Material Handling Automation & Drives Solutions Presented by Bill Henderson Manufacturing in America March 14-15, 2018

Transcription

1 Material Handling Automation & Drives Solutions Presented by Bill Henderson Manufacturing in America March 14-15, 2018

2 Introduction Bill Henderson P: Siemens DF MC Business Developer Manager Material Handling Siemens Digital Factory OEM Team Lead 20 years Siemens Automation & Drives experience, specializing in Tire, Battery and intralogistics

3 Before we start Please provide feedback via the App At the end of the session, share your feedback via MiA App - and get a chance to win tickets to the Detroit Tigers baseball game!

4 What am I talking about today MHI Survey Typical System Architectures Logistics Hardware Components The Edge and IoT The Total Plant

5 Source Source: MHI 2017 Annual Report:

6 MHI Survey 9 Industry Trends Cloud Computing & Storage Predictive Analytics Sensors & Automatic Identification 3D Printing Inventory & Network Optimization Autonomous Vehicles & Drones Robotics & Automation Internet of Things Wearables & Mobile Source: MHI 2017 Annual Report:

7 9 Evolving Trends Disrupting the industry 50% 5 Year Growth Rate of Technologies 40% 30% 20% 10% Cloud Computing Sensors & Auto ID Inventory & Network Optimization Tools Robotics & Automation Wearables Predictive Analytics 3D Printing Drones & Autonomous Vehicles Internet of Things Source: MHI 2017 Annual Report:

8 The Fourth Industrial Revolution

9 Our customers have essential requirements throughout the material handling industry Speed Flexibility Quality Efficiency Security

10 Digitalization Effect 1 Retailer Source: MHI 2017 Annual Report:

11 9 Evolving Trends Disrupting the industry 50% 40% 30% 20% 10% Cloud Computing Sensors & Auto ID Inventory & Network Optimization Tools Robotics & Automation Wearables Predictive Analytics 3D Printing Drones & Autonomous Vehicles Internet of Things Source: MHI 2017 Annual Report:

12 Top to Bottom Intralogistics Solution All components from one supplier that are completely connected

13 Conveyors Best in class automation technology for all of your requirements Typical Conveyor System Solution Description Weighing system Automation Systems Automation System PLC or PC based control solution for stand-alone to highly complex applications. Process Instrumentation Transmitters for maximum efficiency in process instrumentation. Industrial communication Broad range of components to implement efficient industrial networks and bus systems Operator control and monitoring systems Optimized operator control and monitoring systems using open and standardized interfaces. Motors Industrial communications Process instrumentation Integrated drive systems Integrated Drive Systems (IDS) are consistently integrated drive components - frequency converters, motors, gear units, couplings - working perfectly together

14 Totally Integrated Automation Portal (TIA Portal) the gateway to automation solutions within the Digital Enterprise Totally Integrated Automation Portal One common database Integrated Engineering Common data management WinCC STEP 7 SCOUT Startdrive Distributed HMI IPC Controller I/O Motion Control Drives Consistent and unified usability concept for all devices and engineering Inclusive for no charge : Libraries, Diagnostics, Scalability, Flexibility Security integrated Safety integrated Diagnostics Energy Management PROFINET

15 The Totally Integrated Automation - Concept and Advantages Easy engineering and integration High availability TIA Portal TIA Portfolio TIA Portal System diagnosis One framework for the complete project Scalable and seamless TIA portfolio fits for each application Increased availability by using one tool for controller, HMI, drives, etc. Uniform, integrated and selfexplaining diagnosis for all devices Production lifecycle Vertical integration Device replacement Vertical integration Connect old and new machines thanks to compatible components Uniform Ethernet communication from field to management level Device replacement in maintenance case without tools or engineering Direct connection to MES and cloud systems for improved data transparency

16 Sensing and communication Sensor systems SIMATIC Vision sensor Vision sensors for application-specific image processing Identification systems SIMATIC Ident RFID systems for an optimization of material flow and logistics Code reader systems for flexible reading and verification of 1D/2D codes Communication SIMATIC NET Industrial Ethernet / WLAN PROFINET PROFIBUS AS-i

