English. KRONES Academy Automation Concept and IT Solutions

Transcription

1 English Academy Automation Concept and IT Solutions

2 Table of contents krones Automation Concept 5 krones Filler Simulation 29 On-site Training Center 8 Digital krones Academy 31 Rack overview, training opportunities and possible combinations 10 krones Automation Notebook 33 krones SIMATIC S7-300 Rack 13 krones Automation Engineer 34 krones SIMATIC S Rack/TIA 15 Siemens S controller and STEP 7 in the TIA portal 37 krones Touch-Screen Rack 17 krones 39 krones Touch-Screen/SIMATIC S7 Rack 19 Line Documentation System (LDS) 43 krones AS-i Safety Rack 21 Line Performance Analyser (LPA) 45 krones B&R Rack 23 krones Asset Management (KAM) 47 krones frequency inverter rack for Danfoss 25 Line Management System (LMS) 49 krones LCT4 Rack 27 The krones course navigator

3 Automation Concept The overall package for best training concepts Nothing will happen in your production as if by magic. You rather need precise knowledge about automation technology, the option to quickly intervene into the software, and suitable tools for a safe programming of the procedures. krones offers the ideal overall package for you with its Automation Concept. In co-operation with you, we will develop your individual overall concept for all tasks of Automation Technology tailored perfectly to your needs. Your success is based on three elements: Automation Engineer Automation Equipment Automation Notebook Regardless if racks, machine simulation units, notebook or training offers, on the following pages we will inform you in detail about all services of the krones Automation Concept. Contact: Claudia Bruckbauer Telephone: Fax: claudia.bruckbauer@krones.com 4 5

4 Automation Engineer Automation Equipment Automation Notebook Automation Concept Die magischen Drei Our Automation Concept is the formula for your electronics and automation specialists for accurate diagnostics and optimisation of the Automation entire Rack automation technology. One concept, three components Automation Notebook Using different racks and machine simulation units, all Automation staff Engineer members can learn and Automation Equipment deepen the ideal use and expand their knowledge of handling the machines without any standstills during production. Automation Notebook It contains the required software as well as all adapters necessary for the diagnostics and data back-up of your line. Automation Engineer We offer modular basic courses and workshops for IT system technology, for line documentation systems, for visualisation systems as well as an automation and network concept. Benefits to you Components that are attuned to one another The three elements of the krones Automation Concept can be used separately, as single automation modules, or as interacting components. Maximum efficiency for all automation tasks Regardless if training own staff members or troubleshooting: The krones Automation Concept is a benefit for your production in daily operation on the machine and in simulation sequences. 6 7

5 On-site Training Center a plus for your production process Your request: Optimum training of your staff without travel expenditure or even interruption of your production? krones will assist you in meeting these challenging requirements. All you need to do is provide us with an empty room. krones will take care of the rest. We will plan your ideal training room with all required connections and simulation units and create comfortable and optimal training conditions according to your requirements. One room, many fields of applications Once it has been installed, your On-site Training Center can be put to versatile use, depending on your equipment. Machine training for: Automation Technology Operator training Maintenance training Targeted training and advanced training of your staff: Simulation of machine functions Troubleshooting via simulation of malfunctions Practical exercises for replacement of components without affecting the current production Testing own programs Custom-made training environment We offer different equipment possibilities depending on the size of the room and individual requirements. Sub-modules of a machine (racks) Mechanical Training Units for individual machines such as Contiform blowing station, hotmelt labelling station, filling valves Please ask your krones contact person if you have more questions about the Mechanical Training Units. Exemplary planning of the room for an On-site Training Center with racks and machine simulation units 1x 1x Smartboard Projector 1180mm 1900mm 2700mm 1900mm 2720mm 1900mm Table 4850mm Table Table Table Projector/HDMI 1x 1x Table 8000mm labellingstation gripper cylinder filling station 1x 1x Smartboard Projector 1x 1x Trainer Rack Rack Table Table 5000mm Rack 5500mm big table big table Rack Table Rack Table 1200mm Projector/HDMI 1x 1x 8700mm USB/VGA Smartboard 400 V electric socket Electric socket LAN port blowingstation working bench add. Valvestation Light switch 8 circuit 1 circuit 2 3x 3x circuit 1 circuit 2 9

