- Bachmann

Transcription

- Bachmann

maritime.application
Integrated Automation Systems
Complete ships and offshore plants
with up to
20,000 I/OS
automated
A system availability over
99.96 %
confirmed by customers
Together with our
CUSTOMERS
we develop perfectly integrated
automation solutions
BACHMANN KEEPS
YOU ON COURSE
We automate the offshore and shipbuilding sector:
Safely, flexibly and in a modular system
Bachmann electronic offers customers worldwide in the marine and offshore
sector sophisticated automation solutions. All our activities are focused on
the benefit to the customer: We deliver tailored solutions and set ourselves the
highest standards. Meeting highly specialized market and customer requirements has long become a standard task for us.
With Bachmann solutions you are benefiting
from the technologies of the market leader:
Over 40 years of experience in the automation
sector provide the critical edge in know-how
to bring your marine solutions quickly to market, with the optimum support of our worldwide
network of technical branches.
Since 1970 Bachmann has been growing with
every new challenge. Amongst the largest
global manufacturers of machines and plants
in the marine and offshore sector, the name
Bachmann is recognized as a benchmark for
first-class automation and control technology.
Thinking ahead, setting new directions, and
implementing today the customer requirements of the future – these are the key principles of Bachmann’s philosophy. The requirements placed on the automation of modern
machines and plants have increased tremen-
dously in recent years, demanding from suppliers a high degree of flexibility, openness
and innovative know-how. Our customers are
provided with highly reliable complete solutions
that increase the productivity and controllability of their applications, release the resources
required for their core business activities and
ensure reliable use long into the future. The
harsh conditions of the marine and offshore
industry place tough demands on machines
and plants. That’s why Bachmann solutions
have the toughness to match: They stand out
on account of their extremely high availability, very long service life of over 20 years, and
the use of state-of-the-art technologies. This
enables us to guide our customers to success.
Technically and financially.
THE SAFE FUTURE
OF YOUR MARINE AND
OFFSHORE PLANT
Everything under control with Bachmann system solutions
Our broad and modular product range meets really every customer requirement.
We provide you with a homogeneous and holistic system solution that also
ensures a high level of availability and is future proof. We offer you everything
from a single source and in the highest quality.
Integrated automation
One tool
One hardware
Open
Flexible
Web-based
… the right solution for every requirement
Redundancy
Scalable with standard components
Network redundancy with warm standby / hot standby
Maximum availability
Integrated diagnostics
Automatic switching within one cycle
Affordable
Technologically tested
… secures productivity and plant availability
Maritime&Offshore Essentials
Perfect engineering tools
Certified
Impressive redundancy
Maintenance through integrated CBM
Integrated power management
Open communication with all standards
... for the maximum availability and efficiency
of your ships and offshore plants
Condition Monitoring System
O
ver 15 years of CMS expertise
O
ver 3,000 CMS installed worldwide
T
he world’s first GL certification of a
PLC-integrated CMS
Individual retrofit solutions made to measure
… because a weather forecast on its own is not enough
Power Management
Fully integrated solution
Easily scalable
Individually adaptable templates
Measuring, protecting and synchronizing
Responding in milliseconds
... for developing highly innovative
solutions using our templates
THE BACHMANN SYSTEM
The automation solution for marine and offshore
We have the big picture and are always thinking ahead for you.
Our innovative solutions ensure the efficient engineering
for your plants. This is what the intelligent automation of
state-of-the-art marine and offshore plants looks like.
AUTOMATION
Top technology
without limits
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COLD CLIMATE
Solution for every
environment
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SOLUTION CENTER
All-in-one engineering
MARITIME&OFFSHORE
ESSENTIALS
Efficiency at all levels
REDUNDANCY
Safety net in case
of emergency
POWER MANAGEMENT
Grid measurement
at the highest level
SAFETY CONTROL
Safety without
compromise
MODEL BASED DESIGN
Regulation, sequence and HIL/
simulation fully under control
CONDITION
MONITORING SYSTEM
More safety, greater yield
M1 WEBMI PRO
SCADA and HMI
of the future
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TOP TECHNOLOGY
WITHOUT LIMITS
Automation
Automate your offshore plant with Bachmann, secure
in the knowing that every eventuality is covered.
Our automation systems stand out on account of their
extraordinary robustness, high performance and
open interfaces. The latest and most innovative platform
for your requirements.
Openness in hardware
and software
Equipped for
challenging climates
The M1 system operates as a real-time system. Different open-loop and closed-loop control programs are adapted in modules and run
simultaneously in a preemptive multitasking
environment. Like the hardware, the software
system is also modular and can be structured
and extended as required following our “no
limits” principle. The controller offers additional reserves for expansions or plant-specific
adaptions.
The ColdClimate modules of B achmann
electronic are the solution for all applications
in demanding climatic conditions, especially
where maximum plant availability is critical.
The ColdClimate modules are first choice,
especially when demanding environmental
conditions (e.g. temperature, air humidity, salt
spray) are involved. For you this means: Safe
operation, even with extreme transient temperatures as low as -40 °C and when condensation is present.
Functionality means
“ready-to-use”
The modular M1 system offers an extensive
range of hardware, consisting of over 200
devices and modules. This system contains
a large number of configurable modules for
all necessary plant functions, such as visualization, networking, closed-loop control and
diagnostics, to provide you with all the basic
functions from the start. Here we place great
importance in ensuring that all tools are developed according to international standards,
and can also be integrated and parameterized
flexibly.
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System concept
Scalable and open
In order to minimize complexity and maximize ease of maintenance,
all components of the M1 controller system are consistently developed as part of a modular system. In this way, optimum scalability is
ensured for a wide range of requirements. The M1 system perfectly
combines the openness of a PC-based controller with the reliability
of industrial hardware platforms. A state-of-the-art system architecture designed for effective networking capability enables it to be
integrated easily in the area of the controller and plant peripherals.
Regardless of the type of ship
or offshore and marine application involved: We offer you
products for tailored solutions.
Meeting highly specific requirements has long become a standard task for us.
Loading system
Thruster
Power management
Stabilization system
Ship management
Alarm & monitoring
Condition monitoring system
Rudder control
Machine plants
Heeling compensation
ROV
Dynamic wave compensation
Certified systems
Internationally accredited test institutes verify
the conformity of our Bachmann systems
with the most important global standards and
thus provide approval for the most demanding
applications.
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SOLUTION FOR EVERY
ENVIRONMENT
ColdClimate
Anyone working in extreme climatic conditions values
a reliable partner. Bachmann is renowned worldwide
for its quality promise to supply products with only the
highest level of reliability.
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We are glad that our customers are so
demanding. They are looking for unique solutions for challenging environments, particularly
wherever maximum plant availability is critical.
On shipboard applications in particular, or in
offshore installations such as wind turbines,
oil and gas production platforms, ColdClimate
modules are the first choice. Whether it is condensation or operating temperatures between
-30 °C and +60 °C (extreme temperatures
between -40 °C and +70 °C), Bachmann solutions can withstand them all. The ColdClimate
modules are the ultimate answer to extreme
climatic conditions.
Our quality promise is also based on a number
of testing procedures that go far beyond the
mandatory minimum standard – starting with
the 100 % test for all modules in an active RUN
IN, to extreme temperature change phases in
climatic chambers, right through to measuring
compliance with standards in the company’s
own EMC 3 meter absorber chamber.
Wide temperature range and
condensation proof
The perfectly matched ColdClimate versions of
M1 modules and terminals have two things in
common: A very large operating temperature
range and moisture condensation resistance.
Thanks to a special polymer-based protection
of the electronic modules, reliable operation
is also ensured when condensation is present.
The modules can be used at extreme temperatures from -40 °C to +70 °C, and reliable uninterrupted operation is guaranteed in the temperature range from -30 °C to +60 °C when
condensation is present.
Thanks to the high quality protection for temperatures between -40 °C and +85 °C, all
ColdClimate components can be stored without
any restriction.
Bachmann products are also ideally equipped
for other severe environmental conditions: For
example for operation in high altitude conditions at low pressure and reduced heat capacity. And not to be forgotten: severe mechanical
stresses caused by shock and vibration that
are no match for Bachmann controllers.
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ALL-IN-ONE
ENGINEERING
SolutionCenter
The Bachmann SolutionCenter represents a genuine
milestone in the reduction of engineering costs. A single
all-round software solution covers all aspects of the
engineering process – from configuration, programming,
closed-loop control, motion, communication, safety,
visualization, right through to testing and commissioning.
One tool for
everything
Project engineering
SolutionCenter –
the all-in-one engineering tool
Thanks to the highly modular Eclipse plug-in
concept, the SolutionCenter can be expanded
simply, even for integrated user-specific
requirements.
Programming
Visualization
arameterization and
P
communication
Tools and add-ons
Diagnostics and service
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The SolutionCenter is perfectly matched to
Bachmann devices and systems, and was
designed in collaboration with experienced
users. It saves time, generates synergies and
increases usability. Users can benefit from the
integrated operating concept and avoid the
manual entry of redundant or unnecessary data.
An open system
Bachmann offers control system developers
the latest in modern and standardized development tools. The M1 system can be programmed in IEC PLC languages, and highlevel languages C/C++ or Java. Extensive
closed-loop control tasks can be modeled and
simulated and can be tested and run directly
online on the system.
The M1 controller supports all standard networks such as Ethernet TCP/IP, PROFINET,
EtherCAT, CAN bus or Modbus. The configurators required are also included as well as diagnostic and testing tools.
EFFICIENCY
ON ALL LEVELS
Maritime&Offshore Essentials
With features such as the Project Manager, the Maritime&Offshore
Essentials package supports the workflow of a programmer,
starting from the list of measuring points of the shipyard right
through to the creation of the PLC program.
Diagnostics and service
The system can be commissioned and optimized with a high degree of transparency
thanks to the tools integrated in the SolutionCenter. The various monitoring and debugging
tools can be used in a wide range of applications
and considerably reduce commissioning times.
Increased system availability is also possible
thanks to efficient process diagnostics.
Visualization
Visualization and plant operation are webbased and protected with access authorizations and SSL encryption. A security concept
that has already been tried and tested in thousands of different plant configurations.
Freely configurable and
parameterizable controller
application during the runtime
The M1 marine automation system gives the
opportunity to adapt the functions you provide
to your customer to his specific requirements.
This can be carried out without the need for
an expert system or any specialists. Your
customer or end user are thus able to make
these adaptions themselves. A configuration
layer makes it possible to map or parameterize
Measuring
point list
is supplied
by the shipyard.
Import list
created from the
information in the
measuring point list.
hardware and software during operation. It is
also possible to define the number and scope of
these parameters. This ensures that the application is always in a safe and operable state.
Project manager
The Project Manager supports the workflow of
a programmer starting from the list of measuring points of the shipyard right through to
the creation of the PLC program. The Project
Manager ensures the error-free generation of
the PLC program by a project designer or service technician in a very short time. Even if
your customer stipulates some special requirements shortly before the deadline, these can
be included very simply and, more importantly,
without any risk of programming errors. Your
service technicians can set parameters to
modify important functions. All possible function parameters are already pre-tested 100 %
in advance in order to avoid the need for troubleshooting on board the ship.
MOE functions –
»Ready-to-use«
Holistic project development
and management
LC program
P
Programs and functions
Logic operations Variables
Visualization
Object creation Connecting
objects with the PLC variables
Simulation
Generation of PLC simulation
code 3D animation
Documentation
Connection diagrams
Ordering data Technical data
Project manager
The reading in of the import list
generates all objects.
Editing of object parameters
if necessary adding of new objects.
PLC program
is generated.
Project Manager supports the workflow of a
programmer.
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Bridge
Alarm & monitoring
Cruise control
Configuration
Maneuvering controls
Information management
Automatic track keeping
Remote diagnostics
Autopilot
Teleservice
Simulation
Alarm & monitoring
Cabin
Extending alarm system
Information system
Active heave compensation
Cranes
Deck
Winches
Gangways
Cable drums
Trenchers
ROV
A frames
Alarm & monitoring
Dynamic position
Machine control room
Energy management
Drive control
Rudder control
Ship automation general
Diesel electric drive control
Transient recorder
Anchor & winch control
Ballast compensation control
Condition monitoring
Machine/cargo room
Motor control
Fuel conditioning
Process control
Water treatment
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Network 1
Network 2
2nc Master CPU (optional)
Connection to I/O stations
MODBUS
NMEA
SAE J1939
Connection to I/O stations
or third-party system
MODBUS
NMEA
SAE J1939
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SAFETY NETWORK
IN CASE OF
EMERGENCY
Redundancy Control
Bachmann automation solutions stand out on account of
their highly robust design and maximum availability.
