Small deburring machines with Simatic S7-1200 hit the big time. 10 A Clean
Program. Simatic S7-1200 controls a self-service car wash with six ...... Hans
Berger.
GO!
Automation with LOGO! and SIMATIC S7-1200 Volume 15, Number 1, 2011
Simatic S7-1200 controls deburring machines
A Fine Line
GO! LOGO! Now Supports Ethernet: New LOGO! series with enhanced functionality
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A Clean Program: Simatic S7-1200 controls a selfservice car wash with six stations
Editorial
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Gerhard Busch GmbH
Siemens AG
inamoomani – Fotolia
Automation with LOGO! and SIMATIC S7-1200
Bundled Strength: Simatic S7-1200 controls feed bander and pile turner
A Clean Program Simatic S7-1200 controls a self-service car wash with six stations
LOGO! Now Supports Ethernet New LOGO! series with enhanced functionality
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Sitop Selection Tool
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Quickly and Easily Find the Right Power Supply
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Sitop PSU100C
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A Fine Line Small deburring machines with Simatic S7-1200 hit the big time
Maritime Weightlifter A new control system and a mobile, wireless operator device make ship lifting systems safer
Efficient Power Supply Series up to 100 Watts
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Bundled Strength Simatic S7-1200 controls feed bander and pile turner
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Book review
Cover pictures
Rubrik Contents 2 GO! 1/2011
Siemens AG
A Fine Line: Small deburring machines with Simatic S7-1200 hit the big time
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Dear readers,
I
n the new edition of GO!, I’m pleased to be able to again present to you a series of interesting applications relating to our new Simatic S7-1200 control system. The applications again
show the versatility of the new S7-1200. For example, our piece from the French port of Concarneau explains how large loads can be safely moved with a mobile controller thanks to the IWLAN coupling of the control systems. Or, as a contrasting example, the precision work of the deburring machines of the machine manufacturer Rausch, which found the ideal control solution for these machines in the Simatic S7-1200.
As the most important innovation in the field of Micro Automation, we introduce you to the new LOGO! generation, which had its premiere at the Hanover Fair and with which we are taking an important step into the future of compact control systems.
Heinz Eisenbeiss Director Marketing and Promotion Siemens Industry Sektor, Industry Automation, Industrial Automation Systems, Sales and Marketing
With the 0BA7 LOGO! generation, Industrial Ethernet is finding its way into the LOGO! series. With the new LOGO! 0BA7 basic devices, completely new application fields present themselves through the networkability via Ethernet both in industrial applications and in terms of application possibilities in building automation. It is important to emphasize that the established products remain, that is, the LOGO! 0BA6 with all basic devices, extensions and functions. But if networking via Ethernet would be advantageous in the context of your application, then the new LOGO 0BA7 basic devices are available. The entire range of extensions is used for both LOGO! 0BA6 and 0BA7.
Editorial GO! 1/2011
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New LOGO! series with enhanced functionality
LOGO! Now Supports Ethernet
QQ7 – Fotolia.com
Two new basic devices are being added to the LOGO! series, substantially expanding its functionality. An integrated Industrial Ethernet interface gives the new devices support for communication and networking without add-on components. Program memory that has been doubled in size, data logging, and various software enhancements create new application options while maintaining the familiar ease of configuration and operation.
New Products 4 GO! 1/2011
S
imple configuration and operation and excellent value for the money are making compact controllers more and more popular. But with the increasing popularity of these systems, customers are demanding extended functionality from them. Whether for the control of transport devices, in house and building management systems, in HVAC (heating, ventilation, and air-conditioning) technology, for control of machines, or in monitoring systems, LOGO!, the world’s leading logic module for intelligent switching and control, can now do even more. Two new basic modules, LOGO! 12/24 RCE and LOGO! 230 RCE with integrated Industrial Ethernet interface, have been added to the previous lineup of standard devices. In addition to the recording of data on a PC, these allow the cost-effective networking of up to eight devices of the new generation and their integration into existing infrastructure using a standard Industrial Ethernet switch. This makes entirely new applications possible with small networked machines. It is possible to implement a master/master combination (in which all devices have their own programs and exchange required information through what are known as digital and analog network nodes) as well as a master/slaves combination (in which one LOGO! module executes the entire program and sends output information to the other devices, from which it receives input information in turn). These thus function as pure I/O enhancements. In addition, the new logic modules also communicate with Simatic S7 controllers and Simatic HMI devices. This makes it possible to use graphical visualization, graphical user guidance, and touch technology for LOGO! applications. Online remote access is also possible for service purposes.
