‘Reduce, reuse, recycle’ saves the engineering environment, too, when you replace standard coding with time-saving reusable software objects. 

Industrial users all seem to have unique environments, even plants within environments like food processing or component manufacturing have requirements and processes that vary widely. But throughout the individual enterprises, there are usually many machines that are run using the same setup.

That’s a vexing challenge for original equipment makers who supply manufacturing control systems to customers who now compete in a world that puts more emphasis on mass customization than mass production. It’s fairly easy to create hardware that works in many different environments, but software has to be flexible so plant managers can continuously alter their production runs to meet demands that seem to change constantly.

To meet the demands of mass customization, users need to be able to write applications that are tightly focused on their applications. They must also to be able to reuse this software once it’s written. That makes it easier to set up facilities that produce the same results regardless of where they’re located.

Siemens Industry is addressing this challenging issue with its Totally Integrated Automation Portal, which unifies all automation software tools within a single development environment. The TIA Portal is an engineering software environment that includes a range of tools that simplify programming by providing a broad range of tools within an integrated platform. This engineering framework is based on the core intelligence used in more than 100,000 automation products over 15 years.

One of the TIA Portal’s most important components is the Libraries concept. It addresses the challenge of providing software that can be reused throughout a company’s facilities.

The concept is proving to be very beneficial to customers who credit the TIA Portal with significant engineering time savings. Many of them cite the Libraries concept as a big part of the reason for these gains. In particular was Hurst Boiler, who stated that they saved up to 40% in engineering time savings due largely to their extensive use of this feature.

With this software, users can create their own libraries, containing many various parts of the engineering objects. These software modules can be easily reused in other projects.

For example, complete configurations of various machines and plants can be centrally saved on one server. Fully developed components, tried-and-tested project data and projects from earlier versions can be reused at any time. Established engineering quality is transferred from the first tested program to all future projects.

With a Library of fully developed components, it becomes much easier for the OEM to customize machines based on customer needs. For example an OEM may offer a small, medium and large version of a machine, but there may be parts of that machine that are common across all three product lines. Therefore once the library component is developed and tested, it can be easily reused and such a feature can significantly reduce the OEMs engineering time.

The strength of the Libraries concept within the TIA Portal lies in the mix of objects that can be placed in a library folder itself. STEP 7 and WinCC elements of an automation project can be stored in local or global libraries, and can be stored with the exact parameterization that was done in the original project. The following objects can be stored inside a Library folder:

- Program blocks

- Tags

- HMI screens

- Graphic objects from HMI screens

- Configured I/O or Analog modules (Standard or Failsafe)

- Complete stations

Therefore for an OEM that has sections of a machine that are common across a company’s product line, he can now place the PLC blocks, HMI screens, tags and configured I/O modules for that machine section into a Library folder. A simple drag and drop from the global library allows these objects to be reused on other projects. The global library can be set up in any folder of the Windows® file system. The user can compress this folder and store it on a server or send it by e-mail, for example, around the world. The local library is saved together with the automation project.

A Library folder consists of a “Master Copy” folder and a “Types” folder. Objects that are to be reused in other projects are copied into the “Master Copy” folder. The “Types” folder is quite different in that it allows the user to create a HMI faceplate or HMI user data type (UDT) within the Libraries itself. Once the faceplate or UDT is created and used in the project, they can then be very easily updated and redeployed from the central Libraries location. All references in the HMI program to any usages of the faceplate or UDT are automatically updated with a single click.

With its compact design, the distributed I/O system Simatic ET 200SP takes up less space in the control cabinet and is especially user-friendly in operation.

Users in plant engineering and machine manufacturing benefit from the variable station setup, fixed wiring, and improved device and module identification features. The SIMATIC ET 200SP with IP20 degree of protection supports Profinet, provides a fast cycle time and high system performance, and can be integrated into the automation solution via the TIA Portal or SIMATIC Step 7 engineering tools.

The SIMATIC ET 200SP distributed I/O is based on a scalable design with variable station set-up options.. The compact design means the system is suitable for standard control boxes with a depth of just 80 mm, even observing the standard bending radii. The integrated power module also saves additional space and simplifies load group formation.

