Advance 2011 3 En

Industrial Switching Technology:

Small Technology Making a Big ImpactSirius modular systems in cooling systems and heat pumps

Drive Technology:

Ecologically and Economically SmartReducing costs with 1LE1 motors and frequency converters

Automation Technology:

Trendsetters in PC-Based AutomationBroad range of applications and high functionality for IPCs

Increased Productivity through Remote Access

Products, systems, and solutions for

telecontrol and teleservice

advanceThe Magazine for Totally Integrated Automation

Volume 10, Number 3, 2011

In brief

News 4

Focus

Increased Productivity through Remote Access 5Products, systems, and solutions for telecontrol and teleservice

Effi cient Telecontrol 6

Cost-Effective Plant Monitoring and Maintenance 8

Telecontrol Technology in Wind Power Turbines 10Secure data transfer thanks to GPRS

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Automation Technology

Trendsetters in PC-Based Automation 13Cutting-edge technologies give IPCs a broad range of applications and high functionality

Electricity Costs Effectively Trimmed 16Effi cient load management with Simatic WinCC powerrate

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Remote monitoring in wind power turbines is an ideal application for wireless data transfer

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Simatic WinCC powerrate allows power consumption to be monitored in real time

advance 3-11

Published by: Siemens Aktiengesellschaft, Gleiwitzer Str. 555, 90475 Nuremberg

Drive Technologies DivisionCEO Ralf-Michael Franke

Industry Automation DivisionCEO Anton S. Huber

Editorial Responsibility in Accordance with the German Press Law: Arno Hoier

Responsible for Technical Content: Dr. Thomas Rubach (Automation Technology), Oswald Empen (Drive Technology), Bernd Heuchemer (Motion Control),Christoph Hotz (Industrial Controls), Peter Markus (Sensors and Communication)

Concept: Christian Leifels

Publisher: Publicis Publishing, P.O. Box 32 40, 91050 Erlangen, Tel.: 0 91 31/91 92-5 01, Fax: 0 91 31/91 92-5 94, [email protected]

Editorial staff: Dr. Beate Bellinghausen (ChR), Gabriele Stadlbauer Layout: Jürgen StreitenbergerCover image: Siemens AGFinal editing: Marion SchwabJob number: 002800 34017DTP: M.T., NurembergPrinted by: Wünsch, Neumarkt advance appears four times a yearCirculation: 20,000© 2011 by Siemens Aktiengesellschaft in Munich and Berlin. All rights reserved.This issue was printed on paper manufactured from chlorine-free bleached cellulose.

ISSN 1611 101X (Print)

The following products are registered trademarks of Siemens AG: ET 200, MOBY, MP270, MP370, S7-300, S7-400, SCALANCE, SIMATIC, SIMATIC Multi Panel, SIMOCODE,

SINAMICS, SinaSave, SIRIUS, SITRAIN, STEP, TIA (TOTALLY INTEGRATED AUTOMATION), TIA Portal, WinCC

If there is no special mention of trademarks, trade names, technical solutions, or similar items, this does not mean that these items are not protected.The information in this magazine contains only general descriptions and performance features which do not always apply in the described form in the actual application or which may be subject to change in the course of further development of the product. The specifi c performance features are only binding if they were agreed expressly in the contract.

IWI: TADV

Order number: E20001-M2311-B100-X-7600

Cover photo: Siemens AG

advance | 3-2011 3

Safety Technology

Reaching New Heights in Safety 19Safety in heavy-duty building cranes with Simatic WinAC RTX and Sinamics S120

Drive Technology

High-Tech Organic Potatoes 21High-Feature motor starters make conveyor technology reliable

Modular Handling Solutions 24Increased productivity and process safety with the Simotion Handling Toolbox

Ecologically and Economically Smart 26Reducing costs with 1LE1 motors and frequency converters

High-Performance Gear Units 28Higher torque and more construction stages with the new Flender SIG

Industrial Switching Technology

Perfect Surfaces 29Optimized paint drying with the Siplus HCS724I heating control system

Small Technology Making a Big Impact 30Sirius modular systems in cooling systems and heat pumps

Industrial Identifi cation

Machines Are Learning to Read 32OCR text recognition guarantees the complete traceability of products

A Transparent Cycle 34Sachsenmilch relies on RFID in product and pallets handling

Industrial Communication

Communication in Potentially Explosive Areas 36Industrial Ethernet is suitable for use in potentially explosive environments

Dialogue

Online Portal/Sirius 3SB3/3SF5 38

Library/Dates/Dialogue 39

Teleservice and telecontrol modules give workers in plants that are distributed over large distances access to substations from the central control center

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ET 200S HF motor starters prevent faults from occurring in the potato sorting plant’s conveyor technology Si

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Simatic MV440 reads the lasered serial number within a fraction of a second

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+ Joint venture for magnet production

Strategic Partnership

Siemens and Australia’s Lynas Corporation Limit-ed have signed a joint venture agreement to

produce rare earth-based permanent magnets from neodymium. Siemens will use these magnets in energy-effi cient drive solutions and in wind tur-bine generators. Lynas is to supply the joint ven-ture with raw materials, especially metals contain-ing neodymium, via long-term delivery contracts. The company is setting new standards worldwide in terms of both delivery security and environmen-tally friendly rare-earth extraction. A study by the International Atomic Energy Agency indicated that the plant that Lynas is planning in Malaysia is ex-pected to fulfi ll all international production and environmental standards. The completion of this plant is planned for 2011.

Siemens intends to hold a 55 percent stake in the joint venture, and Lynas a 45 percent stake. “The planned joint venture is strategically signifi cant for us, as it means securing a stable long-term supply of high-performance magnets,” explains Ralf-Michael Franke, CEO of the Siemens Drive Technologies Division. “We are convinced that in Lynas, we have found the right partner to achieve this.” Nicholas Curtis, executive chairman of Lynas, adds: “Lynas is delighted that this fi rst step has enabled us to enter into a long-term partnership with the market leader for large drives. Rare earths have a great deal of potential for growth in these applications.”

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+ Siemens plant in Amberg wins industry contest

Best Factory 2011

The Lynas plant in Malaysia is designed to fulfi ll international production and environmental standards

The Siemens Equipment Manufacturing Plant in Amberg has already received multiple awards

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The Siemens plant in Amberg (GWA) has been awarded the title National

Winner in the industry contest “Best Factory/Industrial Excellence Award 2011.” The industry contest is held un-der the aegis of the German Federa-tion of Industries (Bundesverband der Deutschen Industrie e.V., BDI). Com-peting with its peers, the plant won top marks in the following categories: business model, strategy implemen-tation, value chain, product and pro-cess implementation, service and cus-tomer integration, and continues improvement.

The GWA plant develops and man-ufactures low-voltage controls for the worldwide market, including the full Sirius product range which is used for switching and protecting loads.

The Amberg site has been in oper-ation for over 60 years and com-prises the EWA, which employs about 1,400 staff, and the GWA, which employs about 2,400 staff, as well as development and services departments, effi cient switching test fi elds, and test laboratories. Both plants at the site have received awards in the past few years: “Best Factory” (EWA) and “Factory of the Year” (GWA) in 2007, and the “Bavar-ian Quality Award” and “Starpower Operation” (both awarded to the GWA) in 2010.

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With Industrial Remote Access, users save time, money, and resources because they can maintain their machines from a central

location and can safely monitor and control processes spanning the entire plant from wherever they are. The term “telecontrol” refers to the control, regula-tion, or safety-related connection of process stations that are physically distributed over large distances in one or more central control systems. This is done using telecommunication networks based on technologies such as TCP /IP, GPRS, UMTS, IWLAN, and DSL. The exchange of process data via special telecontrol protocols makes it possible for operating personnel to effectively control the overall process. Teleservice is the exchange of data with plants that are physically located at a distance, for the purpose of fault detection, diagnostics, maintenance, or repair; for the optimization of subsystems and con-trol systems through remote programming; and for updating to the newest program modules. For more detailed information about this, see pages 6 to 9.

Increased Productivity through Remote AccessTo ensure reliable plant monitoring, plant operators require secure and cost-effective access even to machines and plants located far away. Siemens delivers products, systems, and solu-tions for telecontrol and teleservice for use in the process industry, factory automation, and the public infra struc-ture sector.

