Configuration and Commissioning of SIMIT Virtual Controller in a PCS 7 Environment

Transcription

1 Application description 07/2016 Configuration and Commissioning of SIMIT Virtual Controller in a PCS 7 Environment SIMIT SF V8.1 and SIMIT VC 3.0

2 Warranty and liability Warranty and liability Note The Application Examples are not binding and do not claim to be complete regarding the circuits shown, equipping and any eventuality. The Application Examples do not represent customer-specific solutions. They are only intended to provide support for typical applications. You are responsible for ensuring that the described products are used correctly. These application examples do not relieve you of the responsibility to use safe practices in application, installation, operation and maintenance. When using these Application Examples, you recognize that we cannot be made liable for any damage/claims beyond the liability clause described. We reserve the right to make changes to these Application Examples at any time without prior notice. If there are any deviations between the recommendations provided in these application examples and other Siemens publications e.g. Catalogs the contents of the other documents have priority. We do not accept any liability for the information contained in this document. Any claims against us based on whatever legal reason resulting from the use of the examples, information, programs, engineering and performance data etc., described in this Application Example shall be excluded. Such an exclusion shall not apply in the case of mandatory liability, e.g. under the German Product Liability Act ( Produkthaftungsgesetz ), in case of intent, gross negligence, or injury of life, body or health, guarantee for the quality of a product, fraudulent concealment of a deficiency or breach of a condition which goes to the root of the contract ( wesentliche Vertragspflichten ). The damages for a breach of a substantial contractual obligation are, however, limited to the foreseeable damage, typical for the type of contract, except in the event of intent or gross negligence or injury to life, body or health. The above provisions do not imply a change of the burden of proof to your detriment. Any form of duplication or distribution of these Application Examples or excerpts hereof is prohibited without the expressed consent of the Siemens AG. Security information Siemens provides products and solutions with industrial security functions that support the secure operation of plants, solutions, machines, equipment and/or networks. They are important components in a holistic industrial security concept. With this in mind, Siemens products and solutions undergo continuous development. Siemens recommends strongly that you regularly check for product updates. For the secure operation of Siemens products and solutions, it is necessary to take suitable preventive action (e.g. cell protection concept) and integrate each component into a holistic, state-of-the-art industrial security concept. Third-party products that may be in use should also be considered. For more information about industrial security, visit To stay informed about product updates as they occur, sign up for a productspecific newsletter. For more information, visit Entry-ID: , V1.1, 07/2016 2

3 Table of contents Table of contents Warranty and liability Introduction Quality Starts with Engineering Operator training systems with guaranteed performance Ongoing optimization of plant operation The Virtual Controller Real plant to virtualized plant Virtualized plant Preparation Configuring the Emulation Manager Automatic Model Generation Creating the device level Creating the process level Process model of raw material tank RMT1 ( LI111 ) with STANDARD components Process model of Reactor1 with STANDARD components Related literature History Entry-ID: , V1.1, 07/2016 3

4 1 Introduction 1 Introduction 1.1 Quality Starts with Engineering With the SIMIT set of software, an advanced product line for virtual commissioning of automation systems is already available today. Simulation models that were created can be connected to a real (hardware-in-the-loop, HiL) or emulated controller (software-in-the-loop, SiL) without having to make changes to the automation software. The aim of the recently released Simulation Framework version 8.1, including the new SIMIT Virtual Controller Software (SIMIT VC), is to allow integrated virtual commissioning and operator training systems (OTS) with a uniform simulation environment based on a completely virtual plant. Already during engineering, the created simulation models can be used for testing to identify and detect any errors at an early stage. This results in optimized automation concepts. Virtual commissioning allows you to increase engineering quality and considerably shorten real commissioning - for example, this significantly reduces the number of software errors. Project examples from customers prove potential reductions in commissioning time of up to 90% Operator training systems with guaranteed performance From the perspective of an operator training system, the requirements and the complexity are significantly higher, particularly if you want to exactly emulate the real plant by a virtual plant. On the one hand, it is required to model and calculate complex processes and, on the other hand, it is necessary to configure distributed stations. For example, when running the automation programs on emulated controllers that must communicate with each other via multiple distributed PCs or if a subfunction for a specific training should run at different speeds. With Virtual Time Management, SIMIT offers this functionality and, at the same time, ensures coherence and smooth interaction between the simulation and the automation process for all virtual controllers. Furthermore, simulation states, including the controller states, can be saved at any time as snapshots and reloaded at a later time with all matching values, model states, I/Os and controller programs. And last but not least: SIMIT allows you to implement a virtual plant system with minimum space and hardware requirements. Under the name "SIMATIC Virtualization as a Service" (\5\), complete platforms based on virtual machines are available as an additional service Ongoing optimization of plant operation When using simulation for virtual commissioning and operator training systems, the know-how on a plant and its automation is mapped to models. This technology acts as a reliable basis of experience and decision-making and contributes to promoting continuous improvements in quality in terms of plant safety, compliance with standards and productivity over the complete plant life cycle - despite modifications or changes in staff. With the optimized software offer and the dovetailing of all tools, SIMIT Simulation Framework is a link between engineering, plant simulation, virtual and real commissioning, operator training and plant operation. Therefore, it acts as a multiple lever for quality over the complete life cycle of a plant. Entry-ID: , V1.1, 07/2016 4