17 Control and visualization Controllers & I/Os SIMATIC Controller Highest scalability Selection in the software and hardware architecture: Modular / embedded / PC-based Central / distributed HMI SIMATIC HMI The finely graduated product range fulfills the most diverse requirements From operator panels and visualization software through to the scalable SCADA system

18 Gearbox motors Servo gearbox motors SIMOTICS S-1FG1 Based on SIMOTICS 1FK7 with Drice-CLiQ interface (electronic type plate) Compact direct mounting with helical, parallel shaft, bevel or worm gearbox Power range 0.5 to 7kW Different (holding) brakes available Plug in pinion for a high ratio in the first gear stage Available in axis height AH36 to AH100 Market usage installation dimensions Standard asynchronous gearbox motors SIMOGEAR High quality -> long lifetime High versatility due to MODULOG system High performance due to high power density, high output torque and wide range of gear ratio (plug in pinion) Compactness and reduced weight Easy integration due to usual installation dimensions Very high energy efficiency with IE3 motors Power range up to 200kW

19 Safety and Energy Safety Integrated Complete and consistent safety program From the sensor through to the controller to drives Comprehensive service and support Support for the application of safety standards Energy distribution Failsafe and efficient energy distribution using SIVACON switchgear SIVACON busbar trunking systems SENTRON power switches SENTRON multi-function measuring instruments SIMATIC PCS 7 powerrate resp. SIMATIC WinCC powerrate

20 Frequency converters Distributed Central SINAMICS G120D High degree of protection IP kw induction motors Speed control with/without encoder Also with integrated position control Safety Integrated functions Integrated brake control SINAMICS S120 Single-axis and multi-axis groups Modular / high scalability regarding the power and the function Synchronous and induction motors Numerous applications through DCC Safety Integrated functions

21 Distributed concept with SINAMICS G120D Features Degree of protection IP 65 no control cabinet required Installation directly near the motor reduced wiring Energy efficient thanks to energy regeneration capacity Integrated positioner (EPOS) Safety Integrated No line reactor or line filter required Up to 7.5 kw (nominal power); 15kW (peak power)

22 Central concept with SINAMICS S120 Booksize Features Scalable and flexible due to modular structure Up to 12 axes per CU Central infeed / regenerative feedback Highly dynamic control Synchronous / induction motors Integrated positioner (EPOS) Numerous applications thanks to DCC Safety Integrated Energy efficient through regenerative feedback and energy balancing at the dc link; incl. concept for energy storage

23 Engineering Drive dimensioning: SW-Tool SIZER Commissioning: SW-Tool STARTER / STARTDRIVE Project creation Parameterization Optimization Diagnosis Input of mechanical specification Results: Parts list including order numbers Dimension drawings / CAD data Characteristic curves Automatic detection of DRIVE-CLiQ components Graphic-supported parameterization Automatic controller optimization Comprehensive diagnostic tools

24 9 Evolving Trends Disrupting the industry 50% 40% 30% 20% 10% Cloud Computing Sensors & Auto ID Inventory & Network Optimization Tools Robotics & Automation Wearables Predictive Analytics 3D Printing Automatic Drones & Autonomous Guided Vehicles Internet of Things Source: MHI 2017 Annual Report:

25 Flexible Production with Automated Guided Vehicles (AGV) Siemens Industry Inc siemens.com/automotive

26 Flexibility in production The AGV is the backbone of the Smart Factory From fixed chained production to flexible & modular production Siemens addresses this market shift with the development of a comprehensive AGV system package : Enables AGV suppliers and end customers to automate AGV applications with Siemens components and technologies Offers HW automation and drives concepts, SW libraries for carrier control and navigation as well as application SW for master control

27 Siemens & AGV s have a long history NN

28 Key elements of a comprehensive solution for AGVs * Master Control Data Analytics Ressources Digitale Image Route Configurator Maintenance Order Dispatcher Visualization & Diagnostics Carrier Control Navigation Automation components Localization Drive system Path Finding Safety Integrated Obstacle Avoidance TIA-Lib & PC application *: MindSphere: Cloud-based, open IoT operating system

