MediaService Industry News Welcome back from your summer break. The late summer / early fall edition of the MediaService Indus- tries brings you interesting reports of products and applications from the world of drives and automation. We hear how a battery-powered, practi- cally maintenance-free water meter takes care of extreme measurement accuracy even in harsh environ- ments. Also featured: Siemens digital production technology experts use closed control loops permitting pre- cise machine data capture and anal- ysis to produce components used in offshore wind farms. We take a trip to the stables, where equine tread- mill producer Sascotec has devel- oped a pay-per-use version of its lat- est Horsetrainer thanks to drive technology and wireless communica- tion systems from Siemens. And fi- nally, we read how Turnkey Manufac- turing Solutions GmbH relies on Siemens PLM Software in its body- in-white construction facilities to sup- port the manufacture of widely di- verse models – enabling it to simulate complete plants in virtual operation and so reducing the on- site commissioning phase by up to 70 percent. Content PRODUCTS 02 Going with the flow 04 Tracing gears APPLICATIONS 06 Trotting ahead 08 Virtual reality Siemens MediaService September 2017 siemens.com
Transcript
MediaService Industry News
Welcome back from your summer break. The late summer / early fall edition of the MediaService Indus-tries brings you interesting reports of products and applications from the world of drives and automation. We hear how a battery-powered, practi-cally maintenance-free water meter
takes care of extreme measurement accuracy even in harsh environ-ments. Also featured: Siemens digital production technology experts use closed control loops permitting pre-cise machine data capture and anal-ysis to produce components used in offshore wind farms. We take a trip to the stables, where equine tread-mill producer Sascotec has devel-oped a pay-per-use version of its lat-est Horsetrainer thanks to drive technology and wireless communica-tion systems from Siemens. And fi-nally, we read how Turnkey Manufac-turing Solutions GmbH relies on Siemens PLM Software in its body-in-white construction facilities to sup-port the manufacture of widely di-verse models – enabling it to simulate complete plants in virtual operation and so reducing the on-site commissioning phase by up to 70 percent.
Battery-powered water meter Sitrans F M MAG 8000 is also suitable for use in harsh environments and extreme temperatures.
Nuremberg, Germany. With its Si-trans F M MAG 8000, Siemens offers a battery-operated water meter which is suitable for use under even the harshest of environmental condi-tions and provides highly accurate readings despite requiring practically no maintenance. Its functions and product characteristics include re-mote access to measurement data, sabotage protection, logging and ar-chiving options and simple device configuration.
Whether for water abstraction and distribution, consumption metering or irrigation: The Sitrans F M MAG 8000 from Siemens enables water meter-ing for a wide range of applications – even under extreme temperatures. The enclosure of the battery-operat-ed meter is compliant to ISO 12944-2 and IP68/Nema 6P, and can be in-stalled practically anywhere – even underground or in flood-prone loca-tions. Its battery operation means that the meter not only requires prac-
Going with the flowBattery-operated water meter for almost maintenance-free use in harsh environments
tically no maintenance, but can be used in continuous operation over as long as 15 years in regions with no reliable mains power supply. An inte-grated power management program measures consumption and alerts the operator in good time when the re-maining battery charge is running low. The benefits of the F M MAG 8000 include a remote transmitter op-tion with pre-installed connectors and cables, the elimination of wear-prone moving parts, bidirectional accuracy and high-precision water metering to within 0.2 to 0.4 percent of flow rate. An unrestricted flow tube ensures minimal pressure loss even at high flow rates. This allows the general mains system pressure to be re-duced, minimizing the risk of burst pipes and the stress placed on pump-ing stations.
Rapid access to data
To further increase both efficiency and billing accuracy and simultane-
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been installed, users are offered a range of available options to ensure high availability coupled with mini-mal maintenance. These include not only comprehensive data log-ging and archiving of consumption levels, but also a product sizing program which indicates whether the size of the meter is appropriate to the conditions (flow volumes) on site.
International recognition
All Siemens flow measurement in-struments are recognized by the In-ternational Laboratory Accreditation Corporation Mutual Recognition Ar-rangement (ILAC MRA) which en-sures the international acceptance of test results. The ILAC MRA is an ar-rangement which guarantees the ac-ceptance of accredited services across borders.
ously reduce costs, Sitrans F M MAG 8000 comes with built-in wireless au-tomated meter reading. Access is af-forded by a customary web browser with password protection. In addition, a standard IrDA interface is integrated in the meter to enable configuration and documentation using the Simatic Process Device Manager. Remote monitoring is quickly and simply possi-ble using a compact wireless commu-nication module which logs the data optionally over FTP, email or SMS at customizable intervals.
