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advanceThe Magazine for Totally Integrated AutomationVolume 11, Number 3, 2012Wireless inIndustryRequirements forWireless Technologyin Modern ProductionAutomation TechnologyFail-Safe at GreatHeightsF-CPUs ensure fire protectionin an office skyscraper inFrankfurtDrive TechnologyPrecisely Oiled, HigherProcess QualityEven oil application throughservo control with SinamicsIndustrial Switching TechnologyIndustrial Solution forBiogasMotor feeders with IO-Linkensure higher availability

ContentsFocusIn BriefNews 4FocusGaining Ground: WirelessCommunication in Industry 6Requirements for wireless technology inmodern production linesAutomation TechnologyEfficient Energy Production 16Control of CHP unitswith Simatic S7-300Availability is the Key 18Cooling plants of converter stationsbenefit from highly available SimaticcontrollersFail-Safe at Great Heights 22F-CPUs ensure fire protection in anoffice skyscraper in FrankfurtMarkus Weinländer (left) and Karl Glas discussthe importance of wireless technology forIndustry 4.0Cranes on the Team 10Fast and secure communication withwarehouse cranes through wirelesscommunicationAnnette KradischSafety TechnologyUltimate Safetyin Material Handling 25A Swedish manufacturer of roll handlingsystems uses Safety IntegratedSafety en Bloc 26Modular safety system meets the lateststandardsSmart Solutions for theAutomotive Industry 12For the first time, Daimler controlsvehicle production with RFID smart labelsMagic Gates 15Convenient access control thanks to RFIDIMPRINT: advance 3-2012Published by: Siemens Aktiengesellschaft,Gleiwitzer Str. 555, 90475 NurembergDivision Drive TechnologiesCEO Ralf-Michael FrankeDivision Industry AutomationCEO Anton S. HuberEditorial Responsibility in Accordance withthe German Press Law: Arno HoierResponsible 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 LeifelsPublisher: Publicis Publishing,P.O. Box 32 40, 91050 ErlangenTel.: 0 91 31/91 92-5 01Fax: 0 91 31/91 92-5 94magazines@publicis.deEditorial staff: Dr. Beate Bellinghausen (ChR),Gabriele StadlbauerLayout: Nadine SöllnerDTP: Mario WillmsFinal editing: Susanne Wanke, Verena DebnarJob number 002800 42344Printed by: Wünsch, NeumarktCirculation: 12,100© 2012 by Siemens AktiengesellschaftMunich und Berlin. All rights reserved.This issue was printed on paper manufacturedfrom chlorine-free bleached cellulose.ISSN 1611 101X (Print)The following products are registeredtrademarks of Siemens AG:ET 200, MASTERDRIVES, MP170, MP270,PROFIsafe, S7-400, S7-1200, SCALANCE,SIDOPOR, SIMATIC, SIMATIC B.Data, SIMATICHMI, SIMATIC IPC, SIMATIC Multi Panel,SIMATIC NET, SIMATIC PCS 7, SIMATICSafety Integrated, SIMOCODE, SIMOGEAR,SIMOTICS, SIMOTION, SINAMICS, SIPLUS, SIRIUS,SITOP, SITRAIN, Solutions for PowertrainTRANSLINE, STEP, TIA (TOTALLY INTEGRATEDAUTOMATION), TIA Portal, WinCCIf there is no special mention of trademarks,trade names, technical solutions, or similar items,this does not mean that these items are notprotected.The information in this magazine contains onlygeneral descriptions and performance featureswhich do not always apply in the described formin the actual application or which may be subjectto change in the course of further developmentof the product. The specific performancefeatures are only binding if they were agreedexpressly in the contract.IWI: TADVOrder number: E20001-M2312-B100-X-7600Cover photo: W. Geyer

Wireless technologyis used to control thecranes in a steelwarehouseSiemens AG10Drive TechnologyCleaning CottonMore Economically 28The switch to IE2 motors saves powerPrecisely Oiled, HigherProcess Quality 30Even oil application through servocontrol with SinamicsIndustrial CommunicationEfficient Network ControlCenter 36IWLAN controllers allow for centralnetwork managementWireless Technology PreservesLong Beer Tradition 38A Czech beer manufacturer modernizesits barrel filling plant with ProfinetIndustrial IdentificationSelf-Organizing Production 40RFID plays a key role in theIndustry 4.0 conceptThe servo-controlled metering pumpof the Duma oiling machinesModernization Conceptfor Gold Mill 32Modern drive technology in anAustralian gold mine increasesoperating safetyMarschnerIndustrial Switching TechnologyIndustrial Solutionfor Biogas 42Motor feeders with IO-Link ensurehigher availabilityHot Plates 44Precision in thermoforming: The SiplusHCS716I heating control systemStrong on Steep Tracks 34A new drive unit for bucket conveyors isoptimized for extreme conditionsMore Productive Grinding 35New Flender drives improve results inthe cement industryServicesCertification forAutomation Technicians 45Qualified further training withthe Sitrain Certification ProgramDialogueVideo CAD / CAE Data /Siemens Industry Blog /Online Support App 46Library / Events / Dialogue 47advance | 3-2012 3

The winning team (from left to right): Luis Galarza, Christian Dirscherl,Vincent Matthews (all Siemens), Carly Lovejoy of Mining Magazine,and Peter Sehl and Steve Kasper of ThyssenKrupp RobinsIn Brief+ Award forHomag Holzbearbeitungssysteme GmbHIndustrial PCs Chosen aMillion TimesThe industrial PC (IPC) used at Homag HolzbearbeitungssystemeGmbH is the one millionth IPC produced by Siemens.To mark this milestone, Frank Minkwitz, head of customizedautomation at Siemens, presented Winfried Hils, head of researchand development system technology at Homag, withan award at this year’s Hannover Messe.Homag Holzbearbeitungssysteme GmbH is a globally leadingmanufacturer of machines and plants for the woodworkingindustry. The company offersa wide variety of solutionsfor the manufactureof furniture and buildingcomponents and the constructionof wooden houses– from single machinesall the way to complex productionlines.The IPC was manufacturedin the Siemens electronicsplant in Karlsruhe,Germany. It is a customerspecificSimatic Box PC. Forits Simatic PCs, Siemensplaces special importanceon high quality, long-termavailability, compatibility,innovative technology, andindustrial suitability. Thecompact IPCs are multipurpose, sturdy, reliable, and scalablein output. They are also characterized by small space requirementsas well as flexible assembly Hils of Homag is pleasedwith the awardSiemens AG+ Mining Magazine award 2012Successful Collaborationwith ThyssenKruppEvery year, Mining Magazine presents awards to the miningindustry. The awards are given in 12 categories, includingmachines, environmental campaigns, and innovations. This year,the joint project of ThyssenKrupp and Siemens was honored with aMining Magazine award. The two companies together developed agearless conveyor system and for this received the award in thebulk handling category.“Mining Magazine’s award shows that we can offer the miningindustry innovative drive solutions and that the market perceivesthem that way too,” explains project manager ChristianDirscherl. He adds: “The award also proves that the collaborationwith ThyssenKrupp on gearless conveyor systems is a success.”The conveyor system is expected to be put into operation in thePeruvian Antapaccay mine of the Xstrata mining company in the thirdquarter of 2012. In the meantime, worldwide demand for gearlessconveyor systems has been growing strongly. In addition to Antapaccay,Siemens was also able to win two other projects in South America.For these, Siemens delivers the required drive systems of 4 x4,400 kW and 5 x 5,000 kW, respectively.The conveyor system in thePeruvian Antapaccay mineThyssenKrupp Robins Mining Magazine4 advance | 3-2012

Siemens AGThe Energy EfficiencyTruck is on duty inmany cities – here inNuremberg+ Energy Efficiency Roadshow 2012Energy Efficiency Roadshow Gives New ImpulsesSiemens addresses public utility providers as well as industry withits Energy Efficiency Roadshow. Different applications vividlydemonstrate how the demand for increased productivity may beharmonized with ecologically sustainable production using energyefficientcomponents and state-of-the-art energy management.The Energy Efficiency Roadshow mainly focuses on the energy efficiencyportfolio for industry by Siemens. Numerous exhibits andtechnical live demonstrations were installed inside a 55 square metershowroom. In combination with a large-format beamer showthis forms a presentation that has already fascinated many visitorson the show truck’s route. Be it the continuous engine platform SI-MOTICS 1LE1, regenerative SINAMICS converter, innovative SIRIUSswitching devices, PROFIenergy or energy management for buildinginfrastructure and for SIMATIC automated production, the comprehensivepresentation in the truck is convincing and gives importantnew iF product design award 2012Design Award for ComfortPanels and Panel PCsThe high-end operator device of the Simatic HMI Comfort lineand the new Simatic Panel PCs have been honored with theiF product design award this year. The new controllers in thisseries of control panels for controlling manufacturing processescan be installed either in the control cabinet or in the machine.They are available as both touchpad and keypad versions, withscreen sizes from 4” to 22”.The goal of the new development was to update the alreadyintroduced HMI design and offer a greater visualization surface.In this process, familiar design concepts were retained but expressedin a more modern style: Since keypads will become lessimportant in the future, they were designed to be less obvious onthe new panels. They are now reduced to an absolute minimum,and the key assignment now visually complements the keypad.Moreover, sophisticated and elegant aluminum frames emphasizethe modern design and the mechanical stability. A special colorarrangement supports the impression of the display’s size.Thanks to their elegant look andfunctional design, the new ComfortPanels and Panel PCs received thecoveted iF m/siman pcSiemens sAGadvance | 3-2012 5

FocusGaining Ground: WirelessCommunication in IndustrySiemens AGBIA-Galvanik’s electroplating plant. Here too,wireless technology is being used successfullyDuring Hannover noveMesse, e, the German Industry 4.0 initiative stepped into thelimelight lighfor the first time, and quite impressively. The term Industry 4.0describes the ideaof production on based on cyber-physical systems – productionthatcontrols itself, so to speak. This approach is of great importance in particularfor customized mass production. Among thekey technology requirements arereliable identification and powerful connectivity. ctiv We spoke with Siemens expertsMarkus Weinländer and Karl Glas about the role wireless technology plays in thisconcept.6 advance | 3-2012

Focuscontrol,even full HD video data can betransmitted, which in turn can be used notonly for monitoring but also for processcontrol.What does Siemens already offer withregard to the new standard?Karl Glas: Today we already offer a comprehensiveportfolio of access points andclients based on IEEE 802.11n with a bandwidthof up to 450 Mbit/s, both as standaloneversions and as controller-basedversions. Such a WLAN controller – for example,of the Scalance WLC 711 type – canalso take on the central administration ofthe wireless network, which becomes anadvantage when more than a certainnumber of access points are used. Anotherbenefit of the WLAN controller is the optionto also use it for making telephonecalls through a computer network (VoIP).This simplifies the telephony of the officenetwork, integrating it wirelessly into thatof the industrial plant.In addition to the active componentssuch as access points and client modules,we have also expanded our portfolio ofpassive components. Examples are MIMOantennas for the parallel transmission ofup to three data streams as well as the correspondingcabling.Real-time communication and securityare indispensable in automation technology.How can both be guaranteedfor wireless connections?Karl Glas: A wireless network is alsocalled a shared medium, meaning that allusers have to share the transmission link“ Even in critical environments,reliable, strong, and real-timewireless connections can be set upand maintained.”Karl Glas, Head of Product Management, Industrial Network Componentsusing the medium air. The wireless systemsthemselves make sure that the availablebandwidth is dynamically distributedamong the users. In a WLAN system basedon IEEE 802.11, every user is given equalaccess to the entire bandwidth for a certainperiod of time – according to themotto “first come, first transmit.” All otherusers then have to wait. Even if the bandwidthis broad enough and the processfast enough, real-time communication isnot necessarily guaranteed with this typeof system, since the order of the datatransmission is not foreseeable or cannotbe predetermined without additionalmeasures. The patented iPCF (industrialPoint Coordination Function) protocol ofthe Scalance W access points and clientsensures that every user is addressed inevery cycle, thus guaranteeing real-timecommunication. In addition, safety communicationcan also be realized acrosscells using this method.What role do the UMTS (UniversalMobile Telecommunications System)and LTE (Long Term Evolution) mobilecommunication standards play inindustry today?Karl Glas: Global connectivity is playing adecisive role in more and more industrialenterprises. It is no longer possible toimagine the industrial environment withoutweb-based collaboration, servicessuch as maintenance and troubleshooting,or simple texts sent from a mobile phone.UMTS, the third-generation cell network,is the global standard today, even thoughprice-sensitive applications still use GPRS/EDGE-based solutions. As a fourth-generationcell network, LTE now offers a bandwidthof up to 50 Mbit/s, creating a basis8 advance | 3-2012

