fa-1: industrial automation pc technology for the industry 4 · pc based automation and...

FA-1: Industrial Automation PC Technology for

the Industry 4.0Tim Parmer and Alessandra da Silva

Manufacturing in America │ March 20-21, 2019

Unrestricted © Siemens 2019

Unrestricted

Unrestricted © Siemens 2019 All rights reserved. Community. Collaboration. Innovation.

Table of content

SIMATIC PC based automation

▪ Trends and requirements

▪ Why use an Industrial PC?

▪ PC-based Control and PC-based Automation

▪


What digitalization means to the industry

Solutions Technological trends are driving transformation

Current drivers of Digitalization

• Operational excellence

• Big Data and Analytics

• Mobility of Devices

• Virtualization and Cloud computing

• All-time network access

• Simulation

• Integrated solutions

• Cyber Security

• Paperless manufacturing


PC based automation and digitalization

Industry 4.0 is driven by the need for more efficient and cost-

effective manufacturing. It will be supported by advances in

automation as exemplified by the Industrial internet of things

(IIoT), and PC-based controllers. This combination of smarter

devices working with smarter control will help realize the

possibilities of digital manufacturing.

The use of PC technology in the industrial environment is

already a success story, it is due the uniting the advantages of

PC technology with the challenges of industrial manufacturing.

In this way, plants with high requirements on processing speed,

benefit from the computing power and openness of this

technology. Since these plants often operate continuously and

in a harsh industrial environment, the PCs must also be

designed to run under these conditions.


PC-based Control and PC-based Automation

What is it?

PC-based controls are industrial control system that utilizes a PC

as a control platform. PC-Based Automation combines the

features of PLC-Control and open PC-Architecture on one

industrial device!

When use a PC based solution (e.g.)?

When large amount of data needs to be processed and stored

Multitask capability is a requisite

Collaborative execution of processes is needed

Security is required


Industrial PC (IPC) versus White Box

Why an Industrial PC?

What's the main difference between and Industrial PC and White

box?

Hardware construction – all components of an Industrial PC are

“industrial grade”. These components have longer life cycle, better

quality and are built to a higher standard.

Industrial PCs are designed for industrial environments due:

Rugged enclosures: high resistance to vibration and shock. Suitable for

higher ambient temperature

The redundancy that guarantees great system and data availability

The amount and type of interfaces, allow communication towards the

field with all many devices

The flexibility, versatility and high performance

Long life cycle and compatibility that minimizes adaptation and

replacement outlay


Why Do PC Systems Form Part of an Automation Solution?Because, in addition to control and visualization tasks, PC systems

are also employed as:

Data collector & converter

• Data recording directly at the machine

• Interface between machine and IT level

• Link to corporate information systems

Automation tasks

• Control and visualization with one device

• Complex SCADA applications

• Flexible integration of PC hardware and software

Industrial servers and workstations

• PC applications in production

• Machine-level server applications

• Data management in control rooms


PLC vs. PC based Automation

PC-Based Controls

PC-based controls are programmed and run on a computer (normally industrial computers), and communicate and monitor an equipment or

system. They are not tied to any one hardware platform, have fast communication between controls programming and equipment and

support more programming languages.

PLC-Based Controls

A programmable logic controller (PLC) is industrial computer which has been ruggedized and adapted for the control of manufacturing

processes. Unlike a typical computer, a PLC is designed with simple handling targeted at machine automation. It normally has a long life

cycle (around 20+ years), many controls engineers are familiar with how to program the primary PLC manufacturers, so it is easier for

electricians and controls technicians to troubleshoot systems using PLCs.


SIMATIC Controller with common engineering, but which

one is a right choice

Modular Controller PC-based Controller

Robustness ✓✓

(Scalable through to robust Embedded IPC)

Spare parts availability(from Phase Out date)

10 years 5 years

Quick startup ✓

Program execution scalable

viaCPU

Processor (architecture, frequency)

/ application

Inte

gra

tio

n in

on

e d

evic

e

Safety ✓ ✓

Visualization ✓

High-level languages (C/C++)

✓

Windows applications(e. g. database)

✓


PC-based Controllers

Meet the requirements of specialized machine builders

Avoid downtimes

High availability during

running operation

High productivity

High performance of system

reactions, data processing and

communication

Standardization

Re-use of program code and

communication standards

Security

Protection of own know-How

unauthorized access

Special machine building requires open and flexible controllers with high performance

