Archive for the ‘Siemens General Motion Control’ Category

Machine builder utilizes Siemens hardware, software and communications platform on lines up to 11 layers of co-extrusion; achieving <1ºF of temp variation

Hosokawa Alpine American (Natick, Massachusetts) is a leading supplier of blown film extrusion systems to the North American plastics industry; with standard lines ranging from single-layer to 9-layer co-extrusion. The company recently rolled out its new 11-Layer X-Die line, featuring an advanced zone temperature control system that enables faster changes in recipe and data acquisition to allow on-the-fly adjustments for enhanced production performance. A recent installation of this system at a large multi-national Blown Film Company is already yielding trackable performance improvements at their plant.

Hosokawa Alpine blown film system, the X-Die with 11 lines

As Alpine’s VP of Engineering Jay Ragusa observes, “We had a very successful machine design from the 1990’s and it had performed extremely well, but we saw dramatic improvements in new controls and data transmission technology from our longtime partner Siemens together with their local distributor, Dittman & Greer (Middletown, Connecticut), a specialist in electric temperature systems and machine controls.” Among these advancements, Ragusa notes, are a new zone temperature control system, as well as the Box PC with full automation and visualization software onboard running with WinCC.

Alpine had a “light bulb” moment, as Ragusa explains. “We quickly realized this new system would give us the ability to design a machine with a complete zone temperature control system and remote I/O, plus the necessary hardware and touchscreen HMI to give operators and production management an entirely new approach to in-process control and product quality monitoring”.

The company conducted its due diligence, calling in various competitors for the business. Thorough testing in the Alpine lab pilot plant was conducted, with strong emphasis on component failure analysis, system fault detection and the robust qualities of the competing systems for 24/7 use in the harsh environment of the blown film industry.

“Beyond those benchmarks of evaluation,” Ragusa continues, “we were seeking a system with enhanced flexibility, so we could provide our customers a better way to change recipes in a quicker, more efficient manner, while maintaining a very high degree of product quality.”

Siemens motor and drive assembly, plus PLC and HMI, control the processing and allow fast recipe changes.

Siemens motor and drive assembly, plus PLC and HMI, control the processing and allow fast recipe changes.

After the completed testing and evaluation process in-house at Alpine, the decision was made to move forward with the Siemens system, comprising a new zone temperature control, Profinet communication platform, motors, drives, PLC and touchscreen HMI.

As the new system and other improvements were implemented into the first machine built and test-run at Alpine, a documented higher yield was achieved, with a higher degree of control accuracy. Ragusa notes there is an additional benefit of real-time monitoring and adjustment of all machine conditions.

This new machine included up to 120 separate temperature control zones. According to Ragusa typical systems allow for a 2º-3ºF variation in zone temperatures; with the new system that variation is reduced to less than 1ºF.

Jay Ragusa also details other system improvements made by Alpine on the new machine. “The new industrial flat panel on the PC has a wider screen for easy viewability. Plus, our older system, while modular, had little remote I/O and the new system brings us that benefit, too. The auto-tune function, combined with the better CPU in the PLC, gives us a much stronger package of internal software in combination with hardware. Since we were making the transition within a Siemens protocol, no significant software conversion was required and all data feeds continue on Profinet.”

A temperature accuracy better than 1ºF per zone yields superior, consistent quality in blown films.

A temperature accuracy better than 1ºF per zone yields superior, consistent quality in blown films.

Data transmission overall has also improved, he notes, as the communication speeds are significantly faster, plus the open architecture of the system can convey all data to the other departments seamlessly.

Two more advantages of the Siemens system include the plug-and-play remote I/O hardware and the open architecture of the control system. The quick- connect, plug-and-play remote I/O hardware reduces installation, commissioning and replacement time of the system hardware. The open architecture of the control system allows end-user adjustment of control parameters to suit each specific application and stores thousands of recipe data points. Alpine routinely customizes the front end of the controller HMI to facilitate easier customer training and a seamless transition from legacy systems for operators in use.   As Ragusa notes, “The field wiring savings alone are incredible, as our machines are fully tested in our facility, then dismantled and assembled onsite at the customer location.”