“ Nothing stands in the way of theextensive use of UHF-RFID as anintegrated identification solution forall steps of the value chain now.”Markus Weinländer, Head of Product Management, Simatic IdentUHF smart labels, with which we are ableto control this problem very well. Becauseof this, UHF-RFID is now suitable for industry.One example is the use of the SimaticRF600 RFID system in the Mercedes factoriesin Rastatt, Germany, and Kecskemét,Hungary. Here, one-way transponders accompanythe car body from the unfinishedstate to final assembly. With an averagereading rate of 99.99 percent, the systemsuccessfully meets all the client’s requirementsfor reliability and practical application.Even if it took a while, UHF is taking industrialidentification by storm and is evenabsolutely compatible with WLAN, sincethe frequencies don’t overlap.for the integration of additional servicesinto the wireless network.Coming back to Industry 4.0: The trendtoward the individualization of massproduction for the first time grants akey role to the product being created.What role does UHF technology, whichalready exists today and is establishedin industry, play in such a development?Markus Weinländer: The relatively greatrange (approximately 5 to 8 meters), combinedwith low transponder costs, makesUHF-RFID appealing as an integrated identificationsystem in production and logistics.However, the advantage of thegreater range is at the same time also adisadvantage. There are large quantitiesof metal and liquids in the production environmentitself and thus quite a lot of interferencedue to reflection. However, bynow we can say that the UHF-RFID systemsin production are stable at rangesbetween 1 and 2 meters.UHF was developed for industry, with thegoal of capturing as many parts as possiblein what is called bulk reading. The bulkreading ability is an advantage in assemblylines with low manufacturing depth if allsuppliers equip their parts with transponders.However, the system then also has tobe able to select. This means it must beclear during the bulk reading whether, forexample, the airbag or the car body is thetarget. This is not entirely trivial, since thereflections caused by the radio waves maycause relevant transponders to not be detectedwhile transponders that are not relevantare detected.In the meantime, we have developed anew generation of UHF readers as well asGentlemen, thank you very much forspeaking with us.IT security noteSuitable protective measures (including IT security,e.g., network segmentation) must be taken toensure secure operation of the plant. Furtherinformation on industrial security can be found ON THIS TOPIC:+ | 3-2012 9

FocusCranes on the TeamIn order to load and unload more than 6,000 deliveries every month,warehouse technology must combine speed with safety and smoothcommunication. For this purpose, Becker Stahl uses two overheadtraveling cranes that communicate directly with the warehousemanagement system and the safety system through wirelesscommunication.Becker Stahl-Service GmbH, basedin Bönen, Germany, and part ofthe Klöckner Group, produces morethan a million tons of hot-rolled andcold-rolled sheet steel each year with awide variety of surface finishes. Partof the company’s added value includescustomization of the sheets by splittingthem and cutting them to size. In orderto optimize the material flow and combinelocations, Becker Stahl has now builta new warehouse and processing centercovering the entire process chainfrom goods receipt to finished goodsstorage.Outdoor access points:Scalance W pointsenable uninterrupteddata trafficInnovation in warehouse technologyThe goods receipt warehouse consists ofthe loading area, a handover area, and interimstorage for the delivered coils. Twoautomatically controlled overhead travelingcranes handle the material transport.One of the cranes can also be operatedmanually. Both are directly integrated intothe warehouse management system andthe machine control system. In collaborationwith Demag Cranes & Componentsand Siemens, an innovative crane systemwith magnetic pickup – a technology thatallows gentle loading processes and morecompact packing of the coils – was created.To ensure smooth operation, reliablecommunication between the control ofthe crane and the warehouse managementsystem had to be established andcomprehensive safety guidelines neededto be fulfilled. In addition, it was importantto make sure that the cranes couldnot collide with each other.Automatic loading and unloadingUsing one of the cranes, the coils are unloadedmanually from the deliveringtrucks and placed in the handover area.Requirementsfor wireless safety+ iPCF protocol as arequirement for realtimecommunication andthe transmission ofsafety signals+ Profinet with Profisafe+ 5 GHz transmission rateto minimize interferenceAll photos: Siemens AG+ Signal strength of atleast 60 percent as arequirement for iPCF(This can be achievedwith IWLAN and specialantenna solutions suchas RCoax.)10 advance | 3-2012

Based on the automatically measured coilweight, among other things, the warehousemanagement system determinesthe optimal storage location among the6,000 positions. The fully automatedcrane then takes each coil and places it inthe designated location. In this process,the crane control communicates with anumber of safety systems. In order for thecutting and splitting machines to be continuouslysupplied with coils, the automatedcrane places the coils on a rotarytable with four positions. This table servesas a material buffer for a smooth processflow; warehouse management and processcontrol must be closely interlinked tomake this possible.Secure mobility through RCoaxThe close integration of the cranes intothe process control requires reliable wirelessdata communication. Industrial WirelessLAN (IWLAN) is perfect for this. Sincethe high quantity of metal components ina warehouse for steel coils can lead to interferenceand masking, Demag’s projectmanager, Rolf Dechange, decided on asolution with RCoax cables as radiating cables:“With RCoax, we have a stable connectionthat so far has operated without asingle shutdown.” The RCoax radiatingcable runs next to the two rails for theoverhead traveling cranes and is thereforealways near the antenna of the crane. Thisensures a secure IWLAN connection betweenthe process control system and thecrane control through the Profinet IndustrialEthernet standard and the transmissionof safety-relevant data throughProfisafe. With RCoax, all the requirementsof the Machinery Directive can befulfilled and the highest safety standardsrealized, combined with high plant availability.Fast, strong, and fail-safeThe 5 GHz RCoax cabling has been dividedinto three segments, each of whichis connected to a Scalance W786-1RRaccess point. Across from these pointsare two Scalance W747-1RR IWLANclients, located on the two cranes. Theyare designed with roaming capabilities,thus allowing uninterrupted data floweven at the transition point between thesegments. With IP65-type protection, alldevices are perfectly suited for use in therough operating conditions of the steelprocessing industry.The entire crane control system operateswith Safety Integrated and transmits allsafety-relevant signals using Profibus andProfinet. The Profinet and Profibus interfacesenabling the communication betweenthe two standards provide for fastand fail-safe communication throughoutthe entire transmission chain. The managingengineer at Becker Stahl, Michael Pöttger,says, “After the consistently positiveexperiences we’ve had with the system sofar, it is certain that the future at BeckerStahl will be shaped together with DemagCranes & Components and Siemens.” +IT security noteSuitable protective measures (including IT security,e.g., network segmentation) must be taken toensure secure operation of the plant. Furtherinformation on industrial security can be found ON THIS TOPIC:+ cranes in thesteel warehouse canbe controlled safelyusing wirelesscommunicationCONTACT:+ Contact person:Christof Kreienmeier,Senior Promotor, IndustrialCommunication+ E-mail:christof.kreienmeier@siemens.comadvance | 3-2012 11

FocusSmart Solutions forthe AutomotiveIndustryAs one of the leading German car manufacturers, Daimler alreadyrelies on a completely new technology in two of its factories. Forthe first time, vehicle production is now being controlled with radiofrequencyidentification (RFID) smart labels. The advantages of thenew RFID system thoroughly impressed those in charge.12 advance | 3-2012

The advantages of the Simatic RF600 system at a glance+ Reliable and robust operation even in challenging radiotransmissionenvironments+ Flexibility and variability through compact design and remoteantennas+ Sturdy components suitable for industry+ Secure selective individual reading and optional bulk reading+ High reading speed+ Flexible system integration via Profibus, Profinet, or IndustrialEthernet+ Standardized system environment across the entire process chain+ Possibility of direct identification on the product+ Simple and direct Simatic integrationAll photos: W. GeyerThe Mercedes-Benz factory in Rastatt,Germany, produces vehicles forthe global market – including awhole range of variations of the newB-Class and future A-Class cars. Customerscan order these models according totheir individual wishes using a configurator.In order to be able to carry out theproduction of these vehicles efficientlyand flexibly, Daimler has been relying onRFID for many years.Modern technology monitors allproduction stepsFor this purpose, RFID readers were installedwherever information on the vehicleis required during production. Theseread the wireless transponders attachedto the car body, which carry all the data requiredfor the manufacture of the vehicle.This makes it possible, for example, tohave cars with a wide variety of equipmentor color variations go through thedifferent production steps one right afterthe other.Previously, reusable data carriers wereused to store the information, but now theRastatt factory is relying on expendableRFID tags from the Simatic RF600 productline. These wireless tags have been designedas disposable transponders. Theyare installed in the wheel case of the futurevehicle and go with the car bodythrough all the production steps – fromthe unfinished state to enameling to finalassembly.This is the first time that a German carmanufacturer has decided to use UHF-RFIDtechnology that was originally developed forcontrolling logistics processes. However, it isnot only the Mercedes-Benz factory in Rastattthat relies on the modern technology;the new Daimler factory in Kecskemét, Hungary,also decided to use the Simatic RF600system. All the technology is based on theuse of radio frequencies of around 865 megahertz.New, low-cost transponders with awide range make this possible.Further development andimprovement of smart labelsWorking together with Daimler, Siemenswas able to improve the technology sothat it now meets even the special requirementsof industrial production, such asthe ability to withstand high ambient temperatures.Innovative, heat-resistant labelswere developed that must pass a specialtesting process during production.These transponders survive both theenameling and the drying processes withtemperatures of up to 220°C and cantherefore remain on the vehicle throughoutthe entire production process.Another advance was the control of therather unfavorable wireless-communicationconditions in the factory. Throughnew algorithms based on intelligent variationof the transmission power and evaluationof the read results using statisticalprocesses, reliable RFID recognition is possibleeven in difficult locations. For example,even in clean rooms that are completelylined with metal a high degree ofread security can be achieved this way –in spite of overshooting and reflections.The RFID readers are furthermore able toautomatically adapt to changing conditionswithin certain limits – but withoutvoiding the compatibility of the SimaticRF600 components with the EPCglobaland ISO 18000-6C standards.Use of two different types of RFIDreadersTwo types of RFID readers are being used inthe Mercedes-Benz factory in Rastatt: theSimatic RF620R reader, which is especiallyeasy to install thanks to its integratedantenna, and the Simatic RF630R with antennaRF642A, which is suited above all forstrongly reflecting locations. The readersare connected to the existing Profinet/Profibus structure using the RF180C andASM456 standard communication modules.The RFID system is controlled by existingSimatic S7 controls and a visualizationsystem created by Daimler. More than 300RFID readers are in operation in theMercedes-Benz factory in Rastatt; 200RF600 readers were installed in the factoryin Kecskemét.For data storage, Daimler decided ondecentralized storage of the most importantdata on the RFID labels. This way,the required information is quickly available– without having to access a backgroundsystem. If required, all other data advance | 3-2012 13