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Communication networks

+ TCP / IP (Transmission Control Protocol / Internet Protocol): Family of network protocols, also referred to as an Internet protocol family. The computers included are identified using IP addresses.

+ GPRS (General Packet Radio Service): A packet-switched mobile data communication service. This allows optimum use of the entire bandwidth available in the mobile network cell.

+ UMTS (Universal Mobile Telecommunications System): A third-generation mobile communication standard that allows data transfer rates of up to 14.4 Mbit/s downlink or up to 5.76 Mbit/s uplink.

+ IWLAN (Industrial Wireless Local Area Network): Local radio network for the industrial sector based on the IEEE-802.11 standard.

+ DSL (Digital Subscriber Line): Transfer standards for the physical layer in which data can be sent and received at transfer rates of up to 500 Mbit/s.

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Mr. Hoock, what does Siemens have to offer users when it comes to tele-control?

Volker Hoock: Telecontrol has a wide and varied range of applications. In building management, in the transportation sector, and in machine control systems, it is often the case that only a small number of sta-tions with a large volume of data need to be monitored. Siemens offers TeleControl Basic for monitoring and controlling sys-tems of this kind via mobile radio commu-nications (GPRS). However, the situation is quite different when it comes to oil and gas pipelines, water supplies, wastewater disposal, and the energy sector, where the remote stations and measuring stations – sometimes with large data volumes – are often situated more than a thousand kilo-meters away from the central plant or the control center. These stations also need to be connected using a wide range of tele-communication networks, which means that such cases call for a more complex system such as TeleControl Professional.

And what solutions are available for large-scale plants?

Volker Hoock: Typical areas of application in large-scale plants include maintenance and control and the optimized operation

of process-related plants with the aim of saving energy. This spectrum of appli-cations is also covered by TeleControl Basic. The system is capable of more than its name might suggest. It can be used to manage both small plants with a small number of stations and plants with up to 5,000 remote stations.

How does that work, from a technical point of view?

Volker Hoock: The control center is con-nected to the Simatic S7 substations via the TeleControl Server Basic software. The connection to the control and moni-toring application – for example, WinCC fl exible – is made via an OPC interface. The process data are transferred via GPRS, which is particularly convenient and eco-nomical for the user, who incurs low investment costs and benefi ts from cost-effective tariffs. A teleservice function that allows worldwide access to Simatic controllers is also integrated into the system. This is of particular interest to machine and plant manufacturers who work internationally.

In comparison, what characterizes a complex system such as TeleControl Professional?

Volker Hoock: This telecontrol system, constructed using a modular design, is intended for demanding control and monitoring tasks in plants that are distrib-uted over large distances. It allows connec-tions to the Simatic PCS 7, Simatic WinCC, and WinCC OA (Open Architecture) control systems, in addition to control systems from third-party manufacturers. The con-struction of complex telecommunication networks with point-to-point, line, and node structures is supported, and these can be combined as desired. This makes TeleControl Professional tremendously fl exible. For data transfer, the user can choose between conventional networks such as dedicated lines or analog tele-phone networks and communication via IP-based networks. Data security is ensured in all cases, however, because the transfer of data is safeguarded by specifi c VPN solutions. All systems are additionally equipped with a data buffer,

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Industrial Remote Access overview

Telecontrol + TeleControl Basic

+ TeleControl Professional

Teleservice + Simatic TeleService

+ Teleservice Network

+ IPC Remote Manager

+ Simatic Remote Services

“Data transfer with

components from

the Siemens product

portfolio guarantees the

customer data security

and data retention.” Volker Hoock, Marketing Manager for

Industrial Communication, Siemens

advance | 3-2011 7

so data will be retained even if the net-work connection is interrupted.

You mentioned a connection to the control systems. What does that mean?

Volker Hoock: The Simatic PCS 7 and Simatic WinCC control systems combine the automation of centralized plants and the monitoring of distributed remote stations in a single control center. Simatic PCS 7 TeleControl, Simatic WinCC TeleControl, and Sinaut ST7cc allow com-munication with the remote stations, either via the Sinaut ST7 protocols or the standardized DNP3 protocol. Special com-munication modules are implemented for communication using telecontrol proto-cols – for example, Telecontrol Interface Modules (TIMs) – in the Simatic substa-tions and, if necessary, in node stations. Since TIA components are consistently used for the control center and the mod-ular Simatic substations, the user saves time and reduces costs.

Does Siemens offer further telecontrol products?

Volker Hoock: In combination with a Simatic controller, substations can be constructed using the Siplus RIC (Remote Interface Control) system to securely transfer process data from remote sub-units to a central control center. The addition of a Simatic ET 200S or a Simatic S7-300 / S7-400 allows the inte-gration and management of up to 200 or 5,000 information points, respectively. Siplus RIC can also be used with WinAC-based solutions. Data transfer requires little installation work because it is carried out using internationally standardized communication protocols such as IEC 60870-5.

Mr. Hoock, many thanks for speaking

with us today.

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Telecontrol in practice

TeleControl Professional in power supply applications

The utility company for the city of Astana, Kazakhstan, placed an order for an automation system to mea-sure and record energy consumption and quality data for the Kazakh railway network. Data recording for the 182 operative measuring points, seven substations, and 10 trans-former stations is carried out using

Simatic S7-300 and the TeleControl Professional system. Since this auto-mated energy measurement system was introduced, the fl exibility and reliability of the electrical systems has increased, the control of the electricity supply has improved, and operating costs have been reduced.

Siplus RIC in water supply applications

The water distribution system in Innsbruck, Austria, is an example of Siplus RIC in practice. The water network is monitored here, with data transfer being carried out using an IP-based WAN with a GPRS radio network, allowing maintenance costs and the number of fault-recti-

fying operations to be signifi cantly reduced. The new solution means that the entire water network can be monitored, which was not pos-sible using the previous proprietary communication system with a dedi-cated line.

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The new Simatic IPC Remote Manager software package is also available for remote access to industrial PCs. The Simatic IPCs with Intel Core i5 and i7 pro-cessors are equipped for this purpose with Intel Active technology (Intel AMT), which allows password-protected remote access. System or program faults can thus be rec-tifi ed, and BIOS and program updates car-ried out, from the control center via a secure HTTPS or TLS connection. Effi cient energy and service management reduces power consumption through targeted shutdown after production is completed and reduces downtimes by allowing ser-vice work to be carried out outside regular production times via remote access.

Trend: teleservice via Internet

IP-based networks are the fi rst choice when a higher level of availability is needed in the remote connection or when the data to be transferred require more bandwidth. The simplest solution for fl exible global remote maintenance is

GPRS, as it allows fl exible connection options that are not possible with conven-tional maintenance bound to a fi xed-line network. This option requires GPRS cov-erage, the appropriate frequency bands, and approved devices.

The EGPRS (Enhanced GPRS) MD741-1 router, which allows higher data rates than GPRS, creates a secure data connec-tion between the remote stations and the service center via GSM. Data transfer takes place in a secure virtual tunnel with IPsec; the security module (e.g., Scalance S612) acts as a VPN gateway and terminates the tunnel in the control station. If higher data rates need to be reached, UMTS can be used via Scalance M875.

Remote services for monitoring and maintenance via Internet

To allow cost-effective and fl exible remote access to plants, Siemens supplies not only the appropriate products but also the corresponding services. The comprehen-

Even in plants distributed around the world, fast service must be ensured in order to avoid plant stoppages and increase produc-tivity. Teleservice allows plants to be diag-nosed and maintained from anywhere in the world. This reduces the number of on-site service visits needed, and thus saves time and signifi cantly reduces costs. Simatic TeleService delivers a range of coordinated com ponents to make this pos-sible. Four different modules are available for the new TeleService Adapter IE Basic:• Analog modem • ISDN modem• GSM for mobile radio communication• RS232 for the connection of external

modemsRouting makes access possible beyond network boundaries. A fi rewall ensures that only Simatic-specifi c services can be routed through. Multilevel security mech-anisms protect against unauthorized access. From Version 11 and up, the Tele-Service software is integrated into Step 7 Professional – that is, it can be used at no additional cost.

