May MediaService. Industry News

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1 Siemens MediaService May 2018 siemens.com Content PRODUCTS 02 One for all: Sitop 03 Exceptionally long service life 04 Digital precision for industrial 3D printing APPLICATIONS 06 Smooth production 08 Safe landing MediaService Industry News The May issue of the MediaService Industries brings you more news from the world of drives and automation. We start this month s issue by learning about new software for Sitop power supplies designed to simplify engineering and data handling. Also new is a Long Life Repair facility offered by Siemens as an extension of its conventional repair service. We hear how a new competence center for digital precision in industrial 3D printing, the Additive Manufacturing Experience Center, has been opened in Erlangen. The applications section of this issue features a manufacturer of synthetic and mineral lubricants whose new building has been automated using a Siemens control concept. And finally, the MediaService brings you a report on an aviation research center which simulates the performance of brake systems and anti-skid technology in normal and failure modes using simulation software from the Siemens PLM Software Simcenter portfolio.

2 MediaService May One for all New software for Sitop power supplies simplifies engineering and data handling The new Sitop Manager enables the simple commissioning, engineering and diagnosis of communication-capable Sitop power supplies. Nuremberg, Germany. Siemens has launched new Sitop Manager software for Sitop power supplies with communication capability. The software allows online and offline engineering, commissioning, diagnosis as well as operation and monitoring of communication-capable Sitop power supplies. The Sitop Manager enables all the power supplies of a network to be engineered, and certain configurations to be copied and used any optional number of times. In the event of a fault, the Sitop Manager ensures safe shutdown of the PC, preventing the loss of production-relevant data. Communication between the PC with Sitop Manager and connected power supplies takes place over OPC UA (Open Platform Communications Unified Architecture), an open, manufacturer-independent Ethernet-based communication standard. Because OPC UA complies with particularly stringent security standards, it guarantees secure data transmission. Interacting with a buffered Sitop power supply, the Sitop Manager prevents production data and connections to cloud-based data being lost in the event of a power failure. Because it uses a web-based user interface, the Sitop Manager is extremely simple to use in any kind of automation project. The software s web-based user interface also allows users to access the functions from mobile terminals. The extensive software is used wherever Simatic PCS 7 or Simatic Step 7 are not used for plant engineering and programming. In this case, the Sitop Manager can be used to configure both the Sitop PSU8600 power supply system and the Sitop UPS1600 uninterruptiblepower supply. The software has been made available by Siemens as a free download for all popularly used Windows PCs. Sitop Power Supply

3 MediaService May Exceptionally long service life Long Life Repair for extended repair service beyond the standard terms Nuremberg, Germany. Siemens offers its customers a wide range of services beyond the procurement of software and/or hardware. This includes Long Life Repair an extended service package of up to 25 years for machine components and plants in, for example, the automotive industry. Benefits for the customer include advantageous pricing due to low-cost repair work, product upgrades and extended plant availability. Generally, once the period of active marketing for electronic products is over, a spare part and repair service is offered for up to ten years. After this time period, these services are only available in cases of accepted liability for defects. This is not the case with Siemens. For some products, the company offers the Long Life Repair service which permits repairs not covered by the liability for defects to be performed even after ten years, and includes a repair or findings report. Sustainable machine use due to long service availability The Long Life Repair service is available for selected Simodrive modules, Sinamics S120 6SL modules and, in the near future, also for Sinumerik NCU. Siemens is thus offering a complete solution which includes short delivery times, long-term availability of original spare parts, cost-efficient repairs, and service cover for up to 25 years. The objective is to increase the productivity of the components as well as to operate a sustainable and cost-efficient business. In addition to this, customers benefit from avoiding component failure due to wear, constant service and support, and the option of bridging the time to retrofitting or new procurement. With the Long Life Repair offering, Siemens is providing customers with the reassurance of an extended service package for plant components beyond the standard term of ten years and the accepted liability for defects. Motion Control Services Sinumerik Simodrive