Nevertheless, no single system can guarantee complete
freedom from failure on its own. The use of a redundancy
system enables you to increase the availability of your
installation or ship effectively and sustainably.
Malfunctions and failures in important operating components reduce the uptimes of
machines and plants. In addition to this,
they often lead to consequential damage and
lengthy repairs. This involves considerable
costs, and the production downtime leads to
financial losses. Redundancy systems increase
the capabilities of automation systems through
the feature of single fault tolerance. This makes
it possible to ensure continuous productivity –
even while maintenance or modifications are
being carried out on the plant – 24 hours a
day, 7 days a week. Bachmann’s redundancy
solutions enable you to increase the availability of your plant effectively and sustainably:
System variants that are tailored to meet any
particular requirement enable you to optimize
productivity and operational reliability. The
seamless embedding in the proven hardware,
engineering and programming concept already
in place, together with the robustness of tried
and tested Bachmann components, guarantee
Redundant systems have a reputation for being complex, expensive and extraordinarily labor-intensive for
programming and operating. Not so with Bachmann
redundant solutions: They offer full real-time capability,
are easy to program and are fully integrated into the
engineering environment.
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Hot standby
redundancy
Network redundancy included
Two master CPUs
utomatic synchronization
A
of master CPUs
Bumpless switchover
edundancy cycles up to 1 ms
R
possible
the highest level of operational reliability, thus
maximizing yield. This optimum combination not only guarantees single fault tolerance
throughout but also multiple fault tolerance in
many cases.
nhanced diagnostic and
E
programming interfaces for
monitoring and evaluating
the redundancy status
Operator
Terminal
reely adjustable switchover
F
time, automatic switchover in
the event of a fault
Warm standby
redundancy
Network redundancy included
Two master CPUs
Master B
Master A
Slave
Station
iagnostic interface for
D
monitoring and evaluating the
redundancy status
laves decide the CPU from
S
which the data packet is to be
used (voter)
Configurable switchover time
Operator
Terminal
Another benefit of the integration is the voting
mechanism used by all Bachmann terminal
devices. After being configured once in the
application program, redundant process variables here can be used and processed as a single variable without having to manually read or
write the values twice. Management and fault
detection are completely handled by the system, thus reducing the workload for the user.
With Bachmann systems, redundancy can be
tailored to meet the requirements at hand.
The use of standard components offers a wide
choice of powerful CPUs which can communicate with the substations either via copper
or fiber optic connections. Combined with
the product variants, this results in the most
economical solutions – from simple network
redundancy to protection from communication failures, right through to the virtually fully
available system.
onfiguration and monitoring
C
in the SolutionCenter
Slave
Station
Fault detection integrated
in the end points
Scalable and cost efficient
utomatic switchover between
A
variables and process value
sources within one PLC cycle
Time synchronization of all
stations
Short switchover times
The switchover time is a quality feature of a
network redundant system. Typical systems
often operate using a ring topology. In the
event of a failure the network devices reroute
the data packets. However, the detection of
a fault and the subsequent switching takes
time. The redundancy solutions from Bachmann directly integrate the detection and switchover operation in the communication end
points. This approach allows considerably better switchover times, and any topology can be
selected thanks to the comprehensive Ethernet
conformity.
Master B
Master A
omparison of master CPUs
C
not integrated
Network
redundancy
One master CPU
edundant communication
R
(cyclical and acyclical)
ully autonomous, double
F
communication guarantees
optimum reliability for any
selected transmission medium
(copper/fiber optic)
Master
CPU
edundant Ethernet-based
R
networking, full support of TCP/
IP-based parallel communication
Slave
Station
Operator
Terminal
reely selectable network topolF
ogy: Radial, linear, ring
and combinations
imple configuration in developS
ment environment, integrated
diagnostics (status, quality)
rogramming interface, libraries
P
and system variables for easy
creation of applications
witchover in the same
S
PLC cycle
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GRID MEASUREMENT
AT THE
HIGHEST LEVEL
Power Management
Initiatives such as the All Electric Ship (AES) require the increasing
stability and controllability of shipboard energy grids. Capacity
bottlenecks must always be prevented and the ship’s engines must
always have power available. The coordination of grid protection,
the real-time monitoring of loads, and the fast and targeted supply
of electrical energy are fundamental requirements here.
Fully integrated solution and
yet easily scalable
Several technology modules are available for
the power management alone. The GSP274
module provides Bachmann’s experience in the
automation of decentralized energy generation
units for maritime applications. It ensures the
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safe, reliable and automated synchronization of
generators to the ship’s power grid. To do this
the module measures the grid at three points
and actuates two circuit-breakers via a relay
output, taking the switch delay into account.
The GMP232 grid measurement and protection
module from Bachmann integrates the protection
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rid monitoring Additional
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to the GMP232 module – Q/V
protection (reactive power/
undervoltage monitoring)
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module: 4 additional voltage inputs (total 7; GMP 3),
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The system must ensure that sufficient load
reserves are always available at the busbar. In
order to do this, generators are automatically
started and synchronized, and loads with a low
priority disconnected. To record faults with a
high level of accuracy, the GMP232 and GSP274
are equipped with an integrated data recorder.
This enables up to 16 measuring channels to be
recorded with precise synchronization for four
seconds at a maximum resolution of 100 µs.
The recording can be triggered remotely or
activated in the event that predefined limit
values are exceeded. The measuring data is
then available in the SolutionCenter or as an
exportable file in the Comtrade format. In the
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Tasks of the power
management system
To handle all these tasks, the M1 marine automation system comes with a high performance
processing unit and offers high speed and reliable networking options at the same time. The
M1 automation system allows a high degree
of flexibility whilst still ensuring a high level of
functional integration at the same time. Development engineers can thus be certain that
they can even implement non-standard tasks.
Operating and maintenance personnel appreciate the safe and reliable diagnostic options
for system events. The data can be fully
integrated in the central alarm & monitoring
system. This therefore reduces maintenance
work and enables abnormal system loads to be
detected early on before they can cause significant damage.
*X
A central power management control unit
enables you to implement advanced real-time
power management solutions with remote
technology modules connected by fiber optic
cables. This ensures that the coordination
between the power generation units and the
dynamically changing load demands is straightforward and reliable.
High performance PLC
H
Maritime power supply
event of a fault, this makes it possible to safely
and reliably reconstruct the causes without any
additional effort.
DJ
and monitoring functions in the conventional
control tasks. The third module GM260 can be
used for measuring the grid. Modular software
modules with standard and easy to operate
interfaces round off the package.
Loads
Loads
G
ertification –
C
VDE AR 4105: Grid and
system protection; requires
two-channel measuring
and tripping; mandatory in
Germany when connecting
energy generation plants to
the low-voltage grid
Unit certificate FGW TR3:
Simplifies the issuing of plant
certificates. Plant certificates
must be issued in Germany in
order to obtain the “system
services bonus”
(= higher feed-in tariff).
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SAFETY WITHOUT
COMPROMISE
Safety Control
Modern safety solutions using a programmable safety controller
make it possible to implement functions that go far beyond
the conventional emergency-stop chain. Bachmann offers a
complete safety package that is used successfully in a wide
range of different applications under the toughest conditions.
In modern machine and plant building, the protection of personnel and systems is regulated
by the new Machinery Directive. This directive
and the associated safety standards stipulate
the use of the latest methods and measures in
the implementation of safety devices in order
to ensure the optimum protection of people and
goods. In addition to this, each safety component is developed and tested under the supervision of a certification body. Operators of offshore installations and also shipping companies
not only benefit from the increased personal
protection provided but also benefit financially.
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Critical signals can already be acquired and
evaluated using several sensors. An approved
component such Bachmann’s “safety control”
PLC, combined with the integrated testing and
monitoring functions, eliminates the need for
multiple acquisition whilst keeping life cycle
costs low.
Safety engineering
under control
The safety components of Bachmann are ideal
for use on ships and offshore plants. Operational control, safety engineering and operating
devices are perfectly matched and offer open
communication. The fastest possible response
times, intuitive operation and comprehensive diagnostic options guarantee the highest
possible level of safety. All Bachmann safety
modules are certified with the highest safety
category SIL3 and PL3 for machines and systems. The safety modules can be arranged
within the plant control system as required,
thus enabling the implementation of individually tailored solutions. Safety channels that are
not required can be used as standard digital I/
Os without any restrictions. Safety relays can
be replaced thanks to the 2A outputs of the
remote SDO208 output module. This saves
space, wiring effort and additional costs. With
the integration of the Safety Developer in the
SolutionCenter engineering tool, Bachmann
makes safety programming easy for the user
on the basis of established standards such as
IEC 61131-3 and PLCopen Safety.
Benefits for manufacturer
and operator
Programmable safety engineering makes practical implementation and daily use easy.
It enables the secure monitoring of all the internal states of an installation during operation,
including the safety circuits, also via teleservice functions. Bachmann offers you tailored
solutions based on the experience gathered
from the successful use of control components
in offshore installations all over the world.
Keeping it safe with Bachmann
All the safety modules of Bachmann, together
with the necessary programming tools and
function blocks, have all been certified by the
TÜV Süd certification body. UL508 approval
also ensures safety when operating in North
America. All modules are available as coldclimate versions. Safety is thus also guaranteed
in extreme environmental conditions.
Safety standards
and regulations
I EC60945
I EC61508
I SO13849
E
N954
I EC62061
E
N61511
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REGULATION, SEQUENCE
& HIL/SIMULATION
FULLY UNDER CONTROL
Model Based Design
The challenges placed on the automation in offshore
applications and on ships are constantly increasing.
The growing size of plants and the introduction of new
technologies have also increased the complexity of
operational control programs. New development techniques
for creating these programs are needed in order to
minimize the development effort required on the one hand,
and to bring out technically mature and highly available
plants on the other.
If simple analytical advanced calculations can
no longer describe or predict the response of
a system, practical experimentation is the only
solution. Models and prototypes are used to
obtain findings and develop a solution. However, what happens if the production of these
pilot systems is too expensive, offers only
restricted use, or if practical tests are simply
too dangerous?
Today’s answer is: digital simulation. The actual
systems are emulated in a program in the form
of a simulation model. Irrespective of the type
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of modeling, mathematical interrelationships
are used to describe the behavior of the system. If these simulation models are recalculated with different environmental conditions
and parameters, this is the equivalent of a
prototype test in virtual form. Safe, affordable,
repeatable as required and fully automated.
M-Target for Simulink® enables the simple use
of model-based simulation, taking the actual
automation solution into account.
Simulation: Solution
development on the computer
model and direct download to
the M1 controller.
Quality and efficiency
The use of high quality algorithms increases
product quality and plant yields. The increasing
efficiency of plants can be achieved through
the use of new close-loop control and optimization concepts. Solutions which are developed with the help of M-Target for Simulink®
or 20-sim 4C can fully demonstrate their
strengths in these disciplines. The MATLAB®/
Simulink® tool from MathWorks is well-established on the market. 20-sim is the modeling
and simulation software developed by Controllab. It offers tools for modeling dynamic systems. Both products provide support for creating a simulation model of the subcomponent to
be automated.
Standard modeling methods can be used on
the one hand. Alternatively, it is also possible to use the interfaces to several commonly
available domain-specific simulation programs
in order to utilize part simulations that have
already been created. The algorithms required
for automation are then created directly in the
simulation environment and their functional
suitability checked.
Automatic code generation
As soon as the simulation has produced satisfactory results, i.e. when no weaknesses in
the requirements specification and no algorithm errors can be identified, the compilation
from the simulation language into executable
code for the M1 controller is executed at the
push of a button. This is machine compiled by
the system, thus eliminating the possibility of
any random errors. After code generation, the
executable automation program can then be
tested immediately on a hardware-in-the-loop
test rig equipped with actual controller components or on the actual plant.
Cost efficiency
“Getting to market faster with the better solution” – this is the paradigm of our global economy. The many programming options of the
Bachmann M1 automation system help here.
Calculable investments that are also inexpensive compared to their benefits pay for themselves quickly. The customer-friendly license
model of M-Target for Simulink® does not
involve any unit-based purchase of licenses
and thus has no negative effect on product
profitability. 20-sim can be purchased directly
from the manufacturer and has the M1 already
integrated as target.
