Content APPLICATIONS 02 Industrie 4.0 on four legs 04 Just like hand-made 06 Guaranteed riding fun Siemens MediaService June 2017 siemens.com MediaService Industry News The June issue of the MediaService brings you news of applications from the world of drives and automation that could hardly be more diverse. We learn how jack-up ships use automated leg force measurement with the aid of con- dition monitoring systems. The article “Just like hand-made” examines the flexible, future-proof manufacture of multi-layer chocolate products. With Motion Control from Siemens and the “one-shot technique” used by a Bel- gian manufacturer of machinery for purely artisan, partially and fully auto- mated chocolate production, the base, filling and coating of these sweet treats are produced in a single work step. Fi- nally, we turn our attention to the sub- ject of full suspension bikes, and learn how the PLM Software Solid Edge helps cycle manufacturer Pyga Indus- tries to minimize development periods and reduce the time-to-market for its high-performance bikes.
Transcript
Content
APPLICATIONS
02 Industrie 4.0 on four legs
04 Just like hand-made
06 Guaranteed riding fun
Siemens MediaServiceJune 2017
siemens.com
MediaServiceIndustry News
The June issue of the MediaService brings you news of applications from the world of drives and automation that could hardly be more diverse. We learn how jack-up ships use automated leg force measurement with the aid of con-dition monitoring systems. The article “Just like hand-made” examines the flexible, future-proof manufacture of multi-layer chocolate products. With Motion Control from Siemens and the “one-shot technique” used by a Bel-
gian manufacturer of machinery for purely artisan, partially and fully auto-mated chocolate production, the base, filling and coating of these sweet treats are produced in a single work step. Fi-nally, we turn our attention to the sub-ject of full suspension bikes, and learn how the PLM Software Solid Edge helps cycle manufacturer Pyga Indus-tries to minimize development periods and reduce the time-to-market for its high-performance bikes.
The “Innovation” is Europe’s biggest instal-lation vessel for offshore wind turbines. Its jack-up system is able to lift up to 30,000 tons.
shore applications. Not only wind farms but also an increasing number of ships rely on the efficient condition monitoring of technical components such as drives to improve safety and prevent failures. What is known as a Fourier analysis is used for the diag-nosis of component vibrations by an-alyzing selected frequencies. The frequency spectrum of the measured vibrations provides information about a component’s “state of health”. For this kind of analysis, Siemens offers the condition monitoring system Sip-lus CMS 1200, which specializes in predictive maintenance and compris-es a Simatic S7-1200 CPU (com-puter processing unit) with condition monitoring signal module SM 1281. The system is capable of measuring, storing, evaluating and visualizing the data from up to 28 vibration sen-sors.
North Sea/Baltic Sea. Industrie 4.0 is on its way, not just on land but in the offshore sector too. As well as in wind farms, condition monitoring systems are also increasingly being used to monitor the condition of mechanical components on board ship. One such vessel is the “Innovation”, a special ship used for the construction of wind farms in the Baltic and North Sea. To stabilize itself in the water during wind turbine installation, the “Innovation” extends four supporting legs using what is known as a jack-up system, which lifts the ship out of the water. Precise measurement and distribution of the forces acting on each of the four legs are ensured by condition monitor-ing technology from Siemens.
Industrie 4.0 solutions and in particu-lar condition monitoring are enjoying increasingly widespread use in off-
Industrie 4.0 on four legsCondition monitoring technology safeguards offshore wind turbine assembly
Alongside vibrations, other kinds of mechanical stress also have a role to play, for instance in ships used for the offshore installation of wind turbines in the stormy waters of the Baltic and North Sea. This is only possible using specially constructed vessels such as Europe’s biggest jack-up ship, the “In-novation”, which is part of the HGO In-fraSea Solutions GmbH & Co. KG fleet. The “Innovation” carries a crane capable of lifting up to 1500 tons. When the crane is in use, the ship is stabilized on four legs which raise it up out of the water. This jack-up sys-tem, which when fully loaded is re-quired to support a weight of 30,000 tons, is driven by a total of 96 electric motors. To ensure the necessary sta-
bility when raising the ship out of the water, a preloading process has to be used. This repeatedly lowers two pairs of legs in turn onto the sea bed while building up pressure to com-pact the substrate. This process is repeated until the ship is resting completely on all four legs. To en-sure precise distribution of load dur-ing the preloading process, the “In-novation” uses the Siplus CMS 4000 condition monitoring system. This continuously records and displays values such as static and dynamic leg force or motor currents, enables the evaluation of up to 180 channels as well as programming of individual models and algorithms. The data can also be transferred over satellite and the Siemens “Common Remote Ser-vice Platform” (cRSP) to the main-land.
