Material Handling Automation & Drives Solutions · Material Handling Automation & Drives Solutions...

Material Handling Automation & Drives Solutions Presented by Bill Henderson Manufacturing in America │ March 14-15, 2018

Unrestricted © Siemens 2018 All rights reserved. Community. Collaboration. Innovation.

Introduction

Bill Henderson P: 770-331-5144

• Siemens DF MC Business Developer Manager – Material Handling

• Siemens Digital Factory OEM Team Lead

• 20 years Siemens Automation & Drives experience, specializing in Tire, Battery and intralogistics


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What am I talking about today

MHI Survey

Typical System Architectures

Logistics Hardware Components

The Edge and IoT

The Total Plant


Source

Source: MHI 2017 Annual Report: https://www.mhi.org/publications/report


MHI Survey – 9 Industry Trends

Inventory & Network Optimization

Sensors & Automatic Identification

Cloud Computing & Storage

Robotics & Automation

Wearables & Mobile

Predictive Analytics

3D Printing

Autonomous Vehicles & Drones

Internet of Things



9 Evolving Trends – Disrupting the industry

Sensors & Auto ID

Cloud Computing

Inventory & Network

Optimization Tools


Wearables Predictive Analytics

3D Printing Drones & Autonomous

Vehicles

Internet of Things

50%

40%

30%

20%

10%

5 Year Growth Rate of Technologies



The Fourth Industrial Revolution


Our customers have essential requirements – throughout the material handling industry

Security

Speed Flexibility Quality Efficiency


Digitalization Effect

1

426

36

250 24.5

122 1 Retailer




Sensors & Auto ID

Cloud Computing

Inventory & Network

Optimization Tools




Vehicles

Internet of Things

50%

40%

30%

20%

10%



Top to Bottom Intralogistics Solution

All components from one supplier that are completely connected


Weighing system Automation Systems

Conveyors Best in class automation technology for all of your requirements

Solution Description

Automation System PLC or PC based control solution for stand-alone to highly complex applications.

Process Instrumentation Transmitters for maximum efficiency in process instrumentation.

Industrial communication Broad range of components to implement efficient industrial networks and bus systems

Operator control and monitoring systems

Optimized operator control and monitoring systems using open and standardized interfaces.

Integrated drive systems Integrated Drive Systems (IDS) are consistently integrated drive components - frequency converters, motors, gear units, couplings - working perfectly together

Motors Industrial communications

Process instrumentation

Typical Conveyor System


Energy Management

Diagnostics

Safety integrated

Totally Integrated Automation Portal (TIA Portal) … the gateway to automation solutions within the Digital Enterprise

Security integrated

HMI Controller Distributed I/O

Motion Control Drives IPC

PROFINET

Totally Integrated Automation Portal

Common data management WinCC STEP 7 SCOUT Startdrive

One common database Integrated Engineering

Consistent and unified usability concept for all devices and engineering

Inclusive for no charge : Libraries, Diagnostics, Scalability, Flexibility


The Totally Integrated Automation - Concept and Advantages

Easy engineering and integration

One framework for the complete project

Scalable and seamless TIA portfolio fits for each

application

Connect old and new machines

thanks to compatible components

Uniform Ethernet

communication from field to management level

TIA Portal TIA Portfolio

Production lifecycle Vertical integration

High availability

Increased availability by using one tool for controller, HMI,

drives, etc.

Uniform, integrated and self-explaining diagnosis for all

devices

Device replacement in maintenance case without

tools or engineering

Direct connection to MES and cloud systems for improved

data transparency

TIA Portal System diagnosis

Device replacement Vertical integration


Sensing and communication

Communication

SIMATIC NET Industrial Ethernet / WLAN PROFINET PROFIBUS AS-i

Sensor systems

SIMATIC Vision sensor Vision sensors for

application-specific image processing

Identification systems

SIMATIC Ident RFID systems for an optimization of

material flow and logistics Code reader systems for flexible reading

and verification of 1D/2D codes


Control and visualization

HMI

SIMATIC HMI The finely graduated product range

fulfills the most diverse requirements

From operator panels and visualization software through to the scalable SCADA system

