Four Ways to Turn aBasic Controller into anAutomation Dynamo

usa.siemens.com/S7-1200Unrestricted © Siemens Industry, Inc. 2018

© Siemens 2018

The SIMATIC Controllers PortfolioAlways the right controller – plus integrated added value!

Basic ControllersSIMATIC S7-1200(F)

Advanced ControllersSIMATIC S7-1500 Software Controllers

SIMATIC S7-1500

Distributed ControllersSIMATIC ET 200 CPU

Syst

emp

erfo

rman

ce

Application complexity

Engineered with TIA Portal

EfficientEngineering

InnovativeDesign

ReliableDiagnostics

SafetyIntegrated

SecurityIntegrated

TechnologyIntegrated

© Siemens 2018

SIMATIC S7-1200 with Safety IntegratedSmallest Controller for Standard & Safety

Top-HighlightsFeature / Function Benefit

• One Controller for Standard andfail-safe automation τ

• Reduction of types- andcomponents

• Integrated System diagnostics• Integrated Trace functionality τ

• Error messages in plaintext allowa fast fault analysis (even forsporadic problems)

• Free programming of SafetyLogic in FBD or LAD

τ

• Adaptions can easily be appliedby changing the program viaSoftware

• Connection of fail-safe devicesSensors/ Actuators viaPROFIsafe (starting withFirmware V4.2)

τ

• Reduction of wiring efforts• Allows more flexible solutions for

safety related tasks

© Siemens 2018

SIMATIC S7-1200 with Safety IntegratedEngineered with TIA-Portal

Top-HighlightsFeature / Function Benefit

• I-device in a fail-safe PROFINETenvironment

• Option Handlingτ

• Leaner architecture• Simpler communication and

connection

• Simulation with PLCSIM

τ

• Faster commissioningThe program code can bevalidated incl. safety functionsbefore going on site

• Libraries• System-Libraries• User-Libraries τ

• Reduced Engineering time dueto standardization

• Unified display concept• Trace• Webserver τ

• Efficient fault analysis withoutadditional tools reducedowntimes

© Siemens 2018

Protection of intellectualproperty of program codeKnow-how protection forPLC program blocks

Know-how protection

Detection of manipulatedcommunication dataEngineering and HMIcommunication withintegrated security

Communication integrityTIA Portal

Controller HMI

Protection againstunauthorized access andconfiguration changesProtection level concept withdifferent access rights incl.HMI connections

Access protectionEngineering

Maintenance Operation

Remote control

Controller

TIA Portal Protection againstunauthorized duplication ofruntime program codeBind program blocks to hardwareserial numbers (CPU or SD card)

Copy protection

Controller Controller

Storage A Storage B

AA A

B*******

System Integrity –Security use cases with SIMATIC S7 -1200(F) Controller

© Siemens 2018

Easy PLC selection thanks to an optimized Portfolio

CPUsSwitch-module

Power-module

Communication-modules

Signal-modules

Technology-modules

2xTMCPU 1211C-1PN

CPU 1212C-1PN

CPU 1214C-1PN

CPU 1215C-2PN

CPU 1217C-2PN

CSM PM 13x CM / CP 22x I/Q

Signal-boards

11x SB

1x CB

1x BB

© Siemens 2018

www.siemens.com/siplus-cmsUnrestricted © Siemens Inc. 2018

Condition Monitoring Systems forearly detection of mechanicaldamages for S7-1200 controller

© Siemens 2018

SIPLUS CMSThe machine under control

There is no machine without vibrations.

But when do vibrations cause damages?

And what kind of damages?

And will the machine suddenly break down?