During system design, great importance was attached to simple handling and practical use. The low parts variance also reduces warehousing costs for the user. No tools are required for wire installation and the user also saves time  with the no tool required din rail release of the IO modules. Mechanical coding protects the modules from damage if they are wrongly inserted, and a lateral latch mechanism provides a high degree of connection stability, even for vertical installation. In addition, it is possible to replace modules and terminal boxes during operation without risking station failure. Wiring has been simplified by the improved arrangement of the slots on the terminal box (rotated through 90 degrees) and the easy push-in technology. Module markings clearly display the most important wiring and channel information. Color-coded labels also simplify assignment of cables to the terminal box. The user can also identify machine- and plant-specific modules with the help of identification plates and labeling strips.  All these features are designed to facilitate user’s troubleshooting without laptop and minimize downtime.

The SIMATIC ET 200SP is equipped with two Profinet interfaces and an internal data rate of 100 Mbit/s ensures delivery of high system performance. The backplane bus is isochronous with Profinet and can thus provide high-precision, virtually jitter-free data transmission. The bus adapter allows the user to freely select the most appropriate Profinet connection technology: RJ45 or FastConnect. The integrated shield concept, from cables to shield connection elements for the terminal box, to backplane bus and Profinet cable, provides the system with a high degree of electromagnetic compatibility. SIMATIC ET 200SP is equipped with Profienergy functionality facilitating the coordinated deactivation of individual loads or entire production units during unproductive periods.

For more information on this new product, go to usa.siemens.com/et200.  For the mobile site, go to www.siemens.com/et200sp.

Ideally suited for wall mounting in apparatuses and machines, the PSU100D features a rugged, low-profile, aluminium casing with IP20 degree of protection that requires little space while enhancing mounting flexibility. A wide temperature range from -10 to 70 degrees C. accommodates a broad range of applications in harsh environmental conditions.

The six variants of the power supplies provide a regulated supply of 24 volts with rated output currents ranging from 2.1 to 6.25 amperes (A) and 12 volts  with 3 or 8.33 A. Another 24 V version with an output current of 12 A uses a fan for cooling purposes.

For higher outputs, two devices of the same type can be connected in parallel. Single-phase connection to almost any public and industrial supply system is possible thanks to the wide-range input of 85 to 264 V AC, radio interference class B as well as certification in accordance with CE and cULus (Underwriters Laboratories certification for Canada and the USA).   All of the devices are UL listed and do not require derating inside of a panel.

The output voltage can be set between 22 and 28 V DC using potentiometers in the 24 V DC variants, and between 11 and 14 V DC in the 12 V DC variant. A green LED indicates the operating status “Output voltage OK.” Electronic short-circuit, overload and overvoltage protection features ensure safety in the event of a fault.

You can find more information on the Internet at: www.siemens.com/sitop

How charge controllers and photovoltaics lowered the cost of lighting for 50 families in a remote Guatemalan village.

In La Nueva Providencia, a village of 50 families in central Guatemala, candles and kerosene have been the primary sources for lighting for years. Candles don’t provide much light, yet they’re costly – as much as 90 cents a day in a region where daily wages are around $4 when work is available.

Years ago, their prospects for getting electricity would have been bleak. But a number of altruistic engineers are bringing help to those who need it. Since 2002, volunteers have worked through a group called Engineers Without Borders USA. EWB has gotten solid support from philanthropic  engineers – it has worked on 350 projects in over 45 developing countries, changing the lives of millions of people.

The situation in La Nueva Providencia caught the attention of the Marquette University Chapter of EWB. Engineering students at the Milwaukee school decided to use their skills to alter the situation. Marquette is one of the many universities supported by Siemens Cooperates with Education. Siemens provides equipment at low or no cost, and some employees serve as mentors for students.

At the start of the La Nueva Providencia project, the students determined that each home would be wired for three lights and an electrical outlet for small household electronics such as TVs, DVD players and radios owned by many residents.