29 System supplier Siemens Offering a comprehensive AGV system package Software Library Carrier Control incl. Drive control Safety Integrated AGV system package SIMOVE Maintenance App System Documentation Software Master Control incl. Visualization Route configurator Fleet manager Interface Specification List with recommended HW components Software Library Navigation Application support and Training

30 System supplier Siemens Carrier Control Focus Drives Technology Basic functions Communication Track management Drive train Energy supply Safety-functions Additional onboard functions e.g. lifting

31 System supplier Siemens Carrier Control Focus Machine Safety Station control AGV Master control station SIMATIC HMI IPC CPU 1518F-3 SIMATIC HMI IPC CPU 1518F-3 Shop floor network Basic functions Communication Track management Drive train Energy supply Safety-functions Additional onboard functions e.g. lifting Material handling or manufacturing station 7 7 Siemens offers a comprehensive safety solution which connects intrinsic safe AGVs with station controller AGV Industrial Tablet AGV

32 System supplier Siemens Carrier Control Focus Automation SW Basic functions Communication Track management Drive train Energy supply Safety-functions Additional onboard functions e.g. lifting Pretested modules, preconfigured TIA AGV project

33 Carrier Control Automation SW Open to integrate or adapt to customer specific extensions Standardized S7-Function Blocks for Carrier Control STANDARDIZED + CUSTOMIZED Customer specific extentions for new or adapted Functions Standard STEP7 HW-Configuration Customer specific extentions for additional HW components Standard HMI Screens Customer specific HMI Screens PLC-Application Automation application Safety-functions Communication Track control Drive Functions Interface to master control HMI-Panel

34 SIMOVE The AGV system package Master Control Order management and track management Order management Track configuration Plant and track visualization Machine safety Diagnostics Interconnection to external process control PLC controlled and WinCC Proven components Benefits from machine safety Already in use in projects PC controlled (Windows) Simplifies implementation of traffic management and route control Specified and development started

35 System supplier Siemens Master Control Focus order management and tracking Basic Functions Order Management Operating Modes Interconnection to external process control Safety Functions Track Management Visualization Additional track events (Switches, Diagnosis) AGV Simulation Order management: Manage order sequence and product identification Product specific control of AGV behaviour (e.g. lifting) Track management: Mode management (green automatic, red fault) Vehicle status (Good / Maintenance req. ) incl. details Vehicle tracking Realtime visualization incl. position Screenshot

36 System supplier Siemens Master Control Focus route configuration and route management Basic Functions Order Management Operating Modes Interconnection to external process control Safety Functions Track Management Visualization Additional track events (Switches, Diagnosis) AGV Simulation Siemens solution for PC based mater control will be based on existing and proven technologies: Currently evaluation of several products Interaction and use of Siemens PLM tools possible

37 System supplier Siemens Offering a comprehensive AGV system package Software Library Carrier Control incl. Drive control Safety Integrated AGV system package SIMOVE Maintenance App System Documentation Software Master Control incl. Visualization Route configurator Fleet manager Interface Specification List with recommended HW components Software Library Navigation Application support and Training

38 9 Evolving Trends Disrupting the industry 50% 5 Year Growth Rate of Technologies 40% 30% 20% 10% Cloud Computing Sensors & Auto ID Inventory & Network Optimization Tools Robotics & Automation Wearables Predictive Analytics 3D Printing Drones & Autonomous Vehicles Internet of Things Source: MHI 2017 Annual Report:

39 The challenge Connecting your assets Wherever they are What do you need? Global access to assets Ongoing supervision of the machine performance Optimized planning of services New business models for machine business How to get there Secure data acquisition for cloud services with MindSphere?!

