Experience Success.
zenon in action.
Experience Success.
zenon in action. 4 I table of contents
Table of contents.
8 andritz Primary Products | zenon controls bale finishing line.
12 sasol Primary Products | zenon, a future-proof solution – efficient, flexible, easily integrated.
14 arcelor mittal Primary Products | Complex plants clearly visualised.
18 ferriere nord Primary Products | Circular redundancy safeguards steel production.
22 collini Primary Products | Seamless electroplating at Collini.
24 lafarge perlmooser gmbh Primary Products | Lafarge Perlmooser upgrades transport system
26 italcementi Primary Products | Prefabricated automation structures at Italcementi.
30 mabey & johnson Civil Engineering | zenon delivers manufacturing performance. table of contents I 5
Table of contents.
33 krones 60 volkswagen werk emden Machine Building | Getting equipped today, ready for Automotive | Condition monitoring with zenon – tomorrow‘s demands. all the key figures at the press of a button.
36 pepsi-cola 64 ford Food & Beverages | Highest quality bottling for Automotive | zenon – an innovative solution Pepsi-Cola using zenon. is the engine of success.
40 braun-gillette 66 bmw Production | Smiles all round at Braun-Gillette. Automotive | zenon brings precision to a manufacturing operation. 43s clark Logistics | i-Point trusts in zenon. 69 bmw leipzig Building Automation | Operating technical facilities 46 hörmann at modine efficiently and safely. Logistics | Streamlined, sequenced production without stock. 72 allianz arena Building Automation | Kickoff with COPA-DATA in the 48 converteam Allianz Arena. Utility | Transporting heavy loads safely. 76 montblanc 51 cawleys Building Automation | Using energy efficiently. Utility | SCADA waste management and recycling. 79 tcvvv 54 bmw dingolfing Energy | Clean heat for Santa Caterina. Automotive | zenon – Greater flexibility in production. 82 uttendorf 57 audi györ Energy | High tech for ÖBB – power generation. Automotive | Engine conveyor systems are optimized with zenon.
editorial I 7 do it your way. cars, machinery, food, buildings, infrastructure – each sharing something common and highly effective. That something is zenon. Our HMI/SCADA system is a truly universal tool, a fact that is borne out by the stories in our reference brochure. But that‘s not all … zenon is not only a system suited to a wide range of different requirements, it also combines all manner of different functions in a single tool and in one single develop- ment environment. zenon can be used for many different tasks such as control and visualization, communicating and exchanging data with other applications and monito- ring plant operation as well as an optimization tool to increase plant productivity and efficiency. All of this can be done with just a few mouse clicks. zenon will run on any of the current Windows operating systems. In combination with zenon, straton provides a fully-integrated soft PLC and SCADA logic system that interfaces with virtually any hardware. It supports over 300 communication protocols as standard, and our engineers will write additional protocols on request at any time. zenon also exchanges data with other applications and links directly to the ERP level. All this, needless to say, is carried out on a network, configured for multi-user operati- on, across all departments in a company, and conforms to the US FDA 21 CFR Part 11 standard. As for configuring zenon… well, all it takes is a few minutes and a few clicks of the mouse. As you can see in our Reference Brochure zenon has been deployed in a wide variety of applications in a large number of different industries. You will see zenon being used for control and visualization, often with multiple monitors. You will also see zenon being used for plant analysis and optimization. All of these applications use many different interfaces and communication protocols. The common factor in all of these applications is the ease of use and deployment even for very complicated and complex systems.
We would like to thank each of our customers who have participated in sharing their experiences of zenon with us.
Welcome to the world of zenon.
Yours
Thomas Punzenberger (CEO) 8 I primary products I andritz
zenon controls bale finishing line.
The international technology group Andritz (Austria) is the leading provider of process equipment. Amongst other systems, Andritz successfully delivers cellu- lose processing lines (bale finishing lines) around the globe. The software package zenon from COPA-DATA, of Salzburg, was chosen as the HMI/SCADA system, a good start for a long-lasting successful cooperation.
bale finishing seeks the many requirements that needed to be about the system’s functionality, it was visualization fulfilled, included: equally important for Andritz to find a In the beginning of 2005, Andritz began reliability, reliable partner, a partner that would en- to look for a new software platform for decentralized intelligence, able Andritz to keep its position as world the consistent control of all their bale compatibility with Windows CE to market leader and to be able to deliver lines. The legacy visualization package XP, and continuous innovation to the market. An- having reached its limits. full integration of all systems from the dritz chose zenon, the independent HMI/ A project of this size is a real chal- terminal to the control room. SCADA system by the software innova- lenge for automation providers, especial- tors COPA-DATA in Salzburg. The first ly in the HMI/SCADA technology field. Andritz researched the HMI/SCADA experience with the systems turned out There were special requirements in order market carefully, as the previous tools to be very satisfying and zenon has now to provide a successful “Balematic sys- were not able to fully meet their complex been in use for all applications in the Pulp tem” for bale finishing lines. Just a few of demands. However, it was not only all & Paper/BaleMatic™ systems since 2006. andritz I primary products I 9
Gerhard Schiefer, head of the engineering zenon reduces engineering times with be established with a few mouse clicks in and software group of Andritz Automa- intelligent features such as automatic just a few minutes. Several users can work tion in Graz: “We created a very demand- engineering with intelligent wizards for on one project and maintain and update ing catalog of requirements for our new the efficient reuse of sections of existing it online, even if the machines are on a HMI/SCADA provider. We wanted perfect projects. These features also convinced different continent. This can all be done integration, system independence and a Christoph Sedminek, project manager without interruption because zenon can top product based on the latest technol- from Andritz software engineering: “In update projects without the need to stop ogy – and of course, we were also looking modern production sites, it is essential to machines. for mutual understanding and synergy. always have the latest technology. Fast Besides the sophisticated network We were looking for a partner that we information flow ensures efficient and technology, Christoph Sedminek appre- could rely on. As it turned out, it was the effective work. The continuity of zenon, ciated the openness of the zenon PLC right decision to choose COPA-DATA.” i.e. the ability to create completely plat- connectors: “Andritz delivers products form-independent projects, gives us the around the world and our customers have independence wanted freedom to engineer and structure our very different requirements. In South zenon even in its basic form has the fea- systems as we prefer.” America, for example, we have many Sie- tures that meet some of of Andritz’ most zenon also delivers complete hard- mens S7H PLCs. Other customers prefer important requirements: independence ware independence. It comes with over Allen Bradley, yet others prefer B&R. The and continuity. zenon works with all cur- 300 drivers, connecting to any hardware modular structure of zenon is the key to rent Windows operating systems – from without problems. Andritz can use any its success.” CE to XP, Vista and Server 2003/2008. type of machine without worrying about It is also the first HMI/SCADA software connectivity. zenon gives full freedom of overview raises package to be “Certified for Windows action and allows Andritz to use the best productivity Vista”, supporting all the new security technology available in each part of the Those who prefer to be proactive rather features of Windows Vista without con- system and to integrate them seamlessly than reactive need an overview of the straining users. zenon’s scope guarantees to provide a complete solution. zenon production data and information and full compatibility from the terminal to the also has sophisticated network function- their interrelationships. In order to run control room. ality. A fully operable zenon network can large-scale production processes like pulp 10 I primary products I andritz
mills at a high level of productivity, the can always switch to the language they freely definable colors. Operators imme- operator must be able to evaluate data in prefer: an indispensable function – espe- diately see the alarms that need their at- real time and also keep an overview of cially for international companies. Also tention. This reduces the cognitive load, historical events. For that, zenon not only indispensable for Andritz is zenon’s abil- reducing errors and costs and minimizing provides powerful archiving and analysis ity to transfer complete projects to other the effects of downtime. zenon’s wide tools; it also lets ERP systems, such as systems with a few mouse-clicks and range of functions for remote access de- SAP, access its database without hinder- then maintain them easily from afar. The livers speed and convenience. Whether ance. team at Andritz have been convinced by Remote Transport, Web Server, Remote Stefan Reuther, sales manager at zenon’s powerful functions. After all their Desktop or Web Access, its functions save COPA-DATA says: “Cost pressure and fast positive experiences, they have decided operators and developers much time and innovation cycles require safe and flex- to update to zenon 6.22 to benefit from effort during commissioning and main- ible solutions that are state-of-the-art. the features of the latest version. tenance. The integrated Remote Engi- zenon gives users a detailed overview of neering module establishes connections all processes. With its integrated seamless to remote machines displaying the target redundancy, zenon guarantees that this zenon 6.22 screen displays on the Engineering system. clear overview is never lost and the plant With its latest zenon version, COPA-DATA This allows you to easily process messages always stays operable.” Andritz is already sticks to its philosophy of flexible inde- delivered by the operating system of a re- using zenon for other applications besides pendence and certified security. For sever- mote device on your own computer. You bale finishing. As a global player, Andritz al years, zenon has been fulfilling various can also reload projects online or transfer implements projects in many different security regulations such as FDA and vari- projects without the need to restart. markets worldwide. The many intelligent ous European regulations. Additionally, The user can choose how he wants to functions and wizards of zenon make it operators profit from zenon’s operational connect to the target device: in the class- easy to complete projects in a fast and ef- security in runtime.e.g. the clear structure ical way, with a direct network connection ficient way. For example, zenon’s online of the alarm lists. via the zenon Remote Desktop, or with a language switch allows project engineer- Alarm lines can be highlighted with web browser via the flexible zenon Web ing in one language and execution in any colors or grids. There is a separate column Access. Web Access uses a standard web other language. Engineers, commission- acting as an “alarm signal light” that shows browser and enables computers without ers, operators and maintenance staff the status of every alarm at a glance, with zenon installed to access other machines. andritz I primary products I 1 1
The approved Web Server (a very se- Both companies are striking new and cre- COPA-DATA has been known as the cure client-server application) even gives ative paths. Both companies rely on so- innovation leader for HMI/SCADA soft- access to zenon from outside the network. phisticated and easy-to-use technology. ware for 20 years. With zenon, COPA- This can be used, for example, by an ad- The success story of the Andritz group DATA introduced the first graphic visu- ministrator to check alarm messages from begins in 1852 in the small village of An- alization system to run completely under his home computer. Or maybe an operator dritz near Graz, where the Hungarian im- Windows. Many companies worldwide, wants direct access to a station that is lo- migrant Josef Körösi established an iron from diverse industries like automobile cated on a different continent. foundry. Today, the listed Andritz group construction, plant construction, food & All of these features provide essential employs about 12,000 people in over 35 beverage or energy management, enjoy advantages to companies like Andritz who production plants and service facilities the advantages delivered by the hard- deliver powerful solutions to companies and has over 120 subsidiaries and sales ware independent and flexible solution around the globe. Remote systems can be offices worldwide. zenon. maintained and updated in real time, with The Andritz group is one of the lead- The new generation of bale finishing significant reduction in support costs ing vendors of customized lines, systems lines was successfully launched around and services for the pulp and paper in- the globe. Andritz is the market leader partners for perfect dustries, the steel industry, hydroelectric in this area. However, Andritz and COPA- automation plants plus other specialized industries DATA are not resting on their laurels. Andritz and COPA-DATA are two ingen- (solid/liquid separation, animal feed and They are already working together on ious partners who have found each other. biomass). future projects. ❚❙❘ 12 I primary products I sasol zenon, a future-proof solution – efficient, flexible, easily integrated.
Sasol, an international player in the oil, gas and chemistry industry, uses zenon for its pipeline system in the German factory in Brunsbüttel. The innovative solution controls the lines and valves in the pipeline network, ensuring the flexible and reliable transport of alumina products.
❘❙❚ The factory in Brunsbüttel employs 520 people and is a mod- ganic chemicals, such as high purity alumina. Alumina is re- ern and important production unit for the Sasol group. Thanks quired for the production of refining and chemical catalysts, it to excellent infrastructure, the location is also perfect for future helps with cleaning automobile emissions and it is used for the growth. Technological progress, new developments and the use production of heavy-duty plastics (for example, for use in the of modern technologies is day-to-day business for this global aviation industry). player in the chemistry industry. Manfred Rohwer explains SASOL’s philosophy, “We see change as a chance for constant for a successful future: improvement”. Rohwer manages the department for electronics, modernizing the infrastructure measurement and control. The Sasol group is a South African Sasol has a pipeline system with about 300 valves for routing company with 30,000 employees worldwide and a sales volume alumina and chemicals in the alumina halls in their Brunsbüttel of about 10 billion US dollars. factory. This resulted in a total of about 200 different paths of In Germany, Sasol produces raw materials for detergents getting from the source to the required destination. The existing (tensides) and fatty alcohols, ethylene oxide and alkyl phenol, process control system was used for routing control. All function as well as solvents, waxes and oleochemicals. In Brunsbüttel, blocks were developed by Sasol employees. Because of the dis- Sasol produces fatty alcohols, their derivates and special anor- tributed structure of the process control system the valves were sasol I primary products I 1 3
connectedo t different process stations. The cross-communica- the intuitive zenon development environment allows for tion required by this structure resulted in high network loading flexible, quick engineering and implementation of new and performance restrictions. software components, In order to improve the existing infrastructure, and at the zenon has an integrated soft PLC - straton same time increase flexibility, Sasol looked for a flexible control the comprehensive support provided by COPA-DATA. system that could also be extended in the future. Keeping the routing control unchanged after extending the system would automated route selection saves not have been possible. Jörg Brouwer, in charge of the process time and gives a better overview control system at Sasol, decided on a new approach. The task of With the new routing control system, users can now config- finding and evaluating a new solution for routing control was ure 665 different paths. At the same time, they always have an posted as a diploma thesis. The interaction of the new superor- overview of the status of every path. As zenon communicates dinated system for the control of routes OPC. The OPC interface with the process control system, via the OPC interface, which ensures the smooth exchange of information between different also allows for the manual control of each valve, zenon must be control components. The diploma thesis was undertaken in co- able to quickly react to all inputs. This task is performed by the operation with the University of Applied Sciences in Hannover: straton programming system, which is integrated with zenon. The Kamil Janus was supported in this project by Professor Rüdiger sequences developed within straton react to all possible states Kutzner and Jörg Brouwer of Sasol. of the routing control system. “The control system we were us- ing required a lot of maintenance. At the same time, we could zenon as the optimum solution for not extend the system as we wished to”, Jörg Brouwer explains. transport control He states that the process stations and the system bus experi- After extensive market analysis, Manfred Rohwer and Jörg enced such a high load that switching actions would sometimes Brouwer chose the software package zenon from COPA-DATA. take more than a minute with the old control system. “Now, the zenon is now used in the alumina production area. zenon sup- switching actions are limited only by the speed at which the ports the flexible transport of alumina products that have to be valves can move. Users can now react really quickly and easily delivered from the source to the destination while going through to all events and situations.” At the same time, the operators storage, processing and packaging. Now, Sasol uses two redun- can still manipulate the valves with the process control system. dant zenon operating stations in a central control room ensuring “This allows us to act faster and more flexibly.” high availability routing control. There were many reasons for The application of zenon with straton by SASOL demon- choosing zenon: strates the effectiveness and flexibility that this combination Sasol needed a modular solution that would be easy to provides; improving plant operation and providing a reliable and extend expansible solution. ❚❙❘ 14 I primary products I arcelor mittal
Complex plants clearly visualised.