Open for ideas

Easy integration of PC applications

and existing know-how

Scalable

Easy realization of different

requirements incl. safety applications

SIMATIC Industrial PC

Reliable and rugged hardware platform for the

digital enterprise


SIMATIC IPCs - Comprehensive product portfolio with reduced

complexity, thanks to platform concept

IPC2x7

Compact

IPC4x7

Powerful

IPC6x7

High performance

IPC8x7

Maximum expandability

IPC5x7

Maximum performance

IPC3x7

Ex stock*

Embedded industrial PCs

Fanless design

High-end industrial PCs

High functionality

Advanced industrial PCs

Latest PC technology

Basic industrial PCs

Attractive price

Rack PC Box PC Panel PC

IPC647E

IPC847E

IPC547G

IPC347E

IPC827D

IPC627D

IPC427E

IPC227E IPC277E

IPC477E

IPC677D

IPC377EIPC327E

IPC127

Ultra Compact

IPC127E

NEW

Long-term availability:

4–6 years

plus 5 years repair and

spare part service

Long-term availability:

2–3 years

plus 3 years repair and

spare part service

NEW


12/2018

SIMATIC IPC Platforms for Plant Floor

Nanobox (Box und Panel PC) Microbox (Box und Panel PC) Box and Panel PC Rack PC

Embedded Industrial PCsHighly rugged – Highly compact – Maintenance-free

High-end Industrrial PCsVery rugged – High performance – High functionality

• IPC227E

• IPC277E

• IPC627D

• IPC827D

• IPC677D

• IPC647D

• IPC847D

• IPC427E

• IPC477E

• IPC427D

• IPC477D

newnew newnew


IPC 647D / 847DBox PCs with ATEX

Ex – Panel PCInox fully enclosed PRO – Panel PC

SIMATIC IPCs

Quality in industries with special requirements

Software expansions and certificates

(F & B, Pharma, Energy,…)

✓ GMP / FDA-compliant

✓ Audit

✓ Electronic signature

✓ Tracking & Tracing

✓ Order control

✓ Energy management

acc. to DIN ISO 50001

Hardware certificates

F & B, Oil & Gas, Pharma, Chemicals, Marine, Automotive,...

https://de.wikipedia.org/wiki/Datei:Conformit%C3%A9_Europ%C3%A9enne_(logo).svg


SIMATIC IPC

Service for 36 months at no extra charge

1) Wear and tear as well as problems that arise due to

improper handling of devices are excluded from

promotion.

2) For hard disk defects that require system to be restored,

repair service will only cover restoring installation to

original working condition. Uploading of additional

software and drivers used by customer and setting up

operating software are not covered.

3) Additonal 12 months warranty for full 48 months

available as option


Siemens makes easier for customers to get the units faster

Drop shipment or local US-based production

Shipment directly to the customer Drop shipment from German factory to our customers

worldwide

Most popular configurations for U.S. based

customersNano and Micro (box and panel) series

Quality Guarantees Your SuccessSame rigorous processes and quality standards as those

units produced in Germany

Assembled in USAQualify products for government contracts


Totally Integrated Automation Portal (TIA Portal)

… the gateway to automation solutions within the Digital Enterprise

Energy Management

Diagnostics

Safety integrated

Security integrated

HMI ControllerDistributed

I/O

Motion

ControlDrivesIPC

PROFINET

Totally Integrated Automation Portal

Same SW for Modular or PC Based

Common data management

WinCC STEP 7 SCOUT StartdriveOne common framework

Unique and consistent user interface concept

Common and centralized Service

Global library concepts

IPC fully integrated in TIA Portal

SIMATIC S7-1500 Software

Controller

www.siemens.com/software-controllerUnrestricted © Siemens AG 2018


SIMATIC S7-1500 Software Controller –

Easy and flexible use of PC-based controller

𝒇 𝒇 = 𝒇𝒇 +

𝒇=𝒇

∞

𝒇𝒇 𝐜𝐨𝐬𝒇𝝅𝒇

𝑳+ 𝒃𝒇 𝐬𝐢𝐧

𝒇𝝅𝒇

𝑳

Complex control tasks

• Realization of short cycle times

• Integration of complex algorithms

• High program and data memory capacity

Integration of PC applications

• Integration of (existing) high-level language code

• Direct integration of controllers from model-based development

Multiple tasks on a single device

• Controller, HMI and Windows applications on one CPU

• Functions can be centrally expanded with ET 200SP modules

• Integration of third-party software (e.g. Video processing)


