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Auto Code Generation and Rapid Brewery/Distillery Automation
The document outlines a presentation on rapid brewery and distillery automation by Ryan Landwehr from DMC, Inc. It introduces the Siemens brewing template, which is open-source and customizable for craft brewers, detailing its components, benefits, and successful case studies, including Witherspoon Distillery. The presentation emphasizes the ease of use, scalability, and support provided through Siemens and partners, showcasing a live demo of the automation systems.
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Auto Code Generation and Rapid Brewery/Distillery Automation
- 1. Auto Code Generation and Rapid Brewery/Distillery Automation RyanLandwehr Project Director, DMC, Inc. usa.siemens.com/summitUnrestricted © Siemens 2019
- 2. 2019 Automation Summit •Title: Rapid Brewery/Distillery Automation and Success Stories • Track: PE • Presenter: Ryan Landwehr • Company: DMC, Inc. • Session # (for your survey): 1.2
- 3. DMC Overview Established in1996, offices in Chicago, Boston, & Denver and customers throughout the world Established in 1996, DMC serves customers worldwide from offices in Chicago, Boston, Dallas, Denver, Houston, New York, Seattle, and St. Louis employees & growing 170+
- 4. DMC has thehighest number of S7 certified engineers in the US. Siemens Expertise 35+
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- 6. Industries Served Energy &Utilities Printing Automotive Food & Beverage Semiconductor Chemical Oil & Gas Engineering Specialty Machinery Consumer Goods Packaging Machinery Programming Telecommunications Defense Contracting Pharmaceutical Test & Measurement
- 7. Ryan Landwehr Project Director,DMC Dallas • BS Electrical Engineering • Rose-Hulman Institute of Technology • With DMC since 2014 • Siemens Certified Professional (4 years) • PLC/HMI/SCADA, Motion, Failsafe Systems • Dedicated Craft Brewery/Distillery Consumer Presenter Info
- 8. • Who likescraft beer? • Craft spirits? • Anybody tried brewing their own beer? • Distilling their own spirits? Audience Info
- 9. Siemens Brewing Template: RapidBrewery/Distillery Automation
- 10. 1. Siemens BrewingTemplate Intro 2. Project Layout 3. Creating a Project 4. Case Study: Witherspoon Distillery 5. Other Brewing Template Successes 6. Live Demo!
- 11. 1. Siemens BrewingTemplate Intro 2. Project Layout 3. Creating a Project 4. Case Study: Witherspoon Distillery 5. Other Brewing Template Successes 6. Live Demo!
- 12. • A robustand modular brewing template geared towards craft brewers and distillers. • Controls System Components (recommended): • TIA Portal • WinCC Professional What is the Siemens Brewing Template?
- 13. • Open Source– Customize it to meet your application needs Software Overview
- 14. • Based onknown Craft Brewery designs and 35+ years of Brewing Industry Experience Software Overview
- 15. • PLC Compatibility •S7-1200 (Ladder Logic) • S7-1500/ET200SP (S7-Graph) Software Overview
- 16. • HMI Compatibility •WinCC Comfort, WinCC Professional, WinCC 7.4 • Basic? Yes…but no Software Overview
- 17. • 4 VesselBrewhouse with Fermentation Vessels • Mill, Mash Tun, Lauter Tun, Wort Kettle, Whirlpool • Add/Remove/Customize modules as needed Default Setup
- 18. • Control Modulesdeveloped using Siemens Open Library Uses Standard Library
- 19. • Fully testyour system before installing Built-In Simulation
- 20. • Event DrivenReporting built-in Built-In Reporting
- 21. • Enter, save,and modify recipe library using WinCC Recipes Built-In Recipe Management
- 22. • OpenNess –Customize program your CMs using MS Excel • SiVArc – Customize program HMI using MS Excel Rapid Customization
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- 25. • (Almost) Anyone! •Not just limited to breweries, distilleries can be supported Who can use Brewing Template?
- 26. • Built-in supportfor Grain Handling, Brewhouse, and Fermentation Vessels, but can easily be adapted to control: • Filtration Systems • Clean-In-Place (CIP) Systems • Utilities (Boiler, Cooling Towers, Chillers) • Bottling/Packaging Where else can you expand to?
- 27. • Easy touse, scale, and customize both hardware and software • Fully Tested Demo – based on 35+ years of brewing market experience • Standard Programming Library – Siemens Open Library • Support: Siemens, Siemens Partners, and System Integrators • Training Courses provided regularly by SiTrain Why use it?