The world steel market grows on average by ❘❙❚ ArcelorMittal is based on a site of around seven square kilo- just under ten per cent per year, and therefore metres next to the Weser River in Bremen, where it has been demand increases accordingly for steel produc- producing steel since 1957. This integrated steelworks includes ers like ArcelorMittal. In order for the compa- plants for all production steps from pig-iron production to thin ny to benefit from these positive changes it is sheet metal. The company produces exclusively sheet-steel all the more important that production should products and today includes a blast-furnace plant, an LD steel- run smoothly and round the clock. works, a continuous casting facility, a hot-rolling plant, a cold- rolling plant and two galvanising plants. At present this Bremen steelworks employs 3,600 people, and the production target for the current year is 3.2 million tonnes of steel slabs. In addition to its steelworks in Germany, this international group is repre- sented in more than 60 countries, employing a total workforce of around 310,000. The company achieves a turnover of around 70 billion Euros and commands a share of around ten percent of the international market. arcelor mittal I primary products I 1 5
modern galvanising plant – hot-dip is monitored continuously by an automatic surface inspection galvanised strips in a new dimension system. The galvanising plant includes an inspection system for BREGAL (Bremer Galvanierungs GmbH) was founded in 1993, checking the material and its quality, and other systems for air and belongs to the ArcelorMittal Group. It is responsible for hot- conditioning, cooling water, hot water, ventilation flaps in the dip galvanising the cold-rolled thin sheet. BREGAL is one of the roof/wall and, last but not least, a waste water system. most modern galvanising plants in the world, and all its products are supplied to the automotive industry. zenon has been leading the field The galvanising procedure is as follows: two decoilers and Since 2003 ArcelorMittal has been converting its steel galva- a welding machine are combined to form an endless belt in or- nising plant step-by-step for visualisation, and zenon is the der that the plant can be operated continuously. The process software it has been using for this purpose. The software that section itself comprises a strip cleaning station, a continuous had been used for visualisation on these plants up to 2003 was furnace, a melt - a device for adjusting the zinc coating, and a withdrawn as no successor product was announced. What‘s cooling station. The continuous furnace is subdivided into a pre- more, the repair costs that were incurred as a result of using this heat zone (450°C), holding zones (800°C) and a cooling zone. software were huge and its design was inflexible – no longer In the cooling zone the strip is cooled down to a temperature capable of further development and costly to modify. This fell close that in the melt. The strip is immersed diagonally into the a long way short of the criteria set by the management team melt (temperature with zinc is around 460°C), then it is turned at ArcelorMittal Bremen for stability, compatibility and future in an upward direction by a roller in the melt, and passes out of viability. At the end of a thorough evaluation process Josef Val- the melt again. The melt-immersion-refined steel strip is dressed lant from the electrical maintenance team consulted with his and aligned. After this, the strip is wound back into a coil. De- colleagues, and the decision was taken to opt for zenon soft- pending on the thickness of the strip, it can reach a speed of up ware. This team was hoping to find a system that would be neat to 180 metres per minute. and compact, easy to integrate and straightforward to operate. The corrosion-resistant sheets are produced in the galvanis- “zenon (version 6.22) is a server/standby system that has been ing plant to a maximum thickness of 2.8 mm and a maximum carefully designed and is easy to configure. It is also quite in- width of 2,080 mm. As well as products with a conventional tuitive to program”, explains Josef Vallant. Vallant talks about zinc coating, significant quantities of material with a ‘galvan- its impressive flexibility thanks to the integration of VBA, and nealed’ coating are produced (zinc/iron alloy). Surface quality also stresses its excellent driver interface via an Applicom card 16 I primary products I arcelor mittal
and OPC server/client. Another important issue for the team ter circuits, ventilation flaps, a temper pass agent conditioning from ArcelorMittal Bremen is that there is a well thought out system, a project for the waste water system plus the overall gal- and, above all, customer-oriented upgrade strategy. Josef vanising plant, and a mini diagnostic tool. Other projects are the Vallant explains: “We don‘t change our software version every central control module for switching control, the visualisation time there‘s a new release or update. The compatibility of the of error messages, and the inspection system. The visualisation latest version with all earlier versions is therefore vitally impor- now provides the operator with an extremely detailed view of tant to us. It is every bit as important as the facility to incorpo- all the components in the system at all times. This applies across rate all kinds of different control components, some of which the board, from the production sequence in the infeed and con- may be quite old, into the overall solution.” tinuous tracing of the coils (strip rolls) to the plant and transfer to the high-bay warehouse. All the requisite target and actual complex processes visualised in data for each coil is always available such as, for instance, which a way that is thorough and well components (welded sheet metals) it contains. At a more de- thought through tailed level, the user or maintenance engineer can also organise The inspection system with its two servers (standby and duty) the display of the flushing circuits or even the speed of the in- and three clients was the first to begin operation with zenon dividual brushes in the pre-cleaning or main cleaning cycles. At back in 2003. Later the same year the galvanising plant, which the same time target and actual values are shown at all manner also had two servers (duty and standby) plus 18 clients, was of different locations in the systems, for instance values for the visualised. ArcelorMittal Bremen uses both Simatic S5 and degree of temper rolling (percentage thickness reduction of the Simatic S7 PLCs, which are linked either via an H1 bus or TCP/IP. sheet). Values can also be adjusted following the input diagno- The galvanising plant, comprising eight projects plus an umbrel- sis. For example: in zinc stripping, if the coating is too high or la project, is visualised on more than 250 displays containing too low, then the pressure target values must be corrected in approx. 33,200 variables. The team at ArcelorMittal Bremen has order to control the amount of zinc on the metal sheets. The defined the visualisation of the strip cleaning, the zinc stripping whole system is extremely carefully thought out, with finishing device and the data from the process control system as projects. touches like a built-in Wiki for operators. A Wiki is a public-ac- There were further projects for secondary systems such as wa- cess page or website that can be modified by any user or visitor, arcelor mittal I primary products I 1 7
ory b a pre-defined set of users or visitors. “Wiki” is a term de- ration and in everyday operation. COPA-DATA is one-hundred rived from the Hawaiian word meaning “quick” – a place where percent dependable in this respect. Any query – be it directed to information is made available and updated quickly. The best- the managers in Munich or Cologne – receives an immediate and known Wiki is the online encyclopaedia Wikipedia. “Since the professional response, and every problem is solved.” systems and the visualisation software are both extensive and complex, we believe there is a need to provide a knowledgebase galvanisation made transparent for staff to ensure that everyone can obtain information about Another advantage to the zenon automation system: Arcelor- the system components and the processes at any point in the Mittal benefits, thanks to the visualisation module, not only system”, explains Josef Vallant. The Wiki encompasses not only from a consistent, uniform presentation of all processes, but at background information and basic explanations, but also news, the same time has the opportunity to request diagnostics for for instance on all aspects of waste water disposal. the system with all its components to enable it to respond rap- idly to all manner of events. For ArcelorMittal this includes the excellent level of security in so-called “mini diagnosis”, which indicates amongst other states multi-layer operation whether the plant is ready to start up, whether a roller or roller Since operation in the galvanising plant needs to be safeguarded cleaning device is out of position, or whether a light barrier is 24 hours a day and 365 days a year, it was decided to bring zenon not working. In addition there are the conventional error mes- in and run the test phase in parallel with the preceding solution sages that are sent to zenon with a time stamp from the S7 PLCs from statten. The integration phase went smoothly, just as op- via TCP/IP. Josef Vallant stresses: “The diagnostic possibilities eration now runs; thanks to the redundant configuration opera- – including remote diagnosis – automatically reduce the main- tion is now comprehensively safeguarded. The electrical main- tenance costs. But it is not only diagnostic facilities and error tenance team has implemented the system with no assistance messages that provide greater transparency, there is also the of any kind, but nonetheless Josef Vallant is extremely positive Extended Trend. This zenon module takes advantage of Arcelor- about the cooperative working relationship with COPA-DATA: Mittal to gain a detailed overview of the information whilst the “Along with the technical solution itself, support from the com- system is operational, for instance in order to check the fill level pany was equally important to us, both in the course of configu- in the zinc pot.” ❚❙❘ 18 I primary products I ferriere nord
Circular redundancy safeguards steel production.
As far as high-quality rolled steel is concerned, the steel producer Ferriere Nord SpA sets great store by dependable production processes, regulated safety and high availability in its plants. The company is a steel producer based in northern Italy, and it has carried out an ambitious project to create state of the art automation systems. For the purpose of process control the company opted for COPA-DATA and its zenon visualisation system. zenon’s circular redundancy ensures that data is acquired continuously, thus ensuring re- liable production. zenon has also enabled plenty of long-term aspirations to be realised, and functions that were lacking in the past have now been easily added on. ferriere nord I primary products I 1 9
❘❙❚ The Pittini Group has been part of the furnace. This is where the refining proc- availability of the production plant. The history of the steel industry in Italy for esses take place, cleaning and refining the aim was for the new system to make se- generations. The largest company in the material through the addition of other cure data available to users at all times Group, Ferriere Nord SpA, is based in metals. The ladles are then passed on for without having to double the number of Osoppo in northern Italy. It comprises the actual production of rolled steel. computers. This was where zenon, with its an electric steel plant, a wire rolling mill, Ferriere Nord has resolved to thor- circular redundancy, entered the frame. a rod rolling mill and production facili- oughly update its automation systems This SCADA system from COPA-DATA is ties for reinforcement steel meshes and by 2011. This affects all the steps in the based on client-server architecture, and is grid fencing for the construction indus- production process as well as the major- capable of networking servers using cir- try. All the steel products it produces are ity of components, from machinery right cular redundancy. Each computer doubles first-rate in terms of elasticity and safety through to software. The automation up as a stand-by for another computer. standards. They are ideally suited to ap- system has already been upgraded by In this way only three PCs are needed to plications where high quality is a require- RB Automazione, using technology from implement a secure system with circular ment, such as construction of roads and COPA-DATA. redundancy. houses. “We were looking for a solution that circular redundancy would ensure that systems would be safe- converting scrap safeguarding the guarded in the event of failure and could and cast iron into system guarantee uninterrupted data acquisition high-grade steel The plant for producing rolled steel con- without increasing the number of com- The production of rolled steel is an ex- sists of three linked systems: the main ponents. zenon has enabled us to create tremely challenging process requiring furnace, the ladle furnace and the con- a system based on circular redundancy large amounts of energy. Production tinuous casting machine. Each of these between the servers that significantly plants must be controlled and monitored three systems is controlled by a server. reduces both the failure risk and mainte- with great precision. The raw material Ferriere Nord’s previous control system nance costs”, explains the electrical main- used is scrap metal. In combination with a did not operate reliably. Furthermore, tenance and automation manager from number of other substances, whose role is maintenance tasks carried out from a PC Ferriere Nord. to lower its melting point, the scrap is fed frequently resulted in lengthy downtime The network linking the three servers into the main furnace. A system of elec- for the plant, and if the server failed, data is especially fast, and has been reserved trodes raise the temperature to melting would inevitably be lost. The highest pri- for data traffic between the servers. There point. Ladles are then used to move the ority for managers on the technical side at is thus no risk of delays. This solution, metal to a second furnace, the refining Ferriere Nord was to significantly increase implemented using zenon, controls a total 20 I primary products I ferriere nord
of 16,000 tags: 8,000 for the main furnace, Since zenon supports communication protocol. The data – which is constantly 4,000 for the ladle furnace and 4,000 for based on the TCP-IP protocol, the auto- synchronised between the servers – is the continuous casting machine. mation project can be updated very eas- updated and automatically forwarded to ily, and it is also straightforward to link the clients”. This enables the project to client with double the servers, clients and PLCs together. controlled remotely: the system integra- monitor tor, RB Automazione, can access the sys- There are eight zenon clients running with simplified maintenance tem using a remote computer and make the three servers: 2 in the continuous cast- With zenon’s redundant architecture, changes to the program online via an ing machine, 2 in the area containing the each server controls its own section whilst internet connection. The customer thus ladle furnace, and 4 in the main furnace. at the same time acting as a backup server saves both time and expense. One important strength of the new clients for another section. This configuration Roger Bogna is also happy with the is their ability to work with two monitors: ensures that in the event that one server technical support provided by the experts you can decide whether to show the same fails, another one will take over its func- from COPA-DATA: “The technical sup- display or two different displays on the tions. As a result, costly interruptions to port, which COPA-DATA guaranteed they two monitors. This was an important fac- the process are avoided. would provide, was outstanding. From tor for the management team: “This facil- System maintenance is also simplified: our point of view as the system integra- ity is very important to us as it enables us “If you have restored the functionality of tor, support is vitally important”. to visualise a larger quantity of informa- the faulty server, or have replaced that tion for each client at the same time. This server”, explains Roger Bogna, owner of improving performance makes our staff’s work a great deal eas- the system integration firm RB Automazi- and flexibility in the ier.” The data for visualisation originates one, “the machine can be quickly reinte- visualisation module from a number of field controllers. The grated into the circular redundancy, and “With the old system we had a problem continuous casting machine incorporates the clients can resume communication with visualising the trends from one of one S5 135 Sinec H1, six S7 400 RFC1006 with their main server.” the two furnaces in real time because the TCP-IP, six C7 with Echolink and one S7 The fact that the TCP/IP protocol is data simply took too long to capture and 300 RFC1006 TCP-IP. The ladle furnace supported represents another advantage process. zenon, on the other hand, works has two S5 135 Sinec H1s. The main fur- in terms of system maintenance. “With very fast. Thanks also to the fact that data nace, on the other hand, has two S5 135 zenon it is possible to transfer project is updated at a high frequentcy, it can Sinec H1s, three S7 300 RFC1006 TCP-IP changes direct from the development site deliver the trends we want in real time”, and one S7 400 RFC1006 TCP-IP. to the runtime server using the TCP/IP explain Ferriere Nord’s managers happily. ferriere nord I primary products I 2 1
Users can also choose exactly which vari- module monitors consumption in real time the tariffs with the grid operator. We are ables are to be displayed. They can add and predicts the trend for the next 15 to now no longer obliged to remain within any variables they like, they can exclude 30 minutes. Contracts with grid operators a specific consumption window, but in- others, and they can change the colours, define specific windows for consumption, stead merely to maintain a certain bal- etc. As soon as the visualisation mode has and it can become costly if consumption ance to our consumption throughout the been defined that best corresponds to the fails to be kept within these windows. day. Even so, we still find it very useful specific requirements, it can be saved in EMS enables a strategy to be designed and to keep our consumption under control at a profile and retrieved at any time with a implemented to manage the use of energy all times.” simple mouse click. In many different situ- and to prevent the agreed supply from be- ations zenon exhibits excellent flexibility, ing exceeded. This system is valued par- target achieved even when working with historical data. ticularly where production is organised Ferriere Nord has achieved the targets it In this case, zenon’s Extended Trend facil- in so-called production islands and where set itself in terms of reliable plant man- ity proves especially useful. This allows the sequence of frequency-dependent agement: increased reliability, data secu- historical data to be managed in the form load shedding can be programmed. In this rity and continuous operation even in the of a table using the report generator. way blackouts can be avoided, and the event of server failure. zenon ticks boxes most important machines in the plants with its circular redundancy, data backup, precise control will continue to operate. less time-consuming maintenance sched- over energy However, it is not always ideal or even ule, simultaneous display of two screens Energy charges represent an important possible to program load shedding or the for each client, flexible trend configura- cost factor in a production plant. The shutdown of an entire production section, tion and smooth transition from Windows ability to control energy consumption ac- which is very advantageous to compa- NT to Windows XP. zenon performed curately is therefore of key importance. nies like Ferriere Nord: “In our case, load superbly both in terms of accuracy and zenon provides a module for controlling shedding and the associated shutdown of speed: “Redundancy has been implement- energy consumption in the shape of its the plant would prove very costly. Our ed quickly and easily, and the configured Energy Management System (EMS). This preferred approach was to renegotiate system works extremely reliably.” ❚❙❘
The technical support, which COPA-DATA guaranteed they would provide, was outstanding. From our point of view as the system integrator, support is vitally important!
roger bogna, owner of the system integration firm rb automazione 22 I primary products I collini
Seamless electroplating at Collini.
Metal refiner Collini in Vorarlberg, Austria, is one of the biggest refining companies in Europe. When they planned the supervisory control of an electroplating system, they looked for a strong partner that would fulfill their demanding requirements. They found one in experienced system integrator Protec, who tailored a future-proof soluti- on with the zenon process control system by COPA-DATA – including a direct connec- tion from Collini’s SAP® application to the process.
direct connection of erp to scada? zenon refines processes in Protec was given a long list of requirements: It started with the electroplating system design and engineering of all the site electrical equipment and The barrel plating system at Collini was designed and engineered the zenon supervisory process control visualization for operat- down to the last detail. zenon is the heart of the system, pro- ing the system. Production data was to be transferred directly viding redundant central process visualization with continuous from a SAP application at the ERP level to the SCADA system. data synchronization utilizing zenon’s built-in circular redun- As an additional process data acquisition task, all production dancy. Alexander Ettinger of Protec: “With our multi-faceted data was to be measured and logged. Collini attached great im- knowledge of machinery construction and COPA-DATA’s soft- portance to guaranteed data security and operational availabil- ware expertise, we developed a solution using zenon that met ity through the use of a redundant system. Collini’s requirements exactly.” collini I primary products I 2 3
zenon establishes a direct connection to the SAP application zenon made it easy to implement these changes in a fast and via a standard interface and gets its production data from it. secure way. While the truck is still arriving with the raw materials, the SAP It is very easy to enter recipes and target values in the system already has basic data such as lot number and article object-oriented HMI/SCADA system, zenon. Its sophisticated number and assigns them to the appropriate production proc- alarm management and archiving functions make processes se- esses. For this purpose, it combines data from 7 recipe groups, cure and always under control. Data recorded during production each of which has a hundred recipes. is available as trend curves and as numerical values, creating an All that the operator has to do now is read the lot number exact overview. This way, each lot is fully traceable. COPA-DATA of the raw materials with a barcode scanner. It is then auto- product manager Reinhard Mayr: “The open design of zenon matically compared with a table that is held on the server. This is allows communication with many systems. We can directly ad- where zenon gets its production data from. The zenon operator dress SAP applications via different interfaces. Since summer then checks the data, confirms that it is correct and then zenon 2008, we also have a certified bidirectional interface – no ad- automatically sends it directly to the PLC. During the refining ditional software is required”. process, all relevant data such as temperatures, currents and pH-values are logged. This records which lot part was processed security matters where, when and for how long. zenon sends selected production Fore sensitiv applications such as electroplating, fail-safe reli- data directly to the SAP application, thereby keeping the SAP ability is of vital importance. This is where zenon’s circular re- information up to date in real time. dundancy© ocomes int play. With a few mouse-clicks, users can turn nodes into application servers and standby-servers. If one flexible zenon of them crashes, the standby-server takes over its tasks without Owingo t its open interfaces, zenon was perfect for the solu- loss of data. Alexander Ettinger: “Another useful zenon feature tion proposed by Protec. Alexander Ettinger: “We were able to for us as integrators is the remote maintenance of SCADA and use standard interfaces for connecting to SAP, which saved us PLCs. We can use a secure connection to access our system at a lot of detours and additional programs. We were particularly any time, without any time lag.” Protec has used zenon to create impressed by the huge amounts of data that can be processed a solution that meets Collini’s specification exactly – including directly via the SAP application and by the reliability of the functions for process data logging and production data acquisi- archiving function. Ultimately, we store about 2GB per year in tion (PDA) as well as an SAP interface. the zenon file format.” Kurt Klien of Collini: “With its openness, zenon gave us the The Protec engineers benefited from zenon’s ease-of-use flexibility we were looking for. At the same time, it is secure and engineering. Since the system was launched in summer 2003, a makes our production fail-safe, and it gives us a perfect direct number of changes and optimizations have become necessary. link to our SAP application.” ❚❙❘ 24 I primary products I lafarge perlmooser gmbh
Lafarge Perlmooser upgrades transport system
Cement and environmental protection sounds like an unlikely combination, but it is a perfect partnership at Lafarge Perlmooser, where used tyres are used as an alternative energy source for cement production. Controlled by straton and zenon, the completely renewed tyre trans- port system supplies the rotary furnace with about 25 % of the fuel required per hour.
❘❙❚ Lafarge was founded in France in 1833. renew and upgrade several parts of the a perfect team for Today it employs 71,000 people in 70 plant. The objective was to reduce oper- smart solutions: countries. Perlmooser Zementwerke has ating costs and increase production out- straton and zenon been a 100% subsidiary of the Lafarge put. An important subproject was renew- On the way to the furnace the used tyres group since 1997, operating under the ing the tyre transport system. are first picked up by an automatic crane name Lafarge Perlmooser GmbH. Wolfgang Luger, head of the project that places them on to a slat conveyor. department in the plant at Retznei: “We From there, they are moved through a energy from tyres replaced about 25 % of the fuel required separating system where they are an- Cement plants have a great potential for our rotary furnace with used tyres. In alyzed and separated by a laser scanner. for substituting normal fuel with waste the autumn of 2007, we decided to com- The scanner system transfers the collect- materials. Using alternative fuel for ce- pletely renew the electrical equipment ed data via Modbus TCP to straton. In the ment production saves natural resources and automation of the used tyre system. same way, straton sends target values to and reduces CO2 emissions. Lafarge Perl- Above all, we wanted to enable our oper- the system, which then checks tyres for mooser protects the environment and ators to solve transport problems with as parameters such as maximum diameter saves resources in many ways, one of little travel as possible. Until now, solving or the presence of rims. Tyres matching which is by using used tyres as fuel. MGX such problems was a labor intensive task the requirements are conveyed through a Automation was been commissioned to as it involved travelling long distances.” weighing station and then into the rotary lafarge perlmooser gmbh I primary products I 2 5
furnace. For this the transport system, and zenon changes can be made without zation requirements of the operators. In a total of 30 inverter drives, for the slat stopping the system. straton’s binding March 2008, the system was launched in conveyors, roller conveyors and convey- feature offers a very convenient way of its new design. We were able to meet the or belts, had to be connected to the PLC dividing the overall process into several requirements of the operators: They can via Profibus DP. The electro-mechanical decentralized areas that stay in contact now solve 90% of all problems directly in design was completely changed and the without any extra cable connections. In the control station without the need to MCC, Motor Control Cabinets, and the this way, parts of the conveying system travel long distances.” inverters were placed directly by the mo- that are far from each other were inte- straton and zenon were also used in tors. MGX Automation chose the zenon grated into the overall system in a very the LABCONTROL project. This system HMI/SCADA system as the redundant elegant way. zenon and straton interface automates and visualizes the high level control system. straton was chosen to with nearly any hardware. Therefore, La- processes of a fully automated labora- control the WAGO and Siemens slaves. farge Perlmooser can deploy and change tory for production analysis and quality straton and zenon are very open and al- PLCs as required. This allows for the flex- management in the cement production. low easy communication with existing ible extension of the system and the con- LABCONTROL is the communication hub automation components via protocols nection of different projects. between the conveying systems and an- that include Profibus DP, Modbus TCP Marting Grübler, CEO of MGX Auto- alytical devices of the laboratory on the and IEC 60870-5-104. mation: “We found the astonishing depth one side and the existing control system straton also interfaces with the WAGO of the integration of straton with the and process data acquisition system on 750/753 field bus nodes and the Siemens zenon control system to be really helpful. the other. Here straton runs as a soft- ET200S, which has been in use at Lafarge They both use a common database and PLC, together with zenon, on a PC and Perlmooser for a long time. This degree therefore variables are always available in uses the flexible communication features of flexibility and openness was a decisive both systems automatically. Additionally, of the multi-driver concept for connect- factor in selecting straton. we can use sophisticated communications ing to other systems. Another fact that was well received such as Profibus, Modbus and IEC 60870 Rober Meixner is responsible for technol- by Lafarge Perlmooser was straton’s abil- for connecting new and existing system ogy and automation in the plant in Retz- ity to make online changes, which allows components.” nei: “With its convenient user-interface program changes to be imported during and its integration with zenon, straton operation. Interrupting the operation one stop solution makes work easier for our maintenance of process automation systems like the Martin Grübler: “The big challenge for employees and allows us to perform ones at Lafarge Perlmooser would in- us, besides the short time available for program changes and small automation volve problems and costs. With straton the change, was to consider the optimi- projects on our own.” ❚❙❘ 26 I primary products I italcementi
Prefabricated automation structures at Italcementi.
