Date post: | 13-Apr-2017 |
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Engineering |
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Using TIA Portal and the S7-1200 for Simplified, Distributed Control
Overview• Introductions
• Patco Machine and Fab, Inc.
• Project Challenges• The Traditional Solution• Distributed Control
Presenter Info
• B.S., M.S., Ph.D in Mechanical Engineering – University of Notre Dame
• CAD/CAM, Intelligent Systems @ ND• With DMC since 2010• Chicago, Boston, Houston
• PLC/HMI/SCADA, LabVIEW, C#/C++, .NET, • Proficient in Siemens (Step7, WinCC, Portal), AB, Beckhoff,
B&R, and more• Siemens Certified Professional
Jason MayesProject Director (Houston)
DMC Overview
Established in 1996, offices in Chicago, Boston, & Denver and customers
throughout the worldemployees &
growing
85+
Areas of Expertise
Manufacturing & Automation Certifications
DMC has the highest number of S7 certified engineers in the US.
• PLCs• HMIs• SIMOTION• WinAC• WinCC 7• WinCC OA• And more…
What We Do
Automotive Chemical & Food
Processing
Consumer Goods Defense Contracting Energy & Utilities Food
& Beverage Packaging Pharmaceutical Printing & Textiles
Semiconductor
Special Machinery Telecommunications Oil & Gas Test &
Measurement
Industries Served
Presenter InfoJohnny KilpatrickPresident, Patco Machine and Fab.
John R. KilpatrickFounder
• Founded in 1973 by Johnny R. Kilpatrick• Started as job shop/machine shop• Expanded to repairing/building hydraulic
cylinders for the oil field industry
Patco Machine & Fab, Inc.
• Services offerings now expanded to include Design and Manufacturing • Specializing in Production & Drilling Equipment
• Hydraulic Pump Skids• Hose and Cable Reels• Suction and Dump Valves for Mud Tanks• Much more….
• Pride, Quality and Commitment• Servicing Customer World Wide since 1973
Patco Machine & Fab, Inc.
Patco Machine & Fab, Inc.
Patco Machine and Fab
Cable & Hose Reel Systems
Cable & Hose Reel Systems
Challenges• Why automate?
• Looking to modernize the product to meet evolving industry requirements and standards
• Differentiate our products with first in the industry capabilities• Provide our customers with added value
• Potential challenges• Our expertise is in high quality mechanical/hydraulic design
and fabrication, not electronic controls• Limited experience in Zoned/Classified spaces
• ATEX/IECEx Class 1 space• Controls hardware selection/communication/software
• Extreme conditions of offshore drilling environment
Presenter InfoAdam TackerOutside Account Manager (AWC)
• 9 years at AWC• 6 years Applications Engineer/Field Service• 3 years on Account Management Team
• Expert in Siemens PLC and Drives, and Instrumentation• TI505/S5, Legacy Product Expert• Field service and startup experience• Certified Siemens Professional
• 50 years of serving our customers• Winning Together• Products and Services
• Siemens/P&F/Moxa/Phoenix Contact/Rittal• Project Management, System Design, 24/7
Tech Support• Over 400 engineers, 30 locations giving our
customers the best possible solution
AWC, Inc.
Building a Team
AWC – a Complete Solution• Electrical (Hazardous
Areas)• Controls• Project Management
Challenges • ATEX/IECEx Ratings
(dual)• Flexibility/Modularity• Hardware Selection
Challenges
Build a WINNING Team
AWC Project Management • R STAHL• DMC• Dynapar• Siemens
Traditional Solution
• Single Controller with Remote I/OTraditional Solution
Advantages
• Single controller• Initial setup• One copy of code to
manage• I/O local to remote racks• PN communication
Traditional Solution
Disadvantages
• Cost ($$)• 8 Remote Racks• More Complicated Panel
Design for Sheave (EX)• Need Ethernet in addition to
power to sheave• Not Flexible
• PLC program must be modified for different configs
• Reel HMI’s must look at unique tags
Traditional Solution
TIA Portal and the S7-1200
• Each Reel controlled locally• Sheaves all wired into central ET200SP (CPU)
• 4 encoders/load cells
Distributed Control
S7-1200
• Minimizing Cost• Built in I/O on 1200• Single ET200SP
(CPU) in remote panel for load cell/encoder
• Simple junction box on sheave
Leveraging the S7-1200
S7 Comm
CUSTOMER BENEFIT = lower cost per system
• Flexibility• Distributed control• More options
• Tension/payout• Multiple reel options
Leveraging the S7-1200
CUSTOMER BENEFIT = ‘custom’ options for Patco’s customer with no additional development
• Maintainability and Service• Fewer parts to
maintain• Easy to program via
MMC• Transfer Cards• Program Cards
Leveraging the S7-1200
CUSTOMER BENEFIT = easy system setup, service, and configuration without needing DMC
TIA Portal
Leveraging TIA Portal• Integrated Projects
• 5 PLCs + 5 HMIs = 1 Project• Drag & Drop Tags• Easy PLC to PLC
Communication• Easy to configure HMI
Connections
CUSTOMER BENEFIT = easier for Patco to maintain should features need to be added
Leveraging TIA Portal• Extended Diagnostics
• Integrated device level diagnostics
• Webserver/HMI• Improves ability to
remotely diagnose any issues
CUSTOMER BENEFIT = easier troubleshooting inthe field, remote support vs onsite
Leveraging TIA Portal• Library Functionality
• Typed Function Blocks• All reels share same
code• Changes only needed in
one place• Shared PLC/HMI Datatypes
• Easy Faceplate linkingCUSTOMER BENEFIT = minimize testing and
development time, save $$ and time
Leveraging TIA Portal• Configuration Control
• Define optional modules in ET200SP rack
• Can set hardware configuration from HMI
CUSTOMER BENEFIT = One project, multiple hardware configuration options
Conclusions
• TIA Portal and Siemens Factory Automation Products• Flexible/Modular• Expandable• Minimize Cost
Patented “Controlling Cable Spooling Systems,” #9,206,658
End Presentation