Automation Programming Convergence

Transcription

1 Automation Programming Convergence Jeff Brown Siemens Sales Specialist Automation Booth 813

2 Topics Automation Programming Perspectives Siemens Introduction Example Automation Systems Automation Technology Convergence Industry 4.0/Digitalization Automation Programming Convergence Systems Engineering Approach TIA Portal Overview Automated Generation Improved Diagnostics Programming Methodologies Traditional Approach More Advanced Structured Programming/Object Based Most Advanced SDK C++ Integration

3 Go-to-market Digital Factory Siemens Organizational Structure Americas Middle East, CIS 1) Customer Europe, Africa Market Asia, Australia Global Healthcare 9 Divisions are working on the global trends Separately managed Divisions Power and Gas PG Wind Power and Renewables WP Energy Management Building Technologies Mobility Digital Factory Process Industries and Drives Healthcare Financial Services Power Generation Services PS EM BT MO DF PD HC SFS Corporate Services Managing Board Corporate Core

4 The Totally Integrated Automation Portfolio Enterprise Level ERP PLM NX Product Development TEAMCENTER Collaborative PDM TECNOMATIX Digital Manufacturing ERP PLM Management Level Totally Integrated Automation Operator Level Control Level Field Level MES PCS 7 Plant Engineering SCADA SIMATIC NET Industrial Communication SIMATIC IT Production Suite SIMATIC Controllers Motor Control SIMATIC WinCC SCADA System SIMATIC IT R&D Suite SIMATIC HMI SIMATIC IDENT Industrial Identification SIMATIC IT Intelligence Suite SINUMERIK CNC SIMATIC Distributed I/O SIMOTION Motion Control SINAMICS Drive Systems COMOS Plant Engineering TIA PORTAL Engineering Framework for Automation Tasks

5 Example Systems For Manufacturing Complex Machinery Automation Demanding For Specific Tasks Tightly Integrated Motion Control Customized User Interface Purpose Built Machinery High Engineering Value Add OEM supported General Machine/Skid Automation Repeatable Production Machine Medium/Low Level Complexity End User Supported Very Competitive Market Cost Reduction Engineering PC-Based Control VB.NET HMI IEC1131 Programming Languages G-Code Interpreters Embedded Systems Programmable Automation Controllers Integrated Automation Systems Ladder Logic HMI Micro PLC Market End User Standard Driven

6 Example Systems For Manufacturing Production Line/Discrete Integration Of Components Communications Demands Robotics Integration Cell Configuration High End User Support Off The Shelf Equipment Process Manufacturing Systems Approach Emphasis On Measurements/Instrumentation Vendor Supplied Automation Systems DCS Vendor Supports Automation Systems PLC Based Integrated Automation Engineering Ladder Logic/Structured Text HMI Micro PLC Market End User Standard Driven SCADA Networking/Information DCS Based Vendor Supplied Engineering Networking/Information Code Libraries/Re-use Function Block Programming

7 Technology Convergence Hardwired PLC Based Integrated Systems Digitalization SIMATIC SIMATIC N... Rise Of The PLC -Modicon -Siemens -TI -Allen Bradley SIMATIC S3 More than 35 years of SIMATIC S5 Rise Of DCS Analog/Digital Convergence Integrated Systems Industry Consolidation -TI/Moore Process acquired by Siemens -AB acquired by Rockwell Automation -Modicon/SquareD acquired by Groupe Schneider -Fisher/Rosemount/Bristol acquired by Emerson -Bailey acquired by ABB -Foxboro/Wonderware acquired by Schneider -Integrated Systems -Motion Control -PC Based Automation -Hybrid DCS/PLC 2017 Digitalization/Industry 4.0/IOT TIA Portal Simatic S71200/1500 -Digitalization Focus -B&R acquired by ABB -GE spinoff Electrical Assets -Emerson pursuit Rockwell Automation -Digitalization -Information/IOT -Embedded Systems Automation -Diverse Programming Methodologies SIMATIC S7 is and will be the innovative and future-proof Controller system of Siemens Industry

8 Industry 4.0 represents the next paradigm shift in manufacturing and brings huge potential for those whom embrace the concepts First Industrial Revolution Based on the introduction of mechanical production equipment driven by water and steam power Second Industrial Revolution Based on mass production achieved by division of labor concept and the use of electrical energy (electrification) Third Industrial Revolution Based on the use of electronics and IT to further automate production (automation) Fourth Industrial (R)Evolution driven by Digitalization, Integration and enhanced Flexibility Characteristics 30-50% improved Humans, devices and systems efficiency are connected along the entire value chain All relevant information is available in real-time across consumption suppliers, manufacturers and customers 20-25% less resource 1784: First mechanical loom 1870: First conveyor belt, Cincinnati slaughterhouse, 1908: Ford T-Model 1969: First programmable logic controller (PLC) Modicon 084, Value chain can constantly optimize with respect to different criteria, McKinsey, e.g., 2015cost, resources, customer needs 30% higher revenues Time