On the maintenance side, a customer can quickly determine component faults and either take corrective action or literally order a new component from the onboard controller, as the Siemens protocol offers internet connectivity.

 

For more information on this story, please contact:

HOSOKAWA ALPINE AMERICAN
5 Michigan Drive
Natick, MA 01760
Phone: 508-655-1123
www.halpine.com
Attention: Jay Ragusa, VP of Engineering or Alana Carr, Marketing Coordinator

or

SIEMENS
Digital Factory
Factory Automation
5300 Triangle Parkway
Norcross, GA 30092
Phone: 770-871-3848
www.usa.siemens.com/drives
Attention: Hollie Davis or Alisa Coffey

 

About Siemens USA
Siemens Corporation is a U.S. subsidiary of Siemens AG, a global powerhouse focusing on the areas of electrification, automation and digitalization. One of the world’s largest producers of energy-efficient, resource-saving technologies, Siemens is a leading supplier of systems for power generation and transmission as well as medical diagnosis. With approximately 348,000 employees in more than 190 countries, Siemens reported worldwide revenue of $86.2 billion in fiscal 2015. Siemens in the USA reported revenue of $22.4 billion, including $5.5 billion in exports, and employs approximately 50,000 people throughout all 50 states and Puerto Rico.

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Hahn Automation provides “glocal” solution to ThyssenKrupp damper business for stacking and assembly of assorted product types; enables quick recipe changes

Stackers and 4-axis FlexPickers integrated by Hahn Automation for ThyssenKrupp; used in the flexible production of various shock absorber products for customers like Mercedes, Porsche and other high-performance automobile manufacturers.

Stackers and 4-axis FlexPickers integrated by Hahn Automation for ThyssenKrupp; used in the flexible production of various shock absorber products for customers like Mercedes, Porsche and other high-performance automobile manufacturers.

ThyssenKrupp Bilstein of America is a leading supplier of premium shock absorbers, struts and suspensions to the auto, truck, racing and other markets. With its recent development of the DampTronic® Sky, which provides continuously variable damping force adjustment of the shock absorber to accommodate road and driving conditions, the company, with U.S. operations based in Hamilton, Ohio, recognized the need for greater flexibility in its production on a global scale. With a substantial assortment of products for OEM and aftermarket alike, ThyssenKrupp required a scenario for fast recipe changes, with flexible and high-accuracy production of frequent short runs to suit its product demands in the market.

Further, with global operations in its manufacturing, the company sought to partner with an automation supplier who would mesh well with the culture of ThyssenKrupp and the engineering requirements this challenge presented. The solution came their way in Hahn Automation, based in Germany, with its U.S. operations headquartered nearby to ThyssenKrupp’s damper business, in Hebron, Kentucky.

The DampTronic® Sky technology from ThyssenKrupp provides constant variable pressure, adjusted in milliseconds to accommodate road and driving conditions, utilizing two continuously variable valves to adjust the damping force in both extension and compression modes.

The DampTronic® Sky technology from ThyssenKrupp provides constant variable pressure, adjusted in milliseconds to accommodate road and driving conditions, utilizing two continuously variable valves to adjust the damping force in both extension and compression modes.

This combination provided what Dave Vibbard, Senior Process Engineer at ThyssenKrupp terms a “glocal” relationship, a portmanteau word made from global and local.   Correspondingly, John Baines, president of Hahn Automation, says, “We also work under the philosophy that we should build it where it gets used, so we needed a partner for the controls and application engineering assistance who could work seamlessly with both our German and U.S. operations. We found that supplier in Siemens and their local solution partner, C&E Sales.” For the project, the control supplier furnished all drives, PLCs, master HMI and remote control pendants to give freedom of movement to the operators, as they work around the cell stations. Siemens and C&E Sales also provided Hahn their application engineering assistance and the TIA Portal, an engineering network from Siemens which allows all programming of motion controllers, distributed I/O, HMI and other devices through a single point of command. In addition, TIA Portal maintains a library with the operating protocols, hardware designations and performance characteristics of task-specific projects, enabling subsequent recall, system reconfiguration on-the-fly and substantial engineering time savings for the integrator and end user alike. Hahn was able to utilize the TIA Portal at every step in the configuration and commissioning of the work cells devised for ThyssenKrupp on this project. As Baines notes, “The diversity of products being produced were all nonetheless similar in nature and mechanical composition, so many of the motion control commands and assembly sequencings could be done using the library of programmed information in the TIA Portal. Siemens provided us considerable assistance on this project, though we had previous experience with this engineering network.” Baines further notes the TIA Portal resulted in significant cost and time savings for Hahn and ultimately the end user.