6 Krones Automation Racks Overview Krones Automation Racks Training opportunities and possible combinations S7 basic course and advanced course Zenon course Filler operator training SIMATIC S7 Touch-Screen Profibus Ethernet SIMATIC S7-300 rack SIMATIC S rack/tia Touch-Screen rack Touch-Screen/ SIMATIC S7 rack Zenon course B&R workshop Filler operator training ASI safety workshop S7 basic course and advanced course Zenon course Filler operator training Touch-Screen/SIMATIC S7 B&R AS-i Safety SIMATIC S7 Touch-Screen ASI safety workshop Zenon course B&R workshop Filler operator training AS-i Safety Touch-Screen/SIMATIC S7 B&R Bestseller AS-i Safety rack B&R rack Frequency inverter rack for Danfoss LCT4 rack ASI safety workshop S7 basic course and advanced course Zenon course B&R workshop Filler operator training AS-i Safety SIMATIC S7 Touch-Screen B&R 10 Automation Engineer 11

7 Krones SIMATIC S7-300 Rack Description With the SIMATIC S7-300 rack, the user can perform preliminary tests of the program changes made in the S7 controller and learns how to use AS-Interface, Profibus or network technology. The SIMATIC S7-300 rack serves as a basis for the touchscreen rack and the ASI safety rack. Accessories and extensions Options for combination of automation racks (see page 11) Participation in the»basic course Siemens SIMATIC S7-300 for machines«optional: Training documentation Optional: Automation Notebook Learning objectives Hardware and peripherals of a machine with communications to HMI and subsystems; understanding data security/ diagnostics Structure of the user software, Profibus/ASI configuration structure Technical data, scope of supply SIMATIC S7-300 Rack Connection diagram and operating instructions Benefits to you Realistic simulation of changes on the machine controller Development and testing of user programs and projects Practicing the replacement of components without affecting production Training for e.g. S7 control technology, Profibus and ASI bus 12 13

8 Krones SIMATIC S Rack/TIA Description The SIMATIC S Rack/TIA is an ideal tool for testing S7 controller settings and programs you have configured yourself using the SIMA- TIC Step7 (TIA portal), as well as for learning how to handle AS-Interface and Profinet or network technology. The SIMATIC S Rack/TIA, just like the SIMATIC S7-300 Rack, serves as a basis for the touch-screen rack and the ASI safety rack. Accessories and extensions Options for combination of automation racks (see page 11) Participation in the basic course»siemens SIMATIC S for machines«optional: Training documentation Optional: Automation Notebook Learning objectives Hardware and peripherals of a machine with communications to HMI and subsystems; understanding data security/ diagnostics Structure of the»tia portal and SIMATIC Step7 (TIA portal)«user software Structure of the Profinet/ASI configuration Technical data, scope of supply SIMATIC S Rack/ TIA Connection diagram and operating instructions Benefits to you Performing simulations of machine controller changes as realistically as possible Configuring and testing own programs and projects Practicing the replacement of components without affecting production Holding training courses on topics such as S7 control technology with SIMATIC Step7 (TIA portal), Profinet and ASI bus 14 15

9 Krones Touch-Screen Rack Description The Touch-Screen Rack serves as an expansion for the SIMATIC S7-300 or 1500 rack with an integrated machine visualisation system where the user can exercise and call all functions known from the machine on the touch-screen. Accessories and extensions Options for combination of automation racks (see page 11) SIMATIC S7-300 or 1500 Rack (prerequisite) Participation in the course» visualisation technology Zenon touch-screen software«optional: Training documentation Optional: Automation Notebook Learning objectives emergency package solution, practical use of the Zenon tools Alarm handling, diagnostics and interpretation of faults Use of the type and user management system, data back-up Technical data, scope of supply Touch-Screen Rack Connection diagram and operating instructions Customer transponder set Including current filler software project Benefits to you machine visualisation system with all included parameters visible Learn how to use the production machines in a reliable and targeted manner via training with the Touch-Screen Rack Holding training courses on visualisation technology Quicker and more efficient use of the help tools 16 17

