MediaService April 2016 : Industry News

www.siemens.com
MediaService
April 2016
Content
Siemens MediaService
PRODUCTS
April 2016 – Industry News
02 IWLAN antenna for harsh
environments
03 New diagnostic display for
safety relays
04 New 24V DC power supply
05 Physical network access
protection
06 Vehicular subscriber units
for harsh environments
APPLICATIONS
07 Golden age
09 Controlling pallet lifts
10 Perfectly-shaped roses made
of marzipan
11 “Green” railways
Already looking ahead to the Hanover
Fair, the April issue of the Siemens
MediaService Industries looks at new
products and applications and reports
on a new contract award in the field of
drives and automation. Innovations include an IWLAN antenna for rail applications, a diagnostic display for safety
relays and a 24 volt industry power
supply. Rounding off the products
showcased in this issue are an IE
RJ45 port lock providing physical network access protection and a vehicular wireless subscriber unit for harsh
environments.
We hear how a Canadian gold producer has commissioned two gold mill
drives using Siemens Integrated Drive
Systems for its new plant, and also
how machine tools are used for the accurate production of roses made of
marzipan with the aid of Siemens controls. Siemens controls are also used
in the Swiss Canton of Solothurn in
pallet lifts which transport up to 4,700
pallets every day. And finally, the LMS
Amesim Platform from Siemens helps
reduce PLM software development
times and the cost of hybrid powertrains. «
MediaService
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April 2016
IWLAN antenna for harsh environments
Suitable for applications even directly along railway tracks
Nuremberg, Germany. With the
new IWLAN antenna ANT793-8DL,
Siemens is providing a robust and
reliable wireless connection that can
also be used in railway applications.
The antenna is suitable, for instance,
for applications directly along railway
tracks and meets the increased requirements in relation to environmental conditions and fire protection.
wall, facilitating multi-axle, flexible
alignment in the desired radiation
beam direction. The antenna is attached to the active network components via a suitable connection using
two Type N connectors, making it re-
sistant to vibration – even in remote,
harsh environments that are difficult
to access. The antenna offering protection class IP66/67 can also be
used in environments with unstable
weather conditions. «
Communication between mobile subscribers across several radio cells
places high demands on active network components. IWLAN (Industrial
Wireless LAN) components from Siemens provide secure and reliable data
transmission with access points and
clients designed specifically for industrial purposes. This also includes the
provision of suitable antennas for optimum radio coverage when larger distances need to be bridged in fastmoving applications. The new antenna
ANT793-8DL, which is also suitable
for railway applications, complies
with the standards EN50155,
EN45545-2 and EN50121-4. Owing
to its compact design, it can also be
used in very confined spaces such
as tunnels. The highly directional
dual antenna with an antenna gain,
namely antenna directivity and efficiency, of 14 dBi (decibel relative to
isotropic radiator) and 25 to 35 degrees aperture angle each can be
operated in the 4.9 to 5.9 gigahertz
frequency range and therefore in license-free wireless LAN band 5
gigahertz. The mounting support which is supplied
with the antenna enables it to be attached securely to
the
The IWLAN antenna ANT793-8DL provides a robust
and reliable wireless connection specifically for use
in railway applications.
IWLAN-Industrial-Wireless-Lan
www.siemens.com/iwlan
MediaService
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April 2016
New diagnostic display for safety relays
Added benefits for safety applications
Nuremberg, Germany. Siemens has
upgraded its portfolio of Sirius 3SK2
safety relays to include a compact
diagnostic display. This allows plant
status or defects such as faulty sensors or warning messages to be simply displayed. As faults can be localized much faster it reduces
downtime and therefore helps to
save both time and costs.
There is now a new compact diagnostic display 3SK2611-3AA00 available for the Sirius 3SK2 safety relay,
which offers a range of safety functions with only a minimal footprint.
The Human Machine Interface panel
with its titanium colored display and
particularly bright background lighting informs the user about all events
occurring in the system such as
faulty sensors or warning messages.
This allows faults to be more quickly
localized and downtimes to be reduced. Existing projects can be simply saved and reloaded to the device
once the device has been replaced.
