/s7-1200

2 The SIMATIC Controllers Portfolio Always the right controller plus integrated added value! Engineered with TIA Portal System performance Basic Controllers SIMATIC S7-1200(F) Advanced Controllers SIMATIC S Distributed Controllers SIMATIC ET 200 CPU Software Controllers SIMATIC S Efficient Engineering Innovative Design Reliable Diagnostics Safety Integrated Security Integrated Technology Integrated Application complexity

3 SIMATIC S with Safety Integrated Smallest Controller for Standard & Safety Top-Highlights Feature / Function One Controller for Standard and fail-safe automation τ Benefit Reduction of types- and components Integrated System diagnostics Integrated Trace functionality Free programming of Safety Logic in FBD or LAD τ τ Error messages in plaintext allow a fast fault analysis (even for sporadic problems) Adaptions can easily be applied by changing the program via Software Connection of fail-safe devices Sensors/ Actuators via PROFIsafe (starting with Firmware V4.2) τ Reduction of wiring efforts Allows more flexible solutions for safety related tasks

4 SIMATIC S with Safety Integrated Engineered with TIA-Portal Top-Highlights Feature / Function I-device in a fail-safe PROFINET environment Option Handling Simulation with PLCSIM Libraries System-Libraries User-Libraries τ τ τ Benefit Leaner architecture Simpler communication and connection Faster commissioning The program code can be validated incl. safety functions before going on site Reduced Engineering time due to standardization Unified display concept Trace Webserver τ Efficient fault analysis without additional tools reduce downtimes

5 System Integrity Security use cases with SIMATIC S7-1200(F) Controller Know-how protection Copy protection Protection of intellectual property of program code Know-how protection for PLC program blocks TIA Portal ******* Protection against unauthorized duplication of runtime program code Bind program blocks to hardware serial numbers (CPU or SD card) Storage A A A Storage B B A Controller Controller Controller Access protection Communication integrity Protection against unauthorized access and configuration changes Protection level concept with different access rights incl. HMI connections Engineering Remote control Detection of manipulated communication data Engineering and HMI communication with integrated security TIA Portal Maintenance Operation Controller HMI

6 Easy PLC selection thanks to an optimized Portfolio CPUs Switchmodule Powermodule Communicationmodules Signalmodules Technologymodules Signalboards CSM PM 13x CM / CP CPU 1211C-1PN CPU 1212C-1PN CPU 1214C-1PN CPU 1215C-2PN CPU 1217C-2PN 22x I/Q 2xTM 11x SB 1x CB 1x BB

7 Condition Monitoring Systems for early detection of mechanical damages for S controller Unrestricted Siemens Inc

8 SIPLUS CMS The machine under control There is no machine without vibrations. But when do vibrations cause damages? And what kind of damages? And will the machine suddenly break down? SIPLUS CMS The answer to preventive maintenance in industry

9 SIPLUS CMS Possibilities of Condition Monitoring Watch Feel Hear SIPLUS CMS Smoke Heat Noise Early detection Minutes Days Weeks Months Reaction time until breakdown

10 Condition Monitoring with SIPLUS CMS What sort of damage can be detected? An extract Pump / Fan Gear box Drive Blade passing frequency Resonance Alignment fault Field fault Broken rotorbar Unbalance Meshing fault Bearing damage Condition Monitoring with SIPLUS CMS more than just Motor Condition Monitoring Mechanical damages Resonance Bearing damage Alignment fault Unbalance Meshing fault Blade passing frequency Motor Condition Monitoring Electrical faults Field fault stator Broken rotorbar

11 SIPLUS CMS1200: Condition Monitoring with SIMATIC S SM Overview SM 1281 Condition Monitoring Model Features Operating principle Characteristic value diagnostics Frequency-selective diagnostics Expert analysis on- or offline SIMATIC S and web-based Calculations are performed continuously The 4 IEPE channels and the speed sensor are read in and processed simultaneously Connections Diagnosis Up to 4 vibration sensors 1 speed input Ethernet Power supply 24VDC (supply to sensors) Characteristic values via SIMATIC S and TIA Portal Frequency selective via integrated Web Server Expansion option Advantages and Costumer benefits Up to 7 modules can be connected; depending on the S CPU used BERO Speed measurement IEPE-Sensors Vibration measurement No additional software for diagnosis and visualizing needed

