Four Ways to Turn a Basic Controller into an Automation Dynamo ... · Direct Drive Intermediate...
Transcript of Four Ways to Turn a Basic Controller into an Automation Dynamo ... · Direct Drive Intermediate...
Four Ways to Turn aBasic Controller into anAutomation Dynamo
usa.siemens.com/S7-1200Unrestricted © Siemens Industry, Inc. 2018
© Siemens 2018
The SIMATIC Controllers PortfolioAlways the right controller – plus integrated added value!
Basic ControllersSIMATIC S7-1200(F)
Advanced ControllersSIMATIC S7-1500 Software Controllers
SIMATIC S7-1500
Distributed ControllersSIMATIC ET 200 CPU
Syst
emp
erfo
rman
ce
Application complexity
Engineered with TIA Portal
EfficientEngineering
InnovativeDesign
ReliableDiagnostics
SafetyIntegrated
SecurityIntegrated
TechnologyIntegrated
© Siemens 2018
SIMATIC S7-1200 with Safety IntegratedSmallest Controller for Standard & Safety
Top-HighlightsFeature / Function Benefit
• One Controller for Standard andfail-safe automation τ
• Reduction of types- andcomponents
• Integrated System diagnostics• Integrated Trace functionality τ
• Error messages in plaintext allowa fast fault analysis (even forsporadic problems)
• Free programming of SafetyLogic in FBD or LAD
τ
• Adaptions can easily be appliedby changing the program viaSoftware
• Connection of fail-safe devicesSensors/ Actuators viaPROFIsafe (starting withFirmware V4.2)
τ
• Reduction of wiring efforts• Allows more flexible solutions for
safety related tasks
© Siemens 2018
SIMATIC S7-1200 with Safety IntegratedEngineered with TIA-Portal
Top-HighlightsFeature / Function Benefit
• I-device in a fail-safe PROFINETenvironment
• Option Handlingτ
• Leaner architecture• Simpler communication and
connection
• Simulation with PLCSIM
τ
• Faster commissioningThe program code can bevalidated incl. safety functionsbefore going on site
• Libraries• System-Libraries• User-Libraries τ
• Reduced Engineering time dueto standardization
• Unified display concept• Trace• Webserver τ
• Efficient fault analysis withoutadditional tools reducedowntimes
© Siemens 2018
Protection of intellectualproperty of program codeKnow-how protection forPLC program blocks
Know-how protection
Detection of manipulatedcommunication dataEngineering and HMIcommunication withintegrated security
Communication integrityTIA Portal
Controller HMI
Protection againstunauthorized access andconfiguration changesProtection level concept withdifferent access rights incl.HMI connections
Access protectionEngineering
Maintenance Operation
Remote control
Controller
TIA Portal Protection againstunauthorized duplication ofruntime program codeBind program blocks to hardwareserial numbers (CPU or SD card)
Copy protection
Controller Controller
Storage A Storage B
AA A
B*******
System Integrity –Security use cases with SIMATIC S7 -1200(F) Controller
© Siemens 2018
Easy PLC selection thanks to an optimized Portfolio
CPUsSwitch-module
Power-module
Communication-modules
Signal-modules
Technology-modules
2xTMCPU 1211C-1PN
CPU 1212C-1PN
CPU 1214C-1PN
CPU 1215C-2PN
CPU 1217C-2PN
CSM PM 13x CM / CP 22x I/Q
Signal-boards
11x SB
1x CB
1x BB
© Siemens 2018
www.siemens.com/siplus-cmsUnrestricted © Siemens Inc. 2018
Condition Monitoring Systems forearly detection of mechanicaldamages for S7-1200 controller
© Siemens 2018
SIPLUS CMSThe 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 CMSThe answer to preventive maintenance
in industry
© Siemens 2018
Smoke
WatchWatch HearHear
Noise
FeelFeel
Heat
SIPLUS CMSSIPLUS CMS
Early detection
Months
Reaction time until breakdownReaction time until breakdown