Highlights of model
based design
Development of automation
algorithms (open-loop and
closed-loop) directly in Controllab/20-sim or MATLAB®/
Simulink®
A
utomatic code generation
and transfer to the M1
controller
O
nline communication
between the development
environment and the PLC program for convenient parameterization and diagnostics
Integrated simulation modes
for the I/O modules used in
the application
I ntegrated interfaces to
visualization systems and
other PLC systems
I ntegrated interfaces to
automation programs created
in conventional programming
languages (IEC61131-3,
C/C++)
Support for hardware-in-theloop systems (HIL)
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MORE SAFETY,
GREATER YIELD
Condition Monitoring System
Drives for drilling equipment, excavator pumps, pipe handling
systems, propulsion systems, control systems etc. are some of the
critical equipment used in shipbuilding. The prevention of breakdowns and therefore also any unexpected downtimes for this critical equipment is the task of the 24/7 condition monitoring
system for ship operation.
In conjunction with a method of forecast modeling, the CMS is required to detect potential
fault conditions before actual damage becomes
noticeable and critical. This should likewise
provide sufficient time for implementing preventative measures and repairs or procuring
spare parts.
First CMS to be fully integrated
in an automation solution
The wear occurring on plants is primarily
determined by the way in which the plants
are subject to stress. “Stand-alone” condition
monitoring systems were developed primarily for condition based maintenance. Having
access to the relevant process variables online
makes it possible to take the latest operating
states of the ship into account. The M1 marine
automation system is the first fully integrated
and programmable CMS solution available that
provides the appropriate hardware modules
required for incorporating the various signals, as well as the necessary software. The
24
M1 system analyzes the data combined from
oil, water and vibration sensors with operating hours and operating conditions, as well as
environmental factors such as waves, wind and
currents. The wear process is closely related
to the way in which the machines are used. It
is even possible for environmental conditions
and the movement of the ship to accelerate the
wear process even with minor loads.
Minimizing system downtime
The system failures of shipboard machines can
cause the failure of the ship’s entire operation,
thus resulting in a correspondingly high financial loss. For decades, every ship has been
equipped with a central “alarm and monitoring
system” that warns the crew in the event of a
critical fault or critical values. The integration
and use of analyzed CMS data is the next step
towards minimizing system faults and notifying
the crew in good time and as extensively as
possible. However shipboard machinery is subject to a slow process of wear due to the stress
it is exposed to during operation. This stress
depends on environmental factors and on the
way in which the crew operate the system. This
slow process of wear cannot be handled by the
conventional AMS system.
Marine M1 automation solution
The IACMS Integrated Automation & Condition
Monitoring System from Bachmann combines
the control functions with the condition monitoring (CMS) and functions as a redundant
data server for the AMS system. The operating
personnel receive an online warning message
in good time about the increasing wear, thus
enabling the owner to reduce the life cycle
costs of the fleet.
Major benefits for
crew and owner
The use of IACMS means that different systems on board can be controlled with the same
hardware and software. This improves understanding and simplifies training for the crew,
whilst at the same time reducing initial costs
for the owner. If CMS data is fed to the ship
management system, it is possible to make a
continuous assessment of the current status
and availability of the ship.
Increased performance
and know-how
This display of online and on board information
about the machine status with the same hardware that these systems are controlled and
regulated with is not the only expertise that
we offer.
Follow-up
control
An example of the
monitoring screen
of an operator station. This example is
of a semi-submersible
with six controllable
thruster s and four
gensets driven by diesel engines.
Follow-up
control
Hydraulic power-pack
or
frequency converter
M
Azimuth
sensor indication
Critical components
that can be monitored
with condition monitoring
systems.
Indication
duties
Driving Motor
M
Azimuth
sensor indication
Seal
Radial roller bearing
Axial roller
bearings
Propeller
Main gear
Seal
Thrust bearing
Radial roller bearing
25
SCADA AND HMI
OF THE FUTURE
M1 webMI pro
The widespread global use of Internet-enabled devices has
taken place at breathtaking speed. Their simple and intuitive
operation is impressive. Internet and software applications
no longer have a fixed location but can be used from anywhere
in the world. With ‘M1 webMI pro’, Bachmann electronic is
impressively demonstrating its technology leadership: Each
M1 controller is turned into the central server for fixed or
mobile HMI devices.
Engineering and maintenance –
an important cost factor
Benefits of
M1 webMI pro
at a glance:
alue displays with high
V
refresh rate
ny browser-based device
A
becomes an HMI
peration and visualization
O
when and where you need it
oss-free scaling to all screen
L
sizes
s safe as Internet banking
A
(HTTPS)
hort refresh in the browser
S
instead of time-consuming
software rollouts
se of the application on
U
different devices (smartphone, tablet or stationary
HMI devices)
I ntegration in higher-level
SCADA applications
26
Plants are becoming increasingly more complex with ever increasing requirements. This
also naturally increases the effort required
for engineering and maintenance as well. It is
often not only necessary to allow for local visualization in the field, but also for the connection
to a control center, a separate visualization for
teleservice and sometimes also solutions for
mobile terminal devices. Often each requirement here has to be implemented with separate
applications. With many visualization products,
the handling of different terminal devices and
screen resolutions is also not possible.
Pure web visualization for the
Bachmann M1
Bachmann electronic is now launching a powerful product for pure web visualizations on the
market called ‘M1 webMI pro’. A slim-line web
server that is directly installed on the M1 controller enables the connection of any visualization devices such as smartphones but also
powerful operator terminals. Provided the necessary authorizations are in place, the application can now be accessed from anywhere in the
world. Thanks to ‘M1 webMI pro’ all the important information can be shown in a single view
and with stunning definition. Perfect graphic
results can be achieved on any visualization
page without any losses in quality when scaling
and zooming. This is thanks to the extraordinary benefits of HTML5 and SVG (scalable vector graphics), the basis for all graphic objects.
State-of-the-art project engineering and simple delivery
The ‘atvise builder’ engineering tool is used for
drawing process pictures, configuring animations and events as well as for other settings.
A number of ready-made graphic objects and
layouts, as well as the flexible reuse of pages
using parameter transfers make it possible
to create visualizations efficiently. Integrated
editors even allow the drawing of new SVG
graphic objects or the creation of additional
functions with user-defined Java scripts. Once
the visualization is completed, this is transferred to the web server via FTP with just a
single click. This makes the delivery of visualizations to large and distributed installations
child’s play. Time-consuming software installations to all HMI devices involved become completely unnecessary. The latest version of the
application is always shown as soon as a client
connects with the central web server or reloads
the web page. Special installations or a restart
Client
Client
Client
Client
Ethernet/Internet
PLC
M1 webMI pro
of the HMI devices are no longer necessary. All
operator units are thus automatically brought
up-to-date – without any interruption and irrespective of time and place.
Increased efficiency included
The development of web technologies had to
allow from the outset for a wide range of different terminal devices, since different screen
sizes and resolutions are normally used. Visualization design in ‘M1 webMI pro’ is much easier however, since only a single application has
to be created for all devices. If the visualization solution is also implemented directly on
the controller, the configuration of the relevant
data interfaces is also unnecessary: The variables can be accessed directly, an OPC server
or any proprietary protocols become obsolete.
Ultimately, this kind of web solution not only
means more efficiency in engineering but also
a real increase in cost efficiency.
The web ser ver on the
Bachmann M1 forms the “visualization center”, any clients can
access it with a web browser,
regardless of time and place.
the latest processors increases system efficiency. At the same time, the 64-bit data width
enables the utilization of considerably more
main memory which ultimately allows larger
projects with more process variables (nodes).
Released operating systems include Windows
XP SP3, Windows 7 (32-bit and 64-bit), Windows 8 (32-bit and 64-bit), Windows Server
2008 and Windows Embedded Standard 7.
Besides other minor improvements, version
2.5 also contains functions for filling in the
process history (value archive) at a later time,
such as when the transfer of only temporarily
connected process connections is blocked.
State-of-the-art visualization solution on an
Apple iPad™: Ship control in
pure web technology.
SCADA with 64-bit power
The increasing complexity and the constantly
rising level of automation in a wide range of
different installations require future-oriented
technologies for monitoring and controlling
processes effectively. SCADA systems make a
key contribution here and ensure a high level of
safety. This is especially the case if they offer,
like the atvise® product line, operation that is
not restricted to a particular location or device.
The atvise scada control station combines the
latest web technology with a high performance
client-server architecture.
While user interfaces can be displayed in web
browsers without any installation required,
central functions such as process connection, historization, alarm signaling can be run
in highly efficient server structures. The full
utilization of the internal data structures of
27
OUR CUSTOMERS
Applications in the maritime sector
Many of the leading global manufacturers and operators of
ship and offshore plants rely on us. Together with them,
we are setting new benchmarks and achieving new successes.
30
TOGETHER ON COURSE
SAM Electronics GmbH
EVERYTHING IN VIEW AND
WELL DOCUMENTED –
ALSO ON THE HIGH SEA
34
KNOW-HOW IN
A TWIN PACK
CSI Control Systems
SAFELY THROUGH
THE FOG
TTI GmbH
TANK MANAGEMENT
WITH SAFETY
Wilhelm Sander
Fertigung GmbH
INNOVATION THROUGH
COLLABORATION
Bakker Sliedrecht Electro
Industrie B.V.
REVOLUTIONARY PROCESS
IN SHIPBUILDING
Bakker Sliedrecht Electro
Industrie B.V.
STRAIGHT TO
THE TARGET
Controllab Products B.V.
ON THE TRAIL
DIMAR-TEC PTE LTD
ALWAYS ON THE
RIGHT COURSE
SCHOTTEL GmbH
2,500 METERS
UNDER THE SEA
seatools
LOTS OF SAND –
AND LITTLE WATER
Van Oord Dredging and Marine
Contractors
68
64
60
54
56
40
44
48
52
36
TOGETHER
ON COURSE
Redundant controllers for diesel electric
propulsion systems on ships
Special safety concepts ensure a high level of reliability and
safety for a ship propulsion system. New functions are
continuously being integrated in the ship’s control system.
A collaboration between SAM Electronics and Bachmann
electronic produced an innovative concept for use with diesel
electric propulsion systems.
The Royal Princess with
diesel electric propulsion –
controlled by the Bachmann
M1 automation system.
30
SAM Electronics GmbH is a company headquartered in Hamburg, Germany, and is one of
the leading international suppliers of ship automation solutions. Its offering includes systems
for seagoing navigation and communication.
The extensive expertise of the company in the
field of shipbuilding and the shipping industry is
based on over 100 years of experience.
Concept: redundant propulsion
also saves on cabling and enables an improved
monitoring of the interfaces. If a single I/O
system fails, the decentralized arrangement of
the I/Os also ensures that not all of the system
information is lost. Appropriate processes are
triggered depending on which I/O system is no
longer available. If the fieldbus to the bridge
fails, for example, the drive saves the last control lever setting and initiates an alarm: The
failure of a steering console is indicated and
control can be switched to another console,
such as in the engine control room.
The main components of a diesel electric drive
are the diesel generator(s), frequency inverters, propulsion motor, propeller and controller.
Unlike conventional systems with two engines,
Changeover to the M1
which are each coupled directly to a propeller,
controller
with diesel electric propulsion systems the dieThe implementation of these complex consel engines drive generators. These all feed the
cepts and control tasks requires the use of a
same busbar from which both the drives as well
powerful controller. SAM Electronics therefore
as the other loads are supplied. This therefore
decided to use here the M1 automation system
makes the availability of a drive independent
from Bachmann electronic. “The scalable M1
of an individual diesel engine since a reduced
system comes with the certificates required for
propulsion capacity is still provided in the event
ship applications and offers the right controller
of a failure. Considerable importance is placed
for every performance level, whilst still ensuron a high level of redundancy, particularly with
ing downward compatibility,” explains Hermann
the design of diesel electric propulsion systems
Knirsch, drives and special systems manager of
for cruise liners. This redundancy is always
technology and design at SAM Electronics. “It
based on a single
thus offers the
fault event. Simullevel of flexibility
taneous multiple
required, whilst
» The scalable M1 system
faults are not conthe guaranteed
sidered here. The
long-term availoffers the right controller
propeller motors
ability ensures
for every performance
themselves
are
also the level of
level. «
provided with two
safety required
s t at o r w i n d i n g
for current projsystems, each fed
ects and those in
by a separate 6/3
the future.”
Hermann Knirsch,
Drives and Special Systems Manager
phase, 12/6 pulse
of Technology and Design,
power section
All
of a frequency
interfaces
i n v e r t e r. E a c h
“on board”
converter section
The M1 controller
is supplied by an independent transformer with
covers all the interfaces required: Modbus
its own circuit-breaker.
