Material Handling Automation & Drives Solutions Presented by Bill Henderson Manufacturing in America │ March 14-15, 2018
Material Handling Automation & Drives Solutions Presented by Bill Henderson Manufacturing in America │ March 14-15, 2018
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Introduction
Bill Henderson P: 770-331-5144
• Siemens DF MC Business Developer Manager – Material Handling
• Siemens Digital Factory OEM Team Lead
• 20 years Siemens Automation & Drives experience, specializing in Tire, Battery and intralogistics
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What am I talking about today
MHI Survey
Typical System Architectures
Logistics Hardware Components
The Edge and IoT
The Total Plant
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Source
Source: MHI 2017 Annual Report: https://www.mhi.org/publications/report
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MHI Survey – 9 Industry Trends
Inventory & Network Optimization
Sensors & Automatic Identification
Cloud Computing & Storage
Robotics & Automation
Wearables & Mobile
Predictive Analytics
3D Printing
Autonomous Vehicles & Drones
Internet of Things
Source: MHI 2017 Annual Report: https://www.mhi.org/publications/report
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9 Evolving Trends – Disrupting the industry
Sensors & Auto ID
Cloud Computing
Inventory & Network
Optimization Tools
Robotics & Automation
Wearables Predictive Analytics
3D Printing Drones & Autonomous
Vehicles
Internet of Things
50%
40%
30%
20%
10%
5 Year Growth Rate of Technologies
Source: MHI 2017 Annual Report: https://www.mhi.org/publications/report
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The Fourth Industrial Revolution
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Our customers have essential requirements – throughout the material handling industry
Security
Speed Flexibility Quality Efficiency
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Digitalization Effect
1
426
36
250 24.5
122 1 Retailer
Source: MHI 2017 Annual Report: https://www.mhi.org/publications/report
Unrestricted © Siemens 2018 All rights reserved. Community. Collaboration. Innovation.
9 Evolving Trends – Disrupting the industry
Sensors & Auto ID
Cloud Computing
Inventory & Network
Optimization Tools
Robotics & Automation
Wearables Predictive Analytics
3D Printing Drones & Autonomous
Vehicles
Internet of Things
50%
40%
30%
20%
10%
Source: MHI 2017 Annual Report: https://www.mhi.org/publications/report
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Top to Bottom Intralogistics Solution
All components from one supplier that are completely connected
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Weighing system Automation Systems
Conveyors Best in class automation technology for all of your requirements
Solution Description
Automation System PLC or PC based control solution for stand-alone to highly complex applications.
Process Instrumentation Transmitters for maximum efficiency in process instrumentation.
Industrial communication Broad range of components to implement efficient industrial networks and bus systems
Operator control and monitoring systems
Optimized operator control and monitoring systems using open and standardized interfaces.
Integrated drive systems Integrated Drive Systems (IDS) are consistently integrated drive components - frequency converters, motors, gear units, couplings - working perfectly together
Motors Industrial communications
Process instrumentation
Typical Conveyor System
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Energy Management
Diagnostics
Safety integrated
Totally Integrated Automation Portal (TIA Portal) … the gateway to automation solutions within the Digital Enterprise
Security integrated
HMI Controller Distributed I/O
Motion Control Drives IPC
PROFINET
Totally Integrated Automation Portal
Common data management WinCC STEP 7 SCOUT Startdrive
One common database Integrated Engineering
Consistent and unified usability concept for all devices and engineering
Inclusive for no charge : Libraries, Diagnostics, Scalability, Flexibility
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The Totally Integrated Automation - Concept and Advantages
Easy engineering and integration
One framework for the complete project
Scalable and seamless TIA portfolio fits for each
application
Connect old and new machines
thanks to compatible components
Uniform Ethernet
communication from field to management level
TIA Portal TIA Portfolio
Production lifecycle Vertical integration
High availability
Increased availability by using one tool for controller, HMI,
drives, etc.