Minutes Days Weeks
SIPLUS CMSPossibilities of Condition Monitoring
© Siemens 2018
Mechanical damages
Electrical faults
Drive
Condition Monitoring with SIPLUS CMSWhat sort of damage can be detected? An extract
Resonance
ResonanceBlade passing frequency
UnbalanceMeshing fault
Alignment fault
Bearing damage
Field faultBroken rotorbar
Unbalance
Bearing damage Meshing fault
Alignment fault Blade passing frequency
Pump / Fan Gear box
Condition Monitoring with SIPLUS CMS – more than just Motor Condition Monitoring
Motor Condition Monitoring
Field fault stator
Broken rotorbar
© Siemens 2018
SM 1281 Condition Monitoring Model
SIPLUS CMS1200: Condition Monitoring with SIMATIC S7-1200SM1281 - Overview
IEPE-SensorsVibration measurement
BEROSpeed measurement
Features• Characteristic value diagnostics• Frequency-selective diagnostics• Expert analysis on- or offline• SIMATIC S7-1200 and web-based
Connections• Up to 4 vibration sensors• 1 speed input• Ethernet• Power supply 24VDC
(supply to sensors)
Expansion optionUp to 7 modules can be connected;depending on the S7-1200 CPU used
Operating principle• Calculations are performed
continuously• The 4 IEPE channels and
the speed sensor are read in andprocessed simultaneously
Diagnosis• Characteristic values
via SIMATIC S7-1200 and TIA Portal• Frequency selective
via integrated Web Server
Advantages and Costumer benefitsNo additional software for diagnosis andvisualizing needed
© Siemens 2018
SIPLUS CMSThe analysis methods of condition monitoring
Expert analysis
• Freely configurable analysis withdiagnostics software CMS X-tools, e.g.orbit, histogram, vector/waterfall diagramFrequency-selective
analysis• What damage is imminent?• Every type of damage has its own
frequency spectrum
Sign
ifica
nce
ofth
ean
alys
is
Parameter-based analysis
• Is damage imminent?• Trend history of characteristic values
© Siemens 2018
SIPLUS CMS – Analysis methodsParameter-based analysis
Characteristic values
Advatage:• Easy and quick to implement• Minor condition monitoring expertise required
• Monitoring of
characteristic values
• Trend
• Signal-light display
Monitoring for
RMS: machine vibration
DKW: e. g. bearing damage
Signal Mode of operation
Disadvatage:• Type of looming damage not discernable• Troubleshooting required
Alarm
Warning
OK
RMSafter ISO 10816-3
DKWafter VDI 3832
© Siemens 2018
Vibration velocityv [rms]
10-1
000
Hz,
n>
600
1/m
in(2
-100
0H
z,n
>12
01/
min
)mm/s inch/s11 0,447,1 0,284,5 0,183,5 0,112,8 0,072,3 0,041,4 0,030,71 0,02
Rigid Soft Rigid Soft Rigid Soft Rigid Soft Foundation
Pumps > 15 kWRadial, axial, diagonal
Medium-sizedMachines
15 kW < P ≤ 300 kW
Large Machines300 kW < P < 50
MW Machine typ
Direct Drive Intermediate ShaftBelt Drive
Motors160 mm ≤ H < 315
mm
Motors315 mm ≤ H
Group 4 Group 3 Group 2 Group 1 Group
A Newly commissioned C Short term operationB Unlimited long term operation D Vibrations cause damage
Realizing the practical example with SM1281Evaluation of limits for characteristic values
Basic Information to provide limitvalues after ISO10816
Motor Power: 20kWShaft height: 200mmFoundation: rigidFan got newly commissioned
Limit values
Alarm threshold : 4,5 mm/s
Warning threshold: 2,8 mm/s
© Siemens 2018
SIPLUS CMS – Analysis methodsTroubleshooting an example
Possible imbalance or housing displacement:Perform soft foot check
Vertical change of foot position
Imbalance probable:Measure housing vibrations without an output element, insertfull key or half key in keyway in accordance with the balancing
method (secure feather key!)