For most companies automation takes time; sometimes taking several weeks to get from a project plan to a completed system. Italcementi now creates its projects within an hour and the complete design and engineering phase takes no more than three days. This enormous acceleration was achieved by using a Wizard created by JS Automation using COPA-DATA’s zenon, which is now in use in Italcementi’s French plants.
italcementi: more efficiency requirements. We also wanted to become thanks to automation independent of external services and also Italcementi is one of the biggest international producers of to lower our costs. Additionally, we want- aggregates, ready-mixed concrete and cement. To increase the ed to make our projects easier to maintain efficiency and productivity of their plants the French subsidiary than before. The perfect interaction of all of this Italian company was looking for a solution that would components is very important for us. Our bring with it several advantages. Paulo Pereira, Technical Manag- main criterion was a maximum degree of er Automation for Granulates and Concrete, France and Belgium, automation during project creation.” explains: “We wanted a reliable system for simplifying the crea- After considering the various solu- tion of our projects in over 80 plants with differing automation tions available on the market, Italcementi italcementi I primary products I 2 7
application generator for italcementi: Application Generator automatically creates projects for straton and zenon direct connection via I/O straton masters all current protocols zenon Reports zenon Industrial Maintenance Manager faster automation less time required simple maintenance independence
opted for JS Automation. The managers are lowered significantly, as are on-going a network interface. If required, straton of Italcementi asked, “Can you automate support costs. Automatic engineering at can also communicate with any PLC. But our engineering?” and JS Automation an- Italcementi now means: Answering some the really important thing is the tight in- swered with a clear “Yes”. The French dis- questions about the design and then tegration of zenon and straton. tributor of COPA-DATA’s innovative solu- watching the Wizard create the produc- tions used the joint power delivered by tion tool – the Application Generator per- collaborative work zenon and its fully integrated soft-PLC, forms about 90% of the required tasks for direct control straton. In January 2008, JS Automation automatically. This means that less expert zenon handles the visualization for Ital- started implementing the Application knowledge is required in the company, cementi projects, collects data and ana- Generator that would permit a completely which in turn means less training costs, lyzes it. This data is used, for example, automated engineering process. For this, less consulting costs and reduced depend- by the zenon “Industrial Maintenance they used the freely programmable inter- ence on external resources. Manager” module (IMM) to optimize face of straton and zenon. By fall, the first How does this Wizard by JS Automa- maintenance activities and to make sure four plants had been equipped with the tion work? After starting the Application there is only minimum interference with Generator. Then, all plants will be using Generator, the user defines the project everyday operations. It allows for the zenon, straton and the Wizard. using an interactive dialog. The Wizard exact and targeted scheduling of mainte- Hervé Seyfried, technical project then creates the complete automation nance activities. At a glance, the user sees manager at JS Automation, “straton and project for straton and zenon. straton, an which devices, systems and machines zenon were the obvious choice. This ‘team IEC 61131-3 programming environment, require maintenance and when. Addi- of two’ was the only solution on the mar- is integrated seamlessly into the zenon tionally, it logs all the maintenance work ket that easily fulfilled all requirements. HMI/SCADA system, via one single da- performed in the past. As the data is in The tight integration of straton and zenon tabase. Functional blocks have been de- a SQL database, it can easily be used by made our task much easier. Additionally, veloped in IEC 1131-3 standard languages other applications. In addition to seam- straton can communicate readily with for all types of machines encountered on less integration with straton, zenon fea- many different networks. This allows di- production sites. The Application Genera- tures a truly open design, including over rect addressing of the machines via I/O.” tor maintains a connection between the 300 communication protocols, and also block’s inputs and outputs. The process with connectivity to superordinated sys- automatic staff then only need to configure ele- tems. Italcementi is profiting from this engineering: the appli- ments such as the machine’s startup and teamwork, which was also one of their cation generator shutdown sequences, timing, alignment requirements. Many sources of error Automatic engineering creates new space etc. It connects directly to I/O systems of are ruled out in advance; time-consum- and liberty. Engineering times and costs different manufacturers such as Wago via ing and expensive detours are avoided. 28 I primary products I italcementi
Practice has shown that project mainte- straton guarantees optimum real-time Italcementi Group. zenon is provided by nance effort has also decreased. zenon behavior and allows processing of large COPA-DATA, an innovative European itself is really easy to use and makes work amounts of data in a short time. Both sys- company specializing in HMI/SCADA simple even for inexperienced users. tems can be easily configured for redun- systems, and delivers striking advantag- Changes can be implemented at any time, dant operation to increase security. stra- es with its truly open design. Just like even during operation - an advantage also ton makes it easy to run the HMI and the straton, it supports any kind of hardware provided by straton. PLC on a single system, ensuring a good and all current Windows operating sys- overview and saving costs. The straton tems. But above all, it can create secure straton: power at workbench – an IEC 61131-3 program- networks with only a few mouse clicks. all levels ming environment – is integrated seam- Within minutes, it creates a redundant At Italcementi, straton plays the role of lessly into zenon, delivering considerable system where every computer can be an intelligent field bus controller, commu- advantages for engineering tasks: redun- the server or the standby server. If one nicating directly with physical inputs and dant variable pools or variable list imports of them crashes, the standby server will outputs on the I/O level. However, the are no longer necessary. With a few mouse seamlessly take over its tasks, without main reason for choosing straton was its clicks in the straton Workbench, the user data loss. Additionally, zenon – just like capability to act at other levels as well. can configure the data to be shown in straton – features a hot reload capability: On the process control level, it acts as zenon. The straton Workbench supports engineering changes can be implemented a powerful, real-time control unit in the all five programming languages defined in during operation without having to stop form of a soft-PLC that receives data via the IEC 61131-3 standard and allows for the system. all commonly found field buses. This al- the smooth conversion of one language zenon also ensures a good overview. lows for the simple use and integration of into any other IEC language. With only a few adjustments, several existing PLCs of many different manufac- projects can be combined in an integra- turers. By integrating straton into the in- zenon: perfect tion project. The integration project dependent SCADA system, zenon, it can teamwork takes over the role of an index, listing all also work as the computing centre. The straton and the zenon HMI/SCADA soft- projects and providing fast access – even powerful interface between zenon and ware work as a team in the plants of the across plants or countries. Italcementi can italcementi I primary products I 2 9
The decision to use zenon was a very logical and obvious one. It ensures optimum connectivity to existing systems in our plants, it gives us exactly the automation that we need and it convinced us with its excellent integration with straton.
paulo pereira, technical manager automation for aggregates and ready-mixed concrete, france and belgium
now combine any number of projects and also monitor and control them remotely. The foundation for this already exists; the actual engineering procedure required for this feature is a standard task. A finely structured user rights system allows defi- nition for every user and which projects they can view and which settings they are allowed to change. more productivity, lower costs By specifying zenon with straton, JS Auto- mation made it easy for the Italcementi Group to select them... zenon and straton was the only system that was able to meet all the automation requirements: a gener- ator that would adjust to the individual requirements of the users. The Applica- tion Generator lowers the effort required for engineering and maintenance. As do zenon and straton, enabling the targeted use of resources in many ways. For exam- ple, with zenon’s network functionality, it only takes a few mouse clicks to create a completely functional network. It enables secure redundant operation and creates a clear overview – across different plants. If at any time, Italcementi wanted to com- bine several plants or maybe all of them and monitor, control and visualize sta- tions remotely, that would be an easy task for JS Automation, zenon and straton. ❚❙❘ 30 I civil engineering I mabey & johnson zenon delivers manufacturing performance.
Mabey & Johnson builds modular bridges; the welding and drilling machines to the company’s complex metal fabrications require both precise management system coincided with the develop- control and monitoring so that factory efficiency ment of an easier manufacturing cell interface and stays high. To achieve this Mabey & Johnson man- data acquisition for OEE; both tasks were com- agers have to have accurate and timely manufactur- bined into one project using COPA-DATA’s flexible ing information. Integrating the various cutting, zenon SCADA solution.
❘❙❚ Mabey & Johnson designs and manu- sential link to the development of agri- factures a range of steel modular bridging culture, health and education in overseas - and have been doing so successfully for rural communities. Through a number of almost 35 years. At the Mabey & Johnson supported programmes, Mabey & John- facility in Lydney, Gloucestershire (United son works alongside the customer to build Kingdom), they manufacture on average bridges quickly and efficiently at low 30,000 tonnes of bridging per annum and overall installed cost. export to a wide range of countries. There Mabey & Johnson bridges are con- are 250 employees locally and many more structed from standardised and inter- located across the world. Customer re- changeable components that are easily quirements range from a single bridge to transported and erected – the basic con- a fully supported project for supply and cept being field proven in the 1940’s. Raw installation. New bridges provide an es- material steel stock arrives at the plant mabey & johnson I civil engineering I 3 1
and is converted by cutting to length and tion of the reclaiming of grit from a road- production and capacity planning to be at various angles to become components deck “grit shaker” coating machine. Here optimised. of their bridge modules. The modules the solution was again Beckhoff hardware Initially this requirement resulted in themselves are assembled by welding on but with embedded zenon (running on two projects; one by the control engi- large automatic machinery, fixing holes Windows CE). The engineers at Lydney neers to improve the cell user interface are drilled, the final product is galvanised quickly realised that in zenon they had and obtain data for OEE and the other by and is then ready for shipment. The bridg- a very flexible tool for many other tasks IT to obtain KPI and manufacturing in- es are assembled at the delivery site from that were in their improvement plan. formation through keyboard manual data sets of modules using large diameter pins. It was here that Steve Grice, Electrical entry (material usage, historical data). The metal decking of the bridge is also Project Engineer found that, “you can get The experience of using zenon on the Grit supplied and can be supplied with various zenon to do whatever you want it to do, Reclamation project created the realisa- optional road-deck coatings such as grit- with virtually no barriers.” tion that with zenon both projects could ted tarmac for improved vehicle traction. not only be rolled into one but also made The current automation project finds simple for oee better by automatic data acquisition and its roots in a new Robotic Welding Cell up- measurement menu driven machine stoppage and fault grade in Sweden – where to have remote As with many manufacturing industries reporting. zenon was easily configured access for maintenance and diagnostic most machines are standalone and the for this task and was able to communi- from the UK was required. The robotics workflow is governed by material flow. cate with the company’s OEE package us- vendor (ABB) recommended Beckhoff as Mabey & Johnson knew that much in- ing OPC, the data being collected from all the control solution and further consulta- formation was locked up in each machine other networked zenon controlled manu- tion with Beckhoff in the UK resulted in and in particular OEE (Overall Equipment facturing cells by a host zenon running on the specification of suitable hardware. The Efficiency) was the key to their competi- the OEE database server. visualisation was undertaken as a bespoke tive position and to sustaining customer solution and although this was function- satisfaction. The workflow is organised high level of ally satisfactory it presented a significant according to the production plan, a ma- connectivity learning curve for the UK engineers if they chine’s overall capacity and then adapt- The communication layout in the factory were to adopt this as a standard. The first ed when maintenance is required. OEE is by a fibre optic backbone that has both UK-located project was for the automa- reveals machine utilisation and allows wired and wireless connection to various 32 I civil engineering I mabey & johnson
machines. The machines are very large be accessed remotely to provide flexible ness System Analyst, “zenon was a whole and have PLC controllers as well as spe- supervision and monitoring by control new world for me as an IT specialist, how- cialist robot controllers for welding, with engineers and for maintenance diagnosis. ever, the training showed me what could 9 motion axes being typical. The weld- Mabey & Johnson has thousands of part be achieved and the result is highly auto- ing motion programmes are developed numbers and many bridge variants within mated and error proof management data both by using the 3D CAD drawings and its range of bridge products. Although acquisition.” by teach-mode, the correct program be- they provide bridges on a non-emergency All development work has been un- ing selected by the operator via the plc. basis for planned development they also dertaken with in-house resource follow- Touch screen interfaces have been added provide complete bridge kits at short no- ing some self-training and later formal to each cell these are the operator’s in- tice usually following an environmental training by COPA-DATA UK and support terface to the zenon supervisory system disaster. They pride themselves in being and guidance by COPA-DATA’s compre- using Windows XP. Access to each ma- able to ship reliably at very short notice. hensive support services. OEE is being chine’s PLC is facilitated by zenon’s high All of this takes a great deal of back- driven towards 85%. Traceability is impor- level of connectivity through its exten- ground planning, and requires knowl- tant to Mabey & Johnson quality control sive library of drivers, in some cases the edge of what is being produced, OEE and and each manufactured part can be traced PLC programmes are sensitive and non- schedule adherence. The use of zenon back to its original raw material batch, this invasive data acquisition is accomplished as the supervisory cell controller has al- is being expanded to automate the “qual- by slave I/O devices that can be accessed lowed access to all this information, de- ity pack” that is sent out with each bridge directly by zenon’s integrated logic con- livered intuitive cell control and provided set. The future planned extension of the troller, straton. drop-down menu reporting of faults and system will be to progressively add all the stoppages. other manufacturing cells to the system flexible and intuitive Steve Grice, Electrical Project Engi- (5 out of 14 currently being integrated), It is worth noting that the zenon editor neer, “zenon has allowed us to develop to also obtain energy data for energy sav- is the same for PC or CE runtime operat- a single solution that meets both our cell ing, and to intelligently integrate the fac- ing systems, therefore training and ex- control and IT reporting requirements, tory lighting system. As Steve Grice puts perience was reusable across these tech- it is flexible to use and in many ways is it, “with zenon you are limited only by nologies. Each zenon controlled cell can intuitive to develop.” Andy Phillips, Busi- your imagination”. ❚❙❘ krones ag I machine building I 3 3
Getting equipped today, ready for tomorrow‘s demands.
The demands placed by the market on the ❘❙❚ Unlike other production plants, filling and packaging plants beverage industry are increasing all the time: are now generally not controlled from one central point. Many companies are now facing up to the challenge control panels on individual machines and conveyor systems of optimising their filling and packaging proc- look after the material flow throughout the plant. The drawback esses and becoming ever more competitive. to this approach is that individual machines cannot always be This can only be achieved by using state-of- reached directly in the event that operator intervention is re- the-art information technology. quired or problems arise. It is also not always possible to man every station with an operator, since this results in excessive time and expense. In order to remain competitive and to manage the plant more efficiently, an operator must have an overview of every operator station, musthave the ability to intervene rapidly in the production process where necessary, and must have the ability to detect problems and respond immediately. Krones AG, a company specialising in installing and configuring complete filling and packaging lines, understands that information flow has today become every bit as important as material flow. This 34 I machine building I krones ag
company, based in Neutraubling in Bavaria, is in the vanguard when it comes to installing state-of-the-art network technol- ogy and software. Krones has already set up countless filling and packaging lines for glass bottles, PET containers and cans on behalf of breweries, soft drink manufacturers and companies involved with the wine and spirits industries. network technology underpins further development visualisation and efficient Manufacturer-specific bus systems have so far been the most management of plants commonly used means of connecting individual machines with Krones believes in state-of-the-art technology for its human- a system for the purpose of sending and receiving information. machine interface too, and has therefore chosen zenon from Industrial Ethernet has now emerged as the best medium for COPA-DATA GmbH for its machines. zenon is a software ap- transferring large volumes of data between IPC devices. Krones plication whose strengths include scaleability, flexibility and uses fibre-optic cables here, thus avoiding electromagnetic in- openness. zenon features a drag & drop interface for network- terference from the word go. Krones installations are also un- ing individual machines to form an integrated system; a separate affected by any limitation on the length of fibre-optic cables, machine (known as a “stand-alone project”) is activated with a since cables within the plant will never exceed the maximum click of the mouse and converted into a network project when permitted length of 2 km. When a network is implemented with the user drags it to the desired position in the zenon network copper cable, on the other hand, the picture is quite different: manager’s project tree. If the user enters the corresponding data transfer can become unreliable as soon as cable lengths ex- computer name or selects a computer, then the desired operator ceed 100 metres. The network structure favoured by Krones for terminals will become available immediately. An intelligent to- its filling and packaging lines has a star configuration with a ken ensures that all operator actions are managed in an orderly central network server. fashion. If an authorised user submits a request, then the token This guarantees the user maximum freedom from interfer- is passed to that user in order to avoid actions being duplicated ence since the connections in the network are exclusive. Fur- and errors occurring. The project manager can define in advance thermore, every single machine can avail itself of a 100 Mbit/s which functions zenon is allowed to perform on the network, bandwidth, and all applications – including the line diagnostics and which are not permitted. There is one more plus point with system, the line management system, the process control system this software, which is that zenon does not require a central and the mobile service information system – can run concur- server. Any control panel that is assigned to a controller can rently and without any form of mutual interference. act as a server for another client – an operator terminal, for in- krones ag I machine building I 3 5
stance. In this way, data is transferred between the terminals and projects are also harmonised as soon as any changes are carried out on a project. One further advantage is that there is no need for any additional server hardware since the system has a distributed configuration and can thus operate on a Compact Flash-card basis. Maintenance can be carried out remotely on the HMI as well as the PLC systems. The basic philosophy be- hind the networked visualisation is that operators can perform whatever actions are required at any time and from anywhere in the plant. Such actions include configuring systems, chang- ing types, switching on units and, if necessary, retrieving alarms and trend data. cost efficiency in filling and packaging In terms of improving efficiency and plant availability, innova- tive IT technology has a crucial role to play. State-of-the-art software and network technology ensure that systems are as safe and user-friendly as they possibly can be, that filling and packaging processes take place as efficiently as possible, and that as a result the costs per unit produced can be reduced ever further. ❚❙❘ 36 I food & beverages I pepsi-cola
Highest quality bottling for Pepsi-Cola using zenon.