Uniform, integrated and self-explaining diagnosis for all
devices
Device replacement in maintenance case without
tools or engineering
Direct connection to MES and cloud systems for improved
data transparency
TIA Portal System diagnosis
Device replacement Vertical integration
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Sensing and communication
Communication
SIMATIC NET Industrial Ethernet / WLAN PROFINET PROFIBUS AS-i
Sensor systems
SIMATIC Vision sensor Vision sensors for
application-specific image processing
Identification systems
SIMATIC Ident RFID systems for an optimization of
material flow and logistics Code reader systems for flexible reading
and verification of 1D/2D codes
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Control and visualization
HMI
SIMATIC HMI The finely graduated product range
fulfills the most diverse requirements
From operator panels and visualization software through to the scalable SCADA system
Controllers & I/Os
SIMATIC Controller Highest scalability Selection in the software and
hardware architecture: Modular / embedded / PC-based
Central / distributed
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Gearbox motors
Standard asynchronous gearbox motors SIMOGEAR
High quality -> long lifetime High versatility due to MODULOG system High performance due to high power density, high output torque and wide
range of gear ratio (plug in pinion) Compactness and reduced weight Easy integration due to usual installation dimensions Very high energy efficiency with IE3 motors Power range up to 200kW
Servo gearbox motors SIMOTICS S-1FG1
Based on SIMOTICS 1FK7 with Drice-CLiQ interface (electronic type plate) Compact direct mounting with helical, parallel shaft, bevel or worm gearbox Power range 0.5 to 7kW Different (holding) brakes available Plug in pinion for a high ratio in the first gear stage Available in axis height AH36 to AH100 Market usage installation dimensions
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Safety and Energy
Energy distribution
Failsafe and efficient energy distribution using SIVACON switchgear SIVACON busbar trunking systems SENTRON power switches SENTRON multi-function measuring instruments SIMATIC PCS 7 powerrate resp. SIMATIC WinCC powerrate
Safety Integrated
Complete and consistent safety program From the sensor through to the controller to drives Comprehensive service and support Support for the application of safety standards
Page 19
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Frequency converters
Central
SINAMICS S120 Single-axis and multi-axis groups Modular / high scalability
regarding the power and the function
Synchronous and induction motors Numerous applications through DCC Safety Integrated functions
Distributed
SINAMICS G120D High degree of protection IP 65 0.75-7.5 kW induction motors Speed control with/without encoder Also with integrated position control Safety Integrated functions Integrated brake control
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Distributed concept with SINAMICS G120D
Features Degree of protection IP 65
→ no control cabinet required
Installation directly near the motor → reduced wiring
Energy efficient thanks to energy regeneration capacity
Integrated positioner (EPOS) Safety Integrated No line reactor or line filter
required Up to 7.5 kW (nominal power);
15kW (peak power)
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Central concept with SINAMICS S120 Booksize
Features Scalable and flexible due to
modular structure
Up to 12 axes per CU
Central infeed / regenerative feedback
Highly dynamic control
Synchronous / induction motors
Integrated positioner (EPOS)
Numerous applications thanks to DCC
Safety Integrated
Energy efficient through regenerative feedback and energy balancing at the dc link; incl. concept for energy storage
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Engineering
Input of mechanical specification
Results: Parts list including order numbers Dimension drawings / CAD data Characteristic curves
Drive dimensioning: SW-Tool SIZER
Automatic detection of DRIVE-CLiQ components
Graphic-supported parameterization
Automatic controller optimization
Comprehensive diagnostic tools
Commissioning: SW-Tool STARTER / STARTDRIVE
Project creation
Parameterization
Optimization
Diagnosis
Page 23
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9 Evolving Trends – Disrupting the industry
Sensors & Auto ID
Cloud Computing
Inventory & Network
Optimization Tools
Robotics & Automation
Wearables Predictive Analytics
3D Printing Drones & Autonomous
Vehicles
Internet of Things
50%
40%
30%
20%
10%
Source: MHI 2017 Annual Report: https://www.mhi.org/publications/report
Automatic Guided Vehicles
Flexible Production
with Automated Guided Vehicles (AGV)
siemens.com/automotive © Siemens Industry Inc. 2018
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Flexibility in production – The AGV is the backbone of the “Smart Factory”
From fixed chained production …
… to flexible & modular production Siemens addresses this market shift with the development of a comprehensive “AGV system package”:
• Enables AGV suppliers and end customers to automate AGV applications with Siemens components and technologies
• Offers HW automation and drives concepts, SW libraries for carrier control and navigation as well as application SW for master control
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Siemens & AGV‘s have a long history
NN
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Key elements of a comprehensive solution for AGVs
