Content

PRODUCTS

02 Network communication in 19-inch format

03 Efficient network management

APPLICATIONS

04 Prevention of excess weight

06 Digitalization in coal gasification

08 More cost-effective production of heavy-duty vehicles

Siemens MediaServiceJuly 2017

siemens.com

MediaService Industry News

The July issue of the MediaService In-dustries starts with two product news items describing innovations from the world of drives and automation. The first of these is a series of new man-aged and unmanaged rack switches as an addition to the Scalance portfo-lio. The other looks at the Sinema Server management software which now supports Network Address Trans-lation (NAT). The latest release V14 comes with new functions enabling ef-ficient network management. Applica-tion reports featured in this month’s is-

sue include a feature on a Dutch vegetable grower who avoids excess pack weights by using a final check weighing process with Siwarex tech-nology from Siemens. We also hear about how digitalization is used by a Chinese technology provider to in-crease the efficiency of its crushed-coal gasification plant. And finally, a transporter manufacturer has opti-mized its group-wide purchasing pro-cesses using Siemens PLM Software, allowing it to cut the cost of producing its heavy-duty vehicles.

MediaService | July 2017 2

Scalance XR-300WG (Work Group) managed layer 2 switches come with the same hardware characteristics as the unmanaged XR-100WG (Work Group) rack switches, and permit space-saving installation.

Nuremberg, Germany. Siemens is expanding the Scalance product port-folio to include new unmanaged Scalance XR-100WG (Work Group) rack switches as well as the managed variant Scalance XR-300WG (Work Group). The new switches come in a 19-inch aluminum housing with a low-er overall mounting depth, allowing a large number of Ethernet users to be connected to a network using only a single device. Available in a wide range of variants, the new switches come with up to 28 ports in a 24-volt direct voltage (DC) and 100 to 240 volts alternating voltage (AC) version.

To allow sensors and actuators to transmit their data to higher-level con-trollers and systems, Ethernet switch-es with a higher port density are use-ful right from the field level. Siemens has addressed this need by extending its Scalance product family to include a number of new switches. The first is its Scalance XR-100WG (Work Group) unmanaged switch series, which can be simply linked to the network as a plug-and-play solution. Also new is the Scalance XR-300WG (Work Group) series. As managed switches, these are configurable and offer a web-based management (WBM). The Scalance XR-100WG switches are particularly suited for rack control cab-inet mounting in small control rooms

Network communication in 19-inch formatSiemens expands Scalance portfolio with new managed and unmanaged rack switches

and in potentially explosive atmo-spheres (Atex Zone 2). Another ben-efit is the 19-inch aluminum housing, which has a low overall mounting depth. The switches of the Scalance XR-100WG series allow a total of up to 24 users to be connected with data rates ranging from 10 to 100 Mbit/s (mega bit per second) using RJ45 copper ports. The switches are available in two variants – either with 100 to 240 volts AC or with a redun-dant 24-volt DC power supply.

Wide application scope

The new switches can also be used in larger control centers for the inte-gration of small networks, in this case using the Scalance XR-300WG managed layer 2 version with man-agement functions and the same hardware characteristics as the un-managed variant. Both with the Scalance XR100-WG and the XR-300WG switches, this allows two de-vices to be mounted one behind the other for optimum space savings. The Scalance XR-300WG switches also allow a maximum configuration of up to 28 ports and a data transfer volume of 1 Gbit/s (giga bit per sec-ond) at each port. The Scalance XR-300WG offer many firmware func-tionalities such as the configuration of Virtual Local Area Networks

(VLANs) for structuring larger net-works. Ensuring greater availability within networks are redundancy mechanisms such as MRP (Media Redundancy Protocol) and HRP (High Speed Redundancy Protocol) Standby. Where greater distances are involved, this function is supplied by fiber optic transceivers. Extensive diagnostic capability such as SNMP (Simple Network Management Proto-col) diagnostics for integration into network management systems such as Sinema Server and end-to-end system diagnostics over Profinet simplify system handling and mainte-nance. This capability also benefits from an option to switch between di-agnostic modes in web-based man-agement to enable diagnostics on Scalance XR-300WG devices to be performed using Ethernet/IP-based tools.

Scalance XR-100WGwww.siemens.com/xr-100wg

Scalance XR-300WGwww.siemens.com/xr-300wg

MediaService | July 2017 3

The latest release of the Sinema Server network management and network diagnostics software V14 offers a range of new and improved functions including optimized display of network topologies and link-up to the Siemens cloud.

servers within a production network. Version 14 of this software has now been released with a range of opti-mized monitoring and data acquisi-tion functions. V14 allows plant and machine diagnostic data to be cap-tured using Network Address Trans-lation (NAT), for instance, even if the subordinated plants and machines have identical IP addresses. Java Runtime installations are now no lon-ger required, as Sinema Server V14 uses Java Script to display network topologies, which speeds up installa-tion and commissioning of the soft-ware on PC-based systems.