9 Systems Engineering Approach Real automation systems involve a lot of equipment PLCs and distributed I/O CNC and motion controls HMI panels and computers Motors and drives Safety systems Computers Communications networks Real automation projects require extensive engineering PLC programming HMI configuration and programming Drive system parameterization and engineering Network design and integration Integration of OEM machines into the process Real automation projects require teamwork to succeed Multiple specialists working together Under a Project manager to organize the effort In a coordinated effort To deliver an integrated solution

10 Systems Engineering Approach Step 1 Defining the System Architecture Factors influencing the system architecture: Speed of System Response Program Size I/O Count Local I/O versus Remote I/O Equipment Environment Space Cost Existing System and possible expansion capability Drive and Motion Control Integration and many more.

11 Systems Engineering Approach Step 2 Managing Project Data and Versions/Revisions The task of automating a machine or process requires creating and storing all of the information for each piece of automation equipment. While each component has the ability to be programmed and operated individually, these components are managed as a single entity known as a Project. In many cases, this Project may consist of many, many files in multiple directories on an engineering station, especially if there are multiple manufacturers supplying equipment.

12 Systems Engineering Approach Step 3 - Configuring and Testing PLC System Components Configure and parameterize the PLC» CPU» I/O modules» I/O networks» communications cards» any special function modules Save, compile, download and test the PLC hardware station

13 Systems Engineering Approach Step 4 Building and Testing a PLC Program Once the hardware is configured and tested, program creation begins. Programs define the operation and response of the system Programs can contain main sections, start-up routines, error response routines, timebased routines, process-initiated routines, and hardware fault routines, all of which need to be organized logically. Programs can be further broken down based on control zones within the machine, individual function within a zone, and so on. In modern automation systems, the potential complexity of the program essentially requires the organization of a program into logical areas for ease of programming and fault isolation.

14 Systems Engineering Approach Step 5 Integrating an HMI Once the PLC program is defined, an HMI can be added. Define the roles to be filled by the HMI Operation Maintenance Diagnostics Reporting Create the HMI project Select the HMI device Define connections to the PLCs Add Elements to the HMI Screens and Navigation Users and Security Alarms and Messaging Recipes Tags Download and test

15 Systems Engineering Approach Step 6 Maintaining and Operating the System Once the system is fully operational and accepted by the end user, the project data needs to be archived and system documents need to be created. Assembling project documentation, specifically in the case of multiple suppliers, can be a massive undertaking. Accuracy of documentation is vital for ongoing maintenance and for effective engineering support. Managing different revisions of program changes, HMI changes, and other changes is equally as challenging. While this is the final step, it is the most important step to the end user.

16 Totally Integrated Automation Discover efficiencies with the TIA Portal Totally Integrated Automation Portal STEP 7 V14 Safety V14 WinCC V14 Startdrive V14 Simocode V14 SIMATIC PC & PLC Safety SIMATIC HMI SINAMICS Simocode Single engineering framework for systems engineering

17 TIA Portal editor layout Main Menu Bar Task Cards HW Catalog Project Tree PLC, HMI and Drive project data Editor view Device & Networks Inspector Window Status Bar

18 TIA Portal Overview of the functional scope of the products SIMATIC STEP 7 Programming languages LAD, FBD, SCL, STL *), S7-GRAPH *) Option STEP 7 Safety SIMATIC WinCC Machine-level operator control and monitoring SCADA applications SINAMICS Startdrive Drive configuration, commissioning, diagnostics WinAC (incl. Failsafe) SCADA G120 S S7-300 / S7-400 ET 200 CPU, (incl. Failsafe) S Professional Basic Basic Comfort Advanced Professional PC single user Comfort Panels and x77 (without micro), mobile Basic Panels Startdrive G120D G120P G120C Communication PROFIBUS, PROFINET, network topology, (AS-i, IO-Link, but only SIMATIC products) Shared functions System diagnostics, import/export to/from Excel, undo, *) Only in Professional for S7-300/400/1500/WinAC

19 Automation Of Engineering Tasks Eliminate redundant steps, and programming avoid errors... by automating identical steps within the work. by automatically generating Devices, Network and IO... by automatically generating program code, screens... by project development based standards and libraries

20 TIA Portal V14 TIA Portal Openness API 1) Functions Allows automated access to program data Allows projects/project data to be generated, modified and tested Allows remote control of TIA Portal functions Public API 1) Export/Import functionality Exporting, modifying and importing project data Fully automatic execution of actions Own program EXE Import / export XML Simple operator control with own user interface 1) Application Programming Interface T