FocusSpecial algorithms enable RFID operation with high availability even indemanding radio-transmission environments and in parallel with thelegacy systemEvery vehicle is controlled by a heat-resistant smart label throughall the production stepscan be called from the production controlsystems. For this purpose, every labelhas a unique ID number.Challenges overcomeDuring the introduction of the new system,Daimler was confronted with several challenges.For example, the new RFID systemhad to be installed in parallel with the oldsystem while production was running, sincethe existing vehicle generations were not tobe changed until their respective series’end. During the changeover to the new system,RFID experts, control programmers,and plant specialists from Daimler andSiemens all worked together. They madesure that production continued without ahitch. Further developments were appliedto the firmware of the RF600 readers duringthe changeover and are now also usedin other applications and industrial areas.Technology switch paid offThe new smart labels and readers fromSiemens completely fulfilled the requirementsDaimler had established regardingreliability and practical application. As aresult, it was possible to achieve an averagereading rate of 99.99 percent for thesurface. Due to its ambient conditions,this area is considered especially criticalfor RFID. However, the new technology offerseven more advantages for the factory:Unlike the previously used systemwith active transponders, there is now nolonger any need for batteries. In addition,the previously required cleaning and inhouserecirculation of the transpondersfrom final assembly to the unfinished stateis no longer necessary. The new solutionhas also proven beneficial from a coststandpoint.Daimler in Rastatt is pleased with the successresulting from the switch to SimaticRF600 and the heat-resistant smart labels.The technological objectives – replacing theprevious RFID system with a more powerfulone – have been met, and the changeoverwas realized with as few problems as possiblewhile production was running. So nowthere are no more obstacles to hinder vehicleproduction using RFID smart labels in thefactories in Rastatt and Kecskemét. +MORE ON THIS TOPIC:+ Contact person:Markus Weinländer,Head of Product Management,Simatic Ident+ E-mail:markus.weinlaender@siemens.com14 advance | 3-2012

Magic GatesFocusA different approach to accesscontrol: Thanks to radiofrequencyidentification (RFID)and a Nanobox PC, accessbadges are a thing of the past.The gate opens fully automatically,saving time for those witha parking permit and makingthings more convenient.W. GeyerThe automated pass control with RFID technology at Karlsruhe’sindustrial park has already proven its worthEverybody knows how tedious it is tohave to deal with parking badges inorder to pass through a gate leadingto a car park or the company premises: Rolldown the window, hold the badge as closeto the reader as possible, scan it – that alltakes time. If the person in front of youdoes not find his or her badge right awayor does not hold it the right distance fromthe scanner, you have to wait even longer.At the Siemens industrial park in Karlsruhe,Germany, an automated pass control systemusing RFID technology has recentlybeen implemented. Persons with an accesspermit receive file transponders (RFIDtags) for the windshields of their vehicles,which measure just a few centimeters andcontain the required access data. A longrangereader of the Simatic RF600 seriesreads each RFID tag when the vehicleapproaches, and the gate opens automatically.Savings in logisticsThe same technology has already provenits worth in a variety of logistical tasks. Forexample, an electronics wholesaler in Belgiumidentifies transport vehicles usingRFID tags and then guides them via thefastest route to the unloading bay withthe goods waiting for them. Correspondingtags on the cargo ensure that the loadsare complete before the transportersleave the premises again.A large cement plant in Turkey usesinexpensive passive RFID tags in order torecord the type and quantity of the goodsto be loaded by each customer. This optimizesthe traffic flow on the premises andincreases both plant capacity and planningsecurity.Little effort, great convenience“If the only issue is controlling access permits,direct savings may not be possible.Here, the convenience for those affectedis the main concern,” explains project managerRoland Maier of the Siemens plant inKarlsruhe. “With the Simatic Nanobox PC,we have an affordable and robust industrialPC as a data processing unit. It needsneither a hard disk nor a fan and can be installedin a simple, unheated switchboxoutside because of its expanded temperaturerange. Moreover, it is small and compactand therefore especially suited forthis application, since we were able to installit directly in the gate.” As a full industrialPC, it can be easily combined with thepowerful Simatic RF670R RFID system andseamlessly integrated into the correspondingIT environment. It also processes the96-bit-long ID numbers for the databasecomparison without any problem. Greatconvenience, comparatively low cost, andease of use – this is what a recipe for successlooks like. +MORE ON THIS TOPIC:+ Contact person:Mathias Langhans,Promoter, Simatic Ident+ E-mail:mathias.langhans@siemens.comadvance | 3-2012 15

Successful team: Thilo Schleif (left) and hisemployees in front of a recently built CHPThomas Förderer,project engineer at SchleifAutomation, is happy to haveaccess to all the componentsof the plant with the IPC277D“ We use a Simatic S7-300 as a controlsystem for our CHPs. It regulates thespeed of the combustion engine andsynchronizes the generator.”Thilo Schleif, Managing Director, Schleif AutomationThe CHP is also used as anemergency power generator inbackup power operationAll photos: W. Geyersame time. Thomas Förderer, project engineerat Schleif Automation, managesthis control cascade with the modular controlof the Simatic S7-300. This way, returntemperatures of more than 82°C can beachieved, meeting the greater hygienerequirements of hospitals, for example.Universal communication interfacePart of the standard equipment of SchleifAutomation CHP units is a panel PC functioningas a control and monitoring unit.The IPC277D is the communication interfaceto all intelligent sensors and actuators.The advantage of this central PC platformis, among other things, that devicesfrom different manufacturers can bec onfigured, diagnosed, and adjusted froma single interface – even using remotemaintenance. Schleif says, “This increasesthe ease of servicing our plants and theiravailability.” Schleif Automation purchasesthe Siemens products through theSonepar industrial competence center inKarlsruhe.Virtual power plants –a realistic visionSchleif Automation’s longer-term goal is tooperate several combined CHP units as avirtual power plant and thus be admittedto the power exchange. Trading powerresults in substantially lower purchaseprices, which can then be passed on to theoperators of the plants. A prerequisite isproof that each individual unit and thecombination as a whole feed in and extractpower. With the panel PC as a centralinformation platform, the CHP units fromSchleif Automation are ready for combinedoperation already. Ba dische Kraftwerk,a subsidiary of Schleif Automation,offers various operator models, includingcontracting, to realize this. The customerdoes not need to pay any access fees, butonly purchases the heat and electricity atan especially low price – thanks to publicfunding and the high efficiency of theplants. +MORE ON THIS TOPIC:+ www.sonepar.comCONTACT:+ Contact person:Thomas Feil,Sales Coordinator+ E-mail:feil.thomas@siemens.comadvance | 3-2012 17

AutomationTechnologyAvailability is the KeyThe importance of cooling plants in the functioning of converters for high-voltage DC(HVDC) transmission must not be underestimated. Even though the power loss of thehigh-performance electronics is minimal, the resulting heat would destroy thesemiconductor components within a very short time if the cooling were to fail even fora moment. A highly available Simatic controller ensures the reliable functioning of theappropriate cooling systems or safely switches off the electronics to protect them inthe event of an emergency.18 advance | 3-2012

Siemens is themarket leader ingrid connectionsat sea for offshorewind parksSiemens AGOffshore wind parks make an importantcontribution to the transitionto clean energy. One challenge intheir use is that the electricity they producemust be transported across long distancesto the mainland. HVDC is becomingincreasingly important as a means of minimizingpower loss during transport. Witha capacity of more than 6,000 MW alreadyinstalled or being constructed, Siemens isthe market leader when it comes to gridconnections at sea.Siemens is currently connecting the offshoreVeja Mate and Global Tech 1 windparks to the German power grid on behalfof the transmission network provider TenneTTSO, of Bayreuth. The BorWin2 converterstation transforms the electricity producedby the wind park into direct currentfor low-loss and energy-efficient transmission.The 18-meter-high station is beingconstructed on its own offshore platform.Siemens also supplies the converter stationon the shore, which transforms the directcurrent back into alternating current. TheHVDC grid connection is designed for anoutput of 800 MW. Siemens Energy producesthe power transistors (insulated gatebipolar transistors, or IGBTs) in Nuremberg(see also advance 2/2012).advance | 3-2012 19

AutomationTechnology Collaboration with specialistsAs an expert in the field of heat and flowtechnology, the German company NeundörferAnlagenbau GmbH supplies thecooling systems for the high-performanceelectronics. The company has many yearsof experience with cooling systems forshipbuilding and classical HVDC plants, forexample. The cooling system specialistagain works in close partnership with theGerman company Gesta mbH, which is responsiblefor the electrotechnical equipment,including the control technology.“Every cooling plant has to be designed differently.Offshore converter stations canbe cooled using seawater; installations onland, however, need additional fans. Thelocation also plays an important role. Inthe north, the plants have to be protectedfrom frost, but condensation can also becomea problem. In all cases, we have toensure the highest possible availability ofthe plants from the moment they areswitched on,” explains Martin Haensel,managing director at Neundörfer, outliningthe challenges for the installationsdesigned and built by his company. A plantis avail able only if the water temperatureA. Kradischand flow are within the specified close toleranceranges and if the water in the converterarea is sufficiently deionized so thatno electrical current can flow through it,which could result in short circuits, destroyingthe electronics. The company’s expertisein this area, built up over years, includesnot only the dimensioning of theheat exchangers and pipe systems but alsotechnical, economical, and ecological optimizationthrough the use of componentsand materials that are best suited for thepurpose.Multistage redundancy conceptThe following data illustrate the dimen sionsof the cooling plants of the onshore BorWin2converter station: The plant consists of twocooling circuits. The primary circuit includesthe pipe distribution system with 96 branchesinto the converter area. An impressive kilometerof highest-quality stainless steel pipesleads into the converter area. The deionizedwater, that is, water that is no longer conductive,is led in plastic pipes through the convertersthemselves. The secondary circuit isconnected through a heat exchanger, thewater of which contains antifreeze agents.“ In order to ensure theavailability of the converterstations from thebeginning, every coolingsystem has to bedesigned differently.”Martin Haensel, Managing Director, NeundörferAnlagenbau GmbHThe heat of the secondary circuit is dischargedthrough 14 large outside coolers,which can be cooled with up to 168 fans, dependingon the outside temperature.Redundant temperature sensors, flowmeters,and electric current meters ensurealmost 100 percent availability of the sensortechnology. The pumps were builtwith “two-of-three” redundancy: Thepower needed to circulate 13,000 litersper minute is distributed over two pumps.If one of them should fail, a third pump isavailable as a backup. “However, the probabilitythat a pump will fail is very small,since we continuously monitor the statusthrough an integrated vibration measurement.This increases planning security formaintenance and is another contributionto increasing the availability,” explainsHaensel.Intelligence at the control systemlevelThe Neundörfer cooling plant impresseswith its efficiency. Considering its coolingcapacity, it requires only a very low connectedload. This is very positive from aneconomic and ecological point of view –but also relevant in terms of safety. “Thechallenge for the control system is that excessivecooling, however minor, can leadto condensation and thus to short circuitsin the converter area. During operation,the inertia of the huge system is to ourben efit – the start-up is critical because wehave to be able to prevent even short-termovershoots,” explains Peter Beck, man agingdirector at Gesta. This is why the controlsystem requires not only expertise butalso great experience with cooling systemsof that size. As a longtime automationpartner of Neundörfer, Gesta has alreadyautomated many cooling plants,demonstrating its experience in this area.In the onshore BorWin2 converter station,a highly available Simatic S7-400Hcontroller monitors and controls temperature,flow, and conductivity. It has twoidentical CPUs in hot standby operation,smoothly replacing each other in case offailure. The plant is visualized using an OP277 operator panel. For documentation20 advance | 3-2012

A. Kradisch“ We have had only themost positiveexperiences with thepowerful and robustsystems from Siemensavailable worldwide.”Peter Beck, Managing Director, Gesta mbHand archiving purposes, relevant signalsare passed on to the central control roomof the converter station using a securetransmission protocol. From there it ispossible to turn off the entire plant. However,this is planned and contractuallyspec ified only for a few maintenance daysper year – and all involved are sure thatthey will reach this goal.Well equipped for future projectsHaensel and Beck are convinced that theinnovative HVDC technology will becomevery important in the future and are lookingforward to bringing their knowledgeas pioneers to bear on future projects.“The fact that we have already realizedmany demanding projects in the shipbuildingarea really helped us with theoffshore converter platform projects.These two areas have a lot in common –in terms of both the selection of suitablematerials and the fact that they have tomeet stringent stipulations, for example,by the German Lloyd,” says Haensel. “Inthis process, we’ve had nothing but positiveexperiences with the automationtechnology, drive technology, industrialcommunication, and switching technologyfrom Siemens. The systems arepowerful and robust, and are recognizedand reliably available the world over. Asusers who take advantage of all the technicalpossibilities of the systems, we alsoreally value the fact that we receive experthelp around the clock through the premiumsupport program,” adds Beck. +MORE ON THIS TOPIC:+ Contact person:Karl-Heinz Hetzner,Sales Manager+ E-mail:karl-heinz.hetzner@siemens.comSiemens AGadvance | 3-2012 21