Siemens drives, HMI, remote operator pendants and PLC technology operate the system. Hahn utilizes the Siemens global support of its products, while sourcing many components locally, thus the term “glocal” was coined.

Siemens drives, HMI, remote operator pendants and PLC technology operate the system. Hahn utilizes the Siemens global support of its products, while sourcing many components locally, thus the term “glocal” was coined.

On this project, Hahn provided ThyssenKrupp the first of several cells, comprising six “valve stacker” modules for the pre-assembly, kitting and riveting of the shock absorber washers and piston rod assemblies, plus the gas and oil fill, welding and functional testing procedures. For each model produced, an assortment of washers with various profiles and dimensions is stacked on the piston, assembled and then the shock absorber body is filled with gas and oil, all to pre-programmed levels. The “recipe” for each model made is stored in the HMI onboard, which drives the individual module PLCs. At each station in the cell, an operator can instantly visualize the recipe in progress and enjoys the free movement around the cell, using the remote control pendant. As the model changeover is required, the master recipe exports the particular data requirements to each module, and then the ramp-up of the overall cell begins anew. Washers of various sizes and profile configurations are used for the buildup of each model produced, so the required components are brought to the assembly stations by a series of 4-axis ABB iRB 360 FlexPickers and ceiling mounted Epson G10’s, utilizing Selective Compliance Articulated (Assembly) Robot Arm (SCARA) technology. Functionally, the various commands are executed via the PLC, an S7-1500 from Siemens, which features seamless integration with the TIA Portal, as well as fully integrated onboard safety and security modules.

Each module in the cell is run by a slave PLC, monitored and controlled by the master HMI.

Each module in the cell is run by a slave PLC, monitored and controlled by the master HMI.

As Baines explains, “The setting adjustments are quite substantial for each damper product produced, so the load on the control system required strict monitoring and validation. There’s the master cell with six modules, including four valve stackers and two final assembly stations. Interestingly, half our design and assembly work was done in Germany and half was done here in Hebron, Ky., where we also did the final configuration of the control platform, runout and performance evaluations prior to delivery to ThyssenKrupp.” He noted the support provided by Siemens, both in Germany and local to his facility. Baines also cited the upgrade to the higher level Simatic S7-1500 PLC as a significant advantage for Hahn in the overall achievement of this project’s success. He particularly noted the safety and system security features, plus the fast response time and easy commissioning of this PLC platform for his team and TK personnel.

Greg Earle, VP for sales at Hahn, adds, “The Siemens TIA portal was a terrific engineering tool, as we were able to configure all the motor and drive components in a tag-based protocol for the individual slave PLCs and the master HMI. It was a very fluid connection process and, in the field, the operators enjoy the added benefit of movement, using the remote pendants provided with the system.” As each recipe is called up, he added, the changeover time is significantly reduced, compared to the previous systems in use at ThyssenKrupp. The single supplier for the new component feed systems is located in Germany, so the presence of both Hahn and Siemens there was a further advantage to TK on this project.

Remote pendant gives the operators freedom of movement around the cell

Remote pendant gives the operators freedom of movement around the cell

Vibbard of ThyssenKrupp comments, “Hahn was extremely competent and also price-competitive on this project, a very desirable combination in any business relationship. They were able to complete the build and execute the handshaking between the modules, with full verification on performance, error tracking, safety considerations, fault recovery and alarm alerts.” He noted an extra benefit on the operator screens was a dual language capability, so immediate access and troubleshooting could be accomplished by the engineering teams both in Germany and America.