No
Vibration values significantly lower?
Cause is balancing state of output element:balance output element or check balance type for motor
rotor/output element
Yes
End
Align housing
Yes
Unbalance in motor rotor:Balance motor rotor
End
End
No
Measure housing vibrations under load:DE and NDE horizontal, vertical and axial
Vibration values impermissibly high?
Vibration values impermissibly high?
Vibration values significantly lower?
Alignment fault probable:Align coupling
Yes
No
Yes
No
Start
End
End
Test steps for fault analysis
© Siemens 2018
C:\Users\za3233\Downloads\Fourier_transform_time_and_frequency_domains_(small).gif
Benefits of frequency-selective diagnostics:
• Each type of mechanical damage has its own uniquefrequency spectrum
• One glance at the frequency spectrum is sufficient todetermine the cause of damage to within a highdegree of accuracy
• The search for the actual cause of the damage isreduced to a minimum
• The amplitude is a measure for the extent of damage,which allows conclusions to be drawn about theremaining lifespan. The experience of the operatorplays a decisive role here
Benefits of frequency-selective diagnostics:
• Each type of mechanical damage has its own uniquefrequency spectrum
• One glance at the frequency spectrum is sufficient todetermine the cause of damage to within a highdegree of accuracy
• The search for the actual cause of the damage isreduced to a minimum
• The amplitude is a measure for the extent of damage,which allows conclusions to be drawn about theremaining lifespan. The experience of the operatorplays a decisive role here
SIPLUS CMS - Analysis methodsHow does frequency-selective diagnostics work?
© Siemens 2018
SIPLUS CMS - Analysis methodsFrequency-selective analysis
Monitoring formachine vibration
• Cyclic monitoring• Peaks• Trend
Frequency-selective analysis
Monitoring for rollerbearing damage
Examples of detectablemechanical damage
Resonance
Unbalance
Alignmentfault
Coupling fault
Detectable mechanical damage
Outer racedefect
Inner racedefect
Rollingelementdamage
Cage damage
Signal How it works
Advantages:• Quick and easy to implement• Type of damage identifiable ⇓ less troubleshooting• Electrical faults detectable
© Siemens 2018
Raw data
Signal How it works
Advantage:Raw data used for analysis modelsexactly tuned to the gear unit
Monitoring forgear unit wear
Detectable mechanicaldamage
Meshing faults
SIPLUS CMS - Analysis methodsExpert analysis
Event-driven recordingA message signal “meshingfault detected”Recording + saving sensorchannel raw data
1. Exporting of the raw data:• Via FTP manual• Via FTP event-driven
2. Online raw data streamingto CMS X-Tools
Expert analysis• OFFLINE analysis of exported raw data• ONLINE raw data streaming to CMS X-Tools
• Engineering + project of meshing faultsvia SIMATIC S7-1200 CPU + SM 1281 Web Interface
• Engineering expert analysis via analysis software,such e.g. CMS X-Tools
© Siemens 2018
Efficient EngineeringFast configuration withproject configurator andpredefined libraries
+
Provenused since more than tenyears in many projects
+
Flexible analyticsFree adjustable analyticsfunctionalities areintegrated into the system
+
ConnectivityHigh number of SW andHW devices can beconnected
+
ScalableCMS X-Tools scale fromsmall to large footprint witha flexible software structure
+
CMS X-Tools V4.04… efficient and flexible analytics system
Condition monitoringCMS X-Tools the Siemenscondition monitoring software
+
© Siemens 2018
00111001
10100011100
101000110
101000110
0110001101011010011010010110000
101010011011001
MindSphere Edge Analytics with X-ToolsIntegration in MindSphere
101000110
10010001110
11001
011010000
11
1010
Data processed and sent to MindSphereHigh frequency data from varioussources collected
Data ready for visualization andanalytics
Data transfer to MindConnect Nanovia OPC UA
MindConnectNano
*not necessary with next releaseX-Tools server hostedon Microbox PC
101010011011001 MindSphere –The cloud-based,
open IoT operatingsystem
© Siemens 2018
Connection to MindSphere – application example
MindConnect Nano
S7-1200 + SM1281
© Siemens 2018
SIWAREX weighing modulesfor S7-1200 basic controller
© Siemens 2018
SIWAREX WP2x1 controller for S7-1200
WP231 WP241 WP2517MH4960-2AA01 7MH4960-4AA01 7MH4960-6AA01
ApplicationsPlatform / 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
© Siemens 2018
SIWAREX WP2x1 in TIA Portal
SIWAREX WP2x1
ƒ Technology modules ofS7-1200
ƒ Interrupt generation
ƒ 32 Byte I/O memory per module
ƒ All S7-1200 weighing modulesare integrated part of TIA
© Siemens 2018
Check weighing in packaging processincreases efficiency
Benefits
ϖ Through its integration in SIMATIC S7-1200, the SIWAREX WP231 electronicweighing module provides uniform mountingtechnology and integrated communication.