Program memory doubled As the two LOGO! devices of the new generation 0BA7 can be networked with up to seven slaves and a correspondingly larger number of inputs and outputs can be operated, the program memory has been doubled in comparison with the standard devices of generation 0BA6, representing an increase from 200 to 400 function blocks. This offers notable advantages in the building automation for both residential and nonresidential buildings – for example, when a large number of blinds need to be controlled, or, even more significantly, when more complex configurations need to be carried out. Instead of the previous memory card, a standard SD card can be inserted into the front side of the new devices. This allows inexpensive standard memory media to be used for copying programs as well as for saving data or projects, including comments. Another new feature is that a supercapacitor buffers the built-in real-time clock for 20 days (increased from 80 hours) if the supply voltage is disconnected.
Data logging and new function modules In the new devices, there is now also an area in which data can be saved (data logging). This is advantageous when LOGO! is controlling temperatures or monitoring fill levels, for example. Now the corresponding processes can be easily documented and evaluated. In addition to being stored internally, the data can also be saved directly onto an external SD card.
LOGO! Communication 12/24RCE
12/24RCE + EMs
Simatic S7-1200
+ EMs
Industrial Ethernet Standard 8-port Industrial Ethernet switch
Via defined digital (64) and analog (32) I/O network nodes per LOGO! 0BA7 230RCE
Locally running program
12/24RCE + EMs
+ EMs
LOGO! 0BA7 permits data exchange with various devices via Industrial Ethernet
Simatic panel
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EAsy PrOGrAmmING With LOGO! Soft Comfort, more complex applications can now be programmed with even greater ease than before. For recurring program events (for the control of shutters or blinds, for example), macros can now be used, and macro libraries can be created in order to call up the corresponding program components at any time and reuse them. Due to the addition of three shift registers, a shift register of up to 32 bits can now be set up. The I/O status can be transferred to a PC via the Industrial Ethernet interface and documented there in an Excel table, for example. In the new software, it is possible to swap function blocks without having to create new connections. The users of LOGO! generation 0BA6 also benefit from this simplified operation, which also includes the alignment of the blocks and improved commenting.
uNrEsTrIcTEd cOmPATIbILITy Because the enhanced functionality and communication capability of the new basic devices is not required for all LOGO! applications, the basic devices of generation 0BA6 are not being replaced by these new devices, but instead remain without changes to their functionality. The new basic devices are fully compatible with the previous ones – apart from the greater device width of 108 mm instead of 72 mm due to the Industrial Ethernet interface and SC card reader – and have an integrated display and cursor push buttons. The signal connections correspond to those of generation 0BA6. With their enhanced functionality, these
Siemens AG
In the program, the user can set the time intervals or the triggering event for the recording of temperature data or fill levels, for example. Determining minimum and maximum values as well as average values is also possible with the new devices. The function modules also include a stopwatch that allows the duration of any process to be easily measured – in production, for instance. Additionally included are an astronomical time switch, which can be used for the control of external lighting or for feeding times in animal husbandry, and an analog filter, which helps smooth the influence of interfering impulses.
devices can thus replace the previous standard devices on a one-to-one basis. All previous expansion modules can be used with the new basic devices without restrictions. The text display can be used with the functionality of the 0BA6 generation on the new devices. The only thing that must be kept in mind is that an Industrial Ethernet cable is required in order to directly transfer an existing program from a PC onto one of the new basic devices.
PrOVEN PErfOrmANcE IN INdusTry ANd buILdING mANAGEmENT sysTEms The strong points of LOGO!, which have made compact controllers the ideal platform for a broad spectrum of automation and control applications in industrial and building management systems, are also featured in the new generation of devices, ranging from their flexible, modular design to their easy program creation, project simulation, and documentation using drag and drop, to the integrated text display with HMI functionality. This allows the display of text, set points and actual values, bar graphs, and status notifications of the input and output signals; parameters in the text messages can also be adjusted. In addition, an external text display or touchpanel can be connected for improved user guidance. LOGO! is also particularly suitable for building applications, since the devices are approved for residential buildings and installers are familiar with them from their training.