Quadrant Amroq Beverages (QAB) is one of the largest American investors in Romania, a licensed bottling company and distributor for Pepsi-Cola®, Prigat, Lipton Ice Tea and Roua Muntilor in Romania and in the Republic of Moldova.
❘❙❚ QAB entered the Romanian soft drink huge success was the result of the com- market in 1991, bottling and distribut- pany’s decisive action and the QAB team ing the products of PepsiCo. In 1992, the investing over 14.5 million USD in the company opened the first polyethylene Romanian soft drink market in 2005 to terephthalate (PET) bottling line in the launch new carbonated and still products country, beginning with Pepsi 1.5l bot- and introducing a packing system that tles and launching Prigat in 1993, the first ensures the integrity of their products. still drink manufactured in Romania. The Moreover, QAB was nominated among Company experienced a 48% increase the best bottling companies in the world, in turnover in the year 2004-2005. This in the PepsiCo system. pepsi-cola I food & beverages I 3 7
krones with zenon scada is simplified with handling and visualization of the analysed hmi software the latest technology data and to remain flexible for future QAB’se driv for high quality was also mir- QAB usees the most modern equipment modernization of the production process. rored by the investments made at the and their team wanted to push the lim- We discovered all these advantages using production level, which utilise the latest its of their machines. The specialists have the zenon software”. trends and technologies. One example is the capability to analyze every machine As in every SCADA application, ef- the state of the art bottling line instal- in detail, and furthermore the power to fective communication with the hard- lation at QAB, manufactured by a world monitor the overall characteristics of the ware was essential. QAB used a highly leader, Krones. The productivity, reliabil- plant which has to provide optimal qual- reliable industrial PC, interfacing with ity and optimal operation of the equip- ity and productivity. Mr. Mihai Ciorbaru, equipment using zenon’s built-in driv- ment are determining factors in the suc- Technical Manager of QAB and his en- ers. An advantage of zenon is that over cess of the Pepsi-Cola bottler. gineering team, decided to create their 250 drivers, developed in-house ensure All equipment was designed in such a own SCADA application using zenon, as its integration into complex, heteroge- way that both the operators and specialist the professional tool for visualization and neous projects where interfacing hard- teams have the tools required to operate analyzing the plant data. At the begin- ware components from diverse suppliers and control the complex equipment ef- ning of 2006, during the design phase, is the key to successful implementation. fectively. The software interface had to be QAB had decided that zenon was the best As Ciorbaru highlighted, the zenon soft- direct, immediate and satisfy their needs choice for the SCADA software. Together ware suite gives users the power to work perfectly. COPA-DATA’s zenon software with Kreatron Automation, the Romanian at a high technological level, in a very suite was found to excede these require- zenon distributor, the complete software accessible way. A practical approach, ments and was chosen by Krones for their & hardware solution was identified. the programmer receives highly evolved HMI (human machine interface). Further- Ciorbaru explained, “In complex sys- software instruments, in order to develop more, all new machines manufactured by tems, SCADA has to satisfy three main their own project by freely parameteris- Krones are now supplied with zenon 6.20 criteria: interface simply with most au- ing components. In fact, developing the XP embedded powered HMI’s. tomatic control systems, facilitate in the application is closer to engineering than 38 I food & beverages I pepsi-cola
to classical programming, the focus being ematical functions included in the soft- aspects of the process. on the process and desired functionality ware.” said Ciorbaru. Data archiving is accessible and rather than coding. The modular structure of zenon al- flexible using the zenon archiving As a result, the SCADA tool designed lowed the QAB engineers to select the module. The data is archived not “in house” by QAB could be further devel- software mechanisms that could best only as it is collected directly from oped by the bottling specialists according implement the application requirements. the process, but also in the processed to their technological or organizational The plant effectively “appeared” on their form using so-called “derived needs. Using zenon, they are completely desktop PC with an overwhelmingly archives”. capable of maintaining and developing amount of data, they then transformed it The pieces of information gathered their own system. into extremely useful information using become valuable because they are built in tools so that they could control processed and presented in an high quality perform- the quality and productivity of the bot- advanced graphical system and ance from zenon tling line as described below: analysed with the help of the built-in No matter whether Pepsi, Prigat or Lip- The entire process is presented report generator. ton Ice Tea is produced, at QAB consist- optimally on screen, Accessible, flexible, well founded ent quality control is essential. When the but operators can also “zoom in” on mathematical functions assist with market demands flexibility, the change equipment in the development and expansion of from one bottled product to another has detail, resulting in an effective SCADA projects. to be achieved with minimum production and user friendly top-down Software mechanisms ensure that downtime and maintaining maximum application. users from the operators to the main- quality. “Any process has to be kept un- The operator receives exact and tenance team of the plant, quality der control, and sometimes this involves complete information using alarm and assurance department, production, a large number of parameters that have to event management. By filtering the planning and surveillance team, be managed within a given space of time. information according to their re- receive the most relevant information With the zenon programming system, this quirements, the user’s concentration to perform their individual roles task becomes simpler, due to the math- is focussed entirely on the analyzed effectively. pepsi-cola I food & beverages I 3 9
Any process has to be kept under control. With the zenon engineering tool this task becomes simpler, due to the mathematical functions included in the software.
mihai ciorbaru, technical manager of qab
great future Now, the zenon-based SCADA system is already offering better than the expected results, being a source of ideas for further technological developments and helping more and more departments of the QAB team solve their information and control needs. Because zenon is an open system based on standards such as OPC, SQL, SNMP, the SCADA system is going to be easily integrated into the ERP system of the plant. Such happy meetings between innovation and quality suppliers do not happen by mere chance. Pepsi-Cola and QAB is a continuing success story, driven by the promise of quality and creativity servicing the consumer that relies on the QAB team’s innovation and everything the latest technology can offer. In the same way, COPA-DATA has continued its tradition of innovation and applying its experience in automation to push the lim- its of HMI/SCADA technology, providing customers such as QAB with the techno- logical edge they need to succeed in such a competitive market. ❚❙❘ 40 I production I braun-gillette
Smiles all round at Braun-Gillette.
Braun-Gillette’s toothbrushes promise cus- ❘❙❚ Dittmaier, Project Manager & Computer Engineer, spearhead- tomers a “beaming smile” - and now Braun ed the company’s “ProCICS”project to deploy a Production Cell Project Manager, Gerhard Dittmaier, has Information and Control System which would improve produc- every reason to enjoy a “beaming smile” too! tivity and simultaneously reduce costs at Braun-Gillette’s facto- Under Dittmaier’s leadership Braun-Gillette ry in Marktheidenfeld, Germany. Under Dittmaier’s leadership, developed a requirements profile that formed the project team analyzed the necessary functionality required the basis for the construction of an informa- by any potential new information system. To achieve this, they tion and control system for the company’s reviewed the experiences of every co-worker involved in the in-house plastic part production. The realized daily function of the injection-moulding cell. The requirements application is based on COPA-DATA’s process the team identified included: control system zenon and its embedded control Integration of the peripheral equipment on the injection- solution straton and now gives Braun-Gillette moulding machine such as part removal robots, feed units, universal transparency of production data for temperature-control units. Previously, this had been ex- its plastic parts operations. cluded from the control system but it was thought that as a result of full integration, immense advantages through efficient signalling of incidental error and failure messages could be expected. An appropriate data-transfer to the central sites was necessary to realize this goal. Furthermore, software should be “easy to use” braun-gillette I production I 4 1
By deploying COPA-DATA’s visualization system, zenon, the This variety of interfaces had made it previously impossible to meaningful display of site data was possible. This effective over- create direct communication between the individual devices. view of plant operations could facilitate quick responses and Important technical data was not visible thanks to the pro- manual intervention where appropriate, so production defects prietary communication protocols and heterogeneous environ- would be dramatically minimized. ment. Without integrated communication, if a process com- ponent failed, no remedial action was taken, for example to a single point of administration redirect or restart the process, so production defects or a plant Initially, the project team had not considered it necessary to stand-still could easily occur. integrate business or production data in to ProCICS. However, To deliver the project, Braun worked with local system inte- following their research it became clear that integration was de- grator Prozesstechnik Kropf. For on-site operation, an embed- sirable. Any control system would, therefore, have to support: ded PLC with touch screen from Lauer was chosen. As a special modular upgrades, or the ability to add extra feature, the hardware was equipped with two network inter- functionality as required faces. This enables the entire production cell to be sealed off independence from manufacturers, to allow for from the outside networks so unauthorised access to internal future expansion data could be easily prevented. Through the second network machine independence interface the cell obtains a unique IP-address in the corporate production control from various workstations or other internal network. This allows it to be able to, for example, re- locations, and trieve data from the central control room. Braun decided to use the integration in to a central management system. the software recommended by Prozesstechnik Kropf; the zenon Dittmaier explains: “With ProCICS we wanted to establish a SCADA and straton embedded control application from Aus- single point of administration‘ in our factory.” Faced with these trian software specialists COPA-DATA. One powerful reason for requirements, those involved with the project realised that open selecting the zenon/straton product suite was because the and flexible integration was going to be a key factor for them. straton embedded control system made it possible to achieve the Every injection moulding cell comprised of several independant control of such a wide variety of interfaces and peripheral com- devices with various interfaces and controls: ponents. straton, the zenon-embedded IEC soft-PLC, can utilise modbus-interfaces for the feed units over 100 communication drivers. Modbus, Profibus and serial profibus -interfaces for the temperature control units protocols are available as driver interface and therefore only serial-interfaces with manufacturer-specific protocols for have to be configured. Only the part-drawing robot from Reis the removal robots and injection moulding machines presented communication problems as there was no standard I/O interfaces on older devices. driver for it. However, Prozesstechnik Kropf and COPA-DATA 42 I production I braun-gillette
worked in collaboration to deliver a new driver in a very short raw material cost saving potential over the one billion parts the timescale It is now possible to automatically and continually facility produces in a year. Another advantage realised by the monitor the process parameters of all the components that are integrated control solution is the management of process vari- involved in the production process, and generate error messages ables. An applied variable in zenon is immediately available in when a component fails. the straton control program and vice versa. parallel operation of old and system expansion already scheduled new systems “Having successfully deployed the system on the first injec- A multiplexer was developed especially for this application, tion moulding cell, the pilot phase of the project was success- which reads the data from the injection moulding process. Via fully completed. The deployment of two additional systems are a serial interface it simultaneously shares information and ma- already underway. These two additional systems will be de- chine data with the new ProCICS system and the original Pro- ployed on cells with an even more complex environment” says duction Data Collection system that was in place. The newly de- Dittmaier. He continues: “It makes sense to equip at least two veloped ProCICS system integrates transparently with the PDC thirds of the existing production cells with this system and con- system. By using the integrated zenon/straton solution, data solidate the technical data at one point, to provide a single over- from the various peripheral machines can not only be extracted view of operations.” The project team’s ambition of delivering a but logically combined with each other. But by maintaining the single point of administration could now be realised. PDC front end, for the users on the production team, the famil- Braun are already considering how they can deploy some of iar development environment is still available, which is a major zenon‘s other features in the future. Modules being considered advantage. Engineering times can be shortened and errors mini- include: mised. zenon‘s Report Generator By combining the various process parameters within a single complete data recording using the control application, it is now possible to proactively manage the Chronological Event List (CEL) process. Before, production failures could occur, for instance, Industrial Performance Analyzer when changes to the process temperature values had gone un- the ERP PPS system which enables the writing of all data noticed. With the new system, an error message is generated in a database over a single SQL/ ODBC driver – since this is a immediately through zenon‘s alarm management functions and read and write driver, data can be accessed by a variety of ap- is transmitted to the control personnel via SMS. If the error is plications at any time In addition, zenon‘s networking capabili- not removed within a specific time period, the production proc- ties make it possible to easily integrate the project at a primary ess is automatically stopped. Production errors and scrap have control station or control centre, without the need for additional therefore been dramatically reduced. This represents a huge configuration. ❚❙❘ clarks I logistics I 4 3 The right fit for Clarks shoes.
When Cyrus Clark established a small sheepskin shop in 1825, nobody could have imagined that this would be the foundation stone for one of the most successful companies in the United Kingdom. Today, Clarks produces 41 million pairs of shoes per year, has 13,000 employees, a turnover of 1.4 billion Euros and is one of the largest companies in this business sector.
❘❙❚ Aw ne Clarks’ distribution center has more than 50 years of experience in the field of logistics. The been built in Somerset, UK, because of know-how from more than 700 projects in different business increased order and distribution volume. sectors makes Knapp one of the leading companies in the global The building has gigantic dimensions: 188 market. In addition to a great deal of mechanical automation and m long, 152 m wide, it covers the area of Electronics, the visualization is a core component of each system. six soccer fields, and rises up to 18.5m For this, Knapp supplies its i-Point storage information software. high. It has enough room for the entire Knapp i-Point delivers a consistent user interface for all tasks population of south-west England! The in a storage facility. In addition to the visualization of data and building has the capacity to store up to 6 storage status, i-Point also delivers monitoring, control functions million pairs of shoes and is designed for a and the ability to configure components in the warehouse that daily throughput of 200,000 pairs. are linked to these tasks. This means that the entire storage facil- In order to run such a center success- ity can be operated and monitored from one central station. fully you need a strong partner, for which Clarks turned to the logistics company, informed by zenon Knapp, based in Graz, Austria. Knapp has Knapp’s i-Point storage information system is based on the 44 I logistics I clarks
In a storage many different control levels and interfaces have to be reconciled. One of the many reasons for deciding on zenon.
zenon HMI/SCADA system, from the Salzburg software compa- needs a lot of screen space. After full consideration, and with the ny COPA-DATA. Knapp had selected zenon as their control and support of COPA-DATA, Knapp found an elegant and standard visualisation software of choice as early as 2001. solution. At the top left of each display is a single button which When planning Clarks’ storage facility, it was clear, that the displays a drop down menu detailing all functions that can be i-Point system would play a central and important role. Clarks executed. An entire floor of the Clarks storage facility can be demanded control center software, which could be used as a cen- displayed over all eight monitors at once. tral solution for the entire facility. Based on these requirements, The i-Point at Clarks’ is the central monitoring station, where Knapp identified several elements of core functionality, which all information is gathered. It is here that problems in the ware- the i-Point system must deliver: house are detected, usually before the employees in the ware- Visualization and status display of the entire house would notice them. i-Point is not only used to monitor the storage facility warehouse, but also to manage work allocation. i-Point displays Integration of all systems, the status of all of the 600 ramps of the sorter. If manual inter- High availability and reliability, vention is needed, warehouse workers can be instructed by radio High quality visualization and functionality to ensure from the control room. customer satisfaction. The result is a solution with which Clarks is completely satis- fied: “Even during commissioning, the i-Point system has been In addition, in order to have a clear overview of a facility of this an important tool,” Dr. Rupert Temel, Dipl. Ing., Head of Qual- size, the ability to utilise multiple monitors is necessary. In the ity Management at Knapp. “The Knapp technicians working at Clarks’ application, the decision was made to use an eight moni- Clarks could check the status of the system with the help of the tor system in a central control room. Fortunately, this was easy to i-Point system. This was useful at the start of the project, for deliver because multi-monitor administration is a basic function example, defective and incorrectly connected motors were eas- of zenon. At the same time, the Client wanted it to be possible to ily identified and repaired. With the i-Point system we simply access the project from any workstation via their intranet or the printed out the alarm list and handed it to the electrician, who internet and to display the data on one single screen. To do this, could quickly fix the problem. For a facility of this size with it was necessary to develop a completely new display concept for around 1,000 motors, this would have taken considerably longer user guidance. On the one hand, each function should be avail- without the i-Point system. With the i-Point system we have in- able in each picture; on the other hand, a menu bar with buttons creased the efficiency of the facility considerably.” clarks I logistics I 4 5
easy to network, flexible, open channel is considerably reduced and, at the same time, Dr. Temel continues: “The demands and functions of visuali- transfers time date stamping and the status value from the zation in our industry sector can differ from one customer to PLC – so accurate data recording becomes possible. another. Even if the storage facilities have the same structure, parallel operation - diverse hardware environments are each customer has their own requirements. This is partly due to part of everyday life; it is very easy to connect to several the great variety of the types of products that could be stored – PLCs of the same type directly and in parallel, because any shoes, pharmaceutical products, tobacco, CDs, etc; the size of the number of drivers – even identical drivers – can be used storage facility; the machines that are used; and the customer’s simultaneously. method of operation. In a warehouse, many different control Many direct PLC connections - there are drivers which levels and interfaces have to be reconciled; these include ma- communicate with a wide variety of standard interfaces, chines, PLCs and warehouse management systems, etc... This such as OPC, SQL, DDE, SNMP or Modbus. was one of the many reasons, why we decided in favor of zenon. zenon is an open system and offers more than 300 different con- standardization is a real benefit nectors or drivers, so it can connect to nearly every system as For. Dr Temel at Knapp the way zenon allows for the creation of standard.” Stefan Reuther, Ing., of COPA-DATA agrees: “A very standard projects is a real bonus. He says: “An important benefit good HMI/SCADA system should run on any hardware and com- is the standardization of the modules and the automated crea- municate with any system. In this way, you can stay flexible and tion of process pictures.” For project automation purposes, the secure your investments. Above all, you can react quickly. zenon zenon Editor has an extensive VBA interface which allows it to has been created for exactly this purpose.” elegantly solve recurring tasks. All process pictures, functions, menu entries, alarm messages, etc. can be created automatically. That means zenon delivers: The VBA development environment integrated in zenon helps An open system which empowers the customer to decide when creating special scripts. In addition to the time savings, this which hardware he wants to work with solution has another big advantage: complete accuracy. An error more than 300 different driver connectors out of the box – free script always produces error free results. These scripts can so no loss of time when connecting to new machines and then be re-used in any project at any time. Quality increases and modules, the time and cost of development decrease considerably. This, in spontaneous data transfer – the load of the communication turn, increases competitive advantage and End User benefits. ❚❙❘ 46 I logistics I hörmann at modine
Streamlined, sequenced production without stock.
In its conveyor and storage system from Modine, Hörmann Logistik has imple- mented a production concept that gives customers the ability to manufacture their products in a streamlined, sequenced manner. This has enabled Modine to reduce its stock of finished goods considerably. zenon from COPA-DATA is re- sponsible for the visualisation and efficient operation of the conveyor processes.