Link to the cloud

Another new feature is an upgraded function allowing Internet Standard IPv6 Basic Support. Version V14 of Sinema Server enables the identifi-cation of network users with IPv6-IP (Internet Protocol) addresses, mean-

Nuremberg, Germany. Siemens has released the latest version of its Sine-ma Server network management and network diagnostic software. V14 comes with an array of software im-provements to enable tangibly simpler monitoring and data acquisition across the entire production network of a company. Another major addition is fa-cility for link-up to the open cloud-based IoT (Internet of Things) operat-ing system MindSphere via the Industrial IOT Gateway Ruggedcom RX1400 with MindConnect. Serial ma-chine diagnostic functions now also take place using Network Address Translation (NAT). The new functions also allow network topologies to be displayed more efficiently and in even greater detail than before.

Sinema Server, the network manage-ment and network diagnostic software from Siemens, provides users with a central status overview of all active

Efficient network managementV14 of Sinema Server management software with NAT support

Sinema Serverwww.siemens.com/sinema-server

ing that the user has a permanent overview of all IPv4 and IPv6 devic-es in the network. As regards com-munication with higher-level sys-tems, V14 also comes with OPC UA (Open Platform Communications Unified Architecture) server function-ality, which allows seamless integra-tion of defined network diagnostics into Scada systems such as WinCC or PCS 7. In addition, Ruggedcom RX1400 with MindConnect acts as an interface, transmitting diagnostic data collated with Sinema Server for evaluation and further processing to MindSphere, the open cloud-based IoT (Internet of Things) operating system from Siemens.

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Customized weighing solution featuring an integrated controller from Siemens

Vegetables prior to packaging

`s-Heer Arendskerke/The Nether-lands. A company based in the Neth-erlands cultivates tomatoes and pep-pers on a grand scale for the retail trade. The produce is also packaged on the company premises before set-ting off on its journey to the super-market. Previously, the company was unable to perform a final check weighing process at the end of the vegetable packaging line. This meant that some packs contained more than the specified weight, eating into profit margins. The company has now put a stop to excess pack weights using a customized weighing solution featuring an integrated con-troller from Siemens. The solution has allowed the company to increase the efficiency of its packaging pro-cess and drive down costs.

According to the statistics, tomatoes are Germany’s favorite vegetable. On average, every German con-sumes around 26 kilograms of them every year. Companies like a vegeta-ble producer based in the Nether-

Prevention of excess weightVegetable grower relies on Siemens technology for check weighing

lands work to ensure that there is a plentiful supply to cover this enor-mous demand. Alongside tomatoes, the company also grows peppers, packages the vegetables on site and dispatches them to supermarkets across the whole of Europe. Previ-ously, irregularities in the packaging weights were a daily occurrence for the company, as it lacked the tech-nology to provide a final check weighing operation downstream from the vegetable packaging process. By introducing solutions from the Siwar-ex portfolio from Siemens, all this has changed, leading to a tangible increase in efficiency and primarily a reduction in costs.

Wide-ranging requirements

The company aims to configure its packaging process for greater accu-racy using the Siemens technology, to put an end to a situation where some packs contain a greater quanti-ty than shown. The challenge faced here was that the weighing process-

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nerve center of each of the weighers is formed by Siemens Siwarex WP231 weighing electronics con-nected to a Simatic S7-1215C con-troller. With a resolution of up to +/- four million parts and a measurement rate of ten milliseconds, the weighing module comes fully up to the expec-tations of the Dutch vegetable sup-plier in terms of its speed and accu-racy. A Siemens Sinamics G110 was directly connected as a frequency converter. The components are engi-neered directly in the TIA (Totally In-tegrated Automation) Portal, which permits rapid, simple adjustment of weighing applications as required. For the purposes of analysis and op-timum traceability, all readings are collated in a central memory. RMA owner Michel Remijn is fully satisfied with the outcome of the project: “The Siemens standard components com-bined with our plant allow us to offer customized solutions for the food in-dustry. Use of the TIA Portal signifi-cantly simplifies the design, con-struction and configuration of our systems.”

es not only had to be highly precise, but were also required to run at high speeds, as between 60 and 100 pack-aging units have to be handled per minute depending on the product. This means that a measurement rate of one pack per second has to be achieved to within an accuracy of two grams. The check weigher also had to be capable of weighing differently shaped packs containing a range of product types. Product packs exceeding the targeted weight have to be manually removed from the flow and repackaged. To ad-dress the wide-ranging different re-quirements imposed on the weighing system, the vegetable producer brought the company RMA Techniek (RMA) on board. The plant engineer-ing and weighing technology specialist accompanied the project from the de-sign phase through to commissioning of the check weigher.