RTU / TCP, PROFINET, CANOpen and SAE
J1939 come as standard. “The Modbus UDP
Distributed control has
protocol was specially implemented for us at
major benefits
short notice by Bachmann,” explains Hermann
The SAM propulsion system controller inteKnirsch, delighted with the excellent cooperagrates the frequency inverters in the ship
tion. The controllers can also be expanded with
system. For this various remote I/O systems
serial, CAN, DeviceNet and PROFIBUS commudistributed over the entire ship are connected
nication modules as required.
to the controller via fieldbuses. The frequency
inverters are run in active standby mode. This
Integrated
means that the active controller collects the
controller library
signals and also makes these available to the
“Bachmann electronic is a cooperative partner
standby controller via Ethernet. If one controloffering excellent technical support on site,”
ler fails, the standby system can then take over
says Verena Franzen, from Drives and Special
all control tasks seamlessly. This approach
Systems Technology and Application Design
SAM Electronics is a subsidiary
of the US company, L-3 Communications. The company is headquartered in Hamburg and has
branches all over the world. The
company has been developing
systems for energy generation
and distribution, drive engineering, maritime automation, as
well as ship communication and
navigation for over 100 hundred
years.
31
at SAM Electronics. “The cooperation thus
enabled the joint and successful integration of
a SAM controller library on the Bachmann system. All the tried and tested functions are thus
still available. It offers SAM also the possibility
of using other previously unused fieldbus protocols such as PROFIBUS, PROFINET, Modbus/
TCP etc. In this way, components such as the
frequency inverters can be integrated even
better.”
project. The graphical editor enables the creation and visualization of complete functions.
The status of signals is very clearly displayed
in different colors. Faults can be localized and
rectified quickly. This graphical editor is used
for maintaining the software of the old and the
new system. Partial applications from existing
installations that are still implemented on the
previous systems can thus be used again easily
for new installations.
Clearly designed PLC editor
New functions:
Teleservice
The adaption of SAM Electronic’s own PLC editor specially developed for complex applications
considerably simplified the work processes for
the engineering and commissioning of the first
Port Wing
Center Bridge
I/Os
I/Os
Starboard Wing
I/Os
Ethernet
fiberoptic
redundant
I/Os
I/Os
ECR Panel
ECR Panel
I/Os
I/Os
Local Panel
Local Panel
I/Os
I/Os
PROFIBUS
Converter
I/Os
Propulsion
Transf.
Port 1
32
I/Os
Shaftline
Box
Port 1
SAM
Propulsion
Control
PROFIBUS
Modbus RTU
I/Os
Shaftline
Box
Port 2
I/Os
SAM
Propulsion
Control
I/Os
SAM
Propulsion
Control
Main Switchboard
AFT
Generator Control
IAMCS
I/Os
IAMCS
Ethernet
fiberoptic
redundant
Modbus TCP/UDP
Modbus TCP/UDP
Modbus TCP/UDP
Ethernet
fiberoptic
redundant
Modbus TCP/UDP
Ethernet
fiberoptic
redundant
Main Switchboard
FWD
Generator Control
I/Os
SAM
Propulsion
Control
PROFIBUS
Converter
Converter
I/Os
I/Os
I/Os
I/Os
Propulsion
Propulsion
Propulsion
Motor
Port
Motor
Port
Transf.
Port 2
Propulsion
Transf.
Starbd. 1
I/Os
I/Os
Diesel electric drive
control for a cruise liner:
Redundant controller design
with the M1 automation system.
“Another benefit of Bachmann’s M1 system
is the greater CPU performance and range
of interfaces compared to the controllers we
PROFIBUS
Modbus RTU
I/Os
Converter
I/Os
I/Os
I/Os
Shaftline
Shaftline
Propulsion
Propulsion
Propulsion
Box
Starbd. 1
Box
Starbd. 2
Motor
Starboard
Motor
Starboard
Transf.
Starbd. 2
One of the two propeller
motors in the cruise liner Royal
Princess.
used previously,” Verena Franzen continues.
fault in the power supply: The drive is immediThis enables us to integrate completely new
ately activated and runs at the old speed value.
functions into the system. “For example, it will
This offers additional safety and the availabilbe possible in future
ity of the drive is always
to access the system
ensured in the event of a
directly from shore via
fault.
» Bachmann is
satellite. This means
that diagnostics can
Successful
a cooperative
be carried out withcooperation –
partner. «
out having to send
with a future
out a technician to the
Controllers for diesel elecVerena Franzen,
ship and that expert
tric propulsion systems
Drives and Special Systems
help can be given to
must be able to be inteTechnology and Design,
the crew in the event
grated simply into the
of failures,” Verena
existing network strucFr anze n d e s cr ib e s
tures of the ship, and masthe resulting benefits.
ter the increasing require“Software updates or controller adaptions for
ments with regard to functionality, safety and
refurbishments can thus also be carried out at
availability. “With the Bachmann M1 automaa later time from shore without any problem.
tion system SAM Electronics has been comThis saves time – and money.”
pletely successful in this, ” Hermann Knirsch is
convinced. “We therefore aim to continue the
Perfect redundancy:
cooperation developed from this collaborative
hot standby
work for future propulsion system projects.”
Another new function provided is the ‘hot
standby’ function. Thanks to the high-speed
Ethernet communication between the two controllers of a drive, the standby controller can
be activated quickly in the event of a fault. The
standby controller thus takes over as soon as
the active controller fails, for example, due to a
33
EVERYTHING IN VIEW
AND WELL DOCUMENTED –
ALSO ON THE HIGH SEA
SAM Electronics implements transient recorder
with GMP232 from Bachmann
Modern ships are fitted with a large number of electronic systems. These perform
control and monitoring tasks and have become indispensable in today’s shipping.
SAM Electronics is renowned for its innovative offering in the field of automation for
maritime applications. SAM has developed a transient recorder using the GMP232
grid measuring and protection module from Bachmann as the hardware basis.
This has resulted in a compact product for the measuring of grid quality on ships.
SAM Electronics is a subsidiary
of the US company, L-3 Communications. The company is headquartered in Hamburg and has
branches all over the world. The
company has been developing
systems for energy generation
and distribution, drive engineering, maritime automation, as
well as ship communication and
navigation for over 100 hundred
years.
34
SAM Electronics is a subsidiary of the US company, L-3 Communications. The company is
headquartered in Hamburg and has branches
all over the world. The company has been
developing systems for energy generation and
distribution, drive engineering, maritime automation, as well as ship communication and
navigation for over 100 hundred years.
All relevant grid variables
in view
The growing complexity of the electronic infrastructure on ships increases the probability of
faults. Finding the cause of the fault is also
becoming more difficult. The precise logging
of processes is therefore a vital necessity. “A
transient recorder monitors and logs all the
relevant grid variables on board continuously,”
Martin Weichert, intern at SAM Electronics,
explains and adds: “This makes it possible for
a precise analysis of problems and fault situations to be made. However, a user-friendly and
easy to understand software user interface is
important here.”
GMP232 grid measurement and
protection module
For drive technology the company relies on
the M1 automation system from Bachmann.
The engineers responsible chose the GMP232
grid measurement and protection module from
Bachmann’s extensive product range to implement the transient recorder. “The high resolution and short response time of the module is
outstanding.
This therefore considerably simplifies the analysis of sporadic events in the onboard grid,” the
intern underlines the benefits of the GMP232.
» Bachmann stands out for the quality
of its modules, their reliability even
with extreme conditions and an unbeatable
support. «
Martin Weichert,
Intern at SAM Electronics,
Drives and special systems,
Technology and Design department
The MX213 processor module is used in addition as an interface to the operator terminal.
Software with extensive
features
The transient recorder can monitor up to three
currents and voltages simultaneously. “Besides
current and voltage values, it is also possible to
record the harmonics and their power factor,”
Martin Weichert explains. “The rate of change
of frequency (ROCOF) is also documented.”
The GMP232 comes with two relays. These
can be switched to enable a fast response in
the event of a fault. “Each event occurring is
recorded in a high resolution scope recording,”
Martin Weichert emphasizes the most important function of the transient recorder. The
settings required for the recording are made
in the SolutionCenter in which the recorder
is seamlessly integrated. Naturally the user
does not need any knowledge of the software
since the operation of the transient recorder is
menu-driven. The operator interface was created with the Delphi programming language.
“The duration of the recording, the sample
rate and the pretrigger can be set really easily,” Martin Weichert explains. A manual trigger
function makes it possible to view the actual
values present. The recordings are stored in
Comtrade format, the standard for oscilloscope
recordings, enabling them to be exported as
required.
the delighted intern reports. “Furthermore,
Bachmann provides excellent documentation
and continuous updates of its modules.” This
means that another project at SAM has been
successful and represents another milestone in
the long partnership with Bachmann.
The user-oriented, intuitive
operation of the user interface
was an important requirement
for programming.
The transient recorder is
integrated in the Bachmann
SolutionCenter.
First choice for
demanding tasks
Martin Weichert is extremely satisfied with the
collaboration with Bachmann. The good partnership has proved to be successful once again:
“The support is simply excellent: We were provided with expert solution proposals and were
able to clarify many open issues in advance,”
35
KNOW-HOW
IN A TWIN PACK
CSI relies on Bachmann technology for its system solutions
The Dutch company CSI Control Systems is renowned for its expertise
in the field of alarm and monitoring systems for the marine and offshore
sector. Successful operation on the market with these kinds of solutions
also requires a reliable and powerful hardware as well as extensive knowhow. Criteria that Bachmann electronic fulfills – thus providing the basis
for the successful partnership between both companies. This successful
combination was received by the market with a great deal of interest.
36
37
The 182-meter ferry Kaitaki is the largest of its kind in New Zealand waters. It is equipped with the latest alarm,
monitoring and control system from CSI and Bachmann.
The Dutch company CSI was
founded in Vlaardingen in 1967.
The ten employees are experts
in the development and supply
of alarm and monitoring systems for marine and offshore
applications. Several thousand
ships worldwide are fitted with
solutions from CSI.
38
Alarm and monitoring systems for marine and
CSI. “Bachmann has the necessary know-how
offshore applications have to take over several
and always offers innovative solutions. Another
functions. For example, the level of a ship’s
plus point is the fact that they come with all the
ballast tanks has to
relevant certifications
be monitored, and
for marine and offsometimes valves
shore use, which con» Bachmann has the
and pumps have to
siderably reduces our
be operated. The
workload as a small
necessary know-how
reliable functioning
company.”
and always offers innoof the drive must
vative solutions.
also be guaranteed.
Fast, robust
CSI has already
and affordable
Their products also
supplied thousands
Ronald Epskamp, sechave the necessary
of ships and custor manager at Bachcertification. «
tomers worldwide
mann, knows how
with the systems
important certificates
required for these
are: “175 Bachmann
Antoinette Willemsen,
tasks. “We have
modules have already
Director Business
Development at CSI
been placing our
been certified by DNV
trust in Bachmann
GL and other instituas a reliable partner
tions for use in critifor the hardware
cal applications in the
for around two years,” says Berry de Krieger,
marine and offshore sectors.” Bachmann stand
senior service engineer and co-owner of CSI.
out on account of its fast delivery, competitive
prices and the robust quality of its modules.
Innovative modules
“Another plus point is their speed,” a delighted
from Bachmann
Berry de Krieger explains. The response time
Bachmann mainly supplies CSI with I/O modwithin the CSI system is no more than ten
ules. These are used to integrate a number of
milliseconds. “In the event of an emergency
different sensors and actuators into the conshutdown of the main engine or if a bearing
troller. “The main reason for our partnership is
overheats, this is extremely important,” de
the fact that the further development of these
Krieger adds. Several alarms mostly occur at
modules is very quick,” explains Antoinette
virtually the same time. In order to reconstruct
Willemsen, director of business development at
the event so that the cause of the fault can
Wheelhouse
19" Touch
Screen
24Vdc
LMS3
Valve Control
24Vdc
24Vdc
Network
Switch
Group Alarm Units
17" Touch
Screen
LMS4
56 Digital Inputs
8 Digital Outputs
Network
Switch
128 Digital Inputs
96 Digital Outputs
16 Analogue Inputs
HCR Aft.
19" Touch
Screen
Network
Switch
Cabin Units 8597
19" Touch Screen
24Vdc
24Vdc
24Vdc
Network
Switch
Cabinet ER Aft LMS2
Cabinet ER Aft LMS1
HCR Fwd.