21 TIA Portal options Openness: Standardized exchange between Electro-CAD and Automation Electrical CAD tools TIA Portal V14 SP1 Export/import PLC_1 PLC_2 XML file XML IOfile Device_1 AML file Export/import HWCN + IO Article number Article description Network connections Configured firmware version Tag table Customer benefits Replacement of hardware configuration and icons via XML files Bidirectional workflow CAD systems TIA Portal Free tool support thanks to a standardized interface Apply configuration directly from the TIA Selection Tool New

22 TIA Portal Openness Electrical CAD to TIA Portal Live demonstration Importing existing engineering data from Electrical and Selection Tools into TIA Portal Engineering Software Live demonstration

23 TIA Portal options Openness: Automatic generation of projects, software and hardware Customer benefits TIA Portal Project generator DLL TIA openness Project for Machine A Generation of the complete automation project with TIA Portal openness (hardware & software) Project for Machine B Perfect customer workflow from ordering to the finished automated TIA project Page 23 DF FA AS E&C-PRM

24 TIA Portal V14 Generating instead of programming Automated Engineering generation Generate Conveyor 1 Conveyor 2 Conveyor 3 Drive Generating an application e.g. in MS Visual Studio TIA Portal openness TIA Portal SiVArc 1 Programming manually PLC/HMI Manual Engineering SiVArc Simatic Visualization Architect T

25 TIA Portal V14 What s SiVArc? SiVArc SIMATIC Visualization Architect... for system integrators that want to automatically create in the TIA Portal an operator control and monitoring solution that is simple, quick and flexible!

26 TIA Portal V14 SiVArc - Functionality Control program SiVArc Visualization FC HMI library DB FB FC DB FB Rules regarding the generation of Pictures & picture objects Variables & tables Text lists Automatic generation T

27 TIA Portal V14 SiVArc - Example

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29 Transparent operation with TIA Portal Diagnostics management Diagnostics management Increased availability of machines and production plants Immediately detect errors in the automation system through integrated system diagnostics across all system components Efficient diagnostics of process malfunctions NEW Efficient with diagnostics the standardized of process malfunctions through machine integrated and Trace plant or diagnostics SIMATIC ProDiag standardized machine and plant diagnostics ProDiag NEW USP USP USP reduce production outages

30 Ensuring Uptime with Integrated systems diagnostics Diagnosis can be run in PLC-STOP as well HMI TIA Portal Display Simple configuring without programming Webserver Consistent diagnostics

31 TIA Portal V14 SIMATIC ProDiag - Functionality Analysis of errors in the manufacturing process ProDiag Efficient diagnostics of process disturbances -- using standardized machine and plant diagnostics ProDiag Integrated automatic generation of monitoring systems and visualization Eliminate faults and errors quickly detailed information about fault/error location, fault/error cause and information about troubleshooting Auto Update monitoring systems are independent of the user program Configure alarm Automatic code generation Auto update Visualization PLC code viewer J

32 Machine and plant diagnostics with SIMATIC ProDiag analysis of errors in the manufacturing process Fast identification of errors display of the faulty operands directly in the message with symbol and commentary Fixing errors quickly through clear information about fault location, fault cause and information about troubleshooting "Service without PG" overview representations and detail diagnostics directly on the HMI device

33 Machine and plant diagnostics with SIMATIC ProDiag realized rapidly and simply "Integrated" automatic code generation and visualization of supervisions "Feedback-free" define supervisions independently of the user program Always "up-to-date" automatic synchronization of the HMI devices also after changes in the user program

34 Machine and plant diagnostics with SIMATIC ProDiag full integration into TIA Portal "independent"... of language editors / program code PLC Tag Table DB Data block FB Function block "comprehensive" also for safety and know-protected blocks NEW "consistent"... Integration in cross-reference functions with permanent data consistency

35 Machine and plant diagnostics with SIMATIC ProDiag project-specific specification of the most important settings "efficient" one-off specification of the alarm structure NEW "intelligent" alarm texts are derived automatically from the texts existing in the project "international" complete foreign-language handling of the TIA Portal is available

36 Machine and plant diagnostics with SIMATIC ProDiag automatic update of the operating stations "interruption-free"... HMI devices do not have to exit the runtime mode in case of changes "time-saving" much easier maintenance work Auto update "seamless" system guarantees data consistency

37 Traditional Automation Programming Capabilities Criteria - Easily Setup Configure Inputs and Outputs - Relay Ladder Logic Implementation - Hmi Integration Tasks -Create PLC -Name I/O -Program Ladder -Create HMI -Create Buttons with Tags

38 Program Ladder Logic

39 Add HMI and Logic

40 Simulate And Test PLC and HMI

41 More Advanced Programming Linear Program Partitioned Program Structured Program Recipe A Main Main Recipe B Main Pump Mixer Outlet Outlet All instructions are found in one block, usually in the Main Routine [OB 1] Here, individual functions with fixed addresses are found in individual blocks, which are called from the Main routine [OB 1] one after the other. Individual functions are created with parameters, whereby each call can be made with different addresses. These functions are thereby reusable, vastly shortening development and commissioning times and reducing program size and complexity.