Controllers & I/Os

SIMATIC Controller Highest scalability Selection in the software and

hardware architecture: Modular / embedded / PC-based

Central / distributed


Gearbox motors

Standard asynchronous gearbox motors SIMOGEAR

High quality -> long lifetime High versatility due to MODULOG system High performance due to high power density, high output torque and wide

range of gear ratio (plug in pinion) Compactness and reduced weight Easy integration due to usual installation dimensions Very high energy efficiency with IE3 motors Power range up to 200kW

Servo gearbox motors SIMOTICS S-1FG1

Based on SIMOTICS 1FK7 with Drice-CLiQ interface (electronic type plate) Compact direct mounting with helical, parallel shaft, bevel or worm gearbox Power range 0.5 to 7kW Different (holding) brakes available Plug in pinion for a high ratio in the first gear stage Available in axis height AH36 to AH100 Market usage installation dimensions


Safety and Energy

Energy distribution

Failsafe and efficient energy distribution using SIVACON switchgear SIVACON busbar trunking systems SENTRON power switches SENTRON multi-function measuring instruments SIMATIC PCS 7 powerrate resp. SIMATIC WinCC powerrate

Safety Integrated

Complete and consistent safety program From the sensor through to the controller to drives Comprehensive service and support Support for the application of safety standards


Frequency converters

Central

SINAMICS S120 Single-axis and multi-axis groups Modular / high scalability

regarding the power and the function

Synchronous and induction motors Numerous applications through DCC Safety Integrated functions

Distributed

SINAMICS G120D High degree of protection IP 65 0.75-7.5 kW induction motors Speed control with/without encoder Also with integrated position control Safety Integrated functions Integrated brake control

http://www3.ad.siemens.de/bilddb/picDetails.asp?objID=28202&lang=de&visMode=

http://www3.ad.siemens.de/bilddb/picDetails.asp?objID=33352&lang=de&visMode=


Distributed concept with SINAMICS G120D

Features Degree of protection IP 65

→ no control cabinet required

Installation directly near the motor → reduced wiring

Energy efficient thanks to energy regeneration capacity

Integrated positioner (EPOS) Safety Integrated No line reactor or line filter

required Up to 7.5 kW (nominal power);

15kW (peak power)


Central concept with SINAMICS S120 Booksize

Features Scalable and flexible due to

modular structure

Up to 12 axes per CU

Central infeed / regenerative feedback

Highly dynamic control

Synchronous / induction motors

Integrated positioner (EPOS)

Numerous applications thanks to DCC

Safety Integrated

Energy efficient through regenerative feedback and energy balancing at the dc link; incl. concept for energy storage


Engineering

Input of mechanical specification

Results: Parts list including order numbers Dimension drawings / CAD data Characteristic curves

Drive dimensioning: SW-Tool SIZER

Automatic detection of DRIVE-CLiQ components

Graphic-supported parameterization

Automatic controller optimization

Comprehensive diagnostic tools

Commissioning: SW-Tool STARTER / STARTDRIVE

Project creation

Parameterization

Optimization

Diagnosis



Sensors & Auto ID

Cloud Computing

Inventory & Network

Optimization Tools




Vehicles

Internet of Things

50%

40%

30%

20%

10%


Automatic Guided Vehicles

Flexible Production

with Automated Guided Vehicles (AGV)

siemens.com/automotive © Siemens Industry Inc. 2018


Flexibility in production – The AGV is the backbone of the “Smart Factory”

From fixed chained production …

… to flexible & modular production Siemens addresses this market shift with the development of a comprehensive “AGV system package”:

• Enables AGV suppliers and end customers to automate AGV applications with Siemens components and technologies

• Offers HW automation and drives concepts, SW libraries for carrier control and navigation as well as application SW for master control


Siemens & AGV‘s have a long history

NN


Key elements of a comprehensive solution for AGVs

Master Control

Carrier Control Navigation Automation components

TIA-Lib & PC application

Drive system

Route Configurator

Order Dispatcher

Visualization & Diagnostics

Safety Integrated Path Finding

Localization

Obstacle Avoidance

Maintenance

Data Analytics Digitale Image Ressources

*: MindSphere: Cloud-based, open IoT operating system

*


System supplier Siemens – Offering a comprehensive AGV system package

Software “Master Control” incl. Visualization Route configurator Fleet manager

Software Library “Navigation”

