Summer time is party time: Right on cue for the soaring summer tempera-tures, the July issue of the Siemens MediaService looks at Siemens soft-ware used in the design of items such as party kegs. Also featured: Simple, efficient project engineering of produc-tion facilities such as packaging ma-chines with Simotion Scout for micro-second-precise time-based IO signal acquisition. RFID and control techno-logy are used to increase cycle times in the manufacture of sockets. We visit the world of aerodynamic testing in the Audi Wind Tunnel Center, where the wind of change is blowing with Siemens technology. Specially design-
ed gears are used to optimize ore crushing in a Russian gold mine. Staying in Russia, we learn about an individual maintenance solution used to optimize inspections, repair work and the stocking and supply of spare parts for the new Mercedes Benz plant in Yaroslavl. Integrated Drive Systems are used to enhance plant efficiency in the world’s biggest sugar mill in Thailand. Siemens software is working on land and in the air to en-hance the efficient planning of trans-port infrastructure such as civil engi-neering and bridge building projects, and to improve acoustic insulation in aircraft. «
Particularly intuitive: symbolic configuration enables time-based IO to be easily con-figured in Simotion Scout.
As of now, time-based IO can be configured directly in Simotion Scout and Simotion Scout TIA.
Precise and fastEasily configure time-based IO in Simotion Scout
Simotion
www.siemens.com/simotion
Nuremberg, Germany. In modern pro-duction processes, two things are criti-cal: precision and speed. Time-based IOs such as Siemens‘ technology mo-dule TM Timer DIDQ enable micro-second-accurate signal acquisition and/or output based on accurate time information. As of now, these modules can also be configured using Simotion Scout and Simotion Scout TIA, increas-ing productivity and at the same time saving costs.
Bottling, filling, pouring or packaging. In production machinery – such as packaging machines – it is all about speed. The faster a machine is, the higher the productivity. But this also makes controlling the individual pro-duct stages all the more difficult. Auto-mation systems like the Simotion Mo-tion Control System make configuring motion processes easy and efficient. As of now, it is also possible to pro-gram time-based IOs in Scout and Scout TIA.
Intuitive symbolic engineering
Time-based technology modules en-able microsecond-accurate signal out-put. They make precise placement of glue points on packaging possible even in packaging machines running at high throughput speeds, for instance. This makes production processes more precise and faster, with switching points being set based on practical po-sition values. Time-controlled activation enables signal acquisition and output independently of the PLC cycle, avoid-ing high costs for more powerful con-trollers and, at the same time, saving valuable engineering time because con-figuration is intuitive and symbolic. «
Video: Time-based IO with Simotionhttp://w3.siemens.com/mcms/mc-systems/en/automation-systems/mc-system-simotion/supplementary-system-compo-nents/Pages/supplementary-video.aspx
Different customer preferences have to be taken into account in the design of metal packaging, as shapes and sizes can vary considerably.
fluctuating temperature and pressure levels, it also has to enable easy oper-ation and recycling, and be cost-ef-fective to manufacture. “Using Solid Edge from Siemens PLM Software, we are able to address every one of these wide-ranging design chall-enges”, says CAD Project Manager Timo Pietsch from the Industrial Engi-neering Division.
Operating simplicity and useful supplementary programs
Because Solid Edge is intuitive to oper-ate, users quickly become familiarized
Öhringen, Baden-Wurttemberg/Germa-ny. Huber Packaging Group GmbH needs to respond with the utmost flexibi-lity to seasonal fluctuations and wide-ranging customer tastes. This is a chal-lenge the design department has met using the Solid Edge portfolio from Siemens PLM Software. Simple opera-tion and supplementary programs provide valuable support to the company’s metal packaging development engineers.
The 5-litre party keg is something of a highlight in the Huber product range. Not only does it have to be capable of withstanding tough conditions such as
Software expertise in a kegSolid Edge used to design metal packaging
Solid Edge
www.siemens.de/plm/solidedge
Solid EdgeSolid Edge from Siemens PLM Software was used in the design of the 5-litre party keg from Huber.
with the software. Through its partner PBU CAD-Systeme GmbH, Siemens also supplies supplementary programs such as the “FastFinder”. Drawings can be quickly located and their update status checked by entering a key word or date. Another benefit is the simple exchange of data between the design, sales and production departments and with external partners. A number of different file formats are ported and transformed directly using Solid Edge – whether non-standard formats such as “dft” or neutral formats such as “DXF” or “PDF”. This saves time and simpli-fies cooperation. «
Huber Packaging Group offers a broad range of metal packaging types familiar to everyone from supermarkets or DIY stores.
