In its last issue of 2016, once again the MediaService Industries introduces new products and applications from the world of drives and automation. These include new panel and exten-sion unit sizes for the IP65 rated Si-matic Human Interface Pro systems, and new functions for the network tran-sition IE/PB Link PN IO. Applications featured in this MediaService cover a
range of topics which could hardly be more varied. Atomic clocks in a vacu-um: we read about how Siemens tech-nology is used for monitoring and con-trolling an experimental lab which is destined to dock onto the International Space Station ISS as an outpost of the Columbus space lab. Coming back to earth, we hear about an automatic box opener which enables the efficient slit-ting open and unpacking of boxes. Just in time for the Christmas season, we read about varieties of confection-ery wafer and how their production is optimized by a Simatic WinCC control system. And finally, our attention is turned to complete solutions for plastic molds, die-casting tools, thermoform-ing tools, press dies, fixtures and much more, an area in which the NX soft-ware from Siemens PLM Software has succeeded in improving quality and substantially reducing engineering time.
Profinet IE/PB Link PN IO network transitionProcess Device Manager (PDM). The IE/PB Link PN IO can now also be configured without Step 7 using the free Primary Setup-Tool (PST). The newly integrated switch with its two RJ45 ports also offers facility to con-nect the IE/PB Link PN IO network transition to an Industrial Ethernet network using star, linear or ring to-pology – including media redundancy with the Profinet MRP protocol. The alternative use of a bus adapter from the Simatic ET 200SP product line additionally enables a wide variety of connection methods for Industrial Ethernet, such as direct implementa-tion of a fiber optic line for linking up different factory halls. If replacement is required in an existing project in-stallation, the new IE/PB Link PN IO can be exchanged for its predeces-sor by simply replugging the C-plug with the configuration data.
Nuremberg, Germany. Siemens has upgraded its IE/PB Link PN IO net-work transition to include a range of new functions. The device links Indus-trial Ethernet/Profinet with Profibus networks, allowing for instance Profi-bus users to be linked into over-arch-ing Profinet applications.
In addition to application as a PN IO proxy for subordinate Profibus users, the new IE/PB Link PN IO network transition is also used for cross-net-work PG/OP communication, for in-stance for loading programs and con-figuration data, for test and diagnostic functions as well as for operation and monitoring. Over the IE/PB Link PN IO, for instance, users can parameter-ize and diagnose all Profibus field de-vices from a central engineering sta-tion connected to an Industrial Ethernet network using the Simatic
New IE/PB Link PN IO network transitionNew functions for added application scope
Simatic netwww.siemens.com/simatic-net
IE/PB LINK PN IOhttp://w3.siemens.com/mcms/industrial-communication/en/ie/network-transition/ie-pb-link-pn-io/Pages/ie-pb-link-pn-io.aspx
Siemens is extending its IP65 protection rated system family Simatic HMI Pro to include new panel and extension unit sizes. The picture shows the example of an extension unit assembly.
The modular system of the extension units allows the rapid, simple combination and fitting of components in line with individual customer requirements.
Nuremberg, Germany. Siemens has extended its IP65 protection rated Si-matic HMI (Human Machine Interface) Pro systems family to include a 15-inch panel and extension units in sizes 12, 15, 19 and 22 inches. The modular de-sign of the system enables even more individual combination of the standard components for customized system so-lutions in line with specific customer needs. The extension units can be sim-ply and quickly equipped by customers themselves with the operating ele-ments they require.
A high protection rating, control cabi-netless installation, a large screen surface and high computation perfor-mance – the IP 65 protection rated Simatic HMI Pro system family comes with an array of benefits. Sie-mens has now extended the existing portfolio comprising 19 and 22 inch panels to include a 15-inch panel version which, like all other PC-based systems of the family, can be directly mounted on a pedestal or support arm at the machine. This range has now been extended to in-clude new units in sizes 12, 15, 19 and 22 inches and can be equipped
Modular and user-friendlyNew panel and extension unit sizes for Simatic HMI Pro
with the required buttons by custom-ers themselves. The modular design of the system allows all the system components to be individually com-bined – to suit the individual needs of customers using whichever but-tons they require.
