Solutions for any requirements: Conveying you to an integrated success. conveyor technology

Transcription

1 Solutions for any requirements: Conveying you to an integrated success conveyor technology

2 Conveyor technology: Moving industries to new heights What you can expect: III Greater productivity, increased profitability with an integrated product portfolio and comprehensive solutions III Lower operating costs through targeted minimization of energy requirements III Higher plant availability through higher product quality, reliable support from a single source and fast spare parts service III Complete protection of investments through customized services, including training III New possibilities for modifications and expansions through a scalable portfolio and modular system components

3 Mobility simplifies and improves our everyday life. Conveyor applications also keep the industry moving right along. Whether used in a production process or production area, for further processing or storage and delivery, or for a variety of other different requirements, the focus is always the same: conveyors need to span the distance efficiently and transport objects as quickly as possible from Point A to Point B. An optimum solution for any application task from conveying to sorting to storage and order picking involves a range of high requirements. The trick is to find an integrated solution that links mechanical and electronic systems intelligently with one another. It must also offer a compelling answer to questions regarding user friendliness, innovation and cost efficiency. At the same time, it must grow with the complexity of your system and meet increasingly stricter legal specifications. To find the right solution, you need a partner that can support you in every aspect of the matter: III with the right products and systems: covering everything from automation and drive technology to safety engineering to power supply and distribution III with qualified advice and comprehensive support III with future-oriented concepts and on-target configuration support We re the partner you re looking for. Conveyor technology 03 Our comprehensive product portfolio for conveyor technology is your key to new potential for efficiency.

4 A product range that meets your demands: Moving more than you ever imagined Siemens Automation and Drives offers a wide range of products and systems for conveyor technology applications in a variety of different industries. But there are a number of things they all have in common: III They are part of our integrated systems and technologies III They feature flexible scalability III They meet the highest standards as regards quality, reliability and future orientation III They are available worldwide In fact, our comprehensive system range for conveyor technology offers many different advantages, providing lasting benefits to machine manufacturers, plant engineering companies and plant operators. 04 Customized solutions for any requirements, from the automotive industry to airports...

5 Advantages for mechanical engineers and plant engineers Are you a mechanical engineer or plant engineer searching for cost-efficient possibilities for fast implementation of a conveyor technology application? Do you want to employ state-of-the-art technologies for your customers while maintaining profitability? Then you came to the right place. Based on our fieldtested, comprehensive portfolio, we can offer you both standard products and customized systems and services. Intelligent tools provide you support in the configuration phase, laying out components, setting up power supply and distribution systems, parameterization, programming and commissioning. Our products and systems let you standardize and modularize your conveyor technology components, for instance, with uniform interfaces or power bus systems with a high degree of protection for distributed plant concepts. In turn, you can reduce your assembly and commissioning overhead while increasing flexibility and system availability. In the end, you benefit from our unique system and sector-specific expertise and from maximum future orientation ensured by the use of state-of-the-art technologies and their constant further development, now and in the future. Advantages for plant operators Do you depend on reliable conveyor technology for the productivity of your company? Are you a plant operator intent on taking full advantage of all efficiency potentials presently offered by modern, integrated solutions? Let us be your partner who takes individual approaches to attain your goals. We offer a solid foundation with a complete product portfolio featuring geared motors, motor starters and converters, sensors and switchgear, automation devices and everything else you need for efficient conveyor technology applications. Smooth commissioning means you can ramp up your plant quickly. The simple expandability of our systems and fast exchange of devices minimize downtimes and conversion times. The high quality of our products and comprehensive diagnoses for preventative maintenance ensure high availability. Furthermore, our energy-saving motors in the efficiency class EFF1 or EFF2 offer a high potential for saving energy. That way, you can reduce the overall overhead for the set-up and maintenance of your machines and plants while optimizing all your processes. Conveyor technology and the food & beverage industry all the way to postal automation, warehouse & logistics and anywhere else efficient conveyor technology are in demand.

6 Conveyor technology processes: Conveying permanent acceleration of productivity Conveying means transporting goods or products horizontally or vertically from one place to another. When spanning the distance, the goal is to move the objects as quickly and reliably as possible since transport time is actually unproductive time. However, the stakes are even higher for production lines: in the automotive industry, for example, drives need to be exactly positioned and an identification system must be in place to reliably track production processes. Increasing personal safety is another important issue. If the conveying process is integrated into a uniform operator control and automation system, it is possible to achieve a markedly higher throughput at the end of the line. Conveying 06 Examples of conveyor technology applications for assembly lines in the automotive industry: III Monorail overhead conveyors III Automatic guided vehicle systems (AGVS) III Skid conveyor technology with roller conveyors, rotary tables, lifting stations, etc. III Sliding platform systems Whether you require a solution in the automotive or food & beverage industry, in airports, postal and package distribution centers or general intralogistics, our standardized yet customized products and systems are the right solution for your conveyor technology applications in any industry.