Mobile data storage tags MDS D160 embedded into the workpiece carriers using spac-ers allow for the simple and accurate tracking and tracing of assembly and test steps.
Berker produces the Hager series “Tehalit C-Profile” in around 80 different variations on its Ecoline.
Compact, reliable and cost-efficient: RFID readers Simatic RF240R integrated directly into the transport line.
is maintenance-free and therefore cost-efficient.
Quicker and more productive read-out
Another advantage of the Simatic RF200 RFID system lies in its greater reading distance of up to 65 millime-ters compared with only four millime-ters in the version used in the past. This advantage also affords a signifi-cantly enhanced installation leeway. Ten Simatic RF240R readers with inte-grated antenna are installed for read-ing out the workpieces along the line. The controller identifies the process-ing status of each socket and would also guide wrongly placed workpiece carriers to the next processing station. Berker has thus been able to increase the cycle rate originally specified at five sockets per minute to almost sev-en units per minute. «
Blieskastel, Saarland/Germany. Great-er reading distance, compact readers and more cost-effective mobile data storage: Decisive arguments for the first time use of an RFID system in au-tomated assembly and testing lines. Berker GmbH & Co. KG, a leading manufacturer of electrical installation systems, uses RFID and control tech-nology from Siemens to significantly enhance the cycle rates in its produc-tion of sockets.
Berker GmbH & Co. KG relies on its “Ecoline” modular assembly and test-ing line. Technology from Siemens is used in the various assembly and testing steps: The RF240R high fre-quency (HF) readers are used to co-ordinate and control these process-es. 25 workpiece carriers are now in circulation at the same time, uniquely encoded and identified by the mobile data storage media MDS D160 which
A constant eye on the socketRFID technology in assembling and testing
Identwww.siemens.com/ident
RFIDwww.siemens.com/rfid
Berkerwww.berker.com
Enhanced cycle ratesSiemens RFID and control technology enhances cycle rates in production of sockets
Wind Tunnel Center with state-of-the art technique The Audi wind tunnel fan
Aerodynamics plays a pivotal role in the development of a new vehicle. Today’s consumers are demanding ever lower fuel consumption – which can only be achieved with minimized drag. The Wind Tunnel Center in Ingolstadt is used to test the aero-dynamic and aeroacoustic properties of VW Group vehicles. It uses a 2.5 megawatt fan to generate the re-quired wind, simulating vehicle speed. The latest automation components such as Simatic S7-300 and ET 200M, and a Sinamics DCM Cabinet converter are used to control its speed.
The vehicle under test is placed in the wind tunnel, where it is exposed to different wind levels to recreate vehicle speeds. This allows a variety of aerodynamic and acoustic measure ments to be performed which evaluate the vehicle’s aero-dynamic characteristics, in other words its air resistance (cw value), commonly termed drag. The acoustic properties of a vehicle, such as noise development inside and out, are also tested. «
Ingolstadt, Germany. Audi AG has commissioned Siemens to upgrade its wind tunnel center located in Ingol-stadt in Bavaria in line with the very latest technology. The drive of the 4 megawatt fan has been modernized using the latest converter and control technology from Siemens.
Wind of change for aerodynamicsAudi modernizes wind tunnel center using Siemens technology
Audi in the wind tunnelOptimum economy and convenience
Wind Tunnel Center
The Audi Wind Tunnel Center in Ingolstadt is one of the most modern facilities of its kind in the world. It has three wind tunnels: The aeroacoustic wind tunnel for aerodynamic and acoustic measurements, the thermal wind tunnel which enables thermo-management of a vehicle and the climatic wind tunnel for testing the effects of vehicle exposure to extremely high and low temperatures. «
Equipment supplied by Cemtec for a gold mine in Russia included two gigantic mills driven by modern drive and gear technology from Siemens.
The required power trans-mission is provided by two DMG2 gears at each of the mills.
Modern gear technology ensures extreme efficiency
A conventional drive variant enables only one pinion to engage on each side of the gear rim, limiting economi-cal out-put to
Russia. One of the world’s biggest mechanically driven horizontal mills has been constructed for a gold mine in Russia. Driving the mill to achieve an above-average high output are specially designed gears from Siemens.