12 SIPLUS CMS The analysis methods of condition monitoring Expert analysis Significance of the analysis Parameter-based analysis Is damage imminent? Trend history of characteristic values Frequency-selective analysis What damage is imminent? Every type of damage has its own frequency spectrum Freely configurable analysis with diagnostics software CMS X-tools, e.g. orbit, histogram, vector/waterfall diagram

13 SIPLUS CMS Analysis methods Parameter-based analysis Characteristic values Monitoring for Signal Mode of operation RMS after ISO DKW after VDI 3832 RMS: machine vibration DKW: e. g. bearing damage Alarm Warning OK Monitoring of characteristic values Trend Signal-light display Disadvatage: Type of looming damage not discernable Troubleshooting required Advatage: Easy and quick to implement Minor condition monitoring expertise required

14 Realizing the practical example with SM1281 Evaluation of limits for characteristic values Basic Information to provide limit values after ISO10816 Motor Power: 20kW Shaft height: 200mm Foundation: rigid Fan got newly commissioned Vibration velocity v [rms] mm/s inch/s 11 0,44 7,1 0,28 4,5 0,18 3,5 0,11 2,8 0,07 2,3 0,04 1,4 0,03 0,71 0, Hz, n > 600 1/min ( Hz, n > 120 1/min) Limit values Alarm threshold : Warning threshold: 4,5 mm/s 2,8 mm/s Rigid Soft Rigid Soft Rigid Soft Rigid Soft Foundation Medium-sized Pumps > 15 kw Large Machines Machines 300 kw < P < 50 Radial, axial, diagonal 15 kw < P 300 kw MW Machine typ Motors Intermediate Shaft Motors Direct Drive 160 mm H < 315 Belt Drive 315 mm H mm Group 4 Group 3 Group 2 Group 1 Group A Newly commissioned C Short term operation B Unlimited long term operation D Vibrations cause damage

15 SIPLUS CMS Analysis methods Troubleshooting an example Test steps for fault analysis Start Possible imbalance or housing displacement: Perform soft foot check Measure housing vibrations under load: DE and NDE horizontal, vertical and axial Vertical change of foot position Yes End No Vibration values impermissibly high? No Align housing Yes Vibration values impermissibly high? Imbalance probable: Measure housing vibrations without an output element, insert full key or half key in keyway in accordance with the balancing method (secure feather key!) End Vibration values significantly lower? No Vibration values significantly lower? No Yes Yes Unbalance in motor rotor: Balance motor rotor Alignment fault probable: Align coupling Cause is balancing state of output element: balance output element or check balance type for motor rotor/output element End End End

16 SIPLUS CMS - Analysis methods How does frequency-selective diagnostics work? Benefits of frequency-selective diagnostics: C:\Users\za3233\Downloads\Fourier_transfo rm_time_and_frequency_domains_(small).gi f Each type of mechanical damage has its own unique frequency spectrum One glance at the frequency spectrum is sufficient to determine the cause of damage to within a high degree of accuracy The search for the actual cause of the damage is reduced to a minimum The amplitude is a measure for the extent of damage, which allows conclusions to be drawn about the remaining lifespan. The experience of the operator plays a decisive role here

17 SIPLUS CMS - Analysis methods Frequency-selective analysis Monitoring for machine vibration Examples of detectable mechanical damage Signal How it works Resonance Alignment fault Cyclic monitoring Peaks Trend Unbalance Coupling fault Monitoring for roller bearing damage Detectable mechanical damage Outer race defect Inner race defect Rolling element damage Cage damage Frequencyselective analysis Advantages: Quick and easy to implement Type of damage identifiable less troubleshooting Electrical faults detectable