7 Conveyor technology processes: Sorting on-target organization of efficiency Sorting means arranging goods according to defined characteristics. In the case of hub airports, for example, sorting involves strict requirements to ensure smooth sorting and proper rearrangement of luggage for numerous airplanes that need to be loaded and unloaded. An additional logistic challenge for hub airports is dealing with a high amount of transfer luggage in transit from its respective arrival to departure gate. These requirements demand high-speed transport, fast and reliable sortability as well as adequately dimensioned buffer capacities. In this context, highperformance automation technology, precise luggage identification and highly dynamic drives ensure that the right suitcase is delivered to the right loading station at the right time. Sorting Examples of conveyor technology applications for luggage sorting in airport logistics: III Check-in III Conveyor belt systems III Tray conveyors III Tilt-tray sorters III Baggage claim conveyor technology Whether you need to convey, sort, store or pick, we work with you to bring your processes up to their full potential no matter what the task quickly and reliably.

8 Conveyor technology processes: Storage permanently securing your lead Storage means ensuring the availability of material or products to ensure continuous production and delivery. Meeting these market demands requires a powerful storage logistics system. Fully automated roller conveyors or conveyor belts are used for filling and clearing order picking zones, while highly dynamic storage and retrieval machines handle pallets and containers and transport them to the respective storage bays. Reliable automation and drive components tuned to one another ensure high handling rates, quick storage and retrieval cycles along with high availability for a highly efficient warehouse. Storage Examples of conveyor technology applications for storage in the food & beverage industry: III Storage and retrieval machines III Pallet conveyor technology including corner transfer units, lifting platforms, etc. III Monorail overhead conveyors Whether you handle pallets, containers, trays or skids or work with automatic guided vehicle systems, we deliver a customized automation and drives solution for efficient and cost-effective storage no matter what goods you need to move or what means of transport you use to move them.

9 Conveyor technology processes: Order picking unleashing the full potential Order picking means bringing together various items and materials as required for further internal processing in the production cycle or for external forwarding to logistics centers. Order picking solutions demand a high degree of logistic know-how and plant engineering expertise. The spotlight is on fast throughput of goods and minimization of any errors in the order picking process. The ordered goods need to be supplied to the right location in the exact quantity requested. Helpful solutions for order picking are provided by flexible drive components, precise identification and messaging systems as well as a carefully conceived operator guidance system. Order picking 09 Examples of conveyor technology applications for order picking in warehouse & logistics: III Container conveyor technology (with belts or rollers) III Preselection using on barcode scanning III Goods retrieval including a unit count through weight monitoring Whether your plant uses roller, belt or chain conveyors, lifting stations, sorters, rotary tables, corner transfer units, storage retrieval machines, monorail overhead conveyors or circular buffers, we serve as a reliable partner for any application contributing our experience while remaining open to new approaches.

10 Ethernet Comprehensive solutions: Totally Integrated Automation our concept for your entire value chain Totally Integrated Automation: The plant-wide approach for conveyor technology With Totally Integrated Automation, we offer our customers a uniform and unique range of products and services for process and production automation including conveyor technology applications. Every increment of a conveyor technology can be integrated along with the information flow into an overall solution across all production levels from the field level to enterprise management. This holds the promise of more lucrative engineering and efficiency as well as greater profitability across all processes. Thanks to the consistent integration concept, TIA is also a major factor in minimizing costs throughout the entire life cycle and reduces the complexity of industrial plants. Totally Integrated Power: Power distribution and management from one source Our Totally Integrated Power (TIP) concept offers you integrated solutions for power distribution in non-residential and industrial buildings, from low-voltage transformers to power outlets. Equipped with the same communications and visualization standards as Totally Integrated Automation, all the components for automation, power distribution, power management and building automation can be integrated into plant-wide solutions for your industry. 10 ERP Enterprise Resource Planning Ethernet Totally Integrated Automation MES Manufacturing Execution Systems Ethernet Production Order Management Production Operations Recording Material Management Equipment Management Control SIMATIC NET Industrial Communication SINAUT Telecontrol System SIMATIC Software SIMATIC Controllers/ Automation System SIMATIC Sensors Industrial Industrial Ethernet Safety Integrated PROFIBUS PC-based Automation AS-Interface Building Technology GAMMA instabus Micro Automation and Actuator-Sensor Interface Level ECOFAST IP65 Distributed Automation System