5 1 Introduction 1.2 The Virtual Controller The Emulation Manager (SIMIT EMU) is an emulation platform that allows you to virtually commissioning complete plants. The Emulation Manager is used to generate virtual controllers (SIMIT VCs) that, unlike PLCSIM, can be operated independently of the engineering station; i.e., the emulated controllers can be distributed over multiple computers and communicate with OS servers. Therefore, virtual commissioning on a single station, the engineering station, is no longer necessary. You can virtualize your complete plant, configure an unlimited number of virtual AS and virtually adjust your simulation time. For slow processes, you can accelerate your simulation in synchronization with the emulated AS. Likewise, for fast processes, you can slow down the complete plant. When the plant is in the operating point, snapshots allow you to save the state of the complete plant, including the SIMIT VC image. A virtual plant consists of the following components: ES, engineering system OS, OS server(s), OS clients, can be a subnet of a real plant system, but at least one OS server is required for the visualization SIMIT SF, simulation framework SIMIT EMU, emulation manager tool that is used to configure the SIMIT VC, an extension to SIMIT SF SIMIT VC, virtual controller(s) SIMATIC NET, Ethernet drivers The following table lists the options for deployment Table 1-1 ES OS Component SIMIT SF SIMIT EMU SIMIT VC SIMIT NET Option for deployment Can be part of the virtual plant or shared with the real plant. If shared, network considerations must be taken into account to create a thorough separation. OS server (s) and clients (s) dedicated to the virtual plant Can be installed on a separate PC or the ES. Emulation manager, MUST reside on the same PC as SIMIT SF Virtual controllers run on a PC separate from the OS server PCs. These can be the ES, the PC where SIMIT SF runs or a separate PC, the distribution is based on performance requirements. The ES, OS and SIMIT VC systems are communicating via SIMATIC NET Ethernet drivers and therefore SIMATIC NET must be installed on PCs where any of these components run. Entry-ID: , V1.1, 07/2016 5

6 1 Introduction Figure 1-1 shows the basic structure of a virtual plant. It is mandatory that SIMIT and the Emulation Manager (SIMIT EMU) be installed on the same computer. If SIMIT is not installed on the computer, the SIMIT VC installer will automatically install Runtime, which is the case for the SIMIT VC stations. SIMATIC NET must be additionally installed on the SIMIT VC stations. Figure 1-1 Basic structure of a virtual plant The following table lists the communication interface between the components in the real plant and the virtual plant: Table 1-2 Communication interface between ES-AS (SIMIT VC) AS (SIMIT VC) for ES AS-AS (SIMIT VC- SIMIT VC) Real plant SIMATIC NET driver, TCP/IP or ISO protocol, PC internal Ethernet port on the CPU or separate CP card with TCP/IP or ISO address downloaded from hardware config (Step7) AS S7 protocol, TCP/IP or ISO protocol, identified by connection defined in NetPro with counter side IDs Virtual plant SIMATIC NET driver, TCP/IP protocol, PG/PC interface assigned Ethernet card PC where the SIMIT VC(s) are running, its network interface card (NIC), TCP/IP addresses of the SIMIT VC(s) are added to the NIC (Advanced settings of the TCP/IP address configuration of the NIC) SIMIT VC-Internal protocol, configured in SIMIT EMU, defined between virtual controllers, uses communication interface(s) between PC(s) where the SIMIT VC(s) are running as needed Entry-ID: , V1.1, 07/2016 6