The new generation: important innovations p p p p p
Integrated Industrial Ethernet interface LOGO!/LOGO! communication LOGO!/S7-CPU/HMI communication Significantly more usable I/O channels Doubled program memory of 400 function blocks
p Data logging p SD card interface p Software enhancements such as an astronomical calendar and macro library functionality
New Products 6 GO! 1/2011
The basic devices of the new 0bA7 series (right) have expanded functionality and remain fully compatible with the devices of the 0bA6 series
Sitop PSU100C: Efficient Power Supply Series up to 100 Watts The slim and energy-efficient Sitop compact power supply series has been extended to include three more powerful power supply units: 24 V/2.5 A, 24 V/4 A, and 12 V/6.5 A. With widths of just 45 mm (24 V/2.5 A) and 52.5 mm, the new Sitop PSU100Cs are particularly suitable for distributed use in the lower power range up to 100 W. Like the previous 24 V/0.6 A (22.5 mm wide) and the 24 V/1.3 A and 12 V/2 A (30 mm wide) variants, the more powerful DIN rail devices also win over customers with high efficiency over the entire load range and low no-load losses. The wide input range enables connection to single-phase 120 V AC and 230 V AC networks as well as to DC voltage networks with DC 110 V to 300 V. The operating temperature range of -20 °C to +70 °C allows their universal use. The removable plug terminals ensure user-friendly connection. www.siemens.com/sitop
The new Sitop Selection Tool allows the user to quickly and easily select a suitable power supply, and then save the selection or put it in the shopping basket of the Siemens Industry Mall and place an order there. The tool is available on the Internet and in the Industry Mall. The appropriate parameters can be selected step by step based on just a few technical characteristics. The Sitop Selection Tool displays the relevant products immediately. Changes to the selection parameters are possible at any time. To provide additional support in product selection, several products can be compared on the basis of their technical specifications. When displaying the technical specifications, the user can choose between all specifications, all matching specifications, or all specifications that differ. The products selected in this manner are then transferred to a product list. This list can be exported into a variety of file formats or placed directly into the shopping basket of the Siemens Industry Mall. The user can also call up additional product information about the selected products, including 3-D data and schematic macros as well as certificates and operating instructions.
1st step: Select products
2nd step: Compare products
3rd step: Export product list or transfer it to the shopping basket of the Siemens Industry Mall
All pictures: Siemens AG
Sitop Selection Tool: Quickly and Easily Find the Right Power Supply
www.siemens.com/sitop-selection-tool www.siemens.com/industrymall/de
New Products GO! 1/2011
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Small deburring machines with Simatic S7-1200 hit the big time
A Fine Line
For machine control systems in the low-cost range, Siemens previously had a clear answer: LOGO! But a manufacturer of deburring and chamfering machines wanted to take a step toward a complete programmable logic controller (PLC) without driving up the costs. This was a task for which the new Simatic S7-1200 control system was particularly suited.
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ausch GmbH & Co. KG, founded in 1919 in the North Rhine-Westphalian town of Haan, is a textbook example of a medium-sized company. In the 1960s, the decision was made to expand the existing expertise in broaching machines to include deburring machines. Since then, Rausch, with around 30 employees, has been associated first and foremost with the brand name Gratomat. One specialty in this area is deburring machines, which are used in the production of gear wheels, pinion shafts, crown wheels, ball-and-socket heads, and synchronous rings. In up to four work steps, they free workpieces of burrs that would stand in the way of smooth functioning. For the development of a new generation of single-spindle deburring machines, Rausch wanted to move on from the previously used simple control systems using logic modules of the LOGO! series in order to be able to offer an easy-to-use user interface and to be able to take advantage of more technological development
Mechanical Engineering 8 GO! 1/2011
potential. Rausch considered the options for using a much more powerful PLC in this lower price segment for the first time. This was an idea that came at just the right time for Siemens systems integrator Paul-Mierko Fortak.
A technology leap with a cost advantage “I immediately thought of the Simatic S7-1200 controller,” recalls Fortak. He also knows precisely which argument he used to convince Rausch: “The control system does cost a bit more, but you get back this investment two and three times over just in the engineering costs – not to mention the functional advantages.” The Simatic S7-1200 was developed especially for the field of micro automation. It is designed to be flexible and scalable and is suitable for all tasks in the lower performance range, including challenging ones. For the new machine series from Rausch, a Simatic S7-1212C control system was combined with a 5.7-inch KTP600 color touchscreen as the user interface. For the actuators, a Sinamics S110 positioning drive was used, and a CNC package for highspeed cutting was added to the overall system. In addition, an interface for remote maintenance of the machine over the Internet was included.