- 28. 1. Siemens BrewingTemplate Intro 2. Project Layout 3. Creating a Project 4. Case Study: Witherspoon Distillery 5. Other Brewing Template Successes 6. Live Demo!
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- 33. Mash Cooker SubsystemRunning
- 34. Lauter Tun SubsystemRunning
- 35. Wort Kettle SubsystemRunning
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- 41. 1. Siemens BrewingTemplate Intro 2. Project Layout 3. Creating a Project 4. Case Study: Witherspoon Distillery 5. Other Brewing Template Successes 6. Live Demo!
- 42. Openness Setup • DeviceList Generated using included MS Excel Sheet Unit UnitName Tag Name Description Style Network Comment IO Field 1 1Mill M-801 Malt Mill Motor Motor Horizontal M801 1Mill M-802 Silo to Mill Auger Motor VFD Horizontal M802 1Mill M-803 Specialty Malt to Mill Auger Motor Motor Horizontal M803 1Mill M-804 Mill to Grist Case Chain and Disk Motor Motor Horizontal M804 1Mill M-805 Grist Case to Mash-in Chain and Disk Motor Motor Horizontal M805 1Mill AV-801 Grain Inlet Valve Valve Vertical AV801 1Mill AV-802 Bulk Bag #1 Bottom Valve Valve Vertical AV802 1Mill AV-803 Bulk Bag #2 Bottom Valve Valve Vertical AV803 1Mill WT-801 Malt Silo Weight AnalogInput Horizontal WT801 1Mill WT-802 Grist Case Weight AnalogInput Horizontal WT802 1Mill WT-803 Bulk Bag #1 Weight AnalogInput Horizontal WT803 1Mill WT-804 Bulk Bag #2 Weight AnalogInput Horizontal WT804 2MashCooker M-101 Mash Pump Motor Motor Horizontal M101 2MashCooker M-102 Mash Mixer Motor Motor Vertical M102 Subsystem Index Subsystem Name Device Name Device Description Device Type Used for SiVArc Used for Tag Declaration
- 43. Run the OpennessTool1. Open Portal with Openness API 2. Open Template Shell Project
- 44. Run the OpennessTool3. Load Excel File 4. Generate Project
- 45. Results! Unit UnitName TagName Description 1Mill M-801 Malt Mill Motor 1Mill M-802 Silo to Mill Auger Motor 1Mill M-803 Specialty Malt to Mill Auger Motor 1Mill M-804 Mill to Grist Case Chain and Disk Motor 1Mill M-805 Grist Case to Mash-in Chain and Disk Motor 1Mill AV-801 Grain Inlet Valve 1Mill AV-802 Bulk Bag #1 Bottom Valve 1Mill AV-803 Bulk Bag #2 Bottom Valve 1Mill WT-801 Malt Silo Weight 1Mill WT-802 Grist Case Weight 1Mill WT-803 Bulk Bag #1 Weight 1Mill WT-804 Bulk Bag #2 Weight 2MashCooker M-101 Mash Pump Motor 2MashCooker M-102 Mash Mixer Motor
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- 47. What’s next? • BaseProject: • All Device FBs and Global/Instance DBs have been created • Subsystem FBs have been created • What’s left? • Add Sequencing Logic • Add OB’s • Run SiVArc to generate base HMI project
- 48. Screen Name Device MillValve Horizontal Mill Valve Vertical Mill Analog Input Mill Analog Valve Mill PID Mill Flow Totalizer Mill Flow Indicator Mill Motor Horizontal Mill Motor Vertical Mill Motor Pump Horizontal Mill Motor Pump Vertical Mill VFD Motor Horizontal Mill VFD Motor Vertical Mill VFD Pump Horizontal Mill VFD Pump Vertical Mash Cooker Valve Horizontal Mash Cooker Valve Vertical Mash Cooker Analog Input Mash Cooker Analog Valve Mash Cooker PID Mash Cooker Flow Totalizer Mash Cooker Flow Indicator Mash Cooker Motor Horizontal Mash Cooker Motor Vertical Mash Cooker Motor Pump Horizontal Mash Cooker Motor Pump Vertical SiVArc Setup • SiVArc Rules generated using included MS Excel Sheet HMI Object Type Screen Name
- 49. Screen Name Device MillValve Horizontal Mill Valve Vertical Mill Analog Input Mill Analog Valve Mill PID Mill Flow Totalizer Mill Flow Indicator Mill Motor Horizontal Mill Motor Vertical Mill Motor Pump Horizontal Mill Motor Pump Vertical Mill VFD Motor Horizontal Mill VFD Motor Vertical Mill VFD Pump Horizontal Mill VFD Pump Vertical Mash Cooker Valve Horizontal Mash Cooker Valve Vertical Mash Cooker Analog Input Mash Cooker Analog Valve Mash Cooker PID Mash Cooker Flow Totalizer Mash Cooker Flow Indicator Mash Cooker Motor Horizontal Mash Cooker Motor Vertical Mash Cooker Motor Pump Horizontal Mash Cooker Motor Pump Vertical SiVArc Setup • Create Blank Master Copies in Portal Project
