How can you get your tire production rolling?

Transcription

1 How can you get your tire production rolling? With consistent solutions for the optimization of the entire manufacturing process. Answers for industry.

2 Flexibility and economy combined with top quality Global competitive pressure in the tire industry is constantly growing in intensity. This is one of the major reasons why more and more enterprises are pushing the internationalization of their production and the construction of new plants around the world in countries which offer local benefits. When doing so, it is absolutely essential that the same quality standards are maintained at all production sites around the world with, ideally, the same production techniques and automation products being used. Manufacturing processes characterized by a maximum in productivity, efficiency and flexibility are the prerequisite for lasting success in the tire industry. This makes energy-efficient automation and drives solutions all the more important. Present and future statutory requirements also need to be reliably met e.g. to ensure complete traceability of a tire following an accident. Totally Integrated Automation from Siemens provides the answer to these requirements. From a single source. Manufacturing Execution System (MES) Product Lifecycle Management Logistics & Transport Mixing & Extrusion Semi-Products Tire Building Vulcanization Quality Control 2

3 Higher productivity in the tire industry As a partner to the tire industry, we supply first-class products and solutions for all-round production optimization from plant engineering through to the production process itself. The basis of our solutions: unrivaled competence in automation and drives and solid knowledge of the industry. For example, increased vertical integration of production data in a manufacturing execution system (MES) significantly increases plant productivity: it ensures complete data consistency from field to ERP level. Experienced specialists take care of engineering and product support. Integrated diagnostic functions and scalable service strategies enable an increase in productivity and reduce downtimes for each production step in your tire plant. Leading partner in the industry With Siemens as your partner, you will have over 30 years of experience on your side. During this time, our experts have realized projects all round the world from the initial planning steps, engineering, simulation and commissioning right through to maintenance and service.

4 Solutions for the entire tire production process Mixing & Extrusion Semi-Products Tire Building Vulcanization Quality Control Recipe Management/ Statistics 15 LCD Monitor SIMATIC IPC Central Visualization Industrial Ethernet Industrial Touch Pad IPC Rack SIMATIC IPC Service Engineering Server (Database) Server SIMATIC IPC 10 LCD Touch Pad Database SQL Visualization WinCC flexible SIMATIC Flat Panel Ethernet SIMATIC IPC427C with WinAC RTX PROFINET PROFIBUS Main Control Cabinet ET 200S I/0 Modules control cabinet SINAMICS S120 SINAMICS S120 I/O SIMATIC ET 200S Motion, Drives SIMOTION & SINAMICS PROFINET IO SIMATIC IPC 27 Drives PROFIBUS DP S7-400 SIWAREX FTA ET 200S SINAMICS Servomotors Siemens 1FK/1FT Servomotors Siemens 1FK7 Servomotors Siemens 1FK/1FT Safety SIMATIC F-CPU, F-I/Os, registration equipment PROFINET IO with PROFIsafe Mixing and extrusion Customer-specific concepts and solutions for the entire rubber mixing process including the mixing management system and storage of the mixing products such as rubber strips or treads (in automated high-bay storage areas for semi-products). Mixing follows a specified recipe in which the speed, energy per unit of weight, temperature etc. are prescribed. Optimization of energy efficiency Optimization of mixing results in a shorter time Improved visualization of process values Production of semi-products A broad spectrum of products and solutions for the numerous requirements placed on the calender and extruder for manufacturing steel belts, inner-liners and treads. High level of standardization Lean automation solutions Energy savings Tire building High-performance drive solutions which optimize energy consumption by means of integrated reactive power compensation (cosφ = 1) and which are characterized by a high level of productivity Optimization of cycle times Open, robust automation concepts High level of availability 4

5 PROFINET IO SIMATIC IPC ET 200S ET 200S SIMATIC IPC ET 200S Industrial Ethernet SIMATIC Flat Panel PRO DVI-I USB SIMATIC IPC with WinAC RTX-F Measurement PC Other Ethernet equipment e.g. camera PROFINET / PROFIsafe 32 Drives ET 200S CPU Hydraulics Press 1 Press 2 Press n... SIMATIC ET 200S HF Stations and fail-safe I/O (mixed) PROFINET IO with PROFIsafe PROFINET and/or PROFIBUS connections possible Sensor/ Actuator SINAMICS S120 Stations Other PROFINET equipment Vulcanization Reliable, scalable and lean control solutions for hot presses which ensure an ergonomic workflow in the vulcanization process thanks to the integration of efficient operator panels, with the result that the corresponding parameters in the hot press, such as pressure, temperature and time, are dependably controlled. Cost-efficient solutions Efficient automation processes Tailor-made solutions Quality control Solutions which enable fully automatic final inspection with centralized data management for the X-ray and balance inspection as well as for the force variation test. Enhanced test performance Space-saving and cost-saving design Tracking and tracing for complete traceability of tires 5