Compact design and an unobstructed view of the work pieces are features of the new machine generation
all photos: Fa. Rausch
Less time and effort for greater performance
Flexibility in a compact format In sum, the Simatic control system allows functional characteristics that were previously out of reach in the lower performance segment. But Rausch took the opportunity a step further, bringing about a completely new technology generation with the Gratomat GR 500 ECO, which also sets standard in terms of ergonomics and design. The machine is extremely compact and space saving and does not need a separate control cabinet. It is integrated into the machine just like the pneumatic control system and the suction device. The mechanical structure is also designed so that the operator has an unobstructed view of the ongoing process at all times. The safety doors open in the roof area of the protective enclosure, which enables the feeding of heavy workpieces with a crane, for example. The new Gratomat GR 500 ECO is not designed for maximum speed, but it offers a great deal of flexibility. For example, both machining units can be equipped with any combination of milling cutters, grinding discs, or brushes. The touchscreen of the control system not only allows for intuitive user guidance – its digital display also supports fast and easy setting of the machining axes and visualizes all important setting parameters.
With the new Simatic S7-1200 control system and the associated Simatic Step 7 Basic software generation, Totally Integrated Automation (TIA) is finding its way into small machines for the first time. The setup is carried out easily on the control unit. The entire deburring and chamfering process runs reliably and on a program-controlled basis. “All the engineering is much simpler than before,” concludes systems integrator Fortak, who was glad to be able to develop both the process sequences and the associated visualization and user interface within the familiar Simatic programming environment. “It is obvious that Siemens placed special emphasis on seamless integration with the Simatic S7-1200. The interaction between the controller, HMI, and software is simply perfect,” he commented. This saves engineering costs for machine manufacturer Rausch, which more than makes up for the slightly higher hardware costs in comparison to the previous generation of devices – not to mention that the company can score points with functionality that clearly distinguishes it from the competition. In turn, the user gets a machine with real TIA functionality without having to pay a higher price for it.
With a Simatic S7-1200 and a Simatic ¬Basic Panel, an easy-to-use user interface can now be realized
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Simatic S7-1200 controls a self-service car wash with six stations
inamoomani/Fotolia
A Clean Program
Either LOGO! or Simatic S7-1200 – an electrical installation company from Germany’s Rhine region appreciates both compact controllers in equal measure. During the modernization and expansion of a self-service car wash, for example, the Simatic S7-1200 was able to fully demonstrate its strengths.
T
he daily routine of an engineering office and an electrical installation company is characterized by a diverse array of tasks. The engineering office founded in 2002 by Oliver Fuchs complements the services offered by the electrical installation company Fuchs Elektro-Technik, which has been based in Siegburg, near Bonn, for more than 50 years. The engineering office is responsible for consulting with individual customers as well as for schematic design and execution planning – whether for a residential complex or a commercial property. For the energy consumption and process optimization of self-service car washes, company owner Oli-
Control Engineering 10 GO! 1/2011
ver Fuchs depended on the LOGO! logic module from the very beginning. “What was crucial for our decision was that this system series was suitable for many different automation tasks,” the engineer explains. “The efficient LOGO! Soft Comfort configuration software and the good price/performance ratio were what convinced us.” Thanks to the digital and analog expansion modules, the networkability using KNX/EIB, and the onboard text display, LOGO! was of interest to Fuchs for building automation, among other applications. In this context, he uses the controllers primarily for fan control with heat recovery, for security provided by external lighting, and for time-controlled shutters or blinds.
the selected wash program in the individual station boxes, the high-pressure pump and the cycling pumps for the wash additives are switched on and controlled to save energy and supplies. The pumps for the wash additives are controlled using a signal of 0–20 mA. The more wash stations that need the same wash additive at the same time, the faster the cycling of the pump control system.
From LOGO! to Simatic S7-1200 At the self-service car wash, each individual station box received a LOGO! control system for its various wash programs with a coin checker, a high-pressure pump, and corresponding control valves. While a LOGO! module with a display for showing messages was found to be the optimal solution in the central control cabinet, a less-expensive but sufficient solution was found for the individual station boxes: a LOGO! unit without a display but otherwise with the same functionality, and with an optional KNX/ EIB connection option.