ϖ Commissioning of the electronic weighingmodule using SIWATOOL or directly via aconnected HMI panel is quick and easy.
ϖ With a resolution of up to +/- four millionparts and a sampling rate of 10 ms/ second,the weighing module was the right choicefor the company’s high demands for speedand accuracy.
„The Siemens standard
components combined withour plant allows
us to offer customizedsolutions for the food
industry.“
Michel Remijn, owner RMA Techniek
© Siemens 2018
Check weighing in packaging processincreases efficiency
1. Final check weighing did not take place.Irregularities in the packaging weight are adisadvantage for the company since thepackages often contain more vegetables thanthe amount required by the package size.
2. The plan was to install a check weigher at theend of the packaging process to eliminate thisuncertainty factor. The weight control shouldfocus not only on accuracy, but also work veryquickly throughout the packaging process.
3. Another demand was that it should be possibleto weigh different types and shapes ofpackages containing a variety of products.
Challenges
1. SIWAREX WP231 - the core element ofall weight measurements is the SiemensSIWAREX WP231 weighing electronicsconnected to a SIMATIC S7-1215Ccontroller.
2. SIWATOOLCommissioning of the electronic weighingmodule using SIWATOOL or directly via aconnected HMI panel is quick and easy
3. Siemens KP700 ComfortThe weighing process can be controlledand monitored, and parameters can beedited with the Siemens KP700 ComfortHMI panel.
Products/solutions
1. With a resolution of up to +/- four million partsand a sampling rate of 10 ms/ second, theweighing module was the right choice for thecompany’s high demands for speed andaccuracy.
2. For data analysis and improved traceability, allmeasurement results are collected in a centralmemory.
3. All system components were connected andconfigured directly through TIA Portal. Thisalso enables quick and easy adaptation andexpansion of the weighing application shouldit become necessary.
Customer benefits
Transparent operationEnergy efficiency with S7-1200SM1238 Energy Meter
siemens.comSiemens Inc. 2018
© Siemens 2018
Energy efficiency offers added potential
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)
Change of energysupply
Energy costs Lawsand climate protection
Responsibility forenvironment / image
Significant cost factorin production
Statutory measures to achieveenvironmental targets
New boundary conditions as aconsequence of changingenergy resources and continuedrequirements for supplyreliability
Energy-efficientproduction as a key marketingargument
~6%Average annual increasein electricity price (Ø ’00 – ’15)
2 °CLimiting the temperature riseworldwide
32%From 6.5% in the year 2000.Should rise to 80% by 2050
59%A green image is decisive for thepurchasing decisions of markets andcustomers3
Energy costs 2000-20151,Germany, industry
UN climate summit 2015, Paris Share of renewable energies: 20162
in power consumption in GermanyOpinion research 2015
© Siemens 2018
The way to save energyTransparency is the first step to reduce costs
Increase the transparency level toassign the consumption per room
Install additional electric meters(measurement devices) to get a moreprecise overview, which consumer needshow many energy
E
Saving measures can now beevaluated based on facts Realization of profitable measures
!!