With their meticulously designed com-ponents, the basic units from the Si-matic IFP (Industrial Flat Panel) and IPC (Industrial PC) spectrum permit simple mounting and rapid extension. Their all-round IP65 protection rating (NEMA4) also makes them suitable for switch cabinetless visualization and automation. The customized system solution comprising base unit, exten-sion unit, mounting adapter, optional keypad and support (at a later delivery date) can be quickly adapted in line with individual customer requirements. Customers benefit from outstanding security and reliability as well as an at-tractive, user-friendly design.
Controllerwww.siemens.com/simatic
Operator Control and Monitoring Systemswww.siemens.com/ip65-hmi-devices
The comparison of the Aces clocks in orbit to reference clocks on the ground allows a check of the theory of relativity with unprecedented accuracy. Scientists worldwide may look forward to gaining new insight into the combination of gravitation with the world of quantum physics. The launch and start of the Aces mission are expected in 2018.
A failsafe Simatic S7-317F monitors the criti-cal systems, in particular the vacuum condi-tions inside the measurement chamber.
Immenstaad, Germany. The Atomic Clock Ensemble in Space, Aces is currently taking shape at Airbus DS in Immenstaad am Bodensee for the European Space Agency ESA. The experiment, which is destined to dock onto the International Space Station ISS as an outpost of the Columbus space lab, accommodates two atomic clocks operating along different func-tional principles. The goal of the ex-periment is an ultimate check of the theory of relativity by comparing the space clocks to ground clocks. The pressure and temperature of the vacuum chamber used to test Aces on earth are monitored and con-trolled by Siemens technology.
Relativity theory only relatively accurate
Albert Einstein’s theory of relativity has been experimentally confirmed many times. However, combining it with quantum theory remains a chal-lenge for today’s physicist. The Aces
Atomic clocks in a vacuumSiemens technology monitors and controls experimental lab
experiment will contribute significant-ly. One of Aces functions will be to experimentally validate the constan-cy of the speed of light - one of the fundamentals of the theory of relativ-ity. The Aces clocks support such ex-periments by an ultimate accuracy equivalent to less than one second in 300 million years.
Cooperation on the European level
Under contract to ESA, Airbus De-fence and Space in Immenstaad is building the Aces space model. This experimental lab is due to dock onto the International Space Station ISS as an outpost of the Columbus Space Lab. It will contain two atomic clocks with different functional princi-ples. The French contribution Pharao (Projet d’horloge atomique par re-froidissement d’atomes en orbite) is a laser-cooled caesium clock, while the Swiss contribution is the SHM (Space Hydrogen Maser). The mea-
matic controller from Siemens. The sensors, heating and cooling ele-ments for the 36 control loops are connected via the distributed I/O ET 200SP.
Elimination of risks
The most important function under-taken by the automation system is to monitor the vacuum pump. If it were to fail or if only a minimal increase in pressure were measured, the testing would need to be stopped immedi-ately. The pressure increase could otherwise result in a short-circuit of the high voltage power supplies due to the corona effect. This would be a catastrophic failure for Aces. Achim Kirchmaier, AIT Manager at Airbus Space Systems, selected a failsafe Simatic S7-317F to fulfill this vital safety function based on his previous positive experience of the Siemens controller and its outstanding reliabil-ity in a number of other highly safety-critical applications.
Fundamental research
It hardly seems conceivable, but in the long term the improved measure-ment accuracy will not only help fun-damental research, but will also have practical benefits. These include sat-ellite navigation systems that hinge on the performance of atom clocks and world-wide time synchronization relevant for instance for high speed data networks.
surement time in Pharao, that is the time of free flight of the caesium at-oms within the clocks, can be extend-ed significantly in weightlessness. This directly results in improved accu-racy. The complementary features of both clocks allow the generation of a combined signal more effectively than the individuals ones within Aces. The resulting Aces signal, affected by rela-tivistic effects due to the high velocity of eight km/s (kilometers per second) and a change in gravitational potential at the orbit altitude, will be compared to several reference atomic clocks on earth. The National Metrology Institute of Germany (PTB) based in Braunsch-weig operates such a reference clock. Clock comparisons with Aces take place simultaneously using micro-waves and a laser path to compensate for atmospheric effects.
