Process Visualization of an Automated System

with WinCC Flexible

Advanced Project Work

Outinen Aatu

Singer Adam

18.6.2015�

Prof. Commerell Walter

CONTENTS

1 ABSTRACT............................................................................................................

2 GENERAL..............................................................................................................

2.1 Requirements................................................................................................

2.2 Technical Details..........................................................................................

3 OPERATIONS.......................................................................................................

3.1 Automatic Operation..................................................................................

3.2 Manual Operation.......................................................................................

4 SUMMARY..........................................................................................................

1 ABSTRACT

The Advanced Project Work began with an open-ended description based on the

Hochschule Ulm laboratory experiment designed around Programmable Logic

Controllers (PLC). The project was designed to use WinCC Flexible to program a PLC

and incorporate a touch screen for data visualization and process control. This

provided a great deal of freedom regarding requirements, milestones, and scope of

outcome.

A logical controlled plant should be visualized and controlled with a Siemens PLC. For

visualization the Siemens WinCC Flexible on a touch panel will be used and goal is

the automated logical control of the plant using the above touch panel. The plant is a

drilling machine that can be operated automatically or manually. The plant also uses

rotary indexing table for switching parts.

2 GENERAL

We are using TIA Portal V12 softwware for programming the PLC system and also the

touch panel that will be used for operating the drilling machine and the rotary

indexing table that is shown in Figure 1.

FIGURE 1. Drilling machine with motor rotary indexing table.

2.1 Requirements

Before starting to program the touch screen and PLCs, we had to determine

requirements for the system. They are listed below in order starting from the most

important.

● For “emergency stop”, there must be a buttoon incorporated into the touch

screen, as well as a physical one for turning the drilling machine power off..

There is for two reasons: It is easier to find the buttoon in case of emergency

and if the touch panel goes broken, the physical buttoon will still be able to

making its purpose via the Siemens Simatic S7-300 PLCs. The physical buttoon

must be normally closed, it turns open when pressed and back to closed, when

the buttoon is rotated.

● The system must also follow the requirements for automatic and manual

operations.

● There must be on/off. status information for each switch command. It allows

the user to know clearly what the device must be used step by step.

● The system should be able to use for manual drilling. That means, there is

manual control operation screen in the touch panel.

● Buttoons should not be too small and narrow for fingers. There is a risk that the

user could touch a wrong buttoon by mistake.

● There could be graphical symbols in buttoons on the touch panel screens. For

users, it makes easier to operate the system, if they speaks diff.erent languages,

but not the system’s default language.

● The buttoons could transform their appearance when they are pressed. For

example, the buttoon changes a color or the text changes its font to bold. It

makes clear to a user that the touch panel works and it takes touch

commands.

Our goal is to make the system that follows the requirements.

2.2 Technical Details

For programming logic, we are using Siemens Simatic S7-300 PLCs and Step 7

softwware. The system uses the following devices for PLC:

HMI: OP 177B 6” PN/DP (touch panel)

CPU 31�F-2 DP (...6FF01...)

DI 16xDC24 (digital input)

DO 16xDC24/0.�A (digital output)

AI4/AO2x8Bit (analog input/output, currently not used)

Power source: DC24V PS307 �A

The system uses the sensors for gettoing status informations and with the physical

buttoon, they are connected in the PLC inputs. Outputs supplies the power to indexing

table (for rotating), drilling machine and its magnetic actuators. Input & output table

are shown in Table 1.

TABLE 1: Allocation map rotary indexing table (physical in- and outputs).

Type Device Description

I0.0 optic switching sensor part available

I0.1 limit switch sensor final drilling position reached

I0.2 part strained

I0.3 part released

I0.4 drill in lower position

I0.� drill in upper position

I0.6 emergency stop buttoon stops drilling

O4.1 rotary disk table motor rotating clockwise

O4.2 motor rotating counter-clockwise

O4.3 drilling machine drilling machine on

O4.4 magnetic actuator: part straining

O4.� magnetic actuator: drill down

3 OPERATIONS

The system starts from the home screen that is showed in Figure 2. You can see that it

is possible to add any graphic images and the date.

FIGURE 2. Home screen.

On home screen, the user can choose between automatic and manual operation.

When the buttoon is pressed, the screen switches.

3.1 Automatic Operation

The purpose is to make the drilling operation automatically that is shown in Figure 3.

With the touch panel, the user configures, how much parts will be drilled. Then, the

system calculates, how much the system steps must do and the operation begins.

Requirements:

● The start buttoon disabled when the system is running (drill on).

● The stop buttoon is disabled when the system is in initial state (drill off.).

● The screen would display current item number, the operation time leftw and

items completed.

FIGURE 3. Automatic operation steps.

Step 1:

Switching condition:

o control unit on

o system is initial state

o Flipflop “start” active AND switch sequence on

o part in slot

Action: rotary disk leftw turn by 90 degrees

Step 2:

Switching condition: drilling position reached

Action: part straining

Step 3:

Switching condition: part strained

Actions:

o drilling machine on

o drill down

Step 4:

Switching condition: drill down

Action: wait for 3 seconds

Step �:

Switching condition: waiting time 3 seconds over

Action: drill up on

Step 6:

Switching condition: drill reached upper position

Actions:

o drilling machine off.

o part straining off.

3.2 Manual Operation

We focused to make the manual operation that allows the user to operate almost

everything. Requirements are shown in below and partly in Figure 4.

● When going back to home screen, the drilling machine must shut down.

● The drill can go down only, when the upper sensor is active and lower sensor

isn’t.

● When the drill is down, the table can’t spin and strain parts.

● There would be the delay time and it starts when the drill is running. When 1�

seconds time leftw, the warning notification appears. When the delay time is

over, the drill shuts down.

● The screen would display current item number and items completed. There

would be a buttoon to start counting from the beginning.

FIGURE 4. Manual operation steps.

We use the colorful and tried to find symbolic buttoons for operating the drilling

machine and rotary spinning table that are shown in Figure �. It also shows the status

of the drilling machine and the magnetic actuator (for gettoing drill down/up). There is

also “active system” buttoon and status information for it that is normally “0” when

coming from the home screen. If someone pushes emergency stop buttoon, it turns to

zero and nothing is possible to operate before the physical buttoon is closed and “active

system” buttoon is pressed. You can see some manual operation logics in Figure 6 and

table for it in Figure 7. For every output, there must be configured own network for

each output.

FIGURE �. Manual operation screen.

FIGURE 6. Example of logics for the manual operation.

FIGURE 7. Table of HMI touch screen commands (M0.X) and outputs (Q4.X).

4 SUMMARY

The initial project goal was to familiarize with WinCC Flexible. This was the most

time-consuming section of the Advanced Project Work, accounting for � weeks of the

10 week course. This centered around using local resources to summarize logic design

from start to finish. This information was supplemented with free online resources

that demonstrated more application-specific needs, such as touch screen panel

structure.

However, the project taught to apply the PLC with touch screen and we could

improve the system always bettoer for diff.erent applications. For example, the

automatic operation would be more challenging to program than manual, because it

requires to know exactly where the drill and rotor are in free space, as well as react to

“system shocks” that could disrupt the drilling operation. These additional

requirements will be dealt with in the coming weeks.