4 MediaService May Digital precision for industrial 3D printing Additive Manufacturing Experience Center opens in Erlangen Additive Manufacturing Experience Center in Erlangen Erlangen, Germany. Siemens has opened the Additive Manufacturing Experience Center in Erlangen, a new competence center which offers plenty to inspire and educate visitors with a hands-on integrated approach to industrial 3D printing. Siemens has opened a competence center for additive manufacturing on the site of its factory in Frauenauracher Straße, Erlangen. The Additive Manufacturing Experience Center (Amec) targets machine builders, machine operators and companies who use 3D printing to design and construct workpieces. The new Center is designed to showcase Siemens holistic approach to digitali- zation in the field of industrial additive manufacturing, and features a range of exhibits and interactive screen presentations. From digital product design and development through preparation for printing to actual industrial 3D printing, the new competence center offers customers the opportunity to learn more about the process, experiment with additive manufacturing machines and robots, and to work with the Siemens experts to devise their own solutions. Additive manufacturing is revolutionizing industrial production for machine and product manufacturers poised at the transition from prototype and small series production us-

5 MediaService May ing stand-alone machines to fully industrialized series manufacturing. What count here are productivity, process stability, end-to-end data chains, speed and quality as well as IT security. Additive manufacturing provides the answer for highly flexible, fast and efficient production. The 3D printing of workpieces enables even the most complex designs to be seamlessly manufactured in a single process for outstanding timesavings. It allows the creation of contours and shapes to a degree of precision and complexity that are impossible to achieve using conventional methods of manufacturing. Digitalization has a central role to play here. Using integrated software and hardware solutions for every value creation phase, the entire digital additive manufacturing process chain can be depicted in a single, integrated software environment. The workpieces are digitally designed and their production is simulated and tested in the digital world before the order to print is sent to the 3D machine. The tools used for engineering, simulation, production preparation and 3D printing are collated in a single integrated system, and operated using a standardized user interface. This eliminates the need for data conversion with all the associated potential for loss of information content. Just how this works in practice will be demonstrated in the new Additive Manufacturing Experience Center using equipment including a hybrid 3D printing machine using laser technology and a multi-axis robot with print head. Amec: Lasertec 65 Hybrid 3D printing machine using laser technology from DMG Mori Amec: multi-axis robot from Comau runs via Run MyRobot /Direct Control Also supported is the complete range of processes from design through engineering and production to the manufacture of spare parts using data from MindSphere, the open cloud-based IoT operating system from Siemens. This allows process data to be collated and evaluated, resulting in continuous process improvement. The Siemens approach to additive manufacturing entails performance of the continuous product and production optimization process by the comprehensive digital twin, which incorporates all the data and information relating to the product, its production and its performance. As a result, industrialized additive manufacturing is no longer just a futuristic vision, but already a reality with the aid of the Digital Enterprise from Siemens. There are thousands of AM machines already in operation performing industrial applications around the world. Siemens is also already making intensive use of AM machines in its own production plants, and plays a leading role as a provider of additive manufacturing and associated services. The company plans a significant expansion of its activities in the field of industrial additive manufacturing. Additive Manufacturing home/company/innovation/research-topics/additive-manufacturing.html