Along with many architecturalhighlights, the safety technologyfor the fire protection measures inthe 200-meter-tall office buildingis exceptionalAutomationTechnologyFail-Safe at Great HeightsSafety systems play an important role in buildingautomation – especially with regard to fire protection.Fail-safe industrial controls now regulate the pressureaeration and smoke extraction systems in Tower 185,an office skyscraper in Frankfurt, Germany.Heinemann/westend6122 advance | 3-2012

With a height of about 200 metersand a total of 55 floors, Tower185 proudly reaches into theFrankfurt sky. “For buildings like this,safety aspects are a top priority,” explainsThomas Sturm, project manager at HermosAG, based in Mistelgau, near Bayreuth.One of the core competencies ofthis family business that operates worldwideis in exactly that area: Hermos offerssolutions for building automation.For the pressure aeration and smoke extractionsystems in the office skyscraperin Frankfurt, fail-safe control systemsfrom Siemens were used for the first time.Hermos has proven that building automationcan benefit from the experience ofindustrial applications, because industryhas already been using these controls foryears. “The standards of industrial andprocess automation are increasinglybeing taken into account in building technology,such as in this case for the smokeextraction system or fire protection andpersonal security,” explains Sturm.In the event of a fire, both the pressureaeration system and the mechanicalsmoke extraction system are activatedthrough these controls. In addition,ventilation flaps are closed so that thesmoke cannot spread. “In an office buildingof this size, a control system likethis is an invaluable advantage,” emphasizesSturm.Increased flexibility throughfail-safe controlsA fire alarm panel located on the groundfloor of Tower 185 records all data fromthe distributed control units in the building.In case of an emergency, the fire departmentcan see the individual fire zonesin the tower from there and manuallyswitch certain sectors if required. A failsafeSimatic S7-319F programmable logiccontroller (PLC) controls these processes.The communication takes place througha closed circuit based on Profinet, an IndustrialEthernet-based bus system thathas long represented the state of the artin industry. Use of the Profisafe communicationstandard allows fail-safe data exchangeboth between the different failsafePLCs and with the correspondingdistributed I/O stations, using fail-safemodules that have been installed accordingly.“Thanks to their comparatively easyinstallation and programming, fail-safecontrol systems are being used more andmore frequently in large buildings,” explainsMatthias Maisel, software projectmanager at Hermos.“ Thanks to their easy installation andprogramming, fail-safe controls arebeing used more and more frequentlyin large buildings.”Matthias Maisel (left) and Thomas Sturm,project managers at Hermos AGAbout 2 kilometers of Profinet closedcircuitcabling wind their way through theoffice building, connecting the distributedcontrol units. These units have mostlybeen realized intelligently – meaning withan integrated CPU – in order to be able tosafely process signals from the central firealarm system even without bus communication.For this purpose, the fail-safe SimaticS7-315F control system used for smoke extractionand the scalable Simatic ET 200Sdistributed I/O stations were realized withfail-safe electronic modules.Smoke extraction system ensuresclear escape routesDistributed fail-safe intelligence is used toclose the fire dampers, since the dampersgo into safe mode when they are not activated.If the central fire alarm system detectsa fire and initiates the correspondingmeasures, the situation is different, however;predefined smoke extraction measuresmust then be taken based on the firematrix.The large fans of the pressure differentialsystem in the basement are the heart of thesmoke extraction system. They are activatedby the fail-safe controls in order tobuild up predefined overpressure in thestaircases of the tower. This keeps the staircasessmoke-free in an emergency, so theycan be used as escape routes. At the sametime, the distributed control units on all thefloors activate the corresponding isolatingdampers in order to ensure the requiredpressure conditions for smoke extractionthe entire height of the tower. The smokeextraction valves for the supply air and exhaustair are allocated to about 40 smokeextraction groups. They are all connectedwith fail-safe Simatic controls. There arealso several pressure relief windows onevery floor, letting the volume flow of thepressure aeration fans escape. In addition,the overflow valves are opened so that theoverpressure can ensure smoke-free escaperoutes outside the staircases as well.Distributed I/O stations passon the signalsCommunication also takes place via theProfinet closed circuit with the Profisafeprotocol. There are 12 distributed I/O stationsof the Simatic ET 200S type in theentire building for closing the fire dampers.One such unit covers six floors. Here, Siemens AGadvance | 3-2012 23

AutomationTechnologyMain TowerVentilationET 200S PNBlock Edge WestVentilationPressureAerationVentilationVentilationAirflowET 200SPN/DP CPUBlock Edge EastVentilationET 200S PN ET 200S PN ET 200S PN ET 200S PNET 200S PNVentilationControlSmokeExtractionCPU315F-2PN/DPCPU315F-2PN/DPCPU315F-2PN/DPET 200SPN/DP CPUCPU315F-2PN/DPCentral FireAlarm SystemProfinetProfisafeCPU 319F-2PN/DPSiemens AGAutomation architecture for controlling smoke extraction measures: The central fire alarm system centrally controls the fansand the smoke valves. The underlying distributed intelligence relieves the main PLC.thefail-safe connection to the Profinetclosed circuit takes place through theIM151-3 head assembly of the Simatic ET200S. These units are also able to read thesignals of the central fire alarm system ina fail-safe way using the input assemblies.“Both standard and fail-safe signals canbe processed flexibly according to the task –this is one great advantage of these modularstations,” says Maisel. In Tower 185,the stations have, among other things,also been supplemented with standardcards for additional building automationtasks.Smooth process thanks todistributed all-in-one solutionprogram, without having to switch platforms.”Hermos AG shows on a daily basishow smoothly all this works, becausecommissioning and service tasks can nowlargely be performed through remoteaccess. “This, too, is one of the greatbenefits of Ethernet-based automationand safety systems,” stresses Sturm. Witha password, the experts access the buildingmanagement system through anencrypted VPN tunnel. This system is connectedwith the distributed informationcenters through a Profinet circuit. Usingthe visualization, the correct functioningof the entire building automation systemcan be checked and adapted at any timevia PC.flexibility, the simple programming withStep 7 software, and the additional DistributedSafety feature created a solid basis forthe further development of the building automationsystem during the realization ofthe project. Sturm and Maisel agree: “Thebus-based safety technology for buildingshas great potential.” +MORE ON THIS TOPIC:+ the fail-safe controls are placed in socalledinformation centers. Programminga distributed all-in-one solution like thishas proven to be especially easy, as Maiselemphasizes: “On the programming level,you only have to install the additionalDistributed Safety feature in addition toSimatic Step 7. The safety technology canthen be treated the same way as the mainIndustrial Ethernet–based safetytechnology is the futureFor Hermos AG, the Tower 185 building automationis one of the largest projects realizedin this business segment so far. One ofthe many advantages is that the hardwarecan process both standard and fail-safe signalson the same platform. The resultingCONTACT:+ Contact person:Timo Mühlhausen,Marketing Manager,Industrial AutomationSystems+ E-mail:timo.muehlhausen@siemens.com24 advance | 3-2012

Ultimate Safetyin Material HandlingSafetyTechnologyWith Safety Integrated, a Swedish manufacturer of roll handling systems is able to meet allsafety requirements while providing the highest level of flexibility. The company was one ofthe first in Sweden to choose a fail-safe programmable logic controller (PLC) to control itsmachines.Ann-Louise LindmarkA view of the Trancel Restatic workshop showing a machine for producing environmentallyfriendly plastic bags from biodegradable materialOverview of SafetyIntegrated+ Fail-safe Simatic S7-319F controller+ Simotion D445 motion controlsystem+ Sinamics S120 servodrive+ Simotics M-1PH7 and S-1FK7motors+ Sizer configuration software+ Programming with Simatic WinCCflexible, Simotion Scout, Starter,Simatic Step 7, and DistributedSafety+ Bus communication via Profinetand Profibus+ Simatic ET 200S distributedperiphery+ Controlling and monitoring withSimatic WinCC flexible runtime on PC+ Sitop power supplyTrancel Restatic AB in Hisings Kärra,near Göteborg, is part of the TrancelGroup, which is headquartered inVästra Frölunda. Among other things, thecompany manufactures custom-tailoredsafe and flexible roll handling systems forthe processing of material such as plasticand paper. Trancel Restatic supplies leadingcompanies all over the world.The mechanical engineering companyhas relied on integrated safety solutionsfrom Siemens down to the drive levelsince 2005. “We are working in a sensitiveand dangerous industry with large machinesand the risk of severe accidentswhere people might get trapped or evendie,” explains Bengt Andreasson, who isresponsible for the engineering departmentat Trancel Restatic. For this reason,the retrofitting of machines that did notconform to current safety requirementsbecame one of the company’s specialfocuses.Flexible systems from the verybeginning“With a fail-safe control system andintegrated safety we are able to configurevery flexible systems already at the projectplanning stage,” emphasizes Andreasson.“The functions can be amended atwill, depending on changing conditions,so we avoid having to modify the circuitsevery time.” Erik Lundén, sales engineer atSiemens, helps the company develop theappropriate solutions with electronic, automation,and drive components. Sometimesthat takes two weeks, but sometimesalso up to six months. “These arecomplex machines that require special engineering,”empha sizes Lundén. He helpsTrancel Restatic in particular with dimen-sioning the drive systems and documentingthe calculations by means of the Sizerconfiguration software. The SimotionScout engineering software, with theStarter commissioning software andSimatic Step 7, is used for programming.“It is a pleasure to collaborate with TrancelRestatic, as the company is a leaderwhen it comes to integrated systems includingHMI, logic, motion control, andsafety,” says Lundén. +MORE ON THIS TOPIC:+ Contact person:Ann-Louise Lindmark,Marketing CommunicationsSweden+ E-mail:ann-louise.lindmark@siemens.comadvance | 3-2012 25

SafetyTechnologySafety en BlocTo be able to comply with the safety requirements of the newEuropean Machinery Directive in an economical way, amanufacturer of linked assembly systems relies on asoftware-based modular safety system (MSS). S).Thanks to expansion modules and a Profibuscommunication module, the basic applicationcan be extended to create a compact “safetyblock.”Up to nine modules can beconnected with MSS AdvancedJansen Automation, established in Pulheim,near Cologne, Germany, in1989, specializes in the developmentand construction of linked assembly systems.A unit recently delivered to an enginemanufacturer assembles and verifiesair mixers for large-volume diesel enginesin construction machines. The unit featurestwo cells with partially automatedassembly processes and 10 automated stations.It features modular construction, sothat any changes or modifications can beimplemented with only short idle times.Impressive flexibilityJansen Automation realized a softwarebasedsafety concept for the engine manufacturerfor the first time. “The modularsafety system is exactly the right solutionfor our demands, as the handling is easyand flexible,” explains the director andfounder of the company, Dipl.-Ing. PeterJansen. Division of labor enables paralleloperations and saves time during engineering,installation, and final commissioning.The safety engineering is carriedout by Jansen‘s electrical engineering department,while control engineers takecare of programmable logic control (PLC)programming. That works perfectly becausethe Sirius 3RK3 MSS can be easily parameterizedvia the MSS ES software – byan electrician as well.Even complex safety concepts can beclearly represented by means of a graphiceditor as well as drag and drop. The Forcingfunction enables the employees ofJansen Automation to simulate all risk scenariosin the program before the plant iseven commissioned. “In the end, we areable to conform to the safety requirementsof the new Machinery Directivewith EN 62061 and EN ISO13849-1 withoutany problems,” says Jansen.Enormous time savings,detailed diagnosticsInitial experience showed that considerablyless time is required for the preliminaryplanning of a plant with the MSS comparedwith conventional safety engineering.As far as the time required for engineeringand installation, the company saves morethan 20 percent on each. Up to seven expansionmodules can be connected to thebasic component of the MSS Basic system,and nine modules can be connected withMSS Advanced. Inputs and outputs can beadapted individually this way. “Most importantly,the expansion or modification ofplants becomes a lot easier and much lesscostly,” explains Jansen.Another advantage of MSS is the easy diagnostics.A Profibus module enables thetransmission of detailed information onthe status of the safety engineering to thecontrol unit. In the event of an error, theoperator is able to immediately recognize,for instance, where a safety door has notbeen closed properly or where there is abroken wire. “That considerably increasesthe availability of such a plant with cycletimes of 30 or 45 seconds, depending onthe workpiece,” says Jansen. Allocationand text layout of messages can be storedin the MSS ES software as plain text by the26 advance | 3-2012