In use, all the communications in the cell, whether from the robotics PLC, Siemens hardware and software systems or Hahn proprietary logic, are transmitted on a field bus to a single point of control and command, according to Vibbard, who cites this seamless protocol as a significant upside for our process engineers and maintenance personnel alike. “The assembly and testing procedures are all TCP/IP friendly, so the cell controls are easily accessible both by our team and remotely by Hahn for troubleshooting and faster resolution of any issues.”

Washers of various sizes are stacked on a piston rod for assembly, with differing levels of air and oil fill to suit the specifications of the individual products at ThyssenKrupp; modular, programmable work cells provide great flexibility in production.

Washers of various sizes are stacked on a piston rod for assembly, with differing levels of air and oil fill to suit the specifications of the individual products at ThyssenKrupp; modular, programmable work cells provide great flexibility in production.

According to the official ThyssenKrupp description of the new shock absorber technology that partially drove the development of this project, “The new DampTronic® Sky damper (shock absorber) is a further milestone in resolving the conflict between driving comfort on the one hand – an aspect of particular interest in the premium segment – and the driving safety and agility of the car, on the other hand. In this new generation, two continuously variable valves adjust the damping force in each damper: one valve controls the rebound phase – i.e. the force that ensues when the wheel travels down – and the other controls the compression phase. Using the data it receives from the acceleration and wheel-path sensors, the control module of the suspension system can individually adapt the damping forces for each wheel within just a few milliseconds to eliminate the effects of rough road-ride conditions that may detract from the driving comfort for the passengers, while at the same time controlling the dampers in such a way that the chassis is stabilized to the best possible degree. Thanks to the use of two adjustable valves, the damper is also able to ensure that the damping force can be adjusted according to the skyhook principle even in the high-frequency spectrum of the wheel vibrations. By independently adjusting the extension and compression forces, the new ThyssenKrupp DampTronic® Sky damper constitutes the high-end system in the semi-active damper segment.”

The customer here, ThyssenKrupp, expects significant improvements in the production schedules with the Hahn Automation master cell on the floor at the facility in Hamilton, Ohio.

Baines concludes, “The relationship we established with and the solution we proposed to ThyssenKrupp would not have been possible without the assistance of the Siemens team, both here in our area and in Germany, supplying product, engineering know-how and controls expertise in both locations.”

A “glocal” success, indeed.

For more information on this story, please contact:

SIEMENS
Digital Factory
Factory Automation
5300 Triangle Parkway
Norcross, GA 30092
Phone: 770-871-3848
www.usa.siemens.com/drives
Attention: Hollie Davis, Sandra Tigert or Alisa Coffey

Or

HAHN AUTOMATION
3012 Kustom Drive
Hebron, KY 41048
Phone : 859-283-1820
www.hahnautomation.com
Attention : John Baines

Or

THYSSENKRUPP BILSTEIN OF AMERICA
8685 Bilstein Boulevard
Hamilton, OH 45015
Phone: 513-881-6394
www.bilsteinus.com
Attention: Fabian Schmahl or Dave Vibbard

 

About Siemens USA
Siemens Corporation is a U.S. subsidiary of Siemens AG, a global powerhouse focusing on the areas of electrification, automation and digitalization. One of the world’s largest producers of energy-efficient, resource-saving technologies, Siemens is a leading supplier of systems for power generation and transmission as well as medical diagnosis. With approximately 348,000 employees in more than 190 countries, Siemens reported worldwide revenue of $86.2 billion in fiscal 2015. Siemens in the USA reported revenue of $22.4 billion, including $5.5 billion in exports, and employs approximately 50,000 people throughout all 50 states and Puerto Rico.

 

Siemens announces immediate availability of two new compact quick disconnect switches used with the popular Sinamics G120D distributed drives. This new disconnect switch design mounts directly onto the input power connector of the drive and locks in place to provide a tight, reliable interface, in accordance with ISO 23570-3. Many applications exist in the decentralized distributed power environments, where control cabinets are being replaced with IP65 protected products.

