Component Based Automation. Flexibility in automation ... - Siemens

Communication between machines:Configuring instead of programmingThe commissioning time needed for a machine in a productionline is determined to a very large degree by the programmingof communication links to other plant sections. Suchprogramming costs time, can be very expensive, particularlyin the case of machines with different automation systems,and can often not be precisely planned. Since itis necessary to intervene in the user program, the operatoris normally unable to grant final acceptance untilthe machine is networked. Subsequent problems result infurther delays.Component Based Automation encapsulates the userprogram, completely separating the programming of amachine from the configuring of the communication linksto achieve a significant reduction in the commissioningtime.The advantages at a glance:• Thanks to the encapsulation of the user program, theprogram need no longer be modified when the communicationlinks are configured.• The machine can be accepted prior to commissioningof the plant. Improvements can be made by the machinebuilder – without the time pressure of commissioning.• Simple graphical configuration of the communicationlinks replaces time-consuming expensive programming,and significantly reduces commissioning overheads forthe plant operator.• The creation and re-use of standardized componentssaves time and increases quality thanks to systematicmaintenance of re-usable software functions.• Improved diagnostic functionality enables unambiguouserror allocation during operation.5

SIMATIC iMap V3.0:Easy to use with numerous functionsFor Component Based Automation and configuration ofmachine-machine communication, the current Version V3.0of SIMATIC iMap incorporates a series of new functions. Forexample, the new “Plan View” of a plant enables transparentnavigation in large-scale projects and a simple method ofstructuring thanks to plan-in-plan displays. This makes itvery easy to copy whole parts of a plant, thus considerablyaccelerating the entire process of engineering.A real highlight of SIMATIC iMap V3.0 comes in the formof several technological functions which can be mappedon a device – at the present time, on devices based on theCPU 319-3 PN/DP as well as modules with PROFINET CBARuntime V2.2. This enables finer granularity and thus bettertechnological structuring of the application in question. Inrespect of flexibility of use, the current version of the triedand-testedengineering tool has been optimized as well inthat users can now activate and deactivate individual functions.It is therefore possible to check the functions of a componentin individual steps and start up the component in a flexiblemanner. Other advantages are created by the various languagesin which the new version is available: not only English andGerman but also Italian, French and Spanish as well.Plant viewNetwork view9

Advantages at a glance• Several technological functions in one device – basedon the CPU 319-3 PN/DP as well as modules withPROFINET CBA Runtime V2.2• Simpler structuring through plan-in-plan display• Shorter engineering time through copying of whole plantsections• Faster program downloads through download via list• Simple diagnostics through marking of critical signals• Improved general overview as connections can be displayedor concealed as required• Only altered data are loaded into the CPU in order to retainprocess data that has already been acquired• Simplified loading of several CPUs – without pop-up dialogs• Improved project documentation in HTML format• Optimized printing function for project data, includingcross-references• Command interface for higher-level CAD tool landscapeProject view10

Graphical interconnection of PROFINET components:Significantly reduce overhead with SIMATIC iMapIn SIMATIC iMap, communication links between intelligentmodules are configured by graphically interconnecting themodules’ technological interfaces. This is done by simplydrawing lines between the technological interfaces.The user works only with technological terms such as”Enable to next station“, “Start”, “Stop”, “Manual Operation”,“Buffer Overflow”, and so on.The technological terms are established by the plant ormachine builder when he defines the component interfacein STEP 7.Communication between the components is also put intooperation and tested with SIMATIC iMap using online functionsand diagnostic options integrated specifically for thispurpose.Following the download, the communication link is establishedand the relevant devices exchange data.The lack of a need for intervention in the user programsof the individual machines during plant commissioningtotally precludes undesired interaction with the pre-testedfunctions.Online diagnosticsAt the interfaces of the relevant software functions, thestatus of the selected signals can be displayed and controlledthrough well-directed test values. The diagnostic windowshows the status of the devices. In the event of an error,the configuring engineer, using the detailed informationdisplayed (e.g. ”Device not available, check physical connection“),can quickly localize and eliminate possible communicationproblems. Following error recovery, specific iconssignal that data interchange between the devices is onceagain problem-free.Characteristic features of SIMATIC iMap:• Builds on the open and component-basedarchitecture of PROFINET.• Each machine/plant module is represented inthe configuration editor by a “PROFINETcomponent”. This component, in turn, is representedin the form of a software function and an associatedintelligent device.• Interconnects technology-oriented library elementsindependent of their origin and functionality.• Online functions and diagnostic options for thecommunication functions simplify commissioning.• PROFINET components can be designed for moremultiple usage in SIMATIC iMap (re-use of libraryelements) or as so-called singletons for one-timeuse only. The central modifiability of multiple-usecomponents saves on engineering overheads.• Sub-configurations allow the machine/plant to behierarchically structured to virtually any depth.• All variables required for general data access,such as visualization, access at the MES level etc.(OPC tag file), are automatically generated fromthe engineering information.For SIMATIC devices it is possible to execute expandeddiagnostics which go significantly beyond the standarddefined by PROFINET. It is then also possible to navigate inSTEP 7 itself. The diagnostic options in STEP 7 can be usedto their full extent.11

