Dmc patco siemens og presentation
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The document summarizes using TIA Portal and S7-1200 distributed control for Patco Machine and Fab's cable and hose reel systems. A traditional single PLC solution with remote I/O was compared to using multiple S7-1200 PLCs in a distributed control approach. The distributed approach leverages the built-in I/O on the S7-1200, provides flexibility and options, easier maintenance and serviceability, and takes advantage of the integrated project and library functionality in TIA Portal. This distributed control solution minimizes costs while providing expandability and customization options for Patco's customers.
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Dmc patco siemens og presentation
- 1. Using TIA Portal and the S7-1200 for Simplified, Distributed Control
- 2. Overview • Introductions • Patco Machine and Fab, Inc. • Project Challenges • The Traditional Solution • Distributed Control
- 3. Presenter Info • B.S., M.S., Ph.D in Mechanical Engineering – University of Notre Dame • CAD/CAM, Intelligent Systems @ ND • With DMC since 2010 • Chicago, Boston, Houston • PLC/HMI/SCADA, LabVIEW, C#/C++, .NET, • Proficient in Siemens (Step7, WinCC, Portal), AB, Beckhoff, B&R, and more • Siemens Certified Professional Jason Mayes Project Director (Houston)
- 4. DMC Overview Established in 1996, offices in Chicago, Boston, & Denver and customers throughout the world employees & growing 85+
- 6. Manufacturing & Automation Certifications DMC has the highest number of S7 certified engineers in the US.
- 7. • PLCs • HMIs • SIMOTION • WinAC • WinCC 7 • WinCC OA • And more… What We Do
- 8. Automotive Chemical & Food Processing Consumer Goods Defense Contracting Energy & Utilities Food & Beverage Packaging Pharmaceutical Printing & Textiles Semiconductor Special Machinery Telecommunications Oil & Gas Test & Measurement Industries Served
- 9. Presenter Info Johnny Kilpatrick President, Patco Machine and Fab. John R. Kilpatrick Founder
- 10. • Founded in 1973 by Johnny R. Kilpatrick • Started as job shop/machine shop • Expanded to repairing/building hydraulic cylinders for the oil field industry Patco Machine & Fab, Inc.
- 11. • Services offerings now expanded to include Design and Manufacturing • Specializing in Production & Drilling Equipment • Hydraulic Pump Skids • Hose and Cable Reels • Suction and Dump Valves for Mud Tanks • Much more…. • Pride, Quality and Commitment • Servicing Customer World Wide since 1973 Patco Machine & Fab, Inc.
- 12. Patco Machine & Fab, Inc.
- 13. Patco Machine and Fab
- 14. Cable & Hose Reel Systems
- 18. Cable & Hose Reel Systems
- 19. Challenges • Why automate? • Looking to modernize the product to meet evolving industry requirements and standards • Differentiate our products with first in the industry capabilities • Provide our customers with added value • Potential challenges • Our expertise is in high quality mechanical/hydraulic design and fabrication, not electronic controls • Limited experience in Zoned/Classified spaces • ATEX/IECEx Class 1 space • Controls hardware selection/communication/software • Extreme conditions of offshore drilling environment
- 20. Presenter Info Adam Tacker Outside Account Manager (AWC) • 9 years at AWC • 6 years Applications Engineer/Field Service • 3 years on Account Management Team • Expert in Siemens PLC and Drives, and Instrumentation • TI505/S5, Legacy Product Expert • Field service and startup experience • Certified Siemens Professional
- 21. • 50 years of serving our customers • Winning Together • Products and Services • Siemens/P&F/Moxa/Phoenix Contact/Rittal • Project Management, System Design, 24/7 Tech Support • Over 400 engineers, 30 locations giving our customers the best possible solution AWC, Inc.