Siemens AGDipl.-Ing. PeterJansen (right),CEO of JansenAutomation, withSiemens salesrepresentativeBernhardHöschler“ The state-of-the-art MSS enables us to comply withthe safety requirements of the European MachineryDirective in an economical way.”Peter Jansen, CEO, Jansen Automation GmbHsafety engineer. The control engineer thenadapts the text layout for visualization onHMI devices. Jansen uses at least 10”TP277 touchpanels to do so, as machineoperators need to have a clear status reportdisplayed at all times.Top safety levelVarious safety circuits can be easily definedwith the MSS ES software. If, for instance,a door is open at one station andassembly stops at this point, the rest ofthe plant continues to run. Because of thisadvantage, some of Jansen Automation’scustomers have already included the MSSin their functional specifications. PerformanceLevel e (the top safety level) solutionsconforming to EN ISO 13849-1 orSIL 3 conforming to IEC 61508/62061 canbe realized, as well as category 4 of formerstandard EN 954-1.As Jansen Automation is a one-stopshop, integrated systems such as thoseSiemens provides with Totally IntegratedAutomation (TIA) play a key role. Via remoteservice, specialists can use the controlto read out targeted diagnostic informationof the MSS – anytime, anywhere.Thanks to all these advantages, it comesas no surprise that in the future all systemsat Jansen Automation will be equippedwith an expandable safety block. +MORE ON THIS TOPIC:+ Contact person:Gerd-Theo Wolf, IndustryAutomation and DriveTechnologies+ E-mail:gerd-theo.wolf@siemens.comadvance | 3-2012 27

Drive TechnologyCleaning CottonMore EconomicallyThe new EU Directive 640/2009 comes at the right time for the textile industry’sefforts to achieve greater economic viability. One renowned manufacturer ofmachines for spinning preparation shows the advantages offered by the switchto three-phase induction motors with higher efficiency levels, using theexample of blowing-room solutions for cotton.The Trützschler Group, headquarteredin Mönchengladbach, Germany, is aworld-renowned manufacturer ofhigh-quality machines and plants for spinningpreparation and the nonwovens industry.A good example of the optimization ofprocessing and fabrication solutions atTrützschler is cleaners for cotton, such as itsCL-C Cleanomat cleaners. “By consistentlyusing consumption-optimized IE2 motors,we set a very high standard with regardto energy efficiency,” explains Peter vonDreusche, head of electrical design andelectronics development at Trützschler.Most of the company’s spinning preparationplants are used in three-shift operation,often in the textile regions of Asiaand in Brazil. Due to the worldwide rise inenergy prices, customers today pay closeattention to energy consumption whenlooking at the return on investment (ROI) –including outside the European economicarea, where EU Directive 640/2009 has appliedsince June 16, 2011, stipulating thatthe IE2 efficiency requirement be met forthree-phase induction motors between0.75 kW and 375 kW.Early switch to IE2 standardThe company switched all the drives in itsspinning machines to the IE2 standardearly on, including the cleaners in theCleanomat series. These are some of themost effective cleaners in the world, withup to three cleaning rollers for a high degreeof purification combined with minimalfiber loss. The cleaning shafts aredriven by three-phase induction motorsfrom Siemens. The opening roller drive requires4 kW, the two sawtooth roller drives3.8 kW each. The motors provided by theautomation partner made a custom configurationpossible during the switch toIE2 motors, and the industry-proven availabilityof the motors contributes to thehigh availability and tool life of themachines.The cotton is usually delivered in tightlypressed bales. A robot mills off thesebales and blows the fibers through an airlockto the next processing steps, with theflow rate reaching up to 1,000 kg/h. In thefirst step, foreign matter is removedthrough a centrifugal cleaner; the cottonis then dissolved into individual fiberswith lengths of up to 30 mm. Differenttypes of raw cotton are mixed uniformlybefore this step to be able to guarantee aconsistent quality – the recipe. The parallelfibers are then bundled into thumbthickskeins and placed in cans, with processingoutputs of about 200 kilogramsper hour. During a complicated controlprocess, six to eight individual strands arethen turned into drawing frame slivers.These fiber slivers can later be processedinto high-quality yarn in the spinning machines.Significantly lowerpower consumptionDue to the energy-efficient solutions necessaryfor complying with the IE2 standard,28 advance | 3-2012

Photo: TrützschlerAt Trützschler, the blowing roomseries for cotton or syntheticfibers is custom configuredAdditional photos: Fotolia / Burtsc, lulu, Gilles Paire, saginbay“ Energy measures such as the general switchto IE2 motors by Siemens improve the returnon investment of our solutions.”Peter von Dreusche, Head of Electrical Design andElectronics Development, Trützschler GmbH & Co. KGthe machines have become more economicalin their operation. “We use motors between0.19 kW and 18.5 kW, making energysavings of quite a few percentage pointspossible,” explains von Dreusche. Thehigher the number of operating hours andthe nominal output, the more significantthe absolute power savings are comparedwith IE1 motors. However, the practicalbusinessman lists additional reasons forusing the IE2 motors from Siemens. First isthe high quality of the products – the basisfor a long-term supplier relationship. Alsoimportant to him was the efficiency withwhich the motors could be switched. Thesupport of the manufacturer during thechangeover – which affected all series andincluded the adaptation of CAD drawings,order lists, and so on – confirmed his choice:“Siemens has the right solution even forspecial cases.”Due to the compact design of the motors,the construction did not need to bechanged. So far, the space provided in theTrützschler machines has always been sufficientfor an equivalent IE2 motor, even inmachine modules with a very compactbuild. It was also possible to retain themaintenance and service intervals, and insome cases even to extend them, sincedue to their construction the IE2 motorsare lower in maintenance than those ofthe previous series from the same manufacturer.Expert partnersFor the head of electrical design, deliveryreliability is an important factor in the selectionof a motor supplier. After all, about100 of the described cleaners alone leavethe Trützschler factories every year. This iswhy the switch to IE2 motors is a doublesuccess for von Dreusche: “With Siemens,we have an expert partner operatingworldwide, and with the new IE2 motors,we can document the cost-effectivenessof our solutions for our global customers –that goes over well.” +MORE ON THIS TOPIC:+ Contact person:Markus Schlink, PromotionManager, Energy Efficiency,Large Drives+ E-mail: markus.schlink@siemens.comadvance | 3-2012 29

Drive TechnologyPrecisely Oiled, HigherProcess QualityFor coils and single rolled sheets, oil serves as protectionagainst corrosion and as a rolling and punching medium.Servo-controlled metering pumps in oiling machines enable amore economical, precise, and even oil application, and betterprocess control.To improve the stability of the surfacequality and provide favorable processingcharacteristics, steel and ironplates receive an oil coating. The oil protectsagainst corrosion and also serves asa lubricant in rolling and punching processes.Usually, an electrostatic field is usedfor the oil application in order to create agap-free oil curtain. The thickness andevenness of the oil application are determinedby the amount of oil supplied bythe metering pump.One globally operating manufacturer ofoiling machines is Duma Maschinen- undAnlagenbau GmbH based in Duisburg,Germany. A trusted partner to manufacturersof industrial-scale equipment in theiron and steel industry for more than 25years, the company has long been usingservo-controlled drives for its precisionaxial piston pumps.“This means that we now have pumpspeeds from zero to 3,000 rotations perminute available for flow control, whichwe can operate with very high resolutionand control accuracy,” explains RobertSchepers, technical plant manager atDuma. This dosing accuracy, which issignificantly higher than that providedby conventional drive technology, enablesthe company to adhere much moreprecisely to the target or minimum quantitiesof oil per square meter of sheetmetal.“ The Siemens systemcomponents offer us asingle-axle servocontrol with very highquality and sufficientdynamics at a goodcost/performanceratio.”Robert Schepers, Technical Plant Manager,Duma Maschinen- und Anlagenbau GmbH30 advance | 3-2012

With their servo-controlledmetering pumps, the oilingmachines by Duma ensure aneven oil application even atvarying speedsMarschnerFurthermore, the necessary safety marginscan be greatly reduced, saving oil anddecreasing costs.Improved processing proceduresEven more important is an even oil application.Schepers gives an example: “Whensheet metal segments are pushed into apress or a punching machine, the positioningaccuracy depends greatly on the slidingproperties of the oiled sheet metal –segments with a thicker oil coating slidefarther on the bedplate than those with athin oil coating.” Even oil applicationtherefore leads to a more consistent coefficientof friction, better process control,Siemens AGgreater yield, and better parts quality. Andthe costly calculation methods of the industryto estimate the remaining oil thicknessbased on the storage duration of thecoils or sheet-metal plates become easierand more accurate when the oil applicationshows less variance.Due to the ramp-like speed processes, forexample, during start-up and shutdown ofthe line, the quantity dosage must beadapt ed precisely and quickly to the speedof the sheet metal passing through the oilingstation. This is why Duma uses servomotorsof the Simotics S-1FK7 type andSinamics S110 frequency converters asdrives for the metering pumps. A Simatic S7with 315-2 DP CPU serves as a controlsystem.“A single-axle servo control with veryhigh quality and sufficient dynamics is possibleat a good cost/performance ratio thisway,” explains the technical director. “Furthermore,engineering, commissioning,and service are comparatively simplethanks to the integrated and open systeminterfaces with drive units, motors, andSimatic S7 control.” For example, for thetransmission of the signals of the highdefinitionengine-speed sensor and themotor monitoring, a single cable joint issufficient – Drivecliq, an open and standardizedserial bus at the drive level thatsupports electronic ID plates. The controlsystem queries the installed componentsduring the initialization phase of the plant.In normal operation, the PLC compares thedrive configuration during run-up with thestored nominal values. This ensures thatfailures at the drive level or changes in aservice are detected immediately.Long useful life, global acceptanceSince the Sinamics S110 frequency converterforms a closed control circuit withthe engine speed sensor, it is sufficient toindicate a speed set point calculated forthe oil application from the current machinespeed and the target quantity. Thisvalue is automatically implemented andmonitored by the drives. Through this systemand also thanks to the support of thenearby Siemens branch in Essen, the machinemanufacturer can implement histechnological expertise with little softwareand hardware effort in a robust applicationsuitable for industrial use.Since the oiling machines are integratedinto etching, hot-galvanizing, or inspectionlines, they do not need guide rollersor supports. The plants by Duma are contact-freeand therefore have a very longuseful life. This is why the company prefersto use durable and reliable components.Dependable long-term, globallyavailable support from the electronicssupplier is also important. Schepers knowsfirsthand that a machine equipped withSiemens components is accepted in heavyindustry around the world: “We can get replacementparts just as easily and quicklyin China or in the United States as inEurope, and the service for the electricalmachinery is available worldwide and onshort notice even after the warranty hasrun out. This gives us and the end userssecurity, knowing that shutdowns due tofailures can be kept short.” +MORE ON THIS TOPIC:+ Contact person:Norbert Maleszka,Sales Coordinator+ E-mail:norbert.maleszka@siemens.comadvance | 3-2012 31