Their initial step was to install enough solar panels to provide two to four hours of electricity to each home every day, splitting the delivery fairly evenly between mornings and evenings. Along with street lights, this translates to energy consumption of five to 10 kilowatt-hours per day and future use of 20-30 kwhrs per day. It is expected that each family could use the TV for 90 minutes in lieu of 80 percent of the lighting in the home.

This yielded a peak demand of approximately 100 watts per home for a total of five kilowatts for the village. Initially, the Marquette students planned to leverage a spring-fed river for hydroelectric power, but it was deemed insufficient for peak demands. They decided to augment the hydroelectric turbine with solar systems.

After further analysis of the challenges of installing a turbine system in the rugged terrain surrounding the village, the team opted to start with photovoltaic generators and install the turbines later.

Those plans were developed using a phased approach. This strategy requires additional trips, but it splits the tasks into a manageable series of projects the Marquette students could fit into their schedules. To date, the five phases of the installation have an estimated cost of around $40,000.

The initial PV system produced approximately four to six kwhrs per day or approximately 20 percent of daily consumption. An expansion added an additional 20 percent of the energy initially required by the system.

The first phase of PV system installation consisted of 15 – 170 watt panels connected for 105 volt operating output. They are connected to a charge controller that supplies regulated power to a bank of 12 – 105 amp-hour batteries. These nickel metal hydride batteries are in turn connected to a 2,500 volt-ampere (va) inverter to power the electrical system.

These system components were chosen to allow flexibility in expanding as the system grew during the phased implementation. That made it simpler to connect more solar components to add nine 235-watt panels, another charge controller and 2,500va inverter.

The final implementation will result in four 2,500va inverters connected to create a 120/240 volt power system with a peak capacity of 10 kilovolt-amperes. The system will be managed by a controller to balance power from inverters and coordinate charge controller output.

Throughout these phases, the size of the community was a challenging factor. La Nueva Providencia has approximately 1,400 feet of pathways, which are now illuminated with pole-mounted street lights.

The team members put termination boxes for individual homes on each street light pole. That minimized the amount of trenching that will be necessary and will allow for more connections to each home.

To avoid unequal use of the resources, volunteers installed a relatively small circuit breaker in the circuit on each house. This provides protection and limits the energy usage so one homeowner can’t access significant portions of the limited system capacity. Each home also receives a ground fault circuit interrupter electrical outlet for safety.

Beyond the desire to create a stable system to provide electricity, one of the key goals was to ensure that the system would continue to reliably deliver power over the long term. So far, that’s been achieved.

The roof-mounted solar panel  has provided reliable operation, but the charging connector and the nickel metal hydride (NiMH) batteries require replacement after 18 months. That’s one reason that maintenance costs were calculated to be $1,200 per year over the expected 25-year life of the system.

This covers cost associated with both the PV system and hydroelectric system. When this total cost is divided among the families, it’s affordable. The average cost per family was determined to be $2 per month, or $24 per year. Eliminating candles and kerosene wicks will potentially save every family an average of $23 per month while eliminating the safety risks and adverse health effects attributed to the open flame.

Marquette’s La Nueva Providencia highlights the effectiveness of programs developed by EWB with help from corporations like Siemens. The system had generated over 2,200 kwhrs in the first 22 months after its installation. That’s an average of 3.25 kwhrs per day. It’s been reliable throughout this period and was not damaged during heavy storms resulting from tropical storm Agatha which damaged surrounding areas in May, 2010.

Yes, and much more – when they transform a driving range into a fully automated entertainment experience.
Programmable logic controllers aren’t usually associated with fun and entertainment, but an entertainment company is using PLCs to transform the driving range experience into a game-playing entertainment outing. PLCs work in conjunction with RFID-equipped golf balls, touch screen displays and other electronics gear to provide a new style of golf outing.

Over the past few years, Dallas-based TopGolf has built up a chain of golfing entertainment centers that turn driving ranges into entertainment centers. Its multi-level golfing centers offer lounges, bars and restaurants along with the ability to play a unique and patented golf gaming experience called TopGolf.

Up to six players can compete in a real (not virtual) game that involves aiming at live targets that resemble giant dartboards.  Each target is equipped with RFID technology that reads each RFID equipped golf ball and provides instant feedback on the yardage the ball was hit, and awards points based on distance and accuracy.  Hitting golf balls is now turned into a competitive fun game.