- 22. Building a Team AWC – a Complete Solution • Electrical (Hazardous Areas) • Controls • Project Management Challenges • ATEX/IECEx Ratings (dual) • Flexibility/Modularity • Hardware Selection
- 23. Challenges Build a WINNING Team AWC Project Management • R STAHL • DMC • Dynapar • Siemens
- 25. • Single Controller with Remote I/O Traditional Solution
- 26. Advantages • Single controller • Initial setup • One copy of code to manage • I/O local to remote racks • PN communication Traditional Solution
- 27. Disadvantages • Cost ($$) • 8 Remote Racks • More Complicated Panel Design for Sheave (EX) • Need Ethernet in addition to power to sheave • Not Flexible • PLC program must be modified for different configs • Reel HMI’s must look at unique tags Traditional Solution
- 28. TIA Portal and the S7-1200
- 29. • Each Reel controlled locally • Sheaves all wired into central ET200SP (CPU) • 4 encoders/load cells Distributed Control
- 30. S7-1200
- 31. • Minimizing Cost • Built in I/O on 1200 • Single ET200SP (CPU) in remote panel for load cell/encoder • Simple junction box on sheave Leveraging the S7-1200 S7 Comm CUSTOMER BENEFIT = lower cost per system
- 32. • Flexibility • Distributed control • More options • Tension/payout • Multiple reel options Leveraging the S7-1200 CUSTOMER BENEFIT = ‘custom’ options for Patco’s customer with no additional development
- 33. • Maintainability and Service • Fewer parts to maintain • Easy to program via MMC • Transfer Cards • Program Cards Leveraging the S7-1200 CUSTOMER BENEFIT = easy system setup, service, and configuration without needing DMC
- 34. TIA Portal
- 35. Leveraging TIA Portal • Integrated Projects • 5 PLCs + 5 HMIs = 1 Project • Drag & Drop Tags • Easy PLC to PLC Communication • Easy to configure HMI Connections CUSTOMER BENEFIT = easier for Patco to maintain should features need to be added
- 36. Leveraging TIA Portal • Extended Diagnostics • Integrated device level diagnostics • Webserver/HMI • Improves ability to remotely diagnose any issues CUSTOMER BENEFIT = easier troubleshooting in the field, remote support vs onsite
- 37. Leveraging TIA Portal • Library Functionality • Typed Function Blocks • All reels share same code • Changes only needed in one place • Shared PLC/HMI Datatypes • Easy Faceplate linking CUSTOMER BENEFIT = minimize testing and development time, save $$ and time
- 38. Leveraging TIA Portal • Configuration Control • Define optional modules in ET200SP rack • Can set hardware configuration from HMI CUSTOMER BENEFIT = One project, multiple hardware configuration options
- 39. Conclusions • TIA Portal and Siemens Factory Automation Products • Flexible/Modular • Expandable • Minimize Cost Patented “Controlling Cable Spooling Systems,” #9,206,658
- 40. End Presentation
Editor's Notes
- DMC locations – Started in Chicago, opened in Boston two years ago, Denver this past year, Houston, New York. We have customers all over the world (China, India, Turkey, Russia, Mexico, etc.). We now have over 85 engineers with many more starting this year.
- TEST & MEASUREMENT AUTOMATION Our Test & Measurement Automation Services help automate laboratory testing using the latest technologies. CUSTOM SOFTWARE & HARDWARE DEVELOPMENT We can help with your product or application development needs. Our services include product conception, custom electronic hardware development, application development for web, desktop, embedded, and mobile, and the development of developer tools (SDK, Drivers, API, etc.). MICROSOFT CONSULTING SERVICES DMC has been a certified Microsoft Gold Partner since 2005. We work on software solutions using Microsoft-centric technologies (SharePoint, Office 365, Azure, CRM, .NET, etc.).
