Answers for industry.

With consistent solutions for the optimization of the entire manufacturing process.

How can you get your tire production rolling?

Flexibility and economy combined with top quality

Global competitive pressure in the tire industry is constantly growing in intensity. This is one of the

major reasons why more and more enterprises are pushing the internationalization of their produc-

tion and the construction of new plants around the world in countries which offer local benefits.

When doing so, it is absolutely essential that the same quality standards are maintained at all

production sites around the world with, ideally, the same production techniques and automation

products being used.

Manufacturing processes characterized by a maximum in productivity, efficiency and flexibility are

the prerequisite for lasting success in the tire industry. This makes energy-efficient automation and

drives solutions all the more important. Present and future statutory requirements also need to be

reliably met – e.g. to ensure complete traceability of a tire following an accident. Totally Integrated

Automation from Siemens provides the answer to these requirements. From a single source.

Mixing & Extrusion Semi-Products Tire Building Vulcanization Quality Control

Logistics & TransportProduct Lifecycle Management

Manufacturing Execution System (MES)

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Higher productivity in the tire industry

As a partner to the tire industry, we supply first-class products and solutions for all-round production optimization – from plant engineering through to the production process itself. The basis of our solutions: unrivaled competence in auto-mation and drives and solid knowledge of the industry.

For example, increased vertical integra-tion of production data in a manufactur-ing execution system (MES) significantly increases plant productivity: it ensures complete data consistency – from field to ERP level. Experienced specialists take care of engineering and product support. Integrated diagnostic functions and scal-able service strategies enable an increase in productivity and reduce downtimes for each production step in your tire plant.

Leading partner in the industry

With Siemens as your partner, you will have over 30 years of experience on your side. During this time, our experts have realized projects all round the world – from the initial planning steps, engineer-ing, simulation and commissioning right through to maintenance and service.

Solutions for the entire tire production process

Mixing & Extrusion Semi-Products Tire Building Vulcanization Quality Control

Production of semi-productsA broad spectrum of products and solutions for the numerous requirements placed on the calender and extruder for manufactur-ing steel belts, inner-liners and treads.•High level of standardization• Lean automation solutions• Energy savings

Tire buildingHigh-performance drive solutions which optimize energy consumption by means of integrated reactive power compen- sation(cosφ=1)andwhich are characterized by a high level of pro- ductivity•Optimization of cycle

times•Open, robust auto-

mation concepts•High level of avail-

ability

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Visualization WinCC flexible

SIMATIC Flat Panel

SIMATIC IPC427C with WinAC RTX

Main Control Cabinet

Servomotors Siemens 1FK/1FT

Servomotors Siemens 1FK7

Servomotors Siemens 1FK/1FT

SINAMICS S120SINAMICS S120

ET 200S I/0 Modules control cabinet

PROFIBUSEthernet

ET 200S

Recipe Management/ Statistics

Central Visualization

Service Engineering

Server (Database)

Server

Database SQL

SIMATIC IPC

SIMATIC IPC

SIMATIC IPC

Industrial Ethernet

PROFIBUS DP

Industrial Touch Pad

IPC Rack

S7-400

SIWAREX FTA

SINAMICS

10” LCD Touch Pad

15” LCD Monitor

PROFINET IOI/O SIMATIC ET 200S

27 Drives

PROFINET IO with PROFIsafeSafety SIMATIC F-CPU, F-I/Os, registration equipment

Motion, DrivesSIMOTION & SINAMICS

SIMATIC IPC

PROFINET

Mixing and extrusionCustomer-specific concepts and solutions for the entire rubber mixing process includ-ing the mixing management system and storage of the mixing products such as rub-ber strips or treads (in automated high-bay storage areas for semi-products). Mixing fol-lows a specified recipe in which the speed, energy per unit of weight, temperature etc. are prescribed.•Optimization of energy efficiency•Optimization of mixing results –

in a shorter time• Improved visualization of process values

PROFINET and/or PROFIBUS connections possible

ET 200S

Press 1ET 200S CPU Hydraulics

Press 2 Press n...

ET 200SET 200S

SIMATIC IPC

PROFINET IO

PROFINET IO with PROFIsafe

32 Drives

SIMATIC IPCIndustrial Ethernet

SIMATIC Flat Panel PRO

SIMATIC IPC with WinAC RTX-F Measurement

PC

Other Ethernet equipment e.g. camera

DVI-I USB

SIMATIC ET 200S HF Stations and fail-safe I/O (mixed)

Sensor/ Actuator

SINAMICS S120 Stations

Other PROFINET equipment

PROFINET / PROFIsafe

VulcanizationReliable, scalable and lean control solutions for hot presses which ensure an ergonomic workflow in the vulcanization process thanks to the integration of efficient operator panels, with the result that the corresponding parameters in the hot press, such as pressure, temperature and time, are dependably controlled.• Cost-efficient solutions• Efficient automation processes• Tailor-made solutions

Quality controlSolutions which enable fully automatic final inspection with centralized data manage-ment for the X-ray and balance inspection as well as for the force variation test.• Enhanced test performance• Space-saving and cost-saving design• Tracking and tracing for complete

traceability of tires

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Controllers at field level

We use our world-leading SIMATIC® controllers for automating tire machines at field level. SIMATIC, our all-round automation system, enables the realiza-tion of scalable machine concepts – a great benefit for both plant operators and machinery manufacturers. Irrespective of whether the concepts include modular controllers or PC-based automation: the automation program is always the same.