This facility for copying projects
lends itself to use in series machine
manufacturing. Typical applications
for Sirius 3SK2 include more complex or sophisticated security applications with several emergency stop
commanding devices, safety doors
with locking function or also material
infeed using light barrier sensors
which are intended to close down
above all partial applications independently. In addition, there is a
function block library available for
the implementation of individual requirements. «
The new compact diagnostic display 3SK2611-3AA00
Safety Relays
www.siemens.com/safety-relays
MediaService
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April 2016
New 24V DC power supply
20 ampere power supply unit for basic requirements
Nuremberg, Germany. Siemens is expanding its portfolio of 24 volt industrial power supplies to include a 20 ampere power supply unit in the lower
price range. The new power supply for
basic requirements in industrial environments is being added to the Sitop
Lite product line and can be connected
directly to single-phase 120 and 230
volt networks and to direct voltage networks with between 88 and 370 volts.
Sitop PSU100L is a 20 ampere DIN
rail power supply unit measuring just
110 millimeters wide. It is characterized by 92 percent efficiency and
can be mounted flush against other
devices on the rail. The output voltage can be adjusted up to 28 volts,
and compensates for voltage drops
across long supply lines. The wide
ambient temperature range of -25 to
+70 degrees Celsius enables its
use in rugged environments. To protect against interference in the power grid or 24 volt circuit, the power
supply unit can also be combined
with supplementary Sitop modules,
for instance to create an uninterruptible DC power supply, or for the selective protection of 24 volt load circuits. Using a DataMatrix code,
users can directly download product
information such as data sheets or
instruction manuals for servicing
over the Siemens Industry Online
Support App. It is also possible to
download 2D/3D data, circuit diagram macros and operating instructions or certificates from the Internet
free of charge for design and project
engineering. «
Power Supply Sitop
The new 24V DC power supply Sitop PSU100L for basic requirements in industrial
environments.
www.siemens.com/sitop
MediaService
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April 2016
Physical network access protection
Protection from unauthorized access
IE RJ45 Port Lock
Physical network access
protection
The IE RJ45 port lock provides physical network access protection
Nuremberg, Germany. Siemens developed the IE RJ45 port lock to protect
open, unused RJ45 interfaces. It connects RJ45 ports mechanically to terminal devices or network components.
As an additional measure, the IE RJ45
port lock can help to protect networks
from unauthorized access, thereby enhancing the security of industrial production plants.
A well-balanced, holistic security concept also includes physical protection
measures. Open, unused RJ45 interfaces that can be used by unauthorized third parties to access networks
are a well-known problem. In order to
mitigate this risk, Siemens is now offering the IE RJ45 port lock which en-
ables RJ45 ports to terminal devices
and network components to be
locked mechanically. The rugged design of the port lock in the form of a
plug means the plug snaps securely
into place at the RJ45 interface, preventing the insertion of RJ45 cables.
This port lock helps to prevent unwanted use of empty RJ45 ports
even on non-configurable network
components. The integrated lock that
can only be locked and unlocked using a mechanical key blocks the
latch of the RJ45 port lock. A mechanical key is used to remove or
unlock the port lock. Additional benefits include the sturdy design suitable
for industrial purposes and the ease
of installation which, because of
RJ45’s compatible design, does not
require any additional tools. «
Industrial Ethernet Security
www.siemens.com/networksecurity
MediaService
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April 2016
New vehicular subscriber unit
Wireless broadband mobile subscriber unit for harsh environments
Nuremberg, Germany. With the Ruggedcom WIN5100-V, Siemens has released a new vehicular subscriber
unit for private wireless networks.
Powered by a 48 Volt direct current
supply, WIN5100-V has been designed specifically for harsh environments. It is available in three frequency bands.
The new Ruggedcom WIN5100-V vehicular subscriber unit supplements
the WIN5100 device and offers high
resistance to shock and vibration.
With its EN50155 certification and
M12 connectors, the new unit is suitable for applications in rail transport,
mining and heavy industries which
require reliable communication at
high transmission rates via a mobile
WiMAX link. WIN5100-V is currently
available in three different versions,
namely WIN5137 for the frequency
band 3.7 gigahertz, WIN5158-V for
5.8 gigahertz and WIN5151-V for
AeroMACS. The Win5100-V device
with a GPS (Global Positioning
System) option transmit its GPS location to the base station via WiMax,
thereby reducing the data volume.
The vehicular subscriber unit location
is displayed on the base station via
the WEB GUI interface and can be
retrieved from the base station by
any management system using
SNMP (Simple Network Management
Protocol), hence avoiding constant
over-the-air messages to the subscriber unit. Hosts behind the mobile
subscriber unit can access the location information from the LAN using
NIP (Network Interface protocol).