18 SIPLUS CMS - Analysis methods Expert analysis Monitoring for gear unit wear Detectable mechanical damage Signal How it works Meshing faults Raw data Event-driven recording A message signal meshing fault detected Recording + saving sensor channel raw data Engineering + project of meshing faults via SIMATIC S CPU + SM 1281 Web Interface Engineering expert analysis via analysis software, such e.g. CMS X-Tools Expert analysis OFFLINE analysis of exported raw data ONLINE raw data streaming to CMS X-Tools 1. Exporting of the raw data: Via FTP manual Via FTP event-driven 2. Online raw data streaming to CMS X-Tools Advantage: Raw data used for analysis models exactly tuned to the gear unit

19 CMS X-Tools V4.04 efficient and flexible analytics system Condition monitoring + CMS X-Tools the Siemens condition monitoring software Efficient Engineering Fast configuration with project configurator and predefined libraries + Flexible analytics + Free adjustable analytics functionalities are integrated into the system Scalable + CMS X-Tools scale from small to large footprint with a flexible software structure Connectivity High number of SW and HW devices can be connected + Proven used since more than ten years in many projects +

20 MindSphere Edge Analytics with X-Tools Integration in MindSphere High frequency data from various sources collected Data processed and sent to MindSphere Data ready for visualization and analytics Data transfer to MindConnect Nano via OPC UA X-Tools server hosted on Microbox PC MindConnect Nano *not necessary with next release MindSphere The cloud-based, open IoT operating system 11001

21 Connection to MindSphere application example S SM1281 MindConnect Nano

22 SIWAREX weighing modules for S basic controller

23 SIWAREX WP2x1 controller for S WP231 WP241 WP251 7MH4960-2AA01 7MH4960-4AA01 7MH4960-6AA01 Applications Platform / hopper scales Conveyor / belt scales Mixing, Blending, Bagging 4xDQ, 4xDI, 1xAQ, Ethernet, RS485 4xDQ, 4xDI, 1xAQ, Ethernet, RS485 4xDQ, 4xDI, 1xAQ, Ethernet, RS485 All industries Mining, Cement, Food and Beverage, Recycling All industries

24 SIWAREX WP2x1 in TIA Portal SIWAREX WP2x1 Technology modules of S Interrupt generation 32 Byte I/O memory per module All S weighing modules are integrated part of TIA

25 Check weighing in packaging process increases efficiency Benefits The Siemens standard components combined with our plant allows us to offer customized solutions for the food industry. Michel Remijn, owner RMA Techniek Through its integration in SIMATIC S7-1200, the SIWAREX WP231 electronic weighing module provides uniform mounting technology and integrated communication. Commissioning of the electronic weighing module using SIWATOOL or directly via a connected HMI panel is quick and easy. With a resolution of up to +/- four million parts and a sampling rate of 10 ms/ second, the weighing module was the right choice for the company s high demands for speed and accuracy.

26 Check weighing in packaging process increases efficiency Challenges Products/solutions Customer benefits 1. Final check weighing did not take place. Irregularities in the packaging weight are a disadvantage for the company since the packages often contain more vegetables than the amount required by the package size. 2. The plan was to install a check weigher at the end of the packaging process to eliminate this uncertainty factor. The weight control should focus not only on accuracy, but also work very quickly throughout the packaging process. 1. SIWAREX WP231 - the core element of all weight measurements is the Siemens SIWAREX WP231 weighing electronics connected to a SIMATIC S7-1215C controller. 2. SIWATOOL Commissioning of the electronic weighing module using SIWATOOL or directly via a connected HMI panel is quick and easy 1. With a resolution of up to +/- four million parts and a sampling rate of 10 ms/ second, the weighing module was the right choice for the company s high demands for speed and accuracy. 2. For data analysis and improved traceability, all measurement results are collected in a central memory. 3. Another demand was that it should be possible to weigh different types and shapes of packages containing a variety of products. 3. Siemens KP700 Comfort The weighing process can be controlled and monitored, and parameters can be edited with the Siemens KP700 Comfort HMI panel. 3. All system components were connected and configured directly through TIA Portal. This also enables quick and easy adaptation and expansion of the weighing application should it become necessary.