10 Krones Touch-Screen/SIMATIC S7 Rack Description The Touch-Screen/SIMATIC S7 Rack is a combination of the SIMATIC S7 Rack and the Touch-Screen Rack. The controller works only with integrated visualisation systems. Accessories and extensions Options for combination of automation racks (see page 11) Participation in the course» visualisation technology Zenon touch-screen software«optional: Training documentation Optional: Automation Notebook Learning objectives emergency package solution, practical use of the Zenon tools Alarm handling, diagnostics and interpretation of faults Use of the type and user management system, data back-up Technical data, scope of supply Touch-Screen/SIMATIC S7 Rack Connection diagram and operating instructions Customer transponder set Including current filler software project Benefits to you machine visualisation system with all included parameters visible Learn how to use the production machines in a reliable and targeted manner via training with the Touch-Screen Rack Training for visualisation technology Quicker and more efficient use of the help tools Inexpensive solution if no S7 training courses are required or no S7 training contents are to be conveyed 18 19

11 Krones AS-i Safety Rack Description The ASI Safety Rack can be used in training courses on the standard components of safety equipment. The rack allows you to exercise with these components and test or replace them. Accessories and extensions Options for combination of automation racks (see page 11) Participation in the course» Electrical Components System Engineering«Optional: Training documentation Optional: Automation Notebook Learning objectives Replacing components Data back-up Online functionality (ASIMon software) Technical data, scope of supply ASI Safety Rack Connection diagram and operating instructions Replacement components of the safety equipment ASI programming unit including adapter and programming cable Benefits to you Safe and quick replacement of the safety components Correct detection and analysis of faults Practical exercises possible by connecting the S7 controller and the touch-screen visualisation system (display and diagnostics on touch-screen) Back-up of safety logic (in conjunction with the ASIMon software) 20 21

12 Krones B&R Rack Description The B&R Rack (filling technology) can be used in conjunction with the SIMATIC S7-300 or 1500 Rack and the Touch-Screen Rack in order to simulate the control of the filling valves and thus the filling process. The operating processes and the parameter settings can be visualised. Accessories and extensions Options for combination of automation racks (see page 11) Participation in»b&r Automation (electrical system) workshop«optional: Training documentation Optional: Automation Notebook Learning objectives Powerlink network and network structure Data back-up and replacement of components B&R AS 3.0.9x basics; integrated help system Technical data, scope of supply B&R Rack Connection diagram and operating instructions Benefits to you Specific training with regard to Automation Studio Fault simulation for B&R controllers, including possible replacement of components Holding of training courses on the topics of the»b&r Automation Workshop«(creation of CF cards, use of tools) 22 23

13 Krones frequency inverter rack for Danfoss Description The frequency inverter rack for Danfoss enables the parameterisation of motors and their parameters to be simulated in a realistic manner. Accessories and extensions Participation in the course» Electrical Components System Engineering«Optional: Training documentation Optional: Automation Notebook Learning objectives Data transmission via Profibus Data back-up and replacement of devices Structure, functions and connection options Parameterisation using the operator panel (LCP) Technical data, scope of supply frequency inverter rack for Danfoss Profibus options card MCA101, Profibus cable USB cable for communications and data back-up Benefits to you Locating and fixing minor malfunctions Use of the MCT10 set-up software from Danfoss Back-up of parameter records 24 25