The newest facility in Allen, Texas, takes the entertainment model even further. There are 94 stations, split over three stories. The new facility makes it quicker and simpler to play through a game. Automated ball dispensers controlled by PLCs provide balls directly to players using a high tech touch. They don’t even have to push buttons before teeing up the next ball.

“You just wave your club in front of the hopper and it kicks out a ball. Then you position it and aim at the target,” says Brian Billiet, Director of IT at TopGolf. “This is more of an entertainment experience than a golf experience.”

These Automatic Golf Ball Dispensers are located at each of the stations. That lets golfers play more games in less time, increasing their satisfaction levels while also boosting TopGolf’s revenues.

“Instead of waiting at a central hopper to get a bucket of balls, now we have a hopper at each bay that holds the balls,” Billiet says. “Customers don’t have to carry a bucket of balls back from a central distribution site, which saves them a lot of time.”

The stations are all controlled by a dedicated touch screen kiosk where players can swipe their game cards and buy games. The kiosk will then activate the PLC so it’s ready to dispense balls.

A PLC handles this critical step. When the customer waves a club in front of the dispenser, a sensor alerts the PLC. This PLC then starts a motor that pushes the ball out onto the station’s putting green.

Reliability is a key requirement for the ball distribution system. TopGolf’s first attempt at the individual dispensers didn’t provide that dependability, forcing golfers at times to wait while a maintenance staffer walked down to the station and reset the PLC.

That obviously didn’t help the company’s goal of making golf more fun and less intimidating than going to a real golf course. When they started looking into the problem, managers realized the problem was the communications link for the PLC.

“The system we had before used serial communications to link the overall controllers and the PLCs,” Billiet says. “Data packets were often lost, which caused the machine to shut down. It took time to open up the box and reset the system, which annoyed the customers who had to stand there and wait.”

To resolve this issue, TopGolf turned to Skledar Enterprises, a system integrator that has done a number of industrial installations. Compared to the complexity of setting up some manufacturing plants, the task of rolling out a ball wasn’t high on the difficulty scale. But achieving high reliability and good performance wasn’t so easy it could be analyzed and solved in an afternoon.

“This wasn’t a real complex installation. Communications was the most challenging aspect,” says Wolfgang Skledar, President of Skledar Enterprises.

Given that high reliability and good communications were the two key issues, the first thing Skledar did was to swap out the PLC technology. Engineers picked the Siemens S7-1200 PLC, which has built-in Ethernet connectivity.

Using TCP/IP technology instead of serial communications did far more than reduce the failure rates. Standardized technology makes it far easier to troubleshoot the system.

“We’ve got features like wire break detection,” Skledar says. “We also came  up with some warning alerts when there are errors, pinpoint which sensor on a bay is bad, for example. Now the maintenance staff  knows exactly what to do when they arrive. They can take the right replacements and tools and have things fixed in a minimal amount of time.”

Perhaps more importantly for TopGolf, which has expanded rapidly over the past several years, the Siemens PLCs have made it very easy to expand with new bays or set up new facilities.

“With the TCP/IP portal, you just connect an Ethernet cable and you’re done,” Skledar says. “We’ve developed a whole new wiring system, now there’s nothing to the wiring. Installation time went from around six months to about a week.”

The new system, which is being made a standard technology component throughout the company’s sites, also makes it easier for TopGolf to update its programs. That’s a big factor in the entertainment world, where offering more variations of a game can bring in more revenue and inspire more return visits.

“Now that we’re networked, we can update the kiosks using a laptop instead of going out to each bay to reprogram the system,” Billiet says. “This technology has made our lives a lot easier.”

While the PLC is a mainstay of the system, it’s far from the only high tech aspect of this golf game. Each golf ball has an embedded RFID chip. This chip helps the system measure the distance and accuracy each time the golfer tees off. This data appears on the golfing station’s computer monitor, which provides scores for each member of the party.