A total of four legs lift the “Innovation” out of the water during the installation of wind turbines.
The Siplus CMS 4000 constantly records values such as motor currents or static and dynamic forces acting on the legs, and is capable of evaluating up to 180 channels.
The condition monitoring system Siplus CMS 1200 comprises a Simatic S7-1200 CPU and the condition monitoring signal module SM 1281.
Condition Monitoringwww.siemens.com/siplus
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Sweet final product: With “one-shot” technology multi-layer chocolate products – for example a base, filling and coating – can be created in a single work process.
With one-shot technology, machines can pro-duce multi-layer chocolate products in a single work step. To make subsequent changes as simple as possible to implement, even the smallest machines from Hacos are equipped with a Simatic liquid crystal display (LCD).
Malle/Belgium. Belgian manufactur-er Hacos specializes in machinery for purely artisan, partially automated and fully automated chocolate pro-duction and is the world leader in this field. To meet its customers’ require-ments in terms of flexibility, produc-tion quality and integrated automa-tion, the company uses control technology from Siemens in its ma-chines, which can be used either as standalone systems or as an inte-grated part of the production line.
The portfolio of manufacturer Hacos from Belgium includes molding ma-chines, dosing machines and enrob-ers, spinning machines and decorat-ing machines, as well as all the accessories required for these appli-cations. The Hacos systems are used in the production of chocolate products. “From our point of view, the market is divided into different application segments: artisan choco-late production, semi-automated chocolate production, smaller auto-mated lines and industrial lines,” ex-plains Sales & Marketing Manager Raf Tuytelaars. To be able to meet the varied demands of these quite different target groups, Hacos uses
Just like hand-madeChocolate machine manufacturer uses integrated automation from Siemens
Siemens components for the auto-mation of its machines.
Smooth function upgrades
“For us, it is important to support growth particularly among the emer-gent smaller and medium-sized chocolate manufacturers. This is why many of our products are designed to work not only as a stand-alone so-lution in a small company or for manu-facturers of hand-made delicacies, but also as an integrated element in partially or fully automated produc-tion environments – and they can also be used as a retrofit solution,” explains Raf Tuytelaars. This ap-plies, for example, also to the expan-sion of existing production capabili-ties. The level of investment required here is reduced noticeably as a re-sult, which makes it easier for small-er companies in particular to take the step from purely hand-made, artisan production towards automated pro-duction. In the process, connectivity between the different machine mod-ules is crucial for the machines from Hacos, as this enables subsequent modifications or upgrades in terms of functionality. To this end, even the
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example a base, filling and coating – in a single work process.
With the aid of the graphical inter-face ChocoCAD (computer-aided de-sign), recipes can be entered for fill-ing different molds or layering up different products on a base plate. A G-Code interpreter, which is avail-able as a standard Simotion module, then directly uses the data generated by ChocoCAD without the user need-ing to worry about converting the data for the mold that is used into coordinates. Recipes generated in ChocoCAD can be saved and re-called for future use, enabling very fast switching between different products.
Quality assurance
Hacos maintains a high production depth in order to meet the quality de-mands of its customers. “For us and our customers, a well-developed ser-vice network and rapid availability of spare parts are really important. This is another reason for us to use con-trol and automation technology from Siemens. This cooperation with an automation partner who can offer such a global presence helps us to meet our high quality standards, and the remote servicing capability of our machines also benefits from the inte-grated system technology,” summa-rizes Raf Tuytelaars.
smallest machines are equipped with a Simatic touch panel with liquid crys-tal display (LCD).