7 1 Introduction Communication interface between OS-AS (SIMIT VC) AS (SIMIT VC) for OS Real plant SIMATIC NET driver, TCP/IP or ISO protocol, named connection configured with NetPro Ethernet port on the CPU or separate CP card with TCP/IP or ISO address downloaded from hardware config (Step7), configured as the end point of a named connection in NetPro Virtual plant SIMATIC NET driver, TCP/IP, named connection that is defined in the PC station configuration, configured in SIMIT EMU, refers to named connection name as defined in NetPro for consistency Gateway definition and connection(s) in the PC station configuration of the SIMIT VC PC, configured in SIMIT EMU as the counter side of the OS-AS named connection The following table lists how communication connections are configured: Table 1-3 Configured communication connections Real Plant Virtual plant ES-AS (SIMIT VC) AS-AS (SIMIT VC- SIMIT VC) OS-AS (SIMIT VC) SIMATIC NET driver, TCP/IP or ISO protocol, PC Internal AS S7 protocol, TCP/IP or ISO protocol, identified by connection defined in NetPro with counter side IDs SIMATIC NET driver, TCP/IP or ISO protocol, named connection configured with NetPro SIMATIC NET driver, TCP/IP protocol, PG/PC interface assigned Ethernet card SIMIT VC-Internal protocol, configured in SIMIT EMU, defined between virtual controllers, refers to IDs as defined in NetPro for consistency SIMATIC NET driver, TCP/IP, named connection configured in SIMIT EMU, refers to named connection name as defined in NetPro for consistency Entry-ID: , V1.1, 07/2016 7

8 1 Introduction The following table lists how the communication interface between the components in the real plant and the virtual plant are deployed: Table 1-4 Communication interface between Real plant Virtual plant ES-AS (SIMIT VC) PC station configuration and download on the ES PG/PC interface points to the network interface to be used AS (SIMIT VC) for ES Hardware config download Add SIMIT VC(s) their TCP/IP addresses to the NIC that is used to connect the PC where the SIMIT VCs are running to the network AS-AS (SIMIT VC- SIMIT VC) NetPro download None, integral part of the SIMIT VC configuration that gets deployed by SIMIT OS-AS (SIMIT VC) PC station configuration and download followed by a NetPro download.xdb file, generated by SIMIT EMU is used to configure and parameterize the PC station configuration of the PC where the OS will be running AS (SIMIT VC) for OS NetPro download.xdb file, generated by SIMIT EMU is used to configure and parameterize the PC station configuration of the PC where the SIMIT VC(s) will be running Entry-ID: , V1.1, 07/2016 8

9 1 Introduction Figure 1-2 shows the communication relationships. After the plant was configured using the SIMIT EMU, the generated *.xdb files are distributed to the computers involved. The *.xdb files must be manually imported into the stations. Then a coupling to the SIMIT VCs can be created in SIMIT SF. NOTE Please make sure that the SIMIT project name matches the SIMIT EMU project name. If this is not the case, there will be no communication between SIMIT VC and SIMIT SF. Figure 1-2 Functional relationship between SIMIT SF, SIMIT VC, SIMATIC Manager and PCS 7 PS After you have started the simulation, the SIMIT VCs are started up on the SIMIT VC stations and a connection between the OS stations is established. Just like you are used to from PCS 7, the AS program can be downloaded to the SIMIT VCs using the PLC Download function. The program remains saved even after exiting the SIMIT VCs and does not have to be downloaded again when restarting. If the S7 connections are "Named Connection(s)", it is not necessary to make changes in WinCC. If the connection is an ISO or TCP/IP connection to WinCC, the "SIMATIC S7 Protocol Suite" must be customized. For example, an ISO connection requires that the MAC address of the SIMIT VC station where the emulated SIMIT VCs run be entered in the "SIMATIC S7 Protocol Suite". NOTE If the system parameters of the "SIMATIC S7 Protocol Suite" are write-protected, start the "emuwinccsetconnprc.exe" application. It can be found in the installation location of the SIMIT EMU in the "tools" folder. Entry-ID: , V1.1, 07/2016 9