11 Integrated, open and cost-effective with safety Safety Integrated: Easy, integrated solutions for your safety tasks Consistent compliance with defined safety standards this is an increasingly important factor especially in the area of conveyor technology. With our Safety Integrated products, which integrate safety technology into standard automation and drive technology, we provide a consistent basis for our safety-relevant products and systems. This includes both drives and controllers as well as the open bus systems PROFINET, PROFIBUS and AS-Interface with the profiles PROFIsafe and ASIsafe, respectively. That way, you can react more quickly and cost-effectively to the customer s safety-related requirements and upgrade your existing machines and plants any time to state-of-the-art safety technology. Totally Integrated Automation 11 SIMATIC IT Framework Production Modeler Plant Information Management Detailed Production Scheduling Product Specification Management System Laboratory Information Management System SENTRON Circuit Breakers SIMATIC PCS 7 Process Control System SIMATIC HMI Human Machine Interface SIMOTION Motion Control System SINUMERIK Computer Numeric Control Field Instrumentation/ Analytics HART SIMOCODE pro Motor Management System SIMATIC Distributed I / O PROFIBUS PA Drive Systems/ SINAMICS SINAMICS SIMODRIVE SINAMICS

12 PROCESS FIELD BUS Integrated automation and drive technology Portfolio System chart for conveyor technology* MES Industrial Ethernet SIVACON SIMATIC S7 SIMATIC HMI 400 V~ PROFINET / PROFIsafe 12 PROFIBUS / PROFIsafe SINAMICS SIMATIC ET 200S SIMATIC ET 200pro SIMATIC ET 200eco SIMATIC FS SIMATIC pushbutton panel DP/AS-i Link SIRIUS Safety relay E-STOP SIMATIC MV SIMATIC RF E-STOP E-STOP AS-Interface / ASIsafe SIMATIC PX Frequency Inverter Motor Starter I/O Module Motor Starter SIMATIC FS Servo Motor Geared Motor Geared Motor COMBIMASTER Geared Motor Geared Motor COMBIMASTER Motor Centralized to PROFIBUS/PROFINET Distributed to PROFIBUS/PROFINET Distributed to AS Interface Based on an integrated automation and drive system, we offer you a complete product portfolio that gives you a free hand in developing your conveyor technology concept. With our Siemens/Flender geared motors, SIRIUS motor starters and SINAMICS frequency inverters, we can provide you optimally integrated drive components and more. In connection with SIMATIC automation systems, the operator control and monitoring components SIMATIC HMI, the SIMATIC sensors for controlling the conveyor technology process including safety engineering and power distribution, you get an integrated, flexible automation solution for your conveyor technology. Whether you prefer centralized or distributed solutions, require devices with a low or high degree of protection, use conventional cabling or fieldbus systems such as AS-Interface, PROFIBUS or PROFINET, we have just the right products and systems for your conveyor technology application. *All configurations depicted here are simply examples of possible connections available.

13 More, integrated drive: Our products and systems for conveyor technology applications Geared motors Our reliable Siemens/Flender geared motors ensure maximum efficiency. They are most costeffective at low speeds, from 0.1 to 1,000 rpm, and with high torque utilization. This range of compelling devices includes energy-saving motors in the efficiency class EFF2 or EFF1 and a large selection of application functions. In addition, they are ideal for particularly flexible solutions thanks to a wide array of designs, mounting options and modularity, as well as their optimum compatibility with SINAMICS converters and SIRIUS motor starters. Geared servomotors are also available for highly dynamic applications. And best of all, our wide range of geared motors comes with a sound know-how of industry-oriented applications, which will certainly facilitate your project planning and installation considerably. Drives Inverters 13 Motor starters SINAMICS frequency inverters SINAMICS is the new inverter family by Siemens that offers a suitable drive for any application with innovative Safety Integrated functions, energy regeneration features, high degree of ruggedness and a PROFINET/PROFIBUS terminal. Thanks to the field-tested tools SIZER and STARTER, our SINAMICS inverters are generally easy to configure and commission for full flexibility in engineering and expansions. Furthermore, they are suitable for use in a wide variety of applications: from simple roller conveyors to highly dynamic, multi-axis storage and retrieval machines. Positioning and motion control functions can be integrated through the drives or included via a separate controller. For more extensive motion control tasks, various SIMOTION versions can be utilized. MICROMASTER 411 frequency inverters The MICROMASTER 411 can be used universally in applications with variable speeds. Its distributed design saves space in the control cabinet. The repeatability of identical conveyor technology elements enables a modular mechanical concept, featuring a high degree of protection up to IP66 and decreasing wear on the mechanical components during ramp-up. Furthermore, a positioning function can be set using external initiators. SIMATIC ET 200S frequency converters This frequency inverter is embedded directly into the distributed I/O system SIMATIC ET 200S with regeneration and safety functionality and offers all the advantages of the SIMATIC ET 200S system: such as a communications and energy bus, hot-swapping of modules, fast assembly without tools or minimized wiring costs thanks to build-as-you-go equipotential bonding strips. Our motor starters are the right choice for switching, protecting and starting motors. Direct, reversing and soft starters cover the complete range of starting tasks from smooth start-up to extra high breakaway torque. Whether located in the control cabinet or directly in the field, our motor starters offer the option of integrated intelligent monitoring functions including preventive maintenance and Safety Integrated functionality. From simple contactor/circuitbreaker combinations to factory-wired load feeders and encapsulated compact starters to motor starters for distributed I/Os SIMATIC ET 200S and ET 200pro, our starters are quick to install and save space. The complete distributed ECOFAST system features direct, reversing and soft starters even available as duo reverser. Our customized motor starters SIVACON-MCU (motor control unit) are an ideal solution when you need tailor-made applications.