The control of opening times and holidays, as well as the operating-hours counter for preventive maintenance, is programmed using the clock integrated into the Simatic S7-1200. In addition, the control system also carries out frost-protection monitoring and other functions specific to the car wash. “The user memory is big enough,” emphasizes Fuchs. A Simatic HMI KTP600 Basic Panel is used for central visualization. It is programmed on an integrated basis and coupled with the powerful 1214C CPU via the TCP/IP of the integrated Profinet interface. The interface is also used for programming the control system. Special programming cables are no longer required – an additional advantage of the Simatic S7-1200.
As in all service areas, customer demands were increasing, along with the number and quality of the wash programs. However, it was becoming more and more important to the operator of the car wash to maximize energy savings through optimized wash programs. The number of wash boxes to be networked was continuously increasing, which necessitated rethinking the concept for the car wash. At this point in time, Siemens introduced Fuchs to the new Simatic S7-1200 modular compact controller with the Step 7 Basic configuration tool. Fuchs quickly recognized the advantages of the innovative and efficient configuration interface with the option of creating application module libraries and the integrated WinCC Basic visualization software. Thanks to the available high-performance hardware components, the Simatic S7-1200 also seemed to be well equipped for the pending modernization concept of a six-station self-service car wash.
Since it was commissioned, the system has been running without any problems. “Our new concept has been a complete success, thanks in part to the functionality integrated into the Simatic S7-1200,” explains Fuchs. “We will continue to use and develop it in systems of this size and larger. The Simatic S7-1200 has enough memory capacity for this.”
Future-proof with TIA Portal In addition, Fuchs can make further use of and expand the programming knowledge he has already gained through the use of the Step 7 programming software in Totally Integrated Automation (TIA) Portal. “That makes the investment future-proof for me,” he says. Since there are also application areas for the Simatic S7-300 at the Fuchs electrical installation company, the company would now like to see Siemens create consistent configuration software for all Siemens programmable logic controllers (PLCs). With Step 7 TIA Portal, this wish will also soon be fulfilled for the supplier.
Large user memory and central visualization In the six individual station boxes, each with an electronic coin checker and five wash programs, four of them with special wash additives, the Simatic S7-1200 receives the start signal through the selection of a wash program. If the coin checker detects that coins have been inserted, it releases the control system of the wash box, which washes during the specified release period. Depending on
Siemens AG
Fuchs Elektro-Technik
Left: For the modernization concept of a six-station self-service car wash, the Simatic S7-1200 was found to be the ideal solution Right: Compact and efficient: the central control system
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Simatic S7-1200 controls feed bander and pile turner
Bundled Strength a manufacturer specializing in printing peripherals and finishing has depended on Siemens control technology for 30 years, not least because of the company’s globally reliable support. For banding with automatic feed and a fully automatic pile turner, the Simatic S7-1200 has proven itself to be the optimal control system.
EXPandEd FUnCTionaLiTy G.
G
erhard Busch GmbH from Seevetal, near Hamburg, Germany, sells pile turners, punch presses, banding machines, collating machines, conveyor belts for cutting, and color mixers. The family business, founded in 1949, stands for state-of-the-art technology; the highest quality standards for development, production, and service; and exceptional value for the money. While feed banders with automatic feed band print products of all kinds, pile turners today replace not just the physically difficult work of manually stacking piles but also the aeration, dedusting, alignment, shaking, and placement of stacks of paper onto special pallets. For the newest generations of feed banders and pile turners, Busch relies on the powerful and cost-effective automation available with the Simatic S7-1200.
Mechanical Engineering 12 GO! 1/2011
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ZFB 32 inline feed banders follow machines with product stacking outlay, such as stackers, and are directly interlinked with them. LOGO! was initially used with them. “Due to the larger number of inputs and outputs, the migration to the S7-1200 at the beginning of the year gave us the option to further extend the functionality of the first prototypes in accordance with customer requirements,” says Roland Schnell, the electrical engineer responsible for design and programming at Busch. “We now have more control systems and evaluate more sensors.” One new feature is the double lateral alignment. If desired, the feed bander can align the goods coming out of the stacker using lateral pushers without the goods being banded. The machine operates on a fully automatic basis. If the integrated sensor technology recognizes a product stack, a roller drive is started that takes this stack and transports it to the feed bander. Holding blades extend and ensure that no stack follows until the material has been aligned several times in the direction of the feed and laterally, as well as pressed and banded. They also ensure that the stack in the machine is stopped for alignment. Four adjustable transport stops allow every stack to be provided with a 30-mm-wide band up to four times. The corresponding sensors are activated by turning on the rack, and the desired bundle intervals and stations are entered in this way.
