Modern software supports the entire value chain in companies that work digitally from end to end - virtual and real production worlds merge. Originally sequential processes are processed in parallel, which means that products reach production maturity earlier. By simulating complete production processes, for example, hall layout, machine design and automation can be optimized even before these components are actually built and tie up capital. With additional functions and interfaces, 'TIA Portal', the Siemens engineering framework for production engineering, is driving digitalization forward in the new version 14. It supports the digital workflow by integrating itself into the product and production life cycle via open interfaces.

From the initial idea for a new product to its production, a wide variety of information is generated - a great deal of coordination is required.

Digital workflow

With 'Teamcenter', Siemens offers PLM (Product Lifecycle Management) software that digitally maps the entire product lifecycle. It manages product designs, documents, parts lists and data. The software supports standardized workflows and change processes in order to optimize efficiency throughout the company. The aim is to make information available project-wide at an early stage in order to enable parallel working and thus shorten the time-to-market. Thanks to the project-wide consistent database, subsequent changes to the product or production design can be implemented more quickly. Version 14 of 'TIA Portal' has interfaces to 'Teamcenter'. This means that production automation remains part of a product's consistent database throughout its entire life cycle.

With 'Simatic S7-PLCsim Advanced' and 'Tecnomatix Process Simulate', it is possible to simulate the control system in the context of the entire plant.

© Siemens

Virtual commissioning is another step towards becoming a digital company. This refers to the simulation and optimization of a running machine even before the performance class of the controller has been selected and the real machine exists. The new 'PLCSim Advanced' simulation software is an option for 'Step 7' in the TIA Portal. It allows the creation of a digital twin of the 'Simatic S7-1500', with which the behavior of the inputs/outputs can be simulated. The processing speed can be adapted to a virtual time base and synchronized with other process simulations. Know-how-protected modules can also be integrated into the simulation. Configurations with several controllers can be operated virtually and also visualized via a real connected panel. To optimize the production machines, their motion sequences and the hall layout during the design and planning phase, co-simulations such as 'Tecnomatix Process Simulate' can be connected via public API interfaces to map the production process in three dimensions. An early evaluation of key performance indicators (KPI) is also possible if the virtual plant interacts with an existing MES system.

Virtual commissioning enables 'pre-factory acceptance tests' - i.e. a functional test before hardware costs are incurred. This significantly reduces the time and effort required for hardware changes. Companies can also train operators and maintenance staff at an early stage to ensure a high standard of quality in production right from the start.

Enginnering via the cloud

Version 14 also offers new possibilities in terms of cloud technology: With 'Step 7', 'WinCC' and 'Step 7 Safety', it is now possible to work in a private cloud. This allows companies to maintain and manage their engineering software centrally. Employees access the cloud via remote desktops. The hardware requirements for these workstations are low because the engineering software does not need to be installed on them - not even for online access to the controller. For commissioning, the 'Cloud Connector TIA Portal' option enables online access simply from the local workstation.

In model-based software development, automation functions created in simulation environments or on the basis of models can be transferred to the control program via the new 'Target 1500S for Simulink' option using the ODK (Open Development Kit) interface. An executable Step 7 code is generated automatically. Manual input for the translation is not necessary, which eliminates the associated risk of incorrect entries. The often very complex functions can also be included in the simulation and virtual commissioning, which ensures clarity. Simatic Software Controller', 'Open Controller' and the new 'CPU 1518 ODK' have an ODK interface.

Integrated Engineering

In the TIA Portal, 'Integrated Engineering' stands for a standardized user interface with shared services for different tasks. This consistency previously related to the configuration of controllers, HMI and drive systems, including safety and security. Version 14 of TIA Portal also integrates the 'Simatic S7 1500 T CPU' with extended motion control functionality and components for low-voltage power distribution.

The cam editor with graphical user interface provides assistance for optimizing a smooth movement sequence.

© Siemens

One example: electronic gears and cams increase the flexibility and dynamics of a servo drive solution. The new 'Simatic S7 1500 T CPU' has technology objects to control and synchronize corresponding servo drives. A cam disk editor, which is integrated into the TIA Portal, simplifies the project planning of the motion connection between the leading and following axes. Standardized PLCOpen instructions are used as part of the usual PLC project planning.

Low-voltage power distribution devices from the 'Sentron' portfolio, such as '3VA' compact circuit-breakers and '7KM PAC' measuring devices, are also integrated in the new version. The devices are parameterized and diagnosed via Profinet and enable efficient energy management.

There are also new features in the 'Simatic Energy Suite', which was previously used to configure measuring components for the 'Simatic S7 1500' - with the help of energy object tables. In these tables, the project engineer defines measured variables, units and update cycles. The corresponding program code for the controller is generated at the touch of a button.

Visualization modules that can be linked to the corresponding energy object are available for download. In the current version, energy values can now be linked directly to production data. For example, the energy consumption per day, shift, line or production unit can be determined, thus creating the basis for machine-related energy efficiency measures. Data collected by the 'Simatic Energy Suite' can be linked to 'Simatic Energy Manager Pro' for cross-site energy management.

Generate visualizations automatically

The visualization of identical or similar components only needs to be configured once with the help of the new 'Simatic Visualization Architect Sivarc', an option for 'Simatic WinCC'. Corresponding components are, for example, conveyor systems or production cells. The user configures a corresponding template once. In addition, the rules for its use are defined once. Sivarc then automatically generates the corresponding visualization according to the defined rules for each component of the same type in the project and links the HMI variables with the associated control variables. The concept also supports know-how-protected modules and safety modules.

Another important aspect of digital production is detailed diagnostics tailored to the machine. It helps to increase the availability of a machine, as faults can be reported in a targeted manner and rectified more quickly. Wire breaks or short circuits, for example, are automatically detected and displayed by the automation system's diagnostics - even if the PLC is in STOP mode. However, most faults are caused by errors in the mechanical process, such as blockages. The detection and display of these faults no longer requires complex programming. The 'Prodiag' option is new. This allows the user to select the process variables they wish to monitor. He defines critical values for these in a mask and enters the corresponding message texts, if necessary with instructions for troubleshooting.

Coordinated teamwork

The 'TIA Portal Multiuser' option enables simultaneous work on a project in a team. The project to be worked on together is stored on a multi-user server. This can be a separate server or the computer of a team member. The team members work in separate sessions, all have an overview of the entire project and are shown who is working on which device, object or function. System-supported synchronization reduces the coordination effort. If two team members access the same sub-project, the conflict is immediately signaled to both in order to avoid errors.

Transparency in ongoing operations

The 'Prodiag code viewer': The step marked on the left in the S7 graph is shown in detail on the right.

© Siemens

Efficient diagnostics, including for faults in the mechanical process, are essential for high system availability. The option of configuring plain text messages for this extended diagnosis with 'Prodiag' has already been mentioned. Monitoring can be added or existing monitoring can be changed during operation. They are transferred directly to the HMI system without additional loading.

With the help of the new PLC Code Viewer, it is now possible to display a detailed diagnosis of the corresponding point in the user program on the panel. In addition to the simple message texts, the ladder diagram LAD, function block diagram FBD and S7 graph languages can be visualized on the panel and possible causes of a fault can be quickly identified. The TIA Portal engineering software is not required on the panel for this.

'Simatic Controllers' have a web server that can be used to display variable tables, traces and the diagnostics buffer at runtime. It is also possible to design web pages for accessing diagnostic or production data for specific target groups, so that the user receives exactly the information and access options they require.

New is 'WebUX' as an option to 'WinCC' for mobile access to the plant visualization. In addition to the standard WinCC controls, this supports the dynamization of objects via script on a web server.

Access to process data via OPC UA

To ensure access to process data, the 'S7-1500' controllers have an optional OPC UA server. The OPC UA protocol not only allows the exchange of machine data, but also a machine-readable semantic description. This semantic interoperability makes the protocol a core element of Industry 4.0 and plays an important role in the digital enterprise. All an OPC UA client needs to do to access PLC data is to set a checkmark in the CPU settings. Communication can be encrypted and signed using OPC UA security mechanisms.

Author:
Rihab Ehm is Marketing Manager at Siemens.