Cemtec-Cement and Mining Technolo-gy GmbH cooperated with Siemens to develop a plant capable of “washing” up to 30,000 tons of crushed ore per day with the aid of two gigantic mills in the search for gold. The mills, one a semi-autogenous grinding mill and the other a ball mill, are each driven by two special Siemens DMG2 gears, whose de-sign forms the technolo-gical highlight of the entire plant. Two Siemens type 1RR5108-6FA90-Z three-phase asynchronous motors with slip ring rotors get the gears running.
Gold rushGear technology optimizes ore crushing in Russian gold mine
Mining
www.siemens.com/mining
Search for goldWasting up to 30000 tons of ore per day in the search of gold
around eight Megawatts per drive. Using the DMG2 girth gear, this limit can be extended by up to a quarter. What makes this extraordinarily high output possible? The knack: There are two pinions positioned one abo-ve the other which mesh directly with the girth gear at any one time. The self-aligning output pinions are supported in angular contact bear-ings, enabling their optimum en-gagement in line with the girth gear profile. This ensures that the load being transmitted is distributed evenly across the two drive pinions meshing with the girth gear due to the axially free movement of the moveable shafts. The double pinion design offers the benefit that the meshing width of the tooth flanks is smaller than in a conventional single-pinion solution. It was also pos-sible to dispense with costly helical gearing and a large axial bearing. «
Integral Plant Maintenance prevents unplanned downtime at engine, cylinder head and camshaft assembly lines.
Siemens Integral Plant Maintenance offers efficient servicing and optimum control.
Yaroslavl, Russia. Mercedes-Benz Russia and the GAZ Group were looking for a reliable service partner to take responsibility for the entire maintenance management of its new engine plant in Yaroslavl. Within the framework of a service partnership contract, Siemens developed an in-dividual solution to meet all the plant’s servicing needs: Integral Plant Maintenance. Since June 2013, this concept has enabled the service-oriented coordination of all inspections, maintenance measures and spare parts management optimi-zation.
In developing and implementing the computerized maintenance manage-ment system (CMMS), Siemens at-tached particular importance to fulfill-ing the customer’s strict availability requirements. Preventive mainte-nance helps to minimize unplanned downtime at the engine, cylinder head and camshaft assembly lines,
Service at the highest level Integral Plant Maintenance provides a smart approach to servicing
Integral Plant Maintenance
www.siemens.com/ipm
while planned downtime is used to perform necessary maintenance work – ensuring maximum availabili-ty of the production facilities.
Maximum performance plus full cost control
Integral Plant Maintenance enables regular inspections as well as pre-ventive and corrective maintenance. At the same time, it optimizes the stocking and supply of spare parts and provides a sound basis for reli-able maintenance budgeting. Siemens also offers a comprehen-sive range of services such as adap-ting the maintenance management system to the specific process struc-tures in the engine plant. «
Compact, solid and simple to operate: The drive solution from Siemens withstands all demands of sugar processing.
Siemens supplies the world’s largest sugar cane mill with Integrated Drive Systems and boosts plant efficiency by up to 30 percent.
with GH180 converter, 1 PQ4 motor and Planurex 2 planetary gear unit from Flender. Additionally a 2,200 Kilowatt converter, motor and Pla-nurex P3NZ40 planetary gear unit from Flender drives the main mill set.
Efficient, simple, rugged
The use of IDS will ensure an effici-ency increase for the sugar mill in the future of more than 30 percent: So far steam from the factory’s pow-er plant was used to drive the mill. Steam is no longer needed for the new electromechanical drive system and can be used for other purposes – for example to generate electricity. Moreover, the new drive system is more compact and simpler to oper-ate. The Siemens solution is also sufficiently rugged to withstand the harsh demands of sugar processing. Another benefit for the manufacturer is that Siemens is able to provide a rapid on-site service to deal with any questions surrounding the newly in-stalled IDS system. «
Nakhon Sawan, Thailand. Working in association with Allied Tek, an OEM (Original Equipment Manufacturer) for sugar cane mills, Siemens is supply-ing the equipment needed to modern-ize the production plant. The use of In-tegrated Drive Systems (IDS) will boost plant efficiency by up to 30 per-cent.
Kaset Thai Sugar Mill (KTIS) based in Thailand is the world’s biggest sugar factory, processing 55,000 tons of sug-ar cane every single day. Working in association with Allied Tek, Siemens has equipped the mill’s drive systems with IDS, preparing the sugar compa-ny to face future challenges.