19" Touch
Screen
10" wide
Flatpanel pc
24Vdc
10" wide
Flatpanel pc
24Vdc
230Vac
Log printer
19" Touch
Screen
32 Digital Inputs
10 x Terminal board
Analogue
8 x Terminal board
Digital
12 x Terminal board
Analogue
4 x Terminal board
Digital
I /O
Unit
Alarm, monitoring and control system ready for many
safe journeys after the retrofit.
Bow Thruster Room
24Vdc
24Vdc
Fiber Optics Ring
Engine Control Room
Ethernet over Fiber
UTP ethernet Cat5E
be found, a fast and correct recording of the
relevant data is needed. “Only in this way is it
possible to rectify problems swiftly and effectively,” the experienced engineer summarizes.
Positive response
of the market
The partnership between CSI and Bachmann
has attracted the attention of the market.
Croon Elektrotechniek, a company based in
Rotterdam and one of the largest Dutch companies for the electrical equipment of ships, is
already using the system solution of the two
companies: “We will be using the alarm and
monitoring systems of CSI and Bachmann from
now on,” confirms Piet Faasse, technical manager for marine & offshore at Croon.
This kind of recognition is very important for
the companies involved. “The margins in the
shipbuilding and shipping industry are very
small. Only companies that can supply robust
quality at a competitive price are considered,”
Antoinette Willemsen elaborates and adds:
“Together with Bachmann we have been successful here, as shown by the feedback from
our customers.” For CSI the partnership has
definitely been a gain: “For us a long-term collaboration with Bachmann is a simple decision.”
» Delivering robust quality
products worldwide and at a
competitive price is a powerful
sales argument. Together
with Bachmann we can do this
successfully. «
Berry de Krieger,
Senior Service Engineer at CSI
39
40
SAFELY THROUGH
THE FOG
Bachmann solves complex
control loop tasks on ships
The requirements placed on a ship’s crew are extensive
and also extremely demanding. Today many of their
tasks can be taken over by state-of-the-art technology so
that the crew can concentrate on the more essential
tasks. The Institute for System Dynamics at the University
of Stuttgart is developing for this high-performance
closed-loop and open-loop control concepts, which are
also suitable for the automatic track keeping of inland
shipping. For this Bachmann electronic supplies the M1
automation system, thus offering a highly available
solution that is certified for maritime applications.
41
‘3G Navigation’ is part of the
Technology Transfer Initiative
(TTI) of Stuttgart University.
Under the cover of TTI GmbH,
small independent companies
can be formed with their own
cost center. 3G Navigation was
brought to life in November 2010
with the objective of marketing
automation concepts for shipping that were developed at the
Institute for System Dynamics.
A wide range of closed-loop control tasks are
involved on a ship. In order to relieve the work
for the ship’s master on the bridge, even complex tasks such as automatic track keeping
or maneuvering control, which require a high
degree of precision, can only function reliably
with sophisticated technical systems. The M1
controller from Bachmann offers here the
ultimate in performance and reliability: As it
already comes with the certification needed for
the sector, it is ideally suited for applications in
the demanding shipbuilding industry.
Wide range of functions
skillfully bundled
A number of different concepts for shipping
have already been implemented with Bachmann hardware at the Institute for System
Dynamics of Stuttgart University. These are
marketed under the blanket name ‘3G Navigation’, a company founded within the framework of the Technology Transfer Initiative TTI
(see margin text). “The propulsion control for
example is being used daily on five cruise liners
and six more will be implemented in the next
few months,” explains Alexander Lutz, founder
of 3G Navigation and research associate at the
Institute for System Dynamics. Between two
to four diesel engines, each with a rudder propeller, are individually controlled here by separate drive controllers. These are distributed in
two control cabinets in the machine room and
control center. A Bachmann MX213 processor
module forms the core of the automation solution, and is equipped with various digital and
analog I/O modules as well as a CAN module.
Precision: Using the results
of the position calculation, the
track keeping system is able to
detect deviations from the ideal
course. From this the control
algorithm forms manipulated
variables for the rudder and
keeps the ship on track.
42
“We have installed these elements in the control center. Even in the machine room with
high temperatures and severe vibration, the
M1 system is the ideal solution. Here we use
the robust DA3284-C CAN module,” explains
Alexander Lutz. Functions such as the monitoring of the universal drive shaft or teleservice are also provided. “The open structure
of the Bachmann controller is a real benefit to
us here. The number of interfaces available
makes it possible to implement special functions on diesel engines without any additional
effort, such as the J1939 diagnostic interface,”
Alexander Lutz emphasizes. All systems are
tested from top to bottom at his institute prior
to installation on a ship. For this the engineers
have a hardware in the loop simulator (HIL) at
their disposal.
State-of-the-art navigation
A current project is the implementation of automatic track keeping on a Bachmann controller.
“As a higher-level closed-loop control module,
the track keeping function enables the automatic guidance of a ship along nonlinear tracks
or lanes,” Alexander Lutz explains. The navigation system basically has to detect where it
is, where it wants to travel to and control the
rudder system accordingly. “An intricate problem, since rivers take a winding course through
the land and their frequent fast currents present a real challenge, particularly when there
is shipping in the opposite direction,” explains
Alexander Lutz. The automation system has
to offer the appropriate level of power since
complicated mathematical models process
» Our tasks need maximum computing
power. Bachmann also offers the openness of
the M1 system and optimum availability. «
Dr. Ing. Alexander Lutz,
Founder of 3G Navigation and research associate
at the Institute for System Dynamics
at the University of Stuttgart
information from GPS, radar, turn indicators
and other relevant ship data into logical rudder commands. Alexander Lutz summarizes:
“The core of the calculation is a model-based
closed-loop control concept that combines the
ideal route with the knowledge about the ship’s
behavior. In this way, the ship follows the set
track precisely and does not move in an uncontrolled fashion on the river.”
consumption,” Dr. Lutz explains. “We are currently working on transferring the automatic
track keeping system to a separate Bachmann
controller,” adds Alexander Lutz. “We are also
certain here that we can combine maximum
computing power with total flexibility and optimum availability.”
More efficiency, more safety
Saving fuel
This can also be combined with the cruise
control system currently under development.
This regulates the engine speeds for minimum
fuel consumption. For example, the speed is
reduced if the ship encounters increased resistant due to shallow river sections. “In such
cases, higher engine speeds result in virtually
no increase in speed. It only increases fuel
Teleservice
Applications
Cruise control
Maneuvering control
Autom. track keeping
Autopilot
Alarm system
Applications
The benefits of automatic track keeping are
obvious: The advance calculation of movement variables enables rudder operation to
be kept to a minimum. This also reduces the
fuel required. “However, automatic track keeping particularly offers an impressive benefit in
terms of safety: The ship’s master can concentrate fully on waterway traffic,” Alexander Lutz
explains. “Any disturbing water reflections,
thick fog or blinding lights in the night are
finally no longer a problem.” In order to provide
the ship’s master with a constant overview, a
map showing the waterway and the river bank
in appropriate colors combined with the current
radar image, is displayed on the monitor. The
route through the channel, the shipping lane,
is shown in black. The set course, composed of
the lane and a possible lateral offset, are overlaid in red. Additional information, such as river
kilometers and speed, is shown at the side of
the screen.
Condition monitoring
Emergency operation
Drive control
Diverse closed-loop control tasks on a ship: M1
automation systems not only
handle the drive control that
has to be implemented separately for each unit consisting of
engine and propeller. Monitoring
functions, maneuvering control,
track keeping and the autopilot
are also controlled by powerful
M1 solutions.
43
TANK MANAGEMENT
WITH SAFETY
Reducing complexity on board and increasing efficiency
Market conditions are forcing shipping companies and ship owners to achieve
greater efficiency with a reduced crew on board. A safe and reliable controller and
monitoring system are therefore essential. Wilhelm Sander Fertigung (WSF) has
developed SANSYS and the associated SANVISU operator interface, a new integrated
valve control and tank management system for ships that was type tested and
certified by GL. In the event of a disconnection or a failure of the main components,
SANSYS provides universal redundancy and network redundancy. The system is
made up of solutions from the portfolio of Bachmann electronic.
The trading company was
founded in 1926 and Wilhelm
Sander has had its own production since 1984. The Bremen-based company initially
concentrated on valves and
drives and is now a system supplier of remote control systems
for ship valves for the shipbuilding and offshore sector.
The system is what WSF GmbH calls its ‘Task
Carrier’: It gives the user complete control of
the entire tank management of the ship or
installation. SANSYS supplies reliable information about tanks – whether they are filled or
discharged – as well about valves and pumps
– whether they are working precisely. It also
supplies the crew or the owner with information about the tank contents, temperatures
and pressures.
Single or redundant controller
configuration
The company, which is based in Bremen, Germany, uses the powerful MPC240 and MC200
controllers from Bachmann for the implementation. This can be designed either as a single
or a redundant system. The use of a redundant control system for the WSF application
can be designed for both network and CPU hot
standby redundancy. The implementation is
also straightforward since the hardware components and the application software are identical for a single and redundant system. With
44
CPU hot standby redundancy, both masters
run synchronously. Bumpless switching is executed and updates can be carried out whilst the
system is running. The software hot standby
redundancy consists of an automatic system
comparison as well as a time synchronization
and automatic failover. Network redundancy
provides protection from failures in the communication structure with a switchover time
that is shorter than a PLC cycle. It features
an integrated diagnostic function for the status
and quality of the network connection and can
be used for both cyclical and acyclical communication.
Maximum safety for customers
The controller is used together with the robust
input and output system (IO system) consisting of densely packed I/O modules that are a
match for the harshest environmental conditions in the offshore sector. “Bachmann supplies a redundant system with standard components that offer our customers maximum
safety,” says Klaus Milde, technical manager
at Wilhelm Sander Fertigung. The on board
power supply is also redundant in order to prevent failures and can be switched to manual or
automatic. All devices are also protected from
overvoltage.
Further options for more
functionality
SANSY can communicate with other systems
such as a loading PC or an alarm and monitoring system (AMS) using the interfaces provided
and those established in shipbuilding. Remote
maintenance is carried out using secure Internet connections or with a local update of the
application using a memory card (PC, CF) or
standard USB stick. Several applications can
be run in parallel and autonomously using the
Bachmann controller. Water ingress detection
and/or condition monitoring can be added as
an option to standard applications such as
valve control, anti-heeling, tank content measuring, pump control, simulation, deck lighting
and fan cooling if required.
Condition monitoring, for example, can be
used to give early warning of wear on actuating elements such as valves (flaps) and pumps.
“Thanks to the extensions possible, we are well
equipped for the future and can expand our
portfolio without having to change the existing
application,” says Klaus Milde.
The SANSYS can also be controlled and the on board settings
accessed from a remote workstation far away from the ship.
Simple handling thanks
to the Project Manager
The PLC programs required are created by
45
The dialog window parts list system dialog displays the drawing of the
selected device and the spare parts list,
and enables the crew to order the correct
spare part quickly and in a targeted way.
The dialog window manual
valve system dialog shows the
operating instructions for the
selected valve, when clicking
on the tool icon. This shows the
maintenance personnel how to
change the modules.
project designers and service technicians using
the Project Manager of Bachmann’s Maritime &
Offshore Essentials (MOE). “The Project Manager enables us to automatically generate our
PLC software error-free in a short space of
time,” Klaus Milde, technical manager at WSF,
highlights and adds: “Objects such as valves,
pumps and tanks can thus be created in a
library and automatically linked with the PLC
variables.” Frequently used valve movements
with activation sequences, delay times and
the activation of the required pumps can be
defined so that the ship’s crew can call them up
and start them. This application offers greater
convenience and safety. “Thanks to the Valve
Editor we can meet customer requirements
right up to shortly before shipment,” says Klaus
Milde and adds: “All project-related data can be
parameterized. No reprogramming is required
for individual fine tuning.” An OT200 operator
terminal is installed in the control cabinet door
in the machine room to allow local operation.
All Bachmann products come with the necessary shipping approvals such as Germanischer
Lloyd (GL), Lloyd’s Register of Shipping (LR),
Det Norske Veritas (DNV), American Bureau of
Shipping (ABS) and Bureau Veritas (BV), as well
as the SANSYS and SANVISU systems.
Visualization – locationindependent and scalable
» Several applications can be run in parallel
on the Bachmann controller. We are thus
well equipped for the future and can add
condition monitoring, deck lighting and water
ingress detection to our portfolio without
having to change the existing application. «
Klaus Milde,
Technical manager,
Wilhelm Sander Fertigung GmbH
46
The associated SANVISU visualization system
provides the operator interface for controlling
and managing all SANSYS functions. Here also,
the Bremen based company relies on a product
from Bachmann and uses the atvise SCADA
system. “The innovative and scalable visualization system and a browser, or if required
Apple and Android apps, enable me to have my
alarms, tank content data and more instantly
in view,” Klaus Milde says. From the bridge or
from the ship’s office, I can access the web
application with a standard browser from any
location and from any device. The installation of any additional software is unnecessary.