With a reliable PLC helping provide a uniquely special gaming experience, TopGolf is set to grow throughout the U.S. and beyond.  For more information, visit http://topgolf.com/allen/.

Service Pack 2 provides many new functions. One is that migrating WinCC V7.0 SP2 projects is now a straightforward task. The upgrade also improves communication between WinCC Runtime Professional and Siemens S7-1200.

The software now supports even more Windows environments. Windows 7 64-bit software can now run in this environment, augmenting the 32-bit environments that are already supported. Windows XP Home and XP Professional are also supported.

The software should be run on systems with at least a 2 GHz Core Duo CPU.

New functions of this release include individual control of each IndustrialDataBridge connection (start, stop, connect, and disconnect) during runtime, integration of the IndustrialDataBridge Runtime Control into WinCC screens when installing IDB on a WinCC station (Web Navigator is not supported), creation of independent CSV files upon reaching an adjustable number of entries or upon the value change of a WinCC tag, and block transfer for databases through the support of the operators “<” and “>” in the “select” statement. Possible data sources and destinations for application of the IndustrialDataBridge include:

The SIMATIC WinCC/IndustrialDataBridge V7.0 SP3 is compatible with WinCC 7.0 SP3 and released for the following operating systems:

• Windows XP Professional (SP3)
• Windows 7 (SP1) 32-/64-Bit Professional, Enterprise, Ultimate
• Windows Server 2003 (SP2)
• Windows Server 2003 R2 (SP2)
• Windows Server 2008 (SP2) 32-Bit
• Windows Server 2008 R2 (SP1) 64-Bit

VPN routers save money and allow plant floor personnel to maintain and control access to their automation systems.

Productivity pinch points always prevent processes from moving forward, regardless of whether the issues are related to workflow, product flow, or information flow. This is especially true when a plant floor control system doesn’t keep pace with advancements in industrial networking technology and modern manufacturing information systems.

This was the case with one Detroit area automotive manufacturer that sought to upgrade its control network to improve performance, reliability, and security. There were conflicting network schemes, costly individual network drops for each PLC, and frequent network storms. A solution was needed to address existing issues with a network that could be configured and maintained by plant floor personnel.

The importance of network security is rapidly increasing throughout many industries, and the automotive industry is no different. To maintain tight security, this manufacturer’s IT department wanted to retain some measure of control. Specific network security concerns included viruses, unauthorized PLC access, and the potential for unwanted remote PLC code changes.

Not only did the auto manufacturer require a user-configurable and maintainable solution, it also wanted to maintain isolation between the plant and company networks. The network solution also had to limit the number of Ethernet drops, permit zone-to-zone communication, and restrict communications to only the plant-to-IT direction. To meet these requirements, the company chose a flexible, economical, and user-friendly routing and firewall device that suited both plant floor engineering and IT.

Network Architecture Evolution

The plant floor is where products are made and work happens. The company manufactures components for some of its vehicle brands at this plant. Workflow is strategically divided into zones that contain combinations of Auto Stations, Manual Stations, and Test Stands.

Auto Stations are composed of an HMI, PLC I/O, RFID readers, motor drives, nutrunners, robots, cameras, and/or other Profinet- or Ethernet-enabled devices. As the name implies, automated assembly work is performed within an Auto Station using various types of CNCs, robots, and other machines. Nutrunners are a type of assembly tool driven either by servo motors or pneumatically. Many have torque measurement and torque limiting capabilities. Manual Stations are similar to Auto Stations, but don’t have drives or robots because operators assemble parts by hand within these stations. Test Stands don’t contain HMIs, drives, or robots.

The original plant floor network architecture didn’t connect to the company-wide network and the IT department didn’t manage it. In this architecture, a peer-to-peer Ethernet network connected the entire plant PLC population. This caused a host of problems, including a peer-to-peer PLC network that didn’t connect to main company network; no support from IT for the plant floor network; frequent network storms; different departments applying different network strategies; network security concerns, including viruses, unauthorized PLC access, and remote PLC code changes; and increased costs due to separate network drops per PLC.