14 Krones LCT4 Rack Description The LCT4 Rack is a mobile training module which is suitable for machines. Accessories and extensions Participation in seminars on conveyor technology. Optional: Training documentation Learning objectives Data back-up Replacing components Diagnostics options Technical data, scope of supply LCT4 Rack Operating manual Customer transponder set Benefits to you Specific training with regard to parameterisation Training courses in the field of Glideliner and block synchronisation 26 27

15 Krones Filler Simulation our bestseller Description Looking for the ideal combination for the best training results? ASI Safety Rack, Touch-Screen/SIMATIC S7 Rack and B&R Rack that is what we recommend if you want to simulate the visualisation system of the filler in a realistic manner. This way it is possible to visualise operating and diagnostics processes that relate to the control of filling technology. Accessories and extensions» Electrical Components System Engineering«,» Visualisation Technology Zenon Touch-Screen Software«and»B&R Workshop«Optional: Training documentation Optional: Automation Notebook Learning objectives Quick and efficient use of the comprehensive diagnostics and test functions Understand effects of changes in the process (filling program) Replacement of components and data back-up Technical data, scope of supply ASI Safety Rack, Touch-Screen/ SIMATIC S7 Rack and B&R Rack Connection diagram and operating instructions Customer transponder set Including current filler software project Benefits to you machine visualisation system with all included parameters visible Simulation and understanding of the filling process or the filling program 28 29

16 Digital Krones Academy Your direct line to know-how All machine information stored at a central location and available for calling up by a range of different devices? The Digital Academy makes it possible. The concept is simple yet ingenious at the same time: Via integrated Wi-Fi you can access all the materials in the training terminal using your smartphone or tablet. You will therefore be able to carry out crucial tasks on the machine confidently and reliably. You get operating manuals, customtailored training materials and short video sequences and all in one place: the training terminal. But the Digital Academy is more than a central storage space. After all, it goes without saying that you also need to have the right tools to hand where they are needed - which means at the machine itself

17 Krones Automation Notebook Description Regardless if for training support in automation training or for diagnostics and troubleshooting on the line with the krones Automation Notebook, you can start right away. The krones Automation Notebook contains the most important krones software applications; all required cables and adapters are included in the scope of supply. Accessories and expansions As an option, the software packages Allen Bradley RS Logix 5000 Standard Edition, B&R Automation Studio 3.0.9x Maintenance Set, S7-PLCSim V5.4 simulation software or AsiMon software with connection cable are also available. Learning objectives Suitable for all training modules in the field of automation Developing and testing own programs (Step7, Zenon HMI, etc.) Data back-up using krones back-up and diagnostics tools Technical data, scope of supply DellE6540 with adequate equipment (professional series) software and utilities according to specification in the quotation Pre-installed notebook with all required krones software and utilities, among other, with: Siemens Step7 SIMATIC Manager, Zenon emergency package, Microsoft Office Home and Business 2013 Acronis Backup & Recovery Danfoss MCT 10 set.up software, B&R-CPU diagnostics, K-DOT, PDWIN, PDEXE, DCopy, EasyConfig, MOVITOOLS, DbaMGR2k Benefits to you Expanded fault diagnostics for quick troubleshooting All tools for data back-up already installed Communication interfaces, cables and adapters for data back-up and on-line connection are included in the scope of supply Turn on the system and get started at once Zenon emergency package contains: Machine control using the Automation Notebook if system-relevant hardware has failed 32 33