Before Aces can be launched and in-stalled, it must prove its capability to withstand the harsh conditions in space. Its full performance has to be tested on the ground under realistic conditions. For this, Aces is installed inside a vacuum chamber. Testing en-tails exposure to changes in magnetic fields and temperatures equivalent to the environment it will experience in orbit. To guarantee optimum perfor-mance of the atomic clocks, the tem-perature must be maintained at be-tween -30 and +70 degrees Celsius by heating and cooling elements. These conditions are controlled pre-cisely in simulated operation by a Si-
Simaticwww.siemens.com/simatic
Aces has been assembled in the Airbus DS cleanrooms in Immenstaad. To protect the sensitive instruments, electromagnetic dis-turbances have to be minimized. Given the strict magnetic cleanliness rules, any metal-lic part but also devices such as cell phones are forbidden close to Aces. For the same reason, camera equipment and tripods also have to be kept at a distance.
MediaService | December 2016 6
head then cuts along the side edges of the box or perforates the box, ad-justing the depth of the specified cut-ting or perforating technique. The patented blade system ensures that the goods inside are never damaged.
Less time, more security
Visualization with the aid of the Simat-ic TP700 Comfort Panel enabled ALS to benefit from the integrated engi-neering capability of the Totally Inte-grated Automation Portal. In future, all machine variations will be parameter-ized, engineered, networked and diag-nosed through the TIA Portal. Flexible safety zones can be easily implement-ed using seamless communication via Profinet implementing the Profisafe protocol. Moreover, the company not only saves on additional security hard-ware but can also save up to 15 per-cent in wiring time. Development engi-neers at ALS are certain the TIA
Erligheim, Baden-Württemberg, Germany. ALS Automatic Logistics Solutions GmbH, a Bavarian-Swabian manufacturer of special purpose ma-chines, has developed the patented, fully-automated BOS Box Opening System. This system opens packaged merchandise cost efficiently without ever damaging the goods within. In doing so, the young company relies on integrated automation technology from Siemens, with impressive results: The BOS handles a throughput of up to 600 boxes an hour and minimizes the risk of injury for employees.
In the wholesale trade and industry, millions of goods are unpacked and repacked each day – many of them manually. ALS provides an automated solution with its patented BOS Box Opening System. The system auto-matically records the dimensions of in-coming boxes, centers them and fixes them in place. An adjustable blade
Efficient box opening systemAutomated box opening system
The BOS Box Opening System can open a box in around six seconds, meaning a throughput of up to 600 boxes per hour.
Cut types Box Opening System
MediaService | December 2016 7
Portal will also prove to be most useful in future plants because the function block library will reduce development and delivery times. This means ALS has just the right solution to meet the growing demand for automatic pack-age opening.
Integrated automation
Several factors were crucial for ALS in selecting the right compo-
nents. The high processing speed means efficient motion control needs to be ensured at all times. Swift commissioning of the systems and integration into different infrastructures are also essential. The components from Siemens meet all these require-ments. It was also important for ALS to ensure it had access to a long-term supply of spare parts at short notice.
Simatic HMI Comfort Panel
sie.ag/1Ua4Hn9
TIA Portalsie.ag/1LFoaYO
Profinetsie.ag/1Nc0PA7
The first thing people tend to associate with opening parcels is the countless number of re-turns in the mail order industry. The return rate in the mail order industry is rising continuously owing to free returns and the boom in online trade. The most recent surveys carried out by Bamberg University revealed that between 250 and 290 mil-lion parcels were returned to sender in the German mail in-dustry in 2014 alone. The num-ber of boxes to be opened and the growth rates in industry are even higher where materials al-
ways need to be unpacked for production or repacked for ship-ping and sales by wholesalers and fulfillment service providers, some products up to seven times. It is estimated that more than one billion boxes need to be opened manually with a knife each day. Accident statistics show that these activities involve a high risk of injury. Furthermore, goods in-side boxes are frequently dam-aged, causing major financial losses – up to seven-digit amounts per year and company. To have an automated solution is definitely the answer.