Master Control
Carrier Control Navigation Automation components
TIA-Lib & PC application
Drive system
Route Configurator
Order Dispatcher
Visualization & Diagnostics
Safety Integrated Path Finding
Localization
Obstacle Avoidance
Maintenance
Data Analytics Digitale Image Ressources
*: MindSphere: Cloud-based, open IoT operating system
*
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System supplier Siemens – Offering a comprehensive AGV system package
Software “Master Control” incl. Visualization Route configurator Fleet manager
Software Library “Navigation”
Software Library “Carrier Control” incl. Drive control Safety Integrated
System Documentation
Interface Specification
List with recommended HW components
AGV system package
“SIMOVE” Maintenance App
Application support and Training
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System supplier Siemens – “Carrier Control” – Focus Drives Technology
• Basic functions • Communication • Track management • Drive train • Energy supply • Safety-functions • Additional onboard
functions e.g. lifting
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System supplier Siemens – “Carrier Control” – Focus Machine Safety
Siemens offers a comprehensive safety solution which connects intrinsic safe AGVs with station controller
CPU 1518F-3 SIMATIC HMI IPC
Shop floor network
Station control
7
7
AGV Master control station
SIMATIC HMI IPC CPU 1518F-3
Material handling or manufacturing station
AGV AGV
Industrial Tablet
• Basic functions • Communication • Track management • Drive train • Energy supply • Safety-functions • Additional onboard
functions e.g. lifting
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System supplier Siemens – “Carrier Control” – Focus Automation SW
Pretested modules, preconfigured TIA “AGV project”
• Basic functions • Communication • Track management • Drive train • Energy supply • Safety-functions • Additional onboard
functions e.g. lifting
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Carrier Control – Automation SW Open to integrate or adapt to customer specific extensions
+ +
PLC-Application
• Automation application • Safety-functions • Communication • Track control • Drive Functions • Interface to master control
Standardized S7-Function Blocks for Carrier Control
Standard STEP7 HW-Configuration
Customer specific HMI Screens
Customer specific extentions for additional HW
components
STANDARDIZED CUSTOMIZED +
HMI-Panel
Customer specific extentions for new or
adapted Functions
+ + Standard HMI Screens
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SIMOVE – The AGV system package “Master Control” – Order management and track management
PLC controlled and WinCC • Proven components • Benefits from machine safety • Already in use in projects
• Order management • Track configuration • Plant and track
visualization • Machine safety • Diagnostics • Interconnection to
external process control
PC controlled (Windows) • Simplifies implementation of traffic
management and route control
• Specified and development started
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System supplier Siemens – “Master Control” – Focus order management and tracking
Order management: • Manage order sequence and
product identification
• Product specific control of AGV behaviour (e.g. lifting)
Track management: • Mode management
(green – automatic, red – fault)
• Vehicle status (Good / Maintenance req. ) incl. details
• Vehicle tracking Realtime visualization incl. position
Screenshot
• Basic Functions • Order Management • Operating Modes • Interconnection to
external process control • Safety Functions • Track Management • Visualization • Additional track events
(Switches, Diagnosis) • AGV Simulation
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System supplier Siemens – “Master Control” – Focus route configuration and route management
Siemens’ solution for PC based mater control will be based on existing and proven technologies: Currently evaluation of several products
• Basic Functions • Order Management • Operating Modes • Interconnection to
external process control • Safety Functions • Track Management • Visualization • Additional track events
(Switches, Diagnosis) • AGV Simulation Interaction and use of Siemens PLM tools possible
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System supplier Siemens – Offering a comprehensive AGV system package
Software “Master Control” incl. Visualization Route configurator Fleet manager
Software Library “Navigation”
Software Library “Carrier Control” incl. Drive control Safety Integrated
System Documentation
Interface Specification
List with recommended HW components
AGV system package
“SIMOVE” Maintenance App
Application support and Training
Unrestricted © Siemens 2018 All rights reserved. Community. Collaboration. Innovation.
9 Evolving Trends – Disrupting the industry
Sensors & Auto ID
Cloud Computing
Inventory & Network
Optimization Tools
Robotics & Automation
Wearables Predictive Analytics
3D Printing Drones & Autonomous
Vehicles
Internet of Things
50%
40%
30%
20%
10%
5 Year Growth Rate of Technologies
Source: MHI 2017 Annual Report: https://www.mhi.org/publications/report
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The challenge – Connecting your assets – Wherever they are
What do you need?
• Global access to assets • Ongoing supervision of the
machine performance • Optimized planning of services • New business models for
machine business
?
How to get there
• Secure data acquisition for cloud services with MindSphere
!