18 Automation Engineer Your own expert will support you with all questions around Automation Technology. Our objective is keeping your staff always up to date with the latest technology. With your certificate of the krones Automation Engineer we will guarantee high-quality enhanced training and you will have your personal expert on-site. Modular design In theoretical and practical units, the future krones Automation Engineers will learn technology of krones components. the optimum interaction of network technology and control technology. performing maintenance and malfunction diagnostics without any problems. minimising sources of errors in the system. performing changes in the program. performing safe and quick data back-up. Individual and efficient On his way to krones Automation Engineer, the participant will only take the courses he really needs for his successful certification. The krones course navigator will help you to find the rights courses from the broad offer. Always up to date At the end of the course, the participant will receive the krones certificate which is valid for two years. This way, krones will guarantee that the qualification of the owner of the certificate is at the state of technology. Your route to the Automation Engineer Level 0 Basic machine knowledge Basic electrical engineering knowledge System engineering Electrical components Electrical components * Electronics engineer Mechatronics engineer Step 7 basic course / Zenon Visualisation B&R Automation Workshop ControlLogix control technology Filling and Packaging Processing Preventative maintenance Maintenance Troubleshooting Electrical components System Engineering Assessment Step 7 Advanced course network technology Logistics Execution Maintenance Automation Engineer (KAE) Administration Diagnostics Connectivity Manufacturing Intelligence On-site Training Center: Automation Notebook and Automation Rack with introduction Certificate KAE Continuous Improvement Planning line efficiency Quality Business Intelligence Line Management IT consultant Compulsory modules your learning path to krones Automation Engineer in 9 days: 4 days: Step 7 basic course 2 days: Zenon 2 days: B&R 1 day: Assessment KAE certificate 34 * Electrical components level is the prerequisite for the KAE 35

19 Siemens S controller and STEP 7 in the TIA portal Innovations in the field of machine controllers: The latest generation of machines features Siemens S controllers and the latest engineering software»step 7 in the TIA portal«. To enable you to use this software structure to optimum effect, the Academy now also offers courses on this system. In addition you will also receive the corresponding SIMATIC S Rack/TIA from. Your route to TIA Expert in 8 days TIA basics TIA system set-up Program basics Krones TIA structure Step 7/ TIA basic course PLC system Variables and addressing Communication PLC configuration Bus systems Hardware configuration TIA portal handling Diagnostics options Bit programming Profibus communication Programming Communication Documentation State machine TIA System Advanced Program modules Interaction with machine Programming languages Step 7/TIA advanced course TIA basics System set-up shift register Signal transmission TIA module functions Touch-screen/ HMI communication Working with the shift register Program modifications SCL and S7-Graph Basics Programming structure Commands 36 37

20 : all Krones IT solutions under one roof. Krones MES (Manufacturing Execution System) helps you to plan, visualise, document and control your entire production. The module as part of the Krones Automation Engineer comprises various courses. Comprehensive IT knowledge is conveyed to the participants who are perfectly trained on the topic of maintenance. Optimal Total Cost of Ownership for the entire production A Krones MES allows you to ensure that your line is working to capacity. That s because the system helps you schedule production jobs quickly and coordinate the relevant workflows optimally. Clear and continuous batch tracking Thanks to the automatic recording of all production data, you will get a seamless overview of the backward as well as the forward tracking of products and their components. Transparency is everything Collect all the information and data from production operation and make it available across the whole company: That s how to create optimal production processes and high transparency for all decisions. Costs and availability in hand You can be sure that all products can be delivered rapidly and that jobs are completed efficiently even when schedules are tight. Optimally informed even with paperless production The comprehensive flow of information from company headquarters down to the individual machines puts all production departments equally in the picture. Flexibility whatever the batch size The system even copes with a wide range of products and containers

21 The IT solutions cover a wide range of functions in production. The individual tools are therefore used by different people who have their own tasks and roles. It shows you at a glance the topic, target group and duration of each training course you can then compile the course program which exactly suits you or your employees. KAM Course IT 14 4 days Maintenance personnel Each of the Academy IT courses is aimed at a special group of participants and deals with their individual requirements and questions. Which employees profit most from which course can be seen on the right in the overview. You can look up a list of the corresponding courses in the krones Academy program. You will find it online under: > Academy > Training program Operators 1.5 days 0.5 days 0.5 days KAM Web Course IT 15 KAM HMI Course IT 16 LMS Courses IT 17 and IT days 2 days 4.5 days Shift leaders 0.5 days LPA Courses IT 12 and IT 13 1 day 5 days LDS Course IT 10 2 days 40