Cost-Effective Plant Monitoring and Maintenance

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MORE ON THIS TOPIC:

+ www.siemens.com/ industrial-remote-access+ www.siemens.com /siplus-ric+ www.siemens.com/

simatic-pcs-7-telecontrol+ www.siemens.com/industrialsecurity

sive service range from Simatic Remote Support Services covers the monitoring, maintenance, and repair of machines and plants via remote access. The various ser-vices are graded modularly and are avail-able in three packages that can be adapted to suit any user’s requirements. The Starter Package is the solution for fast and eco-nomical reactive fault rectifi cation. The Enhanced Package uses special diagnostic tools to remotely ensure the problem-free operation of the plant. With this option, the user has a fi xed contact person who is familiar with the features of the indi-vidual plant. The top-level Comprehensive Package additionally includes preventive inspection services according to DIN 31051.

This range of services is based on the Siemens Remote Service (SRS) platform, a particularly secure and high-performance remote connection that is certifi ed according to ISO /IEC 27001. The system not only gives Siemens personnel remote access to the plants, but the company’s own specialists also have the same access.

Users also have the option of being able to view and monitor all changes made by the service personnel in real time via a dedicated Customer Web Portal (CWP). The system keeps a log of who has accessed the individual plants and at what time, thus making changes reproducible later on. +

Internet (VPN)3)Internet (VPN)

Customer

WebPortal

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Access GatewayCustomer Site

IT-SystemAdministration

Business Partner

DMZ1)

Customer Web Portal

1) Demilitarized Zone 2) common Remote Service Platform 3) Virtual Private Network

DMZcRSP2)

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The secure connections in the Customer Web Portal mean that service personnel can access machines and plants, and that external partners can also be integrated

WebPortal

DMZ1)

Customer Web Portal

The Siemens Remote Service platform

Advantages at a glance

Simatic Remote Support Services

+ Graded security and access concept

+ Collaboration & Customer Web Portal

+ Central monitoring, logging and reporting

+ Transparent accessing through e-mail notifi cation

+ Reaction-free thanks to isolation of networks

+ State-of-the-art security concept

+ ISO/IEC 27001 certifi cation

+ Compatible with plant IT security concepts

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Of all the renewable energy sources, wind power is the one being devel-oped fastest around the world. Not

even the recession of 2009 could halt its progress. But wind power turbines are not only becoming more and more effi cient; they are also becoming larger and more technically complex. The consequence: monitoring the operation and condition of important components is essential in order to guarantee a high level of plant avail-ability.

In large wind farms today, Internet access is largely ensured via telephone lines. However, many wind power turbines in lower output classes are not retrofi tted with condition monitoring systems such as Siplus CMS when the service contracts with the manufacturer expire and the operator takes responsibility for main-taining the turbines. In the case of indi-

vidual wind power turbines and small wind farms, the number of available communi-cation connections is frequently insuffi -cient. This means that the telephone lines installed by Deutsche Telekom do not reach the gondolas of the wind turbines, and the requirement for wireless commu-nication here is consequently especially high.

The economical solution: GPRS routers

Package-oriented transmission services such as GPRS can be implemented here. Long gone are the days when these ser-vices were only to be found in cell phones with mobile Internet access. This radio communication service, which is based on the GSM network, has another important function in telecontrol technology.

A particularly economical solution is on offer from Service International. The GPRS MD741-1 router gives the Siemens service provider a wireless Internet connection that is independent of the respective plant operator and allows unambiguous alloca-tion of costs for that communication channel. The communication system and the VPN are very easy to install, making parameterization via the Scalance S secu-rity network component possible without specialist IT personnel.

In this way, condition-based mainte-nance becomes possible permanently and economically – despite some locations being diffi cult to reach – via condition monitoring. The use of EDGE technology, which is supported by the MD741-1, means that data transfer rates can be achieved that are more than suffi cient for the appli-cation. Another crucial factor for Service International is the high level of data secu-rity in the VPN, which in the case of the MD741-1 is ensured by the IPsec security protocol.

Online monitoring is possible

In the spring of 2008, the experts from Service International tested the applica-tion over a period of three weeks in a wind power turbine situated near Hannover. The main components to be implemented were the GPRS MD741-1 router and the Scalance S612 security module. The creation of a VPN tunnel between the station and the control center was relatively easy, thanks to the presence of a common confi guration

Telecontrol Technology in Wind Power TurbinesWind power turbines are among the applications in which remote monitoring is particularly critical. At the same time, these applica-tions also have particularly high requirements when it comes to data transmission. Wireless communication via the mobile phone network not only fulfi lls the requirement for high data transfer rates and high levels of data security, but its low installation costs mean fi nancial benefi ts at the same time. For precisely these reasons, the EGPRS MD741-1 router was chosen for a wind power turbine near Hannover, Germany.

Service International

Service International is a service provider within the Mechanical Drives business unit of Siemens Industry Drives, which provides services for components used in mechanical and electrical drive technology – primarily maintenance and repair work on and problem analyses of gears, for example, in wind power turbines. The range of services provided includes both on-site measuring operations and telediagnostic services for vibration-based con-dition monitoring of gears and so-called troubleshooting visits for problem analyses with mobile measuring systems.

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MORE ON THIS TOPIC:

+ www.siemens.com/telecontrol

CONTACT:

+ Contact person: Dr. Jörg Deckers, Diagnostics Expert, Mechanical Drives

+ E-mail:[email protected]

tool. Online access was ensured throughout the entire test period, and no loss of data was detected.

The MD741-1 router is currently being implemented in a temporary Siplus con-dition monitoring system in a plastic extruder. This monitoring system is beneficial wherever and whenever an Internet connection cannot be made via telephone lines. However, the advan-tages of this type of system are also clear when it comes to troubleshooting oper-ations where continuous online moni-

toring is not necessary – in other words, operations that require a diagnostic system to be created only temporarily (for a period of up to 12 weeks), for example,

if it is suspected that mechanical prob-lems are occurring in a plant.

Fast and secure

Using the MD741-1 means that Service International is not dependent on tele-phone lines being available. Thanks to the ease of installation and the combina-tion with Scalance S, the application is ready for operation in a very short span of time, while the IPsec security protocol integrated into the MD741-1 also ensures data security. Since the integrated IPsec function frees the user from dependence on a small number of mobile telecommu-nication providers, there are additional financial benefits to be reaped through flexible selection of the GPRS providers and tariffs available both nationally and internationally. The national approvals that the MD741-1 has received in many countries are another decisive factor in making this monitoring system a viable solution around the world. +

Advantages of GPRS

+ Low costs thanks to volume-based billing and specifi c M2M (machine-to-machine) tariffs

+ VPN security without additional costs thanks to the GPRS MD741-1 router, which allows bidirectional communication between two stations without additional charges

+ Higher data transfer rates: GPRS achieves a data transfer rate of 107 kbit/s, compared to 9.6 kbit/s in GSM networks

+ High level of data security through the use of the IPsec protocol to protect process data exchanges in automation applications

DSL modem

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Mail server

VPN tunnel

Database

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Installation in the gondola of a wind power turbine

Confi guration example for using the GPRS MD741-1 router in a wind power turbine

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Siemens has been an expert in indus-trial control technology for many years. Simatic programmable control

systems have been around for 50 years now, and the fi rst IPCs appeared on the market 20 years ago. These have been under continuous development and also present a functional alternative to tradi-tional hard PLCs. Today, modern IPC tech-nology is not only found in production and process technology; it can also be found in the warehouse management, building management, and energy management sectors – in other words, wherever large quantities of data need to be processed. “It’s also no longer possible to imagine re-newable power generation without indus-trial PCs,” emphasizes Heinz Eisenbeiss, marketing director for the Simatic product line at Siemens.

Uniform product line

Siemens provides a comprehensive line of PC-based automation products to suit this diverse range of applications. These prod-ucts include IPCs in various versions, as well as software controllers and visualiza-tion software. True to the Totally Integrated Automation motto, the utmost importance is attached to the compatibility of Simatic devices with one another and with other devices from the automation product port-folio. Users can also use their existing pro-grams with different hardware, as Step 7 is used for programming both the conven-tional Simatic S7 and the PC-based control-ler Simatic WinAC. Eisenbeiss continues: “Our WinAC software PLC is compatible with Simatic S7. A Step 7 program runs on both control systems, irrespective of the

Trendsetters in PC-Based Automation

physical implementation and the version. In this way, we provide the user with out-standing fl exibility in addition to a high level of investment security.”