6 All-round product range for your tire production plant from a single source Our unique Totally Integrated Automation portfolio covers the entire production process: from field level and high- performance gear units for mixers and extruders through to the interface to the ERP system from software design tools and factory planning through to maintenance. Controllers at field level We use our world-leading SIMATIC controllers for automating tire machines at field level. SIMATIC, our all-round automation system, enables the realization of scalable machine concepts a great benefit for both plant operators and machinery manufacturers. Irrespective of whether the concepts include modular controllers or PC-based automation: the automation program is always the same. Mixing and extrusion SIMATIC PCS 7 is the best choice for controlling your rubber mixing. Our solutions for the mixers include transformers, converters and drives and are especially designed for the demands of the tire industry. Our solutions also include mechanical drives for example with an attached maintenance station for preventive maintenance. Our mixing management system based on SIMATIC IT ensures data consistency throughout. It includes a special application for managing rubber mixing. Semi-products The scalability of the SIMATIC product portfolio really comes to bear in the production of semi-products perfectly customized to the various machines for the pre-manufacture of individual tire components. Whether calenders for manufacturing steel belts, inner-liners or textile cords or extruders for manufacturing sidewalls or tread, we will always supply you with drive solutions for the various tire machines. Motors in the power range up to 400 kw which satisfy the exacting quality requirements and the application-specific throughputs of the extruders and calenders are usually deployed for such applications. Machine- level visualization can also be realized by integrating operator panels. Tire building Besides SIMATIC controllers, we also provide SIMOTION and SINAMICS drive systems for tire building machine. These systems are characterized by their optimal energy consumption and set standards in performance (integrated reactive power compensation with cosφ = 1). Tire building machines are usually fitted with synchronous motors controlled by frequency converters. These fast and variable drives have been especially attuned to the requirements of a tire building machine. Vulcanization We provide extremely reliable, lean controller solutions for vulcanization using hot presses. Thanks to their highperformance operator panels, they ensure a cost-efficient workflow for your tire production and reliably control the relevant parameters such as pressure, temperature and time. Each hot press is equipped with a local operator console for machine-level operation and control. The controller and the operator unit can be installed together in the operator console in one housing (centralized) or they can be separated (decentralized option). In the latter case, the controller is mounted in the control cabinet and connected to the operator unit in the console. Quality control Our quality management solutions allow fully automated final inspection of individual tires (X-ray and balance inspection as well as the force variation test) with centralized data management. Logistics and transport To connect all the individual steps in tire production, we provide logistics and transport solutions as well as automated storage systems as product and dispatch buffers all perfectly designed to fit your individual needs. Furthermore, integrated traceability solutions allow reliable documentation and monitoring of all relevant production, logistics and process data. When it comes to such applications, you will receive the full benefit of our long years of experience in turnkey solutions for the tire industry. Factory planning with product lifecycle management (PLM) The Tecnomatix PLM software provides a comprehensive portfolio of digital manufacturing solutions which promote innovation by connecting all manufacturing areas in tire production with tire development from process definition, process planning, simulation and review through to actual tire manufacturing. Tecnomatix has been built up on a foundation for product lifecycle management (PLM) and today encompasses the most varied range of manufacturing solutions available on the market. With this software, tire manufacturers quickly find the best strategies for raising productivity and lowering costs in tire production. 6

