05.15 The B&R Technology Magazine Process and factory automation Take control of every process mapp technology Full focus on innovation Automation Studio Standardization paves the way to the future HMI systems What goes around, comes around Process control APROL – For stepwise migration editorial As environmental regulations and demographic chang- publishing information es continue to shape the future of the process manu- facturing industry, one of the most prominent themes will be plant modularization. The challenge of the mod- ular plant will be how to quickly and effectively inte- automotion: grate intelligent units into a complex production line The B&R technology magazine, Volume 16 without excessive engineering overhead, yet retaining www.br-automation.com/automotion the ability to satisfy customers' individual requirements and requests. Media owner and publisher: Bernecker + Rainer Industrie-Elektronik Ges.m.b.H. B&R Strasse 1, 5142 Eggelsberg, Austria In spite of all this newly gained flexibility, there is no Tel.: +43 (0) 7748/6586-0 room for compromise with regard to product quality, [email protected] seamless documentation and traceability, and sustain- able production methods. Managing Director: Hans Wimmer B&R's APROL process control system satisfies the requirements of flexible and modular Editor: Alexandra Fabitsch process manufacturing plants without neglecting the high demands on availability Editorial staff: Craig Potter Authors in this edition: Eugen Albisser, and data consistency. This innovative distributed control system already facilitates Yvonne Eich, Vitor Hayakawa, Stefan Hensel, the design of machinery and plants that meet the needs of Industry 4.0 production. Peter Kemptner, Jana Otevrelova, Franz Joachim Roßmann, Jaehoon Sa, Huazhen Song APROL has taken the next step in this direction with a fully integrated business intel- ligence solution that gives users powerful and convenient reporting functions that Graphic design, layout & typesetting: allow for exploratory analysis of plant and production data. Linie 3, www.linie3.com Printing: VVA Vorarlberger Verlags- In this edition of automoton, you'll find out more about the potential for advanced, anstalt GmbH, Dornbirn Published at: B&R Strasse 1 modular process and factory automation. 5142 Eggelsberg, Austria Cover photo: iStock. We also look forward to welcoming you at ACHEMA 2015 in Frankfurt. All articles published in this magazine are protected by copyright. Translation, reproduction and Happy reading! duplication are prohibited without the expressed permission of the publisher. B&R assumes no liability for any errors they may contain. Follow us Stefan Lau Head of B&R's Competence Center for Process & Factory Automation, Northern Europe 05.15 01 contents 14 04 18 main topic APROL news 04 Take control of every process 12 Competence Centers for Process & Factory Automation Complex manufacturing processes need fully integrated B&R’s industry specialists share years of process systems to control, monitor and coordinate every aspect manufacturing expertise at the new international APROL of production. Competence Centers. 08 Managing migration risk with B&R process control 25 Standardization paves the way to the future Sanofi Aventis relies on APROL for producing Automation Studio makes programming and configuring pharmaceutical products. multi-axis systems easier than ever. PLCopen-certified function blocks have been added to the proven Generic 14 APROL – For stepwise migration Motion Control solution. CHT’s migration project shows how stepwise migration helps avoid unnecessary production downtime. 44 Technology day: Open Robotics & Industry 4.0 Invited by the EPSG, more than 120 industry and 18 Fully automatic, automatically full university experts came to Lyon to discuss the latest Lenzing produces cellulose fibers for textiles and developments in the field. sanitary products. APROL’s model predictive fill level control relieves operators and improves reliability. 62 Break free from hardwired safety Thanks to B&R’s new safe digital mixed modules, 22 Energy savings on a dairy basis integrated safety technology is now no more expensive In less than six months, Charalambides Christis than a conventional relay solution – even in the implemented APROL’s energy monitoring solution to smallest applications. reduce resource consumption 20% over three years. 63 POWERLINK approved as Korean Standard 64 More OPC UA in APROL POWERLINK is the first 100% open source protocol OPC UA now makes it even easier for controllers, registered by the Korean Industrial Standard Commission HMI panels and SCADA systems from any manufacturer for industrial communication networks. to exchange data within B&R’s APROL process control system. 