Innovations open new areas of application

Customer demands relating to IPCs show two clear trends: on the one hand, custom-ers are consistently requiring increased computing power, and on the other hand, the demand for compact designs is on the rise. Siemens has therefore made corresponding innovations in its range of IPCs. To ensure maximum performance, the 19“ PCs now come equipped with high-performance multicore processors such as the latest-generation Intel Core i7 quad-core processor. The rack PC’s high com-

The demand for industrial PCs (IPCs) is constantly on the rise – in part because more and more data must be processed in machine-oriented applications. Siemens focuses on easy scalability, high reliability, operating safety, and ease of maintenance in its IPCs.

The right hardware for every application: the Simatic IPC family

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puting power and high system and graph-ics performance makes it particularly well suited to the fast processing of large quantities of data – for example, in indus-trial image processing and in process visuali zation.

For applications in which size is a deci-sive factor, Siemens has developed the Nanobox PC Simatic IPC227D, which is about the size of a milk carton and works

with the latest generation of process-op-timized Intel Atom processors, which re-quire next to no electric power. The com-pact PCs are also available in a Nanopanel PC Simatic IPC277D version, with a high-resolution industrial touch display in widescreen format (7” size and upward). These robust devices are used in the machine building, building management, and transportation sectors.

The new developments aren’t confi ned solely to the hardware, however. The soft-ware too has been developed further. Siemens is the fi rst and only supplier to set trends in the implementation of fail-safe applications with PCs. In the Simatic WinAC RTX F real-time software controller, the safety functions are completely integrated, and the user does not require a further controller for control intelligence. TIA

“We want to provide outstanding fl exibility for our customers in the machine and plant engineering industries through our range of products. We achieve this through easy scalability of the auto-mation solution with uniformity between Simatic S7 and the PC-based control, and with TIA Portal – the effi cient, common engi-neering tool for the entire controller family. As the hardware basis, we supply a line of IPCs that covers the entire performance range. Our aim is also to reduce hardware and engineering costs through a reduction in the complexity of the automation solution by Siemens – for example, through the implementation of fail-safe applications in IPCs without any special additional components and with only one network.”

Heinz Eisenbeiss, Head of Marketing and Promotion, Industrial Automation Systems, Siemens

“As a leading automation supplier to the manufacturing and process industries, Siemens is a highly valuable Win-dows Embedded partner. The Windows Embedded Stan-dard 7 platform is designed for developers and device makers to quickly create innovative user experiences and reliable devices that provide high performance, and smooth connectivity to other Windows devices, PCs and servers through Windows 7 technologies,” said John Doyle, Group Product Manager, Windows Embedded. “As a participant in Microsoft’s early technology adopter programs, Siemens provided valuable feedback from manufacturing system end users that helped us provide precisely the features that machine and plant engineers need.”

John Doyle, Group Product Manager, Microsoft Windows Embedded

“The close collaboration between Siemens and Intel means that we can take the spe-cifi c requirements of industrial custom-ers into account during product develop-ment. This is especially important in industrial automation, because custom-ers’ needs here differ greatly from those in other industries. The result is Intel pro-cessor platforms that are optimally suited for use in PC-based automation.”

Hannes Schwaderer, Managing Director, Intel GmbH

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Portal is another leap forward. In addition to the Simatic S7 controller family, Siemens will also integrate the PC-based control sys-tems into the new engineering framework. IPC Remote Manager software package means that remote maintenance is also possible for IPCs (see Focus article on pages 8–9).

Investment security and minimal installation work

Investment security is an important issue for IPC users. “We are very targeted in the way we innovate, our purpose being to give the customer a competitive advantage through the use of new technologies and, at the same time, allow investment security through long-term availability and compatibility,“ Heinz Eisenbeiss explains. “In this way, we guarantee that our IPCs are available for up to fi ve years and provide repairs and service work for a further fi ve years.” The develop-ment partnership with Intel and Microsoft, which allows Siemens to react quickly to – and to implement – innovations, plays an important role in this context. “Our close Microsoft makes it possible for us to supply operating systems with our IPCs for the long term. Users thus need to carry out less adap-tation work, and sometimes they can even skip a generation in terms of the operating system,“ adds Eisenbeiss. “The partnership

with Intel in turn allows us to make the most up-to-date processor technology in IPCs available to users at an early stage – for ex-ample, in the new IPC547D rack PC with the latest-generation multicore processor.”

The development and production of all IPCs, including the mainboards, takes place in Siemens’ own plant in Karlsruhe, where the staff have made it their mission to ful-fi ll the customer’s need for long service life and fl exibility. The developers rely on a platform concept in order to achieve this – that is, various design types such as rack PCs, box PCs, and panel PCs are developed on the basis of a common mainboard. The evaluation work required is reduced be-cause all the devices of one generation use the same processors, chip sets, and drivers. To reduce installation work, users have embedded PC bundles at their disposal, which have HMI software and/or a software controller installed and ready to use.

Effi cient service and support

IPC users receive the customary Simatic service, with the addition of certain spe-cial offers. Thirty-three authorized repair centers in 27 countries are on hand to take care of repairs to defective Simatic IPCs and PDs. Customers can obtain a 36-month service option for their Simatic IPCs and PDs, which entitles them to repairs

free of charge for 36 months and is valid in any repair center in the world. Today, the first port of call for technical prob-lems with automation is usually the In-ternet. Online support provides users with around-the-clock expert advice in several languages, including Chinese. The Online Service Tool at www.siemens.com/ped provides product equipment data on the relevant devices and the Simatic IPC/PG spare parts available. +

MORE ON THIS TOPIC:

+www.siemens.com/pc-based-automation

CONTACT:

+ Contact person: Elske Meyer, Head of Marketing and Promotion, Simatic PC-Based Automation

+ E-mail: [email protected]

The Nanobox PC has all its interfaces on one side, simplifying installation and reducing space requirements in the control cabinet

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Mounting type

Mounting without tools by snappingonto standard mounting rail

Advantage

Wallmounting

Flexible choice of mounting position(e.g., horizontal, vertical)

Portraitmounting

Easy access to operator controlsand narrow footprint

Sidemounting

Minimal footprint in the controlcabinet with simple cable routing

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High peak loads are expensive. To eliminate violations and adhere to the limit set by the utility company, Gardena Manufacturing has installed a solution for effi cient load management in its production facilities. Simatic WinCC powerrate monitors power consumption in real time and automates reductions at peak power.

Since its founding in 1961, Gardena has evolved from a gardening tool retailer to a global manufacturer of products

and systems for garden maintenance. The company was acquired by Sweden’s Husqvarna Group in 2007. Subsidiaries of Gardena GmbH, headquartered in Ulm, Germany, include Gardena Manufacturing GmbH in Heuchlingen, Germany, which produces plastic products for garden tools, cleaning equipment, and irrigation tech-nology, in addition to various storage and transportation containers for a range of applications. In addition, the company also develops and manufactures OEM products.

Every year, the 260 employees at the plant in Heuchlingen process 11,000 t of plastic granulate on 100 injection molding machines to produce around 500 million parts. Production runs 7 days a week, 330 to 335 days per year. “Our goal was to fi nd a solution that would quickly provide a pre-cise overview of the consumption values and cover cost-intensive peak loads at an early stage,” explains Harald Wöhrle, who

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additional costs. This cost increase can be eliminated with a load management sys-tem that measures the load profi le, evalu-ates energy pulses and time signals, and creates a projected calculation for the end of the quarter-hour measuring cycle. If there is danger of exceeding the consump-tion limit, the system automatically shuts down individual loads according to a pri-ority list.

The load management system, which was installed at Gardena in spring 2010 during renovation work on a transformer station, includes a PC workstation with Simatic WinCC powerrate software for monitoring, visualizing, and controlling the load management processes. The Gardena employees customized the powerrate faceplates themselves. Wöhrle explains: “Real-time monitoring and eval-uation of measured values was very impor-tant for us, as was automatic load shed-ding. Since we started using this system, we have been able to precisely measure and log the consumption values.”

