MediaService April 2016 www.siemens.com Siemens MediaService April 2016 – Industry News Already looking ahead to the Hanover Fair, the April issue of the Siemens MediaService Industries looks at new products and applications and reports on a new contract award in the field of drives and automation. Innovations in- clude an IWLAN antenna for rail appli- cations, a diagnostic display for safety relays and a 24 volt industry power supply. Rounding off the products showcased in this issue are an IE RJ45 port lock providing physical net- work access protection and a vehicu- lar wireless subscriber unit for harsh environments. We hear how a Canadian gold produc- er has commissioned two gold mill drives using Siemens Integrated Drive Systems for its new plant, and also how machine tools are used for the ac- curate production of roses made of marzipan with the aid of Siemens con- trols. Siemens controls are also used in the Swiss Canton of Solothurn in pallet lifts which transport up to 4,700 pallets every day. And finally, the LMS Amesim Platform from Siemens helps reduce PLM software development times and the cost of hybrid pow- ertrains. « Content PRODUCTS 02 IWLAN antenna for harsh environments 03 New diagnostic display for safety relays 04 New 24V DC power supply 05 Physical network access protection 06 Vehicular subscriber units for harsh environments APPLICATIONS 07 Golden age 09 Controlling pallet lifts 10 Perfectly-shaped roses made of marzipan 11 “Green” railways
Transcript
MediaServiceApril 2016
www.siemens.com
Siemens MediaServiceApril 2016 – Industry News
Already looking ahead to the Hanover Fair, the April issue of the Siemens MediaService Industries looks at new products and applications and reports on a new contract award in the field of drives and automation. Innovations in-clude an IWLAN antenna for rail appli-cations, a diagnostic display for safety relays and a 24 volt industry power supply. Rounding off the products showcased in this issue are an IE RJ45 port lock providing physical net-work access protection and a vehicu-lar wireless subscriber unit for harsh environments.
We hear how a Canadian gold produc-er has commissioned two gold mill drives using Siemens Integrated Drive Systems for its new plant, and also how machine tools are used for the ac-curate production of roses made of marzipan with the aid of Siemens con-trols. Siemens controls are also used in the Swiss Canton of Solothurn in pallet lifts which transport up to 4,700 pallets every day. And finally, the LMS Amesim Platform from Siemens helps reduce PLM software development times and the cost of hybrid pow-ertrains. «
Content
PRODUCTS02 IWLAN antenna for harsh
environments
03 New diagnostic display for safety relays
04 New 24V DC power supply
05 Physical network access protection
06 Vehicular subscriber units for harsh environments
APPLICATIONS
07 Golden age
09 Controlling pallet lifts
10 Perfectly-shaped roses made of marzipan
11 “Green” railways
MediaService April 2016 2
The IWLAN antenna ANT793-8DL provides a robust and reliable wireless connection specifically for use in railway applications.
wall, facilitating multi-axle, flexible alignment in the desired radiation beam direction. The antenna is at-tached to the active network compo-nents via a suitable connection using two Type N connectors, making it re-
Nuremberg, Germany. With the new IWLAN antenna ANT793-8DL, Siemens is providing a robust and reliable wireless connection that can also be used in railway applications. The antenna is suitable, for instance, for applications directly along railway tracks and meets the increased re-quirements in relation to environmen-tal conditions and fire protection.
Communication between mobile sub-scribers across several radio cells places high demands on active net-work components. IWLAN (Industrial Wireless LAN) components from Sie-mens provide secure and reliable data transmission with access points and clients designed specifically for indus-trial purposes. This also includes the provision of suitable antennas for opti-mum radio coverage when larger dis-tances need to be bridged in fast-moving applications. The new antenna ANT793-8DL, which is also suitable for railway applications, complies with the standards EN50155, EN45545-2 and EN50121-4. Owing to its compact design, it can also be used in very confined spaces such as tunnels. The highly directional dual antenna with an antenna gain, namely antenna directivity and effi-ciency, of 14 dBi (decibel relative to isotropic radiator) and 25 to 35 de-grees aperture angle each can be operated in the 4.9 to 5.9 gigahertz frequency range and therefore in li-cense-free wireless LAN band 5 gigahertz. The mounting sup-port which is supplied with the antenna en-ables it to be at-tached se-curely to the
IWLAN antenna for harsh environmentsSuitable for applications even directly along railway tracks
IWLAN-Industrial-Wireless-Lan
www.siemens.com/iwlan
sistant to vibration – even in remote, harsh environments that are difficult to access. The antenna offering pro-tection class IP66/67 can also be used in environments with unstable weather conditions. «
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The new compact diagnostic display 3SK2611-3AA00
New diagnostic display for safety relaysAdded benefits for safety applications
Safety Relays
www.siemens.com/safety-relays
Nuremberg, Germany. Siemens has upgraded its portfolio of Sirius 3SK2 safety relays to include a compact diagnostic display. This allows plant status or defects such as faulty sen-sors or warning messages to be sim-ply displayed. As faults can be local-ized much faster it reduces downtime and therefore helps to save both time and costs.