Precision, speed and handling simplicity

A total of three check weighers were commissioned. The weight recording

Weighing Systems www.siemens.com/siwarex

Frequency Converter www.siemens.com/sinamics

Automation www.siemens.com/simatic

TIA Portalwww.siemens.com/tia-portal

Above: The Siwarex WP231 weighing electronics are integrated in the Simatic S7-1200, but can also be used without Simatic CPU (Central Processing Unit).

Below: The company uses three Siwarex WP231 units for check weighing, each connected to a Simatic S7-1200 controller and a Sin-amics G110 frequency converter.

A Dutch vegetable producer uses solutions from the Siwarex portfolio from Siemens for check weighing at the end of the packaging process.

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Taiyuan/China. Sedin Engineering Co. Ltd. (Sedin) is China’s largest technology supplier to the coal in-dustry. When a crushed coal pres-surized gasification reactor needed to be designed for Henan Yima Coal, the company decided to explore a new avenue. Sedin worked in part-nership with Siemens to develop the entire plant, harnessing intelligent manufacturing principles by adopting an “Integrated Engineering to Inte-grated Operation” approach. In the long term, Sedin plans to optimize the plant concepts still further to im-prove operational efficiency and product quality for the customer in cooperation with Siemens and its so-lutions for the process industry – in-cluding a digital twin of the planned facility. Benefits for the customer in-clude trouble-free commissioning and simplified plant management.

The smart, economical manufacture of customized products has long since become standard practice in the discrete manufacturing sector. Due to the complexity of the continu-ous processes, flexible production has proven more of a challenge in

Digitalization in coal gasificationChinese technology supplier increases plant efficiency

the process industries. However, when tasked with the design of a crushed-coal pressurized gasification reactor for Henan Yima Coal (Henan) as part of a complete factory rede-velopment project, Sedin Engineer-ing Co. Ltd. (Sedin) from China was not willing to settle for a standard so-lution. Sedin chose Siemens as its partner to develop the digitalization solution for the factory, aiming to in-crease its efficiency, to reduce cost and to achieve the best possible en-vironmental balance.

End-to-end design boosts efficiency

As part of its cooperative involve-ment in developing the Henan facto-ry, Siemens supplied its Comos engi-neering software, the Walkinside virtual reality platform and the Simat-ic PCS 7 process control system. Added to these were the Simit pro-cess simulation system and XHQ, the operational intelligence software for the processing and display of pro-duction data. Using Comos, Sedin was able to fully integrate the engi-neering process data, resulting in an end-to-end factory design. The level of detail and amount of data Comos provided allowed Sedin to increase design efficiency by 20 percent. The bidirectional data exchange between Comos and PCS 7 ensures that the design data and automation system always remain consistent. One of the benefits is that engineers are able to use the design data directly for engi-neering the corresponding process control solution, eliminating the need for manual data handling. This ap-proach helped reduce system config-uration time by around 25 percent. Data exchange between the systems also simplifies maintenance.

Realistic simulation

Using the simulation software Simit, Sedin created a virtual twin of the plant. This simplified processes such as commissioning of the actual plant,

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as it enabled Sedin to perform a vir-tual commissioning process and to identify and work around potential faults beforehand. Simit also sup-ports operator training, as it can be used for workshops before and dur-ing commissioning. With the Comos Walkinside virtual reality platform, a 3D model of the plant is also made available which allows users to move around virtually and practice various scenarios such as emergency drills.

Big plans

Using the Siemens XHQ solution, Sedin is able to permanently track the status of different gasifiers and to monitor and optimize their perfor-mance from any location. The plat-form permits smart plant operation by aggregating, reviewing and ana-lyzing data from a range of different sources. XHQ provides plant opera-tors with a solid base of data on plant status, allowing plant managers to make rapid, real-time decisions – for instance on how to maximize possible optimization potential. Zhang Qinggeng, the General Man-ager of Sedin, is delighted with the results of the partnership to date: “Our goal is to help our customers further increase engineering and op-eration efficiency, reduce operation costs, and improve product quality. Forging a strategic cooperation with Siemens is the first step we have taken towards achieving those objec-tives.”

Sedin Engineering Co. Ltd. (Sedin) is a technology expert for the coal industry. When designing a crushed-coal pressurized gasification reactor for Henan Yima Coal (Henan) as part of a plant rede-velopment project, Sedin opted to partner with Siemens.