The range of necessary applications is covered by nine Sentron PAC power mon-itoring devices – corresponding to the number of transformers. These monitor voltage, current, and power, and forward the corresponding data to Simatic WinCC powerrate. The software compares the measured values with the data from the energy supplier and, based on this infor-mation, creates a projected calculation for the end of the quarter-hour measuring cycle. If the power supply reaches a criti-cal level, Simatic WinCC transmits a com-mand to the higher-level Simatic S7 con-troller via the building management system to shed the load in stages of 20 or 25 kW according to the priority list until the increase has stopped. When the limit is undershot again, Simatic WinCC reen-ables the loads.

The nine transformers are designed in such a way that they run at 50 to 65 per-cent of their rated output, which accord-ing to Wöhrle is the perfect operating range. At a higher load, the power loss

is in charge of the Maintenance Building and Equipment sector at Gardena Manu-facturing GmbH in Heuchlingen. “We work with a three-shift system from Monday to Friday, with an average consumption of 2 to 2.3 MW per day. On weekends, power consumption drops to between 1 and 2 MW, depending on how much of our capacity is being utilized. Requirements increase again on Monday morning – an ideal con-sumption pattern for any utility company,” Wöhrle continues.

Peak power means signifi cant additional costs

Power supply contracts have two compo-nents: the price of the supplied power in kilowatt-hours and the price per kilowatt of the peak connected power. While no credit is given when peak power consump-tion is undershot, excess consumption is always charged at the end of the relevant settlement period. A power peak of as lit-tle as 15 minutes already brings signifi cant

WinCC powerrate – all the functions at a glance

+ Sensing, monitoring, evaluation, and display of energy fl ows

+ Trend calculation and comparison with a predefi ned limit

+ Alarm signal when a limit is about to be exceeded

+ Enable/disable signal generated according to priority list

+ Predefi ned faceplates for displaying the current status

+ Precise knowledge of the consumption profi le at all times

+ Increased energy effi ciency

+ Optimized energy-purchasing contracts

+ Adherence to the utility company’s contractual conditions

+ Energy cost assignment to individual cost centers

Gardena relies on effi ciency – both in fi nished products and in production

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would increase disproportionately. “We have confi gured our system so that the transformers have suffi cient reserves to deal with power peaks that might occur. Even a short-term increase to 100 percent output can be handled without problems. If we were to operate at full power from the outset, however, then a critical situa-tion could arise,” continues Wöhrle. He stresses that at high loads and high exter-nal temperatures, cooling requirements in-crease signifi cantly, which in turn also means an increase in power consumption.

Optimized power costs

The drying processes used by the company provided the initial incentive to optimize power costs. To be able to process the plas-tic granulate in the injection molding ma-chines precisely, the remaining moisture is fi rst removed from it using an energy-intensive hot air treatment process. At the end of the drying process, the raw mate-rial retains only 0.02 to 0.05 percent mois-ture. This additional drying is necessary, as a higher water content could cause entrap-ment and surface streaks could form in the injection molding process. Since the gran-ulate is cast at a temperature of 200°C to 300°C in the machines, the moisture that remains in the material evaporates and can burn the plastic.

Gardena’s employees use the load man-agement software to determine when it is best to initiate energy-intensive processes such as that used to dry the plastic granu-late. The drying system extracts the re-maining moisture from the granulate and binds it in the drying agent. During the regeneration phase, the water is then re-evaporated by heating. Admittedly, the regeneration process occurs during peri-ods of reduced load, but should shortfalls arise, the software also provides a multi-stage load shedding function for drying. Gardena now has the capability of shed-ding total loads of up to 300 kW for 30 to 60 minutes during times of peak demand. That is equivalent to around 10 percent of the power drawn by the plant.

Transparency in power consumption

Before the load management system was implemented, the employees had only the fi gures provided by the utility company to help them trace the plant’s power con-sumption. Today, Simatic WinCC provides ongoing energy and performance values and monitors the limits according to spec-ifi ed parameters. Curve charts make power consumption transparent and display the relevant load profi le. The faceplates that are supplied allow data to be transferred to the SAP system in Excel format. The data

can then be used by controlling for usage-based allocation of energy costs and for load and consumption prognoses, which means that planning becomes more reli-able. This optimized energy utilization helps Gardena avoid expensive consump-tion peaks and take better advantage of unused reserves. Consequently, the com-pany plans to take the next step and use the management system to optimize its gas and water consumption in addition to its power consumption. +

MORE ON THIS TOPIC:

+ www.siemens.com/wincc

CONTACT:

+ Contact person: Carsten Schmidt,Marketing Management HMI

+ E-mail:[email protected]

Simatic WinCC powerrate monitors power consumption in real time and displays the performance values. Analog displays and curve charts provide a fast and precise overview of current consumption (Note: The screens are in German only)

Simatic WinCC powerrate makes the power consumption of all transformers transparent. When the power limits agreed with the utility company are exceeded, the software automatically shuts down predefi ned loads to prevent load peaks from occurring

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High-performance construction site logistics are essential if the ambitious deadlines and budgets common to construction projects

are to be met. In this context, tower cranes – which quickly and reliably deliver construction materials to the exact spot where they are needed – play a key role in building construction. Wilbert, based in Waldlaubersheim in Germany, specializes in the de-sign, construction, and rental of this type of crane.

The company’s wide range of luffi ng jib and boom cranes also includes its Heavy Lifter series: the WT 2405L e.tronic model, which is used in power plant construction, has a tower height of 120 m, a nominal lifting capacity of up to 128 t, and a max-imum load torque of 2,400 mt – fi gures that can only be achieved with high-performance drive tech-nology and comprehensive safety equipment. This allows the hoist gear’s drive to be monitored for deviations in the speed and direction of rotation and safely shut down in the event of a fault, before the load is dropped and causes damage.

Reaching New Heights in Safety

Crane specialist Wilbert relies on IPC-controlled safety technology to ensure the productivity and reliability of its building cranes. A tower crane with a nominal lifting capacity of 128 t was designed and realized effi ciently using a combination of Simatic WinAC RTX-F and Sinamics S120.

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A complete overview at all times

The crane operator is constantly kept up to date by a Simatic MP277 multipanel that continually supplies the required data, so he or she can always maintain an overview from the high cabin and deliver materials safely and precisely to where they are needed. Wilbert relies on Simatic S7 for safe crane control. The central component here is the IPC-based WinAC RTX-F safety control system, which, together with an additional ET 200 IM151-8F safety control system (in distributed operation), records and processes the entire range of safety-relevant signals. In this way, the rotary movements of the motors and the load torques, as well as the distance limit switches and operation area limits, are all

reliably monitored. This combination of safety components and the remaining con-trol functions in a common PLC reduces both hardware and engineering costs. Even the transfer of the safety-relevant sig-nals and data together with the standard signals using Profi net as a common bus contributes to the cost savings: the amount of cabling work required remains small, wiring errors are avoided, and commission-ing times shortened.

Reliable and effi cient

Wilbert uses motor modules from the Sinamics S120 multiple-axis drive system with outputs of 75 to 250 kW to carry out all moving functions – lifting and lower-ing of loads, rotating the crane, and luff-ing the crane’s boom. To raise and lower the crane’s hook with no load or with only a minimal load, the motors are operated in a delta connection and with the con-verter in fi eld-weakening operation. This leads to higher rotational speeds, which in turn means shorter lifting/lowering cycles and thus increased productivity. In-novative Safety Integrated products are used to implement the overall crane safety concept. Drive-integrated safety functions such as Safe Torque Off (STO) are also in-cluded in addition to the fail-safe control components. The Sinamics S120 drive sys-tem is supplied with power via a central Active Line Module (ALM), which corrects mains fl uctuations and thus allows the motor modules to be reliably supplied via a DC link. Even on construction sites with unstable power supplies, Sinamics S120 guarantees a high level of safeguarding against crane failures. Another positive feature of Sinamics ALM: energy that is freed up in generator operation is fed syn-chronously back into the grid.

Collaboration with the systems integrator

Automation technology also has a role to play in shortening on-site installation and commissioning times for Wilbert. The implementation took place in close collab-oration with HW-Elektrotechnik, based in Laudert, Germany, which allowed the ini-tial commissioning of the new Heavy Lifter to be carried out quickly; the systems inte-grator also took over service and mainte-nance for the crane’s automation solution. Remote diagnostics and maintenance via GPRS data transfer, which is possible any-where in the world, means that faults can be responded to immediately and ensures a high level of availability for the crane.