There is now a new compact diag-nostic display 3SK2611-3AA00 avail-able for the Sirius 3SK2 safety relay, which offers a range of safety func-tions with only a minimal footprint. The Human Machine Interface panel with its titanium colored display and particularly bright background light-ing informs the user about all events occurring in the system such as faulty sensors or warning messages. This allows faults to be more quickly localized and downtimes to be re-duced. Existing projects can be sim-ply saved and reloaded to the device once the device has been replaced. This facility for copying projects lends itself to use in series machine manufacturing. Typical applications for Sirius 3SK2 include more com-plex or sophisticated security appli-cations with several emergency stop commanding devices, safety doors with locking function or also material infeed using light barrier sensors which are intended to close down above all partial applications inde-pendently. In addition, there is a function block library available for the implementation of individual re-quirements. «
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The new 24V DC power supply Sitop PSU100L for basic requirements in industrial environments.
110 millimeters wide. It is character-ized by 92 percent efficiency and can be mounted flush against other devices on the rail. The output volt-age can be adjusted up to 28 volts, and compensates for voltage drops across long supply lines. The wide ambient temperature range of -25 to +70 degrees Celsius enables its use in rugged environments. To pro-tect against interference in the pow-er grid or 24 volt circuit, the power supply unit can also be combined with supplementary Sitop modules,
Nuremberg, Germany. Siemens is ex-panding its portfolio of 24 volt industri-al power supplies to include a 20 am-pere power supply unit in the lower price range. The new power supply for basic requirements in industrial envi-ronments is being added to the Sitop Lite product line and can be connected directly to single-phase 120 and 230 volt networks and to direct voltage net-works with between 88 and 370 volts.
Sitop PSU100L is a 20 ampere DIN rail power supply unit measuring just
New 24V DC power supply20 ampere power supply unit for basic requirements
Power Supply Sitop
www.siemens.com/sitop
for instance to create an uninterrupt-ible DC power supply, or for the se-lective protection of 24 volt load cir-cuits. Using a DataMatrix code, users can directly download product information such as data sheets or instruction manuals for servicing over the Siemens Industry Online Support App. It is also possible to download 2D/3D data, circuit dia-gram macros and operating instruc-tions or certificates from the Internet free of charge for design and project engineering. «
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The IE RJ45 port lock provides physical network access protection
ables RJ45 ports to terminal devices and network components to be locked mechanically. The rugged de-sign of the port lock in the form of a plug means the plug snaps securely into place at the RJ45 interface, pre-venting the insertion of RJ45 cables. This port lock helps to prevent un-wanted use of empty RJ45 ports even on non-configurable network components. The integrated lock that can only be locked and unlocked us-ing a mechanical key blocks the latch of the RJ45 port lock. A me-chanical key is used to remove or unlock the port lock. Additional bene-fits include the sturdy design suitable for industrial purposes and the ease of installation which, because of
Nuremberg, Germany. Siemens devel-oped the IE RJ45 port lock to protect open, unused RJ45 interfaces. It con-nects RJ45 ports mechanically to ter-minal devices or network components. As an additional measure, the IE RJ45 port lock can help to protect networks from unauthorized access, thereby en-hancing the security of industrial pro-duction plants.
A well-balanced, holistic security con-cept also includes physical protection measures. Open, unused RJ45 inter-faces that can be used by unauthor-ized third parties to access networks are a well-known problem. In order to mitigate this risk, Siemens is now of-fering the IE RJ45 port lock which en-
Physical network access protectionProtection from unauthorized access
Industrial Ethernet Security
www.siemens.com/network-security
IE RJ45 Port LockPhysical network access protection
RJ45’s compatible design, does not require any additional tools. «
New vehicular subscriber unit for harsh environments
Nuremberg, Germany. With the Rug-gedcom WIN5100-V, Siemens has re-leased a new vehicular subscriber unit for private wireless networks. Powered by a 48 Volt direct current supply, WIN5100-V has been de-signed specifically for harsh environ-ments. It is available in three frequen-cy bands.