42 More Advanced Programming S7 Program Blocks at a Glance Operating System Cycle Time Process Error Legend: OB = Organization Block FB = Function Block FC = Function DB = Data Block

43 More Advanced Programming Anatomy of a Function Local variables referred to as formal parameters Input Parameters Local Variable Definition User program code That operates on the Local Variables and calculates one or more output values Output Parameters A B Add A to B Put results Into C C Answer = 141

44 More Advanced Programming Adding Functions (FCs) to the Project

45 More Advanced Programming Developing a Function Block Interface Code Section

46 More Advanced Programming Assigning Parameters to Code Blocks

47 More Advanced Programming Calling Functions in the Program

48 More Advanced Programming Overview of Data Blocks OB1 Function FC10 Function FC20 Accessible to all blocks Global (shared) data DB20 Function Block FB1 Instance DB for FB1 Instance data DB5

49 More Advanced Programming Creating a New Data Block Double-click Add new block Select Data Block Data Block as Block Type

50 More Advanced Programming Data Block Element Properties Global data blocks contain data items for use anywhere in the program. As such, they require the following Properties: Name a way to identify the data item Data type a way to specify the type or format of the data item Default value Default value of the tag in the interface of a higher-level code block or in a PLC data type. Determined either by the data type default value or by the FB variable default value. Start value (Optional) - Value that the tag should assume at CPU startup or upon new download. If unassigned, it s the default value. Retain sets whether the element will retain it s current value through a PLC restart. Comment further documentation to explain its use or meaning Setpoint- identifies an element as a setpoint value. Used with the snapshot feature.

51 More Advanced Programming Multi-Instance FBs FB 100 My Motors DB 100 My Motors Data DB 1 My Logic Data 1 FB 1 Motor Logic FB 1 Motor Logic FB 1 Motor Logic FB 1 Motor Logic DB 2 My Logic Data 2 DB 3 My Logic Data 3 DB 4 My Logic Data 4

52 More Advanced Programming PLC User Defined Data Types

53 Most Advanced Programming - SIMATIC ODK 1500S Why should C++ be used for real time applications? Controlling programs are already available as C++ source code Migration Embedded Computer Program available as C/C++ code Re-utilization of existing code: many man-years of invest in development, maintenance and know how Performance of modern PLC- and bus systems (e.g. PROFINET) sufficient for this task Model-based software development: Exporting control codes über C++ Direct use of automatically generated C++ source code for control tasks Utilization as black box, preferably without manual rework Cross-platform programming Re-utilization of central functions on several platforms, even in Non-PLC-systems Programming with C++ more efficient than with SCL in certain cases

54 Most Advanced Programming SIMATIC ODK 1500S Execution of C/C++-Code with a S Controller Controller Execution of functions in loadable libraries at runtime Windows Real-time ODK application dll OB FB Load ODK application so Real-time: SO (shared object) algorithm, closed loop controller, S CPU 1518(F)-4 PN/DP ODK S Software Controller Fct1 FB Fct1 Fct1 Fct2 FB Fct2 FB Unload Fct2 Windows: DLL (dynamically linked library) Connection to Windows applications Complete Windows functionality usable S Software Controller The ODK 1500S enables to develop such applications

55 Most Advanced Programming SIMATIC ODK 1500S Typical Development Environment Engineering SIMATIC ODK 1500S (incl. Eclipse) SIMATIC Target 1500S (optional) Microsoft Visual Studio C++ (optional) SIMATIC TIA Portal Development of ODK application binaries Real-time: Eclipse Windows: Visual Studio Runtime SIMATIC S Software Controller SIMATIC S CPU 1518(F)-4 PN/DP ODK Execution of ODK application binaries Real-time: Shared Object (.so) Windows: Dynamical Linked Libraries (.dll) On target development possible No additional runtime licenses

56 Most Advanced Programming SIMATIC ODK 1500S Simple Call of C Functions by PLC Program Automatic generation of function blocks for use of ODK applications Real-time ODK applications have a synchronous interface Windows ODK applications have a asynchronous interface Import of function blocks using External source file feature of STEP7

57 Conclusion TIA Portal Engineering System Software Platform for Engineering Automation System Converge C++ with TIA structured Code Incorporate Ladder for Troubleshooting Booth 813 Engineering Efficiency Automate Hardware Config Automate PLC Code Generation Automate HMI/SCADA Generation Simulate PLC/HMI Diagnostics Built Into Systems Auto Generate Alarms/Diagnostics