Mixing and extrusion

SIMATIC PCS 7 is the best choice for controlling your rubber mixing. Our solu-tions for the mixers include transformers, converters and drives – and are espe-cially designed for the demands of the tire industry. Our solutions also include mechanical drives – for example with an attached maintenance station for preven-tive maintenance. Our mixing manage-ment system based on SIMATIC IT ensures data consistency throughout. It includes a special application for managing rubber mixing.

Semi-products

The scalability of the SIMATIC product portfolio really comes to bear in the production of semi-products – perfectly customized to the various machines for the pre-manufacture of individual tire components. Whether calenders for manufacturing steel belts, inner-liners or textile cords or extruders for manufac-turing sidewalls or tread, we will always supply you with drive solutions for the various tire machines. Motors in the power range up to 400 kW which satisfy the exacting quality requirements and the application-specific throughputs of the extruders and calenders are usually deployed for such applications. Machine-

All-round product range for your tire production plant from a single source

Our unique Totally Integrated Automation portfolio covers the entire production process: from field level and high-

performance gear units for mixers and extruders through to the interface to the ERP system – from software design

tools and factory planning through to maintenance.

level visualization can also be realized by integrating operator panels.

Tire building

Besides SIMATIC controllers, we also provide SIMOTION and SINAMICS drive systems for tire building machine. These systems are characterized by their optimal energy consumption and set standards in performance (integrated reactive power compensationwithcosφ=1).Tirebuild-ing machines are usually fitted with syn-chronous motors controlled by frequency converters. These fast and variable drives have been especially attuned to the re-quirements of a tire building machine.

Vulcanization

We provide extremely reliable, lean controller solutions for vulcanization using hot presses. Thanks to their high-performance operator panels, they ensure a cost-efficient workflow for your tire pro-duction and reliably control the relevant parameters such as pressure, temperature and time. Each hot press is equipped with a local operator console for machine-level operation and control. The controller and the operator unit can be installed together in the operator console in one housing (centralized) or they can be separated (decentralized option). In the latter case, the controller is mounted in the control cabinet and connected to the operator unit in the console.

Quality control

Our quality management solutions allow fully automated final inspection of indi-vidual tires (X-ray and balance inspection as well as the force variation test) with centralized data management.

Logistics and transport

To connect all the individual steps in tire production, we provide logistics and transport solutions as well as automated storage systems as product and dispatch buffers – all perfectly designed to fit your individual needs. Furthermore, integrated traceability solutions allow reliable docu-mentation and monitoring of all relevant production, logistics and process data. When it comes to such applications, you will receive the full benefit of our long years of experience in turnkey solutions for the tire industry.

Factory planning with product lifecycle management (PLM)

The Tecnomatix™ PLM software provides a comprehensive portfolio of digital manufacturing solutions which promote innovation by connecting all manufac-turing areas in tire production with tire development – from process definition, process planning, simulation and review through to actual tire manufacturing. Tecnomatix has been built up on a foun-dation for product lifecycle management (PLM) and today encompasses the most varied range of manufacturing solu-tions available on the market. With this software, tire manufacturers quickly find the best strategies for raising productivity and lowering costs in tire production.

All you require for lasting success in the tire industry with Totally Integrated Automation

All components under the umbrella of Totally Integrated Automation are perfectly attuned to meet the many and varied requirements demanded by the tire industry with a top level of efficiency.

Engineering: Choosing Totally Integrated Automation will give you an engineering tool for every auto-mation job in tire production. Effi-cient software will provide you with comprehensive support over the entire lifecycle of your tire plant – from the first planning steps, commissioning and operation right through to service and maintenance.

Communication: Totally Integrated Automation provides the prerequisites for complete consistency in commu-

nication. By using an open bus system from the terminal through to the control system, you benefit from the highest possible level of transparency across all levels of the tire manufactur-ing process.

Diagnostics: Thanks to efficient remote diagnostics down to the last terminal in the tire plant, any malfunc-tion which may arise can be quickly identified and dealt with – without the need for any programming work. This leads to minimized downtimes and op-timizes productivity in tire production.