Software Library “Carrier Control” incl. Drive control Safety Integrated

System Documentation

Interface Specification

List with recommended HW components

AGV system package

“SIMOVE” Maintenance App

Application support and Training


System supplier Siemens – “Carrier Control” – Focus Drives Technology

• Basic functions • Communication • Track management • Drive train • Energy supply • Safety-functions • Additional onboard

functions e.g. lifting


System supplier Siemens – “Carrier Control” – Focus Machine Safety

Siemens offers a comprehensive safety solution which connects intrinsic safe AGVs with station controller

CPU 1518F-3 SIMATIC HMI IPC

Shop floor network

Station control

7

7

AGV Master control station

SIMATIC HMI IPC CPU 1518F-3

Material handling or manufacturing station

AGV AGV

Industrial Tablet




System supplier Siemens – “Carrier Control” – Focus Automation SW

Pretested modules, preconfigured TIA “AGV project”




Carrier Control – Automation SW Open to integrate or adapt to customer specific extensions

+ +

PLC-Application

• Automation application • Safety-functions • Communication • Track control • Drive Functions • Interface to master control

Standardized S7-Function Blocks for Carrier Control

Standard STEP7 HW-Configuration

Customer specific HMI Screens

Customer specific extentions for additional HW

components

STANDARDIZED CUSTOMIZED +

HMI-Panel

Customer specific extentions for new or

adapted Functions

+ + Standard HMI Screens


SIMOVE – The AGV system package “Master Control” – Order management and track management

PLC controlled and WinCC • Proven components • Benefits from machine safety • Already in use in projects

• Order management • Track configuration • Plant and track

visualization • Machine safety • Diagnostics • Interconnection to

external process control

PC controlled (Windows) • Simplifies implementation of traffic

management and route control

• Specified and development started


System supplier Siemens – “Master Control” – Focus order management and tracking

Order management: • Manage order sequence and

product identification

• Product specific control of AGV behaviour (e.g. lifting)

Track management: • Mode management

(green – automatic, red – fault)

• Vehicle status (Good / Maintenance req. ) incl. details

• Vehicle tracking Realtime visualization incl. position

Screenshot

• Basic Functions • Order Management • Operating Modes • Interconnection to

external process control • Safety Functions • Track Management • Visualization • Additional track events

(Switches, Diagnosis) • AGV Simulation


System supplier Siemens – “Master Control” – Focus route configuration and route management

Siemens’ solution for PC based mater control will be based on existing and proven technologies: Currently evaluation of several products

• Basic Functions • Order Management • Operating Modes • Interconnection to

external process control • Safety Functions • Track Management • Visualization • Additional track events

(Switches, Diagnosis) • AGV Simulation Interaction and use of Siemens PLM tools possible


System supplier Siemens – Offering a comprehensive AGV system package

Software “Master Control” incl. Visualization Route configurator Fleet manager

Software Library “Navigation”

Software Library “Carrier Control” incl. Drive control Safety Integrated

System Documentation

Interface Specification

List with recommended HW components

AGV system package

“SIMOVE” Maintenance App

Application support and Training



Sensors & Auto ID

Cloud Computing

Inventory & Network

Optimization Tools




Vehicles

Internet of Things

50%

40%

30%

20%

10%

5 Year Growth Rate of Technologies



The challenge – Connecting your assets – Wherever they are

What do you need?

• Global access to assets • Ongoing supervision of the

machine performance • Optimized planning of services • New business models for

machine business

?

How to get there

• Secure data acquisition for cloud services with MindSphere

!


