siemens project
TRANSCRIPT
Business Problem
A paint manufacturing company has approached Siemens India to study and automate their process which has a legacy system in place and increase the current production value. Client has maintenance issues with no process visualization tool to monitor runtime process and check alerts or trends.
Project goals
• This project aims at developing a logic for an automated paint emulsion industry using ladder networks in Siemens Simatic Manager
• The simulated and tested logic is practically realizable on the Siemens S7-300 series PLCs a much advanced version PLC
• It provides a process visual display of the real-time field process on a SCADA screen using Siemens WinCC
• The automated solution will improve productivity • The maintenance issues will be resolved with
both automatic and manual set up provided
SIMATIC MANAGER
• Core of every SIMATIC S7 project .• Objects used:
Organization Blocks Function Blocks Data Blocks Variable Tables
• The ladder networks make use of NO/NC contacts, Counters, Timers, Comparators
WinCC
• Powerful HMI system• Used to visualize the
process and develop the graphic user interface for the operator. • Allows the operator to
observe and control the process.
1. Graphic Designer: The SCADA screens depicting the process in runtime are created with the help of the Graphics Designer tool of WinCC. It enables a visual display of the plant process by means of various objects and animations
2. User Archive: The quantities of the ingredients to make different emulsions is stored in the form of recipes in the archives.
3. Alarm logging: The editor for configuring the alarms is named Alarm Logging. Alarms inform the operator about process malfunctions and errors. Alarm Logging is used to define when and what type of an alarm is to be displayed with what content.
4. Authorization/User Administration: The User Administrator is used to issue and control access rights to users. The main task of the User Administrator in runtime is to monitor system logins and access rights
SUBSYSTEMS OF WINCC
5. Tag Logging: Selection and configuration of the process values to be archived is done using Tag logging. It enables archiving the process values during runtime and reading them.
6. Trend Control: It displays process data as a trend in graphic form. The trend type to be used may be selected. There is also an option of displaying current or archived values.
7. WinCC Runtime: With the runtime software, the operator can run and monitor the process. In particular, the runtime software has the following tasks:• Reading of the data stored in the
database.• Archiving of the current runtime data such
as process values and alarm events.• Running of the process, e.g. through
specified set-points or activation/deactivation.
Testing and results• The simulated automation logic was tested• It increased productivity by 52%• Saved process time by increasing cycle time by
35%• Process and runtime visualization provided
alerts and precision• Used to monitor and control the actual field
process, see its real-time status, read the alarms, service them and test all field components for failure, thereby providing a strong HMI system.
• Maintenance was easier with new set ups
References and Citations
• SIEMENS Trainee Manuals:• Totally Integrated Automation – I• Totally Integrated Automation – II• Course Material on SIMATIC HMI WinCC