Safety: No additional controller is required for safety functions. Thanks to an intelligent safety concept which integrates the safety system into the standard automation, you make sig-nificant savings on cabling, space and, consequently, costs compared to con-ventional solutions. Integration into the engineering software also makes

for less programming and considerably speeds up commissioning of your tire plant.

Security: The whole of the tire plant is protected against unauthorized access by means of Totally Integrated Automation. Scalable IT security mechanisms (access protection, user management, firewall, VPN etc.) provide efficient security – with a low administrative input.

Ruggedness: Carefully selected ma-terials and manufacturing processes ensure the first-class quality of our products and systems. Special options are available to meet your heightened requirements in terms of ruggedness – ideal for the tough environmental conditions in the tire manufacturing process.

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Manufacturing Execution System for the tire industry: centralized and uniform data management

Know more with MES

Our MES solutions based on SIMATIC IT enable faster reaction to market changes. Processes can be made visible through-out the entire plant, manufacturing workflows can be synchronized, business decisions can be evaluated on the basis of real-time data and innovations, such as the development of a new type of tire, can be efficiently implemented. What is more, the integration of tracking and tracing functionality ensures complete traceability of tires, thereby giving you access to the production parameters of a specific tire whenever you need it.

Standardized and scalable components

These are based on a plug & play archi-tecture in which the individual functions can be easily combined and configured. Thanks to the hierarchical structure based on ISA-95 and the totally object-oriented architecture, SIMATIC IT can be configured so as to allow provision of all required func-tions via web services. That means that you do not need any special software for data access or data exchange (e.g. recipe data for a tire). As a rule, Internet-compatible devices together with a browser will suffice, e.g. laptops or smartphones which are able to exchange data via XML. All security func-tions are taken into account.

More benefits all along the line

Our MES solutions are a part of the Totally Integrated Automation (TIA) open system architecture. The unique consis-tency on offer ensures perfect interaction among all components, thus creating the conditions needed for highly effi-cient, flexible and therefore productive tire manufacturing. For example, mixing recipes are highly sensitive corporate data, the core competence of any tire manufacturer as it were, and they call for increased security and transparency with respect to access possibilities and access authorizations in the tire manufacturing process.

MES Servers

Curing Area

Bar code roll assignment

Mixing Management System Tire Manufacturing Final Finishing

Web-based MES Clientse.g. recipes, orders, alarms, online monitor

Logical Network #5

Logical Network #1 Logical Network #2

WinCC & S7WinCC & S7 weigh/mix Head PLC WinCC & S7Calender

textile/steel cord

WinCC & S7Tire building machines Cutting/slitting systems

Logical Network #3 Logical Network #4

Tire uniformity machine

WinCC & S7 Curing presses

Transportation system CTTS

Transportation system CTTSWarehouse

Management Server 3&4

Warehouse Management Server 1&2

Chemical parts

Testing station

Final inspection station

Visual inspection station

Transpor- tation

system FFTS

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Mixing Management System: managing rubber mixing processes efficiently

Flexible and scalable server application

Our MES solutions based on SIMATIC IT offer a special application for manag-ing mixing ratios: Mixing Management System. This server application closes the gap between business systems (ERP/SAP) and the controller level. The com-munication is based on proven industry standards such as XML, B2MMl, SAP iDoc, OPC and Industrial Ethernet/PROFINET. For example, the customer wishes to increase process transparency for an individual mixer. This leads to a reduction of the scrap rate and, consequently, to shorter downtimes. What is more, evalu-ation and analysis functions improve the tire manufacturing process and can therefore contribute to production opti-mization.

Wide-ranging functionalities

A client/server architecture has been real-ized for top levels of availability. Its com-ponents cover recipe and purchase order management as well as tracking and trac-ing, calculating KPIs, overall equipment effectiveness (OEE) and reporting. OEE is a measure of a plant’s value creation capability. Recipe, purchase order and ad-ministration data are sent to the respec-tive controllers (head PLCs) so that the mixing process can be performed quickly and smoothly without interruption.

Consistent, efficient recipe manage-ment which leaves no gaps

All information relevant to the mixing process is available in real time at the touch of a button. You will benefit from the highest possible level of transparency and will be able react to your customers’ wishes more quickly. The recipe data and production parameters must be available at each mixer.As the individual mixers are very similar in terms of the automation solution used, it should be possible for the formulation generated for one mixer to be transferred easily and flexibly to other mixers. This standardizes recipe management making it more easily comparable and lower in cost.