22 Line Documentation System (LDS) Filling and Packaging Si Log Knowing exactly what is going on and showing how to do it better: The LDS records and illustrates all production data, online and in real time. The clever software identifies the root cause of faults that lead to performance losses on the lead machine and gives specific advice on how line efficiency can be improved. It analyses losses in production just as reliably as efficiency gaps. Line visualisation Automatic recording of all available production data and losses Display of machine states across all lines Identification of root causes of faults on the lead machine and assigned stations Analysis of production data Processing Freely selectable query period Web reporting: reports on operating status, malfunction analyses, programs, production, product lists or customer-specific information Representation of trends Graphical representation of trend values, e.g., by means of scalable curve generation Si Ma 42 43

23 Filling and Packaging Logistics Execution Connectivity Quality Processing Maintenance Line Performance Analyser (LPA) Manufacturing Intelligence Business Intelligence Do you always know what is happening on your line or maybe you don t? Do you know the reason for non-productive times? With the Line Performance Analyser the answer both times is: yes! That s because this practical tool keeps an eye on your system and serves up all of the key information you need in an easily understandable format with just a few mouse clicks. Transparent production Concrete data on efficiency, availability, performance, quality and OEE Classification, grouping and subdistribution of all standstills, even of those caused by external factors such as cleaning and conversion phases, lack in supply of materials or breaks Representation in daily, monthly or yearly reports Objective benchmark Uniform assessment criteria Concrete target/actual comparison: determination of metrics for a particular job or shift Comparison of different lines, time periods and sites Higher efficiency Full analysis Identification of improvement potential Production optimisation 44 45

24 Filling and Packaging Logistics Execution Si Co Asset Management (KAM) Processing Maintenance Si Ma Int The issue of correct maintenance is a critical factor for the life and efficiency of a system. The KAM maintenance software gives you ideal support in the organisation of maintenance activities and staff. You get precise information on operating hours and maintenance intervals for every single line unit. And a clever reporting system also considers all faults and adds the appropriate preventative work to the schedule. Efficient planning of maintenance jobs Clear indication of the upcoming maintenance tasks Quick start of maintenance jobs Easy compilation of notes and reports Integration of shift schedules and qualification specifications into maintenance planning Rapid access to maintenance manuals and work instructions through integrated document management Intelligent parts management Clear organisation of the magazine Reliable availability of replacement parts through warehouse management system with inventory management and reservation function for parts needed currently 46 47

25 Line Management System (LMS) Filling and Packaging Si Log LMS puts control over the whole production into your hands, from defining the production route according to the order to labelling the pallets. The system provides a continuous flow of information from the ERP system to the PLC and ensures that machinery and materials are used as efficiently as possible. The high degree of automation brings your production up to top speed with shorter change-over times, lower material consumption and maximum availability. Intelligent material and job management Start, change and deletion of all production jobs Order-dependent parameterisation of the machinery involved in production, including printers and dating units Prompt, automatic material call requests via connection to the warehouse management system Parts lists management Feedback on actual production data and consumption Greater efficiency, lower costs Processing Lower production costs thanks to bottle or tank-level precision in production Shorter change-over and cleaning times because jobs can be bundled High line availability with on-thefly order and batch changes High process reliability thanks to operator guidance Si Ma 48 49

26 The course navigator Your individual course recommendation The krones course navigator will pave the way to successful completion of krones Automation Engineer. Use the interactive navigation to test your knowledge in the offered training modules and to receive the optimal course recommendation. Afterwards, you can order your personal offer with just one click. The time you will invest in the krones course navigator will pay off, because of the individual course recommendation you ensure that you will only select the courses that are required for a successful certification for the krones Automation Engineer. You will find the course navigator under: > Academy > Automation Concept 50 51

27 Subject to technical changes PDF_en 03/16 krones ag Academy Böhmerwaldstraße Neutraubling Germany Phone Fax info@krones.com Internet