Distributed intelligence: Flexible use is paramountIn many production plants, distributed automation solutionsare already reality. Component Based Automationsimplifies the configuration of the communication betweenintelligent modules linked to one another and over PROFINET.These modules can be components in a production line orrepresent individual machines and – in addition to thecontroller – may contain lower-order field bus systems aswell as intelligent I/Os on the PROFIBUS.Data interchange between modules on the PROFINET andthose on the PROFIBUS is subject to virtually no restrictions.PROFINET devices on the Ethernet can communicatewith one another as well as with intelligent slaves on thePROFIBUS. The visualization of PROFINET components ispossible via the SIMATIC NET PN OPC server. Variables ofPROFINET devices connected to the PROFINET via a proxyrather than directly may also be accessed.12

Integration of distributed I/Os withComponent Based AutomationIntelligent I/O devices are attaining increased significance.Component Based Automation provides different optionsfor integrating these devices. The configuration below,from left to right, shows the following examples:• As standard slave within a PROFINET component,integrated in the program for the PROFINET device. Inthis case, the PROFINET devices are not displayed inSIMATIC iMap. They are part of the master’s component.• As PROFINET I/O device assigned to a PROFINET I/Ocontroller. I/O devices are part of the component of thePN I/O controller, and are not displayed as independentcomponents in SIMATIC iMap.• Interfaced as PROFINET component via a PROFINET proxy.The proxy is a PROFINET node on the Ethernet and –at the same time – the DP master for the devices on thePROFIBUS. Intelligent PROFIBUS devices or standard slavesinterfaced via a proxy are displayed as independentcomponents in SIMATIC iMap.Combination of central and distributed intelligencewith Component Based AutomationPlant sections with centralized intelligence and those withdistributed intelligence do not influence one another, butrather complement each other optimally with ComponentBased Automation.The entire PROFIBUS segment of a centrally structured plantsection, including the master, forms a single PROFINETcomponent (a so-called “singleton”). The PROFIBUS mastermust be expanded to include an Ethernet interface modulewhich complies with the PROFINET Standard.S7-300 S7-300EngineeringHMI...EngineeringSIMATIC iMapSTEP 7VisualizationOPC serverDistributed intelligenceET 200M Field device MicromasterPlant section with centralized intelligenceS7-300 ProxyPN I/O-controller PN I/O-devicePlant sections with centralized intelligence can be integrated without modificationin Component Based Automation. They are configured as a singlePROFINET component with SIMATIC iMap.ET 200Mstandard slaveET 200MET 200SMicromasterFor every task a suitable solution: Component Based Automation supportsdistributed intelligence on PROFINET and PROFIBUS.13

Products for Component Based AutomationConfiguration editorSIMATIC iMapSIMATIC iMap is a component-based engineering tool for configuring communicationlinks in distributed automation solutions. It is used for the simple graphical configurationof the communication links between plant modules and the communication linksbetween machines in a production line. It significantly reduces the user’s engineeringoverheads.Visualization via OPCPN CBA OPC serverThe PN CBA OPC server provides the PC application interface for communication betweenthe visualization system and the PROFINET components over Industrial Ethernet.Devices for PROFINET with proxy functionSIMATIC WinAC software PLCWith the PROFINET option, the SIMATIC WinAC base can be used as a PROFINET componentfor Component Based Automation. The WinAC base thus supports data interchangewith other PROFINET components over Industrial Ethernet.IE/PB LinkThe IE/PB Link makes it possible to interface PROFIBUS devices to Industrial Ethernet,thus making it possible for these devices to be configured as PROFINET components.SIMATIC S7-300The SIMATIC S7-300 is available with CPU 319-3 PN/DP and CPU 317-2 PN/DP for the upperperformance range and CPU 315-2 PN/DP for the medium performance range with integratedPROFINET interface. These CPUs have a combination PROFIBUS DP/MPI interface and anIndustrial Ethernet/PROFINET interface. The central processing units can also be operatedas an I/O controller for field devices on the PROFINET.14

Devices for PROFINET without proxy functionSIMATIC NET CP 343-1 and SIMATIC NET CP 443-1 AdvancedCommunications processors are available for interfacing SIMATIC S7 to the PROFINET. TheSIMATIC NET CP 343-1 is the communications module for Industrial Ethernet used to integratethe SIMATIC S7-300 in a Component Based Automation application or to directly operatefield devices on the PROFINET as an I/O controller. The SIMATIC NET CP 443-1 Advancedmakes it possible to integrate SIMATIC S7-400 controllers in PROFINET applications.Intelligent slaves for PROFIBUSSIMATIC ET 200S with IM 151-7 CPUThe IM 151-7 CPU of the ET 200S can serve both as stand-alone and for distributed automationsolutions with medium-sized programs. It is equivalent to a CPU 314, and enablesdistributed local preprocessing of production data in both standard and fail-safe versions.It communicates with the higher-order controller over the MPI/PROFIBUS DP slave interface.SIMATIC S7-300All SIMATIC S7-300 CPUs which can be operated as slaves on the PROFIBUS.Standard slaves for PROFIBUSAll standard slaves with a GSD file which comply with the PROFIBUS DP standard.Depending on the application, PROFIBUS DP standard slaves with a GSD file can either bedisplayed as own PROFINET component in the configuration editor (e.g. POSMO A, SIMOCODE)or be assigned to the PROFIBUS master (e.g. ET 200M; are treated like central I/Os).All converters and motor starters which are standard slaves on PROFIBUS DP and have a GSDfile or are integrated in the ET 200 I/O system.15