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MindSphere – the cloud-based, open IoT operating system – from Siemens
Optimization of plants and machines as well as energy and resources
• Open standards for connectivity of Siemens und third-party products
• Plug and play connection of Siemens products
• Cloud for industry with open application interface for individual customer applications
• Transparent pay-per-use pricing model
• Opportunities for completely new service and business models
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Production monitoring, analysis and optimization
Page 41
Application example SIMATIC IOT2040 The intelligent gateway to connect the field level to the IT level / cloud
1
4
2
3
Protocol conversion / customer programmed control
Collecting and concentrating relevant production data of several sources
1
2
3 4
Secure transfer to connected company IT-systems or cloud applications
Flexible Connection to sensors/actors via serial communication, Ethernet or Arduino shields. Communicating with PLCs, drives and motors with e.g. PROFINET1) or OPC OA2)
Data aggregation, conversion of different communication protocols and pre-processing programmed in high-level language e.g. Java, C++
1) planned 2) application examples will be provided at IOT2000 forum
Cloud based analytics to detect optimization potential
Converted data can be transmitted to IT systems / cloud solutions using e.g. OPC UA, MQTT or AMQP 2)
11/29/2017
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SIMATIC IOT2040 Industrial ruggedness. Openness. Connectivity.
SIMATIC quality Designed for 24/7 operation in industrial environment
+
AutomatIon.ConnecTed Easy connection to automation level with PROFINET*) and openness to cloud based solutions
+
Expandability & connectivity With mPCIe, industrialized IO module and various standard interfaces & available protocol drivers
+
Performance & Deterministic Intel Quark® CPU and 1 GB RAM as well as x86-deterministic and battery buffered real-time-clock Openness
Free programmable in high-level languages (e.g. Java, C++) via various IDEs (e.g. Eclipse) and compilers for Yocto Linux
+
+
*) planned
Page 42 11/29/2017
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Target applications – focus on brown-field applications IOT2040 for production data pre-processing, conversion and transfer
Connecting IT/cloud and automation • Secure communication between
ERP/IT systems or cloud applications and production
• Production optimization with vertical data integration from shop floor to cloud
Predictive maintenance
• Capturing and analyzing production data like e.g. speed or operation hours in order to identify the best maintenance interval
• Optimize machine downtimes
Optimized shop floor management • Data transfer in case of undercut
of minimum stock levels of consumables
• Automated alarming in shop floor management system in order to avoid production downtimes
IOT2000 as open platform to connect legacy systems, additional sensors and IT-level
Page 43 11/29/2017
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SIMATIC IOT2040 complements automation portfolio Making legacy automation concepts “IoT ready”
PROFINET1), OPC UA, TCP/IPC, Modbus RTU, ...
Inter-connecting various sources and communication networks
Pre-processing/data acquisition with SIMATIC IOT2040 and data transfer to company network or direct to cloud applications
No need to change existing automation solution
SIMATIC IOT2040 as cost-efficient and open data gateway for retrofitting existing concepts and make them “IoT ready”
3rd party
Protocol conversion to: OPC UA, MindSphere, MQTT, AMPQ, JSON...
Cloud / IT applications 1 0 0 1 0 1 0 0 1 1 1 01 0 1 1 0 1
SIMATIC IOT2040 complements automation portfolio
SCADA / MES
1) Not released yet
Page 44 11/29/2017
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Your benefit – Easy and flexible connectivity of your automation to MindSphere
Data collection and analysis in the cloud • Secure data
connection between automation and MindSphere
• Easy configuring of connection
• Flexibility to realize best fit for connectivity concept
MindSphere Data-driven services, e.g. condition monitoring
MindConnect: SIMATIC S7-1500, SIMATIC IPC SIMATIC IOT2040
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Cloud Based Apps – By Siemens
Manage MyMachines
OEE Monitor
Product Intelligence
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Manage My Machines
• View machines regardless of Type • View machines around the world • Easy connection setup • Cloud based • Siemens Developed
• Track trends in machine status • Show current Status of multiple
machines • Show historical trends • Use the data to predict issues
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O2M – Order OEE Monitor
• Track your production orders • Display Machine effectiveness • Overall representation of process • Recognize operating trends • Virtual KPI Representations
• Plot out metrics for comparison • Quickly identify production rates • Provide decision support for change • Optimize plant operations based upon
data
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Product Intelligence
• Create actionable intelligence • Leverage existing data sources • Data Loads from your source • MES, QMS, ERP, CRM • One Single view and hub
• Fast Data Search • Performance Analytics (Patented) • Analyze and Contextualize Big Data • Empower Data Driven decisions
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Cloud Based Apps – By Siemens
Manage MyMachines
OEE Monitor
Product Intelligence
MINDSPHERE APP STORE
https://www.plm.automation.siemens.com/store/de-de/mindsphere/index.html
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Intosite and MindSphere
Access MindSphere application within IntoSite
Intosite application in MindSphere to monitor selected events and notify Intosite
Status indication in Intosite resulted from MindSphere plant resource related events