40 MindSphere the cloud-based, open IoT operating system from Siemens Optimization of plants and machines as well as energy and resources Open standards for connectivity of Siemens und third-party products Plug and play connection of Siemens products Cloud for industry with open application interface for individual customer applications Transparent pay-per-use pricing model Opportunities for completely new service and business models

41 Application example SIMATIC IOT2040 The intelligent gateway to connect the field level to the IT level / cloud Collecting and concentrating relevant production data of several sources Flexible Connection to sensors/actors via serial communication, Ethernet or Arduino shields. Communicating with PLCs, drives and motors with e.g. PROFINET 1) or OPC OA 2) 2 2 Protocol conversion / customer programmed control Data aggregation, conversion of different communication protocols and pre-processing programmed in high-level language e.g. Java, C Secure transfer to connected company IT-systems or cloud applications Converted data can be transmitted to IT systems / cloud solutions using e.g. OPC UA, MQTT or AMQP 2) 4 Production monitoring, analysis and optimization Cloud based analytics to detect optimization potential 11/29/2017 1) planned 2) application examples will be provided at IOT2000 forum

42 SIMATIC IOT2040 Industrial ruggedness. Openness. Connectivity. SIMATIC quality Designed for 24/7 operation in industrial environment + Expandability & + connectivity With mpcie, industrialized IO module and various standard interfaces & available protocol drivers AutomatIon.ConnecTed + Easy connection to automation level with PROFINET* ) and openness to cloud based solutions * ) planned Openness Free programmable in highlevel languages (e.g. Java, C++) via various IDEs (e.g. Eclipse) and compilers for Yocto Linux + Performance & Deterministic Intel Quark CPU and 1 GB RAM as well as x86- deterministic and battery buffered real-time-clock + 11/29/2017

43 Target applications focus on brown-field applications IOT2040 for production data pre-processing, conversion and transfer Connecting IT/cloud and automation Secure communication between ERP/IT systems or cloud applications and production Production optimization with vertical data integration from shop floor to cloud Predictive maintenance Capturing and analyzing production data like e.g. speed or operation hours in order to identify the best maintenance interval Optimize machine downtimes Optimized shop floor management Data transfer in case of undercut of minimum stock levels of consumables Automated alarming in shop floor management system in order to avoid production downtimes IOT2000 as open platform to connect legacy systems, additional sensors and IT-level 11/29/2017

44 SIMATIC IOT2040 complements automation portfolio Making legacy automation concepts IoT ready Inter-connecting various sources and communication networks Protocol conversion to: OPC UA, MindSphere, MQTT, AMPQ, JSON SCADA / MES Cloud / IT applications Pre-processing/data acquisition with SIMATIC IOT2040 and data transfer to company network or direct to cloud applications No need to change existing automation solution SIMATIC IOT2040 complements automation portfolio 3rd party PROFINET 1), OPC UA, TCP/IPC, Modbus RTU,... SIMATIC IOT2040 as cost-efficient and open data gateway for retrofitting existing concepts and make them IoT ready 11/29/2017 1) Not released yet

45 Your benefit Easy and flexible connectivity of your automation to MindSphere Data collection and analysis in the cloud Secure data connection between automation and MindSphere Easy configuring of connection Flexibility to realize best fit for connectivity concept MindSphere Data-driven services, e.g. condition monitoring MindConnect: SIMATIC S7-1500, SIMATIC IPC SIMATIC IOT2040

46 Cloud Based Apps By Siemens Manage MyMachines OEE Monitor Product Intelligence

47 Manage My Machines View machines regardless of Type View machines around the world Easy connection setup Cloud based Siemens Developed Track trends in machine status Show current Status of multiple machines Show historical trends Use the data to predict issues

48 O 2 M Order OEE Monitor Track your production orders Display Machine effectiveness Overall representation of process Recognize operating trends Virtual KPI Representations Plot out metrics for comparison Quickly identify production rates Provide decision support for change Optimize plant operations based upon data

49 Product Intelligence Create actionable intelligence Leverage existing data sources Data Loads from your source MES, QMS, ERP, CRM One Single view and hub Fast Data Search Performance Analytics (Patented) Analyze and Contextualize Big Data Empower Data Driven decisions

50 Cloud Based Apps By Siemens Manage MyMachines MINDSPHERE APP STORE OEE Monitor Product Intelligence

51 Intosite and MindSphere Access MindSphere application within IntoSite Intosite application in MindSphere to monitor selected events and notify Intosite Status indication in Intosite resulted from MindSphere plant resource related events