The GPS option also enables the
internal clock of the subscriber unit
to be synchronized. The new
WIN5100-V devices are fully compliant with the IEEE802.16e standard
and can therefore be used with the
WIN7000 or WIN7200 base stations
or with any other WIMAX compliant
base station. «
Ruggedcom Wireless
http://w3.siemens.com/mcms/industrial-communication/en/rugged-communication/products/
Wireless/ruggedcom-win/Pages/
win5100.aspx
New vehicular subscriber unit for harsh environments
MediaService
7
April 2016
Golden age
Siemens awarded contract for gold mill drive
Mali. Siemens project partner
FLSmidth was commissioned by
Canadian gold producer B2Gold at
the end of 2015 to supply two mills
for mining the precious metal in its
new plant in Mali. The technology used
to drive the mills is based on Integrated Drive Systems (IDS) from Siemens.
Using IDS, B2Gold is able to reduce
its capital investment and make up to
50 percent savings on spare parts.
The Canadian gold producer B2Gold
Corp. already operates gold mines in
Namibia, Nicaragua and the Philippines. The Canadian firm is now expanding with a new plant in Mali. The
internationally active OEM (Original
Equipment Manufacturer) FLSmidth
has been awarded the contract to
supply the mills used for extracting
the gold, including a ball mill and
a semi-autogenous (SAG) mill.
Siemens Integrated Drive Systems
(IDS) will be used to drive both mills.
Saving through standardization
The use of converter technology allowed Siemens to adjust the rated
speed of the SAG mill motors to the
extent that the four large Flender
gears all work with the same transmission ratio. This allows the user to
standardize the size and the design
of the gears for both mill types. At
the end of the day this results in a 17
percent reduction in capital invest-
Frozen Charge
Protection System
The system enables the controlled dislodging of frozen
charge from the inner walls of
the mill: The mill carries out defined forward and reverse movements to detach the sediment.
The frozen charge no longer
needs to be manually removed
in the pipe. This shortens standstill periods and increases availability, while preventing damage
to the mill caused by material
dropping down in an uncontrolled manner. «
Beispiel eines Simotics HVM 800
MediaService
8
April 2016
ment for the mechanical drives, and
savings of up to 50 percent for spare
parts.
High-powered mill drives
The SAG mill is driven by two 7,500
kW air-cooled asynchronous motors
from the Simotics HV series, oil-filled
drive isolation transformers and two
water-cooled Sinamics GM 150 frequency converters. For the dual-pinion
ball mill, Siemens USA is supplying
two 5,250 kW slip-ring motors, liquid
starters and the “Frozen Charge Protection” package. The gears, couplings and lubrication units for the two
mills will be supplied by Siemens
Flender in Illinois. The “Frozen Charge
Protection” function developed by Siemens protects mills during start-up by
ensuring the charge which has become firmly attached to the mill wall
does not fall rapidly and damage the
mill.
Special features of the mills
The various operating modes of the
mills such as controlled ramp-up, load
balancing, creeping and inching mode
all serve to reduce the load on the mechanical components, drastically extending the service life and preventing
damage. In addition a controlled load
balancing function is provided to help
keep mill downtime periods to a minimum.
For mills which operate at a constant
speed – such as ball mills – Siemens
uses slip-ring motors with fluid starters featuring the PLC-based “Frozen
Charge Detection” function. The customer’s own deactivation signals can
be integrated without problems at
any time, allowing the mill operator
to carry out other measures to protect the mill from damage from
charge “frozen” to the mill walls. «
Integrated Drive
Systems (IDS)
The Integrated Drive Systems
approach smoothens the path
towards digitalization through
the three-way integration of
drive technology, making it the
ideal answer to the growing degree of complexity which customers are required to face, in
particular when it comes to applications in the process industries. The horizontal, vertical
and lifecycle integration of Integrated Drive Systems guarantees that every drive component fits seamlessly into
practically any drive system,
every automation environment
and also into the overall life­
cycle. This optimizes workflows
from engineering through to
servicing, and ensures maximum productivity, efficiency
and reliability for customer applications. Integrated Drive
Systems tangibly reduce not
only time-to-market but also
time-to-profit. «
Mining Industry
www.siemens.com/mining
MediaService
9
April 2016
Controlling pallet lifts
4,700 pallets a day – 40,000 storage compartments – 25,000 trouble-free trips
Neuendorf, Solothurn/Switzerland.