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Intosite Key Capabilities
Create 2D/3D/Panormic representations of your factories
Build a layer structure that represents the business logic and create/share placemarks
Add information and ate from existing IT systems: URLs, Files, Sharepoint, Tool Management, Teamcenter , Mindsphere, …
Start using the extensive discussion board to collaborate on information uploaded to Intosite
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9 Evolving Trends – Disrupting the industry
Source: MHI 2017 Annual Report: https://www.mhi.org/publications/report
Sensors & Auto ID
Cloud Computing
Inventory & Network
Optimization Tools
Robotics & Automation
Wearables Predictive Analytics
3D Printing Drones & Autonomous
Vehicles
Internet of Things
50%
40%
30%
20%
10%
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Digital Enterprise Suite – Our unique portfolio for the digital transformation
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Siemens’ approach to integrating and digitalizing the entire value chain
Cloud-based, open IoT operating system: MindSphere
Third party applications
Suppliers and logistics
Collaboration platform: Teamcenter
Services Production execution
Production engineering
Production planning
Product design
Become a Digital Enterprise by digitalizing your value chain
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Create a powerful Digital Twin of the entire value chain
Cloud-based, open IoT operating system: MindSphere
Third party applications
Suppliers and logistics
Collaboration platform: Teamcenter
Services Production execution
Production engineering
Production planning
Product design Product design
Production planning
Production engineering
Production execution
Services
Collaboration platform: Teamcenter
Suppliers and logistics
Third party applications
Cloud-based, open IoT operating system: MindSphere
Product design
Production planning
Production engineering
Production execution
Services
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Digital Twin for Product, Production, and Performance
Digital Twin of the product
Digital Twin of the production
Digital Twin of the performance
Digital Twin of the product
Digital Twin of the production
Digital Twin of the performance
feed back insights to continuously optimize product and production MindSphere
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Digital Twin Overview
Line Level
Machine Level
Cell Level
Robotic Simulation
Material flow & Logistics Simulation
Mechatronics Simulation
Team
cent
er
PLC & HMI Validation
PLC & HMI Validation
PLC & HMI Validation
Mechatronic Concept Designer
Process Simulate
Plant Simulation
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Plant Simulation - A Digital Twin of Production
For Plant Optimization
For Material Handling and Warehousing Virtual Commissioning
Plant Simulation
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Virtual Commissioning for Material Handling & Warehousing
+ Risk free test
+ Shorter commissioning time
+ Planning confidently
+ Test before build
+ Pretested without damage
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Virtual Commissioning for Material Handling & Warehousing
Material Handling & Warehousing: Sensors and actuators Material distribution HMI ease of use and operation Safety characteristics
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Plant Optimization Benefits
Holistic PLM concept
Profitability
Throughput
Confident planning
Energy efficiency
Process optimization
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Example - Throughput
• Detect low utilized resources • Predict over utilized resources • Balance resource utilization • Eliminate logistical bottlenecks • Optimize buffer quantities • Reduce Work in progress
Holistic PLM concept
Profitability
Throughput
Confident planning
Energy efficiency
Process optimization
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Example - Process optimization
• Reconsider process alternatives • Optimize material flow and logistics • Compare alternatives to achieve KPIs
Holistic PLM concept
Profitability
Throughput
Confident planning
Energy efficiency
Process optimization
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Example - Process optimization
Holistic PLM concept
Profitability
Throughput
Confident planning
Energy efficiency
Process optimization
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Plant Optimization Results
Optimizing complex systems using virtual prototypes Holistic PLM concept
Profitability
Throughput
Confident planning
Energy efficiency
Process optimization 20-60% reduction in inventories
Saving 3 million kilowatt hours of electricity per year
5-20% investment reduction
Detect bottlenecks before they occur in Production
Increase profit: spend the right CAPEX, utilize the right OPEX
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Plant Optimization Customer Testimonials
Heavy Industry Siemens AG Siemens AG
Industrial Equipment Siemens AG
Life Sciences Siemens AG
Energy Power Transmission
ISL Wind Energy
Zwilling Consumer Packaged Goods
Behr
More efficient production line with less waste
Production throughput was increased by 40%
Production costs could be reduced by 30%
Plant Simulation helped us avoid significant capital investments and
operational costs
We could halve our inventory in the
warehouse.
Logistics costs reduced by 10 percent
Reduction of the cycle time and increase in output by 18.2 percent
Automotive T1
Reduced cycle times by up to 66 percent
Bosch Automotive T1
Increased output per month by 10.5 percent
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Thank You. Visit us at the Tech Cafe
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Questions?
Bill Henderson Business Development – DF FA OEM Phone: 770-331-5144 E-mail: [email protected]
After MiA, seminar slides will be available at: http://www.usa.siemens.com/mia-seminars
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