Automated opening of parcels
The BOS Box Opening System is the first automated box opener in the world to go into series production.
tomatically filled with the ingredients. In contrast to the former method in-volving a manual weighing process, dosing of the main ingredients is now performed automatically, ensuring more precise dosing and reducing raw material waste. The automation technology has been provided by Hellebusch Elektrotechnik GmbH, a system integrator based in Steinfeld, which uses the extensive Siemens portfolio for its process automation. The Siemens products used here in-clude a programmable logic control-ler (PLC) Simatic S7-300 CPU 315-2PN/DP, for each mixer, and the Siwarex weighing module, which is connected to the PLC. The mixers are monitored within the factory by a redundant pair of servers in a server room, which can be accessed direct-ly from the factory floor using Simatic Panel PCs.
Future-proof and compatible
To make optimum use of the benefits of automated batter production, in
The end product: flat wafers. The consistently high standard of quality can be verified at the press of a button or a mouse click thanks to detailed product data acquisition in the control system.
Production can be started and monitored using the control system from the operator station at the mixer. Short-notice manual changes to recipes are possible at any time. Visible in the background are the flat wafer production lines.
Venne, Germany. Waffelfabrik Meyer zu Venne GmbH und Co. KG is Germany’s biggest manufacturer of wafer products. To meet growing demand and ensure a consistent standard of quality, the company has introduced a highly automated pro-duction process, and uses Siemens technology for control and visualiza-tion. By investing in the Simatic WinCC control system, Waffel-Meyer has been able to optimize its produc-tion processes, prevent dosing errors and ensure production sequences that are traceable and fully docu-mented.
Around three billion wafer products – from ice cream cones to flat wafers – are baked, packaged and shipped every year by Waffelfabrik Meyer zu Venne GmbH & Co. KG based in Venne near Osnabruck. The produc-tion halls at Waffel-Meyer are equipped with 40 ovens. 33 of them are used to bake ice cream cones, the other seven for flat wafers. The batter is fed by mixers which are au-
Producing the perfect waferGermany’s biggest wafer producer automates production
Flat wafersProduct data acquisition with control system
MediaService | December 2016 9
is continuously changing as a result of line upgrades and modernization processes, and also permits quantity structures of up to 256,000 variables. Additional operating stations can also be connected at any time with a total of 32 clients per WinCC server. There are two possibilities for inte-grating existing and new plants. They are either integrated as an industrial PC into the already existing system, meaning that the Scada project runs locally and its data is synchronized with the server. Alternatively, the complete project can be filed on the WinCC server using Thin Clients to access it.
Ideally equipped for the future
By automating the production pro-cess, and saving and analyzing the production data, Waffel-Meyer has succeeded in further increasing its product quality and at the same time preventing dosing errors by optimizing the input of raw materi-als. Because WinCC is also a fu-ture-proof solution offering easy adaptability and an open architec-ture for changes, the system will al-low rapid, trouble-free moderniza-tion and adjustment in line with future needs.
parallel to the Simatic controller the company also decided to introduce Si-matic WinCC V7 Scada software. This manages the recipes, collects produc-tion data for analysis and so enables seamlessly traceable plant operation. With the Open Platform Communica-tions (OPC) standard, WinCC sup-ports not only an array of automation products from the Siemens Totally In-tegrated Automation (TIA) spectrum, but also a good number of third-party products. Even in its basic version, WinCC offers extensive options for vi-sualization of the production process. These are supplemented by industry-specific add-ons such as PM-Control for controlling wafer production and PM-Quality, which analyzes and stores the logged data. “Detailed data analysis allow us to log and verify the input of raw materials and the produc-tion process for each individual wafer – not using calculated values or speci-fications but based on real production data,” explains the wafer factory’s CEO, Christian Meyer zu Venne. This enables the documentation and verifi-cation of product quality. Another rea-son the company opted for WinCC as a control system is its scope for sim-ple upgrading and scalability. The sys-tem can be quickly adapted in line with a production environment which
Raw materials are fed to the batter mixer using a pipe system, with automation by means of pumps and a worm gear. Integrat-ed sensors measure the batter weight, en-suring precision infeed of the ingredients.