For the Simatic S7-1200, Busch uses the largest 1214C CPU for sequence control, including the integrated proportional-integral-derivative (PID) controller for temperature control to fuse the coated kraft paper during bundling. “This process is less susceptible to error than the previously used electronic circuit board,” explains Schnell. Using the KTP400 mono PN Basic Panel that is adapted for the Simatic S7-1200, various functions can be selected and switched on or off. In this way, it is not necessary in every case to carry out lateral alignment or pneumatic pressing of loose bundles.
The fully automatic operation allows for a protective grating with light barriers as well as a motorized pneumatic aligning gauge with paper detection. In automatic mode, three different operations can be performed: it is possible to turn the paper stack 180°; to combine the turn with a prior aeration, alignment, and shaking program; or to just aerate, align, and shake the paper stack. A vibrating motor that moves the entire table is started along with a fan that drives air jets moving along under the stack. A KTP600 mono PN Basic Panel that includes program memory for repeat orders is located outside the protective grating and is used for easy programming and operation of all functions – for the selection of the work programs as well as for fast and easy error diagnosis. A smaller auxiliary KTP400 mono PN Basic Panel is mounted directly on the machine. “On the control field of the outer panel, the operator selects what he wants before the start – for example, the number and speed of the air jet runs, the volume of air, and the intensity of the shaking,” explains Schnell. “During the aeration, the operator can then go into the protected area if, for instance, it is necessary to pull sheets out of the stack and beat them straight if they have become snagged. There, he can use the auxiliary panel to switch the air jets from automatic to manual operating mode in order to pull out sheets or switch off the fan.”
“The Simatic Step 7 Basic engineering software with integrated WinCC basic HMI software makes programming simple and straightforward,” emphasizes Schnell. “The good documentation, including assignment lists and cross-reference lists, is of great use when programming and for subsequent understanding of the program when searching for errors, for instance.” The well-tested feed bander – a prototype – is now in use in Bremerhaven and is operating to the full satisfaction of the customer.
Easy programming and operation For printing plants with an especially high stack throughput, Busch developed a fully automatic pile turner as part of the SWH model series and has already sold it to a customer in Brazil. “The Simatic S7-1200 has proven to be an exact match for the process requirements. It optimally fills the gap between LOGO!, which controls the semiautomatic pile turner for us, and the Simatic S7-300, which is somewhat oversized for this task,” says Schnell.
The size of the panel on the protective grating makes operation and formula management easier. “If a customer would like to have an even larger panel, that’s not a problem,” says Schnell. “One advantage of the Siemens software is that a program can be transferred from one panel to another nearly on a one-to-one basis.” After these positive experiences, he can very well imagine using the Simatic S7-1200 for additional machines. “I am definitely a big fan,” he concludes. “Not least because of the exceptional value for the money.”
G. Busch GmbH
The Simatic Basic Panel outside the protective grating facilitates ease of operation
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A new control system and a mobile, wireless operator device make ship lifting systems safer
Jean-Louis le Moigne
Maritime Weightlifter
The new automation technology of the hydraulic lifting system in the harbor of Concarneau (Finistère) is based on the KTP400 Basic Panel and the Simatic S7-1200 control system. The 277 IWLAN Mobile Panel with integrated safety concept also fulfills the requirements of the operator for maximum mobility and safety.
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hen the Chamber of Industry and Commerce of Quimper as the owner of the system invited bids for the replacement of the control automation, Barillec SAS, a company of the VINCI Energies Group, submitted a solution that would facilitate the operation of the system in an unprecedented manner. After Barillec won the contract at the end of October 2009, the delivery and commissioning of the equipment followed on January 15, 2010. In spite of an extraordinarily harsh winter and the delays during the Christmas season
Industrial Communication 14 GO! 1/2011
and New Year’s holiday, the planning specifications could be adhered to thanks to the dedicated work of all partners. The lifting system is now operated using a mobile operator device that communicates with the higherlevel Simatic S7-300F controller via IWLAN. Due to the radio connection, the control system runs in one of the control system CPUs and in the safety mode reserved for the Mobile Panel. The data is carried using Industrial Ethernet/Profinet/Profisafe. Why a mobile operator device? “In order to be able to carry out certain operations with the lifting system near the keel, the operator needs to be able to move about freely so as to allow him or her to control different winches from the dock by sight,” explains Eric Bihoues, head of the department of Automation and Processes at Barillec. Although
Keeping big machines under control
Barillec is using the IWLAN and Profisafe technologies with safety control systems for first time here, Bihoues does not see this as a risk: “Our partners assured us that we would receive extensive support and appropriate training.” “In order to successfully complete the project, we also decided in favor of the Simatic S7-1200 controller – on every hydraulic unit – together with the KTP400 panels of the Basic Line on the machine foot,” added Sébastien Le Poder, the control system technician at Barillec responsible for the project.