The automation concept meets all re-quirements regarding reliability, safety, and effi ciency based on the fail-safe Soft-SPS WinAC RTX-F and the Sinamics S120 modular drive system. It also allows safety-relevant signals and other data to be transferred using a common medium – Profi net – as well as enabling easy remote maintenance. A range of high-perfor-mance engineering tools are available to assist users in programming the PLC, inte-grating the components, and commission-ing the drives. +

HW-Elektrotechnik e.K.

HW-Elektrotechnik is a high-per-formance, globally active partner for manufacturers of controls and switchgear, automation technology, and energy systems. The company is a qualifi ed Solution Partner for the Simatic automation system, the Simatic HMI human machine inter-face, industrial communication with Simatic NET, and Safety Integrated for factory automation.

Head offi ce: Rhein-Mosel-Straße 37, D-56291 Laudert, Germany

Founded: 1992

Employees: 60

Contact: Harald Wendling

Tel./fax: +49 6746/9411-90/-925

E-mail: [email protected]

The crane is controlled by the fail-safe Soft SPS WinAC RTX-F (left), and the drives are regulated by the Sinamics S120 CU320 control units (right)

CONTACT:

+ Contact person: Sigmund Förstl, Marketing Manager, Motion Control Systems

+ E-mail: [email protected]

MORE ON THIS TOPIC:

+ www.siemens.com/sinamics-s120+ www.siemens.com/safety-integrated

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Agrata Agrarhandel GmbH & Co KG, based in Beelen, near Münster in Germany, processes around 600 t of

potatoes – of up to 100 different types – every day. Approximately 100 t of these are organic potatoes, which come from ecological cultivation. Agrata installed a fully independent conveyor and storage system specifi cally for these potatoes. When it came to choosing what drive tech-nology to use for sorting, washing, and packaging the organic potatoes in the plant, the decision makers opted for a combina-tion of distributed I/O devices with High-Feature motor starters. These motor start-ers were subsequently installed in around 120 electric drives.

“Thanks to the High-Feature motor starters, we know immediately if a motor isn’t running properly,” explains Klaus Steinkamp, proprietor of the Gevelsberg-based CS Ingenieur-Büro für Automatisie-

rungstechnik. This is because the devices deliver a range of diagnostic information to which the user can respond in a targeted manner, thus reducing costs. Faults always occur, especially during the commission-ing of new conveyor technology systems; one reason can be that the mechanical ad-justment of the belts is not yet exact. “Then there are the occasional overload trips, which are immediately signaled to the technician,” says Steinkamp. “The tech-nician then immediately knows which drive is affected.”

Up to 16 of these High-Feature starters can be mounted side by side on a Simatic ET 200S distributed I/O head module. This means a maximum current load of 50 A for the subordinate I/O devices. Impor-tant parameters such as current flow, voltage, and symmetry can be monitored, which makes the conveyor technology system very transparent. This feature is

particularly beneficial in the case of plants that span large distances and whose construction includes bends and corners.

Easy to parameterize, with signifi cant additional benefi ts

The design of the distributed I/O devices is simple and clear. The ET 200S head modules are connected to the control sys-tem – a Simatic S7-400 in this case – via Profi bus. The starters in their side-by-side arrangement provide standard motor pa-rameterization, which in many cases can be retained. Individual characteristic values can be entered via the Hardware Confi g module in the Step 7 PLC program-ming environment. The drives used in the organic potato conveyor system, with out-puts between 0.75 and 3 kW, must meet similar requirements. Time can be saved

High-Tech Organic PotatoesA company in the food industry is constructing a fully independent production plant for its organic products. For the conveyor tech-nology to work as reliably as possible, the decision makers chose High-Feature motor starters, which deliver a range of diagnostic capabilities and are extremely easy to maintain.

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during parameterization, as the operating data can be copied as lists from one drive to the next in Hardware Confi g. After this routine task, it is relatively easy to indi-vidually adjust the specifi c characteristic values.

In addition, the starters can also be pa-rameterized on-site using the Motor Starter ES software. The same software gives the technician further information about the number of operating hours of each drive, the on-time, the number of switching cy-cles, currents such as the highest tripping current, and the exact cause of fault indi-cations. “This method is ideal for allowing us to perform a detailed analysis of diffi -culties that occur,” emphasizes Steinkamp. If intolerable overloads should occur on the conveyors in particular starting situa-tions, the causes can be determined quickly via Motor Starter ES. It is then usually helpful to set individual start-up ramps on the starters, a task that can be performed using the rotary switches located on the front of the devices.

Drives can also be shut down directly with High-Feature starters. The front of the device features an interface for this purpose, into which an auxiliary contact block with two sensor inputs can be in-serted. If a conveyor belt reaches a fi nal position while fi lling the silos, for instance, the position switch shuts down the rele-vant drive independently of the control system. Of course, the drive is also simul-taneously shut down by the control sys-tem. Direct shutdown, however, provides additional safety and means that the con-

Advantages of Simatic ET 200S High-Feature motor starters

Easy parameterization, diagnostics, and monitoring

+ Parameterization via bus using Step 7 or another Profi bus tool

+ Selective protection concept

+ Remote reset of the electronic overload protection and emergency start function in the event of an overload

+ Acyclic services, current value transmission via Profi bus DP, and current limit value analysis

Clear product range to suit every application

+ Extension of power rating to 16 A / 7.5 kW

+ Only two versions span the entire performance range

+ Available as direct, reversing, and soft starters

+ Increased short-circuit strength

Proven basic functions of the ET 200S

+ Bit modular

+ Fixed wiring

+ Hot swapping: replacement during operation while power is on

+ Self-structuring power bus

Effi cient energy management

+ Targeted stoppage of individual loads or system components during production pauses

+ Load peaks are avoided and electricity costs allocated directly to the relevant loads

Agrata’s new plant for sorting, washing, and packaging or-ganic potatoes em-ploys around 120 drives – all of which are started using Simatic ET 200S High-Feature motor starters

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trol system is relieved during time-critical control processes.

The organic potato conveyor system also includes conveyor belts that need to be operated in a controlled manner – and this is another area in which the modularity of the ET 200S is a great benefi t, as fre-quency converters for outputs of up to 4 kW are available for the distributed I/O devices. Direct starters, reversing starters, and frequency converters can be arranged side by side on a head module up to a length of 2 m.

Device replacement during operation

The ET 200S High-Feature starters are not only available with contactors; they are also available as soft starters with elec-tronic overload tripping. This is especially advantageous in dusty environments. Steinkamp speaks from experience: “In contactor-only control systems, environ-mental infl uences can cause contacts to become stuck or to not connect through at all.” Though there have been no failures in the ET 200S to date, the automation ex-pert appreciates how valuable the ease of maintenance provided by distributed I/O devices is. This is because the devices can be replaced while the plant is still in oper-ation, by simply withdrawing the enclo-sure toward the front and inserting a new starter. The control system then automat-ically transfers the necessary data to the new device via Profi bus. “This is something that every technician can do on-site,” adds

Steinkamp. This feature, combined with the diagnostic capability of the devices, allows technicians to easily carry out re-mote maintenance on the plant.

An additional service for the operator: if a motor starter is tripped, the maintenance personnel can immediately view the cor-responding circuit diagram. This involves interaction between the CAE system and an industrial PC workstation with a CAE viewer. Visualization takes place in the same way as the normal operating display on the WinCC visualization platform. If the maintenance engineer presses the “Help” key, the corresponding circuit diagram sheet, which is saved on the workstation, is automatically displayed. “This solution, which we developed ourselves, is ideal for users,” says Steinkamp, “because the red border allows the technician on-site to immediately see which sector or which starter is affected by a fault, and to view the corresponding circuit diagram.”

Protection against unnecessary no-load operation

Around 100 t of organic potatoes are stored, transported, washed, and pack-aged in small quantities every day using this plant. To guarantee that this through-put is maintained, operation must be as effi cient as possible. Here, too, the ET 200S High-Feature motor starters proved to be an excellent solution, as the signal ex-change of the starters via Profi bus, to-gether with the time stamp from the WinCC visualization software, allows the

maximum runtimes for conveyor belts to be calculated. “This meant that we didn’t need any additional measuring technol-ogy,” explains Steinkamp. If a potato is blocking one of the drive wheels, the con-trol system detects this and shuts down the affected drive. Until that has been car-ried out, the starters protect the motor against overloading.