The plant’s second-generation network architecture was a step up because communications from the plant floor to IT was added. But this interim solution wasn’t optimal, as it required all the PLCs to directly communicate with servers on the IT company network. The direct communication raised technical issues and blurred lines of responsibility between the plant floor and IT. This interim solution also required a second Ethernet port to be added to each PLC in the form of an expensive Ethernet communications processor. The resulting network used the first Ethernet port for peer-to-peer communications among the PLCs, and the second port for direct communication to IT.

An Innovative Design

To address its network issues, the auto maker decided on an innovative network design using a common family of network security products that could accommodate all its applications. A PLC at each station or stand connects to a managed switch using the controller’s built-in Ethernet port. Depending on the function of the station, the managed switch is linked via Ethernet to other devices, including HMIs, RFID readers, safety components, and cameras.

Each zone accommodates up to 48 stations and/or stands. A lower-level managed switch at each station connects to a higher-level managed switch for its zone, so there is one higher-level managed switch per zone. This switch connects to a VPN router module, all of which connect to the Secondary Distribution Router (SDR).

The SDR manages the data flow from all the zones connected to it, and connects to the Main Distribution Frame (MDF). The MDF connects to the company-wide Ethernet backbone and IT network.

The VPN router modules and all plant floor components comprise the Controls Production Network (CPN) that is configured and maintained by plant floor personnel. Components above the CPN (i.e., in the IT network) are called the Manufacturing Production Network and are configured and maintained by IT. Thus, the VPN router modules are the line of demarcation between the plant floor and IT networks. As such, these modules are the key component in implementing the new network scheme.

Powerful New Advantages

Using the VPN routers within this new network architecture provides a host of benefits, including:

• A common product family that allows applications to be scaled as necessary
• Firewall capabilities within the VPN routers, reducing the number of devices needed
• Fewer device-type spares that need to be stocked
• Common devices that allow parts sharing among plants
• Product reliability and built-in diagnostics that increase uptime
• Minimizing Ethernet drops that reduce network traffic, project costs, and required maintenance
• Facilitating the transition of IT and control engineering departments from internal competitors to internal solution partners

The new network eliminated the need for an expensive communications processor at each PLC. At $1,000 per communications processor, this represented significant savings.

The VPN routers enable the IT network to have direct access to the PLCs, but only to pull information up to IT. No communication is allowed from IT to the plant floor, eliminating the possible crossover of viruses and other cyber threats.

The VPN routers include a network address translation (NAT) feature that allows network IP address modification, remapping, and/or reuse. The CPN contains many PLCs and other Ethernet-enabled devices; assigning each one a unique IP address wasn’t an optimal solution.

With NAT enabled, specific address ranges can be reused on different zones that aren’t connected to each other directly. The only PLCs that are assigned a unique or static IP address are those connected to the company network. The NAT feature of the VPN security modules provides the necessary translation between the static and dynamic IP addresses.

The VPN routers allow plant floor personnel to control what the company IT network can see on the plant floor. They also enable plant floor personnel to limit exactly what devices can be connected to the plant floor network. The VPN routers prevent the company network from flooding the CPN with broadcast messages, as well as CPN traffic not relevant to IT from infiltrating the company network.

Secure Solution Partners

One of the primary goals of the automotive manufacturer was to obtain a common network security solution scalable for all its applications. The company also required a network security device that the plant could maintain. Although the company’s goals were focused, strategies for reaching these goals differed between the IT and manufacturing departments.

One of the disagreements concerned internal ownership and control of the Ethernet network. The vendor project manager convinced the automotive company that it could save money by departmental partnering on the security solution. IT could still be involved with security management, but it wouldn’t have to provide 24/7 support.

Additionally, the IT department came to realize the importance of security when it comes to keeping a plant running. IT networks can tolerate occasional downtime, but must never lose critical data related to certain key financial and other parameters. Put another way, not being able to process payments to suppliers for a few hours isn’t critical, but losing data concerning how much is owed to which supplier would be disastrous.

IT users are somewhat tolerant of slow access speeds and response times, and networks are designed accordingly. IT users must also have access to the outside world via email and the Internet. On the other hand, manufacturing networks must maintain uptime and response times at all costs. Lost data isn’t a show stopper, and access to the outside world isn’t normally required; in fact, it must be severely restricted or eliminated to maintain security.