6 MediaService May Smooth production Lubricant manufacturer automates new building with Siemens control concept The Swiss family-owned company Oel Brack AG mixes synthetic or mineral lubricants under its own brand Midland - Swiss Quality Oil. Hunzenschwil, Switzerland. Oel Brack AG is a Swiss family-owned company which produces synthetic and mineral lubricants under the brand Midland - Swiss Quality Oil. To increase its production capacity, the company extended its existing plant by adding a new building which includes storage tanks and production facilities with a production volume of up to 70 tonnes of lubricants a day. Siemens components are used for the plant automation. This provides not only reliable, failsafe operation but also particularly user-friendly management of the whole plant. Whether in motor vehicles, construction machinery or in industry, lubricants are found in every sector where they literally provide frictionless operation for motors and plants. The familyowned Swiss business has been active in the mineral oil sector since the 19th century and has been producing oil under its own brand since The previous production facility in Hunzenschwil has slowly but surely been approaching its capacity and therefore had to be extended. The impressive new building is split into two storage halls containing 20 base oil tanks holding 100,000 liters each and 14 additive tanks, each holding 50,000 liters. Polytech Systeme AG (Polytech) was charged with automating the plant using Siemens technology. Consistent control concept The term plant is understood as a system of pumps, valves and pipework through which the oils and additives are pumped from the truck, initially into various tanks for storage, and then out of the tanks to the production area for further processing. Depending on the formula and subsequent intended use, the base oils are mixed into a range of engine and gearbox oils. The oils are optimized, if required, with a suitable additive. A total of 70 tonnes of lubricant can be produced daily in the new building. This means that not only must the processes be perfectly matched to each other, but they must, above all, be safe as well. System control is provided by a failsafe Simatic S7-1516F controller and the programming is carried out in the TIA (Totally Integrated Automation) Portal engineering framework. This means that all the elements, such as the Sinamics G120C

7 MediaService May frequency converters, can be connected to each other without any problems, explains Lukas Kaufmann, Electronics Engineer at Polytech. The programmers were also able to carry our exhaustive tests on the controls, including the safety functions, in the office during the development phase and adapt them where necessary by using the TIA Portal V14 and the integrated simulator. Kaufmann continues: This is a vast plant. By using failsafe, distributed I/O modules for the sensors and actuators, we have avoided long cable runs. The plant is operated via a TP2200 touch panel which is particularly user-friendly. Remote access from the laboratory or office via the Sm@rtServer option also makes the system extremely userfriendly. Strict environmental regulations satisfied As a lubricant manufacturer, Oel Brack AG is subject to strict environmental regulations, for example, no oil may drain into the environment. The tanks therefore stand in a concrete bund which collects the oil in the event of a leak from a tank. This is registered by the certified leakage detection system and the fail-safe Simatic system immediately locks down the storage area and triggers the alarm. The consistency of the system pays for itself: Focusing on a single supplier simplifies our processes as we have only one point of contact. At the same time, all the components are perfectly coordinated with each other, concludes Kaufmann. The whole plant is easily and comfortably operated via a Siemens TP2200 touch panel. The base oil and additive tanks each hold either 100,000 or 50,000 liters and stand in a concrete bund to ensure no oil can drain into the environment in the event of a leak. Controls, power supply, frequency converters a glance into the main control cabinet in the additive tank store shows all the equipment installed from the most recent generation of Siemens products. Information on the filling level of individual tanks can be called up via the large 22-inch operator interface on the touch panel. Simatic TIA Portal The complex plant comprises pumps, valves and pipework and is automated by a Simatic S7-1516F controller. Sinamics

8 MediaService May Safe landing Aeronautics research institute simulates aircraft brake system with Simcenter The Brazilian Aeronautics Institute of Technology (ITA) is involved in training, research and technological development in the field of aeronautics, working in close cooperation with industry. Sao José dos Campos, Brazil. The Brazilian Aeronautics Institute of Technology (ITA) is involved in training, research and technological development in the field of aeronautics. ITA attaches particular importance to fostering links between research and industry and works in close cooperation with the Brazilian Government to ensure that research aligns as closely as possible to the needs of industry. Issues currently in the spotlight are brake system performance and anti-skid technology in normal and failure modes. To play through possible scenarios, the ITA relies on the use of simulation software from the Siemens PLM Software Simcenter portfolio. This allows students at the ITA to gather experience with the latest features ofthe advanced simulation setup during their course training. Quite apart from this benefit, ITA has also been able to speed up the evaluation of brake system performance under failure conditions, helping to strengthen Brazil s position in the highly competitive aeronautical industry. Aircraft brake systems are not only highly complex but also crucial to aircraft safety. The blocking of brakes during braking maneuvers, for instance, must be avoided at all costs. Traditionally, brake system performance has always been tested by executing multiple load rig tests and test flights. This is a time-consuming and also a costly process and explains why the research team at the ITA set about looking for a new method which would involve simulation of the aircraft s hydraulic brake system. A study carried out by the ITA demonstrated the usefulness of system simulation to design and validate the model of a hydraulic brake system in order to assess functionality in both normal operation and in the event of a failure. The experts at the ITA used the LMS Imagine.Lab Amesim from Siemens PLM Software to model the hydraulic system. Computational parameterized model The researchers at ITA decided to base their study on a braking system supplied with power by the aircraft s own hydraulic power generation system. This system is later duplicated to independently provide hydraulic power to each brake. The model generated in LMS Amesim is composed of three elements: the valve assembly, the brake assemblies and the input blocks. LMS Amesim is a great tool for quickly creating system models, mainly due to its facility for dealing with the physical blocks found in its software libraries, says Mario Maia Neto, a PhD candidate at ITA. As he explained, this enabled