The distributed I/O devices are also eco-nomical to install. The control cabinets for the 120 drives were completely wired in the factory, so all the operator had to do on-site was install the bus cables and con-nect the motors to the starters. “This pro-duces signifi cant savings in terms of time and – most importantly – costs,” com-ments Steinkamp, “because whatever work is involved, it’s always a lot easier to carry out in the factory than it is on-site.” +

MORE ON THIS TOPIC:

+ www.siemens.com/et200s

CONTACT:

+ Contact person: Heinz Czichy, Promoter, Decentralized I/O Devices

+ E-mail: [email protected]

+ Contact person: Arno Theunissen, Sales Coordinator

+ E-mail: [email protected]

“ The High-Feature motor starters with their diagnostic capabilities signifi cantly increase the plant’s availability.”

Klaus Steinkamp, Managing Director, CS Ingenieur-Büro für Automatisierungstechnik

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Whether in packaging, forming, or solar technology, handling is im-plemented wherever the variety

of products and processes makes fl exible motion design necessary. The handling function allows machines to be intercon-nected and products to be transported from one machine to another. In addition to performing the task of movement, there are also other factors to be considered, such as product-friendly transportation and short cycle times.

Optimized mechanism in a modular design

Delta pickers are fast and are intended for highly dynamic handling processes. Short cycle times and thus high productivity can be achieved even with gantry systems, though. The advantage of these modular positioning systems is that the mechani-cal quantities are known and the compo-nents are optimized in terms of their mass and rigidity. This makes it possible to de-sign each system to precisely match the individual positioning task. Additionally, modular positioning systems are easier to adapt to the design of the machine than prefabricated robotic solutions are. The working space for gantry systems can also be fl exibly extended using a modular sys-tem of mechanical components.

Modular Handling Solutions

In innovative handling applications, high productivity and process safety are musts. Highly dynamic motion control requires coordinated interaction between mechanisms and drives, as well as path control that automatically generates optimized motion profi les based on a small number of parameters.

Fast acceleration for high productivity

Bahr Modultechnik GmbH supplies a wide range of spindle and belt-driven position-ing systems. Horizontal gantry systems with a circumferential belt (so-called roller pickers) can be operated in a very dynamic manner, as the motors are fi xed mounted. The ELZU and ELZI gantry systems can run at speeds of up to 7 m/s, which means that lighter components such as wafers, DVDs, and electronic components can be sorted and positioned particularly fast.

Roller pickers are usually plane kinemat-ics. If 3D motion and additional orienta-tions are required, the horizontal gantry can be expanded with the addition of further axes. When using a lifting/rotating

A compact, reduced-mass lifting/rotating system with a pickup paddle for processing fl at piece goods

In Simotion, the handling function

for standard kinematics is

already integrated

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Advantages at a glance

+ Kinematics that are system-integrated and can be defi ned as desired via the free transformation interface allow almost any application to be realized.

+ Workroom monitoring uses exclusion, signaling, and product zones.

+ Synchronization on up to 10 moving conveyor belts, standardized connection of camera systems, and optimized path dynamics form a high-performance bundle for high-end pick-and-place applications.

+ 3D visualizations provide support during commissioning.

advance | 3-2011 25

system, for example, very long cycle times can be achieved through signifi cant weight reductions in the masses being moved. The small masses being moved prevent almost all vibrations in the machine frames. This increases productivity and saves energy at the same time.

Optimum adaptation of control and drive

This type of modular machine concept nat-urally requires a fl exible automation solution. Handling functionality with path interpolation and kinematic transforma-tion for standard kinematics is already integrated into the Simotion family of con-trol systems. Customer-specifi c kinemat-ics can also be integrated via the free transformation interface. The control sys-tem is capable of carrying out synchroni-zation with a moving reference system in addition to linear, circular, and poly-nomial interpolation systems. In this way, pick-and-place applications on moving belts (conveyor tracking) become easily programmable. The Simotion Handling Toolbox, a software library that provides standard modules for the automation of handling applications, can be used to cal-culate an optimized motion profi le for each path, which allows that path to be run as fast as possible without any dy-namic limit values of the system being violated. For example, it is thus possible to set limits for speed, acceleration, and jerk for the machine axes at the Tool Cen-ter Point, as well as moving axes con-nected to the path, which must be ad-hered to while the system is in motion. The free design of the path also allows the dynamic behavior of the system to be in-fl uenced – in order to reduce vibrations or to allow a higher running speed to be achieved, for example.

When vision systems are used to recog-nize products, the product positions are automatically managed in a product reg-ister by the Handling Toolbox. The Han-dling Toolbox is topped of with software that provides support during commission-ing and allows 3D visualization of the han-

dling process. The handling functionality is available on all Simotion platforms. Since the performance of the system is scalable, multiple kinematics can be operated with one control system, which means that less engineering and fewer interfaces are re-quired.

Conclusion

Optimized mechanism components in a modular system allow the implementation of high-performance, modularly extend-able, and cost-effective gantry systems. Coordination of the mechanism and the drive components creates an optimized mechatronic system that runs in a time-optimized way along its dynamic limits,

thanks to motion optimization in the con-trol system. This guarantees high produc-tivity. +

MORE ON THIS TOPIC:

+ www.siemens.com/simotion

CONTACT:

+ Contact person:Holger Schürmann, Motion Control Systems

+ E-mail: [email protected]

Simotion Handling Toolbox

Basic libraries

Simotion Handling Basic Function block for basic handling

Simotion TopLoading Standard library for high-end handling

Extension libraries

Transformation Interface Integration of customer-specifi c kinematics

Product Register Management of products in pick-and-place

applications

Message Handling Management of control system and drive

messages

OMAC 3.0 Operating mode manager

3D visualization

Kinematics Simulation

Center

3D visualization of kinematics

3D Trace Tool Display of space curves

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Since 1970, Knoll Maschinenbau GmbH, based in Bad Saulgau, in Germany’s Upper Swabia region, has manufac-

tured chip conveyors and fi ltration systems for processing coolants in the machine tool industry. Today, the family-run company has a staff of over 700 employees and de-livers its solutions to customers around the world. For more than 20 years, the com-pany has also been developing and manu-facturing its own screw spindle pumps for internal cooling lubricant supply, with max-imum pressure levels ranging from 15 to 120 bar. The experts at Knoll are always working intensively to make these systems even more effi cient. “Our systems are often operated according to a three-shift model, which means that availability is an ex-tremely important factor when it comes to competitiveness,” explains Peter Ludewig, purchasing manager at Knoll. Anton Forsten-häusler, head of Knoll’s electrical engineer-ing section, adds, “Saving energy is another important aspect involved in reducing pro-duction costs for machine tool users.”

Increased effi ciency

After years of using 1LA7-series 3-phase asynchronous motors, Knoll Maschinen-bau GmbH has now taken its KTS pumps into the new era by switching to motors of effi ciency class IE2. Forstenhäusler em-phasizes, “In using the 1LE1 series of IE2 motors, we expect to improve effi ciency levels by an average of 3 percent.” Depend-ing on the size, switching from IE1 to IE2 can mean an effi ciency increase of up to 7 percent. One reason for the higher effi ciency of the 1LE1 motors compared to IE1-class motors with standard effi ciency is that copper is used in the rotor.

Effi ciency increased in defi ned stages

The systematic switch to IE2 motors that has taken place at Knoll is a result of EU directive 640/2009, which puts new reg-ulations in place regarding the energy consumption and energy efficiency of

Ecologically and Economically Smart

According to legislation that came into effect on June 16, 2011, all 3-phase asynchronous motors brought into circulation within the European Union must meet the requirements of at least effi ciency class IE2. This modernization measure affects the bulk of electric motors. Ecological thinking is also economically smart – as one manufacturer of chip conveyors, fi lters, and pumps is demonstrating.