Two versions of the new disconnect switches are now available. A 10-amp rated switch is offered for G120D drives up to 4 kW (5 hp) and features a daisy-chain Power-Y-junction box design to enable power wiring to additional G120D drives. A 25-amp rated version is offered for the heavier-duty 5.5 kW (7.5 hp) and 7.5 kW (10 hp) drive models. This larger unit features a standard Q4/2 pin configuration.

Through the introduction of these new disconnect switches, Siemens can now offer system integrators, OEMs and field maintenance personnel immediate availability to a drive and connector package for a number of applications, according to Robert Soré, product marketing manager, Sinamics general purpose drives at Siemens. “We’ve developed this product line in tandem with our solution partner Harting and we see it expanding our presence in the distributed, decentralized control markets, which include automotive, packaging, metals processing, food and beverage, as well as general conveyorized material handling.”

 

For more information about these new quick disconnect switches, please visit:
www.usa.siemens.com/sinamics-g120d

For specific product information and inquiries, call (800) 879-8079 ext. Marketing Communications or send an e-mail to: SiemensMTBUMarCom.industry@siemens.com.

 

Motor-integrated drive offers onboard safety features and communications

Siemens introduces the Sinamics G110M, a motor-integrated drive for Simogear gear motors, offering flexible control, integrated safety, simple installation and a space-saving design.  With a high degree of protection — up to IP66 — this new gear motor drive provides the perfect solution to most material handling-related challenges, including conveyors, warehousing, logistics, baggage and cargo handling, post and parcel shipping, plus numerous industrial applications in the automotive, appliance and test stand industries.

Simogear gear motors offer high torque density, low noise and high efficiency — and now with Sinamics G110M, it becomes easier for designers and system builders to integrate gear motors into a variety of control architectures. Plug connections for onboard I/O ensure fast installation, while optional power connectors deliver even more time savings.  The system is delivered pre-configured and the drive offers simple yet comprehensive onboard diagnostic features.  Options such as internal braking resistors and motor brakes — operational simultaneously — and integrated features such as “Quick Stop” and the limit switch function make this system ideal for conveyor applications.

For uses requiring safety technology, the Sinamics G110M offers integrated safety functions such as “Safe Torque Off” (STO), which can be activated via a fail-safe input or via Profisafe, without needing additional safety monitoring components.

Sinamics G110M features integral USS/Modbus RTU, Profibus and Profinet / EtherNet/IP communication profiles.

To watch a video of the Sinamics G110M for the material handling industry, please visit: https://www.youtube.com/watch?v=GgDxptBqpHg

For specific product information and inquiries, call (800) 879-8079 ext. Marketing Communications or send an e-mail to: mc.us@siemens.com     

 

SINAMICS_selector_app_title_imageSimply practical. Simply good.
Drive selector app enjoys growing polarity

For some time, it has been apparent that mobile apps have been spreading more and more across the industrial environment and have become a popular medium among users. One special feature in this field is the variable frequency drive app for the easy selection of all necessary components from the respective corporate portfolio. The online selection is always up-to-date, available in many different language versions and saves the user time — laboriously poring over catalogs is now a thing of the past.

Due to the special requirements in some cases, selecting the right drive is not always straightforward and can often waste valuable time. After all, the fields of application and the requirements regarding operating behavior and costs are wide-ranging. Whether the drives are used to operate pumps, fans or compressors, or to drive conveyors, mixers or kneaders, it is important to find the appropriate drive for the required range of performance and voltage quickly and easily for each of these applications. And wherever possible, this must be done without the need for expert knowledge of drive technology.

The Sinamics Selector app helps you to select a suitable drive in just a few simple steps and also suggests alternative options.

The Sinamics Selector app helps you to select a suitable drive in just a few simple steps and also suggests alternative options.