Recognizing these differences led IT and manufacturing to create essentially two networks, the CPN and the Manufacturing Production Network. The VPN routers are the point where these two networks connect, making these components critical to the entire network scheme.

Reaching a common ground via the VPN routers created clear dividing lines for IT and manufacturing regarding their respective responsibilities. It also allowed them to determine what is and is not allowed regarding plant floor to IT communications. Designing the networks as described above allowed the control system professionals within manufacturing to become responsible for plant network security, with IT monitoring their activities via the VPN routers. IT and manufacturing partnered in this solution, whereas previously they were internal competitors. The use of the VPN router was a key component in this partnership.

Security is now determined between the departments, and manufacturing retains responsibility for maintaining the physical hardware in the CPN, including the VPN routers. The new network architecture helped IT and manufacturing transition from internal competitors to solution partners.

WinCC V7.0 SP3 replaces the direct predecessor variant (V7.0 SP2). The following WinCC options, released simultaneously, are compatible with V7.0 SP3:

• WinCC/Server V7.0 SP3
• WinCC/Redundancy V7.0 SP3
• WinCC/User Archives V7.0 SP3
• WinCC/Web Navigator V7.0 SP3
• WinCC/DataMonitor V7.0 SP3
• WinCC/Connectivity Pack V7.0 SP3
• WinCC/Connectivity Station V7.0 SP3
• WinCC/Central Archive Server V7.0 SP3

WinCC V7.0 SP3 can be installed on Windows Server 2008 and Windows 7 32-bit and 64-bit systems, as well as other 32-bit systems. Improvements in the base package of the new version include availability of the Swinging Door algorithm for archiving; extension of the online trend control for stamping online or archive values into the trend control; inclusion of an OPC UA client; and incorporation of the channel for SIMOTION, including documentation.

SIMATIC WinCC V7.0 SP3 is only released under Windows 7 for operation with the SIMATIC NET Edition 2010. Information about SIMATIC NET 2010 as well as ordering information for necessary upgrade packages is available at entry ID: 43264686 on the Web. The SIMATIC Net Edition 2008 is still released for operation under Windows XP.

The task: modernize a control and automation system
while keeping 40,000 PET bottles per hour rolling off the line at Southeastern Container.

In 2010, engineers at Orlando, Fla.-based Southeastern Container (SEC), a major manufacturer of PET bottles for Coca-Cola, decided it was time to make improvements in its Sidel blow-molding machine. While the French-built machine continued to perform well mechanically, its control and automation system, installed more than 15 years earlier, had run its useful course.

The existing S5 PLC that automated the machine was no longer manufactured, and replacements often required long lead times. So continuing use of the antiquated PLC made online troubleshooting difficult for SEC’s plant maintenance staff. Further, newer standalone PLCs included onboard systems for air recovery, air pressure regulation, automatic lubrication, laser printing, and vision inspection. These were not interlocked with the S5 PLC, making system-wide, integrated control impossible.

The machine’s obsolete operator station also challenged plant personnel: the message display was failing and had burned-out LED sections. The display was controlled by digital outputs from the S5 PLC that allowed only brief message texts. Reporting required a nine-pin dot matrix printer, and the English text from the French manufacturer was difficult to understand.

An obsolete loop controller communicated serially to the S5 PLC’s automated lamp heat control. The risk of operator error during product changeover was increased because setup sheets were used for trimming the eight zones, along with 336 on/off pushbuttons for 336 lamps.

Meeting the Challenge

To solve the automation and control issues with the blow-molding machine, SEC turned to Belmont, N.C.-based Solvere Systems, a Siemens solution partner. Because replacing the machine with a similar but new blow-molding machine could have cost up to $4 million, the company chose to upgrade the control system while keeping the mechanical components of the Sidel machine. The upgrade would replace the S5 PLC with a Siemens SIMATIC® S7-319 controller and other Siemens automation products. The end result would improve performance and efficiency while simplifying operations and incorporating more powerful diagnostics and data connectivity.