- 50. SiVArc Setup • ImportSiVArc Rules, resolve any discrepancies
- 51. SiVArc Setup • Generatethe visualization
- 52. SiVArc Tips • Beforerunning SiVArc, PLC project must already be generated and compiled • Create HMI screens in project before dragging to Master Copies • Reuse Brewing Template screens (after deleting devices) to maintain formatting • Template is based on Siemens Open Library, must have this downloaded and pulled into Project Library
- 53. What did wejust create? • By running Openness and SiVArc, we’ve just generated HMI manual control of all of our devices in the entire brewery! • All that is left is to generate automated sequence logic • Start with default layout from Brewing Template Project and adapt to your needs
- 54. 1. Siemens BrewingTemplate Intro 2. Project Layout 3. Creating a Project 4. Case Study: Witherspoon Distillery 5. Other Brewing Template Successes 6. Live Demo!
- 55. Witherspoon Distillery • Foundedin 2011 in Lewisville, TX • All US raw materials • Mash, fermentation, distillation, aging, bottling, and packaging • Primarily whiskey, but distills all spirits for Tasting Hall cocktails
- 56. Previous Automation • AutomationDirect PLC/HMI • Some automated control, but primarily manual process • No recipes, no reporting • No utilities
- 57. Witherspoon Goals • Increasecapacity • Improve consistency • Integrate utilities • Integrate new Still • Have a solution that can be expanded when they are ready to expand again
- 58. Solution • Customize SiemensBrewing Template • S7-1500 PLC, WinCC Professional HMI • Integrate Utilities • Boiler, Chiller, Cooling Tower • Add new Still • 68BBL, previous were both 10BBL • Add new grain delivery system, sour mash pump
- 59. Solution Team • FunctionalSpecification • Controls Programming • Drawing/Instrumentation review • Commissioning • Instrumentation Selection • Panel Design & Build • Commissioning • Specification Input/Approval • Mechanical Installation • Field Wiring • Commissioning
- 60. Results • Currently fermentingfirst batches using the automated system!
- 61. Lessons Learned • SolutionPartner/Distributor Relationship is Great! • WinCC Pro V15 and V15.1 – one or the other, not both • Load Cells • Remove installation hardware • WebUX • Not compatible with faceplates
- 62. 1. Siemens BrewingTemplate Intro 2. Project Layout 3. Creating a Project 4. Case Study: Witherspoon Distillery 5. Other Brewing Template Successes 6. Live Demo!
- 63. Founders Brewery • Brewpubautomation – small scale, R&D brewing • Required mostly manual control, quickly implemented with Siemens Brewing Template
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- 65. Craft Brewing OEM •Full brewhouse and cellar automation • General Product Line with standard customizable options • Support for further customization as needed
- 66. East Coast Microbrewery •Utilized a system from Craft Brewing OEM • Very similar to standard Brewing Template Project (4 vessel brewing and fermentation)
- 67. Siemens Brewing TemplateRecap • Open Source • Built on standard libraries, easy to scale • Built in Reporting, Simulation • Fully Customizable
- 68. 1. Siemens BrewingTemplate Intro 2. Project Layout 3. Creating a Project 4. Case Study: Witherspoon Distillery 5. Other Brewing Template Successes 6. Live Demo!
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- 70. Rapid Brewery/Distillery Automation Name:Ryan Landwehr Company: DMC, Inc. Email: Ryan.Landwehr@dmcinfo.com Phone: (972)-432-5536 Session # (for your survey): 1.2