27 Transparent operation Energy efficiency with S SM1238 Energy Meter Siemens Inc siemens.com

28 Energy efficiency offers added potential Energy costs Energy costs , Germany, industry Laws and climate protection Change of energy supply UN climate summit 2015, Paris Share of renewable energies: in power consumption in Germany Responsibility for environment / image Opinion research 2015 ~6% Average annual increase in electricity price (Ø 00 15) 2 C Limiting the temperature rise worldwide 32% From 6.5% in the year Should rise to 80% by % A green image is decisive for the purchasing decisions of markets and customers 3 Significant cost factor in production Statutory measures to achieve environmental targets New boundary conditions as a consequence of changing energy resources and continued requirements for supply reliability Energy-efficient production as a key marketing argument 1 Prices including taxes, source: statista.com (Link) 2 Source: E.ON-survey 2015 (Link) 3 Source: Federal Environmental Agency (Link) 4 Source: AGORA energy transition (Link)

29 The way to save energy Transparency is the first step to reduce costs Increase the transparency level to assign the consumption per room Install additional electric meters (measurement devices) to get a more precise overview, which consumer needs how many energy Identify the big electrical consumers, which were previously been hidden Amortization time of each planned saving measure can be calculated! E!! Saving measures can now be evaluated based on facts Realization of profitable measures

30 The way to save energy Transparency is the first step to reduce costs Energy Manager also needs reliable facts to decide saving measures min Rate of energy transparency max First step is to create energetic transparency in the factory Possibility to create a high level of energy transparency by integrating measurement devices in the factory Identification of biggest energetic consumer and optimization potential in the process Without a certain level of energetic transparency, a definition of energy saving measures is nearly impossible

31 SM 1238 ENERGY METER 480VAC for transparency in the energy distribution System overview Description Ethernet Energy data Your energy distribution 10 KV HMI Visualization management Ethernet 480V SIMATIC HMI Web Visualization SM 1238 Energy Meter +.. SIMATIC PLC S *) SIMATIC Web server Gathering and processing S CPU SM 1238 Energy Meter 480 VAC *) Current transformer

32 The way to save energy Visualization of energetic data for an easy analysis To identify saving potential, the data have to be visualized and stored After data acquisition in the PLC, they should be visualized for a more easy analysis Visualization of the current consumption values of one machine on a panel near the machine for basic condition monitoring generating a basic energetic awareness Visualization of long term stored values of different machines in one overview i.e. in the office for comparing identical machines and an identification of optimization potential an identification of the biggest energy consumers in the factory Machine visualization Office visualization

33 Continuous energy data acquisition as basis Acquisition Water meter SENTRON PAC Processing S and energy meter, I/O Evaluation and analysis SIMATIC Energy Manager PRO Plant-wide energy management Optimization IE4-motors Flow measurement Current transformer SIMATIC Energy Suite Production-level energy monitoring Energy analytics Converters S and energy meter, I/O S7 Energy Efficiency Monitor for machines Energy efficiency evaluation of machinery Process adaptations Recording and production-related data processing is the basis for energy consumption transparency

34 SIMATIC Automation Tool Unrestricted Siemens Inc.2018 siemens.com/sat

35 Increased productivity due to an extensive range of functions Top-Highlights Feature / Function Benefit Network scan IP-adress- and PROFINET name changes Program/Project download Backup/Restore Mass operaitons API τ τ τ τ τ τ Simple acquisition and display of the reachable PROFINET devices Quick adaption of local network rquirements Update the automation system without TIA Portal Fault-Back support when performing the operation Efficient updating also for extensive machines/plants Automated execution of the operations

36 One tool for commissioning, maintenance and service Independent of the engineering framework Ideal for commissioning, maintenance and service without TIA Portal + Hardware support Extensive support of the Siemens automation portfolio + Usability Easy to use for TIA and non-tia Portal users + Mass operations Parallelizing of tasks to reduce time and costs + API Optimal for automation of tasks +

37 Perfect partner to TIA components TIA Portal engineering is the basis for program/project download Support for many TIA components such as SIMTATIC controllers, distributed I/Os, HMI panels, SITOP and RFID Integrated industrial security mechanisms such as access control of PLCs and HMI panels

38 Jana Kocianova Product Marketing Manager S7-1200/S7-1200F Siemens Industry, Inc. RC-US DF FA MK PLC 5300 Triangle Parkway Norcross, GA , USA Mobile: +1 (470)