SIPLUS CMSThe answer to preventive maintenance

in industry

© Siemens 2018

Smoke

WatchWatch HearHear

Noise

FeelFeel

Heat

SIPLUS CMSSIPLUS CMS

Early detection

Months

Reaction time until breakdownReaction time until breakdown

Minutes Days Weeks

SIPLUS CMSPossibilities of Condition Monitoring

© Siemens 2018

Mechanical damages

Electrical faults

Drive

Condition Monitoring with SIPLUS CMSWhat sort of damage can be detected? An extract

Resonance

ResonanceBlade passing frequency

UnbalanceMeshing fault

Alignment fault

Bearing damage

Field faultBroken rotorbar

Unbalance

Bearing damage Meshing fault

Alignment fault Blade passing frequency

Pump / Fan Gear box

Condition Monitoring with SIPLUS CMS – more than just Motor Condition Monitoring

Motor Condition Monitoring

Field fault stator

Broken rotorbar

© Siemens 2018

SM 1281 Condition Monitoring Model

SIPLUS CMS1200: Condition Monitoring with SIMATIC S7-1200SM1281 - Overview

IEPE-SensorsVibration measurement

BEROSpeed measurement

Features• Characteristic value diagnostics• Frequency-selective diagnostics• Expert analysis on- or offline• SIMATIC S7-1200 and web-based

Connections• Up to 4 vibration sensors• 1 speed input• Ethernet• Power supply 24VDC

(supply to sensors)

Expansion optionUp to 7 modules can be connected;depending on the S7-1200 CPU used

Operating principle• Calculations are performed

continuously• The 4 IEPE channels and

the speed sensor are read in andprocessed simultaneously

Diagnosis• Characteristic values

via SIMATIC S7-1200 and TIA Portal• Frequency selective

via integrated Web Server

Advantages and Costumer benefitsNo additional software for diagnosis andvisualizing needed

© Siemens 2018

SIPLUS CMSThe analysis methods of condition monitoring

Expert analysis

• Freely configurable analysis withdiagnostics software CMS X-tools, e.g.orbit, histogram, vector/waterfall diagramFrequency-selective

analysis• What damage is imminent?• Every type of damage has its own

frequency spectrum

Sign

ifica

nce

ofth

ean

alys

is

Parameter-based analysis

• Is damage imminent?• Trend history of characteristic values

© Siemens 2018

SIPLUS CMS – Analysis methodsParameter-based analysis

Characteristic values

Advatage:• Easy and quick to implement• Minor condition monitoring expertise required

• Monitoring of

characteristic values

• Trend

• Signal-light display

Monitoring for

RMS: machine vibration

DKW: e. g. bearing damage

Signal Mode of operation

Disadvatage:• Type of looming damage not discernable• Troubleshooting required

Alarm

Warning

OK

RMSafter ISO 10816-3

DKWafter VDI 3832

© Siemens 2018

Vibration velocityv [rms]

10-1

000

Hz,

n>

600

1/m

in(2

-100

0H

z,n

>12

01/

min

)mm/s inch/s11 0,447,1 0,284,5 0,183,5 0,112,8 0,072,3 0,041,4 0,030,71 0,02

Rigid Soft Rigid Soft Rigid Soft Rigid Soft Foundation

Pumps > 15 kWRadial, axial, diagonal

Medium-sizedMachines

15 kW < P ≤ 300 kW

Large Machines300 kW < P < 50

MW Machine typ

Direct Drive Intermediate ShaftBelt Drive

Motors160 mm ≤ H < 315

mm

Motors315 mm ≤ H

Group 4 Group 3 Group 2 Group 1 Group

A Newly commissioned C Short term operationB Unlimited long term operation D Vibrations cause damage

Realizing the practical example with SM1281Evaluation of limits for characteristic values

Basic Information to provide limitvalues after ISO10816

Motor Power: 20kWShaft height: 200mmFoundation: rigidFan got newly commissioned

Limit values

Alarm threshold : 4,5 mm/s

Warning threshold: 2,8 mm/s

© Siemens 2018

SIPLUS CMS – Analysis methodsTroubleshooting an example

Possible imbalance or housing displacement:Perform soft foot check

Vertical change of foot position

Imbalance probable:Measure housing vibrations without an output element, insertfull key or half key in keyway in accordance with the balancing

method (secure feather key!)

No

Vibration values significantly lower?

Cause is balancing state of output element:balance output element or check balance type for motor

rotor/output element

Yes

End

Align housing

Yes

Unbalance in motor rotor:Balance motor rotor

End

End

No

Measure housing vibrations under load:DE and NDE horizontal, vertical and axial

Vibration values impermissibly high?

