DT Media Newsletter February 2011 Division Drive Technologies · Simatic PCS7 is the central system...

DT Media NewsletterDivision Drive Technologies

February 2011

• Modernization of rolling mills for Böhler Edelstahl in Austria• Achieving greater success with maintenance data • Siemens modernizes the drives in three copper ore crushing mills for Rio Tinto• CNC training partner certifi ed by Siemens• Switch to high-effi ciency motors• Dates

Division Drive Technologies

DT Media Newsletter February 2011

2

The Siemens Industry Solutions Division starts into

the New Year with an extensive modernization pro-

ject. Until end of 2011 the company will install new

drive and automation equipment on the continuous

rolling mill in the multiline rolling mill and the plate

rolling stand of the blooming mill. The goals of the

modernization project are to reduce energy and

media consumption, widen the range of products,

and improve their quality still further.

Böhler Edelstahl‘s multiline rolling mill in Kapfenberg

has been in operation since 1988, at which time it was

one of the world‘s most modern plants. Siemens will

install a digital control system with Simatic S7-400

programmable logic controllers to bring the automation

in the plant up to the state of the art. A “RollMaster”

specially developed for long product rolling mills will

handle the generation and management of the pass

schedules. This software is the link between the pro-

duction planning system and the plant automation.

The existing hydraulic drive trains will be replaced by

controlled, water-cooled three-phase asynchronous

motors, including gearboxes, couplings and cardan

shafts. The drives will be fed by frequency converters

from the Sinamics product family, configured as

multi-motor drives. This will facilitate precise, highly

dynamic control of the rolling stands and enable Böhler

Edelstahl to extend its range of products and further

improve their quality. The elimination of the hydraulic

systems will reduce the cost of maintenance and incre-

ase plant availability which, in turn, will also increase

the productivity of the rolling lines. The energy requi-

rement will fall by many thousands of megawatt hours

per annum, and the consumption of hydraulic oil and

cooling water.

Siemens will also renew the auxiliary drives on the

continuous rolling mill, and the uninterruptible power

supply (UPS). The scope of the modernization project

also includes equipping the plate rolling stand of the

blooming mill with a new 3.3 megawatt main drive.

Siemens will also be responsible for the installation of

all the electrical systems and the commissioning of the

rolling lines.

Böhler Edelstahl GmbH & Co KG is one of the world‘s

most important producers of high-speed steel, tool

steel and special materials. The multiline rolling mill

produces bar, round and flat steels, as well as wire.

Further information about solutions for steel works,

rolling mills and processing lines is available at:

http://www.siemens.com/metals

Siemens to modernize rolling mills for Böhler Edelstahl in Austria



3

Achieving greater success with maintenance data

Efficient condition monitoring of machine tools is

an indispensable part of a fully streamlined produc-

tion system today. The ePS Network Services from

Siemens offer a high-performance condition moni-

toring system, whose core functions are now also

available during operation without online connec-

tion to locally hosted servers.

Machine tool maintenance is becoming increasingly

important for a cost-effective production process in

terms of productivity, supply capability and competi-

tiveness. Downtimes must be minimized, while a high

level of availability and manufacturing precision must

be guaranteed over long operating periods. For the

maintenance team this presents a major challenge that

can, however, be met by means of efficient condition

monitoring.

Continuous condition monitoring is useful for gaining

reliable information on the current condition of the

machine. It helps to determine maintenance and spare

parts requirements at an early stage, which prevents

prolonged downtimes, particularly in the case of un-

scheduled outages. In normal operation too, condition

monitoring can provide detailed verification of manu-

facturing precision, enabling conclusions to be drawn

about the ageing behavior of the plant and supplies

information on special design requirements placed on

new machinery. This enables hidden potential for im-

provement to be discovered and integrated accordingly

into the design proces.

In practice a great number of demands are made on

high-performance condition monitoring. On the one

hand, the tests required for maintenance must not af-

fect the production procedures. On the other hand, the

flood of data must be edited and compressed in such a

way that it is of value to and can be utilized by the com-

pany. The products available on the market differ from

each other in this respect.

The ePS Network Services from Siemens are the gate-

way to efficient and practical condition monitoring. The

system guarantees a comprehensive functionality and

a fully integrated approach. Condition-based preven-

tive maintenance is linked to the provision of up-to-

date operational metrics, thereby improving planning

reliability and cost control for the production facility.

Whereas the system could previously only be used as

an online service, Siemens has only recently made it

available as a purely local installation for the machi-

ne operator: eP-Satellite offers the option of hosting

data and functions locally and is primarily intended for

manufacturing facilities that require no online con-

nection of their production resources. The integration

of both versions of the ePS Network Services in the

CNC is always seamless, because even controllers from

third-party suppliers as well as external sensors can be

integrated into the condition monitoring system thanks

to the vendor-independent OPC interface. In this way,

Siemens ensures that a single, uniform software system

offers maximum inter-compatibility for the monitoring

and maintenance of all relevant machines in a produc-

tion plant.



4

Siemens modernizes the drives in three copper ore crushing mills for Rio Tinto

The mining company Rio Tinto has commissioned

Siemens Industry, Inc., to modernize three SAG

mills in its Kennecott copper mine in Utah, USA. The

DC drives will be equipped with new control and

automation technology. Together with enhanced

diagnostic features, the modernization ensures

operational reliability and availability of the plant

while at the same time the maintenance costs can

be reduced. Retaining the power section of the

rectifier is the key feature of the modernization con-

cept developed by Siemens, leading to significantly

reduced investment cost for the modernization. The

modernization project will start in early 2011 and

will be finished in the beginning of 2012.