10 At the outset, the task is to virtually commission a small plant using SIMIT. The configuration steps of the SIMIT EMU will be shown and practically performed. The objective is a running simulation project, as a first step up to the signal level. At this level, you can manually set or monitor the signals. The real plant consists of one OS single station, one engineering station and two automation stations. All PC stations are connected via a bus system, see Figure 2-1. The redundant AS controls/monitors the plant parts, Plant 1 and Plant 2, via the PROFIBUS DP fieldbus, see Figure 2-2 and Figure 2-3 In the plant parts, the liquids of the raw material tanks are dosed into the reactors and made into the product by heating and stirring. Bottling takes place in plant part 3 where the product is bottled. The automation program for this plant part is run in the single H station. PROFINET IO is used as the fieldbus, see Figure 2-4. Both AS, i.e. the redundant one and the single H, are implemented with the CPU 410. Figure 2-1 Overview of the real bottling plant Figure 2-2 Plant part 1 with three raw material tanks Entry-ID: , V1.1, 07/

11 Figure 2-3 Plant part 2 with two reactors Figure 2-4 Plant part 3 for bottling the product 2.1 Real plant to virtualized plant The virtual plant settings and definitions are based on the configuration of the real plant. Figure 2-1 shows an example of a real plant configuration. In Figure 2-5 a possible virtual plant configuration that is capable of the real plant control system is being shown. Entry-ID: , V1.1, 07/

12 2.2 Virtualized plant The real plant is fully virtualized using SIMIT Simulation Framework (SF). The SIMATIC Manager, SIMIT SF and the SIMIT EMU are installed on the engineering station (ES). The operator station (OS) is virtualized and runs locally (VC_OSn) on the ES in VMWare. The virtual controllers (SIMIT VCs) are emulated on the SIMIT VC station, VC_ASn. The SIMIT VC's runtime environment is installed on the station. A total of two stations, VC_ASn and VC_OSn, are virtualized on the ES and can be started with VMWare Player, see Figure 2-5. Figure 2-5 Virtualized bottling plant The virtual stations (client computers) are networked with the host system (ES) via a "bridged connection". Therefore, all stations are nodes in a network and can communicate with each other. The Ping command can be used to test this in both directions, i.e., from the host to the client and vice versa. Figure 2-6 Testing the connection using ping command If all nodes in the network are accessible, you can start configuring the virtual controllers. Entry-ID: , V1.1, 07/

13 2.3 Preparation Before configuring, please perform the following steps: 1. Disable the Windows firewall 2. Set the AS IP addresses on the "VC_ASn" SIMIT VC station, see Figure 2-7 Make sure you enter all IP addresses of all the AS you are using (online interface). In this case, they have already been entered. For each emulated AS, exactly one IP address must be assigned in the network. The IP addresses are assigned in the properties of the physical LAN adapter on the "VC_ASn" SIMIT VC station. Due to this, this physical LAN adapter has not only one but multiple IP addresses. The main address for the SIMIT VC station and the sub addresses for the respective emulated AS. Figure 2-7 Setting the IP addresses on the VC_ASn station 3. Network policies, see Figure 2-8. Make sure that there is an uplink to a network. Use this dialog box to set the network policies to "Private". Entry-ID: , V1.1, 07/

14 NOTE The dialog box can be accessed from Start menu, pgedit.msc > Local Computer Policy > Windows Settings > Security Settings > Network List Manager Policies. Figure 2-8 Network policies of the virtual controller 4. Set the access points on the ES, see Figure 2-9. Entry-ID: , V1.1, 07/

15 This setting parameterizes the online connection from the ES to the SIMIT VC station. It makes available communications services such as Download AS program to SIMIT VC station and test mode. Figure 2-9 Communication settings on the ES for the online connections 5. The PCS 7 OS project is located on the OS station. The OS station does not need to be configured. It will be configured later by the SIMIT EMU with the generated data. Entry-ID: , V1.1, 07/

16 2.4 Configuring the Emulation Manager 1. Star the Emulation Manager on the ES and create e new project, see Figure The Launch wizard guides you though the individual menus of the SIMIT EMU and should be used especially at the beginning. CAUTION If you have already created a SIMIT project, make sure that the name matches the SIMIT project. Otherwise a connection to the SIMIT VCs cannot be established. Figure 2-10 Creating a new SIMIT VC project 2. Then the system checks whether the appropriate SIMIT license is available. If a license has been found, the project icon is provided with a green check mark, see Figure Without a valid license, the Emulation Manager remains in demo mode and the icon starts flashing. In addition, "Demo" is displayed in the main window. Figure 2-11 Menu bar when SIMIT license valid Entry-ID: , V1.1, 07/