12/2018

SIMATIC S7-1500 Software Controller

Supported SIMATIC IPC Platforms

Nanobox (Box und Panel PC) Microbox (Box und Panel PC) Box und Panel PC Rack PC

Embedded Industrial PCsHighly rugged – Highly compact – Maintenance-free

High-end Industrrial PCsVery rugged – High performance – High functionality

1) Devices with NVRAM (e.g. buffered SRAM) required for operation of CPU 1507S F

CPU 1507S (F)

CPU 1508S (F)

CPU 1507S (F)

• IPC227E

• IPC277E

• IPC627D

• IPC827D

• IPC677D

• IPC647D

• IPC847D

CPU 1507S (F)

CPU 1508S (F)

1) 1) 1)

CPU 1507S

CPU 1508S

• IPC427E

• IPC477E

• IPC427D

• IPC477D

new new new

newnew newnew


12/2018 SIMATIC S7-1500 Software Controller, technical information

SIMATIC S7-1500 Functions

Also run in the Software Controller

The S7-1500 Software Controller supports full functionality of the modular S7-1500 CPUs

Further Information are available in the corresponding documents for the S7-1500

Security

Motion Control

Diagnosis

PID Trace

Webserver IIOT

OPC UA

Configuration Control




How to provide independence to Windows?

Function Benefit

Parallel performance of

software Controller and

Windows

▪ Real time

▪ Reboot Windows ▪ Fast start-up

Use of the native S7-1500

operating system

▪ Full compatibility with

S7-1500 Advanced

Controller

Exclusive assignment of HW

resources as storage or

PROFINET interfaces

▪ Optimal security and

know How protection

▪ IO access - hard real

time

Direct hardware access from

software controller

▪ No loss of or real time

performance-

Communication between

Controller,

HMI or other Windows

applications

▪ HMI access

▪ Access to web servers

▪ TCP/UDP via Windows

▪ OPC UA

PC

Windows S7-1500

Software Controller

Siemens Hypervisor

SIMATIC

Communication

GraphicsPC HW MemoryEthernet PROFINET PROFIBUS

Normal operation of the

S7-1500 controller




Same Operations as modular S7-1500

PC

CPU S7-150xS (F)Windows

Simple and unified operation for S7-1500 Controller

PC Hardware

• Same development with TIA Portal SW

• The “Display” of the S7-1500 Software Controller

provides same menu structure and functions

like the display of a Modular S7-1500 controller

• Run / Stop control from the S7-1500 Disply

• Displays PLC diagnostic Messages, IP addresses, Safety

program validation, I/O status, ETC

• HMI or SCADA can be running on the same IPC or

distributed to HMIs on the network

• Independent access to HD/CF/SSD from Windows

• OPC UA direct from PLC

• Open Developers Kit (ODK) &1500S imports C / C++ logic

control libraries into the S7-150XS



Highlights V2.6

CPU 1508S F

• Large code and data memory 10 / 100 Mbyte +

• CPU Supports OPC UA Client and Srever

• Open communication Protocols

• C/C++ code exicution from the PLC

+


Windows 10 Support

• IPC2x7E (with Legacy Boot)

• IPC627D/IPC827D/IPC677D (with Legacy Boot)

• IPC647D (with Legacy Boot, standard only)

+

TIA Portal Openness for PC-based solutions

• Configuration

• Download

+

S7-1500 Software Controller Portfolio

CPU Type CPU 1507S (F) CPU 1508S (F)

Program-/

data memory5 MB (7,5 MB)

20 MB

10 MB (15 MB)

100 MB

Bit Performance 1 ns (Microbox, Core i7) 1 ns (Microbox, Core i7)

PROFINET IO Interfaces 1 1

IO Devices128 (STD Ethernet)

256 (CP 1625)

128 (STD Ethernet)

256 (CP 1625)

I/O space 8 KByte 16 Kbyte (CP 1625)

Number off connections 128 192

Standard Motion 60 axis 60 Axis

PlatformsIPC2x7E,

IPC4x7E,

IPC6x7D, IPC8x7D

IPC4x7E,

IPC6x7D, IPC8x7D

Highlights

new




Easy Installation and Engineering

Easy Setup

1 2

3

Installation Project

Download

Operation

• Simple installation

• No local settings/properties

• Efficient Engineering with TIA Portal

• Combine of C/C++ in PLC

• Complete configuration and download




IO Access – Overview

Exclusive assignment of interfaces

for PROFINET and PROFIBUS• I/O Onboard PROFINET interfaces SIMATIC IPC (X2, X3)

• Intel i210T card

• nterfaces are exclusively used by Software Controller

to ensure hard real-time and availability

• Bus cycle, min. 1 ms

• Supported interface types

• 1x PROFINET incl. IO Controller

• 1x PROFINET (data communication only)