Thanks to the vector graphics (SVG) used, the
application is scalable without any loss and can
Network 1
Network 2
BRIDGE
SHIP'S OFFICE
Tank measuring with SANSYS is carried out as
follows: Geometric data for the tanks as well
as other ship-related parameters from the tank
list of the shipyard, the so-called sounding list,
are read in by the Bachmann controller in the
form of a CSV file. The auto configuration of
the individual tanks through the read operation is a key element in the standardization of
the application program. Changes to the PLC
source code thus become unnecessary since
any adaption is carried out by inputs via the
operator interface of the visualization. The
reading in of a file containing the tank data
saves any labor-intensive and error-prone editing of tank lists during commissioning in the
shipyard. Data from the fuel system can for
example be transferred to the ship owner’s cell
phone. The systems from WSF also come with
a type approval from the well-known shipping
classification societies such as GL, DNV and LR.
Wilhelm Sander Fertigung offers its customers
a service for remotely monitoring systems by
its qualified personnel in order to suggest targeted measures in response to changes. For
this the system status is transferred to the
Bremerhaven company for analysis. In recent
years, the company has produced a number
of innovations and further developments. From
the former trading company, WSF, with its
engineering, service and consulting portfolio,
has grown to become a system supplier for
ship building and the offshore industry.
Loading
computer
Modbus RTU
Remote
maintenance
MACHINE CONTROL ROOM
Convenient tank
content measurement
Integrated tank management
CPU
redundant
NMEA
Modbus RTU
Modbus RTU
GPS
AMS
Res.
MACHINE ROOM
be adapted to any screen size – regardless of
whether this is for a laptop, a tablet or a smartphone. The zooming of the details of all ship
areas can be carried out without any problem.
The SANSYS dialog windows provide operators
and maintenance personnel with a particularly
convenient multi-lingual feature. The SanSys
manual system dialog explains the user interface, enabling new crew members to familiarize
themselves with the system. Clicking the icon
in the manual valve system dialog shows the
operating instructions for the selected valve.
This shows the maintenance personnel how to
change the modules. Clicking the information
icon displays the drawing of the selected device
and the spare parts list (parts list system dialog). The crew can order the correct spare part
quickly and in a targeted way. The relevant
documentation is always provided at the correct point, thus preventing panic and misunderstanding on board in the event of a fault.
1-man
bunker station
47
INNOVATION
THROUGH
COLLABORATION
Joint development of redundant and
fast controllers
48
The Bakker Sliedrecht (Netherlands) engineers and the software developers
of Bachmann electronic have developed a fully redundant solution based on
the Bachmann M1 PLC. The secondary CPU (slave) takes over system control
“bump-free” from the primary master CPU within one cycle. Furthermore,
all data for the higher-level BIMAC alarm and monitoring system is available
within the required 50 milliseconds. The next expansion stage is already
planned: The first concepts for the development of a real-time update in less
than 20 milliseconds already exist.
The reason behind the development of this
cooled drives from Bakker. Furthermore, with
fast redundant control system was the technithe dynamic positioning system, they ensure
cal planning of the Boskalis cable ship. Bakker
that the cable ship is brought to the exact
Sliedrecht has already had similar assignments
position required and is also kept there.” After
several times before. However, this time they
all, stringent requirements are placed on the
faced a new challenge: the design of a redunaccuracy of cable laying on the ocean floors.
dant control system
Interruptions in
for the power supthe power supply system, based
ply are there» The network is fully
on standard compofore absolutely
nents, suitable for
i m p e r m i s si b l e
redundant – despite the
standard Ethernet
since they can
fact that only standard
and with sufficiently
result in an
components have been
fast cycle times.
interruption of
the entire offused. This is vitally
Maximum
shore
operaimportant for maritime
reliability
tion and must
applications in particular. «
required
therefore
be
The challenge was to
prevented at all
create a redundant
costs. This has
Bachmann automathus resulted in
Anthon Knoops,
tion solution. Why,
the need for a
Manager Engineering Automation
however, was this so
redundant conbei Bakker Sliedrecht
important for Bakker
trol and moniSliedrecht? Anthon
toring system.
Knoops, head of
“Since we have
engineering, explained: “Our customer requires
already been working with Bachmann controlthe highest possible reliability for the control of
lers for approximately four years, we contacted
the propulsion systems. This cable ship has four
them for a solution,” Anthon Knoops explained.
diesel generator sets that provide a combined
“Since they work with standard Ethernet and
power of 7.000 kW. These power and control
use no dedicated control systems, their PLCs
the four azimuth thrusters and multiple moorare perfectly suited for our applications,”
ing and anchor winches via four directly waterKnoops continued.
Bakker Sliedrecht Electro Industrie B.V. was founded in the
Netherlands in 1919. The company plans, develops and implements electrical engineering
solutions in the maritime and
industrial sector. Maintenance,
technical acceptance and repair
work complete the portfolio of
the company.
49
The new N class ships sail
safely with the redundant Bachmann M1 controller.
Redundant network structure
The networks on board of the cable ship consist of a standard Ethernet configuration that
is laid out as a double ring of fiber optic cable.
The various devices are connected to this double ring, including the remote IO modules and
drives. The protocol used is Bluecom, Bachmann’s Ethernet protocol. All network devices
can be connected to this without any additional effort. “The network is fully redundant –
despite the fact that only standard components
have been used,” Anthon Knoops explains. A
key decision factor for Bakker was the fact
that Bachmann control systems are approved
by agencies such as DNV, Lloyds and Bureau
Veritas: “This is vitally important for maritime
applications in particular,” Knoops elaborates.
Real-time protocol enables
coupling of CPUs
“The people at Bachmann responded to our
requirements very positively. We started to
work with them on the development of the
redundant control system in a very relaxed and
open collaboration,” Anthon Knoops recalls.
The connection of all substations and the two
master CPUs is based on a highly accurate time
synchronization. If one of the CPUs is stopped,
the other CPU takes over the program within
one PLC cycle. “We know from tests that all
tasks are executed error-free,” Anthon Knoops
confirms. “The system as a whole is undergo50
ing final testing in a Super Factory Acceptance
Test at Bakker Sliedrecht.”
First-class products through
collaboration at the highest
level
Sander Doolaege, automation engineer at
Bakker Sliedrecht is delighted: “This redundant
control system really is unique. Bakker Sliedrecht is the first company to use this control
system in a project.” The redundant control
system is combined with the BIMAC alarm
and SCADA system from Bakker. “We have
also developed the necessary drivers for this.
The result has been very successful. We have
now reached a point where we only have to
take care of some minor adjustments,” Sander
Doolaege says. “Of course, this has only been
possible thanks to the excellent collaboration
between the people at our company and the
Bachmann team. The Bachmann engineers are
good listeners: They give us the opportunity
to explain and specify our requirements fully.
They then swiftly implemented our suggestions and ideas.” The partnership particularly
benefited from the direct and personal contact
between the engineers at Bakker and the software developers at Bachmann. “We are growing together and are thus able to meet even
major challenges,” Sander Doolaege summarizes. This means that both sides benefit from
the results of their collaboration.
» The Bachmann engineers are
good listeners: They give us
the opportunity to explain and
specify our requirements fully.
They then swiftly implemented
our suggestions and ideas. «
Anthon Knoops and
Sander Doolaege,
Automation engineers
at Bakker Sliedrecht
Visualization of the power
supply system, Bakker Sliedrecht’s BIMAC system. The
four generators which reliably
provide power for the thrusters
and the anchor and mooring
winches are shown in a redundant configuration.
Overview of the cable ship’s
onboard network.
51
REVOLUTIONARY
PROCESS IN
SHIPBUILDING
Model-based simulation with Bachmann hardware
Propulsion control systems for ships normally undergo factory testing or are
tested with prototypes during commissioning. As these systems are becoming
increasingly more complex, complete testing within a limited period of time is
difficult. Bakker Sliedrecht has joined up with Bachmann electronic and Controllab
to create a new model-based simulation process. The first ships, including the
cable laying ship Ndurance, were tested with the new process – with great success.
Bakker Sliedrecht Electro Industrie B.V. was founded in the
Netherlands in 1919. The company plans, develops and implements electrical engineering
solutions in the maritime and
industrial sector. Maintenance,
technical acceptance and repair
work complete the portfolio of
the company.
Typical testing procedures in shipbuilding are
mostly very complex. New approaches are
therefore in great demand. “We were on the
lookout for new options because the demanding requirements of the ship’s operators are
particularly increasing the complexity of the
control and monitoring systems. A reduction
in diesel and energy consumption is required
whilst maintaining maximum availability at
the same time,” Anthon Knoops, manager of
engineering automation at Bakker Sliedrecht
summarizes. “Normal test procedures are no
longer satisfactory here.” Together with Bachmann electronic and Controllab, we created an
environment that linked a virtual model with
the actual propulsion control system. All signals are exchanged between the systems.
The benefits are obvious: The test engineer
sits at his desk and can perform all the tests
via the Bakker Integrated Modular Alarm Monitoring and Control System (BIMAC). “Far more
scenarios can be run through on the virtual
model than with onsite testing,” Anthon Knoops
emphasizes the benefits of simulations.
52
Dynamic design process
The new implementation of BIMAC also makes
a new kind of design possible. “What has for
a long time been standard practice in mechatronics we are now introducing in the shipbuilding sector. Instead of using fixed CAD models,
we develop a dynamic model that is adapted
to requirements during the design process,”
explains Paul Weustink, manager of industrial
projects at Controllab. Continuous testing
enables faults to be identified already during
the design phase and the architecture of the
controller adapted accordingly. The powerful,
modular M1 controller system from Bachmann
electronic provides here the ideal basis: This
uses standard interfaces and the system is
intentionally designed as an open system. This
makes the transfer of customized programs
effortless.
Revolutionary Procedure
in Shipbuilding
BIMAC has proved to be an ideal solution in
practical applications: Bakker Sliedrecht was
given the order from Shanghai Zhenhua Heavy
The giant cable drum on the Ndurance.
Industries Co. Ltd (ZPMC) for equipping the new
companies to do far more than functional testN class ships of excavator specialists Boskalis
ing. “In future we will be able to show clearly
with the most important electronic systems.
what happens in the entire grid in the event of
The order comprised the planning and supply
a fault and how such faults can be prevented.
of the control cabinets, the multi-drive sysThis not only applies to electronic components
tems for the motors and winches, as well as
but even mechanical components,” Ronald
the controller system based on BIMAC – impleEpskamp stresses.
mented with the
Bachmann M1 conEfficient
troller. Even before
solution
» Far more scenarios can
the cable laying
Model-based simship was launched,
ulation makes it
be run through on
all relevant tests
possible to save
the virtual model than is
could be carried
time and money
possible with testing
out in accordance
for development
with the stringent
p r o j e c t s: T h e
on site. «
r e quir ement s of
construction of
the cer tif ication
expensive protoAnthon Knoops,
and classification
types for test purManager Engineering Automation
bodies. From their
poses is no longer
at Bakker Sliedrecht
headquar ter s in
necessary. Tried
the Netherlands,
and tested conthe engineers at
troller and drive
Bakker Sliedrecht could test the azimuth drives
models are then available for later use with
of the ship, couplings, gears and diesel gennew design tasks. The early testing enables
erators. The availability of the onboard grid
electronic and mechanical components to be
and the adherence to the strict redundancy
selected precisely to requirements. All this
requirements, particularly with regard to the
saves costs and thus reduces the overall budautomatic control of the ship using dynamic
get for shipbuilding. “We are happy that our
positioning, were also successfully tested. “A
efforts have been worthwhile,” says a delighted
large number of certification and approval bodAnthon Knoops. “In Bachmann electronic and
ies were interested in the results, so that they
Controllab we have found some competent
could use the test procedure for their own purpartners with whom we have jointly created
poses in the future,” Ronald Epskamp, marine
an innovative and as yet unique system in the
sector manager at Bachmann, explained the
shipbuilding sector.”
significance of the project. BIMAC enables the
The installed M1 controllers
provide a constant stream of
information on the bridge about
the onboard systems via the
BIMAC system.
Controllab was founded at the
University of Twente, Netherlands, in 1995. The company
develops and sells simulation
software for industry and shipbuilding.