- We are Siemens Solutions partners with the Factory Automation Group and with WinCC OA and as WinCC Specialists. We are certified with the Control Systems Integrators Association. Member of Solution Partner Program since 2003 Exhibited and presented at Automation Summits since 2006 Involved in multiple strategic engagements with SIIL Funded projects Frank Riordan (DMC President) became Chair of Siemens Solution Partner Council in 2010, serves on User Advisory Board Connect Events @ Automation Summit (’11,’12,’13,’14) Awarded Siemens Customer Excellence Award (2011)
- Everything with Siemens except PCS7 and nc/cnc TIA Portal and Step 7 Safety and Wireless Safety SCADA/HMI – WinCC, WinCC Redundant, WinCC Flexible, WinCC Advanced
- Our diverse experience in technology, industry and processes allows us to bring best practices from many areas. We deliver solutions not available from singularly focused organizations. Our experience is broad and deep. We have a proven track record in a wide range of industries.
- Existing system mechanical/pneumatic
- Existing system mechanical/pneumatic
- Existing system mechanical/pneumatic
- Existing system mechanical/pneumatic
- RSTAHL Complicated panel design and build – require ATEX/IECEx Class 1 ratings R Stahl has team of experts familiar with zoned/classified spaces Panel design and fabrication DMC Controls/Automation, guidance on hardware selection and architecture Dynapar Encoder help Siemens The best hardware in the industry
- Traditional approach: Centralized control, remote I/O racks for each reel/sheave -> 8 SIPLUS ET200SPs 1 for each Sheave Encoder input (TPOS INPUT 1) for absolute encoder Load Cell input to measure tension 1 for each Reel Local I/O – discrete and analog I/O for control -> 5 HMIs (1 Remote Stand, 4 reels)
- If we wanted to use 2, 3, or 5 reels, would require hardware and software changes All PLCs
- Build in IO reduced need for remote I/O modules Replaced ET200SP’s in sheaves with signal condition, ran signal wires to remote panel for a single ET200SP Controller (1510) 1200’s set up for distributed control with 1510 as data concentrator to get encoder/load cell data (preconditioned in junction box). Turn ET200SP to simple shared I/O rack aggregating and conditioning data for all reels. Also makes it optional – don’t need the encoder/load cell option to function. Configurable from HMI. Also gives ability to have a single point of access for DCS (Modbus/profinet, etc) if need to tie it into existing system
- Distributed control each CPU controls a specific reels Number of reels flexible No software changes Can operate in stand alone mode Reel HMI programs can be identical – look at the same tags. Configuration on unit to select the ‘theme.’ Just looking at different IP addresses.
- Fewer i/o module types Can easily replace PLC and program using memory card Program cards allow the card to be moved from PLC to PLC (can swap plc’s and move card) Transfer cards allow a ‘master’ card to be inserted to program a PLC
- Many advantages to working in Portal vs other automation software packages
- Integrated projects Working in RSLogix/FactoryTalk View Studio would require 5 controller projects, 5 HMI projects Drag and drop tags between HMI and PLC Custom data types created on PLC can be shared with HMI and mapped to faceplates Library functionality Use libraries and types. Can edit a single type if change to logic needed and update all 4 reels simultaneously. No copy/paste, no export/import.
- Integrated projects Working in RSLogix/FactoryTalk View Studio would require 5 controller projects, 5 HMI projects Drag and drop tags between HMI and PLC Custom data types created on PLC can be shared with HMI and mapped to faceplates Library functionality Use libraries and types. Can edit a single type if change to logic needed and update all 4 reels simultaneously. No copy/paste, no export/import.
- Integrated projects Working in RSLogix/FactoryTalk View Studio would require 5 controller projects, 5 HMI projects Drag and drop tags between HMI and PLC Custom data types created on PLC can be shared with HMI and mapped to faceplates Library functionality Use libraries and types. Can edit a single type if change to logic needed and update all 4 reels simultaneously. No copy/paste, no export/import. Configuration Control Can define what hardware exists and where as configurable in user program (through HMI)
- Integrated projects Working in RSLogix/FactoryTalk View Studio would require 5 controller projects, 5 HMI projects Drag and drop tags between HMI and PLC Custom data types created on PLC can be shared with HMI and mapped to faceplates Library functionality Use libraries and types. Can edit a single type if change to logic needed and update all 4 reels simultaneously. No copy/paste, no export/import. Configuration Control Can define what hardware exists and where as configurable in user program (through HMI)