This is where the batter is baked to produce flat wafers for example for confectionery production: The storage container (on the right next to the viewing windows) serves as a short-term buffer for the oven. The filling level is monitored by sensors and automati-cally regulated.
Controlwww.siemens.com/simatic
Weighing Systemswww.siemens.com/siwarex
Simatic Scadawww.siemens.com/scada
MediaService | December 2016 10
Pune/India. Matrix Tools and Solutions (Matrix), headquartered in Pune, India, provides complete solutions for plastic molds, die casting dies, thermoforming tools, press tools, fixtures and other engi-neering needs. To improve quality, reduce design time by 50 percent, and gain cus-tomer confidence in tooling made in India the company uses NX from PLM special-ist Siemens PLM Software.
Matrix works with some of the world’s largest original equipment manufactur-
NX from Siemens PLM Software helps Matrix Tools and Solutions gain customer confidence in tooling made in India.
By using NX, Matrix has reduced its design time by 50 percent
ers (OEMs) to develop products and tooling for customers in India, the Middle East and the United States. The company’s products and servic-es include product design, die cast-ing dies, injection molds, thermoform-ing tools, compression molds and jigs, fixtures, and trimming tools. Ma-trix is a one-stop shop for product de-velopment, handling all phases of the process, from concept to design and engineering, validation, manufactur-ing and production. Headquartered in
Quality made in IndiaTool construction company uses NX Software
NX SoftwareDesign time reduced by 50 percent with Siemens
MediaService | December 2016 11
pabilities. Matrix relies on Design-Tech Systems, a Siemens PLM Soft-ware solution partner, for system sales, training, technical support, guidance, and customization. Matrix not only uses the complex surface design capabilities of NX extensive-ly for mold core and cavity design but also the data conversion tools available with NX to import CAD models.
Time savings and productivity gain
Starting with a single license of NX, Matrix became comfortable and profi-cient with the software within a year and has added licenses incremental-ly as the business and the design team have grown. “We have realized time savings and productivity gains of up to 50 percent compared to 2D methods, and similar quality improve-ments. Our use of NX has helped build the reputation of our research and development team, and attracted many new customers from overseas as a result,” says Chenat.
Pune, India, the company operates a design lab staffed by highly talented designers and a mold and die manu-facturing facility equipped with ad-vanced machine tools for producing and assembly mold and die compo-nents. Matrix also offers batch and mass production of zinc and aluminum cast components, produced in two plants for cold- and hot-chamber pro-cessing.
Improving efficiency and quality
“For quality tooling, companies have traditionally shopped outside of India,” says Sajith Chenat, director at Matrix.
“We wanted to build confidence among the industry for tooling made in India.” To achieve that goal, Matrix strived to improve tooling design and manufacturing efficiency, and to reli-ably deliver right-the-first-time quality. Therefore, Matrix selected NX soft-ware from product lifecycle manage-ment (PLM) specialist Siemens PLM Software, based on its specialized high-performance tooling design ca-
With the user-friendly software NX, Matrix can train new users easily and complete the product design stage significantly faster.
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 digitali-zation. One of the world’s largest producers of en-ergy-efficient, resource-saving technologies, Siemens is a leading supplier of efficient power ge-neration and power transmission solutions and a pi-oneer in infrastructure solutions as well as automa-tion, drive and software solutions for industry. The company is also a leading provider of medical ima-ging equipment – such as computed tomography and magnetic resonance imaging systems – and a leader in laboratory diagnostics as well as clinical IT. In fiscal 2016, which ended on September 30, 2016, Siemens generated revenue of €79.6 billion and net income of €5.6 billion. At the end of Sep-tember 2016, the company had around 351,000 employees worldwide. Further information is availa-ble on the Internet at www.siemens.com.
MediaService application reports may be based on previously published Siemens technical articles.
Current press releases:Siemens: www.siemens.com/press Siemens PLM Software: www.plm.automation.siemens.com/en_us/about_us/newsroom//
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