Fit for the 21st Century
The traditional drive technology of the sugar mill is based on industrial tur-bines, which are connected with the mill by a gear set. This system was replac-ed by a purely electromechanical so-lution: an Integrated Drive Systems. The system consists of a 1,100 Kilo-watt heavy-duty pressure feeder drive
Energy-saving giantWorld’s biggest sugar mill driven by Siemens IDS
Sugarwww.siemens.com/sugar
Integrated Drive Systemswww.siemens.com/ids
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NX from Siemens PLM Software is used for simulation in civil engineering and bridge design projects.
NX also supports Obermeyer to pro-duce a mass calculation for the new railway bridge.
Quick and easy: Obermeyer Corporate Group is creating a 3D model for the ren-ovation of a railway viaduct with NX from Siemens PLM Software.
Siemens NX put to the test
Certified 2D plans remain an indispens-able element of any infrastructure plan-ning project. Their production is simple using NX, as this type of construction plan can be simply derived from the 3D models – without the need to change systems. The software has already passed a practical test with flying colors: The renovation of a railway viaduct built in 1912 with twelve arches and a total length of 200 meters. The complex via-duct was measured at defined points, modelled in NX and new arches design-ed. The building work is already under way and will be completed by the end of 2015. Hochmuth: “The use of NX gives us more efficiency, more profitability and better consistency in our processes.” «
Munich, Germany. A good infrastructure is a vital driving force behind any mod-ern economy. For Germany as an ex-port country, there is a lot riding on the availability of efficient transport links for both passengers and freight. Obermey-er Corporate Group uses the latest soft-ware to ensure efficient transport infra-structure planning. NX from Siemens PLM Software is used for simulation in civil engineering and bridge design pro-jects.
In its search for a new 3D CAD soft-ware system, Obermeyer’s priorities were economy, efficiency and quality. The search ended with NX from Siemens PLM Software. Markus Hoch-muth, Head of Special Section BIM for Civil Engineering at Obermeyer, ex-plains: “Based on the selection process, we decided to use NX from Siemens PLM Software because it offered the best possibility for integration with our existing planning processes, and be-cause we expected the most output from the 3D model in regard to the de-rived 2D construction plans.”
Building bridgesSiemens NX connects the virtual and real worlds
Product Lifecycle Managementwww.siemens.com/plm
NXwww.siemens.com/nx
NX Softwarefor efficient transport infrastructure planning
Hydraulic pretensioner Hydraulic pretensioning – extended and retracted
LMS Imagine.Lab Amesim Depiction of a model (one-dimensional) based on physical characteristics
stic trouble shooting is not an option since engineers have a very limited slot to test an aircraft,” says simula-tion engineer Christophe Barras.
Fast, simple analysis process
The technicians at Hutchinson use the coupled structural/acoustic ap-proach, which provides an improved insight into an aircraft’s acoustic be-havior. They first carry out a modal analysis to gain an impression of the aircraft’s structural behavior. The en-gineers then use LMS Virtual.Lab Acoustics to create an acoustic mod-el. “The derived simulated acous tics models are huge. We definitely need super-fast solvers to tackle these issues; solvers like LMS Virtual.Lab Acoustics”, says Barras. As the software carries out calculations in parallel, the overall calculation time is reduced, enabling extended utili-zation of computer capacity. «
Montargis, France. A quiet, comfort-able flight: LMS Virtual.Lab Acoustics simulation software from Siemens helps further reduce aircraft cabin noise, as well as cutting development time and costs.
The Hutchinson Research Center is the leading provider of sealing and in-sulation systems for the aviation in-dustry. Its engineers use LMS Virtual.Lab Acoustics Software for the virtual testing of new acoustic insulation sys-tems and absorption concepts and for assessing the benefits of the suggest-ed simulation solution. The Siemens software quickly identifies the opti-mum acoustic solution, helping to sig-nificantly reduce development times and costs. “Only the best-performing solutions will be implemented on the prototype aircraft. The simulation step is crucial to guiding prototyping. With strict test schedules, there is no room for trial-and-error. Last-minute acou-
Sound of silenceImproved acoustic insulation in aircraft
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 combined cycle 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 lead-er in laboratory diagnostics as well as clinical IT. In fiscal 2014, which ended on September 30, 2014, Siemens generated revenue from continu-ing operations of €71.9 billion and net income of €5.5 billion. At the end of September 2014, the company had around 343,000 employees world-wide on a continuing basis. Further information is available on the Internet at www.siemens.com.
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