Assembling components by smartphone

In order to simplify this sometimes complex process, Siemens, for example, has been offering its Sinamics Selector app free-of-charge. This is a solution that displays the entire collection of products from the portfolio of low-voltage frequency drives — Sinamics V20, G120C, G120 and G120P — on the most popular iOS and Android smartphones and can be used both online and offline. This offline capability is of particular importance in regions which do not have full cellphone coverage. Since Version 4.0, not only have brochures, product videos and application examples (Fig. 1) been available to users and electrical distributors, but also more language versions.

Everything up-to-date

Katharina Roehrlein, marketing manager for Sinamics drive systems at the Siemens Digital Factory division, explains additional innovations: “With the latest update, Version 5.0, we have adopted the second generation of the Sinamics G120 modular Frame Size D-E, as well as the Sinamics V20 Power Extension up to 30 kW, into the app. In addition, we have integrated more technical values such as resistance, peak performance and continuous power ratings into the logic of the app. And for good reason, because we want to make it as easy as possible for our customers to find the right drive in order to save valuable time.”

As a matter of principle, when assembling the appropriate components, the Sinamics Selector app offers not only a product-specific, but also an application-specific approach. In other words: either the user knows from the outset which frequency drive is required, or the app guides the user step-by-step to the right drive by asking for key parameters (Fig. 2). The information held by the Sinamics Selector app is kept up-to-date at all times by the central storage of data and continuous updates. Bob Hendrickson, applications engineer at Wesco, one of the largest distributors in the United States, regards this as an enormous advantage over conventional catalogs, especially when the app can save him a great deal of time in preparing a bid. “The Sinamics Selector app is very helpful as it lets me create a complete bill of materials for a customer offer very quickly. This option saves me a huge amount of time since I no longer have to create bills of materials by hand. The app also makes it easier for me to respond to queries arising from projects when I’m on the road and don’t have any catalogs or other documents to hand.”

Bid preparation made easy

After choosing the required type of frequency inverter, the rated output, device options and accessories can then be selected and adapted individually — if necessary, also with the support of the respective Siemens contact, whose details are also stored in the app. Once the components have been selected, the user has the option of either saving or emailing them. To make it easier for end-users to get in touch later, the headers and footers of the email can be adapted individually, for example, with personal contact information. The overview includes actual part numbers for all of the selected components. This can be used as information for the customer, but also as the basis for ordering specific components or preparing an offer at the local dealer/distributor. Kevin Young, application engineer at electrical distributor C&E Sales Inc., in the U.S., also confirms this: “I really like the Sinamics Selector app. I copy the result into my bill of materials, which enables me to immediately present a bid to my customer.” His colleague Jay Swank adds, “I use the application almost every day now.”

Over 15,000 downloads and counting…

Since the introduction of the first version, the Sinamics Selector app has been installed 17,000 times on mobile devices worldwide — and the number is still rising. Apart from Europe, China and the U.S., this trend is being led by key markets such as India, Brazil and Mexico. “It is particularly important in these countries to have a solution in the local language which also functions faultlessly offline. The email containing the results can be stored and then transmitted when sufficient network capacity is available again,” adds Ralf Weber from the Siemens Digital Factory division responsible for the app.

Think global, act local

Due to the great success of the app in all language versions offered thus far, Siemens is planning the integration of additional languages, as well as the continuous support and expansion of the product range covered. The main focus here is on Europe, particularly the eastern regions.

 

For more information about the Sinamics Selector app, visit:
www.usa.siemens.com/sinamics-selector-pr

Access – online and offline
Cost – Free-of-charge
Platforms – iOS, Android
Languages – English, German, French, Italian, Spanish, Portuguese, Chinese, Russian, Korean and Turkish

Quicklink to the Sinamics Selector app: http://ow.ly/WFRe5

 

For more information on this story, please contact:

SIEMENS INDUSTRY, INC.
DIGITAL FACTORY
MOTION CONTROL — GENERAL MOTION CONTROL
390 Kent Avenue
Elk Grove Village, IL 60007
Phone: 847-640-1595
Fax: 847-437-0784
Web: www.usa.siemens.com/motioncontrol
Email: mc.us@siemens.com
Attention: John Meyer, Manager, Marketing Communications