The new Ruggedcom WIN5100-V ve-hicular subscriber unit supplements the WIN5100 device and offers high resistance to shock and vibration. With its EN50155 certification and M12 connectors, the new unit is suit-able for applications in rail transport, mining and heavy industries which require reliable communication at high transmission rates via a mobile WiMAX link. WIN5100-V is currently available in three different versions, namely WIN5137 for the frequency band 3.7 gigahertz, WIN5158-V for 5.8 gigahertz and WIN5151-V for AeroMACS. The Win5100-V device with a GPS (Global Positioning System) option transmit its GPS loca-tion to the base station via WiMax, thereby reducing the data volume. The vehicular subscriber unit location is displayed on the base station via the WEB GUI interface and can be retrieved from the base station by any management system using SNMP (Simple Network Management Protocol), hence avoiding constant over-the-air messages to the sub-scriber unit. Hosts behind the mobile subscriber unit can access the loca-tion information from the LAN using NIP (Network Interface protocol). The GPS option also enables the internal clock of the subscriber unit to be synchronized. The new WIN5100-V devices are fully compli-ant with the IEEE802.16e standard and can therefore be used with the WIN7000 or WIN7200 base stations or with any other WIMAX compliant base station. «
New vehicular subscriber unitWireless broadband mobile subscriber unit for harsh environments
has been awarded the contract to supply the mills used for extracting the gold, including a ball mill and a semi-autogenous (SAG) mill. Siemens Integrated Drive Systems (IDS) will be used to drive both mills.
Saving through standardization
The use of converter technology al-lowed Siemens to adjust the rated speed of the SAG mill motors to the extent that the four large Flender gears all work with the same trans-mission ratio. This allows the user to standardize the size and the design of the gears for both mill types. At the end of the day this results in a 17 percent reduction in capital invest-
Mali. Siemens project partner FLSmidth was commissioned by Canadian gold producer B2Gold at the end of 2015 to supply two mills for mining the precious metal in its new plant in Mali. The technology used to drive the mills is based on Integrat-ed Drive Systems (IDS) from Siemens. Using IDS, B2Gold is able to reduce its capital investment and make up to 50 percent savings on spare parts.
The Canadian gold producer B2Gold Corp. already operates gold mines in Namibia, Nicaragua and the Philip-pines. The Canadian firm is now ex-panding with a new plant in Mali. The internationally active OEM (Original Equipment Manufacturer) FLSmidth
Golden ageSiemens awarded contract for gold mill drive
Frozen Charge Protection SystemThe system enables the cont-rolled dislodging of frozen charge from the inner walls of the mill: The mill carries out defi-ned forward and reverse move-ments to detach the sediment. The frozen charge no longer needs to be manually removed in the pipe. This shortens stand-still periods and increases avai-lability, while preventing damage to the mill caused by material dropping down in an uncont-rolled manner. «
Beispiel eines Simotics HVM 800
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For mills which operate at a constant speed – such as ball mills – Siemens uses slip-ring motors with fluid start-ers featuring the PLC-based “Frozen Charge Detection” function. The cus-tomer’s own deactivation signals can be integrated without problems at any time, allowing the mill operator to carry out other measures to pro-tect the mill from damage from charge “frozen” to the mill walls. «
ment for the mechanical drives, and savings of up to 50 percent for spare parts.
High-powered mill drives
The SAG mill is driven by two 7,500 kW air-cooled asynchronous motors from the Simotics HV series, oil-filled drive isolation transformers and two water-cooled Sinamics GM 150 fre-quency converters. For the dual-pinion ball mill, Siemens USA is supplying two 5,250 kW slip-ring motors, liquid starters and the “Frozen Charge Pro-tection” package. The gears, cou-plings and lubrication units for the two mills will be supplied by Siemens Flender in Illinois. The “Frozen Charge Protection” function developed by Sie-mens protects mills during start-up by ensuring the charge which has be-come firmly attached to the mill wall does not fall rapidly and damage the mill.
Special features of the mills
The various operating modes of the mills such as controlled ramp-up, load balancing, creeping and inching mode all serve to reduce the load on the me-chanical components, drastically ex-tending the service life and preventing damage. In addition a controlled load balancing function is provided to help keep mill downtime periods to a mini-mum.