Component Based Automation at workUnilever increases the productivity of bottling andpackaging linesFast-changing production lines in the consumer goods industryplace high demands on packaging plants, which mustbe capable of being adapted quickly and economically todifferent shapes, sizes and materials. In order to ensurethis, one of the world’s biggest manufacturers of consumergoods depends on Component Based Automation. CBA makesit possible to encapsulate the software functionality of apackaging machine in standardized components. Equippingthese components with a standard interface simplifiesinformation interchange between machines within thecompany network. The SIMATIC iMap editor for graphicalconfiguration simplifies the integration of different plantsections – even when they come from different manufacturers.Cava Girardini chooses flexibilityIn the gravel production industry, it must be possible toquickly and economically expand, modify or convert haulingsystems in order to adapt them to changes in operatingconditions, if possible without impairing production. That iswhy Italian gravel producer Cava Girardini – specializing inthe extraction of high-quality building materials – choseComponent Based Automation. With its intelligent modules,the recently built hauling system near Vincenza proves whata smart choice it was: 20 % fewer trips to empty the silos,a 35 % increase in production, and a reduction in workingas well as in downtime. And thanks to a modular structure,individual plant sections can be implemented without havingto interrupt the ongoing process.16

Corus HTD implements camera monitoring of extensivepremises in real timeThe Corus Group is an international corporation which madea name for itself with innovative steel and aluminum products.The factory grounds in IJmuiden in Northern Holland,an area which encompasses 750 hectares, lies directly onthe North Sea and has its own harbour. The challenge ofmonitoring all incoming and outgoing traffic is thereforeenormous. In order to network the different componentsof the new monitoring system – such as mobile video cameras,barriers and pillar-mounted phones – with the controlcenter, the Corus works security service chose PROFINET.The possibility of real-time communication – even whenlarge volumes of data such as those produced by modernvideo cameras are involved – makes PROFINET so attractive.The advantages of Component Based Automation becomeparticularly apparent when it is necessary to integrateadditional camera systems or modify the software. To integrateadditional cameras, the software of an existing componentis simply copied. If upgrades are required, theycan be done centrally and transferred over PROFINET to allcamera systems.Electrolux shortens its time-to-marketElectrolux, the well-known Italian washing machine manufacturer,is utilizing the advantages of Component BasedAutomation with PROFINET in its most modern coating plant.Electrolux utilizes the maximum flexibility resulting fromits use of CBA to produce washing machines in differentcolors – colors which suit the latest market demands. Themodular plant consistently depends on distributed intelligence.The entire coating plant consists of stand-alone units,each of which is assigned to a SIMATIC S7-300. Data transferbetween the intelligent modules was logically definedwith SIMATIC iMap using simple graphical circuit diagrams.Thanks to Component Based Automation based on PROFINET,the Italian company is able to respond flexibly to the internationalmarket. In addition, Electrolux profits from thefact that it was possible to reduce configuring costs to aminimum thanks to simple integration of the different units.17

Additional information is available on the Internetat the click of a mouse:Everything you want to know about PROFINET, the open Industrial Ethernet standard:www.siemens.com/profinetMore information on Component Based Automation:www.siemens.com/cbaYou will find SIMATIC Manuals in the SIMATIC Technical Documentation Guide:www.siemens.com/simatic-docuOrder other publications about SIMATIC at:www.siemens.com/simatic/printmaterialFor a personal meeting, you will find contacts in your area at:www.siemens.com/automation/partnersVia the A&D Mall you can order electronically over the Internet:www.siemens.com/automation/mallInformation on our current line of educational and vocational training products:www.siemens.com/sitrainSubject to change without prior notice 11/05 | Order No. E20001-A130-M110-X-7600 | Dispo 06334 | 41C9342 ML016DS.52602 WS 11053. | Printed in Germany | © Siemens AG 2005Siemens AGAutomation and Driveswww.siemens.com/automationThe information provided in this brochure contains merely generaldescriptions or characteristics of performance which in case of actualuse do not always apply as described or which may change as a resultof further development of the products. An obligation to provide therespective characteristics shall only exist if expressly agreed in the termsof contract.All product designations may be trademarks or product names ofSiemens AG or supplier companies whose use by third parties for theirown purposes could violate the rights of the owners.