9 MediaService May the creation of complex models without the need to write entire mathematical formulas for each subsystem. Using LMS Amesim helped us develop a computational, parameterized model for the aircraft hydraulic brake system to assess the behavior of its relevant variables in normal operational conditions and when typical failures are simulated. Potential far from exhausted Subsequently the results were compared in order to find a way of compensating for the loss of performance in the failure mode. The last step of this computational method was to devise a strategy or actions such as the definition of specific maintenance tasks to maintain the required system level. Neto envisages enormous potential for the new methodology: In the current context, modeling and simulation has the potential to improve the execution of several design development activities, such as system architecture study, requirements validation, performance analysis and optimization, safety and assessment, fault detection and diagnosis. Using LMS Imagine.Lab Amesim from Siemens PLM Software, the experts at the ITA are able to quickly and simply generate a virtual model of a hydraulic aircraft brake system. The brake system model in LMS Amesim is composed of three elements: the valve assembly, brake assemblies and input blocks. The LMS Amesim model is used to analyze brake system performance and anti-skid technology in the normal and failure modes. The brake s normal torque response is directly compared to braking behavior in the simulated failure mode. Simcenter PLM Software com/global/en/

10 MediaService May Siemens AG (Berlin and Munich) is a global technology powerhouse that has stood for engineering excellence, innovation, quality, reliability and internationality for 170 years. The company is active around the globe, focusing on the areas of electrification, automation and digitalization. One of the world s largest producers of energy-efficient, resource-saving technologies, Siemens is a leading supplier of efficient power generation and power transmission solutions and a pioneer in infrastructure solutions as well as automation, drive and software solutions for industry. With its publicly listed subsidiary Siemens Healthineers AG, the company is also a leading provider of medical imaging equipment such as computed tomography and magnetic resonance imaging systems and a leader in laboratory diagnostics as well as clinical IT. In fiscal 2017, which ended on September 30, 2017, Siemens generated revenue of 83.0 billion and net income of 6.2 billion. At the end of September 2017, the company had around 377,000 employees worldwide. Further information is available on the Internet at MediaService Industries: MediaService Industries Digithek for downloading individual articles from all issues: MediaService Industries application reports may be based on previously published Siemens technical articles. Current press releases: Siemens: Siemens PLM Software: com/en_us/about_us/newsroom// Contact MediaService Industries Process Industries and Drives Evelyne Kadel Tel.: +49 (0) evelyne.kadel@siemens.com David Petry Tel.: +49 (0) david.petry@siemens.com Katharina Zoefeld Tel.: +49 (0) katharina.zoefeld@siemens.com Stefan Rauscher Tel.: +49 (0) stefan.rauscher@siemens.com Digital Factory Katharina Lamsa Tel.: +49 (0) katharina.lamsa@siemens.com Claudia Lanzinger Tel.: +49 (69) claudia.lanzinger@siemens.com Gerhard Stauß Tel.: +49 (0) gerhard.stauss@siemens.com Contact MediaService Industries Ursula Lang Tel.: +49 (0) ursula.lang@siemens.com Siemens industry topics on Social Media MediaService Industries: Blog: Twitter: YouTube: