1. The document discusses a project to automate a paint emulsion manufacturing process using Siemens automation software and hardware.
2. The goals of the project were to develop an automated logic for the process using ladder networks in Siemens Simatic Manager, test it on a Siemens S7-300 PLC, and provide a process visualization display using WinCC SCADA.
3. The automated solution improved productivity by 52% and reduced process time by 35% while also providing runtime monitoring, alerts, and precision process control.
2. Business Problem
A paint manufacturing company has approached Siemens
India to study and automate their process which has a legacy
system in place and increase the current production value.
Client has maintenance issues with no process visualization
tool to monitor runtime process and check alerts or trends.
3. Project goals
• This project aims at developing a logic for an automated
paint emulsion industry using ladder networks in
Siemens Simatic Manager
• The simulated and tested logic is practically realizable on
the Siemens S7-300 series PLCs a much advanced
version PLC
• It provides a process visual display of the real-time field
process on a SCADA screen using Siemens WinCC
• The automated solution will improve productivity
• The maintenance issues will be resolved with both
automatic and manual set up provided
4. Technology Used
• Simatic Manager
• WinCC SCADA
• MS Office
• Windows Paint
• VMWare
• Ladder, FBD etc.
6. SIMATIC MANAGER
• Core of every SIMATIC S7 project .
• Objects used:
Organization Blocks
Function Blocks
Data Blocks
Variable Tables
• The ladder networks make use of NO/NC
contacts, Counters, Timers, Comparators
7. WinCC
• Powerful HMI system
• Used to visualize the process
and develop the graphic user
interface for the operator.
• Allows the operator to observe
and control the process.
8. 1. Graphic Designer: The SCADA screens depicting the process in
runtime are created with the help of the Graphics Designer tool of
WinCC. It enables a visual display of the plant process by means of
various objects and animations
2. User Archive: The quantities of the ingredients to make different
emulsions is stored in the form of recipes in the archives.
3. Alarm logging: The editor for configuring the alarms is named
Alarm Logging. Alarms inform the operator about process
malfunctions and errors. Alarm Logging is used to define when and
what type of an alarm is to be displayed with what content.
4. Authorization/User Administration: The User Administrator is
used to issue and control access rights to users. The main task of the
User Administrator in runtime is to monitor system logins and access
rights
SUBSYSTEMS OF WINCC
9. 5. Tag Logging: Selection and configuration of the process values to be
archived is done using Tag logging. It enables archiving the process values
during runtime and reading them.
6. Trend Control: It displays process data as a trend in graphic form. The
trend type to be used may be selected. There is also an option of displaying
current or archived values.
7. WinCC Runtime: With the runtime software, the operator can run and
monitor the process. In particular, the runtime software has the following
tasks:
• Reading of the data stored in the database.
• Archiving of the current runtime data such as process values and
alarm events.
• Running of the process, e.g. through specified set-points or
activation/deactivation.
26. Testing and results
• The simulated automation logic was tested
• It increased productivity by 52%
• Saved process time by increasing cycle time by 35%
• Process and runtime visualization provided alerts
and precision
• Used to monitor and control the actual field process,
see its real-time status, read the alarms, service
them and test all field components for failure,
thereby providing a strong HMI system.
• Maintenance was easier with new set ups
27. References and
Citations
• SIEMENS Trainee Manuals:
• Totally Integrated Automation – I
• Totally Integrated Automation – II
• Course Material on SIMATIC HMI WinCC