Twelve HMI of the Basic Line for local control The lifting system consists of a 76-meter-long and 17-meter-wide platform that is supported by six parallel iron girders. Each girder is driven on the ends by two hydraulic units. Each hydraulic unit has its own control cabinet with the micro PLC Simatic S7-1200 and a Simatic HMI KTP400 Basic Panel. This means that each hydraulic unit can be operated manually and independently. “This local interface simplifies the execution of test runs on every station. It also allows latch mechanisms to be released or winches to be synchronized in order to prepare for an operating sequence,” says Romain Daniel.
2,000 tons controlled using a mobile panel
Siemens AG
Due to the brisk business in dockyard service, the harbor of Concarneau has several facilities for dry-docking and launching ships. The hydraulic ship lifting system can be used for ships of up to 90 meters in length, 17 meters in width, and 2,000 tons of weight. The described system can be used to lift the carrier platform of 76 x 17 meters over a distance of up to 10 meters (at a speed of 5 m/h). For maintenance of the ships, the ship’s hull must be lifted out of the water up to the height of the dock. The ship, which was secured on the movable platform using wedges and winches, is then lifted horizontally up to the grounds of the wharf. The mobile panel gives the operator the required freedom of movement for controlling the system from right up next to the ship.
Each controller of the hydraulic units receives signals from several sensors via cable connections: – analog laser position encoders of the two winches; – latch position encoders (lifting system through the alternating use of two winches through placement on a rack rail); – measurement of the hydraulic pressure of each winch. The height of each iron girder for the support of the platform is constantly measured on the level of the two hydraulic units using a cable extension transducer that is directly connected with the Profinet network. The distance between the two iron girders may differ by at most ± 2.5 cm if the transport operator has not decided in favor of inclined transportation of the platform. With the exception of the cable extension transducer, which is directly connected via Profinet, the S7-1200 controller assigns the local sensors using a cable connection.
“The controller also gives us the option to switch to local controllers, e.g. when a sensor is being replaced.”
Mobility creates safety In spite of all safety measures before the lowering operation, the control over the process of bringing the platform closer to the keel is a delicate operation, during which the transport operator should be able to move as freely as possible.Using the IWLAN panel, the operator is provided with a mobile device that is connected on a wireless basis with the higher-level Simatic S7-300F controller. The radio network covers the entire work area using a Scalance W antenna mounted on a 15-meter-high mast. “To expand the IWLAN radio zone, this interface was intentionally slowed from 54 Mbit/s to 24 Mbit/s due to the limited throughput rate of this application,” explains Le Poder. All 12 of the hydraulic units installed around the lifting system (including the central operator panel) have an independent transponder that is not connected to the control system network. It sends an RFID signal in a conical area with a range of 8 meters. When starting the control system session with a mobile controller, transport operators must identify themselves with an RFID signal in one of the 13 radio ranges in order to ensure secure execution using IWLAN. The operator device then displays the controller that a transport operator has logged onto using a transponder. “When the operator leaves the IWLAN area with the mobile panel, the operation is immediately halted,” emphasizes Vincent Dujardin, technical assistant in the Support & Service department at Siemens for the region “Atlantic coast of southern France.” “If transport operators want to maintain the connection while they are in the range of a transponder, they also need to press the dead-man’s switch.”
GO! 1/2011
15
Micro Automation in the Internet Out of the Printining Machine
Profound know how
T
he Simatic S7-1200 micro PLC offers a modular design concept with similar functionality as the well-known S7-300 series. Being the follow-up generation of the Simatic S7-200 the controller can be used in a versatile manner for small machines and small automation systems. Simple motion control functionalities are both an integral part of the micro PLC and an integrated Profinet interface for programming, HMI link and CPU-CPU communication. As part of Totally Integrated Automation (TIA) Portal, the engineering software Step 7 Basic offers a newly developed user interface, which is matched to intuitive operation. The functionality comprises all interests concerning automation: From configuring the controllers via programming in the graphics-oriented languages LAD (ladder diagram) and FBD (function block diagram) to program testing. The book presents the new hardware components of the automation system S7-1200, as well as its configuration and parameterization. A profound introduction into Step 7 Basic illustrates the basics of programming and trouble shooting. Beginners learn the basics of automation with Simatic S7-1200 and advanced users of S7-200 and S7-300 receive the knowledge required to work with the new PLC.