7 All you require for lasting success in the tire industry with Totally Integrated Automation All components under the umbrella of Totally Integrated Automation are perfectly attuned to meet the many and varied requirements demanded by the tire industry with a top level of efficiency. Engineering: Choosing Totally Integrated Automation will give you an engineering tool for every automation job in tire production. Efficient software will provide you with comprehensive support over the entire lifecycle of your tire plant from the first planning steps, commissioning and operation right through to service and maintenance. Communication: Totally Integrated Automation provides the prerequisites for complete consistency in communication. By using an open bus system from the terminal through to the control system, you benefit from the highest possible level of transparency across all levels of the tire manufacturing process. Diagnostics: Thanks to efficient remote diagnostics down to the last terminal in the tire plant, any malfunction which may arise can be quickly identified and dealt with without the need for any programming work. This leads to minimized downtimes and optimizes productivity in tire production. Safety: No additional controller is required for safety functions. Thanks to an intelligent safety concept which integrates the safety system into the standard automation, you make significant savings on cabling, space and, consequently, costs compared to conventional solutions. Integration into the engineering software also makes for less programming and considerably speeds up commissioning of your tire plant. Security: The whole of the tire plant is protected against unauthorized access by means of Totally Integrated Automation. Scalable IT security mechanisms (access protection, user management, firewall, VPN etc.) provide efficient security with a low administrative input. Ruggedness: Carefully selected materials and manufacturing processes ensure the first-class quality of our products and systems. Special options are available to meet your heightened requirements in terms of ruggedness ideal for the tough environmental conditions in the tire manufacturing process. 7

8 Manufacturing Execution System for the tire industry: centralized and uniform data management Web-based MES Clients e.g. recipes, orders, alarms, online monitor MES Servers Logical Network #5 Mixing Management System Tire Manufacturing Final Finishing Curing Area Logical Network #1 Logical Network #2 Logical Network #3 Logical Network #4 Warehouse Management Server 1&2 Chemical parts Warehouse Management Server 3&4 Transportation system CTTS WinCC & S7 Curing presses Tire uniformity machine Transportation system FFTS Testing station WinCC & S7 weigh/mix Head PLC WinCC & S7 WinCC & S7 Calender textile/steel cord WinCC & S7 Tire building machines Cutting/slitting systems Transportation system CTTS Final inspection station Bar code roll assignment Visual inspection station Know more with MES Our MES solutions based on SIMATIC IT enable faster reaction to market changes. Processes can be made visible throughout the entire plant, manufacturing workflows can be synchronized, business decisions can be evaluated on the basis of real-time data and innovations, such as the development of a new type of tire, can be efficiently implemented. What is more, the integration of tracking and tracing functionality ensures complete traceability of tires, thereby giving you access to the production parameters of a specific tire whenever you need it. Standardized and scalable components These are based on a plug & play architecture in which the individual functions can be easily combined and configured. Thanks to the hierarchical structure based on ISA-95 and the totally object-oriented architecture, SIMATIC IT can be configured so as to allow provision of all required functions via web services. That means that you do not need any special software for data access or data exchange (e.g. recipe data for a tire). As a rule, Internet-compatible devices together with a browser will suffice, e.g. laptops or smartphones which are able to exchange data via XML. All security functions are taken into account. More benefits all along the line Our MES solutions are a part of the Totally Integrated Automation (TIA) open system architecture. The unique consistency on offer ensures perfect interaction among all components, thus creating the conditions needed for highly efficient, flexible and therefore productive tire manufacturing. For example, mixing recipes are highly sensitive corporate data, the core competence of any tire manufacturer as it were, and they call for increased security and transparency with respect to access possibilities and access authorizations in the tire manufacturing process. 8

9 Mixing Management System: managing rubber mixing processes efficiently System architecture of the server applications ERP level Recipe Specification SAP Scheduling, Orders, Inventory, Warehouse of Compounds MES level Mixer Recipes Data Integration Service Orders/ Batches LAB System Sample Data Lab Results Reports Material Administration Track Process Data Overall Equipment Effectiveness (OEE) Pallet Management Label Printer Controller level Head PLC Mixerline 1 Head PLC Mixerline 2 Head PLC Mixerline n Flexible and scalable server application Our MES solutions based on SIMATIC IT offer a special application for managing mixing ratios: Mixing Management System. This server application closes the gap between business systems (ERP/ SAP) and the controller level. The communication is based on proven industry standards such as XML, B2MMl, SAP idoc, OPC and Industrial Ethernet/PROFINET. For example, the customer wishes to increase process transparency for an individual mixer. This leads to a reduction of the scrap rate and, consequently, to shorter downtimes. What is more, evaluation and analysis functions improve the tire manufacturing process and can therefore contribute to production optimization. Wide-ranging functionalities A client/server architecture has been realized for top levels of availability. Its components cover recipe and purchase order management as well as tracking and tracing, calculating KPIs, overall equipment effectiveness (OEE) and reporting. OEE is a measure of a plant s value creation capability. Recipe, purchase order and administration data are sent to the respective controllers (head PLCs) so that the mixing process can be performed quickly and smoothly without interruption. Consistent, efficient recipe management which leaves no gaps All information relevant to the mixing process is available in real time at the touch of a button. You will benefit from the highest possible level of transparency and will be able react to your customers wishes more quickly. The recipe data and production parameters must be available at each mixer. As the individual mixers are very similar in terms of the automation solution used, it should be possible for the formulation generated for one mixer to be transferred easily and flexibly to other mixers. This standardizes recipe management making it more easily comparable and lower in cost. 9