17 3. Select "OK" and "Next" to confirm the general information of the wizard. In the next dialog box, "Computer configuration", define all PC stations involved. To do this, right-click to open the context menu and open the "Insert" dialog box. NOTE During this step you will configure the PC station that will be used for the simulation system. The Number of PC stations depends on the distribution of AS system(s) and OS system(s) within the simulation system. You can combine one or more AS systems and the SIMIT and the SIMIT SF on a single PC. The names of the PC stations in the simulation system can be different from the names of the PC stations used in the PCS 7 project. If the name of the PC station in the simulation system that hosts the OS is different from the name used in the PCS 7 project, then the download path of the OS must to be adapted to reflect that name Assign the "role" to the appropriate PC station: ESn > Emulation/simulation SIMASn > Emulation/simulation SIMOSn > Operator station (HMI) 4. Assign the appropriate computer name with the associated IP address, see Figure You can select the IP address from the drop-down menu. The MAC address is entered automatically. Figure 2-12 Configuration dialog box for the engineering station NOTE All visible PC stations are displayed in the drop-down menu represented by their IP addresses. 5. To allow the emulation manager to deliver configuration files to the PCs that are used for the simulation system, a "Share" folder must be defined for the PC stations, SIMOSn and SIMASn. To do this, use the folders used in Figure The "Update" button (see Figure 2-12, right hand figure) allows you to make the current share folders available and select them using the drop-down menu. User name and password have to be entered as well. Enter a valid user name (in our example system "WSuser") in the user field and the password for that user in the password field, see right-hand figure in Figure Entry-ID: , V1.1, 07/

18 NOTE Please make sure that the share folder on the SIMIT EMU computer points to the same folder path as on the SIMIT VC computer, i. e. D/Siemens/Emulation. When installed to C:, the path has to be changed accordingly. Figure 2-13 Configuring the PC stations 6. Once all PC stations have been configured, select "Next" to continue the wizard. The next step is to define the AS systems within the simulation system. This is accomplished by importing the hardware configuration for each AS. The hardware configuration is exported from PCS 7 as described in Figure Make sure to export the "default values" by selecting this option as shown in Figure Figure 2-14 Exporting the hardware configuration from PCS 7 Entry-ID: , V1.1, 07/

19 NOTE Since the complete hardware configuration of AS system is exported from the SIMATIC PCS 7 project and subsequently imported into SIMIT EMU, there is no need to download hardware to the SIMIT VC soft-controller in a later stage. That also means that the user must perform an update of the AS as defined in SIMIT EMU after every modification to the AS in the SIMATIC PCS 7 project. Figure 2-15 Exporting the hardware configuration 7. Import the hardware configuration by pointing at the file that was obtained by performing the export described above, see Figure Figure 2-16 Hardware configuration dialog box of the SIMIT EMU Entry-ID: , V1.1, 07/

20 Before the import take place, the next dialog box allows you to specify information that was not obtained from the hardware configuration file. Confirm the properties such as "CPU type" and "Order number", see Figure In case of the system being a High Availability controller, in our example for AS1, check the "H-system" check box. Once you have imported AS1, the next step asks whether you want to import additional resources, you can repeat the steps until all AS systems have been imported. Figure 2-17 Hardware configuration import 8. In the wizard menu, click "Click here to import new resources" to import the second AS. Select the hardware configuration of AS2 and proceed as in the previous step. Entry-ID: , V1.1, 07/

21 9. SIMIT VC is a soft-controller, several function used in the application program of the AS are intended to manage hardware related functionality like diagnostic interrupts. The SIMIT VC controller uses run-time block replacement to replace these hardware related functions with functions that are suitable for the soft-controller. The functions that are used as a replacement are known as HLL blocks, they are functions with an identical name and interface definition as standard (or custom) PCS 7 library function blocks. Since the standard PCS 7 library blocks have different interfaces depending on the version of SIMATIC PCS 7 that is being used for the PCS 7 project, the user must select the appropriate version of the HLL blocks to be used as a replacement in the soft-controller. After importing the AS system(s) you are prompted to import the "HLL blocks" for each AS, see Figure Make sure that the correct PCS 7 Basis Library is selected, in our example that is PCS 7 Basis Library V8.1. Figure 2-18 Import HLL blocks dialog box 10. AS systems are imported by selecting hardware configuration export files, OS (WinCC) (and other runtime components, e. g. a SIMATIC NET OPC server) must be configured manually. To do so select "Click here to add new resources manually" to add the OS (WinCC) resource. Right-click to open the context menu and add a new resource. In "Resource type", select "Runtime component" and assign it a name such as "WinCC". Select "OK" to confirm the dialog box. Entry-ID: , V1.1, 07/

