31 Piepenbrock Dr Georg Virtual Commissioning PSWUC2017 · 6lhphqv 3/0 6riwzduh 7hfqrpdwl[3odqw...

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Siemens PLM SoftwareTecnomatix Plant Simulation Worldwide User Conference

June 20-22 2017 Stuttgart, Germany

Virtual Commissioning in Plant Simulation utilizing the new SIMATIC S7-PLCSIM Advanced Interface and OPC UA

www.siemens.com/plm/plantsimulationUnrestricted

Unrestricted © Siemens AG 2017

June 22nd 2017Seite 2 Dr. Georg Piepenbrock

Plant Simulation and Siemens AutomationClosed Loop and Tool Coverage

TIA

TIA Portal Engineering

TIA Portal Monitoring

WinCC HMIPLCSIM Advanced

Plant Simulation





Pro

ce

ss

PLCSIM Advancedas basis for Software in the Loop

Virtual world

Co

ntr

oll

er

Co-Simulation

API

PLCSIM Advanced

virtual S7-1500 controller

S7-1500 hardware controller

Real world

PLCSIMAdvanced

as basis for“Software

in the Loop”

Extensive functionalsimulation withoutadaptions of the STEP 7 program

Interface to easily connectto different co-simulationsvia an API



PLCSIM Advancedsupported controllers: S7-1500 CPU incl. C/F/T and ET200SP CPU incl. F

reflection of the real controller

S7-1500

S7-1500F

S7-1500T(F)

S7-1500C

ET 200SP(F) CPU

virtualcontroller





PLCSIM AdvancedMultiple and distributed instances

PC1 S7-1500Instance 1

S7-1500Instance 2

PCclock

PC2

WinCC Panel

S7-1500Instance 3

STEP 7

PCclock

Support of different set-ups:

Support of multiple instances

to simulate several controllers

Support of distributed instances

for load distribution

communication via TCP/IP

Connecting real devices (HMIs / controllers) possible

Connection of real I/Os not possible

PROFINET IO communication is not supported

Slow Mode Fast Mode

Virtual Time

Virtual Time



PLCSIM AdvancedMultiple instances in combination with a Co-Simulation

PC1 S7-1500Instance 1

S7-1500Instance 2

PCclock

PC2 Co-Simulation

Support of different set-ups:

Support of multiple instances in combination with a Co-Simulation

coupling of the PLCSIM Advanced instance with the Co-Simulation through the virtual time

PLC instances can be distributed on several PC

Our recommendation:

start with “all-in-one” configuration,at least Plant Simulation and PLC Intances on the same PC

STEP 7

Slow Mode Fast Mode

Virtual Time

Virtual Time

software in the loop





Automationwith TIA Portal

PLCSIM AdvancedCoupling with a Co-Simulation

Engineering

Layout modelling with

Plant Simulation

or

Line Designer

Result

STEP 7 program

Layout Model

Hardwareconfiguration(incl. signal list)

Test in virtual environment

PLCSIM Advancedvirtual controller

Co-Simulation

• Machines and Buffer

• Conveyor Lines

• System Control Logic

• Simulation ofMaterial Flow

• Definition of Sensorsand Actuators

signal coupling through API

software in the loop



Virtual Commissioning Show Case and Proof Point:EOM Saganer Straße, Siemens Nürnberg

The EOM control is implemented as PLC control, based on the Siemens PLC template library EMS400S

The control is running on a S7-1516F PLC

TIA Portal is used to build the specific EOM control logic

30 EOM track segments

n EOM vehicle with local control and behavior

Realized are several drive and control logics in the EOM ring

User interface implemented with standard HMI devices





Tecnomatix Plant Simulation Virtual EOM + Virtual PLC Control as Digital TwinEmbedded in a Laser Scan Point Cloud

Tecnomatix Plant Simulation Model

The simulation model can be connected to a real or a S7-1516F PLC a virtual S7-1516F PLCSIM Advanced PLC

EOM vehicle communicate with the PLC and get their driving information from the PLC

User interface is done through standard HMI(Part of the TIA-Portal engineering project)

Automatic mode Manual mode Lift height settings Speed …



Virtual Commissioning Overhead MonorailTest Scenarios for System Logic

The PLC program defines the EOM control logic and the conditions for coordinating the EOM vehicles that are driving on the rails.

The correctness and completeness of the PLC control program can be tested when using it together with a digital model of the EOM system.

Test Scenarios

Only one vehicle is allowed in a curve segment.

When a vehicle leaves a curve segment, the first waiting vehicle in front of the curve needs to be started.

Vehicles with variable load lift height can get a new lift height when entering a new EOM rail section.Is the lift height ion all sections correct?

Are settings for switches done early enough and correct?

…





Virtual Commissioning Overhead MonorailUse Cases through HMI Dialog

The PLC program defines the EOM control logic and the conditions for coordinating the EOM vehicles that are driving on the rails.