10 Products and systems for the tire industry The first-class standard products and systems from our portfolio are the intelligent answer to the enormous challenges faced by the tire industry. Furthermore, you benefit from numerous other advantages for example preventive maintenance, intelligent diagnostics, the integration of safety systems in the standard automation or permanent condition monitoring. Quicker from the initial idea... to the finished workpiece Product Lifecycle Management Process control system (Distributed Control System, DCS) Far more than a classical Distributed Control System (DCS): SIMATIC PCS 7 The centerpiece for consistent and safe automation of the complete tire production process from goods in to goods out Unique scalable architecture Powerful engineering tools A number of seamlessly integrable additional functions e.g. alarm management, process safety or asset management Integrated safety concepts for the highest level of system availability and reliable protection for people, machines and the environment Controller and Human Machine Interface (HMI) Comprehensive, consistent range of control solutions for all requirements in the tire industry Modular controllers: SIMATIC S7 PC-based controllers: modular embedded controllers S7-mEC or industry PCs SIMATIC IPC with software controller SIMATIC WinAC with integrated fail-safe system as an option Solutions for operator control and monitoring (HMI) perfectly attuned to the needs and requirements of the tire industry SIMATIC WinCC as SCADA system or SIMATIC WinCC flexible as HMI operator system on various hardware platforms Product Lifecycle Management (PLM) Extensive portfolio of digital manufacturing solutions Intelligent management of product innovations by connecting all manufacturing disciplines with product development from process planning, simulation and validation through to actual production Industrial communication Complete hardware and safety portfolio for PROFIBUS, PROFINET, Industrial Ethernet, AS-i Industrial Ethernet PROFIBUS or PROFINET with integrated PROFIsafe technology PROFIBUS DP and PA (e. g. SIMOCODE, pressure, temperature) AS-i components for direct installation on the machine Compliance with safetyrelevant standards and legislation (up to SIL 3) No extra cabling and no special safety controller required for your tire plant Support for fail-safe communication also via industrial wireless LAN 10

11 Manufacturing Execution System Siemens will provide you with the ideal basis for a perfectly customized manufacturing execution system with which you can access all your process information throughout the company in real time: SIMATIC IT our sophisticated, finely scalable MES product meets the ISA-95 standard. It offers you a whole range of benefits: faster planning, better capacity utilization and higher quality in production with lower costs. Distributed I/O Industrial identification Motion control and drives Mechanical drives SIMATIC ET 200 is a multifunctional, modular and finely scalable system for distributed automation: for solutions in your control cabinet or without a control cabinet directly on your tire machine as well as for use in potentially explosive atmospheres Extensive family of distributed I/O systems: SIMATIC ET 200M / S / ISP / pro / eco Available in standard and fail-safe versions Extremely rugged in IP65 / 67 and can be deployed up to + 60 C for use without control cabinet in adverse environmental conditions Reduced size requires little space M12 connectors highly resistant to vibration Broad portfolio of identification systems for machine applications especially for tires SIMATIC RF RFID systems for optimizing production, material transport and logistics SIMATIC code reading device for reliable, flexible and automatic tracing Easy system integration into automation system Technology-neutral application consulting Scalable motion control solutions for single- and multi-axis applications. SIMOTION Smart Drives Management masters power failures with SINAMICS Active Line Modules SIMOTION SIMATIC T-CPU SINAMICS MICROMASTER Motors and drives for all applications in the tire industry Gear units and couplings for industrial applications and energy production FLENDER standard drives Application-specific FLENDER gear units Customer-specific FLENDER gear units Geared motors 11

12 Further information on the automation of your tire production: Your direct contact to our team of experts for the tire industry: Siemens AG Industry Sector Industry Automation P.O. Box NUREMBERG GERMANY Subject to change without prior notice 02/11 Order No.: E20001-A1000-P200-X-7600 Dispo WÜ/26217 MI.AS.TA.XXXX WS Printed in Germany Siemens AG 2011 The information provided in this brochure contains merely general descriptions or characteristics of performance which in actual case of use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract. All product designations may be trademarks or product names of Siemens AG or supplier companies whose use by third parties for their own purposes could violate the rights of the owners.