52 Intosite Key Capabilities Create 2D/3D/Panormic representations of your factories Build a layer structure that represents the business logic and create/share placemarks Add information and ate from existing IT systems: URLs, Files, Sharepoint, Tool Management, Teamcenter, Mindsphere, Start using the extensive discussion board to collaborate on information uploaded to Intosite

53 9 Evolving Trends Disrupting the industry 50% 40% 30% 20% 10% Cloud Computing Sensors & Auto ID Inventory & Network Optimization Tools Robotics & Automation Wearables Predictive Analytics 3D Printing Drones & Autonomous Vehicles Internet of Things Source: MHI 2017 Annual Report:

54 Digital Enterprise Suite Our unique portfolio for the digital transformation

55 Siemens Become a approach Digital Enterprise to integrating by digitalizing your value chain and digitalizing the entire value chain Third party applications Cloud-based, open IoT operating system: MindSphere Product design Production planning Production engineering Production execution Services Collaboration platform: Teamcenter Suppliers and logistics

56 Create a powerful Digital Twin of the entire value chain Third party applications Cloud-based, open IoT operating system: MindSphere Product design Product design Production Production planning planning Production Production Services Production engineering Production execution Services engineering execution Collaboration platform: Teamcenter Suppliers and logistics

57 Digital Twin for Product, Production, and Performance MindSphere feed back insights to continuously optimize product and production Digital Twin of the product Digital Twin of the production Digital Twin of the performance

58 Digital Twin Overview Line Level PLC & HMI Validation Material flow & Logistics Simulation Cell Level Plant Simulation PLC & HMI Validation Robotic Simulation Teamcenter Machine Level Process Simulate PLC & HMI Validation Mechatronics Simulation Mechatronic Concept Designer

59 Plant Simulation - A Digital Twin of Production For Plant Optimization Plant Simulation For Material Handling and Warehousing Virtual Commissioning

60 Virtual Commissioning for Material Handling & Warehousing + Test before build + Risk free test + Pretested without damage + Shorter commissioning time + Planning confidently

61 Virtual Commissioning for Material Handling & Warehousing Material Handling & Warehousing: Sensors and actuators Material distribution HMI ease of use and operation Safety characteristics

62 Plant Optimization Benefits Profitability Throughput Confident planning Energy efficiency Process optimization Holistic PLM concept

63 Example - Throughput Profitability Throughput Confident planning Energy efficiency Process optimization Holistic PLM concept Detect low utilized resources Predict over utilized resources Balance resource utilization Eliminate logistical bottlenecks Optimize buffer quantities Reduce Work in progress

64 Example - Process optimization Profitability Throughput Reconsider process alternatives Optimize material flow and logistics Compare alternatives to achieve KPIs Confident planning Energy efficiency Process optimization Holistic PLM concept

65 Example - Process optimization Profitability Throughput Confident planning Energy efficiency Process optimization Holistic PLM concept

66 Plant Optimization Results Profitability Increase profit: spend the right CAPEX, utilize the right OPEX Throughput Detect bottlenecks before they occur in Production Confident planning 5-20% investment reduction Energy efficiency Saving 3 million kilowatt hours of electricity per year Process optimization 20-60% reduction in inventories Holistic PLM concept Optimizing complex systems using virtual prototypes

67 Plant Optimization Customer Testimonials Production throughput was increased by 40% Production costs could be reduced by 30% Plant Simulation helped us avoid significant capital investments and operational costs We could halve our inventory in the warehouse. More efficient production line with less waste Siemens AG Siemens AG Siemens AG Siemens AG Heavy Industry Energy Power Transmission Industrial Equipment Life Sciences Increased output per month by 10.5 percent Logistics costs reduced by 10 percent Reduction of the cycle time and increase in output by 18.2 percent Reduced cycle times by up to 66 percent Automotive T1 Bosch Wind Energy ISL Zwilling Consumer Packaged Goods Automotive T1 Behr

68 Thank You. Visit us at the Tech Cafe

69 Questions? Bill Henderson Business Development DF FA OEM Phone: After MiA, seminar slides will be available at:

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