High flexibility
Thanks to the integrated open automa-tion, the systems can be adapted to new requirements at any time. For Raf Tuytelaars, the advantages are plain to see: “The integrated technology offers the benefits of simpler programming and communication, and it also offers improved diagnostic capabilities. This enables us to realize modular con-cepts more easily and means that our modules can be combined more flexi-bly. The engineering framework we use for this is the TIA (Totally Integrat-ed Automation) Portal and Simotion Scout, which helps us to ensure that our machines can be easily upgraded and expanded in terms of functionality, operation and combination options. This is really important for our custom-ers, since it means that the machines can be constantly reconfigured in new constellations over a long period of time.” The motion control of the ma-chines, which in some cases can imi-tate handmade chocolates, is imple-mented via the Simotion motion control system. This enables the performance of even complex motion sequences and patterns like the ones required for “one-shot” technology. This concept describes the process of creating multi-layer chocolate products – for
The engineering of the machines is imple-mented in the TIA portal, which allows the machines to be quickly upgraded and ex-panded in terms of functions and operation.
Thanks to the precise automation based on Simotion technology, the machines from Hacos are not only capable of manufactur-ing high-quality chocolate products, but also of decorating them.
For the design of the components, which are often made of carbon, Pyga uses the design software Solid Edge from Siemens PLM Software.
world. Pyga bikes impress particu-larly with their combination of fun and competitiveness, which is based on high pedaling efficiency and agile ride comfort. The current portfolio comprises five types of full-suspen-sion bikes, and two hardtail versions on which only the front wheel has suspension. In order to optimize the development process and develop-ment times, reduce time-to-market and implement complex frame de-signs under kinematic aspects – i.e. aspects relating to motion and aes-thetics – Pyga uses Solid Edge from Product Lifecycle Management (PLM) specialist Siemens PLM Soft-ware.
Exacting standards
“Most bicycle companies design their bicycles outright for perfor-mance and speed,” says Patrick Morewood.” At Pyga, however, we put a lot more emphasis on making our bikes fun and comfortable to ride.” Pyga does this primarily by relying on innovative technologies and materials in the development and construction of the bikes. The switch from conventional compo-nents made of aluminum to compo-
Pietermaritzburg/South Africa. South African company Pyga Indus-tries (Pyga) develops and manufac-tures high-performance bicycles that are great fun to ride yet competitive on the racetrack. The bikes from Pyga are up among the best in terms of performance and quality. When it comes to design, in addition to pedaling efficiency and agile ride comfort Pyga places great value on incorporating the latest leading edge technologies and materials such as carbon. To simplify the design pro-cess and to allow for last minute changes, Pyga uses Solid Edge from Siemens PLM Software. As a result, development times can be re-duced from around four months to two and a half months, and short-term adaptations even to advanced design phases can be rapidly imple-mented.
Patrick Morewood and Mark Hopkins are both passionate mountain bik-ers, and they founded Pyga Indus-tries (Pyga) in 2011 in South Africa. The company has subsidiaries in the UK, Germany and the USA and spe-cializes in the development and pro-duction of high-performance bikes that are among the very best in the
Guaranteed riding funBike manufacturer develops high-performance bikes with Solid Edge from Siemens PLM Software
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nents made of carbon offers design engineers more freedom in the de-velopment and design of the bicy-cles. At the same time, this greater freedom also demands highly sophis-ticated design software. Previous CAD (computer-aided design) soft-ware was inadequate, particularly when it came to imported CAD mod-els and when creating different size variants. Here, Solid Edge is a user-friendly solution that offers a tangible boost to efficiency. The parametric design tools from Solid Edge are par-ticularly well suited to the rapid scal-ing of sizes, and with Synchronous Technology it is possible to quickly make changes to CAD models from any source via direct modeling. This additionally reduces the time it takes to create prototypes.
Faster and better
Thanks to Solid Edge, Pyga now has more design options at its disposal than before. At the same time, it fur-ther improves the performance, aes-thetics and quality of the bicycles. “The implementation of Solid Edge 3D CAD software with options for design-ing complex surfaces allows us to cre-ate the complicated designs of our high-end carbon composite bikes and to redesign our existing aluminum models,” sums up Morewood. Instead of spending three to four months on a new frame design, with Solid Edge the developers now only need two and a half to three months. Last-minute changes no longer take a whole day but just two to three hours, which leads to a shorter time-to-market.
Pyga Industries has been developing high-performance bikes since 2011 that are great fun to ride yet competitive on the racetrack.
With this Siemens solution, Pyga is able to significantly reduce the development time for new frame models and prototypes and therefore to shorten the product launch time.
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.
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