❘❙❚ Modine’s innovations have set stand- assembly plant operated by the company transparency in the production process ards throughout the industry for efficien- that leads the way in the international as well as traceability of each individual cy, cost effectiveness and long service life cooling and heating systems market. Mo- product. Modine’s aim is to achieve flex- in the field of heat transfer. The company dine produces cooling systems for the au- ibility despite fluctuations in capacity, has been in existence for over 90 years, tomotive industry, most of which are used because 100 percent reliability in produc- and has registered more than 2,000 pat- within the BMW Group. Modine products tion and delivery must be ensured at all ents. It is now in the best possible posi- are well known for reliability. In order to times. tion for overcoming challenges now and keep up with the ever-growing volume of in the future in the area of heat transfer. orders and the high demand for product maximum degree To get the solutions to market reliably and diversity, the company got together with of automation and quickly calls for just-in-time and just-in- Hörmann Logistik to redesign the entire efficiency sequence production and logistics proc- production and materials handling opera- The plant in Wackersdorf is now struc- esses. The internal logistics must function tions and build a new plant in which to tured and implemented using a sophis- practically, reliably and economically. set up these operations. Needless to say, ticated intralogistics solution from Hör- the aim was to satisfy the requirements mann Logistik. HiLIS, the intralogistics reliable supply of prod- of their customers, and to supply them system from Hörmann, manages all the ucts to the bmw group with products just-in-time and just-in- storage and buffer areas, controls order Modine Wackersdorf GmbH is an sequence. The aim was to ensure total picking, and with its “Factory Control” hörmann at modine I logistics I 4 7
inspection stations and quality assurance. The inspected coolers then pass into a se- quencing buffer, where they can be made available in the order requested by the car manufacturer. At all times, through- out the entire storage and assembly proc- esses, the cooler data can be accessed. 13 programmable logic controllers (S7), linked together via TCP/IP, are deployed. Approx. 22,000 values are read and proc- essed in zenon. Transponders pass the information on to the suspended electric trains, and barcodes ensure that the data exchanged at the load suspension devices is correct.
zenon ensures that monitoring is carried module, takes control of the entire pro- the intralogistics plant in real time. The out comprehensively duction process. HiLIS thereby ensures ergonomic, graphic display in zenon as- At Modine, zenon also provides a com- maximum transparency and plant avail- sists the user with simple working dialog prehensive system monitoring module. ability in all functional areas. Using the boxes. zenon is set up as a multi-station Users and Maintenance Engineers can ‘target goods out date’ and ‘sequence system, and at each station it provides a rapidly diagnose and rectify potential chain’ parameters, the whole plant is comprehensive overview of the plant and system faults because they can access all controlled in such a way that all the cool- the states occurring within the plant. The the information directly. zenon flags up ing systems are shipped just-in-time and software supplies all the detailed data at any errors that arise, and records them in just-in-sequence. The programmable logic each conveyor device (storage/retrieval a central error-logging module. The statis- controllers (PLCs) supply the informa- device, cross-carrier, suspended electric tics not only permit detailed fault analy- tion for controlling the storage/retrieval train) and at each storage location, be sis, but also enable trends to be analysed equipment and conveyor systems. The that in a grid system, pallet conveyor sys- in the long term. All these systems can HiLIS Warehouse Management System tem, in workpiece carriers or a high-bay also be maintained from a remote location module is responsible for managing stor- warehouse. Altogether there are seven via a VPN (Virtual Private Network). Any age, stocktaking and order handling. operator stations (server, redundant information that is generated and record- Materials flow control coordinates and server, web server pro with five licences). ed in the course of the logistics processes optimises all the manual and automatic The operators and maintenance engineers can also be exported if required. Thanks storage, conveying and transportation can therefore, thanks to zenon, always to the flexible interfaces – in this instance systems. The flow of goods can be ad- see and understand which lattice box or to the SAP software – HiLIS can be linked justed and customised in each functional pallet container contains which individual up with existing ERP systems. Mobile area according to the operational require- components for the coolers, or where they devices like PDAs and tablet PCs with ments. An international transport order are located in the high-bay warehouse. touch screens can also always be reliably can be broken down into partial orders zenon also clearly displays the convey- connected via the wireless LAN. A plant for each specific plant. zenon forms a part ing processes involved in moving cooler operator or the maintenance engineer of this solution. components to where they will be further will be provided with electric vehicles processed. From the high-bay warehouse with integrated mobile computers. If, for intralogistics with the cooler components are moved to the instance, fault messages occur, then the zenon workers’ stations using suspended elec- relevant employee can respond quickly COPA-DATA’s zenon software is respon- tric overhead conveyor in order that they and directly. Thanks to zenon, faults can sible for the plant visualisation at Mod- can be further processed on the work- be displayed directly on the monitor and ine, depicting all the functional areas of piece carriers and then moved on to the rectified using the touch screen. ❚❙❘ 48 I utility I converteam
Transporting heavy loads safely.
Converteam, a specialist in traction technology, deploys COPA- DATA’s zenon software for visualization and control on large-scale cranes. Converteam’s most important reason for choosing zenon: the flexibility of the software makes it easy to adapt a suitable solu- tion for every traction technology project.
❘❙❚ Today, large-scale cranes are used in Specialists in industry automation ports, shipyards and industrial plants can confirm this statement. For exam- worldwide. Customer demands on the ple: a container ship used to stay in port cranes are rising steadily: available re- for several days, but today, it takes only sources must be used more efficiently, a few hours to turn around hundreds of processes must be improved and accel- containers. This task is executed by high- erated. Karl-Heinz Schacht, responsible ly automated cargo handling technology. for automation solutions at Converteam Many movements are now automated. GmbH in Berlin, explains, “The operators The crane operator no longer has to wor- of industrial plants are increasing their in- ry about swinging loads or about where vestments in modern traction technology to place a container – sensor technology to establish a high level of performance on the crane and computer-based logis- and, consequently, to reduce handling tic systems allow him to concentrate on times.” “driving” and supervising. converteam I utility I 4 9
creating tailor-made equipment for large-scale cranes. zenon models, the customer is never “over- technological has been used by the division for the licensed” and the solution always stays solutions visualization of control and drive tech- attractive in relation to costs. In addition, Converteam is represented in 25 loca- nology and the electromechanical equip- the user training effort required is rea- tions in eight countries through which ment of large-scale cranes since the year sonable and employees are able to adapt it supports its worldwide customer base 2003. Before that, the company had used the visualization themselves after a short to efficiency-boosting solutions. Besides an in-house solution, which was power- time using the system. This saves time and power electronics for the drives, the Com- ful but did not satisfy modern hardware costs, because there is no need to employ pany also delivers complete automation and software requirements. It also took a for specialist developers. solutions and electronic equipment. Con- great engineering effort to adapt this in- Another advantage of using zenon is verteam can also handle the project man- house solution, which is why Karl-Heinz that the software runs on Windows CE. agement and the engineering of complex Schacht and his colleagues decided to This means that it can also be used on rug- electronics for drive systems and automa- perform a market analysis and evaluate ged panels that perform in adverse condi- tion for its customers. The company has available tools for visualization and auto- tions. Because they don’t use hard drives, a modern manufacturing plant with pow- mation. Karl-Heinz Schacht explains, “We zenon powered HMI (human-machine in- erful production and system testing fa- have used zenon successfully in several terfaces) can operate in difficult climatic cilities at its disposal. Converteam GmbH parts of our company; for instance in min- environments and can withstand other employs about 800 people in Germany ing. However, our department decided to influences like vibrations. and over 4,500 people worldwide. Their make a new, more comprehensive evalua- total volume of sales reached 876 million tion, in order to test whether zenon would zenon – optimum euros in 2007. satisfy important criteria like flexibility, operation and network capability and an open interface targeted monitoring safe crane architecture. Our evaluation proved zenon Today, Converteam is using zenon as an ef- management did fulfill our requirements.” There were fective tool for operating and monitoring The “Materials Handling” division of several reasons for using zenon. Because large-scale cranes. The software displays Converteam GmbH delivers electronic COPA-DATA offers very flexible license current states, delivers statistics whilst 50 I utility I converteam
archiving all the necessary data and makes advantages of the software. They profit competence of Converteam and the soft- daily operation more secure, thanks to from the openness of the system and can ware from COPA-DATA. its alarm functions. Several cranes are make small changes on their own. The Eurogate is a container-terminal and integrated vertically in a central station. software is based on Windows standards logistics group which operates sea termi- Therefore, employees can access the cur- and enjoys a broad acceptance – which nals on the North Sea, in the Mediterrane- rent states of all cranes and the common protects the investment. Additionally, an and on the Atlantic, with connections alarm list from a central point. the powerful information display in the to Eastern Europe. With nine terminals, Additionally, Converteam uses zenon’s central station and the error detection and the handling of 12.1 million Twenty- Industrial Maintenance Manager to plan support increase the availability of the foot Equivalent Units (TEUs) in 2005, and document maintenance tasks. Both cranes. The state and alarm displays are Eurogate is the Number One in Europe. Converteam (as the equipment supplier) user friendly and easy to understand, Converteam successfully installed cranes and Converteam’s customers, the ultimate according to users. The openness of the for a division of this transport and logis- end users, the operators of the cranes and system is also demonstrated in the abil- tics infrastructure. This included 13 con- industrial plants benefit in several ways ity to interface with other information tainer cranes in Hamburg and 5 container from using zenon. For Converteam, zenon systems and establish connections to cranes in Bremerhaven, each of which supports the configuration of equipment. error analysis tools, electronic docu- have already been - or are in the process Startup times are reduced for several rea- mentation systems or overlying logistics of being equipped with zenon for crane sons: adaptations are simple to perform; solutions. management. projects can be synchronized automati- Karl-Heinz Schacht is pleased with cally; and clients can be launched quickly zenon – proven, this success: “Eurogate is one of the and safely. The user-friendly interface field-tested solutions many satisfied customers who profit of the zenon editor enables even non- zenon is used in the cranes of the world’s from our high quality project standards. software specialists like startup personnel biggest manufacturer ZPMC and also COPA-DATA assists us as an experienced and technicians to work with the solu- serves the cranes of Kocks Krane In- automation specialist and as a competent tion after a very short period of training. ternational GmbH. Customers such as and reliable software provider. zenon This has improved the acceptance of the HHLA CTT Hamburg, China State Ship- meets our requirements and enables us software within Converteam significantly. building Corp. and Eurogate in Ham- to implement customer projects in a fast The customers also value the numerous burg and Bremerhaven benefit from the and competent way.” ❚❙❘ cawleys I utility I 5 1
SCADA waste management and recycling.
Cawleys in Luton, United Kingdom, is a leading waste recycling company. Cawleys’ business is to collect commercial waste and sort it to high grade material for recy- cling. The recycled material income offsets the cost of the landfill which is required for the small amount that is left over after sorting.
❘❙❚ The company has just accepted a new sorting facility designed Thew ne OKLM reclamation facility takes material delivered in and installed by OKLM Recycling Technology, with DB Controls skips through a process of automatic and manual separation to of Doncaster being subcontracted for automation, motor control sort out the main recovered recycling material types of Card, and SCADA – for which they used COPA-DATA’s zenon. Polythene, Paper, Film, Plastic, Metal, Timber and Hardcore. Cawleys offer a professional and expert service for waste man- The plant has many conveyors that transport the waste from agement and recycling requirements. The company has been stage to stage – at each step valuable recyclable material is re- dedicated to recycling and diverting waste away from landfill moved until the final stage has residual material that can only since the 1970’s when its first Waste Reclamation Factory was go to landfill. constructed in Luton. Since then the site has been developed The separation uses various technologies, such as infra-red, and now houses a 40,000 sq ft Materials Recycling Facility magnetic, and sorting by blowers in a large rotating drum. Sort- which enables them to reclaim and recycle as much material as ing operations are undertaken in two shifts. The plant has to run possible. at all times, with care being taken of safe working for operators 52 I utility I cawleys
ando also t protect the machinery. This second aspect is of sig- material. To quickly check the source of the problem CCTV nificance as the inverter-driven motors have to be able to cope cameras are installed in many locations around the plant. The with a wide range of loads as different material is moved by the displays of material input and dispatch are shown on dedicated conveyors. They have sufficient power to do much damage to CCTV monitors in the control room. The internal CCTV cameras the plant if left unsupervised, especially when an abnormal item that monitor the plant are called up as and when needed by the finds its way onto the conveyor system, or build up of material operator using the SCADA display – a video window opens in causes a blockage. the SCADA screen and a high resolution colour display allows the operator to quickly see the problem and then call a mobile supervising operations operator over voice R/T, to clear the problem – keeping the plant The whole motorised conveyor system is powered by a latest- running and protecting plant machinery. generation MCC (Motor Control Centre) – designed and devel- In a similar way all key components in the plant are constant- oped by DB Controls. The plant control room is fitted with the ly monitored and kept running. Situations that do not require zenon SCADA system that communicates with various points immediate attention are notified by a colour change to orange – within the MCC and also across the plant. The primary function drawing the operator’s attention to that part of the plant. When of the SCADA is to provide safe and reliable plant operation. the screen shows all green, then all is well! All alarms are stored As with many SCADA systems colour is used to draw the atten- in an alarm list within zenon in chronological order. tion of the operator to any problems, and also to provide an in- The MCC has high technology inverter drives that allow the dication of how long a problem has occurred. An example of this conveyors to run at the correct speed even though the loading is monitoring of the load of each drive; where this is measured may be continuously changing. Although the drive parameters as being above 80% for several minutes the colour of that area were set at commissioning these can be displayed and changed changes to red and the operator has to take action. Experience directly in a zenon SCADA pop-up window – the window re- and common sense shows that such a load condition is likely sembling the “hard” interface of the inverter itself. This avoids to be a jammed or partially jammed conveyor, probably caused time-consuming trips to the plant floor where the MCC is posi- by an abnormal item on the conveyor or a build up of waste tioned – the ease of use also encourages the supervisor to tune cawleys I utility I 5 3
theo plant t a new state should there be a significant change in assisted us to produce a close to perfect solution prior to installa- the material being handled. In a similar way the status of all of tion and commissioning. The system is fully accessible remotely the main devices within the MCC can be displayed on the central at DB Control’s engineering office; this has also eased the tuning SCADA screen. and resolution of residual teething problems.” The system running at Cawleys is a full development system scada – mcc – cctv integration as zenon’s value makes this an attractive and affordable propo- System Integration was undertaken by DB Controls Ltd on be- sition for ongoing developments as these requirements appear. half of OKLM, the main contractor. The zenon SCADA commu- nicates with a Schneider Electric M340 controller that is at the in operation heart of a Prisma Plus MCC (Motor Control Centre), using the Andrew Pegg, Cawleys Recycling Manager, “the system [zenon standard zenon driver; the protocol being Modbus TCP/IP. The SCADA] allows us to stay in full control of our recycling – we devices within the MCC each have an active web page that is could not run the plant without it”. accessed through zenon to open up windows on the SCADA dis- The system was commissioned on time and the first few play that show device parameters and status – using a standard months have shown reliable operation. User feedback is now zenon HTML picture. being gathered to allow the specification of enhancements to The facility requires visual checking when an alarm is raised, the original system based on experience. One such addition will this is provided by CCTV that is directly interfaced to zenon be an audible warning of plant status changes from the SCADA and appears as full colour video using the zenon video picture in the control room. template – allowing very fast visual diagnosis of an abnormal situation. DB Controls technical director, Graham Allmendinger, Waste management and recycling is an important part of mod- said, “We fully utilised the complex objects and objects struc- ern life. The automation of such recycling plants has to be cost ture within zenon, this allowed us to develop and test each effective so that recycling can be efficient businesses. DB Con- major control element and then re-deploy instances of them as trols use of zenon assisted in this objective and has resulted in a many times as was required in the project. This has significantly fully working system that was producing from the outset. ❚❙❘ 54 I automotive I bmw dingolfing zenon – Greater flexibility in production.
The flexible storage and conveyor system in BMW‘s Dingolfing plant picks up all the doors from the assembly line and reunites them with the bodies at the right moment. This storage system, whose display requirements are handled by zenon, boasts a minimal space requirement whilst at the same time offering excellent flexibility.
❘❙❚ During recent years the automotive Group’s largest production facility which produces around 1,200 industry has been transformed, and the vehicles every day - several thousand components are assem- final assembly phase has changed even bled to create a finished vehicle. zenon also forms part of the more than others: the number of different assembly facilities. This software is used for automation and vehicle models has increased, and a vehi- visualisation of a conveyor system in the assembly plant. This is cle must be delivered to the customer as a flexible storage and conveyor system comprising electric vehi- soon as possible after the order is placed. cles, suspended electric trains and lifts. After painting, the doors This is made possible by ensuring that are removed from body shells, and are then taken in lifts to the production personnel are highly qualified storage level; the doors for different vehicle types are all stored and that production plants are regularly together. These electric vehicles then transport the doors for modernised or replaced. In the assembly further processing, initially to the flexible store and then, when section at BMW’s Dingolfing plant - the requested, on to the door fitting station. Once the body shells bmw dingolfing I automotive I 5 5
have been completed, the doors are brought back to them for specialises in three fields: control systems, plant and mechanical final assembly. The purpose of removing and refitting the doors engineering, and simulation modelling. Staudinger has around in this way is that it is easier and more convenient for workers 150 employees, and produces solutions for challenging open- to carry out the necessary fitting operations on the doors. The and closed-loop control tasks in all types of automation sys- body shells also take longer to assemble than the doors do, and tems. This was the first time that Staudinger had worked on such so the latter need to be put into temporary storage in the best a large product with zenon from COPA-DATA. Another partner space-saving way possible. The new storage and conveyor solu- in the project was the company Rofa Rosenheimer Förderanla- tion was developed in such a way that it takes up very little gen GmbH, which specialises in automated conveyor systems for shop floor space. At the same time, the overview is ensured: all material flow and manufacturing. doors are labelled (model, chassis number, door position, etc.), all load-carrying media are provided with RFID tags, and there- complex control processes fore the location of any particular door is known at all times. At implemented with clarity various points in the plant are located distributed read/write The objective for the door conveyor project at BMW’s Dingolf- stations that control and monitor the suspension gear routes ing plant was to implement and visually represent the complex that can be uniquely identified at each point. Users can read out control processes necessitated by the storage system so clearly the data, but also change and update it if necessary. To make the that the plant manager or maintenance engineer can always re- doors available at the right time and in the right place presents a tain an overview and can see immediately the locations of vehi- particularly large logistical challenge; this is an extremely com- cle bodies and doors. The flexible storage and conveyor system plex task for the control system to achieve. has a full graphical display. The system displays show the opera- tor all the strands of conveying and storage. Each box in a stor- conveyor system professionals age strand represents one door or a set of two or four doors. The optimise the plant’s internal colour provides information about the vehicle type, and the sta- logistics tus of the door’s manufacture (unfinished door, fully assembled The company Staudinger GmbH supplies the software and the door, empty vehicle). In order for the doors to be fitted, a robot entire control system for the door conveyor system. Staudinger transfers them to the suspended electric overhead conveyor sys- has developed a suitable custom solution for operation and vis- tem for pre-assembly. This process, too, is visualised with zenon. ualisation based on COPA-DATA’s zenon. This software depicts Once the doors have been completed on the production lines the entire system. This company, which is based in Loiching they are moved back to storage to await the bodies. A sequence (near Dingolfing) was founded as long ago as 1950, and now list is maintained to keep track of when cars are ready to have 56 I automotive I bmw dingolfing
their doors fitted. Light-grey boxes in the visualisation are unoc- used only a small part of it (fault reporting system) that they re- cupied spaces in the storage and conveyor system. Before doors ally needed. The cost is thereby greatly reduced, and efficiency pass into the lines, a check is carried out automatically to deter- increased. Object-oriented parameter definition makes system mine whether a line of doors of the same type already exists. If configuration very simple: as soon as an object has been defined it does, then the door will be stored there in order that separate centrally, it is available for use throughout the system. And lines are created for each model. There is likewise a colour to whenever any item is modified, it is handed on down quickly, indicate when doors are re-fitted in the vehicle – like door re- securely and accurately without any further input. moval, this is a process that is performed manually. When doors are removed from the storage and conveyor system, the empty all eventualities calculated in hangers return to the door removal station – this completes the The zenon application also enables data sets to be modified, cycle, and the process starts from the beginning again. moved or deleted, and it allows the data system to be accessed The zenon overview display enables operators and mainte- directly should the need arise. With the help of the relevant nance engineers alike to zoom in on any detail of the plant whilst operation the controller can now determine which subsequent at the same time keeping the entire plant on the screen. “The processes are necessary. This entire complex, yet flexible stor- overview display is for me one of zenon’s best functions as it age system is extremely user-friendly. This demonstrates the hugely increases user-friendliness and enables the plant man- high level of automation and efficiency that is made possible ager to work efficiently and retain an overview however com- by this software”, explains Markus März from Staudinger. To plex the plant”, says Markus März, a control software designer at implement their solution Markus März and his colleagues had Staudinger GmbH who is responsible for visualisation systems. to calculate in all the possible eventualities in order to represent the necessary processes and other resulting processes in the so- networking, consistency and lution: if, for instance, a door has been included in the wrong inheritance conveyor line due to a defect in the soft material, then this must The basic idea behind networked visualisation is that operators be corrected immediately. The visualisation includes a waste- can perform all the necessary operations at any time and from paper basket that the user can use to throw away any records that any position: defining parameters, switching units on and re- are not needed. Using drag-and-drop techniques, the responsi- trieving alarms and trend data. zenon’s consistency, in combina- ble person can then move the door data to the correct position tion with its unique network technology, opens up all kinds of in the system. Markus März from Staudinger GmbH continues: options for integrating and optimising production and informa- “This entire project is visualised using zenon. With all its techni- tion flows. Staudinger took advantage of this consistency earlier cally refined hardware and software solutions it is a truly state- when configuring the visualisation system: The system planners of-the-art automation system which not only works extremely have integrated the standard project specified by BMW and reliably, but is also unparalleled in terms of flexibility. ❚❙❘ audi györ I automotive I 5 7
Engine conveyor systems are optimized with zenon.