Recipe Specification

SAP Scheduling, Orders, Inventory, Warehouse of Compounds

Data Integration Service Orders/

Batches

Overall Equipment Effectiveness (OEE)

Pallet Management

ERP level

MES level

Controller level

Track Process Data

Material Administration

Sample Data

Lab Results

Head PLC Mixerline 1

Head PLC Mixerline 2

Head PLC Mixerline n

LAB System Label

Printer

Reports

Mixer Recipes

System architecture of the server applications

Products and systems for the tire industry

Controller and Human Machine Interface (HMI)

Comprehensive, consistent range of control solutions for all requirements in the tire industry

■Modular controllers: SIMATIC S7 ■PC-based controllers: modular embedded control-lers S7-mEC or industry PCs SIMATIC IPC with software controller SIMATIC WinAC – with integrated fail-safe system as an option

Solutions for operator con-trol and monitoring (HMI) perfectly attuned to the needs and requirements of the tire industry

■SIMATIC WinCC as SCADA system or SIMATIC WinCC flexible as HMI operator system on various hardware platforms

Product Lifecycle Management (PLM)

Extensive portfolio of digital manufacturing solutions

■ Intelligent management of product innovations by connecting all manufactur-ing disciplines with product development – from process planning, simulation and validation through to actual production

Industrial communication

Complete hardware and safety portfolio for PROFIBUS, PROFINET, Industrial Ethernet, AS-i

■ Industrial Ethernet ■PROFIBUS or PROFINET with integrated PROFIsafe technology ■PROFIBUS DP and PA (e. g. SIMOCODE, pressure, temperature) ■AS-i components for direct installation on the machine ■Compliance with safety- relevant standards and legislation (up to SIL 3) ■No extra cabling and no special safety controller required for your tire plant ■Support for fail-safe communication also via industrial wireless LAN

Process control system (Distributed Control System, DCS)

Far more than a classical Distributed Control System (DCS): SIMATIC PCS 7

■The centerpiece for consis-tent and safe automation of the complete tire production process – from goods in to goods out ■Unique scalable architecture ■Powerful engineering tools ■A number of seamlessly inte-grable additional functions – e.g. alarm management, process safety or asset management ■ Integrated safety concepts for the highest level of sys-tem availability and reliable protection for people, ma-chines and the environment

The first-class standard products and systems from our portfolio are the intelligent answer to the enormous challenges

faced by the tire industry. Furthermore, you benefit from numerous other advantages – for example preventive mainte-

nance, intelligent diagnostics, the integration of safety systems in the standard automation or permanent condition

monitoring.

From planning the machine ...

…through to optimizing it

… to the finished workpiece

G_N

C01

_EN

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Product LifecycleManagement

Quicker from the initial idea ...

Machine Development

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Motion control and drives

Scalable motion control solutions for single- and multi-axis applications. SIMOTION Smart Drives Management masters power failures with SINAMICS Active Line Modules

■SIMOTION ■SIMATIC T-CPU ■SINAMICS ■MICROMASTER ■Motors and drives for all ap-plications in the tire industry

Distributed I/O

SIMATIC ET 200 is a multi- functional, modular and finely scalable system for distributed automation: for solutions in your control cabinet or without a control cabinet directly on your tire machine as well as for use in potentially explosive atmospheres

■Extensive family of distrib-uted I/O systems: SIMATIC ET 200M / S / ISP / pro / eco ■Available in standard and fail-safe versions ■Extremely rugged in IP65 / 67 and can be deployed up to + 60°C – for use without control cabinet in adverse environmental conditions ■Reduced size requires little space ■M12 connectors highly resistant to vibration

Mechanical drives

Gear units and couplings for industrial applications and energy production

■FLENDER standard drives ■Application-specific FLENDER gear units ■Customer-specific FLENDER gear units ■Geared motors

Industrial identification

Broad portfolio of identifica-tion systems for machine ap-plications especially for tires

■SIMATIC RF RFID systems for optimizing production, material transport and logistics ■SIMATIC code reading device for reliable, flexible and automatic tracing ■Easy system integration into automation system ■Technology-neutral application consulting

Manufacturing Execution System

Siemens will provide you with the ideal basis for a perfectly customized manufac-turing execution system with which you can access all your process information throughout the company in real time: SIMATIC IT – our sophisticated, finely scalable MES product – meets the ISA-95 standard. It offers you a whole range of benefits: faster planning, better capacity utilization and higher quality in produc-tion – with lower costs.

www.siemens.com/automation

Subject to change without prior notice 02/11 Order No.: E20001-A1000-P200-X-7600 Dispo 06303 WÜ/26217 MI.AS.TA.XXXX.52.1.02 WS 02112.0 Printed in Germany © Siemens AG 2011

Siemens AG Industry Sector Industry Automation P.O. Box 48 48 90026 NUREMBERG GERMANY

The information provided in this brochure contains merely general descriptions or characteristics of perfor-mance which in actual case of use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract.

All product designations may be trademarks or product names of Siemens AG or supplier companies whose use by third parties for their own purposes could violate the rights of the owners.

Further information on the automation of your tire production:www.siemens.com/simatic-tire

Your direct contact to our team of experts for the tire industry:tire.industry@siemens.com