Extensive function spectrum
Additional features include error self-detection, real-time clock synchroni-zation with internet NTP server for time-stamped transmission of mea-surement data, and seamless com-munication over 2G and 3G net-works. Once the water meter has
A remote transmission option with pre-installed cables and connectors, the elimination of wear-prone moving parts and outstanding measurement accuracy are just some of the benefits of the F M MAG 8000.
A standard IrDA interface is integrated in the Sitrans F M MAG 8000 to enable me-ter configuration and documentation us-ing the Simatic Process Device Manager.
Sitranswww.siemens.com/sitrans
MAG 8000www.siemens.com/mag8000
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Precise geometric measurement of a gearwheel using optical sensors.
can imagine how complex and ex-pensive maintenance works at sea are. For this reason, the production of components such as drives and gears calls for great precision, so that they can operate smoothly for as long as possible. This is not as easy as it sounds, though, as Carsten Schuh from Corporate Tech-nology at Siemens knows: “Follow-ing a heat treatment, a component’s dimensions can change. The steel that’s supplied may be more or less easy to machine, depending on the batch, so the parameters for manu-facturing are always different.” Schuh works with other production engineers across Siemens. To satis-fy the requirements in offshore com-
Bocholt / Muelheim, Germany. At its Bocholt and Mülheim locations, Sie-mens specialists are applying digital manufacturing technologies. One ex-ample of this is the introduction of closed-loop control – exploiting the precise recording and analysis of ma-chine data to optimize the production of components for offshore wind ener-gy plants. In addition, the traceability of products and processes is enabling steady improvement in design, individ-ual process stages or the selection of materials. Both technologies are key components and steps on the way to the digital factory.
Anyone who has seen the massive plants used in offshore wind farms
Tracing gearsModern manufacturing technologies are smoothing the way to the digital factory and optimizing production
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In Muelheim, Siemens production technol-ogy experts are working across Business Units using modern manufacturing technologies.
data and process data, this allows the engineers to obtain additional information that can be used to adapt the gear wheel machining specifically to the quality of the raw materials.
Modules for a digital factory
However, it is not just closed-loop control that plays a decisive role in production quality: traceability – the ability to track process stages – is also extremely important. This is why as part of the “Smart Trace and Track” pilot project in the Muelheim plant, selected steam turbine com-ponents were fitted with special transmitters, or smart tags. These make it possible both to locate the components precisely, and to net-work them with the production pro-cesses and plants. It allows employ-ees to have a complete overview at all times of the key information on the components supplied, which they can access in real time.
ponent manufacturing, for example, he and his team rely on closed-loop control. This is where machine data is recorded and analyzed, in order to adjust the current production pro-cess – just as happens with closed-loop feedback.
Associating data
In this specific example, a group led by Claudio Laloni in Corporate Tech-nology has developed an integrated optical 3D measurement device to record changes in shape very quick-ly and accurately. Using the result-ing data, systematic changes in di-mensions due to heat treatment can be planned in and taken into ac-count before the actual machining. “The combination of precise mea-surements and adapted machining gives us a higher component quality and shorter processing time,” says Schuh. Together with other proce-dures, such as the systematic corre-lation of machining results, material
Future of Manufacturinghttps://www.siemens.com/inno-vation/en/home/pictures-of-the-future/industry-and-automation/the-future-of-manufacturing-from-digital-twins-to-manufac-turing.html
Use of an equine treadmill allows horses to be exercised under controlled condi-tions without the need to be led or ridden by a human.
have enough space to give their horses the exercise they need. There is also a risk that valuable show horses may injure themselves on rough ground and be forced to miss competitions,” says Oliver Sandma-nn, CEO of Sascotec. The Horse-trainer is used to exercise horses un-der controlled conditions – for instance as part of a recuperation program following an injury – without the need to be led or ridden by hu-mans. As the devices can also be rented out on a pay-per-use basis, Sascotec relies on the Logo! Soft Comfort programming software from Siemens to enable communication with the Horsetrainer.
Remote metering and localization
“Customers rent the Horsetrainer to-gether with 100 hours of use. The ac-tual use time is recorded and charged at the end of the month. Stables can also generate revenue with it by rent-
Stavern, Germany. The company Sascotec develops and produces treadmills for exercising horses, known as Horsetrainers. To allow it to also market a pay-per-use version of its equine treadmill, the company has opted to use solutions from Siemens for communication, wireless data transmission and drive control. This allows Sascotec to record the number of hours operated by their devices in the field and charge customers based on their actual consumption, as well as defining maintenance intervals.