For Audi Hungary based in Györ, COPA-DATA’s integrated software solution zenon, offered additional potential for optimizing its Engine conveyor systems: now zenon’s smooth flow of information enables more efficient operations.
❘❙❚ The Audi brand stands for progres- efficient information The engines that have been dispatched sive design, serious environmental pro- flow enables smooth from different locations in the plant are tection and trend-setting technology, in transportation first buffered and sent to a pre-storage short: “Innovation through technology”. Ino order t ensure the continued success location where a rough sorting by en- The Hungarian Audi plant in Györ, with story at the Audi’s Gyor plant, the engine gine type and reception station is done. more than 500 employees, is part of this conveyor systems were earmarked for From the pre-storage, the engines are success story. Founded in 1993, the Hun- further expansion. The plant manage- transferred to a circulating store where garian plant manufactures up to 6,500 ment decided to extend and optimize the the main sorting with ABC analysis takes engines a day, starting with four, six and facility by adding storage and automatic place. From here, the engines are for- eight cylinders; all the way to ten cylin- sorting mechanisms. The finished engines warded to the appropriate main storage ders and special custom made engines. All are transferred to the conveyor systems location. The Gyor facility currently has in all, Audi Gyor manufactures 1.9 million at dispatch stations on transport pallets. two main storage locations and two re- engines every year for use throughout Audi wanted to improve this process so ception stations. Because the reception the entire corporation including Audi, that important additional data like pallet station is already defined when the en- Volkswagen, Seat and Skoda. This success number, engine number, engine type, re- gines are dispatched, the delivery to the is made possible through sophisticated ception station, dispatch station and oth- reception station or the main storage lo- production and plant technology. er parameters could be submitted to the cation happens safely and easily. control system. Deploying COPA-DATA’s In the reception station the engines zenon software enabled them to do this. are pulled out of the main storage location 58 I automotive I audi györ
in blocks and then prepared for further transport. Additionally, the conveyor system has a reception station before the main storage locations. This way engines can, on demand, be pulled out of the cir- culating conveyer and sent directly to the There are a number of critical require- which are located in different areas of the desired dispatch location through a high- ments the software solution had to meet: plant for fire protection. The additional way. This happens, for example, with cus- Runtime redundancy had to be web server enables the depiction of the tom made engines. guaranteed visualization on the Intranet. Two single Guaranteed system stability workstation displays have been set up on audi has the perfect Extensive alarm management with the plant floor in the engine handling and solution: zenon apropriate alarm statistics maintenance offices. The receiving loca- For an automated facility of Audi Gyor’s A clear depiction of the project tions have a total of eight zenon Client size, it is important to apply a control structure displays at their disposal. software solution that allows status and Extensive and flexible user “Each employee today has access to all operating information to be visualized in administration relevant information, in a fast and reliable a central location. The visualization soft- It was also important to have a way, which is critical in a manufacturing ware zenon has been successfully put to universal solution, from the single facility for competitiveness and success.” use at Audi to help deliver the current work-station through to the Intranet. says Zoltan Ponty, Head of engine han- improvement projects. The project man- Because the plant in Györ, Hungary, is an dling at Audi Györ. agers had already decided to use COPA- international Audi location, the language DATA’s zenon software for the visualiza- switch between German and Hungarian eliminating sources of tion of the SKID facilities in Ingolstadt, had to be guaranteed as well. The zenon error and optimizing Germany, as Johann Mayr, member of the software by COPA-DATA met all of these operations Audi Ingolstadt´s planning group in elec- requirements: “The flexibility of zenon Ino order t avoid sources of error in the trical engineering explains: “We found allows us to meet our requirements in a future and to make the conveyor systems a specialist for Industrial Automation in quick and uncomplicated manner”, adds even more efficient, alarms have to be COPA-DATA. Their professionalism, from Johann Mayr. analyzed regularly and systematically. the planning phase all the way to imple- If an error has occurred, an alarm is im- mentation, has convinced us that with everything at one mediately forwarded to maintenance by COPA-DATA we are relying on the right glance – from any- Message Control via SMS and e-mail. This partner. The performance of the software where in the facility helps to keep the reaction time as short as confirms this again and again in each The individual components of the solu- possible. zenon’s Industrial Performance project. Together, we managed to create tion were deployed at numerous locations Analyzer allows for a statistical analysis an innovative and safe engine conveyor across the plant. The visualization has of errors. This tool displays frequently system.” a Runtime server and a Standby server, occurring errors in a transparent manner audi györ I automotive I 5 9
and detects weak points in the facility. over the complex calculations and regula- path can be followed over the individual Additionally, the sophisticated monitor tions for process control and automation conveyors through to the storage administration helps to make the Mainte- from the zenon Software . This embedded location through the sorting facility all the nance team’s work a lot easier: the process control system, or soft-PLC, is fully inte- way to the receiving location. This path pictures are split between two monitors. grated with zenon in order to make engi- can be corrected and redirected on de- This way, the user can have an overview neering as easy as possible. The variable mand. This enables constant checking and picture displayed on one monitor and a has to be created once only and is then optimization of the sorting mechanisms. detailed picture on the other monitor. available in both systems. From the display terminals, the workers The occupancy of the conveyor sys- in the reception station can see exactly increased transpar- tems at Audi Hungary is displayed in the which engines will be received next and ency allows for faster control application by individual FIFO- can make preparations for their receipt. decision-making components. These data components The detailed alarm administration en- The visualization of the plant encompass- include the pallet numbers that are cur- sures more security and shorter reaction es the elements for display and input, as rently on the conveyor. As it’s not enough times in the case of a breakdown. High well as tablular displays of the occupancy to just display the pallet numbers, straton reliability is guaranteed by the redundant of individual transport channels and stor- ensures that each pallet number is as- configuration of the system. age locations. Together with COPA-DATA, signed the respective pallet parameters Thanks to the visualization of the fa- the project team at Audi Gyor generated such as engine number, type, reception cility, Audi Gyor today has a clear over- several status pictures that depicted the station, dispatch station, etc. view of the status and features of the current condition of the individual trans- Up to 40 parameters per dispatched pallet engines, as well as all required actual and port channels through the use of symbolic can be retrieved. straton generates output target values. The project managers elements. One of the conditions depicted strings that show the engines on a con- Johann Mayr and Zoltan Ponty have al- was the direction the conveyer was mov- veyer with all the additional information ready experienced the benefits: “zenon ing. Additionally, the project-team cre- in individual pictures, either in groups or enables us to use our engine conveyor ated pictures that allow the setting and sorted. systems in an economical way. This year visualization of parameters for the facil- we have benefited from increased trans- ity, such as modes of operation or storage direct and quick pay- parency and optimized operations. With properties. back thanks to zenon the deployment of zenon we were able to In order to generate these tables, Audi For Audi Gyor the visualization of the en- respond to the growing requirements on Györ uses the IEC 61131-3 programming tire engine conveyor system creates more us and a constant need to increase effi- system, straton. straton is able to take transparency than ever. Each engine’s ciency.“ ❚❙❘ 60 I automotive I volkswagen emden
Condition monitoring with zenon – all the key figures at the press of a button.
A streamlined production system is based on all the relevant key figures for production and performance always being available, and on production being standardised to the greatest possible extent. At Volkswagen in Emden, zenon is responsible for transpar- ency in assembly, increased productivity and greater plant availability. Thanks to the zenon-based assembly information system, the maintenance engineers benefit from instant access to all production-related information and key figures.
❘❙❚ The Volkswagen plant in Emden has a daily capacity of 1,200 zenon sets new standards vehicles, and has produced more than 9.5 million vehicles since Several generations of Passats have been manufactured here. the plant was opened in 1964. The Passat Limousine has been Half way through 2003 the 12 millionth Passat, and in Septem- built in Emden since 1977, and the Passat Variant is only built ber 2004 the 13 millionth Passat from any Volkswagen plant was here. The Emden site has been the leading plant in the world for produced. The sixth generation of Passat Variant was launched this successful model. in August 2005. In November 2007 Volkswagen in Emden pro- duced its 15 millionth Passat worldwide. 2008 was the launch year for the new model, Passat CC, that is produced exclusively volkswagen emden I automotive I 6 1
in Emden. The launch of a new model is usually also the transferred to zenon. The entire assembly process is now vis- event that triggers investment in new machines and software. ualised with 172 displays. Another incentive for developing a Volkswagen in Emden took the production of the new series of new application was the fact that the previous operating sys- Passat models as a trigger for modernising the assembly plant tem, Windows NT, was to be discontinued. What’s more, one of and standardising the base software as well as the overlaid visu- the tools used was no longer supported by the manufacturer. alisation software. Here, the zenon software from COPA-DATA, “Overall, the applications from our previous providers were no which is used for the central plant monitoring system, has been longer up to the job with the modern, upgraded structure. We setting new standards in production. compared a number of systems, taking into account our require- ments, and reached the conclusion that zenon met all the crite- consistency in the vw passat ria on our list. We are now using a consistent, standard solution assembly process for the entire assembly process”, explains Georg-Joachim Loger, In the assembly process at Volkswagen’s Emden plant zenon is maintenance engineer at Volkswagen’s Emden plant. This project now responsible for a total of four assembly shops as well as was implemented by process management staff and production for communication with high level and low level systems, for facilities management staff working with staff from COPA- the entire flow of information in the assembly plant and for DATA. Volkswagen was especially happy with the efficient preparing all the data for use in a high-performance, effec- direct approach and the readiness of the COPA-DATA team to try tive information system. There was no other system that was to give us everything we wanted as well as to incorporate chang- capable of satisfying the requirements of Volkswagen’s project es as they presented themselves in the course of the project. managers. An important evaluation criterion for zenon was its use of different controllers and its extensive integration ability. distributed, secure and functional “Because of the increased volume of data in modern plants we zenon features all the modern technology that a car manufac- were not able to capture data from all sections of the plant and turer could possibly ask for. The Volkswagen software is config- to visualise it all. The systems were overloaded and grew con- ured as a client/server system with redundancy, and is therefore siderably slower. A new solution was required”, explains Mario fail-safe. The internal network at Volkswagen now incorporates Ewen, project leader at Volkswagen in Emden. In this case more eight zenon clients. As well as the redundant server pair, there than 120 controllers are involved – different models from dif- is also a database and a web server. The COPA-DATA web server ferent manufacturers. zenon visualises and oversees the entire serves 100 web clients simultaneously. The various process dis- production flow using more than 50,000 variables, which are plays are brought up according to the specific task or functional 62 I automotive I volkswagen emden
area. For storing and archiving data, the managers at VW decid- of graphs and tables. The car manufacturer can now use these ed on a (Microsoft) SQL-Server. The database is automatically key figures to see how cost-effectively the assembly shop is op- populated from the zenon-SQL-Server connector, which also en- erating. In other words, results become measurable. The key fig- sures that the data is read back automatically. Also included is ures might, for instance, include target and actual values for the a powerful user management module for defining access rights overall life of a production line, possible differences, the cycle to the project and system. The user management module is used times, the setting up of events in the plant and their causes, and to specify which users are permitted to view or modify which the number of finished cars. Mario Ewen explains: “Monitoring functions – such as the shift schedules. the key figures ensures that the assembly process is running as efficiently as possible, and at full capacity. This system provides well-thought-out project us with an overview of all the important information, allowing structure us to carry out detailed analyses and react quickly to events as The umbrella project, which integrates all the systems in the necessary.” Volkswagen could also use this data to detect any four assembly shops, includes the system overview displays, delays in the course of the assembly process and the causes, the industrial performance analysis, the production and facility allowing an appropriate response. The integrated soft PLC, manager (for the shift models), the higher-level alarm manage- straton, which complies with the IEC standards, is used to calcu- ment, the chronological events list, counters and plant down- late the buffer, unit, and output counters. To ensure that all the time, plus the initial project for the web client. The individual key figures reflect the assembly processes exactly, Volkswagen sub-projects include the system displays with detailed informa- uses an additional zenon module. The production and facility tion, the driver links and control variables, alarm zones and the scheduler (PFS) controls the chronological sequence of opera- plant’s shift reference. tions in Emden: at this plant a number of working hours models (shift system, lengths of breaks, etc.) are used. The shift hours zenon – successes become entered from the PFS can be classified, grouped and evaluated. measurable They are also fed into the performance calculations. “When all One of the important goals for the new overall system at the figures are combined, they tell the story of how many cars Volkswagen was to gain clear and total control over the assem- we are actually producing. The opportunities for evaluating and bly processes, both for management and for those working in monitoring our assembly processes are more detailed and so- the assembly shop. One of zenon’s exceptional strengths is its phisticated than ever before”, observes Mario Ewen. ability to manipulate large volumes of data and to display them in a useful format to managers or those working in the plant. all the key figures, clearly Volkswagen’s main interest for its Emden plant lay in presenting presented and ready for use the key figures for the production process and output in the form VW managers can view all the key assembly figures in either volkswagen emden I automotive I 6 3
All values displayed in the screenshots in this article are for illustration only.
table or graph form. Individual users can choose how they want 7 (headlamps, batteries, seats, wheels, doors, etc.) and 16 (ini- the information to be presented. They can also select from many tial assembly following paint). All the information is on hand time scales, and different periods of time can be compared with to enable statistical evaluation and analysis with the industrial one another. In this way, Volkswagen workers have access to performance analyser. This information can also be viewed in extensive and at the same time highly condensed information the form of bar charts or pie charts. Filtering options enable that is available at the press of a button in the form of lists and online alarms, historical alarms, pending alarms or reset alarms analyses. to be shown, and to specify their display order: by time, class The report generator shows the archive entries in table form, or priority. and outputs the reports in HTML format - likewise either as a At Volkswagen the alarms are also cleaned up at a break or graph or a table. The Extended Trend module is provided for shift change. This overlaid cleanup process ensures that overlap- preparing data in graph form. At runtime users can arrange for ping messages are not only added, but that the net downtimes various graphs to be displayed, and even for more than one are taken into account in calculating the duration of an alarm. graph to be compared. This ensures that all the relevant opera- Every alarm that has caused a downtime is stored along with tors can view and use analyses, reports and graphs. “The central the possible discrepancy in unit numbers. The discrepancies are plant monitoring application is a tool for improving availability”, evaluated either individually or in total using the line, time, and explains Mario Ewen. shift plan filters, and are displayed on a zenon screen. total control optimising machines actively The higher-level visualisation is now also used as a central point To ensure that the entire system can be serviced, maintained for all events in the plant and system messages. Volkswagen and upgraded efficiently, Mario Ewen and his colleagues have used to operate two systems for this purpose, but these have opted for zenon. It is important to the managers that all future now been replaced by a single standard system. “As well as the system upgrades as well as all maintenance operations can be system and plant monitoring we also wanted detailed analyses carried out without involving a service provider or other exter- – on the one hand to ensure maximum availability and on the nal partner. This saves both time and money. other hand to exploit any potential for optimisation”, explains The industrial maintenance manager is responsible for look- Mario Ewen of Volkswagen. All the operators now know in- ing after the machinery and maintenance data. Service and stantly what they should do if they receive a system message, maintenance intervals are easy to specify, manage and schedule, and can respond straight away. as are the detailed instructions. Those employees who are re- Around 5,500 operating messages and system messages per sponsible for maintenance can now see at a glance when equip- day are produced by the assembly lines in Shops 1 (engine and ment, plant and machinery is due for maintenance. All mainte- gearbox), 2 (main assembly, drive assembly, disks, cockpit, etc.) nance operations are documented in logs. ❚❙❘ 64 I automotive I ford zenon – an innovative solution is the engine of success.
Ford has changed significantly since the introduction of the Tin Lizzy. The cars may have changed, but innovation and modern production technology are still the main focus of the company. For the moderni- zation of its forging and die-casting factory in Cologne, Ford relied on COPA-DATA’s software solution, zenon.