53
STRAIGHT TO
THE TARGET
M1 system as target for 20-sim 4C
Controllab Products B.V. is a company based in Enschede, Netherlands,
and was founded in 1995 as a spin-off of the Technical University
of Twente (NL). It is a specialist in complex closed-loop control tasks.
The Bachmann M1 automation system was implemented as the
first industrial PLC to be the target for 20-sim 4C, the compiler
environment of its 20-sim modeling and simulation program.
Controllab Products B.V. is a
company based in Enschede,
Holland, and was founded in
1995 as a spin-off of the Technical University of Twente (NL). It
is a specialist in complex closedloop control tasks.
The 20-sim graphical modeling tool can be
used to simulate dynamic electrical, mechanical or hydraulic systems or combinations
of them. Open libraries, that allow the equations behind the block diagram elements to be
viewed and adapted, directly support the user
for more efficient modeling. Different toolboxes
for carrying out tests in the time and frequency
range, for designing control structures or for
creating three-dimensional mechanical models
and their animation ensure the considerably
user-friendly design and simulation of even
complex systems. “This enables systems to
be optimized very simply in terms of speed,
vibration and robustness,” emphasizes Christian Kleijn, CEO of Controllab Products B.V..
From the simulation directly
onto the PLC
» I can now copy the
simulated model
directly to the PLC
which controls the
actual installation. «
Tjeerd Heeringa,
Vibration and Control consultant
Heeringa Engineering
54
20-sim 4C establishes the connection of 20-sim
models with the physical system and makes it
into a time and cost saving tool for rapid prototyping. Thanks to the outstanding collaboration
between the development teams of Controllab
and Bachmann, Bachmann’s new M1com communication library can now be used to export
the C code created from the 20-sim model
directly to the Bachmann M1 system without
any intermediate stages. The result is a success that can’t be ignored In 20-sim 4C the
input and output variables of the model simulated and analyzed in 20-sim are connected
directly with the channels on the corresponding
M1 hardware modules. The entire configuration
is then compiled and loaded onto the M1 controller. In this process, the M1com is used to
automatically copy the executable *.m file onto
the PLC and install the software module in the
mconfig.ini file. The 20-sim 4C user interface is
used to start (and stop) the application, monitor and log the relevant variables, and modify
the parameters online. All parameters of the
software module are also available as SVI variables and can thus, as is usually possible in
the M1 system, be embedded in other tasks
(M-PLC, C/C++, Simulink®, etc.) or also in user
interfaces implemented with M-JVIS.
Successful users
The Dutch company Royal Boskalis Westminster N.V. is an international service company
that is active worldwide in 65 countries in the
field of maritime infrastructures, dredging and
earth moving, as well as in terminal services.
Tjeerd Heeringa, senior project engineer at the
company, has been working with the 20-sim
modeling and simulation tool for over 15 years.
He is particularly delighted with the possibility it offers to create bond graph models. This
enables him to link electrical, mechanical and
hydraulic systems in a model without having
to deal with the descriptive equations behind
them. “The ability to combine different systems in one model, to clearly display complex
systems, and to determine the power flow
directly are a great benefit when simulating
controllers used on dredgers,” explains Tjeerd
The dredger “Waterway”
Heeringa. He is pleased with the integration of
the Bachmann M1 as a target for 20-sim 4C: “I
can now copy the simulated model directly to
the PLC which controls the actual installation.”
20-sim from Controllab:
Efficient modeling and simulation with a direct connection to
the M1 automation system.
55
56
ON THE TRAIL
Monitoring fuel consumption in diesel engines
DIMAR-TEC Pte. Ltd. is headquartered in Singapore and is a specialist
in the servicing and predictive maintenance of diesel units in shipbuilding,
offshore applications and onshore plants. The company has developed
the Fuel Efficiency Controller (FEC) based on Bachmann’s M1 automation
system: A solution that ensures ship operators the most effective output
yield of the operating system.
57
DIMAR-TEC offers sensors and
technical services for optimizing
the output of ships engines.
Ship diesel engines run on fuel oil. Unlike gasCharacteristic values
oline or engine diesel, the composition of fuel
measurable for the first time
oil varies and therefore the energy content as
With 10 to 15 sensors located at different points
well. From this it is possible to calculate its calon the ship’s drive system, the Fuel Efficiency
orific value using the specific density, and also
Controller therefore measures these backthe fuel consumption
ground parameters
of a ship based on the
at which the diesel
engine specifications.
engine is run. “The
» This simplifies the
“The engine manuFEC enables us to
facturers determine
make different charinstallation of the
the SFOC value based
acteristic variables
systems worldwide
on the international
really measurable
enormously and helps
ISO3046-1 standard
for the first time and
under defined operatpresent them in real
to keep commissioning
ing conditions for the
time in relation to
and service costs
engine,” Olaf Kuss
the specified data,”
for the customer to a
explains the current
Olaf Kuss explains.
situation. Besides the
The shipping comminimum. «
density of the fuel oil,
pany can therefore
Olaf Kuss, CEO,
the air pressure, the
assess consumption
DIMAR-TEC Pte. Ltd.
ambient temperature
values very accuand coolant temrately or compare
perature, as well as
the data with the
many other parameters have to be taken into
data of other ships. This makes it possible to
account. However, an evaluation of the condraw relevant conclusions and take these into
sumption data is prone to error if these are not
account in day to day operation and during
set for a specific ship and only based on theoregular ship maintenance. The system layout
retical consumption values calculated accordand the parameterization of the FEC is carried
ing to the standard. The maritime sector is not
out by DIMAR-TEC for the specific ship. Taking
yet aware of the fact that these errors can vary
the sensor tolerances on board into account
between 10 to 25 % in magnitude.
ensures further optimization as well as the
accuracy of the overall system and the output
values.
System openness and
flexibility in demand
Meaningful graphics
allow operation at the
ideal engine operating point and thus the
optimization of fuel
consumption: Display of
the shaft power as a function of engine speed.
EC in Ser vice
mode: Simple setup of
the ship parameters.
The development of the FEC involved the
meeting of some complex requirements with
regard to operator guidance, flexibility of the
requests and the evaluation of measured data.
The unrestricted assignment of I/O signals and
measuring points is a fundamental requirement here in order for the system to be used
in different maritime peripheral environments.
“This is important since the FEC is required
to ensure the measuring and presentation of
reliable consumption data on different types of
ships, irrespective of the particular I/O assignment,” Olaf Kuss describes one of the key
requirements for the system.
Safe and straightforward
parameterization and
operation
In collaboration with Bachmann electronic,
the software specialists at Reinholz Software &
Technology GmbH in Itzehoe developed a special feature for this based on the M1 automation
58
system: free I/O assignment. “All input and
output signals can be assigned individually via
a WT205 web terminal or through FTP access
without the operator having to intervene in the
PLC program,” Karsten Reinholz describes this
service oriented function. Users can thus work
safely and simply with the system without any
knowledge of programming. “This simplifies
the installation of the systems worldwide enormously and helps to keep commissioning and
service costs for the customer to a minimum,”
Karsten Reinholz continues. A special service
mode for the software protects particular ship
parameters and prevents operator errors made
by the crew.
Consumption optimization
in sight
“The FEC based on the Bachmann automation
system enables a very accurate assessment
of the efficiency of the propulsion system for
the first time,” DIMAR-TEC boss, Olaf Kuss,
explains. However, he is also targeting the next
potential optimization factors, since fuel consumption per nautical mile not only depends
on the optimum efficiency of the engine. Many
parameters, from propeller efficiency, to rudder setting, trim and draft of the ship, right
through to the mussel fouling on the hull have
Ethernet /
» Using the Bachmann M1
as a basis we were able
to develop a system with
a flexibility and service
friendliness that was previously unachievable. «
Olaf Kuss, CEO,
DIMAR-TEC Pte. Ltd.
an effect on the power at the shaft and ultimately the resulting speed of the ship. The
next project involves the measuring of these
variables and their presentation for the assessment process.
Ideal hardware platform:
M1 automation system as the
core of the FEC.
/ Modbus TCP
5.7” web terminal
RS 232 / 422 / 485 / Modbus RTU
Analog / ISDN
Ethernet
Commissioning in
half the time with
the Scope function
59
ALWAYS ON THE
RIGHT COURSE
Powerful ship controls with the Bachmann M1 system
Schottel has become the market leader in the field of ship propulsion
systems on account of its continuous further development of
products, its insistence on the highest quality standards, as well as
its worldwide presence and proximity to the customer. In order
to meet the more demanding requirements placed on the control
systems, Schottel has recently started to rely on the Bachmann
M1 system. The product line ranges from thrusters up to 1.4 MW to
fully controllable rudder propellers up to 6 MW, right through to
complete propulsion systems up to 30 MW.
Schottel has been developing
and producing propulsion and
maneuvering systems for ships
of all sizes, application fields and
waters for over 50 years. With
over 800 employees worldwide,
the company manufactures a
wide range of rudder and control
systems.
60
Some time ago Schottel decided to extend and
optimize its Masterstick control system. This
was because of the increased demand on the
computing and processing speed of the controller and the resulting need for increased
CPU performance. This was previously not fully
achievable with the system used.
operator console (panel) the captain can select
different drive and control modes as well as
other options. The console also serves to provide the captain with different visual information.
Masterstick – the simple way
to steer a ship
The requirements placed on the new control
system were very high. After intensive searching and comprehensive tests, Schottel decided
to go with Bachmann’s M1 system. “The high
computing power, the compact and robust
design and the total openness of the M1 system absolutely impressed us,” explains Christian Böttinger, project manager for the Masterstick at Schottel. This enabled the company
The Masterstick is a control system that can
control up to 6 ship propulsion systems at the
same time. The drive thrust and ship’s direction are controlled in combination by a joystick.
The ship’s direction of movement is a result
of the movement of the joystick. The degree
of deflection determines the thrust. Using an
Performance – robustness –
openness
to implement a quick migration and meant
considerable savings in time and costs: The
complex control systems that already existed
in C-code could be integrated into the software
of the new controller simply and quickly without
any major changes.
High computing power
required
A further challenge to the ship’s steering
is the implementation of the extremely complex and computing intensive controller for
the “Auto-heading” function that automatically
maintains the ship’s course. To do this, a quick
and precise piloting of the drives is required,
which permanently reads and calculates information from a compass that is attached to
the automation system. The results from the
calculation are then continually transferred in
turn to the manually preset course so that the
selected course is always held. The difficulty
with all of this is in assigning the manipulated
variables to the drives in real-time, according
to the ship and drive specific parameters. To do
this the drive’s actual values such as the steering angle, pitch signal (the propeller’s pitch
control) or the rotation speed must be taken
into account in the calculations in addition to
the compass signal at all times. The control
of the port and starboard swaying of tugboats
presents a similarly complex problem. This too
requires real-time computing power. If a drive
fails, an optimal heading must still be precisely
and quickly determined, especially when towing
61
» The decision to go
with the M1 system
was the right one. «
Stefan Buch,
Manager Electric and Electronic
Development, Schottel
integrated web functionality of Bachmann’s
CPU also impressed Schottel. “We were thrilled
with how fast visualizations could be generated
and saved to the processor module’s compact
ﬂash card as a Java applet using Bachmann’s
SolutionCenter,” says project leader Böttinger.
With systems that are not equipped with a
touch panel, a standard web browser allows for
access to these applets. “These access possibilities and the security standards right up to
the SSL encryption also greatly ease and simplify remote maintenance,” Christian Böttinger
adds.
Brilliant functionality
ships for example into a harbor, which requires
an extremely high degree of maneuverability.
Impressive range of features
The extensive array of interfaces on the MX213
CPU allow an extremely slim design of the
required controller hardware. This allows
the compass to be directly connected to the
CPU via one of the integrated RS232 interfaces. Because the processor module can
operate up to eight different CAN buses, the
six important drive systems can also be operated directly without further intelligence. The
The Masterstick: Simultaneous control of six ship propulsion systems.