Horses are not just herd animals, but by nature also runners. To keep them in tip-top condition, sufficient exer-cise is essential – not always easy to achieve in densely populated coun-tries like Germany. The company Sascotec recognized this need and has developed a product it calls the Horsetrainer, a device not unlike the treadmills found in gyms. “These days, many stables simply don’t
Trotting aheadSiemens technology enables efficient exercising for horses
ing time on the Horsetrainer to their customers. They log in to our system on their smart phones and the treadmill is then unlocked for the booked time,” explains Sandmann. The digital drive control and wireless communication re-quired to implement the concept are provided by a combination of the Logo! logic module and the CMR 2020 GPS module. Using this combination, Sas-cotec is able to precisely locate and re-motely control every one of its ma-chines using the text messaging service, while simultaneously accessing specific parameters such as operating hours. It also enables selective mainte-nance of the treadmill.
Integrated safety stop
Logo! also controls the Horsetrainer’s drive unit with the aid of a Sinamics G120 frequency converter. This spe-cial safety function ensures that the treadmill switches off automatically if a horse stumbles or stops running within the expected movement parameters for any other reason.
A raft of new ideas
Sandmann is already working on tak-ing his idea even further, with what he is calling the Aquatrainer. In sim-ple terms, this is an equine treadmill which works in a water-filled basin, designed to provide the buoyancy needed for gentle resistance training to build muscle and ligaments after joint injuries. This new product will be controlled by a Simatic S7-1200 Basic Controller, and operated using a KTP700 Basic DP panel. Here too, the treadmill is driven by a Sinamics G120. All the components communi-cate over Profinet and are engi-neered in the TIA (Totally Integrated Automation) Portal.
Looking even further ahead, Sand-mann’s next project will be a mobile version of the Horsetrainer, and one which is capable of harnessing the horse’s muscle power for conversion into electrical energy. Siemens tech-nology will also be a core element of this newest venture.
To allow its equine treadmill to be rented out in a pay-per-use version, Sascotec relies on solutions from Siemens for communication, wireless data transmis-sion and drive control.
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isting production lines. For plant en-gineering, TMS uses solutions from Product Lifecycle Management spe-cialist Siemens PLM Software – in-cluding a system for simulating the in-process upgrading of existing pro-duction lines.
A precise simulation of the real world
“Without an in-depth simulation of the entire production plant with all its components, plant reconfiguration would not be possible without pro-longed standstills,” says Ing. Harald Ecker, Head of the Simulation/Digital Factory team at TMS. “At TMS, it is therefore common practice to digital-ly design, test and commission each plant all the way to customer approv-al.” As early as the proposal phase, TMS uses Siemens PLM Software solutions from the Tecnomatix Port-folio – Plant Simulation to create plant concepts, as well as Process Designer and Process Simulate for detailed planning and line develop-ment. TMS can also use Process Designer to configure complex pro-duction processes and at the same time carry out offline robot program-ming. As TMS supplies not only fully automated equipment but also pro-duction lines involving some manual processes, the company benefits from Process Simulate’s ability to
Linz/Austria. Turnkey Manufacturing Solutions GmbH (TMS) based in Linz in Austria is one of the world’s leading suppliers of manufacturing solutions for the automotive sector. To enable it to engineer efficient body-in-white construction facilities and production lines capable of in-process upgrading to accommodate a diversity of models, TMS relies on solutions from Product Lifecycle Management specialist Sie-mens PLM Software. Using Tec-nomatix, NX and Teamcenter, the company is able to simulate and virtu-ally commission complete plants, cut-ting the on-site commissioning phase by up to 70 percent.
An ever greater number of models within an ever dwindling timeframe – this ethos now applies to a whole number of different industries, and the automotive sector is no exception. To make this possible, many automakers produce up to six different types of body-in-white on the same production line. Creating the conditions to make this possible is one of the specialist areas of the company Turnkey Manu-facturing Solutions GmbH (TMS) based in Linz in Austria. TMS devel-ops and constructs process-reliable conveying and assembly facilities as well as complete turn-key plants for body-in-white construction. The com-pany also has plenty of experience in the integration of new models into ex-
Virtual realityPlant manufacturer relies on end-to-end simulation with Siemens PLM Software
verify and optimize aspects such as ergonomics for plant operators. This is made possible using the out-of-the-box Software Jack from the Tec-nomatix portfolio, which uses Jack and Jill avatars to provide a realistic simulation of human actions.
Virtual commissioning yields a smooth start-up
Alongside simulation, one of the key modules enabling efficient plant en-gineering is virtual commissioning, which links the simulation model to the actual control system. While pro-gramming this function in parallel with plant optimization, known as “hardware in the loop”, the actual timing characteristics of the line are incorporated into the simulation. “Vir-tual commissioning in Process Simu-late is particularly comfortable when using Siemens control hardware, as this can easily be fully integrated in-cluding all input and output signals via the Simulation Unit specifically designed by Siemens for this pur-pose. Our plant and software design engineers are relieved from all inter-face-related issues,” notes Ecker. “Our customers love virtual commis-sioning because it yields a smooth start-up of the production facility.” This allows the on-site commission-ing time to be reduced by up to 70 percent.
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.
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