Drive TechnologyModernization Conceptfor Gold MillSiemens modernized the gearless mill drive for Australia’s leading gold-miningcompany. For the first time, two converter types were used in one gearless drive.The solution offers a new diagnostics system as well as additional remote access,increasing the availability and operating safety of the plant.Newcrest Mining Limited is an Australiancompany based in Melbourne.Based on market valuation, NewcrestMining, with eight operating minesworldwide, is considered the fourth-largestgold producer in the world and thelargest in Australia. At the Cadia Valley Operationsmining site near Orange in NewSouth Wales, Newcrest operates two undergroundmines and one surface mine.Modernization concept relies onsmooth implementationThe extracted ore is first processed into acopper concentrate containing a highThrough the modernization of the mill drive at a gold mine in Australia, it was possible toincrease the availability and operating safety of the plantNewcrest Mining Ltd.quantity of gold through comminution,grinding, and flotation. The two-stagegrinding cycle consists of a large SAG(semi-autogenous grinding) mill measuringabout 12 meters in diameter with agearless 20 MW drive and two downstream10 MW ball mills with gear drives.When Siemens delivered the SAG mill in1998, it was the first mill with such alarge diameter – and it is still the largestmill in the world today.Siemens was commissioned to retrofitthe gearless mill drive of one of the goldmills on the premises. The main argumentfor the modernization was that the outdatedmotor control needed to be replacedwith current technology. Thanks tothe modernization concept developed bySiemens, the majority of the electronicequipment already in use could be retained.This helped minimize downtimesduring the retrofitting.First-time use of two differentconvertersFirst, Siemens equipped the SAG millwith a Sinamics SL150 direct converterfor the motor control. A Sinamics DCMpower converter was chosen to actuatethe field current. This was the first timethat two converter types were used inone gearless drive. The Sinamics SL150direct converter is the follow-up modelto Simovert D and is based on the sameplatform as all Sinamics converters. Thenew Sinamics motor control replaces theold Simadyn control system, which hasbeen partially discontinued. The Sinamicscontrol is based on Simotion D 445and on a CU 320 controller for drivecontrol. The Sinamics DCM control moduletakes on the functions of the oldSimoreg power converter. It was installedon a metal plate together withother components and only had to bescrewed into an existing control cabinetand connected.In addition, the Simatic S5 controllerswere upgraded to Simatic S7 and the controlsystem switched to Simatic PCS 7. Themodernization included the installation ofnew air gap and speed sensors. A newrout er for remote access was installed forplant diagnostics as well.The project team was able to replace theoutdated regulation and control systemswithout having to replace the motor, the32 advance | 3-2012

Power ConverterSinamics DCMSimatic S7-400Control SystemHigh-SpeedRecorderTM TerminalModule (I/O)VSMET 200MCBE30CBE20Drive-CliqHub ModuleSMC SensorModules(E.g. SpeedSensor)SimotionD445CU320ConverterPowerSectionOP177Sitor IF BoardsSwitchNotebookSinamics SL150RegulationPSAPSA PSA PSA PSA PSASiemens AGThe drive system of the SAG mill at Cadia Valley Operationstransformers, or the active components ofthe existing frequency converter. The newSinamics platform enables significantly improvedsystem diagnostics, as well as considerablyimproved options for troubleshooting.Fail-safe thanks to the latesttechnologyThe grinding equipment is one of the keybottlenecks during gold production –every hour of downtime translates intogreat financial loss for the customer. Inorder to minimize potential loss, Siemensdeveloped a concept that made downtimesas short as possible. To achieve this,only those parts that really needed to bereplaced were changed. Everything elsethat was still safe to operate could remainin place. In addition, almost all parts in thecontrol cabinets were preassembled andtested in advance at the Siemens test sitein Erlangen, Germany.In this project, Siemens was responsiblefor the engineering of the hardware andsoftware, the delivery and monitoring ofthe installation, and the commissioning.The implementation took place during ascheduled plant shutdown in parallel withother modernization and expansion work.Siemens took advantage of this opportunityto mechanically overhaul the motoras well.In 2010, Newcrest Mining Limited concludedan extensive three-year servicecontract with Siemens, which includes oncallservice and preventive maintenanceas well as troubleshooting and now alsoremote diagnostics. The modernizationproject was a complete success and is considereda global reference in the miningindustry. Other customers have alreadyshown interest in this solution. +IT security noteSuitable protective measures (including IT security,e.g., network segmentation) must be taken toensure secure operation of the plant. Furtherinformation on industrial security can be found ON THIS TOPIC:+ Contact person:Daniel Schmid,Marketing Manager Minerals+ E-mail:daniel.ds.schmid@siemens.comadvance | 3-2012 33

Drive TechnologyStrong on Steep TracksA new drive unit for bucket elevators – with components from the Flender SIG gear unit series andthe new Simogear geared motor series – is optimally designed for the extreme conditions in conveyortechnology thanks to an improved gearing geometry and a modification of the housing.Bucket elevators vertically transportbulk material such as cement, lime,and gypsum, but also grain and rice,to another level and discharge it there. Indoing so, they often lift the material morethan 200 meters, and the weights to betransported are enormous. Central or doublechain strands, link chains, or belts, towhich the buckets are attached, serve assupporting structures. The drive at theupper station requires comparatively highpower, similar to a steep conveyor beltline. Because of the high accelerationforce, the start must be soft. This is guaranteedthrough fluid couplings in thedrivetrain. Usually, bevel helical gear pairsare used as single or twin drives on a baseframe or swing base.Robust and powerfulWith components from the new Simogeargeared motor series and the standardgears of the Flender SIG series, Siemenscreated an especially robust bucket elevatordrive unit that is optimally designed forBucket elevatorstransport bulkmaterial of all typesand need apowerful driveto do sothe extreme conditions in conveyor technology.Warehouses and silos are usuallyfilled in demanding environments. Accordingly,the drive unit must be rugged andpowerful in order to transport bulk materialquickly, with little wear, and in largequantities. The integrated bucket elevatordrive makes maximum energy efficiencypossible through improved gearing geometryand the optimization of the housing,with a very high degree of reliability at thesame time. This in turn results in improvedthermal power limits. The optimallymatched components of the drivetrainmeet the requirements for conveyor technology,such as dust absorption and defineddischarge curves. The sealing systemsand operating supplies within thedrivetrain also contribute to the driveunit’s reliability. The mechanically uncoupledauxiliary drive of the compact driveunit serves as a maintenance and loaddrive and operates at about 10 percent ofthe main drive speed. Backstops are standardin the new bucket conveyor driveunit. +Highlights of the Flender SIGtransmission seriesThe integratedbucket elevator drivemakes maximumenergy efciencypossible with a veryhigh degree ofreliability+ Increase in torque while thesize remains the same(up to +15 percent)+ Harmonized torque rating+ Increased service life of bearings+ Monobloc housing up to125,000 Nm+ Interim phases for single-stagegears+ Weight savings of up to8 percent+ Improved efficiency and thermalratingsAll photos: Siemens AGMORE ON THIS TOPIC:+ advance | 3-2012

More Productive GrindingDrive TechnologyMore and more, faster and faster –this is the trend everywhere, even inthe cement industry. For this reason,larger and larger vertical roller millsare being used. New conceptsoptimize the power transmissionbetween drive and mill, andproductivity and availabilityare increased.Siemens AGNew drive concepts such as theFlender MultipleDrive increasethe productivity of vertical millsin the cement industryThe drive systems usually used for verticalroller mills, consisting of a gearunit and asynchronous motor, transmitpower of up to approximately 8 megawatts.However, larger ball-and-pebblemills, whichareclearlybecomingatrendclearly a trend,require much more driving power. With increasingmill size, the availability requirementsalso grow. In order to enable atleast partial-load operation in case of abreakdown, the drive concepts must bemodularly structured and sufficiently redundantin their functions. If the processesare then also optimized using precisespeed control, it is possible to improve thegrinding results and productivity as well.Innovative systems:Flender MultipleDrive ...Two new drive systems meet these requirements.The central idea of the Flender MultipleDriveconcept is redundancy. The inputshafts of the up to six small and compactstraight bevel gear pairs are each drivenby a frequency-regulated asynchronousmotor. Since the gear unit, motor, and connectorare arranged on one mount, replacinga drive for maintenance purposes is not... and Flender EmppThe Flender Empp mill drive is based on anew motor located in the gear housingbelow the planetary stages. The simple designwithout a bevel gear stage optimizespower transmission. The five planetarygears in the main stage result in a verycompact unit. The Flender Empp is mechanicallycompatible with the previousmill drives but has been optimized with regardto cost and function. The brushlesspermanent magnet motor is wear-free anda problem. Because of the redundancy, themill can continue operation with a reducednumber of drives. The parameterization ofthe Flender MultipleDrive frequency converterensures even load distribution withlowdynamicamplitudesofthedrivesoper-amplitudes of the drives operatingin parallel.The frequency converter enables all therequired operating states along with precisecontrol and regulation of the millspeed. Outputs of up to 16.5 MW are possible.The significantly lower mountingheight (compared with that of conventionaldrives) allows for more efficientmill designs.has an efficient cooling system. Moreover,pressure-lubricated slide bearings prolongthe operating life of the gear unit andmotor. Compared with a system with onebevel gear stage and two planetary stages,the drive system has 20 percent fewer activecomponents, reducing potential errors.Through the integration of the motorinto the gear unit, the mounting volumeand the weight have been reduced by onefourth.Finally, the converter-controlledmotor enables the active damping of theoperation and the optimal adaptation ofthe speed of the grinding pans to changinggrain sizes, resulting in greater efficiencyfor the ball-and-pebble mills. +MORE ON THIS TOPIC:+ Contact person:Dirk Mensing,Mechanical Drives+ E-mail:dirk.mensing@siemens.comadvance | 3-2012 35

IndustrialCommunicationEfficient Network Control CenterIndustry has embraced wireless networks based on the IEEE 802.11standards as part of a reliable network infrastructure, and the numberand complexity of such installations are increasing. They requireefficient central management, however. Intelligent Industrial WirelessLAN (IWLAN) controllers are perfect for this task.Acentral “instance” is required for theefficient set-up and operation of industrialwireless networks, andIWLAN controllers provide the most comprehensiveand efficient solution. Manycontroller-based access points (APs) areconnected via what is also referred to asSwitched LAN on one side of a centralIWLAN controller, and the remaining companynetwork is connected on the otherside.The controller hardware is often a dedicatedPC platform. Via browser-based webinterfaces and the Simple Network ManagementProtocol (SNMP), values such asthe transmission performance or networkname can be modified easily and for agroup of APs at the same time. Licensesmake it possible to activate the number ofadministrable APs or the radio-frequencypermits for a particular country. EfficientIWLAN controllers are able to manage severalhundred controller-based APs –among them robust devices that can be installeddirectly in the production hall oroutside.IWLAN controllers are used primarily forapplications in the transport sector, forlanguage and video transmission, and inwarehouse and harbor logistics. Controller-basedIWLANs can also be used forSupervisory Control and Data Acquisition(SCADA) connections between automationapplications and control center systems.Integrated management functionsIntelligent IWLAN controllers support administratorswith many functions thatmake network operation cheaper andmore fail-safe and that cannot be performedby distributed IWLANs with independentstand-alone APs. These controllersautomatically recognize newly addedAPs and provide them with the currentfirmware. The IWLAN channels can be automaticallydistributed to the APs. If APsare positioned very close to each other,failures can be compensated for throughautomatically increased sending performanceon the part of the remaining APs.Sophisticated functions for bandwidthmanagement ensure that remote bandsand APs are equally utilized.IWLAN controllers also increase the performanceof services such as Voice or Videoover WLAN, where short roaming times andshort delays between IP packages are critical.Moreover, IWLAN controllers enableroaming scenarios that are impossible toachieve with stand-alone APs, such asseamless roaming between IP subnetworks.This ability can also be used for large IWLANinstallations in which the APs are allocatedto different IP subnetworks due to their36 advance | 3-2012