Mining Industry
www.siemens.com/mining
Integrated Drive Systems (IDS)The Integrated Drive Systems approach smoothens the path towards digitalization through the three-way integration of drive technology, making it the ideal answer to the growing de-gree of complexity which cus-tomers are required to face, in particular when it comes to ap-plications in the process indus-tries. The horizontal, vertical and lifecycle integration of Inte-grated Drive Systems guaran-tees that every drive compo-nent fits seamlessly into practically any drive system, every automation environment and also into the overall life-cycle. This optimizes workflows from engineering through to servicing, and ensures maxi-mum productivity, efficiency and reliability for customer ap-plications. Integrated Drive Systems tangibly reduce not only time-to-market but also time-to-profit. «
MediaService April 2016 9
equipment to the required floor, where they are placed on the un-loading conveyor. Five pallet lifts transport up to 4,700 pallets loaded with non-food and specialist retail ar-ticles in the newly constructed halls every day. There are 40,000 storage compartments available over five floors with a total capacity of 385,000
cubic meters. The high turnover of goods calls for the fast and also safe transport of pallets from A to B. “The systems run automatically, and have to work with absolute reliability and safety”, says Markus Stebler, CEO and owner of Stebler Automation, which implemented the complete project for Migros from the initial placement of order through to com-missioning in just four months.
The technology in brief
The freight lifts are controlled over Profinet by a Simatic S7-1500 con-troller. There is one control cabinet installed per lift on each of the five floors. The five systems differ in terms of their configuration. They are independently operated and net-worked to the building control center via the main control cabinet. AWL and SCL languages were used to program the control system in the
Neuendorf, Solothurn/Switzerland. The Swiss retail corporation Migros relies on Siemens technology for the smooth running of its distribution cen-ter in Neuendorf in the Canton of So-lothurn, where five automatic pallet lifts transport up to 4,700 pallets safe-ly to the right floor on a daily basis. There are 40,000 storage compart-
ments available over five floors, pro-viding a total capacity of 385,000 cu-bic meters for pallets loaded with non-food and specialist retail articles. The pallets weigh up to two tons each. Controlling efficient loading and un-loading of the freight lifts is a Simatic S7-1500 controller, which Migros ex-pects to generate energy savings of up to 40 percent.
In the recently completed halls of the Migros distribution center, two fully loaded pallets emerge from the pallet lift, while the truck driver simultane-ously places two pallets in the adja-cent deposit station. Using a switch panel, the driver selects the relevant floor for the pallets and uses a pull switch to activate the lift, which auto-matically takes care of the pallet trans-port. As soon as the unloading con-veyor on the chosen floor is free, the door of the lift opens and the pallets are transported using load handling
Controlling pallet lifts4,700 pallets a day – 40,000 storage compartments – 25,000 trouble-free trips
Simatic S7-1500www.siemens.com/simatic-s7-1500
Totally Integrated Automation portal. Pallets generally run on rollers: with-in the Migros distribution center the goods are transported on floor-level conveyor belts. “This allows us to po-sition and remove the pallets more quickly and simply”, explains one of the fork lift drivers. Operation of the lifts is also simple: Instead of modern touchscreens, a conscious decision was taken here to use control panels with mimic diagram and clearly ar-ranged buttons. Stebler explains:
“This may have an old-fashioned look, but the intuitive nature of a mimic diagram makes this in our view still the best solution for operat-ing personnel.”
Saving energy while braking
Peter Bärtschi, Head of Engineering/Projects at Migros-Verteilbetrieb Neuendorf AG is delighted with the availability of the lifts in Neuendorf: “One of the pallet lifts completed 25,000 trips in its first two months of operation – without any major inter-ruptions”. Bärtschi is also pleased with the system’s energy efficiency. Electrical energy is recovered during braking operations and returned to the grid, resulting in major savings. Measurements indicate an energy saving of 40 percent. «
ranged buttons. Stebler explains:
The loading and unloading conveyors lead straight into the lift shaft. The transverse shuttle in the lift car eliminates the need for a lifting transfer unit between the incom-ing and outgoing conveyor.
The Romi machining centers at K&S also run automatically for many hours during the night. The Easy Message feature notifies the duty manager promptly if and when faults occur. Siemens’ ShopMill graphical work step programming software is extremely user-friendly. That is why K&S production staff enjoy programming directly at their Romi machine tools.
cookies have an appealing and above all clearly-defined shape. Yet having the right shape is not just im-portant in the confectionery industry, it is also important in the pharmaceu-tical industry. K&S uses machines manufactured by Romi fitted with Siemens’ Sinumerik CNC automation system. It was a four-axis D 1500 milling center controlled by Sinumer-ik 828D that persuaded Maskow to opt for this particular machine. He is thrilled with the quality, reliability and costs of the integrated solution pro-vided by Romi and Siemens.