• 1x PROFIBUS incl. DP

Windows S7-1500 Software Controller

SIMATIC

Communication

Interfaces for PROFINET:

Windows

Exclusive

SIMATIC IPC onboard (X1) • SIMATIC IPC onboard (X2)

• Intel I210T (Springville)

• CP 1625

Interfaces for PROFIBUS:

Windows

Exclusive

– • SIMATIC IPC onboard (X3)

• CP 5622

• CP 5623

Ethernet PROFINET PROFIBUS

Add on CP1625 card for

PROFINET IRT (PCIe board)

• Bus cycle, min. > 500 µs

• Isochronous operation yes

• MRP/MRPD (Ethernet Ring) yes


SIMATIC ODK 1500S

Typical Development Environment

Development of• CPU function libraries

• Real-time: Eclipse

• Windows: Visual Studio

• C++ Application

• Eclipse

• On target development possible

• No additional runtime licenses

En

gin

ee

rin

gR

un

tim

e

SIMATIC ODK 1500S

(incl. Eclipse)

SIMATIC TIA Portal

SIMATIC Target 1500S

(optional)

SIMATIC S7-1500

Software Controller

SIMATIC S7-1500

CPU 1518(F)-4 PN/DP MFP


Microsoft Visual Studio C++

(optional)



SIMATIC ODK 1500S

Highlights

• Execution of real-time algorithms

• Call to Windows DLLs

Execution of function libraries out of the PLC program

• “Sandbox” execution for ODK RT applications

• No debugging of know how protected S7 blocks

Security

• Intuitive use of S7 FB for call to ODK applications

Usability

• Complete decoupling of Windows functions through asynchronous

operation

• Preemptive execution of ODK RT applications

Robustness and Real-time

𝒇 𝒙 = 𝒂𝟎 +

𝒏=𝟏

∞

𝒂𝒏 𝐜𝐨𝐬𝒏𝝅𝒙

𝑳+ 𝒃𝒏 𝐬𝐢𝐧

𝒏𝝅𝒙

𝑳


• Re-utilization of existing code: many man-years of invest in development,

maintenance and know how

• Performance of modern PLC- and bus systems (e.g. PROFINET) sufficient for

this task

Migration Embedded

Computer

Program available as

C/C++ code

• Re-utilization of central functions on several platforms, even in

“Non-PLC-systems”

• Programming with C++ more efficient than with SCL in certain cases

Cross-platform programming

• Direct use of automatically generated C++ source code for control tasks

• Utilization as black box, preferably without manual reworkModel-based

software development:

Exporting control

codes using C++

Algorithms or closed loop control programs are already available as C++ source code

SIMATIC ODK 1500S

Why use CPU function libraries for real time?



Direct use of Windows functions and –software for control tasks, examples

▪ Connection vision systems

▪ Connection scanner or printerConnection

computer hardware

▪ SECS/GEM or PV2

▪ IEC ….Complex

protocol implementations

• Direct connection to SQL-Database (local or remote)

• Standard application availableDatabase access

▪ Saving data in files

▪ Support of different file formats

▪ Standard application available

Efficient exchange of

large data volumes

SIMATIC ODK 1500S

Why use CPU function libraries for Windows?



What If I do not want a more compact

controller?


S7-1500S PC-based controllers with integrated safety functionality

The worldwide sole software controller with integrated safety functionality


– CPU 1507S (F)

- CPU1508S (F)

SIMATIC ET 200SP Open Controller

– CPU 1515SP PC (F) (T)


SIMATIC ET 200SP Open Controller 2 –

PC-Based automation system

… for assembly of an

automation system with centralized

IO based on ET 200SP

HMI functionality using

WinCC RT Advanced

… with integrated

graphics connection

Open system for

Windows applications

and C++PROFIBUS DP connection

via ET 200SP CM

PLC functionality with

innovative S7-1500

Software Controller

… with replaceable CFast

flash memory card for

operating system, runtime

and project

PROFINET IO with ET 200SP

BusAdapter


SIMATIC ET 200SP Open Controller 2 –

Highlights of CPU 1515SP PC2

Hardware

• Intel Quad-Core-Processor GHz/8 GB RAM

• DisplayPort

• 2 x USB 3.0/2 x USB 2.0/8 GB RAM/30 GB CFast

Software

• Newest features SW Controller V2.6

• Available as preinstalled bundles (Standard/Failsafe/HMI)

• Support of SIMATIC ODK 1500S

Operating System

• Windows 10 Enterprise 64 Bit LTSB 2016

• Restore process via USB stick

• Powerful Windows side for applications

SIMATIC ET 200 SP family

• Support of all released ET200SP Bus Adapters and CM DP

• Support of ET200 AL assembly line


Can I get these high end features in a

Modular Controller?