IWLAN controllers areused primarily inapplications in the fieldsof transport andwarehouse and harborlogisticsIndustrial EthernetANT795-6MTScalanceW786-2CET 200SContainer TerminalScalanceW786-2CANT795-6MTET 200SAutomation CenterIWLAN-ControllerScalance WLC711ScalanceXR324-12MAGVScalanceW748-1 RJ45ANT795-6MTAGVScalanceW748-1 RJ45ANT795-6MTW748-1RJ45ET 200SAGVW748-1RJ45AGVET 200SScalanceW786-2CContainer ShipScalanceW786-2CAGV = Automated Guided VehicleVia a controller-basedIWLAN, logistics data canbe transmitted toautomated guidedvehicle (AGV) transportsystems, for instance, ina container terminalAll photos: Siemens AGnumber. The APs can be furnished withidentical features and safety settings bymeans of AP groups, and users can be allocatedto user positions with different rightsand features.Switching modes anddeterministic I/O dataIn controller-based switching mode, allthe data communication is centrallychanneled through the controller. In additionto enhanced roaming features,this mode has the advantage that thereis only one central network exit pointExplanatory videoA new video explains the useof IWLAN with the Scalance Wproduct line based on standardIEEE 802.11n and introduces thenew generation of the Scalance WIWLAN product line.Video Scalance W:To watch the video, go and searchfor Scalance W.from the IWLAN and that the configurationeffort of LAN switches is low. Inlocal switching mode, user data communicationcan be directly linked to thewired LAN behind the AP. The controlleris then required primarily for managementtasks such as authentication ofIWLAN clients.The pinnacle of wireless network performanceis the transmission of deterministicreal-time data, as in Profinet IO (PNIO), for example. Self-sufficiently operatingstand-alone APs can have log enhancementsthat optimize IWLANs for deterministicI/O data transmission andaccelerate roaming as well. ControllerbasedIWLANs in controller-based switchingmode are not yet suitable for deterministicI/O data transmission, but suchdata can be transmitted in local switchingmode, as there is no time-consumingtransmission of packages back to the controller.Redundant controllers for betteravailabilityTo guarantee the fail-safe operation ofnetworks, IWLAN controllers can be operatedredundantly. Because every controllerof a redundant pair is licensed tomanage 32 APs, each controller is able tomanage 64 APs if the other controllerfails, and the network remains fully functional.Network protection is very important,in terms of both access by IWLANclients to the network and the encryptionof data. Again, IWLAN controllers facilitatethe administrator’s work by distributinguniform safety policies to allAPs. The encryption of data is reliably executedvia standardized methods. +IT security noteSuitable protective measures (including IT security,e.g., network segmentation) must be taken toensure secure operation of the plant. Furtherinformation on industrial security can be found ON THIS TOPIC:+ Contact person:Marcus Brühne, ProductManager, Industrial WirelessLAN+ E-mail:marcus.bruehne@siemens.comadvance | 3-2012 37

IndustrialCommunicationWireless Technology PreservesLong Beer TraditionThe British systems integrator FMA managed the successful migration of one of theworld’s most efficient barrel filling plants to a new control system with only 12 lostworking days. An innovative automation concept featuring wireless technologycontributed to the project’s success.Plzeňský Prazdroj, a.s., a company ofthe SABMiller Group, operates one ofthe world’s most efficient barrel fillingplants in the Czech Republic, a noted beercountry. The Pilsen plant, established in1994 by GEA Till (now KHS), with a capacityof 1,000 barrels per hour, works 24/7in the event of strong demand. To guaranteethis efficiency, SABMiller decided in2009 to modernize the automation technology.The plant’s downtime during themigration was to be minimized.Intelligent modernization conceptTechnology partner Siemens developed adetailed risk analysis for the filling plantthat served as a basic concept for thequick, cost-saving, and intelligent retrofittingproject. A key component was the replacementof 14 Simatic S5-115U and S5-95U controls in the central control cabinetby a Simatic S7-400, and 5 Simatic ET200M peripheral units with Profinet. CPUsand distributed Simatic ET 200S I/O devicestook the place of the 12 Simatic S5-95U units in the three main rotating tables.For a quick migration from theSinec-L2 fieldbus communication systemto Profinet, the friction ring transmissionto the rotating tables was replaced bywireless Scalance W access points. Thesemeasures enable maintenance-free operation,and provide maintenance engineersaccess to the entire Profinet network andthe linked components via standard PCs –during operation and from any locationwithin the plant. Based on the modernizationconcept, the English systems integratorand process engineering specialistFMA developed a precise plan for themodernization that would be carried outwithin 12 days.Quick implementationWhile FMA reworked the software of theSimatic S5 control and modified it accordingto Simatic S7 standards, the fillingplant continued running around the clockafter the end of the demand peak in thesummer in order to produce enough warehousestock for the downtime period.Plzeňský Prazdroj specified Simatic TP 177and Simatic MP 277 panels made of stainlesssteel. FMA engineers dimensionedand parameterized nine multifunctional1,000 barrels per hour are cleaned and filled 24/7 at the Pilsen filling plantAll photos: Siemens AG38 advance | 3-2012

Network managementwith Sinema EThe Sinema E (Simatic NetworkManager Engineering) planning,simulation, and configurationsoftware simplifies the installationand commissioning of an IndustrialWireless LAN (IWLAN) network. Itvisualizes the signal coverage, datarate, signal-to-noise ratio, andoverlapping access points of anIWLAN network. Catalog entriesand standard graphic formatsfacilitate planning and installation.A consistency check reduces possibleerrors, and report functionsdocument the performance of theinstallation.From nine operator stations, the plant operators are able to control functions both locally andin remote parts of the plant, and perform diagnosticscontrol panels for better operating control.After the solution had passed the factoryacceptance test, the British specialistsstarted with the retrofitting process inSeptember. After the scheduled downtime,the barrel filling plant was able to returnto operation as early as the beginningof October.Use of the wireless Profinet network hadrequired some convincing from the FMAspecialists. “We were skeptical about thissolution in the beginning,” says OndřejSykora, head of process and control engineeringat Plzeňský Prazdroj. “Therefore,FMA contacted a company that monitorsthe wireless operation and guaranteessmooth operation.” The reliable operationof the plant finally convinced Sykora. Thehigh speed of 54 Mbit/s is more than sufficientfor the exchange of large data volumesbetween the higher-level CPU,smaller processors, and control panels.Operators and service employees canmonitor and adapt the entire system wirelesslyfrom a laptop. The two stationaryScalance W786-1PRO access points withprotection class IP65 are perfect for therough and wet industrial environment andcommunicate wirelessly with ScalanceW784-1 client modules on each of the rotatingtables. To ensure that the wirelesstechnology would work in an environmentwith many metal structures and rotatingparts, the solution was simulated in advancewith the Sinema E software tool andsuccessfully tested after implementation.Increased availability“We have moved away from a technologyfor which there won’t be support for muchlonger and have secured ourselves servicesupport for the future,” says Sykora, outliningthe main benefits. “In addition,modifications and changes have becomemuch easier, and in the event of a powerfailure all the components restart quicklyand without delay now.” The migration increasedthe availability and safety of thebarrel filling plant and reduced the numberof system components and the diversityof the system. As a result of the positiveexperience with this project, PlzeňskýPrazdroj is now upgrading all its Simatic S5systems in the Czech Republic to SimaticS7, in cooperation with local systems integratorsand Siemens as the system supplier.+IT security noteSuitable protective measures (including IT security,e.g., network segmentation) must be taken toensure secure operation of the plant. Furtherinformation on industrial security can be found ON THIS TOPIC:+ Contact person:Robert Freller, BusinessDevelopment, AutomationSystems+ E-mail:robert.freller@siemens.comadvance | 3-2012 39

IndustrialIdentificationSelf-Organizing ProductionRadio-frequency identification(RFID) has long established itselfin many fields of application as ameans of automaticallyidentifying objects of all kinds.RFID and networks play a keyrole in the individualization ofproducts and are therefore anintegral part of the Industry 4.0concept.For the automation of business processessuch as individual productionsteps, warehouse updating, receiving,shipping, and so on, the automaticidentification of goods is essential. Thegoods are therefore furnished with machine-readableindividual bar codes, 2-Dcodes, or electronically saved information.Data carrier with added valueA well-established concept in the automation industry: nonstop productionof individual productsRFID systems have more to offer than justidentification. Because the transponderscan carry more data than just code numbers,and because such data can bechanged as often as the user wishes, RFIDis also perfect for data carriers that can bepermanently integrated into any object.The systems have evolved rapidly in thepast few years, and ultra-high frequency(UHF) technology with frequencies around865 megahertz and the use of smart labelshave represented tremendous progress.However, traditional RFID in a highfrequency(HF) close range of 13.56 MHzhas established itself for reading devicesand transponders due to its robust communicationand ability to perform welleven under unfavorable environmentalinfluences.The automotive industry would be radicallydifferent without the RFID systemsthat enable the manufacture of bulk goodstailored to individual customer requirements.But many medium-sized companiessuch as the Westphalian shower andbathtub manufacturer Bette, the Turkishfabric wholesaler Tetas, and the Franconianplastic specialist Rehau have also acquireda strategic competitive edge thanksto RFID.Self-organizing productionThe term Industry 4.0, coined by a Germaninitiative, refers to new approaches to industrialproduction such as distributedsystems, new communication technologies,and the interconnection of productand production parameters. These technologieshave great potential, especiallywhen it comes to the individualization ofproducts, that is, the production of manydifferent product versions according to individualcustomer requests.Cyber-physical systems, a self-organizingform of production, are attracting a lotof attention. These are systems in whichthe workpieces communicate with themachines. The product comes along withits blueprint and coordinates its own waythrough production.Today, RFID technology already providesa more than functional basis for the implementationof such concepts. The blueprintand all the required quality information canbe saved on the RFID data carriers attachedto the products or components. Individualproduct features such as color or specific40 advance | 3-2012

design can either be saved on the RFID datacarrier directly or retrieved from the serverby using the globally unique identificationnumber of the chip.The interconnection of the field levelwith higher-level databases enables theRFID chips, whose storage capacity is limited,to refer to large data records andcomplex instructions as well.This approach requires flexible machinesthat are able to carry out a multitudeof processes. Moreover, flexible materialflow control is required to conveyparts through the plant so that it works efficiently.A central control unit prioritizesthe jobs and introduces them into the productionnetwork.Successful use in real productionThe first examples at German companiesprove that the concept of self-organizingproduction really works. The productionline for switching devices at Siemens inAmberg produces 250 versions of electricalswitching devices for the global marketin a made-to-order production process.For this purpose, special tool carriersare equipped with Simatic RF300 RFIDtransponders. This system makes it possibleto retrieve the necessary data particularlyquickly so that the workpiece carriersdo not need to stop when they reachthe reading device. The transponder containsthe detailed blueprint that enables atesting machine to carry out an individualtest program for every device. The resultsand other quality information are, dependingon the quantity of data, eithertransmitted to the control systems via aProfinet connection or saved on the RFIDchip.Thanks to the RFID chip, the specialist operatorsknow exactly what needs to bedone, as the necessary instructions are displayedon-screen. Moreover, parts can beconveyed back to previous stations thanksto a two-line material flow control. Thecombination of material flow and manualworkstations results in an efficient, workload-controlledbut still highly flexible productionline. +At the manufacturing plantin Amberg, an intelligentmaterial flow controlsupplies workstations basedon workloadMORE ON THIS TOPIC:+ photos: Siemens AGCONTACT:+ Contact person:Markus Weinländer, Head ofProduct Management,Simatic Ident+ E-mail:markus.weinlaender@siemens.comadvance | 3-2012 41