Vibration values impermissibly high?

Vibration values significantly lower?

Alignment fault probable:Align coupling

Yes

No

Yes

No

Start

End

End

Test steps for fault analysis

© Siemens 2018

C:\Users\za3233\Downloads\Fourier_transform_time_and_frequency_domains_(small).gif

Benefits of frequency-selective diagnostics:

• Each type of mechanical damage has its own uniquefrequency spectrum

• One glance at the frequency spectrum is sufficient todetermine the cause of damage to within a highdegree of accuracy

• The search for the actual cause of the damage isreduced to a minimum

• The amplitude is a measure for the extent of damage,which allows conclusions to be drawn about theremaining lifespan. The experience of the operatorplays a decisive role here

Benefits of frequency-selective diagnostics:

• Each type of mechanical damage has its own uniquefrequency spectrum

• One glance at the frequency spectrum is sufficient todetermine the cause of damage to within a highdegree of accuracy

• The search for the actual cause of the damage isreduced to a minimum

• The amplitude is a measure for the extent of damage,which allows conclusions to be drawn about theremaining lifespan. The experience of the operatorplays a decisive role here

SIPLUS CMS - Analysis methodsHow does frequency-selective diagnostics work?

© Siemens 2018

SIPLUS CMS - Analysis methodsFrequency-selective analysis

Monitoring formachine vibration

• Cyclic monitoring• Peaks• Trend

Frequency-selective analysis

Monitoring for rollerbearing damage

Examples of detectablemechanical damage

Resonance

Unbalance

Alignmentfault

Coupling fault

Detectable mechanical damage

Outer racedefect

Inner racedefect

Rollingelementdamage

Cage damage

Signal How it works

Advantages:• Quick and easy to implement• Type of damage identifiable ⇓ less troubleshooting• Electrical faults detectable

© Siemens 2018

Raw data

Signal How it works

Advantage:Raw data used for analysis modelsexactly tuned to the gear unit

Monitoring forgear unit wear

Detectable mechanicaldamage

Meshing faults

SIPLUS CMS - Analysis methodsExpert analysis

Event-driven recordingA message signal “meshingfault detected”Recording + saving sensorchannel raw data

1. Exporting of the raw data:• Via FTP manual• Via FTP event-driven

2. Online raw data streamingto CMS X-Tools

Expert analysis• OFFLINE analysis of exported raw data• ONLINE raw data streaming to CMS X-Tools

• Engineering + project of meshing faultsvia SIMATIC S7-1200 CPU + SM 1281 Web Interface

• Engineering expert analysis via analysis software,such e.g. CMS X-Tools

© Siemens 2018

Efficient EngineeringFast configuration withproject configurator andpredefined libraries

+

Provenused since more than tenyears in many projects

+

Flexible analyticsFree adjustable analyticsfunctionalities areintegrated into the system

+

ConnectivityHigh number of SW andHW devices can beconnected

+

ScalableCMS X-Tools scale fromsmall to large footprint witha flexible software structure

+

CMS X-Tools V4.04… efficient and flexible analytics system

Condition monitoringCMS X-Tools the Siemenscondition monitoring software

+

© Siemens 2018

00111001

10100011100

101000110

101000110

0110001101011010011010010110000

101010011011001

MindSphere Edge Analytics with X-ToolsIntegration in MindSphere

101000110

10010001110

11001

011010000

11

1010

Data processed and sent to MindSphereHigh frequency data from varioussources collected

Data ready for visualization andanalytics

Data transfer to MindConnect Nanovia OPC UA

MindConnectNano

*not necessary with next releaseX-Tools server hostedon Microbox PC

101010011011001 MindSphere –The cloud-based,

open IoT operatingsystem

© Siemens 2018

Connection to MindSphere – application example

MindConnect Nano

S7-1200 + SM1281

© Siemens 2018

SIWAREX weighing modulesfor S7-1200 basic controller

© Siemens 2018

SIWAREX WP2x1 controller for S7-1200

WP231 WP241 WP2517MH4960-2AA01 7MH4960-4AA01 7MH4960-6AA01

ApplicationsPlatform / hopper scales Conveyor / belt scales Mixing, Blending, Bagging