Advanced Controller – CPU 1518(F) MFP

Multifunctional Platform based on RealS7-1500 Controller

Multifunctional Platform CPU 1518(F)-4 PN/DP MFP

• C/C++ Code can be used in the STEP 7 program code by calling

blocks

• A second runtime for C/C++ applications can be run in parallel to

STEP 7 user program code

• Standard-, Safety- and complex high level language program code

can be executed on one single platform.

• Spare part exchangeability of a S7-1500 CPU is available, so

that in the case of changing the hardware only the SIMATIC

memory card has to be plugged to the new hardware module.

Customer Benefit:

There is no need of additional PC hardware.

Integration of high level languages via SIMATIC ODK 1500S/Target

1500S

Re-use of existing technological know-how in C/C++ CodeStandard- and failsafe CPU

SIMATIC-S7-1500-Multifunctional-Platform--Video-2017-12-22-EN.mp4



Memory Concept concerning User Data at CPU 1518(F) MFP

FWUpdate.S7S

(optional)

SIMATIC.S7S

S7_JOB.S7S

user.img

system.img

<root>

CppEnv1.MFP

data.img

RT 2

C+

+ a

pp

lica

tio

n

CP

U R

un

tim

e:

ST

EP

7 p

roje

ct

RT 1

Central data storage on one SIMATIC Memory Card

Easy handling at hardware change:

• Common data storage for CPU and

C/C++ runtime on FAT32 data system

• Pre-condition:

min. 2GB SIMATIC Memory Card

• CPU runtime (STEP 7 project):

• Project files in the well-known STEP 7

containers on SMC

• C/C++ runtime (C/C++ application):

• Limited to 256 MB on SMC

• container in linux Ext4 file system:

• system.img for C/C++ runtime

• user.img for C++ applications

• data.img for user data

• Diagnostic alarms in CPU diagnostic

buffer if the file system is corrupted

12/22/2017 SIMATIC S7-1500 / ET 200 CPUs | Technical slides



Execution of Function Libraries and C/C++ Applications

Execution of functions in loadable libraries at

runtime and/or as an independent C/C++

application:

Real-time: so (shared object):

• C/C++ code is called as a function block directly in

an OB, e.g.

• algorithms, closed loop controller, …

C/C++ Runtime:

• C/C++ code will be executed as an independent

C/C++ runtime application in parallel to the CPU

user program code, e.g.

• Connection to SQL-Database,

• Implementation of complex communication

protocols like IEC 61850, …

C/C++ Runtime CPU

Application OB CPU-

Function

Library

so

FB Load

FB Fct1

FB Fct2

FB Unload

Fct1

Fct2

✓

CPU 1518(F)-4 PN/DP MFP

✓

exec.


eclipse


Common Interface for Engineering

Inputs

Outputs

ST

EP

7 P

roje

kt

Communication, Shared Data

X1 X3X2

TIA Portal

Engineering via

PROFINET-Interface X3

• Interface X3 can be used for download

and debugging with eclipse for the

C/C++ application.

• Interface X3-Schnitstelle can be used

for download and online scenarios for

the STEP 7 project.*

*) possible alternatives are interface X1 and X2

RT 2

C+

+ A

pp

lica

tio

n

CP

U R

un

tim

e:

ST

EP

7 p

roje

ct

RT 1

Easy handling at hardware

change

Common data storage for CPU

and C/C++ runtime


TIA Portal

Integrated within the TIA Portal



Security Information

Siemens provides products and solutions with industrial security functions that support

the secure operation of plants, solutions, machines, equipment and/or networks. They

are important components in a holistic industrial security concept. With this in mind,

Siemens’ products and solutions undergo continuous development. Siemens

recommends strongly that you regularly check for product updates

For the secure operation of Siemens products and solutions, it is necessary to take

suitable preventive action (e.g. cell protection concept) and integrate each component

into a holistic, state-of-the-art industrial security concept. Third-party products that may

be in use should also be considered. For more information about industrial security,

visit http://www.siemens.com/industrialsecurity

To stay informed about product updates as they occur, sign up for a product-specific

newsletter. For more information, visit http://support.automation.siemens.com

http://www.siemens.com/industrialsecurity

http://support.automation.siemens.com/

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