The Swiss retail corporation Migros
relies on Siemens technology for the
smooth running of its distribution center in Neuendorf in the Canton of Solothurn, where five automatic pallet
lifts transport up to 4,700 pallets safely to the right floor on a daily basis.
There are 40,000 storage compart-
equipment to the required floor,
where they are placed on the unloading conveyor. Five pallet lifts
transport up to 4,700 pallets loaded
with non-food and specialist retail articles in the newly constructed halls
every day. There are 40,000 storage
compartments available over five
floors with a total capacity of 385,000
The loading and unloading conveyors lead straight into the lift shaft. The transverse
shuttle in the lift car eliminates the need for a lifting transfer unit between the incoming and outgoing conveyor.
ments available over five floors, providing a total capacity of 385,000 cubic meters for pallets loaded with
non-food and specialist retail articles.
The pallets weigh up to two tons each.
Controlling efficient loading and unloading of the freight lifts is a Simatic
S7-1500 controller, which Migros expects to generate energy savings of
up to 40 percent.
In the recently completed halls of the
Migros distribution center, two fully
loaded pallets emerge from the pallet
lift, while the truck driver simultaneously places two pallets in the adjacent deposit station. Using a switch
panel, the driver selects the relevant
floor for the pallets and uses a pull
switch to activate the lift, which automatically takes care of the pallet transport. As soon as the unloading conveyor on the chosen floor is free, the
door of the lift opens and the pallets
are transported using load handling
cubic meters. The high turnover of
goods calls for the fast and also safe
transport of pallets from A to B. “The
systems run automatically, and have
to work with absolute reliability and
safety”, says Markus Stebler, CEO
and owner of Stebler Automation,
which implemented the complete
project for Migros from the initial
placement of order through to commissioning in just four months.
The technology in brief
The freight lifts are controlled over
Profinet by a Simatic S7-1500 controller. There is one control cabinet
installed per lift on each of the five
floors. The five systems differ in
terms of their configuration. They are
independently operated and networked to the building control center
via the main control cabinet. AWL
and SCL languages were used to
program the control system in the
Totally Integrated Automation portal.
Pallets generally run on rollers: within the Migros distribution center the
goods are transported on floor-level
conveyor belts. “This allows us to position and remove the pallets more
quickly and simply”, explains one of
the fork lift drivers. Operation of the
lifts is also simple: Instead of modern
touchscreens, a conscious decision
was taken here to use control panels
with mimic diagram and clearly arranged buttons. Stebler explains:
“This may have an old-fashioned
look, but the intuitive nature of a
mimic diagram makes this in our
view still the best solution for operating personnel.”
Saving energy while braking
Peter Bärtschi, Head of Engineering/
Projects at Migros-Verteilbetrieb
Neuendorf AG is delighted with the
availability of the lifts in Neuendorf:
“One of the pallet lifts completed
25,000 trips in its first two months of
operation – without any major interruptions”. Bärtschi is also pleased
with the system’s energy efficiency.
Electrical energy is recovered during
braking operations and returned to
the grid, resulting in major savings.
Measurements indicate an energy
saving of 40 percent. «
Simatic S7-1500
www.siemens.com/simatics7-1500
MediaService
10
April 2016
Perfectly-shaped roses made of marzipan
Getting just the right shape for products using Siemens controllers
The Romi machining centers at K&S also run automatically for many hours during the night. The Easy Message feature notifies the
duty manager promptly if and when faults occur. Siemens’ ShopMill graphical work step programming software is extremely userfriendly. That is why K&S production staff enjoy programming directly at their Romi machine tools.
Bad Schwartau, Schleswig-Holstein/
Germany. Special machines are needed to mass produce confectionery such
as marzipan. The required molding
tools are manufactured by the machine
manufacturer Krüger & Salecker from
Schleswig- Holstein using its own molding machines and Siemens’ controllers.
The machine manufacturer Krüger &
Salecker Maschinenbau GmbH (K&S)
which is based in Bad Schwartau
manufactures machines and tools that
are used not just in the food processing industry but also in the chemical
and pharmaceutical industry. Jörg
Maskow, CEO of K&S, says the technical molding roller principle and the
modular structure of his machines are
the secret to the company’s success.
Not only do molding rollers determine
the shape of the end product, the
changeover of the molding rollers is a
simple one-man job.