Using the simulation software Simit, Sedin created a digital twin of the plant which allowed virtual testing of the plant prior to actual commissioning. This allowed potential faults to be identified and worked around before the actual startup.

Comos Walkinside allowed Sedin to create a 3D model of the plant in which users can move around virtually and practice various scenarios such as emergency drills.

Chemicalswww.siemens.com/chemicals

Comoswww.siemens.com/comos

Simatic PCS 7www.siemens.com/simatic-pcs7

Walkinsidehttp://w3.siemens.com/mcms/plant-engineering-software/en/comos-lifecycle/comos-walkin-side/Pages/Default.aspx

XHQwww.siemens.com/xhq

Simulationwww.siemens.com/simit

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More cost-effective production of heavy-duty vehicles Transporter manufacturer optimizes group-wide purchasing with products from Siemens PLM Software

Heilbronn, Germany. Based in Heil-bronn, Germany, the TII Group (TII) is widely regarded as the world mar-ket leader in the production of vehi-cles with hydraulically supported pendulum axles. For the group of a total of four subsidiaries, TII was able to introduce a uniform purchas-ing management system in the form of Teamcenter Product Cost Man-agement from Siemens PLM Soft-ware – with a noticeable impact in terms of cost reductions for supplier components. Teamcenter PCM helps to reduce the costs per vehicle by up to 25 percent and shorten delivery times from six to four weeks, afford-ing TII a decisive competitive edge.

The total of four subsidiaries of the TII Group (TII), some of which used to be independent, are worldwide leaders in the production of vehicles with hydraulically supported pendu-lum axles such as self-propelled modular transporters (SPMT), ship-yard transporters and military trans-

porters, as well as transporters for the aerospace industry. Since the subsidiaries used to be independent before joining the group and they were, in some cases, in direct com-petition with each other, it was diffi-cult to establish a central purchasing organization without redundancies in the supply structure. TII solved this challenge with Teamcenter Product Cost Management from Siemens PLM Software. The application is supported by the Siemens solution partner BCT Technology.

New structure

“Our greatest challenge is that we come from the project business and that, therefore, this is still how our production control is set up,” explains Hervé Richard, Head of Purchasing at TII. A mind change within the group was required, during the course of which TII introduced Teamcenter Product Cost Management in order to centralize its purchasing setup.

TII also manufactures vehicles for the aerospace industry that are capable of transporting even a space shuttle.

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The TII Group is seen as one of the world’s leading manufacturers of vehicles with hy-draulically supported pendulum axles, such as modular transporters for excavators and other mining equipment or for wind power equipment.

The self-propelled modular transporters (SPMT) are made up of several modules with driving units that, in some cases, can be engaged or disengaged as required.

Seventy percent of all transports over 3000 tons and ninety percent of all transports over 5000 tons are performed on modular, self-propelled vehicles from the TII Group.

PLMwww.siemens.com/plm

The primary objective was to establish a benchmark for assessing offers in order to be able to negotiate accord-ingly with suppliers and manufacturing partners. “Teamcenter Product Cost Management helps us to map our knowledge about suppliers, their per-sonnel costs, procurement chains, manufacturing processes, machine equipment etc. in a structured form and to check whether or not offers are based on serious calculations,” ex-plains Richard. He also added that manufacturing partners were happy to accept this help to assist with im-provements to their processes.

Solid data base

Teamcenter Product Cost Manage-ment incorporates various databas-es, which can be individually adapt-ed. This includes the national database with the average wage costs, surcharges and other relevant data for each individual country or re-gion. Then there is a product data-base with over 2000 machines, a ma-terial database and a process database that can be used to com-pare alternative technologies with each other. The databases are sup-plemented with a cycle time calcula-

tor for the standard motion se-quences in classic processing machinery. These different databas-es not only enable improved costing calculations, they also offer the op-tion of simulating the procurement of a new machine on the basis of production times and costs or on the basis of the processing parame-ters for a particular material on the machine. Thanks to the centralized purchasing that is made possible by Teamcenter Product Cost Manage-ment, the TII Group has managed to reduce costs per vehicle by up to 25 percent and, at the same time, to shorten delivery times from an average of six weeks to four weeks.

Widening the scope of application

Following on from the successful use of the Siemens PLM Software solu-tion, TII is planning to widen its use of Teamcenter Product Cost Man-agement in future from Purchasing to Controlling, where it will also be used to help with costing calculations for new products. “Although we haven’t quite finished optimizing the new system, we are not far off the target we hoped to reach,” summarizes Richard.

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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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