Hans Berger Automating with SIMATIC S7-1200
Worldwide available You need information about our Micro Automation products and solutions, technical documentation or support? Tools and downloads? You prefer to order online or simply want to find a local partner? Please visit
www.siemens.com/logo www.siemens.com/s7-1200
Simatic S7 Basic Podcast
Meet the next Generation of Engineering Though with Simatic Step 7 Basic ease-of-use is guaranteed take a look at our Simatic Step 7 Basic podcast. Learn more about the Simatic S7-1200 innovations by watching the podcast on your iphone, ipod or simply in your web browser. Watch how to load configuration of a CPU and attached modules directly to Step 7 Basic and lots of useful tips at
www.siemens.com/ simatic-step7-basic
Hardware Components, Programming with STEP 7 Basic in LAD and FBD, Visualization with HMI Basic Panels 2011, 413 pages, 290 illustrations, hardcover ISBN 978-3-89578-356-2
Publisher: Siemens IMPRESSUM Herausgeber: AG, Sector Siemens Industry, AG,Industry BereichAutomation, Automation and Automation Drives, Sales Systems, und Marketing, Sales and Marketing, Gleiwitzer Gleiwitzer Str. 555, 90475 Str. 555, Nürnberg, 90475 Nuremberg, Tel.: +49 (911) Germany, 8 95-48Tel.: 11,+49 Fax:(9 11) +49 (911) 8 95-48 11, 8 95-27 86 Verantwortlich: Fax: +49 (9 11) 8 95-27 Heinz Eisenbeiss, 86 Editorial I IAResponsibility: AS S MP Redaktionsleitung: Heinz Eisenbeiss, Eva-Maria I IA AS SBlockus MP In-house Verlag: editorial Publicisstaff: Publishing Eva-Maria Redaktion: Blockus Robert Publishing Engelhardt, House:Dorit Publicis Gunia Publishing, Kreation: Erlangen, Kerstin Germany Rosenow staff: Editorial Projektmanagement: Robert Engelhardt,Marion Dorit Gunia Schwab Layout: DTP-Satz: Kerstin Mario Rosenow Willms Copy Druck: editor: Wünsch, Marion Neumarkt Schwab GO! DTP: erscheint Mario Willms halbjährlich Printed Auflage: by: Wuensch, 27.000 Neumarkt, Bestell-Nr.: Germany E20001-M1970-P270 GO! appears twice a year, ISSN-Nr.: ©2011 by1434-7008, Siemens AG©2011 Munichbyand Siemens Berlin.Aktiengesellschaft All rights reserved Berlin by theund publisher. München. The Alle information Rechte vorbehalten. provided in this Die magazine Informationen contains in diesem merelyHeft general enthalten descriptions lediglich orallgemeine characteristics Beschreibungen of performance which, in bzw. of case Leistungsmerkmale, actual use, do not welche always apply im konkreten as described Anwendungsfall or which may nicht change immer as ainresult der beschriebenen of further development Form zutreffen of thebzw. products. welcheAnsich obligation durch Weiterentwicklung to provide the respective der Produkte characteristics ändern können. shall only exist if Die gewünschten expressly agreed upon Leistungsmerkmale in the terms of sind contract. nur dann ET 200, verbindlich, S7-200, S7-300, wenn sieS7-400, bei Vertragsschluss S7-1200, Siemens ausdrücklich LOGO!,vereinbart SIMATIC, SINAMICS, werden. ETSITRAIN, 200, S7-300, STEP, TOTALLY S7-400, S7-1200, INTEGRATED Siemens AUTOMATION LOGO!, SIMATIC, (TIA), WinCC are SINAMICS,trademarks registered SITRAIN, STEP, of Siemens TOTALLYAG. INTEGRATED If trademarks, AUTOMATION technical (TIA), solutions WinCC or similar sind eingetragene products areMarken not listed, derthis Siemens does not AG. imply Wennthat Markenzeichen, they are not Handelsnamen, registered. All other technische products Lösungen and system odernames may be dergleichen of trademarks nicht their besonders respectiveerwähnt ownerssind, and must bedeutet be treated dies nicht, accordingly. dass sie keinen Schutz genießen.