Getting products in just the right
shape
The rollers ensure confectionery such
as rose petals made of marzipan and
cookies have an appealing and
above all clearly-defined shape. Yet
having the right shape is not just important in the confectionery industry,
it is also important in the pharmaceutical industry. K&S uses machines
manufactured by Romi fitted with
Siemens’ Sinumerik CNC automation
system. It was a four-axis D 1500
milling center controlled by Sinumerik 828D that persuaded Maskow to
opt for this particular machine. He is
thrilled with the quality, reliability and
costs of the integrated solution provided by Romi and Siemens.
Integrated motion control and
user-friendliness
The company uses the Sinumerik
MDynamics technology package
supplied by Siemens for production
planning at the machining center
where Siemens installed Sinumerik
838D. The integrated Advanced Surface motion control with Look Ahead
and data compressor enables planners to configure the program sequence to ensure the machines have
the required surface quality while of-
fering optimum machining velocity at
the same time. What is more, the
Sinumerik Operate user interface
with the graphical ShopMill work step
programming provides a clear structure and is easy to use.
Error messaging via SMS
K&S is equally impressed by further
developments in Siemens technology and is planning, for instance, to
retrofit the Easy Message feature.
Easy Message diagnoses machine
faults and notifies the duty managers
via SMS, facilitating prompt troubleshooting, minimizing system failures
and increasing production. «
CNC Sinumerik
www.siemens.com/sinumerik
MediaService
11
April 2016
“Green” railways
Innovative vehicle drive systems with Siemens software
Since only 35 percent of the world’s railway networks are electrified, it is critical to make diesel propulsion “greener”. With LMS
Amesim, Voith Turbo engineers predict the reduction of fuel consumption and lifecycle costs while accounting for rail vehicle and
track characteristics
Heidenheim, Germany. Voith Turbo is
a German rail vehicle component supplier and manufactures intelligent
drive systems. The Voith Turbo portfolio also includes hybrid drive and propulsion concepts, a challenging area
as a result of the multi-domain complexity that is involved. To help them
address this challenge, Voith Turbo
uses LMS Amesim – part of the Siemens PLM Software portfolio. The results are reduced development time
and costs of hybrid powertrains.
LMS Amesim allows Voith Turbo engineers in the rail division to easily simulate the interaction between various rail
vehicle systems comprising components from different physical domains.
These include cooling circuits, combustion engines, hydraulic circuits, gearboxes and onboard system generators
– truly reflecting the multi-domain engineering challenge involved. LMS Amesim means that they understand how the
system behaves when parameters are
changed – even before a real system
has been produced – allowing them to
reduce the time and costs when opti-
mizing their products and when developing new ones. In fact, physical testing can sometimes even be
completely eliminated. LMS Amesim
is teamed up with LMS Imagine.Lab
Sysdm software, a team-oriented
model management solution that
helps specialists efficiently manage a
wide range of model versions.
Propel innovative drive solutions
Fully leveraging these powerful
Product Lifecycle Management solutions has helped the Voith Turbo rail
division to improve the quality of conventional diesel multiple units and
shorten the development time for innovative hybrid powertrain solutions
based on powerful simulation models
and leading-edge mechatronic system design. This creates an outstanding basis for continuing to engage interactively with their
customers to reduce the environmental footprint of diesel-driven rail
vehicles, cut train operating costs
and offer efficient, innovative hybrid
drive solutions. «
Siemens PLM Software
www.siemens.com/plm
LMS Imagine.Lab Amesim
www.siemens.com/plm/lmsamesim
LMS Imagine.Lab Sysdm
www.siemens.com/plm/lmssysdm
MediaService
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April 2016
Siemens AG (Berlin and Munich) is a global technology powerhouse that has stood for engineering
excellence, innovation, quality, reliability and internationality for more than 165 years. The company
is active in more than 200 countries, focusing on
the areas of electrification, automation and digitalization. One of the world’s largest producers of
energy-efficient, resource-saving technologies,
Siemens is No. 1 in offshore wind turbine
construction, a leading supplier of gas and steam
turbines for power generation, a major provider of
power transmission solutions and a pioneer in infrastructure solutions as well as automation, drive
and software solutions for industry. The company
is also a leading provider of medical imaging
equipment – such as computed tomography and
magnetic resonance imaging systems – and a leader in laboratory diagnostics as well as clinical IT.
In fiscal 2015, which ended on September 30,
2015, Siemens generated revenue of €75.6 billion
and net income of €7.4 billion. At the end of September 2015, the company had around 348,000
employees worldwide. Further information is
available on the Internet at www.siemens.com.
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