Solvere was faced with a major challenge: for the first time in its history, SEC couldn’t take the machine out of service for the upgrade. So they devised a strategy that allowed the S5 and new S7 controllers to cohabitate while maintaining production.

The Siemens SIMATIC® S7-319 controller was a logical replacement for the S5 because it preserves the functionality of the original controller. Many aspects of machine operation were easily converted from the S5 to the S7 platform, and the new control system also included a 15-inch MP 377 HMI color touchscreen with recipe management and Profinet/Ethernet connectivity for the automation and data network.

The S7 controller was installed in three racks with 224 digital inputs, including 32 high-speed inputs requiring two interrupt input modules; it also features 96 digital outputs, seven analog inputs, and 10 analog outputs. The high-speed inputs are used to monitor safety I/O: if a problem occurs, the machine must stop immediately. The input modules generate a hardware interrupt in the controller that applies brakes and stops the machine in less than two mold stations or 18° of rotation.

One, Two, Three—Go!

To maintain SEC’s production requirements, Solvere completed the conversion in three steps:

Step One

The first step was to install the S7 controller and debug the S7 program during downtime on the weekend. The S5 PLD was then put back in control to accommodate production demands. Once the S7 controller upgrade was completed and tested, the S5 would be no longer needed, serving only as a backup system during conversion.

As part of the upgrade, Solvere provided a new control panel for the S7 controller that sat atop the existing Sidel control panel. This was installed during weekends when the machine was scheduled for preventive maintenance.

Twenty conductor cables pre-installed on each S7 controller module were threaded down to the S5 control panel and landed on the Sidel terminal strip, connecting I/O points to both PLCs. The S7 control panel was shipped to SEC’s facility, where 224 inputs and 96 outputs were wired to the Sidel main panel I/O terminal strip.

Switching between the PLCs took only 15 minutes. The inputs stayed connected to both PLCs; only the output module terminals needed to be unplugged. Having the S7 controller connected to the inputs while the S5 was running the machine was an important benefit, as it allowed the S7 program to be debugged.

Regulated heat zone control was accomplished with a dedicated PID loop controller that communicated serially with the S5 PLC. Solvere eliminated the loop controller by taking the 0.20 mA signal from the infrared camera into the S7 controller. Logic in the controller handled the PID loop and a temporary 10-inch MP277 touchscreen was used in place of the dedicated loop controller. The touchscreen HMI displayed alarm messages and provided a way to control the oven temperature. When restored to the S5 controls, the original message display, dot-matrix printer, and standalone PID loop controller were used.

Debugging the S7 program went so smoothly that the conversion was nearly completed before the scheduled maintenance time was up. The plant needed to go back into production to meet seasonal demand, and the team returned the following week. Step one was completed in three days.

Step Two

Four months passed before step two began because once the original pilot devices (i.e., pushbuttons, panel meters, and potentiometer controls) were removed, it would no longer be possible to go back to the S5 PLC. A plate was installed to cover the old pilot device mounting holes in the panel on the front of the machine.

Solvere permanently replaced all pilot devices with a 15-inch Siemens MP 377 touchscreen HMI. This provided detailed alarms and a graphical representation of I/O devices. Each device is color-coded green or, when indicating a fault state, red. Trend screens display temperatures, motor amps, and blow mold air pressures.

Step Three

Step three involved installing heat controllers on Profibus under the lamps at the oven. Also installed were heat controls that provide individual on/off, 0-100 percent regulation, and lamp break detection for each of the 336 lamps in the infrared oven. New recipe screens facilitated more efficient product changeovers.

Smooth Sailing for New Production

The machine upgrade was completed and became operational without any problems. Complementary systems for air recovery, air pressure regulation, automatic lubrication, laser printing, and vision inspection are now interlocked or controlled entirely by the S7 PLC and HMI.

Furthermore, if any adjustments are needed to improve operation, SEC can now make changes to the control system. For example, the blow-molding machine stopped because of a fault. The PET pre-forms were in danger of sticking to the stretching rods inside the molds. A simple program change was made to hold the pre-blow and high-blow air pressure on for five seconds after the machine stopped. Issue fixed, problem averted.