❘❙❚ The name Henry Ford stands for inven- considerations for Ford’s forging and die- tive talent, ideas and innovations. He in- casting factory in Cologne focused on troduced the assembly line, he relied on how to raise the quality and productivity the standardization of components and of the equipment there. “Above all, we he led the company to success, thanks wanted to check the effectiveness of the to rationalization and division of labor. machines that produce transmission com- Today, Ford plants still regularly mod- ponents and engine parts“, explains Frank ernize and optimize existing machinery, Tils, project manager of process visualiza- in order to stay competitive. The current tion, in hall R at Ford-Werke Köln GmbH. ford I automotive I 6 5 high expectations visualization projects. Besides visualiza- “This tool [the IPA] enables us to make Together with his team, Tils aimed at tion, the process control system should a very detailed analysis of facility down- maximum system availability to ensure also allow for machine data acquisition time and the reasons for each instance of smooth production and quality control. and failure statistics. downtime.“ The project manager expects For this, they tested and rated different an additional rise in the efficiency of pro- process control systems for their suitabil- visualization, mde duction from their new ability to analyse ity, among them zenon from COPA-DATA. and performance downtime effectively. The IPA also offers zenon had already been introduced to analysis – all in one a detailed report of past messages and some parts of the plant, but now the en- After the evaluation of the several short- failures for later analysis. gineers wanted to review its performance listed systems, Ford chose the software in terms of downtime analysis. Basic re- solution of COPA-DATA. zenon: “zenon top performance quirements were: is powerful, easy to use and very flex- required continuity, ible. For example, we can adjust projects Thew ne process control system easily Scalability, and even during runtime”, explains Frank Tils. meets the high demands of the produc- modular structure. Another important reason for selecting tion environment at Ford-Werke Köln In addition, the solution had to allow for zenon was its scalability: ranging from GmbH. For example, zenon provides clear the use of other controller hardware. the machine-oriented operation at the and simple visualization of the procedures Other important goals of the project team Windows CE-Panel to the control system during the production of a die cast com- at Ford included: on the PC. Thanks to that, projects can be ponent, thanks to the numerous display vertical integration so that informa- created platform-independently in a sin- options of moving picture elements. tion can be shared with the manage- gle development environment. “In case of machine downtime we ment level, and Over 300 drivers guarantee compat- can get a fast and detailed understanding simple and safe maintenance. ibility with all PLC and bus systems on of the causes for that particular case of the market. Furthermore, the user can downtime. As a consequence, we can re- Frank Tils was looking for a process link different zenon projects in a safe and act quickly and apply counter-measures control solution that is so simple to use powerful way and configure database to reduce downtime”, says Frank Tils. that the service personnel could perform connections simply by using parameters. Thanks to zenon, Ford now uses a special modifications quickly and easily. Even The Industrial Performance Analyser of system to identify the machine operator if they don’t have programming knowl- zenon 6.22 allows for a statistical analysis at the process control system. As a result, edge, the users should be able to adjust of error messages. Ford’s Frank Tils says: there are generally fewer input errors to- day. During machine operation, the zenon archive server also records production and machine data. The machine operator can view this data in a row, in trend curves or in a report. This allows a comprehensive overview of the current production proc- ess. Ford plans to develop the system in the future, and a zenon web server will be deployed to provide relevant production data for management via the company network. ❚❙❘ 66 I automotive I bmw
zenon brings precision to a manufacturing operation.
Welding, bonding, riveting, screwing – in vehicle body construction several hundred components are combined to form a single finished product. Nowadays industrial robots and state-of-the-art technology ensure that vehicle bodies can be produced to the most precise specifications. zenon is an automation and visualisation tool, representing production processes in detail and offering control of all aspects of these processes.
❘❙❚ With a degree of automation of between 90 and 95 per cent, automotive industry. The BMW Group has been using zenon in vehicle body construction represents the most automated area different divisions and plants since 1999 – and now it is intro- of automotive production. Industrial robots finish the individual ducing zenon in vehicle body construction too. components from sheet aluminium or sheet steel here. The sheet metal components of a vehicle bodyshell are first joined to form zenon offers excellent consistency smaller assembly groups such as doors, front section or floor and hardware independence assembly, then welded, bonded or screwed together. A vehicle Users are now benefiting from the many advantages offered body consists of several assembly groups that are manufactured by the zenon software. The system is scaleable, hardware inde- in advance on separate welding lines. Increasing automation in pendent and consistent, and the software runs on CE machines the automotive industry means that production plants and sys- just as efficiently as on PCs. zenon’s consistency means that con- tems must be monitored and controlled ever more efficiently. figuration procedures only need to be carried out once, and this Moreover, as the degree of automation increases, more and allows the user to make significant savings in terms of both time more data is produced that needs to be analysed quickly and and money. The new display system also allows the S7 graphi- with great precision. This is why zenon is of such interest to the cal sequences to be diagnosed in detail. zenon Runtime displays bmw I automotive I 6 7 thee sequenc data from the S7 graphical sequences. The data is This control system, together with the display computer, is in- copied automatically from the programming software. In this stalled in the central BVS cabinet. “BVS” stands for “bedienen, way, users can monitor the statuses of the sequences independ- visualisieren, steuern” (operation, display and control). In the ently from the programming system. At run time zenon shows a central station zenon assembles all the data for control, moni- graphical display of the currently active steps in the PLC togeth- toring and inspection, displays it and prepares it for the higher- er with their statuses. All this information can be subsequently level statistics system. The operators also use zenon if they need evaluated and analysed. In the event of an error, this module to make any kind of manual intervention in the manufacturing will carry out a heuristic evaluation of the disrupted step and process. Distributed stations, most of which are based on zenon will then deliver a probable cause of the error in the form of CE, enable local display and operation (BVO = Bedienung-Vor- plain text. Another advantage to the COPA-DATA solution is that Ort (local operation)). zenon scores a lot better than competing products in terms of the By way of example, is a task that may be performed in the big financial/economic picture. This takes into account licence plant: the sheet-metal parts are positioned, fixed in place with costs as well as configuration and training overheads. clamps and then welded or bonded together. These processes are performed largely by robots. Different measuring methods high level of automation in convey- (including ultrasound and laser) must be employed in order to or systems and manufacturing check constantly and thoroughly to detect any positional de- In vehicle body construction, bodyshells and other components viations in the bodies or other parts at an early juncture. The such as doors and covers are manufactured. The sheet metal conveyor system brings the separate components in and carries parts are produced in the pressing plant and then transported the manufactured bodies out. zenon provides a visual display of via conveyor systems to the manufacturing facilities, where the all these processes. process is continued. Each of these plants is subdivided into various different manufacturing cells known as operating mode planning is the key sections (BA). Each operating mode section represents an au- Definition of standards represents a tried-and-tested means of tonomous sub-cell in technical and organisational terms. A sys- setting up a project efficiently and implementing software. This tem can comprise of up to 15 operating mode sections and uses includes the definition of functions that the finished system an S7-400 as its central controller. All the connected processes, must offer, the special characteristics that need to be included including robots and the safety system, are linked via Profinet. in the corresponding production process, together with the 68 I automotive I bmw
interfaces and the visual presentation. Once these pre-defined robot and another one will represent a conveyor. The graphical standards and methods have been successfully tested in a symbols contain all the graphical properties of the object, and project or a system, then the user can use them at different match the data types. If the display is created using drag-and- production facilities throughout the company or group of com- drop techniques, then a logical link is automatically established panies. between the graphical symbol and the variable. standards ensure reuseability avoiding problems at an early stage and efficiency In zenon, alarm processing shows detailed messages in such a The relevant personnel have developed and documented sample way that the plant operator can rectify the cause of an error projects for these standards, which define the functions, visual rapidly and, if possible, without any help from the maintenance appearance and interfaces. Based on these sample projects, sys- engineers. For alarm definitions, too, the planners and respon- tem projects can be set up quickly and effectively either now or sible personnel have drafted templates for PLC programming to in the future. The sample project contains templates for the dis- ensure that the messages always contain the required details – play objects. Thus pre-defined data types for communication on the one hand for the plant operator, and on the other hand are stored, and these already contain all the necessary elements for the purpose of statistical analysis. The details in question such as value ranges, limit values, colours or graphic objects. may be the operating mode code, the operand (physical address) Based on a data type, the variables for the display are then cre- and the operand’s symbol name (“Forward movement at rear”) ated. Here, the variable name and the PLC start address must for easy identification and labelling for a radio communication be specified. All its other properties are already stored in the system. Apart from alarm management there are also many oth- data type, and the variable inherits these automatically. Graphi- er advantages and strengths to impress users in the automotive cal symbols are stored in a library for creating system-specific industry: The zenon solution ensures flexibility, consistency and images. For instance, one graphical symbol will represent a quality in production. ❚❙❘ bmw leipzig I building automation I 6 9
Operating technical facilities efficiently and safely.
From the very start of the planning process, ❘❙❚ If the facilities of a company are not operated and managed BMW decided to use only the most modern efficiently, costs will rise and resources will be wasted. BMW building automation technology for optimal Leipzig therefore decided to strike a new path. Already in the operation of the technical facilities and build- design phase, BMW Leipzig aimed at creating an efficient, ings - with minimum personnel expenses. reliable and secure system with the new building automation The project implementation was entrusted technology; a system that would monitor, control and direct the to Cegelec, while zenon by COPA-DATA technical facilities. In cooperation with Cegelec, facility and au- GmbH was chosen as the software for build- tomation technology GmbH & Co. KG, from Frankfurt, BMW ing automation. designed an integrated control system for the complete techni- cal and electrical facility equipment. All relevant subsystems are connected with standardized, open and mostly non-proprietary protocols. The communication between these components takes place via TCP/IP in the network of BMW.
analysis and optimization Building automation technology displays the operating condi- tions and technical parameters with clearly structured facility pictures: altogether, it processes about 53,000 real data points 70 I building automation I bmw leipzig
(sensors, actuators and readings) and 70,000 virtual data points responsible service provider for this project at BMW Leipzig, from different information sources (data collection points, con- explains: “BMW has created the foundation for efficient en- trol cabinet with PLC) of the whole plant and it visualizes op- ergy and cost management, because all information about all erating conditions with over 1,500 facility pictures. With zenon buildings and technical facilities are available for analysis at all software by COPA-DATA and the project implementation by times.” Building automation with zenon® makes it possible today Cegelec, BMW can now get a clear overview of all cost-relevant to change all relevant target values either manually at the work processes concerning their technical facilities and buildings. This place or automatically through an interval timer program. allows for professional facility management and plant control. For this purpose, the convenient Production and Facility The data collected in building automation is based on a newly Scheduler of zenon is employed. This allows, for example, for developed equipment identification system (AEI). This system the flexible operation of ventilation facilities in different oper- identifies all the components of the technical and electrical ating and load conditions. A further example: The responsible building equipment, even the passive components of the IT, employees can control all lighting systems (manually through across different assembly sections. the user interface or automatically depending on lighting and time conditions) and therefore adjust them to the changing re- the logical structure of the quirements of the production flow. aei supports an efficient alarm management working efficiently with minimal Process management by operating personnel makes it possible resources to run all technical facilities in the Leipzig plant in an efficient, It was very important for BMW to combine flexible workplaces energy-saving and cost-efficient way. Required parameters that with relatively low license costs. The integration of all techni- are not generated on field level (like performance data) are cal- cal systems administered by Facility Management into a supe- culated in the building automation system. The solution saves rior building automation system makes it possible to control all parameters in archives and provides reports for individually the whole plant from a relatively small control room with two configurable trends. The powerful zenon SQL interface stores redundant zenon workplaces. The operator can watch, control relevant values in an Oracle database for a long-term plant and direct the facility processes here. An additional stand-alone optimization. These values include meter readings or detailed server is used as an engineering workplace for future mainte- consumption data. Collecting this data makes it possible to nance and optimization processes of the system. Apart from the optimize control loops. BMW, for instance, calculates the NET two fixed workplaces in the control room, there are only about value (Normal Effective Temperature = temperature as per- ten laptops that are used as additional zenon operating stations. ceived by employees) from temperature, humidity and air speed On these laptops, employees of Facility Management can watch and displays it online. Kurt Fingerhut, manager at Cegelec and and test technical facilities. Because of the system concept and bmw leipzig I building automation I 7 1
the high availability of the GLT, BMW Leipzig decided against against the installation of permanently recording alarm print- fixed on-site operating stations and saved costs for hardware ers because of the high availability of the complete system and software. and the possibility of access from every spot of the plant via mobile computers. Instead, powerful color laser systems de- secure servers control the liver all the lists, hardcopies and protocols, in color and in sizes facilities up to A3. Two separate alarm systems were designed and im- The system concept of building automation consists of two plemented, in preparation for running the control room with redundant zenon servers, which are installed in the two com- reduced personnel. The most important alarm groups of the puter centers of the plant. They form the central element of building-specific facilities can be transferred to the perma- the building automation system and they control the entire nently occupied work places of the factory security offices of communication with the underlying information sources of the the Leipzig plant. automation level and the connected operating stations. Fur- Failures of the plant-wide infrastructure (e.g. compressed thermore, those two servers handle data administration, data air, heat and power supply) are reported additionally via SMS archiving and many other additional functions of the control to the stand-by duty of the Facility Management Provider system software. outside of the plant. For this, the project team at Cegelec These functions include performance calculations and in- has developed an interface for the automatic transmission of terval timer programs. With these functions, all the relevant alarm data to an SMS server, which was installed for the whole target values and operation modes of the building-specific sys- plant. tems can be adjusted according to the different operating, load and time conditions. If production is active in a hall, the tem- complete monitoring and control perature is automatically lowered if it is getting too hot in the Thew ne system for building automation was tested thoroughly production halls. The IT department is in charge of server opera- over several months – under the most demanding conditions: tion and data backup. The two servers for building automation, The system survived a plant-wide blackout of the power sup- which are running Windows 2000 Advanced Server, are on the ply without problems. Kurt Fingerhut summarizes “We were same level of availability as the servers in vehicle production. able to reach all the goals that we had in this project: Complete The plant’s Facility Management is responsible for the opera- monitoring and control of the facilities with minimal use of per- tion and maintenance of the application software zenon. sonnel and resources.” Professional building automation creates possibilities for cost reduction and delivers a significant boost alarm management for security of effectiveness. BMW was able to tap those possibilities for Alarme messag handling and failure resolution is another im- cost reduction thanks to the technical possibilities of the zenon portant process in building automation. BMW Leipzig decided software. ❚❙❘ 72 I building automation I allianz arena
Kickoff with COPA-DATA in the Allianz Arena.
From match day to match day, the Allianz Arena shows us how perfectly organized a football stadium can be. Ranging from the individually controllable lighting system and the sophisticated building control to the efficient security measures. This can only work when the different technologies and products are perfectly coordinated and visual- ized for the control room. This job is done by zenon, which was the only HMI/SCADA system to fulfill all the requirements of the operators regarding flexibility and compat- ibility. zenon maintains an excellent overview, puts all the important processes on the screens in the control room and even keeps watch in unoccupied stations, if necessary.
❘❙❚ From match day to match day, the Allianz Arena shows us how perfectly organized a football stadium can be. Ranging from the individually controllable lighting system and the sophisticated building control to the efficient security measures. This can only work when the different technologies and products are perfectly coordinated and visualized for the control room. This job is done by zenon, which was the only HMI/SCADA system to fulfill all the requirements of the operators regarding flexibility and com- patibility. zenon maintains an excellent overview, puts all the important processes on the screens in the control room and even keeps watch in unoccupied stations, if necessary. allianz arena I building automation I 7 3 open and independent COPA-DATA also feels committed to making work easier for the One of the biggest challenges in the Allianz Arena was to main- users. Easier, because they can see all the important information tain the overview in a complex system and to ensure the smooth at a glance. But also because they can handle the system in an interaction of all components. COPA-DATA Sales Manager Hans- intuitive and simple way.” The technicians in the Allianz Arena Peter Ziegler: “Today, it is easy to monitor and control all sorts highly appreciate the fact that they can usually work with their of things, but the problem usually lies in the overview and the familiar user interface. By the way, this is one of the special ad- appropriate visualization. It is important not only to realize that vantages of zenon: The integration of applications into a uniform something happens, but also to see at a glance what is happen- user interface. It works with the different Windows operating ing where. Preferably, with clear messages that leave no room systems and cooperates with the most different kinds of hard- for interpretation to the technician; this is the only way he can ware and software. This is due to its consistent design, the vari- react quickly and correctly.” For zenon, this means displaying a ety of drivers and – not to forget – its well-engineered security few thousand sensors and many different signals in a clear and mechanisms. concise way, so the operating technician gets a clear overview. Complex processes are supposed to be packed into simple sym- zenon – on the ball long bols and messages. Hans-Peter Ziegler explains: “If you want to before kickoff use the best technology in every subsystem, you often have to Attractive matches fill the stadium up to the roof in a height of 52 coordinate very different systems. With zenon, we can correctly meters. On seven levels, the perfectly engineered infrastructure receive, interpret and forward a large amount of data and sig- bestows an untroubled match experience upon an audience of up nals from different sources in a very safe and straightforward to 70,000 people: quick yet safe access control, simple paths to way. The main task of zenon is to merge all the substations and the viewer seats, climate control adjusted to every situation. connections into one zenon integration project, creating a clear Long before kickoff, the systems in the stadium are launched; overview. “ zenon makes life easier for engineers, when it comes the energy supply is checked, the electronic access control with to integrating different types of hardware and software. On the video surveillance provides for a smooth stream of visitors and one hand, zenon brings along over 250 fully developed driv- high security. All of this happens without much effort; the or- ers. On the other hand, it enables engineers to create their own ganization of a match day’s procedures is pre-programmed quite individual connections, for example with VBA. For controlling simply on the PC. After entering time and date, all the necessary the exterior lighting, the engineers can access the colored neon actions are launched in the background. All employees of the lamps quite simply and create shining colors on the stadium’s Arena are equipped with transponders, which enable a constant 24,500 m² of membrane exterior cover. surveillance of accesses and routes traveled. The access to the 74 I building automation I allianz arena
stadium without transponder or a valid ticket is de facto impossi- overview in the control room: ble. The control system keeps a seamless record of all actions and automatic messages and remote messages and the sophisticated filtering and sorting functions of configuration zenon give a comfortable overview in the flood of data. With a The central control room is constantly collecting all informa- mouse click, the currently important data is filtered out. Security tion and interpreting it. The interpretation is so clear and con- is of course an important issue, also for the HMI/SCADA system. cise, that one single person can handle the control room during We were able to provide the operators of the Allianz Arena with calm phases. Even during peak periods, the overview is always a user administration system, which fulfills even the extremely maintained.The best foundation for this is exact planning – strict requirements of the pharmaceutical and food industry. the Extended Trend Module (ETM) of zenon does just that. It User rights can be defined very exactly and individually, and shows current or archived data and creates the foundation for each manipulation of the system is recorded in detail. exact evaluations. For example, the operators get an overview of power consumption, visitor streams, parking-lot utilization snmp – all clear in the net and much more – at present or over any space of time. With A stadium as big as this depends on a high-performance power this reliable basis, developments and requirements can be pre- supply. zenon Product Manager Reinhard Mayr: “In the case of dicted and consumption peaks can be anticipated and their im- the arena, we are talking about a 12 Megawatts power input. pacts reduced. Additionally, the zenon Web Server supports the Two independent transformer stations guarantee a seamless technicians. It always displays the system in its current state power supply. This puts fail-safety on top of the list. We advise and with the same familiar interface as on the terminals. The against any compromises here. Redundant wiring, distributors technicians use web clients to access the system directly, which and networks are a must.” In the Allianz Arena, the energy infra- enables them to react quickly to alarms, even from outside the structure is also monitored by way of SNMP. With a few mouse control room. clicks, SNMP-compatible components are read out and their data On match days, the central control room is filled with techni- points are created. Per drag & drop, they can be put immediately cians. They monitor and control lighting, network, access control, into the appropriate process pictures. Without disturbing or even parking lot, ventilation, heating and cooling. Things are getting interrupting the system, the altered process pictures are trans- busy and everybody’s full attention is required. Now, they are ferred back via Hotreload. Consequently, new components can profiting from zenon’s multi monitor technology. Multiple screens also be added without problems. The combination of redundant show all the important information simultaneously, so that noth- components and zenon functionality guarantees the seamless ing of importance gets out of sight. Nothing can be overlooked; availability of power supply in the Arena. potential problems are recognized from the very start. allianz arena I building automation I 7 5
zenon in the allianz arena – a summary: around-the-clock Control and visualization of the complete During its operation, zenon handles thousands of data points, building services prepares and archives data and transmits clear messages. Mod- Smooth integration of hardware from ules like the Extended Trend Module (ETM), Archiving, Alarm- different providers with our own drivers ing, Scheduler, but also SNMP and Beckhoff drivers, VBA mac- Open interfaces for VBA and OPC ros and many other zenon features are active. They guarantee High security standards a safe power supply, they monitor entrances and parking-lots, Multiple project administration check the UPS or alarm technicians, if necessary. And when the Simple administration and monitoring lights go down and the parking lots become empty and the build- of network devices with SNMP ing services are shut down to a minimum after a long match day, Analysis and forecast with the Extended zenon stays vigilant and keeps watch. Trend Module Web server technology for remote administration 76 I building automation I montblanc
Using energy efficiently.