Knoll’s KTS series of high-pressure pumps for internal coolant supply is equipped with IE1 motors, and in the future will be expanded to include 1LE1 high-effi ciency IE2 motors

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advance | 3-2011 27

asynchronous motors. Since June 16, 2011, asynchronous motors in the perfor-mance range of 0.75 kW to 375 kW that are brought into circulation on the Euro-pean market must meet the requirements of at least energy efficiency class IE2. This applies – with several exceptions in the new IEC 60034-30 efficiency standard – to motors of up to 1,000 V at 50/60 Hz, with operating mode S1, and for all de-signs. The next stage in the efficiency im-provement process will begin on January 1, 2015. From this date onward, 3-phase asynchronous motors that are operated directly from the power grid in Europe must meet the minimum efficiency re-quirements of the IE3 rating (Premium Efficiency).

It pays to use frequency converters

A possible alternative to this is to use an IE2 motor in combination with a frequency converter. Forstenhäusler explains: “While carrying out our energy evaluation, it became clear to us that system variants

defi nitely exist that greatly benefi t from the use of a frequency converter solution.” An example tested by Knoll in which the potential savings were obvious was pres-sure regulation when processing a trans-mission enclosure: The initial system (100 percent) has a constant pressure of 90 bar, which is set via an uncontrolled pressure-limiting valve. This has an energy con-sumption of 0.55 kW per enclosure, which means energy costs of 2,970 euros per year. When variable pressure generation is combined with pressure-limited fl ow, only 64 percent of these energy costs are incurred. The best results were obtained by adapting the speed with frequency con-verters in combination with variable pres-sure generation. This reduced the energy consumption values to around 29 percent of those under the initial conditions de-scribed above, which translates into en-ergy costs of only 864 euros per year. The company therefore also offers frequency converter solutions that are specially op-timized for use with pump systems, such as the Sinamics G120P. Combined with the

1LE1 series of IE2 motors, solutions of this kind are already optimally prepared to meet the next legally required effi ciency increase set to come into effect in 2015.

New motors reduce costs

Because 1LE1-series motors have the same fl ange connection as the previously used 1LA7 3-phase asynchronous motors, Knoll experienced no problems in making the transition to using the new motors with the company’s innovative rotor technol-ogy. For customers, however, the most de-cisive factor is the high effi ciency of the drives. For Forstenhäusler and Ludewig, one thing is for certain: “Electric motors with improved effi ciency according to the IE2 standard, such as the Siemens 1LE1 series, provide an effective solution for saving energy and therefore reducing costs.” Experts believe that the extra costs of the high-pressure pump systems with IE2 motors will be amortized within one year if they are operated according to a three-shift model. +

It pays to use frequency converters

“ We don’t need energy-effi cient drive solutions only for the sake of the environment – they will also be a key factor for maintaining our competitiveness in the future.”

Peter Ludewig (left) and Anton Forstenhäusler, Knoll Maschinenbau

MORE ON THIS TOPIC:

+ www.siemens.com/international -effi ciency

+ www.siemens.com/1LE1-motors

CONTACT:

+ Contact person: Ernst Prill, Sales Coordinator for Machine Building

+ E-mail: [email protected]

Constant pressure via an uncontrolled pressure-limiting valve

Variable pressure withpressure-limited fl ow

Variable pressure via frequency converters

100%

64%

29%

Electricity costs per year: € 2,970

€ 1,901

€ 864

28 advance | 3-2011

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MORE ON THIS TOPIC:

+ www.siemens.com/gearunits

CONTACT:

+ Contact person: Steffen Rintsch, Head of Sales, Siemens Industriegetriebe GmbH

+ E-mail:[email protected]

High-Performance Gear Units

Siemens has further developed its range of gear units with the new Flender SIG line. These new units feature higher torque than their predecessors, and the size grading has

now been harmonized.

The new gear units offer exceptionally high perfor-mance

ries. This means that the same tasks can now be carried out with smaller gear units. The revised logistics concept also allows greater availability in comparison to the previous series. The customer therefore benefi ts from shorter delivery times for both new gear units and spare parts.

In response to the increasing demand for integrated systems, the new line of gear units features an optimized casing design that provides fl exible installation and mounting options. Flender SIG units can be mounted in both horizontal and vertical mounting positions and on the front of the device. The gear units are pre-pared as standard for the connection of systems for temperature control, oil sup-ply, condition monitoring, and so on. This makes system planning and design more fl exible.

The right solution for every application

Flender SIG units can be used universally in many sectors – for example, as drives for conveyor belts in the materials han-dling and building materials industry or as drive components in the environmental technology and steel industries. In the fi rst stage of the introductory phase, Flender SIG gear units are available as 2- to 4-stage helical as well as 3- or 4-stage bevel-heli-cal gear units with torques ranging from 7,000 to 125,000 Nm. In further develop-ment stages, the range will be expanded to include a total of 20 sizes (503–522) with a torque range of up to 500,000 Nm. The new series will thus gradually replace the existing modular system. Existing Flender gear units in sizes 23 to 28 can be connected seamlessly, with torques of up to 1.4 million Nm. The range of features described above makes Flender gear units and the SIG line the largest standard range of gear units on the market. +

Users today want to be able to employ standard gear units for application-specifi c drive tasks instead of being

restricted to custom-made designs. Stan-dard gear units must also be constructed in such a way that they can be adapted fl exibly to the application. Siemens has made provision for these requirements with its newly developed Flender SIG gear units.

Finely graded modular system with high torque

Because the size grading has been harmo-nized, drive tasks can now be performed with precisely the right gear unit, which saves weight and reduces costs. Further-more, the torque has been increased by up to 15 percent compared to the previous se-

advance | 3-2011 29

In terms of environmental sustainability, manufacturing technology, and produc-tion systems, Opel Eisenach, a wholly

owned subsidiary of Adam Opel AG, is one of the world’s most modern car manufac-turing plants. The Eisenach plant is cur-rently producing the Opel Corsa model using a three-shift system. The production capacity stands at approximately 180,000 vehicles per year. The Siplus HCS724I heat-ing control system ensures that the plant’s drying tunnels are able to dry the cars’ paint perfectly. In just one week, the paint-ing and drying experts from Blumenbecker IPS Polska Sp. z o.o. were able to com-pletely convert the production line to use the new system.

Precise, space-saving, and effi cient heating control

The most infl uential factors in car painting are the drying process, the cycle times, and the space requirements and energy con-sumption of the plant – and these param-eters naturally affect the quality of the fi n-ished paint job. The target temperature must be precisely maintained, but at the same time the application of energy needs to be economical and effi cient. In the dry-ing tunnel, the heating control system uses three central interface modules to pre-

cisely control 920 infrared heating ele-ments. Siplus HCS724I communicates with the higher-level Simatic S7-400 via Profi bus, with a transfer rate of 12 Mbit/s. Control of the outputs, fuse protection of each individual channel, and the integra-tion of various diagnostic functions di-rectly into the heating control system mean that 30 percent less space is required in the control cabinet, compared to the previous solution. Since the application of energy in drying processes must be lim-ited and controlled very precisely, the sys-tem operates in an extremely energy-effi -cient manner.

Versatile diagnostics ensure process safety

Although the radiant heaters are con-trolled in pairs, Siplus HCS724I can detect and localize a defective heater, thanks to its integrated current diagnostics func-tion. During operation, Siplus HCS724I also detects internal module faults and external faults – such as fuse failures, cable breaks, and the failure of heaters not connected in parallel – using the stan-dard voltage diagnostics and signals these via the Simatic control system to the WinCC process visualization system and thus to the operator. In this way, the ac-

tivation of a drying cycle with a defective heater can be safely prevented. During commissioning, the extended diagnostics function helps detect possible wiring er-rors in the radiant heaters.

Perfect service and availability

Developers, commissioning engineers, and end users can obtain qualified sup-port via the Siplus hotline. Both Blumen-becker IPS Polska and Opel Eisenach were impressed by the simple engineering, low space requirements, and good diagnostic and service features of the flexibly con-figurable Siplus HCS724I. +

Perfect Surfaces

To help achieve a rapid shine and maximum color consistency in high-quality car paints, the Opel plant in Eisenach, Germany, is perfecting its drying technology. The control of radiant heaters is particularly important in this process, and the Siplus HCS724I heating control system proved its worth when it came to fi nding the right solution for this technologically and economically challenging task.

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Infrared heating elements ensure surface perfection in automobile painting

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MORE ON THIS TOPIC:

+ www.siemens.com/siplus

CONTACT:

+ Contact person: Christian Helmrich, Sales Coordinator, Siplus HCS

+ E-mail: [email protected]

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