MindSphere – the cloud-based, open IoT operating system – from Siemens

Optimization of plants and machines as well as energy and resources

• Open standards for connectivity of Siemens und third-party products

• Plug and play connection of Siemens products

• Cloud for industry with open application interface for individual customer applications

• Transparent pay-per-use pricing model

• Opportunities for completely new service and business models


Production monitoring, analysis and optimization

Application example SIMATIC IOT2040 The intelligent gateway to connect the field level to the IT level / cloud

1

4

2

3

Protocol conversion / customer programmed control

Collecting and concentrating relevant production data of several sources

1

2

3 4

Secure transfer to connected company IT-systems or cloud applications

Flexible Connection to sensors/actors via serial communication, Ethernet or Arduino shields. Communicating with PLCs, drives and motors with e.g. PROFINET1) or OPC OA2)

Data aggregation, conversion of different communication protocols and pre-processing programmed in high-level language e.g. Java, C++

1) planned 2) application examples will be provided at IOT2000 forum

Cloud based analytics to detect optimization potential

Converted data can be transmitted to IT systems / cloud solutions using e.g. OPC UA, MQTT or AMQP 2)

11/29/2017


SIMATIC IOT2040 Industrial ruggedness. Openness. Connectivity.

SIMATIC quality Designed for 24/7 operation in industrial environment

+

AutomatIon.ConnecTed Easy connection to automation level with PROFINET*) and openness to cloud based solutions

+

Expandability & connectivity With mPCIe, industrialized IO module and various standard interfaces & available protocol drivers

+

Performance & Deterministic Intel Quark® CPU and 1 GB RAM as well as x86-deterministic and battery buffered real-time-clock Openness

Free programmable in high-level languages (e.g. Java, C++) via various IDEs (e.g. Eclipse) and compilers for Yocto Linux

+

+

*) planned

11/29/2017


Target applications – focus on brown-field applications IOT2040 for production data pre-processing, conversion and transfer

Connecting IT/cloud and automation • Secure communication between

ERP/IT systems or cloud applications and production

• Production optimization with vertical data integration from shop floor to cloud

Predictive maintenance

• Capturing and analyzing production data like e.g. speed or operation hours in order to identify the best maintenance interval

• Optimize machine downtimes

Optimized shop floor management • Data transfer in case of undercut

of minimum stock levels of consumables

• Automated alarming in shop floor management system in order to avoid production downtimes

IOT2000 as open platform to connect legacy systems, additional sensors and IT-level

11/29/2017


SIMATIC IOT2040 complements automation portfolio Making legacy automation concepts “IoT ready”

PROFINET1), OPC UA, TCP/IPC, Modbus RTU, ...

Inter-connecting various sources and communication networks

Pre-processing/data acquisition with SIMATIC IOT2040 and data transfer to company network or direct to cloud applications

No need to change existing automation solution

SIMATIC IOT2040 as cost-efficient and open data gateway for retrofitting existing concepts and make them “IoT ready”

3rd party

Protocol conversion to: OPC UA, MindSphere, MQTT, AMPQ, JSON...

Cloud / IT applications 1 0 0 1 0 1 0 0 1 1 1 01 0 1 1 0 1

SIMATIC IOT2040 complements automation portfolio

SCADA / MES

1) Not released yet

11/29/2017


Your benefit – Easy and flexible connectivity of your automation to MindSphere

Data collection and analysis in the cloud • Secure data

connection between automation and MindSphere

• Easy configuring of connection

• Flexibility to realize best fit for connectivity concept

MindSphere Data-driven services, e.g. condition monitoring

MindConnect: SIMATIC S7-1500, SIMATIC IPC SIMATIC IOT2040


Cloud Based Apps – By Siemens

Manage MyMachines

OEE Monitor

Product Intelligence


Manage My Machines

• View machines regardless of Type • View machines around the world • Easy connection setup • Cloud based • Siemens Developed

• Track trends in machine status • Show current Status of multiple

machines • Show historical trends • Use the data to predict issues


O2M – Order OEE Monitor

• Track your production orders • Display Machine effectiveness • Overall representation of process • Recognize operating trends • Virtual KPI Representations

• Plot out metrics for comparison • Quickly identify production rates • Provide decision support for change • Optimize plant operations based upon

data



• Create actionable intelligence • Leverage existing data sources • Data Loads from your source • MES, QMS, ERP, CRM • One Single view and hub

• Fast Data Search • Performance Analytics (Patented) • Analyze and Contextualize Big Data • Empower Data Driven decisions


Cloud Based Apps – By Siemens

Manage MyMachines

OEE Monitor


MINDSPHERE APP STORE

https://www.plm.automation.siemens.com/store/de-de/mindsphere/index.html


Intosite and MindSphere

Access MindSphere application within IntoSite

Intosite application in MindSphere to monitor selected events and notify Intosite