4xDQ, 4xDI, 1xAQ, Ethernet, RS485 4xDQ, 4xDI, 1xAQ, Ethernet, RS485 4xDQ, 4xDI, 1xAQ, Ethernet, RS485

All industries Mining, Cement, Food and Beverage,Recycling

All industries

© Siemens 2018

SIWAREX WP2x1 in TIA Portal

SIWAREX WP2x1

ƒ Technology modules ofS7-1200

ƒ Interrupt generation

ƒ 32 Byte I/O memory per module

ƒ All S7-1200 weighing modulesare integrated part of TIA

© Siemens 2018

Check weighing in packaging processincreases efficiency

Benefits

ϖ Through its integration in SIMATIC S7-1200, the SIWAREX WP231 electronicweighing module provides uniform mountingtechnology and integrated communication.

ϖ Commissioning of the electronic weighingmodule using SIWATOOL or directly via aconnected HMI panel is quick and easy.

ϖ With a resolution of up to +/- four millionparts and a sampling rate of 10 ms/ second,the weighing module was the right choicefor the company’s high demands for speedand accuracy.

„The Siemens standard

components combined withour plant allows

us to offer customizedsolutions for the food

industry.“

Michel Remijn, owner RMA Techniek

© Siemens 2018

Check weighing in packaging processincreases efficiency

1. Final check weighing did not take place.Irregularities in the packaging weight are adisadvantage for the company since thepackages often contain more vegetables thanthe amount required by the package size.

2. The plan was to install a check weigher at theend of the packaging process to eliminate thisuncertainty factor. The weight control shouldfocus not only on accuracy, but also work veryquickly throughout the packaging process.

3. Another demand was that it should be possibleto weigh different types and shapes ofpackages containing a variety of products.

Challenges

1. SIWAREX WP231 - the core element ofall weight measurements is the SiemensSIWAREX WP231 weighing electronicsconnected to a SIMATIC S7-1215Ccontroller.

2. SIWATOOLCommissioning of the electronic weighingmodule using SIWATOOL or directly via aconnected HMI panel is quick and easy

3. Siemens KP700 ComfortThe weighing process can be controlledand monitored, and parameters can beedited with the Siemens KP700 ComfortHMI panel.

Products/solutions

1. With a resolution of up to +/- four million partsand a sampling rate of 10 ms/ second, theweighing module was the right choice for thecompany’s high demands for speed andaccuracy.

2. For data analysis and improved traceability, allmeasurement results are collected in a centralmemory.

3. All system components were connected andconfigured directly through TIA Portal. Thisalso enables quick and easy adaptation andexpansion of the weighing application shouldit become necessary.

Customer benefits

Transparent operationEnergy efficiency with S7-1200SM1238 Energy Meter

siemens.comSiemens Inc. 2018

© Siemens 2018

Energy efficiency offers added potential

1 Prices including taxes, source: statista.com (Link) | 2 Source: E.ON-survey 2015 (Link) | 3 Source: Federal Environmental Agency (Link) | 4 Source: AGORA energy transition (Link)

Change of energysupply

Energy costs Lawsand climate protection

Responsibility forenvironment / image

Significant cost factorin production

Statutory measures to achieveenvironmental targets

New boundary conditions as aconsequence of changingenergy resources and continuedrequirements for supplyreliability

Energy-efficientproduction as a key marketingargument

~6%Average annual increasein electricity price (Ø ’00 – ’15)

2 °CLimiting the temperature riseworldwide

32%From 6.5% in the year 2000.Should rise to 80% by 2050

59%A green image is decisive for thepurchasing decisions of markets andcustomers3

Energy costs 2000-20151,Germany, industry

UN climate summit 2015, Paris Share of renewable energies: 20162

in power consumption in GermanyOpinion research 2015

© Siemens 2018

The way to save energyTransparency is the first step to reduce costs

Increase the transparency level toassign the consumption per room

Install additional electric meters(measurement devices) to get a moreprecise overview, which consumer needshow many energy

E

Saving measures can now beevaluated based on facts Realization of profitable measures

!!