22 11. Once the AS and OS resources have been imported and configured, the AS resources must identify which (Ethernet TCP/IP capable) communication processor or on-board interface will be used to download and debug the PCS 7 controller application. This definition is named Online interface. Perform these steps to select the online interfaces. Select each AS resource (in the figure AS1), than select the CPU or CP card whose interfaces is to be used, than check the box Online interface. Repeat this for every AS (in our example AS2), see Figure 2-19 and Figure Then select "Next" to continue the wizard. Figure 2-19 configuring the online interface of AS1 Figure 2-20 configuring the online interface of AS2 Entry-ID: , V1.1, 07/

23 12. SIMIT SF addresses IO by its symbol name, the user must export the symbol table of each AS and subsequently import them into SIMIT EMU. This is performed in the next step, select "Click here to import a symbol table" to import the symbol tables for resources AS1 and AS2, see Figure Select "Next" to continue the wizard. NOTE When exporting the symbol table, make sure that is has *.seq format. Figure 2-21 Symbol import dialog box 13. After all resources (AS system and OS or other run-time component) have been defined, the resources must be assigned to the PCs that were configured in step 1. This process is named Resource distribution. In the next dialog box, distribute the resources to the PC stations, see Figure NOTE The user distributes AS, OS and run-time resources. When AS resources is being assigned to a PC station the location of the Process model (= SIMIT SF hosting PC station) must be also selected. The AS relies on SIMIT SF to define the status of its IO signals. Figure 2-22 distributing the resources to the respective computers Entry-ID: , V1.1, 07/

24 14. Continue the wizard until you get to "Resource timing-behavior". Here you can separately define the individual time slices. In the example, the "default" setting is retained, see Figure NOTE The purpose of adjusting time behavior is to more efficiently make use of the available PC performance. Figure 2-23 Execution cycles of the individual OBs in the VC 15. Within a Simulation system, communication will occur between the AS resources and between AS resources and OS and other runtime components. Within the SIMATIC PCS 7 project, this communication is defined in NETPRO. There are basically two types of connections that must be defined: AS to AS connections and AS to OS (or other run-time component) connections. AS to AS connections are managed within the architecture of the Simulation system. Therefore these connections use a protocol that is internal to the Simulation system. The applications refer to these connections by means of an ID, these IDs can be read from the corresponding AS to AS connection in NETPRO. AS to OS connections use a SIMATIC NET communication protocol (S7 connection). These connections are typically defined as Named connections They are identified by means of a so named TSAP, hexadecimal number. These numbers must be unique and can be read from the existing NETPRO configuration. Continue the wizard to configure the connections in the next dialog box. Rightclick to insert four new connections and parameterize them as shown in Figure Figure 2-24 configuring the communications connections Entry-ID: , V1.1, 07/

25 16. For the "Named Connection" to WinCC, enter the following parameters, in case of two AS system you will create two connections see Figure The easiest way to do this is to use the local "TSAP" from NetPro (TSAP of the WinCC application). In both connections, enter "0200" for the TSAP of the remote partner, WinCC. Generate the second "Named Connection" with the appropriate parameters. Figure 2-25 Configuring a Named Connection Emulation Manager In the sample project, the two AS communicate with each other. In the SIMIT EMU, configure AS-AS communication as follows: Figure 2-26 Configuring AS-AS communication in the SIMIT EMU Manager Entry-ID: , V1.1, 07/

26 17. For the IDs, also refer to NetPro. When you have configured all four connections as shown in Figure 2-24, you can select "Next/Finish" to exit the wizard. In the last step, all required data is generated and distributed to all stations, i.e. the SIMIT VC station and the OS station. However, the "Consistency check" dialog box appears first. Select "No" to confirm this dialog box, see Figure Figure 2-27 Consistory check at the end of the SIMIT EMU project 18. For connections that rely on SIMATIC NET, the station configuration of SIMATIC NET must be adapted. This applies to all PC stations of the Simulation system that support a connection that relies on SIMATIC NET. Generally these are the PC stations where AS systems will run as a SIMIT VC and the PC stations where the OS (WinCC) or other runtime resources will run. SIMIT EMU produces configuration files (so named.xdb files) that are used to configure and parameterize the station configuration of each PC that uses SIMATIC NET for communication within the Simulation system. Import the *.xdb files generated by the SIMIT EMU Manager into the "SimOSn" and "SIMASn" PC stations their station configuration. You can find these files in the previously defined share folders of each PC station of the Simulation system, their name indicates which PC station they are intended for. Entry-ID: , V1.1, 07/