Simple management of the technical systems in a building and efficient monitoring of all the equipment and systems is the dream of every facility manager. zenon turns this dream into reality. One site to benefit from the zenon system is the Montblanc site in Hamburg, with its workshops and administration building.
❘❙❚ As an open, manufacturer-independent ory an type of error message is displayed these systems and processes in the most system, zenon is ideally suited for use in a and managed in the system. Loading efficient way possible. This is also the task building management system. The visuali- patterns (power consumption over a pe- that falls to Claus-Dieter Brandt and his sation and monitoring of operating states riod of time) and temperature graphs are colleagues who are responsible for op- and the optimisation of operating modes in stored in zenon‘s long-term archive. The erational systems at Montblanc, the tra- complex systems enables a building to be facility manager can retrieve this informa- ditional company based in Hamburg. The managed efficiently. zenon communicates tion using the zenon “Extended Trend” team must respond quickly to fault mes- with the automation level via standard module. The information is also available sages and either restore the functionality interfaces like OPC (OLE for Process Con- in the form of reports for the purpose of of the device or the system or start repair trol), LON (Local Operating Network) and precision analysis. zenon thereby creates work – this applies to the production fa- BACNet (Building Automation and Control a facility for monitoring complex techni- cilities as well as administration. “Our par- Networks). Every event, such as the fail- cal systems and control-engineering proc- ticular challenge in building management ure of a unit, the violation of a limit value esses, but most importantly for operating systems is to reflect growing structures montblanc I building automation I 7 7
and changes in a company as quickly as possible, and to monitor all systems efficiently”, explains Claus-Dieter Brandt, building technology manager at Mont- blanc Simplo GmbH in Hamburg. This company is now characterised by growth because the demand for Montblanc prod- ucts is stronger than ever. For several gen- erations Montblanc has been well-known as the manufacturer of exclusive writing equipment, and more recently the compa- ny has also established itself as a supplier of watches, jewellery and leather items in the luxury goods sector. writing culture and craftsmanship These exclusive products are produced by Montblanc, which was founded in 1906. They satisfy the strong demand for tradi- are the artisans‘ studios located in Ham- partner eNeG to work on this project. tional European craftsmanship and time- burg but also the company‘s main admin- eNeG is also based in Hamburg, and spe- less design. Montblanc employs around istration and international headquarters. cialises in designing and installing intel- 2,400 people in 28 subsidiaries, and sup- Montblanc has around 1,000 employees ligent building automation systems based plies its luxury products to some 6,000 re- based at this site. The production branch on BACNet, LonWorks and Profibus, tail outlets in 70 different countries and to of the company is called Montblanc Sim- eNeG works with state-of-the-art compo- 70 Montblanc boutiques. Montblanc be- plo GmbH. It is located in Hamburg and nents and makes certain that they interact longs to the Richemont Group, which was has 820 employees. perfectly. eNeG is involved not only with founded in 1988 and is based in Geneva. building automation but also power sup- The Group specialises in luxury goods, zenon offers ply systems. The range of services they and its member companies include the re- security and protec- offer extends to maintenance, servicing nowned jewellery and watch firms Cartier, tion of investment and monitoring. eNeG has 60 employees, Piaget, Van Cleef & Arpels, IWC, Jeager- Montblanc sets very high standards for and its customers include various well- LeCoulture, Lange & Söhne and Panerai. safety, comfort and air conditioning in its known companies including Jungheinrich The Group also includes other well-known production facilities and administration AG, Beiersdorf AG, Hamburger Sparkasse names such as Dunhill, Baume et Mercier offices in Hamburg. At the same time the as well as MontBlanc Simplo GmbH. and the fashion company Chloé. Mont- company aims to keep power consumption blanc manufactures its products in Germa- and operating costs to a minimum. Claus- the quest to find a ny, Italy and Switzerland in order to use Dieter Brandt therefore set out to find a stable standard solu- and also to preserve the expertise of tra- building management system that would tion was successful ditional European craftsmanship. Mont- be capable of meeting these criteria. “What The Montblanc team was keen to install blanc produces its writing implements at we were looking for was some standard a standard solution that would be stable its original factory in Hamburg. The proc- software that would offer protection of and capable of running twenty-four hours ess is still very much a manual one involv- our investment. It was also important to a day. Claus-Dieter Brandt already had ing the skill of craftsmen, and production us that we could count on professional positive experience with zenon from ear- remains centred on the artisan‘s studio. support from experts and professionals lier in his career. He evaluated a number These studios produce very limited num- while installing and operating such a sys- of other solutions too, but ultimately his bers of ornate collectors‘ pieces and indi- tem”, explains Claus-Dieter Brandt. Mont- decision was an easy one to reach. Three vidually made special editions. Not only blanc has chosen the COPA-DATA system buildings – the administrative offices and 78 I building automation I montblanc
the operator can, for instance, determine which system component is in operation or has triggered a fault message. The cooling and ventilation systems feature an over- view display, from which you can move on to the detailed views. Filters, heaters, coolers, fans – detail displays are available as required for each component in a ven- tilation system. These displays clearly in- dicate whether valves and sensors, for in- stance, are operating correctly. Thanks to this comprehensive visualisation, Claus- Dieter Brandt is now able to run and regu- larly update a complex building manage- ment system with just a small team and low overheads. And there are even plans to extend the system: the system manager can easily conceive being able to monitor two production facilities – are now moni- between target values and actual values these systems remotely and to upgrade the tored centrally using zenon. In total these are logged in zenon, whereby any con- alarm management system so that alarms buildings have been fitted with five tech- sequences they may have will become are forwarded to the mobile phones of nical hubs. There are 25 ventilation sys- apparent. Claus-Dieter Brandt views the relevant staff; such systems are already in tems (HVAC systems), two compressed-air target values and actual values and any place at the new Montblanc logistics cen- systems each with two compressors, two differences between them in the form of tre. This ensures that thorough monitor- heating systems each with two boilers, a graph. This is made possible by the “Ex- ing can be carried out twenty-four hours and two cooling systems with ten com- tended Trend” module. This module allows a day. As old systems are replaced one by pressors. Each technical hub also includes historical data (e.g. all the information re- one, all the new systems are automatically a heat-recycling system. The company has corded in the course of a heating cycle) as integrated with the zenon system. This will now been working with zenon since 2002, well as on-line data to be retrieved and result in central monitoring, an increased with the primary focus on operating and viewed in the form of a graph. In this way, concentration of data, and thus an even observing the technical systems in the those responsible for the building man- more comprehensive flow of information. buildings. At Montblanc these systems agement system can see how the systems “All new systems are now linked in with include HVAC, compressed air and extrac- are performing, when critical states in the the building management system – zenon tion systems in the laboratories, heating systems occur, and where immediate in- will play a part in every single project”, and hot water supply. To condition the tervention is required. It is equally impor- explains Claus-Dieter Brandt with a look air in the administration building alone tant to observe systems over a consider- of conviction in his eyes. The manager is Montblanc uses 77 coolers and four exter- able period of time – ambient conditions planning to gradually step up the use of nal cooling systems. such as outdoor temperatures vary and this system. His intention for the future affect the performance of a system. is to store detailed system descriptions as trend analysis is well as dependencies so that in the long essential easy to operate term data can be analysed even more spe- In total, the systems in the main build- Claus-Dieter Brandt finds zenon very easy cifically and preparation can be carried ing include some 2,800 data points, with to use: when an alarm is selected in the out for maintenance operations. Likewise, a further 600 data points in the new alarms list, a simple click on the “System the management team in Hamburg is to be Montblanc logistics centre. All these sys- display” button will automatically open linked up with the new logistics centre in tems are comprehensively visualised in the relevant alarm display. This allows sys- Ellerbek, so that this second site can also zenon. Any problems or discrepancies tem components to be inspected in detail; be monitored and checked centrally. ❚❙❘ tcvvv I energy I 7 9
Clean heat for Santa Caterina.
There are plenty of winter sports enthusiasts who count Santa Caterina as their favour- ite resort. Santa Caterina has also hosted more than its share of exciting world-cup ski- ing. Cold temperatures may be welcomed out on the piste, but whether you’re a casual weekend skier or a top international athlete, you’ll still want to be snug and warm once you’re back indoors: This represents a challenging task for TCVVV AG and its district heating plant in Santa Caterina Valfurva.
❘❙❚ The company TCVVV AG was founded in 1997 to produce The district heating plant uses mainly waste products from and distribute clean energy from biomass, and use it for heat- wood processing, tree surgery and afforestation. Weekly deliv- ing and electricity generation. This company builds production eries from local sawmills and other local suppliers guarantee the facilities, and designs and constructs district heating plants and plant’s supply of renewable energy sources. To protect the en- electricity stations. Managing director Walter Righini: “Our pri- vironment, the waste gases produced in the combustion process
mary objective is to use and add value to local resources; by are constantly monitored. The amount of CO2 produced when using renewable energy sources we aim to reduce our depend- the plant is in operation is exactly the same as the amount of
ence on energy from external sources. The municipality of Santa CO2 yabsorbed b the trees during their life cycle; this is why Caterina Valfurva is not connected to the methane gas network, the district heating plant can justifiably claim to operate on a
but it does have access to renewable energy sources, in particu- CO2-neutral basis. lar wood. This is the main pre-requisite for building a district For control and data acquisition in its district heating heating plant fuelled with biomass.” plant, TCVVV AG was keen to go specifically with PC-based 80 I energy I tcvvv
technology and an Ethernet network. For safety reasons, re- Both systems – server and stand-by – are always supplied dundancy was to be built into the PC network. In the words with the latest data. They also both communicate with the con- of the engineer Fabio Pola, who held overall responsibility for trollers; in other words all the data sent by a PLC arrives simul- all the hardware and software: “We were particularly keen to taneously on both computers. If the control computer fails, then avoid as far as possible working with conventional PLCs, be- the stand-by machine will take over immediately. As soon as cause redundant hard PLCs are difficult to find and also costly. the first server is operational again it will automatically retrieve We were looking for modern, open technology that would allow all the latest data and will resume control, again with no inter- us to work in a flexible way whilst at the same time reducing ruption. our costs.” integrated solution for safe, designing a clean energy supply economical operation COPA-DATA proposed a redundant, integrated solution to Different controllers are addressed from the control station, and TCVVV AG to safely supply the district with heating. The dis- by using Profinet the existing network structure can continue trict heating plant in Santa Caterina features a zenon control to be used. As the standard fieldbus, Profibus replaces the in- system that gives the operator central access to all the parame- convenient serial connections and expensive special plugs with ters for the burners. The IEC 61131 compliant straton is already Industrial Ethernet. This provides considerably more functions, integrated into zenon. This is a soft PLC which is also embedded simpler operation and greater speed. It also spares TCVVV AG in a hardware PLC, and it created the link with the controllers. the time and expense of special cabling. Redundancy can easily be incorporated in both these systems. straton checks via its Profinet link five Wago 750-340 Profi- The zenon operating system and straton work extremely net devices at a distance of 30 to 40 metres and, as a soft PLC, well together, and this brings the project a number of benefits, controls various steam boilers using these fieldbus couplers and especially in terms of speed, data security and cost reductions. retrieves temperature values for archiving in the control system, zenon and straton run on the same server. They are so close- where they are analysed in trends. Analog signals from the boil- ly linked that they even use the same database, which makes ers are retrieved and the relevant valves controlled. The cycle configuration considerably simpler, quicker and safer. Variables time is 100 ms. therefore only need to be created and maintained once. However, straton is used not only on the I/O level. Being a The server for the TCVVV project is also designed with built- versatile tool and an embedded solution, it also carries out im- in redundancy, and it will continue to work perfectly even if a portant functions in controlling the pressure compensating tank. module in a computer should malfunction. For safety reasons, the standard requires that a hard PLC should tcvvv I energy I 8 1
be installed. Even if the device loses its link with the network, and needs to interface to another control system that moni- it is essential to ensure that the tank is carefully controlled. The tors the gas concentration and is used for certifying the system. device selected was a Wago 750-860 fieldbus controller in which straton therefore uses the Profinet couplers from Wago to read straton, embedded as a runtime PLC, ensures reliable perform- out the values, and then makes them available to the control ance. As an embedded solution, straton is particularly conven- system via Modbus. In this situation straton is acting as a slave, ient for the end customer as it simply needs to be unpacked but it could also act equally well as a master. But another point and connected. All the configuration modules are created using illustrated by straton and zenon in Santa Caterina is how easily the straightforward intuitive straton configuration tool with its existing systems can be integrated into a project. In parallel with graphical interface, and variables are linked via a menu or using the district biomass heating plant, a collective boiler also had to drag-and-drop techniques. The district heating plant in Santa be integrated with the visualisation and control modules. This Caterina benefits above all from the extremely productive inte- “VAS” boiler is controlled with an S7-300 which is linked directly gration between straton and zenon. Both straton and zenon can to zenon by using a dedicated S7-TCP driver. The alarm sensor be operated as redundant systems with just a few mouse clicks. and analog data, for instance, can be evaluated simply without Only two PCs are needed to implement a redundant system: all any need to invest in any additional hardware or software. straton projects, just like visualisation running under zenon, will run on a single PC. The second computer is present in a stand- knowing what’s going on by capacity. This combination of redundant visualisation, soft Data produced during ongoing operation is available at all times. PLCs and fieldbus I/O produces a highly secure solution that It is collected by straton and zenon and archived by zenon. The is very easy to configure and can, moreover, be implemented plant operator alone makes the decision regarding where these affordably. The straton projects, like the visualisation modules, archives are stored. If they wish, zenon can even write archives are configured in the zenon editor. Software engineer Fabio Pola direct to databases, ensuring that no data is lost in the event of comments: “We found this integrated solution especially effec- system failures. Like on-line data, archived data can also be dis- tive from the point of view of configuration. Not only do the played at any time in the form of an informative trend display: visualisation module and the PLC share the same database, but The Extended Trend feature in zenon converts historical and the same, familiar editor can also be used to configure different current values into smooth curves. This feature gives full con- target systems.” trol over curve parameters, axis configuration, zoom factor and The versatility offered by straton is demonstrated by the way much more. Any number of curves can be displayed simultane- it can operate as a gateway for an ABB gas measuring device. ously, even if their scaling varies. Since the Extended Trend can Interestingly, the gas measuring device has only analog outputs display two time axes at the same time in the same chart, it is simple to compare different time periods or batches.
quick and secure configuration TCVVVG A succeeded in commissioning its district heating plant within 12 months. It didn’t take long to get zenon configured either. Klaus Rebecchi from COPA-DATA Italia commented: “The TCVVV AG engineers are particularly enthusiastic about the way all the details, including straton, are configured in a single development environment. In other words only one tool is re- quired, and it takes next to no time to learn how to use it.” This brings down both training and running costs consider- ably, and at the same time reduces dependence on outside ex- perts. The redundant technology increases operational reliabil- ity and ensures that the control system is available at all times. Software engineer Fabio Pola comments: “zenon and straton have enabled us to make use of innovative and affordable PC- based technologies with our existing Ethernet, and to communi- cate directly with the PLCs from a PC. This solution has signifi- cantly reduced our investment and maintenance costs.” ❚❙❘ 82 I energy I uttendorf
High tech for ÖBB – power generation.
ÖBB’s hydro-electric power plants in Stubachtal have a 210 mega- watt rating.The plants produce the main part of ÖBB’s electricity supply. Obviously, the control and monitoring of such a plant is laid into competent hands.
❘❙❚ Apart from several “museum-wheez- valleys were analysed by the K&K Rail- es”, almost 100 % of all railroads are driv- road Cooperation concerning their suit- en with electrical locomotives. 97 % of ability for hydro-electric power plants. In the required current is produced by local 1929 the generating plant Enzingerboden hydro-electric power plants. ÖBB tradi- started operation. The gradual extension tionally draws the current, required for of the plants Schneiderau and Uttendorf its trains, also from Salzburg’s province in diverse preliminary reservoirs fol- Pinzgau. Shortly after the beginning for lowed. The reservoirs provide water that the 20th century, the Kaprunertal-Valley is conducted via adits and penstocks to and afterwards also the neighbouring the plants’ turbines with generators. Due uttendorf I energy I 8 3
to a rating of 210 MW, Stubachtal’s plants controller, visualisation of power sup- are able to provide about half ofthe surge ply units, control of headwater systems current required by ÖBB. Without own (for involvement of reservoirs), control plants this current would have to be pur- of home requirement systems, security chased; Ing. Wolfgang Steiner, Stubachtal service (gate control, door monitoring), Group’s foreman concerning control req- counter logging, as well as message log- uisites in the plant domain: “The entire ging and alarming for all. Stubachtal plant group is controlled via SAT 230. This process control system is smooth considered as one of the most innovative implementation products in this field and also provides This system has been perfectly installed visualisation.” SAT 230 is a modified ver- and implemented by VA TECH SAT to- sion of the process control system zenon gether with ÖBB plants’ employees. by COPA-DATA qualified for automation Steinberger: “We transmit high energy of plants and transformer stations. quantities via 110 kV main or with power switches and breakers from the amazing potential transformer station to the consumer The following features are offered: con- (locomotives). Coping this task requires trol of 110kV-16,7 Hz substations (ÖBB a modern and reliable control system. uses current with 16,7 Hz unlike house Therefore the implementation of this frequency of 50 Hz), handling of start new system was necessary. SAT 230 and shut down action of machines (the satisfies most modern handling- best provides a capacity of 33 MW), principles. During the implementation visualisation of machine sets, water shut process we were competently supported systems, turbine controller and voltage by VA TECH SAT.” ❚❙❘
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