Status indication in Intosite resulted from MindSphere plant resource related events


Intosite Key Capabilities

Create 2D/3D/Panormic representations of your factories

Build a layer structure that represents the business logic and create/share placemarks

Add information and ate from existing IT systems: URLs, Files, Sharepoint, Tool Management, Teamcenter , Mindsphere, …

Start using the extensive discussion board to collaborate on information uploaded to Intosite




Sensors & Auto ID

Cloud Computing

Inventory & Network

Optimization Tools




Vehicles

Internet of Things

50%

40%

30%

20%

10%


Digital Enterprise Suite – Our unique portfolio for the digital transformation


Siemens’ approach to integrating and digitalizing the entire value chain

Cloud-based, open IoT operating system: MindSphere

Third party applications

Suppliers and logistics

Collaboration platform: Teamcenter

Services Production execution

Production engineering

Production planning

Product design

Become a Digital Enterprise by digitalizing your value chain


Create a powerful Digital Twin of the entire value chain





Services Production execution


Production planning

Product design Product design

Production planning


Production execution

Services





Product design

Production planning


Production execution

Services


Digital Twin for Product, Production, and Performance

Digital Twin of the product

Digital Twin of the production

Digital Twin of the performance

Digital Twin of the product

Digital Twin of the production

Digital Twin of the performance

feed back insights to continuously optimize product and production MindSphere


Digital Twin Overview

Line Level

Machine Level

Cell Level

Robotic Simulation

Material flow & Logistics Simulation

Mechatronics Simulation

Team

cent

er

PLC & HMI Validation



Mechatronic Concept Designer

Process Simulate

Plant Simulation


Plant Simulation - A Digital Twin of Production

For Plant Optimization

For Material Handling and Warehousing Virtual Commissioning

Plant Simulation


Virtual Commissioning for Material Handling & Warehousing

+ Risk free test

+ Shorter commissioning time

+ Planning confidently

+ Test before build

+ Pretested without damage


Virtual Commissioning for Material Handling & Warehousing

Material Handling & Warehousing: Sensors and actuators Material distribution HMI ease of use and operation Safety characteristics


Plant Optimization Benefits

Holistic PLM concept

Profitability

Throughput

Confident planning

Energy efficiency

Process optimization


Example - Throughput

• Detect low utilized resources • Predict over utilized resources • Balance resource utilization • Eliminate logistical bottlenecks • Optimize buffer quantities • Reduce Work in progress


Profitability

Throughput

Confident planning

Energy efficiency



Example - Process optimization

• Reconsider process alternatives • Optimize material flow and logistics • Compare alternatives to achieve KPIs


Profitability

Throughput

Confident planning

Energy efficiency



Example - Process optimization


Profitability

Throughput

Confident planning

Energy efficiency



Plant Optimization Results

Optimizing complex systems using virtual prototypes Holistic PLM concept

Profitability

Throughput

Confident planning

Energy efficiency

Process optimization 20-60% reduction in inventories

Saving 3 million kilowatt hours of electricity per year

5-20% investment reduction

Detect bottlenecks before they occur in Production

Increase profit: spend the right CAPEX, utilize the right OPEX


Plant Optimization Customer Testimonials

Heavy Industry Siemens AG Siemens AG

Industrial Equipment Siemens AG

Life Sciences Siemens AG

Energy Power Transmission

ISL Wind Energy

Zwilling Consumer Packaged Goods

Behr

More efficient production line with less waste

Production throughput was increased by 40%

Production costs could be reduced by 30%

Plant Simulation helped us avoid significant capital investments and

operational costs

We could halve our inventory in the

warehouse.

Logistics costs reduced by 10 percent

Reduction of the cycle time and increase in output by 18.2 percent

Automotive T1

Reduced cycle times by up to 66 percent

Bosch Automotive T1

Increased output per month by 10.5 percent


Thank You. Visit us at the Tech Cafe


Questions?

Bill Henderson Business Development – DF FA OEM Phone: 770-331-5144 E-mail: [email protected]

After MiA, seminar slides will be available at: http://www.usa.siemens.com/mia-seminars

mailto:[email protected]

http://www.usa.siemens.com/mia-seminars




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