The three mills equipped with Twin Pinion DC motor

systems installed in the Kennecott Mine in 1998 will

be equipped with a new control system. The system is

based on Simatic S7 for the general control of the mill

and a Sinamics DCM converter for the drive specific

control of the rectifier. Thanks to the modularized

concept of Sinamics DCM to implement control and

power section separately, a modernization concept

was designed where the power section of the existing

rectifier remains in operation. Together with the

possibility to also retain transformer and motor, in-

vestment cost for the modernization can be reduced

significantly and the length of the shutdown period is

minimized.

Simatic PCS7 is the central system for all visualization

and diagnostic tasks for all three mills. The scope of

supply also includes an additional diagnostic system

for enhanced diagnostics, as well as operating data

acquisition and remote service features: This will

enable unplanned shutdowns to be largely avoided

and maintenance costs to be reduced. Siemens is

responsible for the hardware and software engineering

including installation and commissioning at site.

The Kennecott Bingham Canyon Mine run in Utah by

Rio Tinto is one of the world‘s largest copper mines.

In addition to copper, it also extracts gold, silver and

molybdenum. There are four SAG mills with Siemens

drives working in the mine.

Further information about solutions for the mining

industry can be found at:

http://www.siemens.de/mining



5

The Institute for Economic Advancement of the Upper

Austrian Chamber of Commerce (WIFI OÖ) in Linz is

now an official „Siemens CNC Training Partner“ for

the training courses Operation and Programming of

ShopMill, Operation and Programming of ShopTurn

and Programming of Sinumerik DIN/ISO – making

it the first CNC Training Partner in Europe outside

Germany to be certified by Siemens. On January 12,

2011 Erich Döberl, Head of Training for CNC technology

at WIFI OÖ, accepted the certificate from Austrian

Sinumerik Training Adviser Andreas Göstl. In order

to extend the certification on a regular basis, the

instructors in Erich Döberl‘s department will have

to attend an annual refresher course at the Siemens

Technology and Application Center (TAC) in Erlangen.

WIFI OÖ is one of the largest professional training centers

in Europe, offering over 7,000 courses to more than

75,000 participants each year. These include more than

30 apprenticeship and adult training courses for CNC

machining technicians each year. The CNC workshop in

Linz has numerous machine tools, including two CNC

horizontal machining centers (Emco MaxxTurn 45), for

the efficient production of complex turned and milled

components with the maximum thermal stability,

machining accuracy and rapid traverse velocity. Both

machines are equipped with SINUMERIK 840D sl

(Solution Line) controllers and the fully graphical ShopMill

and ShopTurn programming software. Programming

with ShopMill or ShopTurn ensures maximum efficiency

with extremely short programming times, especially

when manufacturing individual parts and small batch

sizes.

WIFI OÖ has about 20 PC training terminals at which

the Sinutrain training software is used for accurate

control simulation. This means that programs can

be written on standard PCs without additional CNC

hardware, then transferred directly to the machine

and processed.

First CNC training partner outside Germany: Siemens certifies the Institute for Economic Advancement of the Upper Austrian Chamber of Commerce

Sinumerik Training Adviser Andreas Göstl (right) presents the certificate to Erich Döberl, Head of Training for CNC Technology at WIFI OÖ



6

As from June 16, 2011, minimum efficiency class IE2

will become mandatory in the European Economic

Area. After this date, manufacturers are only per-

mitted to ship high-efficiency motors. The EU Direc-

tive 640/2009 applies to low-voltage asynchronous

motors between 0.75 kW and 375 kW. From January

2015, efficiency class IE3 will become mandatory

for the power range between 7.5 kW and 375 kW.

Alternatively, an IE2 motor with a frequency converter

can be used.

For further information, go to:

http://www.siemens.com/press/de/index.php?id=68316

1. 3. - 4. 3. 2011

Intec, trade fair for manufacturing, machine tools

and special-purpose machine manufacturing, Leipzig

http://www.messe-intec.de

15. 3. - 19. 3. 2011

ish, the world‘s leading trade fair for bathroom

design, building systems, energy and air-conditioning

systems and renewable energies, Frankfurt/Main

http://www.ish.messefrankfurt.com

About 100 days to go: switch to high-efficiency motors

DATES



Media Contact:

The Siemens Industry Sector (Erlangen) is the world’s

leading supplier of environmentally friendly produc-

tion, transportation, building and lighting technolo-

gies. With integrated automation technologies and

comprehensive industry-specific solutions, Siemens in-

creases the productivity, efficiency and flexibility of its

customers in the fields of industry and infrastructure.

The Sector consists of six divisions: Building Technolo-

gies, Drive Technologies, Industry Automation, Industry

Solutions, Mobility und Osram. With around 204,000

employees worldwide(September 30), Siemens Indust-

ry achieved total sales of approximately €34.9 billion in

fiscal 2010.

www.siemens.com/industry

The Siemens Drive Technologies Division (Nurem-

berg) is the world‘s leading supplier of products, sys-

tems, applications and services for the entire drive train

with electrical and mechanical components and motion

control systems for production machinery as well as

machine tools. Drive Technologies serves all segments

in manufacturing industry, process industry and ener-

gy/infrastructure. The Division addresses key customer

requirements in terms of productivity, energy efficiency

and reliability. With around 36,000 employees of the

Division (September 30), achieved total sales of €7.0

billion in fiscal 2010.

www.siemens.com/drivetechnologies

Siemens Industry Sector

Drive Technologies

Julia Kauppert

Phone +49 (0)911 - 895 7952

[email protected]

Siemens Industry Sector

Drive Technologies

Franz-Ferdinand Friese

Phone +49 (0)911 - 895 7946

[email protected]

The Industry Sector and Drive Technologies Division in brief

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