Correctness and ease-of-use of HMI dialogs can be tested upfront together with a digital model

Are all system states displayed in the HMI correct and consistent?

Position and ID of EOM vehicles

State and attributes of vehicles

…

Are commands given through the HMI correct executed?

Start/Stop of the system

Settings for operating modes (manual/automatic)

Changes of e.g. speed and lift height

Group building and synchronous drive

Vehicle: ID and position



PLC Control:Signal Definition PLC to Track Segments in Siemens TIA PortalData Block: PSB_Output_Send





PLC Control:Signal Definition Track Segments to PLC in Siemens TIA PortalData Block: PSB_Input_Receive



PLCSIM Interface in Plant SimulationSignal Mapping to Plant Simulation Object Attributes

Simulation Object Attribute(or SimTalk Method)

PLC Variable or I/O Signal





PLCSIM Advanced Interface

The PLCSIM Advanced interface object connects Plant Simulation models with a PLC program running in a virtual PLCSIM Advanced

PLC-Out signals are copied to Plant Simulation variables and simulation object attributes

Plant Simulation writes PLC-In signals that are send to and used by the PLC program running in PLCSIM Advanced

Time synchronization between PLCSIM Advanced and Plant Simulation supports aligned time progress on both sides.

Real time mode and time scaling with factors between 0.01 and 100 are supported (not always possible/achievable)



PLCSIM Advanced InterfaceItem Tables and Live View

The Import Button imports data items that are defined through the PLC program to Plant Simulation

More convenient signal grouping in the item table of the interface dialog is possible by creating new groups and copying items between the groups

A live view table of the configured items shows the current data item values in case a connection to a running virtual PLC is active





PLCSIM Advanced InterfaceImporting PLC Items / Tags

After Importing PLC tags from PLCSIM Advanced to the PLCSIM Interface object you get 4 groups added to the items table. The group names are

• I : PLC input, data and signals that are sent from Plant Simulation attributes to the virtual PLC

• O : PLC output, data and signals that are sent from the virtual PLC to Plant Simulation variables, attributes or methods

• M : Merker variables in the virtual PLC, reading and writing is supported

• DB : Data in PLC data blocks, reading and writing is supported

In the column Interval [ms] you can define a time interval for the data exchange between Plant Simulation and PLCSIM Advanced. For 0 or no setting the data exchange is done after each PLC cycle



PLCSIM Advanced InterfacePLC Out: Using PLC Items in Plant Simulation

You can map a simulation object attribute, a variable or checkbox object in the column Simulation Model Attribute:The Interface object copies the PLC data value into the assigned attribute

You can insert a SimTalk method into the same column. Plant Simulation executes the callback method when a new data value arrives. The new value is passed as parameter to the method.

You can always read a PLC Item value directly out of SimTalk, using the Alias for addressing the relevant item:

myVariable := PLCSIM.setOnBeltActive





PLCSIM Advanced InterfacePLC In: Sending Plant Simulation data to PLCSIM Advanced

You can map a simulation object attribute, a variable or checkbox object in the column Simulation Model Attribute:The Interface object propagates the addressed simulation data value to the PLC item/variable addressed in the first column Identifier of the items table.

Alternatively you can directly assign a value out of SimTalk, using the corresponding Alias for addressing the relevant item:

PLCSIM.BufferAlias := true



PLCSIM Advanced InterfaceGetting Started…

Start Siemens PLCSIM Advanced Control Panel

Type in PLC Instance Nameand start the instance

Status LED of running Instances

Type in PLC Instance Name

Type in IP address and port for Control Panel

on remote PC

Create PLC program andload to PLC Instance

Data exchange interval





PLCSIM Advanced InterfaceGetting Started…

Import PLC Items

Adjust Item Groups and eliminate irrelevant items

Define settings for larger timing/interval Assign simulation

object attributes, …

EOM + VC Live DemoSiemens Showroom Nürnberg, Saganer Straße



Few Notes on OPC UA Interface



OPC UASimilarities and Settings…

OPC UA server address isPrefix + IP address + :port number:opc.tcp://144.244.344.60:4840

OPC UA Server provides namespaces, these are logical groups.For Siemens PLC: Namespace 3 gives access to the PLC program data

Read and write interval settings define the time slice for data exchange between Plant Simulation and OPC UA server





OPC UASimilarities and Settings…

OPC UA items identifier can be of type string, numeric or GUID (==> online help)

OPC UA item name, typically the name/path of PLC variables

Simulation Variable, checkbox,…or SimTalk callback method



Contact:

Dr. Georg Piepenbrock

Product Manager Plant SimulationSiemens Industry Software GmbH

Weissacher Str. 1170499 Stuttgart

E-Mail: [email protected]

www.siemens.com/plm/plantsimulation

31 Piepenbrock Dr Georg Virtual Commissioning PSWUC2017 · 6lhphqv 3/0 6riwzduh 7hfqrpdwl[3odqw...

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