Integrated motion control and user-friendliness
The company uses the Sinumerik MDynamics technology package supplied by Siemens for production planning at the machining center where Siemens installed Sinumerik 838D. The integrated Advanced Sur-face motion control with Look Ahead and data compressor enables plan-ners to configure the program se-quence to ensure the machines have the required surface quality while of-
Bad Schwartau, Schleswig-Holstein/Germany. Special machines are need-ed to mass produce confectionery such as marzipan. The required molding tools are manufactured by the machine manufacturer Krüger & Salecker from Schleswig- Holstein using its own mold-ing machines and Siemens’ controllers.
The machine manufacturer Krüger & Salecker Maschinenbau GmbH (K&S) which is based in Bad Schwartau manufactures machines and tools that are used not just in the food process-ing industry but also in the chemical and pharmaceutical industry. Jörg Maskow, CEO of K&S, says the tech-nical molding roller principle and the modular structure of his machines are the secret to the company’s success. Not only do molding rollers determine the shape of the end product, the changeover of the molding rollers is a simple one-man job.
Getting products in just the right shape
The rollers ensure confectionery such as rose petals made of marzipan and
Perfectly-shaped roses made of marzipanGetting just the right shape for products using Siemens controllers
CNC Sinumerik
www.siemens.com/sinumerik
fering optimum machining velocity at the same time. What is more, the Sinumerik Operate user interface with the graphical ShopMill work step programming provides a clear struc-ture and is easy to use.
Error messaging via SMS
K&S is equally impressed by further developments in Siemens technolo-gy and is planning, for instance, to retrofit the Easy Message feature. Easy Message diagnoses machine faults and notifies the duty managers via SMS, facilitating prompt trouble-shooting, minimizing system failures and increasing production. «
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Since only 35 percent of the world’s railway networks are electrified, it is critical to make diesel propulsion “greener”. With LMS Amesim, Voith Turbo engineers predict the reduction of fuel consumption and lifecycle costs while accounting for rail vehicle and track characteristics
mizing their products and when devel-oping new ones. In fact, physical test-ing can sometimes even be completely eliminated. LMS Amesim is teamed up with LMS Imagine.Lab Sysdm software, a team-oriented model management solution that helps specialists efficiently manage a wide range of model versions.
Propel innovative drive solutions
Fully leveraging these powerful Product Lifecycle Management solu-tions has helped the Voith Turbo rail division to improve the quality of con-ventional diesel multiple units and shorten the development time for in-novative hybrid powertrain solutions based on powerful simulation models and leading-edge mechatronic sys-tem design. This creates an out-standing basis for continuing to en-gage interactively with their customers to reduce the environ-mental footprint of diesel-driven rail vehicles, cut train operating costs and offer efficient, innovative hybrid drive solutions. «
Heidenheim, Germany. Voith Turbo is a German rail vehicle component sup-plier and manufactures intelligent drive systems. The Voith Turbo portfo-lio also includes hybrid drive and pro-pulsion concepts, a challenging area as a result of the multi-domain com-plexity that is involved. To help them address this challenge, Voith Turbo uses LMS Amesim – part of the Sie-mens PLM Software portfolio. The re-sults are reduced development time and costs of hybrid powertrains.
LMS Amesim allows Voith Turbo engi-neers in the rail division to easily simu-late the interaction between various rail vehicle systems comprising compo-nents from different physical domains. These include cooling circuits, combus-tion engines, hydraulic circuits, gear-boxes and onboard system generators – truly reflecting the multi-domain engi-neering challenge involved. LMS Ames-im means that they understand how the system behaves when parameters are changed – even before a real system has been produced – allowing them to reduce the time and costs when opti-
“Green” railwaysInnovative vehicle drive systems with Siemens software
Siemens AG (Berlin and Munich) is a global tech-nology powerhouse that has stood for engineering excellence, innovation, quality, reliability and inter-nationality for more than 165 years. The company is active in more than 200 countries, focusing on the areas of electrification, automation and digita-lization. One of the world’s largest producers of energy-efficient, resource-saving technologies, Siemens is No. 1 in offshore wind turbine construction, a leading supplier of gas and steam turbines for power generation, a major provider of power transmission solutions and a pioneer in in-frastructure solutions as well as automation, drive and software solutions for industry. The company is also a leading provider of medical imaging equipment – such as computed tomography and magnetic resonance imaging systems – and a lea-der in laboratory diagnostics as well as clinical IT. In fiscal 2015, which ended on September 30, 2015, Siemens generated revenue of €75.6 billion and net income of €7.4 billion. At the end of Sep-tember 2015, the company had around 348,000 employees worldwide. Further information is available on the Internet at www.siemens.com.
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