27 NOTE Within SIMATIC NET its station configuration, the Station name and the physical PC name can be different. It is recommended to make both names identical. Figure 2-28 Importing the generated *.xdb files into the SIMIT VC station Entry-ID: , V1.1, 07/

28 19. The last step completes configuration and setup of the simulation system PC stations. The next step is to combine the SIMIT EMU project with the SIMIT SF project. SIMIT VC controllers are managed as an integral part of the SIMIT SF project, also if the SIMIT VC controllers reside on other PC stations than the SIMIT SF installation. To create a SIMIT SF project that integrates the SIMIT EMU configuration open SIMIT SF on the engineering station and create a new project with the exact same name as the SIMIT EMU project. Create a new coupling, "Virtual Controller", see Figure Figure 2-29 creating the SIMIT VC coupling in SIMIT SF Entry-ID: , V1.1, 07/

29 After you have created the coupling, all the AS systems that were configured in SIMIT EMU, including their signals, are visible in the coupling editor, see Figure Now you can immediately start the simulation and manually test the signals. NOTE Since SIMIT VC relies on SIMATIC NET for its communication, it may sometimes be required to reboot the PC stations where the SIMATIC NET station configuration has been configured by means of the.xdb file import. These stations include the PC stations that will host the SIMIT VC controllers. Figure 2-30 Created VC coupling in SIMIT SF Now check whether the runtime of the SIMIT VCs runs on the SIMIT VC station and whether a connection has been established between the PCS 7 OS and the AS. If the check is successful, you have successfully completed the first step for virtual commissioning of the complete plant. The next chapter shows you how to test alarms, warnings and the hysteresis on a semi-automated basis. Entry-ID: , V1.1, 07/

30 3 Automatic Model Generation 3 Automatic Model Generation In the previous chapter, the AS level was configured using the SIMIT EMU and the respective coupling to SIMIT was created. SIMIT allows read and write access to the IO image of the emulated PLCs. When the SIMIT VC sends its control signals, they are sent to the actuators in the real use case. Then the actuators at the field level perform an action that changes the process. For example, this can be the increase of a temperature or the lowering of a mass flow. This change, in turn, must be detected by sensors at the field level and sent back to the AS, see Figure 3-1. Figure 3-1 Basic structure of a simulation project using the example of valve control In the following chapter, you will emulate the process level. You will get to know the CMT import function provided by SIMIT SF that allows effective engineering. You will use this to create all device models for the sensors and actuators of the SIMIT project. Entry-ID: , V1.1, 07/

31 3 Automatic Model Generation 3.1 Creating the device level 1. Create two new folders: "DeviceLevel" and "ProcessLevel" in the "Charts" folder. Right-click "Charts", select > "New folder" in the context menu. Figure 3-2 creating a new folder in SIMIT SF All process models, for example the ones of the raw material tank, will later be stored in the "ProecessLevel" folder. The "DeviceLevel" folder stands for all actuators and sensors in the plant, for example valves and motors. 2. Generate a XML file with the plant hierarchy and all control modules (CMs) of your PCS 7 project. 3. Open the Plant view in PCS 7. Use the context menu to navigate to Export XML. Plant view > right-click the project > Export XML. Figure 3-3 CMT export to PCS 7 Entry-ID: , V1.1, 07/

32 3 Automatic Model Generation 4. Instantiate the SIMIT SF templates with the aid of the generated XML file. Select the "Charts" folder and right-click to open the "Automatic modeling CMT import" function. Select the exported XML file and the Template folder, see Figure 3-4. Figure 3-4 CMT import dialog box The preview allows you to specifically exclude individual charts from the import. At the same time, you can control which charts are imported and which symbolic placeholders are replaced by values in the XML file. Clicking the "Import" button starts the import process. Now SIMIT SF instantiates all simulation templates in the folder to a plant hierarchy identical to PCS 7. In the template, all symbolic placeholders are replaced by values in the XML file. This step allows you to check, for example, feedback from the valves and motors on a semi-automated basis. Open, for example, valve "NK111" in WinCC. Does the valve open and close as expected? To check warnings, alarm limits and hysteresis, open, for example, simulation chart Plant > RMT11 > LI111. Double-clicking the basic icon of the " SinusGen" component opens the operating window, see Figure 3-5. Make sure that the simulation is running! NOTE The SinusGen component was created in a previous project using the CTE tool and is therefore not part of the SIMIT SF basic library. Entry-ID: , V1.1, 07/