IndustrialSwitchingTechnologyIndustrial Solutionfor BiogasBecause biogas plants must work around the clock, great emphasis is placed ondiagnostics and availability. A company specialized in the production andservice of biogas plants therefore uses motor feeders with IO-Link activation,which allow service and remote maintenance to be optimized.“We explicitly look for integratedsystems that enable high qualityand availability,” emphasizes RalfBreckling, CEO of biogas plant supplierNorth-Tec Maschinenbau GmbH in Bredstedt,near Husum, Germany. For this reason,the entrepreneur uses robust and reliableindustrial control systems andintegrated system solutions based onTotally Integrated Automation (TIA): “It isa great advantage for us, with regard totime and cost-efficiency, that the componentscan be easily integrated and wiredfrom the control unit to the contactor andthat performing diagnostics is simple aswell.” A high degree of availability – andthus diagnostics (especially remote diagnostics)– is of significant importance inthe biogas industry. Longer feedingdowntimes result in considerable economiclosses, as biology needs time to getback on track.Cost-saving motor feeders withplug and playThis is why North-Tec used motor feederswith IO-Link for the first time at a plant inLeck-Eng, near the Danish border. Thefacil ity with a wet digester, a post-digester,and a digestate storage containersupplies two combined heat and powerstations with a capacity of 400 kW each.“The combination of a Sirius 3RT2 contactorand a circuit breaker for the Sirius 3RV2motor contactor enables us to configurefeeders up to 18.5 kW very safely andquickly via plug and play,” explains Breckling.He considers the intelligent IO-Linkconnection a smart complement thatsaves further wiring effort and provides awide variety of diagnostic informationBiogas plantin Leck-Engthat would not be available in the case ofconventional wiring. North-Tec also hasturnkey solutions mastered: The WinCCflexible visualization software features astandardized IO-Link template for Siriusmotor feeders, which provides importantdiagnostic information without any additionalprogramming effort.Easy communication via IO-LinkUp to four IO-Link groups, that is, up to 16motor feeders, can be linked to the IO-Linkmaster of the Simatic ET 200S distributed periphery.A simple plant controller based on ET200S is adequate for all the control processeswithin the biogas plant or linked subsystemswith their own control – such as a combinedheat and power station in this case. That is,the distributed periphery is also availablewith an intelligent IM151-8 head componentwith integrated CPU.Communication is effected via Profinet.Breckling considers IO-Link the best technologycurrently available, as it is easy tointegrate into automation via IP addressing,it offers safe and simple remote access,and it can be expanded according to theuser’s needs. If there is a great distance betweenautomation units, another SimaticET 200S distributed periphery can simplybe linked to the control via Profinet, whichis very useful if there are satellites for combinedheat and power stations, as in thecase of the biogas plant in Leck-Eng. Here,the second combined heat and power stationis 2 kilometers away in the engineeringroom of a residential building; this allowsthe generated heat to be used withouthaving to cover long distances.Deep insights into the plantAs diagnostics on this plant can be performedup to each motor feeder via remoteaccess, the service staff of North-Tecimmediately knows what alarm or errorhas been triggered for what reason and42 advance | 3-2012

A tangled wiring mass with standardized Sirius connection components is a thing of the pastAll photos: Siemens AG“ Thanks to Totally Integrated Automation wehave developed an economic solution that isrobust, reliable, and flexible.”Ralf Breckling, CEO of North-Tec Maschinenbau GmbHIO-Link saves wiring effortIO-Link is an open concept forconnecting sensors, switchingdevices, and actuators to thecontrol level by means of a pointto-pointconnection. Up to fourmotor feeders can be connectedto each other and to the associatedIO-Link master. Only thefirst starter of a row is wired tothe master; a plug connectionsuffices for the others.what is the quickest way to remedy it. Informationon power demand, power consumed,power supplied, and grid qualityalso provides valuable reference points forthe optimization of the system’s operation.That is why North-Tec integratesSentron PAC 3200 multifunction measuringinstruments as standard procedure.Exceeding the maximum consumptionagreed in the reference contract with thepower supplier (EVU) means high costs forthe plant operator. To avoid this scenario,the limits are monitored by means of themeasuring instrument, and units areswitched off or switched on with a delayvia software, depending on what the situationcalls for. “That way, we can sort ofprogram operational expense optimization,”explains Breckling.In the biogas expert’s opinion, there areabout 400 biogas plants in Schleswig-Holsteinalone that are running around theclock – and that should be equipped inthe same way for cost-optimized remotemaintenance. “The only way to perfectlycomply with the service requirements inthe long term is to use an industrialsolution for which the standard componentsare available over decades,” hestates. +MORE ON THIS TOPIC:+ Contact person:Jürgen Heiker,Industry Automationand Drive Technologies+ Contact person:Frank Schlachter,Industry Automationand Drive Technologies+ E-mail:frank.schlachter@siemens.comadvance | 3-2012 43

IndustrialSwitchingTechnologyHot PlatesHombach produces high-quality plasticdiscs on Geiss thermoforming machinesusing the twin-sheet process with top andbottom mold halvesSiemens AGBy vacuum forming with twosheets, a Franconian manufacturerof precision parts formsfoil material into high-qualityplastic discs. Hombach relies ona compact package solution fortemperature control.Ernst Hombach GmbH & Co. KG, a manufacturerof high-quality plastic partsin Uehlfeld, Germany, uses the twinsheetprocess to form plates with insidemolding out of smooth foil. For thisvacuum deep drawing with two sheets,the company uses T9 thermoformingmachines from Geiss AG in Sesslach, nearCoburg. A very precise process is essentialfor the high quality of the finished product,but exact temperature control is oneof the most demanding challenges.High degree of function integrationThe Siplus HCs716I heating control used forthe control of heating elements in the topand bottom heating of the T9 machine wasan impressive part of the competitive packagesolution from the Totally IntegratedAutomation (TIA) integrated product line.“The high degree of function integration ofthis heating control saves space and makesmachines clearly arranged,” emphasizesHombach CEO Timo Tobolla.Each heating control system has a circuitbreaker for each outlet channel, a 5A fuse,and communication via Profibus DP on theassembly carrier. There are 16 channelsfor each assembly group. Up to 12 assembliescan be strung together, which enablesthe control of 192 heating elementsaltogether – and all that on an area of only0.16 m 2 . The modular assembly makes itpossible to easily modify the heating areasat a later stage.Parameterizing is simple and compact.Within the TIA concept, all the componentsare well matched, from theSimatic S7-317 2DP machine control, theHMI, to the heating control. There is afunction block for the heating controlsystem (HCS) for the Step 7 automationsoftware or TIA Portal, which is attachedto the hardware as a file. The preset parameterscan be adjusted to the machinequickly and easily.Comprehensive diagnostic optionsThe halogen spotlights can be adjusted sensitivelyand precisely. The machine controldetermines the target value in the functionblock in increments of 1 percent, and thetarget value is then processed in the HCS.The percentage values are indicated in detailwith the WinCC flexible visualizationsoftware.Heating elements are grouped by thesoftware in the functional block to create asmooth production process. There are comprehensivediagnostic options: Hombachemployees immediately recognize errorsand deviations in the process and are ableto record them. The HCS informs the higherlevelcontrol about broken cables and lights,for instance, and even performs selfdiagnoses.+MORE ON THIS TOPIC:+ Contact person:Bernhard Schmidt,Product Manager,Control Components andSystems Engineering+ E-mail:schmidt.bernhard@siemens.com44 advance | 3-2012

Certification for TotallyIntegrated AutomationServicesIn addition to qualified further training on the company’s entire range ofproducts and solutions, Siemens also offers its employees various possibilitiesto earn certificates that confirm the knowledge gained. This is why the SitrainCertification Program has been developed and now updated.Employee qualification is gaining increasingimportance for both employeesand employers. In April 2012the Central Association of the GermanElectrical and Electronics Industry e.V.When does it start?Siemens Certified Service TechnicianLevel 1 & 2Description of course contents(ZVEI) defined a new standard for the furthereducation required to become an automationtechnician, as the continuousskill enhancement of automation engineering,moving toward Totally IntegratedStep 7 V.5TIA PortalOctober 2012 Summer 2013Siemens Certified Programmer October 2012 Summer 2013Totally IntegratedAutomation CertificationsLevel 3Automation (TIA) solutions, required anupdating of the previous certificate forprogrammable logic controller (PLC) technicians.The new certificates for automationwith Simatic S7 based on Step 7 V.5– or TIA Portal – are called Siemens CertifiedService Technician Level 1 and 2 andSiemens Certified Programmer.Both certificates address the entire TIArange and both require a three-step trainingprocess before the test itself can betaken. The further education program developedby Siemens offers various possibilitiesfor interested employees to achievethe certificates defined by the ZVEI and toconsequently keep pace with the latesttrends in the industry.The benefits of the SITRAIN CertificationProgram are– Up-to-date qualification through the certificateeven though the professional qualificationmay have been some time ago– Satisfaction through performance byfaster and safer completion of tasks usingthe acquired knowledge– More efficient completion of projectsthrough the same technical knowledge ofemployees from different cultures andlanguages backgrounds in internationalprojects. +PLC TechnologyIndustrial CommunicationHuman-Machine InterfaceMotion ControlConnection of DrivesFunctionalSafety EngineeringLevel 2Level 1MORE ON THIS TOPIC:+ Contact person:Marianne Schoch, RegionalManager, Sitrain+ E-mail:marianne.schoch@siemens.comadvance | 3-2012 45

DialogueSiemens Industry Online SupportService 2.0 via theWebProduct videoConfigurationin No Time at AllSiemens AGWhether they are on the road or need informationon products directly at a plant or machine, moreand more customers are using the Industry OnlineSupport portal with their smartphones or tabletPCs, as the Industry Online Support app providesaccess to all product information. It’s fast, simple,and clearly organized.The most important functions of the app includea product scanner, a product view, offlineThe new product video “Efficient Configuration with CAD/CAE Data” shows howthe configuration process can become much more efficient and how time savingsof up to 80 percent can be achieved. The video addresses everything from theprovision of high-quality current product data and their integration into engineeringsystems to individual standardized plant documentation.There is also the option of free CAx application support, which can reveal furtherpotential in your engineering process, creating room for more innovation. +To watch the video, go to and search forSIEMENS Industry – CAD/CAE data.New Siemens industry blogAlways Well InformedSiemens AGThe Siemens IndustrySector has launched anew blog. Since April,this blog has beenkeeping readers updatedon integratedtechnologies, industrycompetencies, and servicesto increase productivity.The blog is availablein both English andGerman. +caches, and support requests. The product scanneruses the smartphone’s or tablet PC’s camerato scan the codes that are included on more andmore products. After the scanner has recognizedthe product, the new product view, which nowalso shows graphical information, opens automatically.The app saves pages marked as favoritesin the smartphone’s or tablet PC’s offline cache,so that the most important information is availableanytime.It is now also possible to send support requests –service inquiries to Technical Support – while onthe road. Pictures as well as text can be attachedto describe the situation as clearly as possible. +Siemens AGCompetitive Industry (German version): Industry (English version): advance | 3-2012

EventsKeep up to date with the latest dates and events on TotallyIntegrated Automation. +Event Location DateHUSUMWindEnergyMINExpoInternationalHusum September 18–22, 2012Las Vegas September 24–26, 2012Motek Bielefeld October 8–11, 2012Glasstec Dusseldorf October 23–26, 2012EuroBLECH Hannover October 23–27, 2012Brau Beviale Nuremberg November 13–15, 2012SPS IPC Drives Nuremberg November 27–29, 2012LibraryAutomating with STEP 7 inSTL and SCLSimatic S7-300/400 Programmable Controllers6th revised and enlarged edition, 2012, 553 pages, 168 illustrations,151 tables, hardcover,ISBN 978-3-89578-412-5, €69.90This book is aimed at all users of Simatic S7 controllers. First-time users areintroduced to the field of programmable controllers, while advanced userslearn about specific applications of the Simatic S7 automation system. Thebook gives an introduction to the latest version of engineering softwareStep 7, V5.5. It describes elements and applications of the text-oriented programminglanguages statement list (STL) and structured control language (SCL) for use with both Simatic S7-300and Simatic S7-400, including the new applications with Profinet and for communication over Industrial Ethernet. +MagazinesOur technical magazines are a real added valuefor your business. Regardless of whether youchoose process news, move up, motion world, oradvance, in our technical magazines for all areasof automation and drive technology the informationand technology are interestingly presented,well researched and up to date, and describedwith application examples. You as a plant operatoror machine manufacturer are always well informed– with information specially adapted toyour industry. If you don’t want to miss an interestingissue, you can order a free subscription toyour professional magazine immediately. NewslettersSiemens offers you electronic newsletterson various topics for subscription at example, with the Totally IntegratedAutomation Newsletter you will be informedby e-mail about new hardwareand software, services, application examples,and important dates and eventsrelating to Totally Integrated Automation –electronically and always right up to date.Simply register with your e-mail are three waysto get your subscriptionWould you like to subscribe toadvance free of charge?1 Just send a fax to +49 911 9783321,or2 send an e-mail, or3 order on the Internet | 3-2012 47

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