02 26 50 46 58 report 26 Shear genius 50 Fast and fluid, steady and safe While reducing production costs, EHT managed to step b+m surface systems called on B&R to help get up performance and simplify access to the versatile their custom painting lines to market faster without functionality of its power squaring shears. compromising on safety. In a year and a half, they’ve delivered more than 100 robots featuring the 32 Generating high availability with POWERLINK new controller. POWERLINK offers high availability at minimal added cost. Czech control system specialist ZAT uses a POWERLINK ring 54 Engineered to order network for its redundant control systems. Switching to a single, integrated control system from B&R helped Pillar Induction achieve its ambitious goals. 36 What goes around, comes around Kilian Tableting boosted its order volume by 15%. The 58 Safe ascent in any weather award-winning KTP420X rotary tablet press and new HMI To ensure cabins full of passengers reach their lofty system helped make it happen. destinations safely no matter how hard the wind blows, the control specialists at SISAG trust in the expertise of B&R. 40 Air of sophistication Small quantities of purified, conditioned air are in increasing demand among manufacturers of cars, semiconductors and pharmaceuticals. With its low volume climate control units featuring B&R technology, interview pure engineering has the solution. 30 “Full focus on innovation” 46 Hot tech B&R caused quite a stir at the 2014 SPS IPC Drives with Opelka’s continuous pastry fryer is a baker’s dream. mapp technology. Christoph Trappl, manager of Inter­­ B&R’s integrated automation solution facilitates its national Applications at B&R, explains how it works. flexible, modular design. 05.15 03 Process control Take control of every process As industrial manufacturing processes grow more complex, increasing numbers of sensors flood the control system with input, while increasing numbers of actuators require highly precise output. When conventional SCADA and PLC solutions run up against their limits, what's needed is a fully integrated system to control, monitor and coordinate every aspect of production. iStock. Photo © 04 main topic APROL news report interview “The days when each machine and line in a factory could be treat- One solution for any manufacturing process ed like a self-contained unit are over,” explains Martin Reichinger, The other thing the market demands is flexibility. “You need to be manager of B&R’s Process Automation business unit. “To name able to make product changes on the fly with minimal setup,” ex- just one example: If you want to guarantee maximum productivity plains Reichinger. “That’s the only way you can hold your own in and product quality, then the packaging machine at the end of the today’s market.” Custom-printed bottles and packaging may be line needs to coordinate with the filler at the beginning.” Produc- found in isolated marketing campaigns for now, but in a matter of tion processes have grown so complex that it is no longer feasible years they will become the norm. to configure and monitor key production parameters manually. Big data is a big challenge. Channeling and filtering the overwhelming Even small and mid-sized plant owners need to be thinking about flood of machine data, process data and operating data into co- how they are going to offer this level of flexibility. The only answer herent, actionable information calls for what is known as a manu- is a fully integrated solution that unifies control, monitoring and facturing intelligence solution. coordination of all aspects of production. iStock. Photo © 05.15 main topic APROL news report interview 05 Intelligent systems filter relevant information from a rising flood of data. APROL makes it easy to design high-availability systems with redundancy at every level. “For a long time, you would only find these systems in large pro- grate control and monitoring of that equipment into the process cessing plants,” recalls Reichinger. It is this history that gave rise control system to ensure optimal environmental conditions at all to the term process control system. Yet, the underlying principle of times.” You don’t need to purchase, install and maintain a whole a process control system can just as easily be applied to any man- new system. You don’t need new software, and you don’t need any ufacturing process or infrastructure system. additional control stations. Factory, process and infrastructure automation with APROL Systems with 50 to 200,000 I/O channels The transition to a process control solution is notoriously compli- With APROL, it makes no difference whether you’re building a demo cated and costly. This has led many process control system sup- plant at a technical school with 50 I/O channels, or a large-scale pliers to offer a separate system for factory automation and an- infrastructure project with 200,000. The architecture can even be other for infrastructure automation in an attempt to clear the expanded during operation. For specific applications such as en- initial hurdle. “This approach presents plant operators with a major ergy monitoring, condition monitoring and advanced process con- disadvantage,” explains Reichinger. “They end up with three differ- trol, APROL offers out-of-the-box solutions that come preinstalled, ent systems, each generating its own costs for training, replace- preconfigured and ready to use.