33 3 Automatic Model Generation Then you can set the amplitude, offset and frequency according to the alarm limits, warning and hysteresis, e.g for the raw material tank. Figure 3-5 Testing the alarm limits with the SinusGen component 3.2 Creating the process level Up until now, you have used ready-made components to emulate the behavior of an actuator such as a valve. Modeling processes is a bit more complex. First, it is recommended to think about how the process to be simulated can be emulated. The overhead involved in developing the process model must not exceed the benefits. In many cases, a simple process model is sufficient to test the automation software. To examine this in greater detail, we will develop and discuss simple models for the process models RMT1 and Reactor1 in the following exercises Process model of raw material tank RMT1 ( LI111 ) with STANDARD components 5. Use drag and drop to insert the following components from the "Basic components" task card into the "LI111" chart ( /Charts/Model/LI111): From the Connectors folder: 15 Connector components From the Standard/AnalogExtended folder: 1 INT component From the Standard/AnalogExtended folder: 2 Selection components From the Standard/AnalogExtended folder: 2 MinMax components From the Standard/AnlogBasic folder: 1 MUL component. From the Standard/AnlogBasic folder: 1 SUB component From the Standard/BinaryExtended folder: 2 RS_FF components. From the Standard/AnalogExtended folder: 1 Compare component Entry-ID: , V1.1, 07/

34 3 Automatic Model Generation 6. In the LI111 chart, connect the components as shown in Figure 3-6. Figure 3-6 Simulation model for raw material tank LI111 The integrator is the core component of this model. It is used to simulate the level in the tank. If the input at the integrator is not equal to zero, the level continuously rises or drops until it reaches an upper limit of 500l or a lower limit of 0l. Once the integrator has reached the lower limit of 0, the "selector" switches its output from 100 to 0 and thereby causes the volume flow to drop to zero due to the outflow. The inflow/outflow is emulated by the subtractor. The volume flow into raw material tank 1 is defined by a constant value and added to the volume flow out of the raw material tank. The outflowing volume flow is negatively added and intended to emulate the outflow. Mathematically, this can be expressed as follows: V R = V In V Out The change of the volume in the reactor equals the inflows minus the outflows. As a process variable, we want to calculate the reactor height h. To do this, we replace the reactor volume by V R = A h(t). V R = V In V Out d dt (A h(t)) = V In V Out dh = 1 A (V In V Out)dt t h(t) = 1 (V In V Out)dτ A 0 The reactor area A can be calculated using the boundary condition of a cylindrical container and the volume and height. The volume flow out of the reactor is directly proportional to the opening angle of the drive. The proportionality constant is 0.1 m³/s and represented by the multiplier Process model of Reactor1 with STANDARD components 1. Use drag and drop to insert the following components from the "Basic components" task card into the "Reactor1" chart ( Charts/Model/Reac1/LI11x): From the Connectors folder: 2 Connector components From the Standard/AnalogExtended folder: 1 INT component. Entry-ID: , V1.1, 07/

35 3 Automatic Model Generation 2. Connect the components using the global connectors a shown in Figure 3-7. Figure 3-7 Model of Reactor1 After you have created the simulation model for the raw material tank and the reactor, you can fill the raw material tank and start the "RMT1" sequencer. You can also check the automation program for errors such as motor trip, "NP111". The previous chapters have introduced you to the basic structure of the three simulation levels of SIMIT: Signal level, device level and process level This enables you to implement simple use cases and virtually commission your plant. An OTS requires more steps, for example modeling the complete process behavior. How detailed this has to be differs from case to case. For in-depth information about, visit the SIMIT workshop or send an to simit@siemens.com. Entry-ID: , V1.1, 07/

36 4 Related literature 4 Related literature Table 4-1 Topic Title / Link \1\ Siemens Industry Online Support \2\ Download page of this entry 9https://support.industry.siemens.com/cs/ww/en/view/ \3\ SIMIT Simulation Framework (Video) \4\ SIMIT Simulation Framework / SIMIT Virtual Controller \5\ SIMATIC Virtualization as a Service \6\ SIMIT Virtual Controller (SIMIT VC) - User Manual History Table 5-1 Version Date Modifications V1.0 10/2015 First version V1.1 07/2016 Corrections in chapter 2.3 Preparation Entry-ID: , V1.1, 07/