62
Beside the high performance, the range of
interfaces and the robustness of the system,
the Schottel engineers appreciate the powerful
SolutionCenter engineering tool. This enabled
the Masterstick project to be implemented on
a standard controller system in a very short
time. The key benefit was the fact that Schottel’s core expertise in closed-loop control technology, which had been collected over many
years and resulting in a large number of tested
closed-loop control C routine modules, could
be ported easily and efficiently onto the M1
controller. Schottel’s control engineers were
Gyro Compass
Wind Sensor
AFT Panel (group 4)
Visualization Masterstick
Ship Ethernet (LAN)
RS232/
RS485
RS232/
RS485
router
LAN
STB Panel (group 3)
PS Panel (group 2)
CAN
24V DI
Main Panel (group 1)
CAN
CAN
Global propulsion CAN system
connector plug
1
Switchbox 1
Switchbox 2
Switchbox 3
Switchbox 4
Switchbox 5
2
3
Switchbox 6
CAN
Portable Panel (group 5)
The high performance and the
wide range of interfaces allow an
extremely compact design for
the ship’s control system.
also impressed by the integration of MATLAB®/
Simulink® into the M1 system, which dramatically saved time during calibration. “Last but
not least, the excellent and competent customer and application support from Bachmann
engineers confirmed to us that our decision to
go with the M1 system was the right one,” Stefan Buch, manager of Electric and Electronic
Development at Schottel, sums up.
63
The Bachmann M1 automation system – packed in a
pressure tube for use at great
undersea depths.
64
2,500 METERS
UNDER THE SEA
Bachmann controller in the ROV (underwater robot)
The Dutch company, Seatools b.v., offers complete
solutions for nearly all underwater industrial
applications. For several years the company has
been employing the Bachmann M1 automation
system in its installations.
Before the customized individual solutions are
constructed, their functionality has already
been tried and tested in extensive simulations in the company’s development center in
Numansdorp, a few kilometers south of Rotterdam in the Netherlands. In addition to the
robustness of the system, the Seatools developers particularly appreciate M-Target for Simulink®, with which they generate the program
code for the Bachmann controller, saving time
and working directly from the familiar simulation environment.
Among the most remarkable developments
from the Dutch innovation center are excavator systems for precise excavation at depths of
up to 2,500 meters (Grab Excavation System
GES), measuring systems for precise placement of tunnel segments underwater (Tunnel Segment Measurement System TSMS) or
the unmanned monitoring and control system
(Remotely Operated Vehicle ROV) for precisely
maneuvering fill material pipes. The Rotterdam
company is the world leader for this last application: In the last few years, it has supplied
more ROVs to offshore and deep-sea excavation companies than any other manufacturer.
Exact filling on the sea bed
The rock dump vessel La Boudeuse of the Jan
de Nul Group based in Luxembourg, one of the
market-leading companies in excavation and
earth and stone moving in the ocean, is likewise equipped with a robot from Seatools. The
La Boudeuse holds up to 4,600 tons of rocks.
Via a movable downpipe they are precisely piled
at a depth of up to 200 meters, for example,
as a protective wall to protect subsea pipelines
from the effects of currents. The controller
system of the ROV is directly connected to the
maneuvering unit of the ship. It takes over the
dynamic positioning of the downpipe along a
predefined path, without the necessity for any
manual intervention. “The exact positioning
of the bulk material is extremely important,”
says Arjen Klop, head of sales & marketing at
The company Seatools b.v.
based in Numansdorp, south of
Rotterdam in the Netherlands,
offers complete solutions for
virtually every industrial underwater applications.
65
Seatools. After all, this is used to protect for
example offshore foundations reliably against
undermining.
» In addition to the robustness of the
M1 automation system from Bachmann,
the Seatools developers particularly
appreciate M-Target for Simulink®, with
which they generate the program
code for the controller, saving time and
working directly from the familiar
simulation environment. «
Every system is unique
Every ROV is unique, being built according to
the application field of the rock dumping vessel.
The design depends on the maximum depth at
which the fill material is to be deposited and
the temperatures and flow conditions that are
present there. These determine, for example,
the number of thrusters that are used for the
precise positioning the ROV and thus the precise orientation of the downpipe. The number
of ultrasound sensors and cameras that monitor the filling of the rocks is also crucial to the
system structure.
Efficient simulation
environment
For this, Seatools uses the Simulink® simulation
environment from The Mathworks Inc. “The
crucially important point for our work is that
the Bachmann M1 automation system is completely embedded as a target in the Simulink®
environment,” says Arjen Klop, and adds: “All
the components of the control system already
exist as Simulink® function blocks, which saves
time on the one hand, and on the other hand
also ensures that the characteristics of the
hardware used are correctly modeled.”
Full access:
hardware-in-the-loop
‘Connecting’ the two models is extremely convenient: The development environment and the
controller communicate by means of an automatically created communications relationship
via Ethernet and the TCP/IP protocol. Process
values and variables of the M1 system can be
observed in dynamic operation from the Simulink® simulation environment and recorded
over time. Values, regulator parameters or
module parameters are written by Simulink®
directly to the controller during program execution. “This enables us to adapt the parameters online, without having to regenerate the
Laborious parameterization
The difficulty in parameterizing each design is
estimating the behavior of the overall system
under actual conditions of use. Merely the fact
that the place of use may be several hundred
meters below the surface of the sea requires
the expensive and personnel-intensive commissioning of the system over several days. The
Seatools development team therefore models
the dynamic system in its entirety already in
the design process. This enables the effects
of modifications of subsystems to be assessed
before they are implemented in practice. The
simulation is based on two models: one model,
the so-called ‘world model’, describes the ROV
as a whole, taking into account the responses
of the movable parts and valves, as well as the
forces that act on the ROV from the thrusters. The second model, the ‘controller model’,
describes the complete controller system of
the ROV.
66
ROV (remotely operated vehicle)
for monitoring and controlling stone
filling by ships at sea.
The rocks precisely positioned with the ROV protect
pipelines or offshore units from
undermining and the effects of
currents.
object code for the system,” a pleased Arjen
have a completely new level of safety in the
Klop describes the considerable time savimplementation on the actual control system,
ing and accuracy of his hardware in the loop
because coding errors can be avoided,” Arjen
simulation enviKlop describes the
ronment. “ Since
extra benefit.
we can model the
» M-Target for Simulink®
mechanical and the
Shortest
enables us to achieve a
electrical behavpossible
speed and accuracy in
ior of the overall
commissionsystem together,
ing saves
simulating our systems
we can describe
money
never possible before. «
the reaction of the
“With this developactual system very
ment and hardware
precisely.”
environment, we
Arjen Klop,
can be sure that a
Head of Sales & Marketing
Efficient procontroller program
at Seatools
cess ensures
that functions in
short delivthe model, behaves
ery times
as expected on the
Seatools customers expect short delivery
actual controller,” says the Seatools engineer.
times even for individual one-off systems. The
The several days of tuning required for adaptautomatic code generation and porting to the
ing the system and controller to the actual
controller with the aid of the Real-Time Workworking and environmental conditions are no
shop® from The MathWorks and M-Target for
longer necessary.
Simulink® software from Bachmann provide
a key improvement: The time required for
porting is reduced to zero. “Moreover, when
designing complex closed-loop controllers we
67
AS MUCH SAND
AS POSSIBLE
AND LITTLE WATER
Automation of high-precision dredgers on the sea floor
When excavators are used on land, you can see every shovel moving and the
sand pile getting bigger. On the sea floor, however, this same work is
not quite as easy. A highly technical process is required instead: A large
volume of measuring data is collected continuously, the position of the
dredger has to be determined precisely, and the devices used must operate
trouble-free in extreme conditions. In addition to this, the sand has to be
separated from the water. These are all tasks for which Van Oord are specialists,
and the company was impressed by the Bachmann M1 controller system.
68
Van Oord is a Dutch-based, independent family business that offers solutions for demanding
marine infrastructure projects. Since its founding over 140 years ago, Van Oord has been
constructing and maintaining ports and building
defences for rivers and coastlines in order to
protect land from the hazards of environmental influences resulting from climate change.
The company is also active in the construction of offshore wind parks or pipelines. Land
reclamation is another one of the company’s
strengths: One of its most well-known projects
is the ‘Palm Jumeirah’ – one of the three palm
shaped islands off Dubai. For all these projects,
Van Oord has to move large quantities of sand:
Trailing suction hopper dredgers are the tools
for the task.
Large device in operation
The dimensions of these types of dredgers,
such as the Vox Maxima, are enormous: Giant
pumps with an output of over 31,000 kW convey the sand through suction pipes up to 100 m
in length from the sea floor onto the ship. The
hopper, with a capacity equal to that of 1,250
trucks, is filled in only two hours: This is the
equivalent of more than ten truck loads of sand
per minute. A kind of ‘mouth’ is fitted at the
end of the suction pipe and is provided with
‘teeth’ to loosen up the sand on the sea floor so
that it can be sucked in. The process of loading
as much sand but as little water as possible at
the same time is complicated. Several parameters have to be monitored and processed by
the control system.
outstanding: “The openness of the system
helped us a great deal: We were able to continue the use of our own tried and tested programs,” Igor Jeuken expresses his delight and
adds: “There are no limits to developments in
the future since the M1 can be expanded without any problems.” The ColdClimate modules
of the M1 controller are perfect for Van Oord:
The temperature range from -30 ° to +60 °C
and the operational safety even when condensation is present are impressive features. The
fact that the Bachmann system also comes
with the necessary type tests from ABS, DNV,
LRS, BV and GL was also a key factor.
Van Oord Dredging and Marine
Contractors is a family-owned
enterprise based in Rotterdam
(NL). The company is active in
the field of marine infrastructure projects. Van Oord has
4,500 employees worldwide in
25 branch offices. It has a fleet
of 95 ships.
Profitable collaboration
Twenty engineers from Van Oord took part
in a one-day training program in Bachmann’s
Veendaal offices in Holland, and nine of them
were then trained up as specialists for the
Bachmann controller system at Bachmann’s
headquarters in Feldkirch. “Our engineers
gained an excellent impression of the high standard maintained by Bachmann during development and production,” Igor Jeuken explains.
“We were very pleased to meet the experts
at Bachmann, who are also available to us for
» We’ve been impressed
by the openness and
flexibility of the Bachmann
M1 controller system. «
Impressive M1 performance
Van Oord has developed the Vodas automation system for these kinds of tasks. On the
Vox Maxima this determines the exact position
and dredging depth of the suction dredger, as
well as measuring the vacuum, the sand and
the water flow. As in other applications, Van
Oord was faced with the increasing demands
placed on the actual control system and its
interfaces to its Vodas system. For this reason,
the company started looking some time ago for
a replacement for its previously used controller platform and came across Bachmann: “The
Bachmann system is being used on an increasing number of ships so that we have been able
to have a closer look at it. The first impression
was already promising and we were pleased
with the compact, robust design,” Igor Jeuken, technical manager at Van Oord, describes
the initial contact. The technical evaluation
and a comparison with other controller systems showed that the operation of the M1 was
Igor Jeuken,
PA Engineer at Van Oord
special technical issues.” The combination of
Bachmann’s M1 and Van Oord’s experience will
allow more efficient and more precise work in
the future. “We intend to use the M1 more for
the automation of our processes,” Igor Jeuken
sums up. “Our aim is to own the most stateof-the-art fleet in our sector. The use of Bachmann’s M1 is an important part of this.” 69
PEOPLE
AT BACHMANN
Together with you. Every day.
We are living in a fast changing sector – customers and employees
are required daily to meet the increasing demands on automation.
That is why we place the person at the center of what we do.
We are there wherever our customers are and know them personally.
We don’t work alongside each other but with each other.
LOOKING AHEAD
TOGETHER
Progress. Respect. Responsibility.
You can rely on us: Together with you we design the right
product for the right application. Our corporate culture
and our values determine our thinking and doing, and are the
driving force in collaboration with you.
Progress
In collaboration with you, we strive
to achieve outstanding results
and constant further development.
Curiosity, courage and the willingness
to change are the fuel of our success.
We approach new opportunities
together, with commitment and
consistency.
72
Respect
Our strengths are based on
constructive togetherness.
We listen and make ourselves
strong for you.
We place importance on long-term,
healthy and partner-based
collaboration on an equal footing.
Responsibility
We impress you with the quality of our products and services.
With our comprehensive know-how we give tailored answers to
the sector-specific requirements and individual needs.
From the initial meeting to successful implementation, you benefit
from our absolute solution orientation and over 40 years of experience.
73
THE TWO BISHOPS
Why it helps to stay human in technology
We at Bachmann would never force people to follow convention but give
them the space they need to develop their own abilities. This allows
the unfolding of new and unconventional solutions – during a chess break
as much as during an impromptu meeting.
We don’t work alongside each other but with each other. This provides
the basis of trust that also connects our customers. One strategy tip
from chess says: Keep the space open for your two bishops to effectively
use their enormous scope.
This is what we want to live. Together with you. Every day.
74
75
Brochure maritime.application EN | Subject to alterations without notice © 05/2014 by Bachmann electronic
www.bachmann.info

- Bachmann

Transcription

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