!Identify the big electrical consumers,which were previously been hidden
Amortization time of each planned savingmeasure can be calculated
© Siemens 2018
The way to save energyTransparency is the first step to reduce costs
Energy Manager also needs reliablefacts to decide saving measures
First step is to create energetictransparency in the factory
Without a certain level of energetictransparency, a definition of energysaving measures is nearly impossible
Possibility to create a high level ofenergy transparency by integratingmeasurement devices in the factory
Identification of biggest energeticconsumer and optimization potentialin the process
min maxRate of energy transparency
© Siemens 2018
Your energy distribution
SM 1238 ENERGY METER 480VACfor transparency in the energy distribution
System overview Description
Gathering and processing
HMI Visualization
SIMATIC HMI480V
10 KV
Web Visualization
SIMATIC Web server
Ethernet
Ethernet
*)
*) Currenttransformer
Energy data
management
+ ..SIMATICPLC S7-1200
SM 1238 Energy Meter
S7-1200 CPU
SM 1238 Energy Meter 480 VAC
© Siemens 2018
The way to save energyVisualization of energetic data for an easy analysis
To identify saving potential, the datahave to be visualized and stored
After data acquisition in the PLC, they shouldbe visualized for a more easy analysis
Visualization of the current consumptionvalues of one machine on a panel near themachine for……basic condition monitoring…generating a basic energetic awareness
Visualization of long term stored values ofdifferent machines in one overview i.e. inthe 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
© Siemens 2018
OptimizationAcquisition
Continuous energy data acquisition as basis
Recording and production-related data processing is the basis for energy consumption transparency
Evaluationand analysis
Processing
IE4-motors
Energy analytics
Process adaptations
SIMATIC EnergyManager PROPlant-wideenergymanagement
SIMATIC Energy SuiteProduction-levelenergy monitoring
S7 Energy Efficiency Monitorfor machinesEnergy efficiencyevaluation ofmachinery
Water meter
Currenttransformer
Converters
Flowmeasurement
SENTRON PAC
S7-1500 and energymeter, I/O
S7-1200 andenergy meter, I/O
SIMATIC Automation Toolsiemens.com/satUnrestricted© Siemens Inc.2018
© Siemens 2018
Increased productivity due to an extensive range of functions
Top-Highlights Feature / Function Benefit• Network scan
τ• Simple acquisition and display of
the reachable PROFINETdevices
• IP-adress- and PROFINET namechanges τ
• Quick adaption of local networkrquirements
• Program/Project downloadτ
• Update the automation systemwithout TIA Portal
• Backup/Restoreτ
• Fault-Back support whenperforming the operation
• Mass operaitonsτ
• Efficient updating also forextensive machines/plants
• APIτ
• Automated execution of theoperations
© Siemens 2018
One tool for commissioning, maintenance and service
Hardware supportExtensive support of theSiemens automationportfolio
+Independent of theengineering frameworkIdeal for commissioning,maintenance and servicewithout TIA Portal
+
Mass operationsParallelizing of tasks toreduce time and costs
+ APIOptimal for automation oftasks
+UsabilityEasy to use for TIA andnon-TIA Portal users
+
© Siemens 2018
Perfect partner to TIA components
TIA Portal engineering is the basis for program/projectdownload
Support for many TIA components such as SIMTATICcontrollers, distributed I/Os, HMI panels, SITOP andRFID
Integrated industrial security mechanisms such asaccess control of PLCs and HMI panels
© Siemens 2018
Jana Kocianova
Product Marketing Manager S7-1200/S7-1200FSiemens Industry, Inc.RC-US DF FA MK PLC5300 Triangle ParkwayNorcross, GA 30092-2538, USAMobile: +1 (470) 809 2421mailto:[email protected]