!Identify the big electrical consumers,which were previously been hidden

Amortization time of each planned savingmeasure can be calculated

© Siemens 2018

The way to save energyTransparency is the first step to reduce costs

Energy Manager also needs reliablefacts to decide saving measures

First step is to create energetictransparency in the factory

Without a certain level of energetictransparency, a definition of energysaving measures is nearly impossible

Possibility to create a high level ofenergy transparency by integratingmeasurement devices in the factory

Identification of biggest energeticconsumer and optimization potentialin the process

min maxRate of energy transparency

© Siemens 2018

Your energy distribution

SM 1238 ENERGY METER 480VACfor transparency in the energy distribution

System overview Description

Gathering and processing

HMI Visualization

SIMATIC HMI480V

10 KV

Web Visualization

SIMATIC Web server

Ethernet

Ethernet

*)

*) Currenttransformer

Energy data

management

+ ..SIMATICPLC S7-1200

SM 1238 Energy Meter

S7-1200 CPU

SM 1238 Energy Meter 480 VAC

© Siemens 2018

The way to save energyVisualization of energetic data for an easy analysis

To identify saving potential, the datahave to be visualized and stored

After data acquisition in the PLC, they shouldbe visualized for a more easy analysis

Visualization of the current consumptionvalues of one machine on a panel near themachine for……basic condition monitoring…generating a basic energetic awareness

Visualization of long term stored values ofdifferent machines in one overview i.e. inthe office for……comparing identical machines and an

identification of optimization potential…an identification of the biggest energy

consumers in the factory Machine visualization Office visualization

© Siemens 2018

OptimizationAcquisition

Continuous energy data acquisition as basis

Recording and production-related data processing is the basis for energy consumption transparency

Evaluationand analysis

Processing

IE4-motors

Energy analytics

Process adaptations

SIMATIC EnergyManager PROPlant-wideenergymanagement

SIMATIC Energy SuiteProduction-levelenergy monitoring

S7 Energy Efficiency Monitorfor machinesEnergy efficiencyevaluation ofmachinery

Water meter

Currenttransformer

Converters

Flowmeasurement

SENTRON PAC

S7-1500 and energymeter, I/O

S7-1200 andenergy meter, I/O

SIMATIC Automation Toolsiemens.com/satUnrestricted© Siemens Inc.2018

© Siemens 2018

Increased productivity due to an extensive range of functions

Top-Highlights Feature / Function Benefit• Network scan

τ• Simple acquisition and display of

the reachable PROFINETdevices

• IP-adress- and PROFINET namechanges τ

• Quick adaption of local networkrquirements

• Program/Project downloadτ

• Update the automation systemwithout TIA Portal

• Backup/Restoreτ

• Fault-Back support whenperforming the operation

• Mass operaitonsτ

• Efficient updating also forextensive machines/plants

• APIτ

• Automated execution of theoperations

© Siemens 2018

One tool for commissioning, maintenance and service

Hardware supportExtensive support of theSiemens automationportfolio

+Independent of theengineering frameworkIdeal for commissioning,maintenance and servicewithout TIA Portal

+

Mass operationsParallelizing of tasks toreduce time and costs

+ APIOptimal for automation oftasks

+UsabilityEasy to use for TIA andnon-TIA Portal users

+

© Siemens 2018

Perfect partner to TIA components

TIA Portal engineering is the basis for program/projectdownload

Support for many TIA components such as SIMTATICcontrollers, distributed I/Os, HMI panels, SITOP andRFID

Integrated industrial security mechanisms such asaccess control of PLCs and HMI panels

© Siemens 2018

Jana Kocianova

Product Marketing Manager S7-1200/S7-1200FSiemens Industry, Inc.RC-US DF FA MK PLC5300 Triangle ParkwayNorcross, GA 30092-2538, USAMobile: +1 (470) 809 2421mailto:jana.kocianova@siemens.com