14 Controllers, I/Os, software SIMATIC Controllers To ensure a high degree of flexibility, SIMATIC offers maximum scalability with standard or fault-tolerant controllers, compact devices, distributed or PC-based automation solutions. For a cost-effective solution to your technological tasks such as metering/measuring, cam control, closed-loop control and motion control, our SIMATIC technology is available in different configurations: from loadable software modules to technology controllers to closed-loop control systems. To meet specific standards for personnel and machine safety, you can use the fail-safe SIMATIC Safety Integrated system integrated into the standard automation. Communication SIMATIC ET 200 The modular SIMATIC ET 200 I/O family lets you implement distributed solutions for any requirements: compact or modular, exclusively digital I/O interfaces or complete distributed systems with drive technology, in the control cabinet or direct in the harsh industrial environment. SIMATIC Software SIMATIC Software is a universal configuration and programming environment for all SIMATIC Controllers, including the HMI systems. SIMATIC Software supports your entire engineering workflow with its basic STEP 7 package and numerous engineering tools. SIMATIC NET Within the scope of Totally Integrated Automation, it is very easy to configure connections even across different networks and all systems. To convert from PROFIBUS to Ethernet or vice versa, you only need to change the communication processor no changes to the user program or additional engineering work is necessary. For open and integrated industrial communications, SIMATIC NET offers solutions for any requirements: III AS-Interface, the simple bus system for the sensor/actuator level III PROFIBUS, the recognized standard for the field III PROFINET, the international Ethernet standard for real-time communications down to the field level Automation and communication Operator control and monitoring SIMATIC HMI SIMATIC HMI offers a finely tuned product range from operator panels and visualization software for machine-level HMI to the scalable SCADA system for a wide variety of requirements in process visualization.

15 Sensors Proximity switches When recording, counting, measuring, monitoring or positioning solid, liquid or powdery substances, our proximity switches always have the right sense. Optical fail-safe sensors Maximum process safety must be guaranteed when protecting both man and machine in an industrial environment. This is done not only to prevent damages, but also to achieve maximum system availability and cost-effectiveness. A clear case for our optical fail-safe sensors, which provide safe and reliable all-around protection for personnel, machines and systems. RFID systems Whether in manufacturing, logistics or distribution, if you want to know everything about the production or the flow of goods at all times and all locations then you cannot go wrong with our intelligent electronic RFID systems. These systems identify safely, quickly and efficiently, are unaffected by dirt and store data directly on the product or object. Image processing systems The image processing systems simply have eyes everywhere. They control, monitor and secure the material flow as well as the quality of your industrial production. More reliable and better than human eyes, these systems make decisions based on visual information. Thus, they contribute significantly to an optimized and fail-safe workflow. Position switches A complete conveyor technology also includes mechanical sensors. SIRIUS sensing devices register any movements reliably and with the necessary precision and forward the information in the form of an electric signal. Sensors 15 Safety systems Safety Integrated safety products Your plant can be made safe with the safety products from Safety Integrated already integrated into the standard automation system from drives to controllers, switching systems, sensors and even motion control. Power distribution SIVACON power distributors and SENTRON circuit breakers The most efficient power distribution can be implemented within the scope of Totally Integrated Power with SIVACON switchgear and busbar trunking systems as well as with SENTRON circuit breakers.

16 Conveyor technology references: Automotive Car body conveyor technology in the automotive industry The challenge At a height of 35 meters and a length of 140 meters, the requirements for the conveyor system are extreme. It connects the body-in-white assembly line with the paint shop. Up to 1,300 car bodies are moved ahead with the same amount of empty body racks moved back each day. During conveying, the bodies are arranged in a specific order. At the end, they are delivered to a two-story buffer storage zone perfectly presorted. Of course, absolute reliability and fast communication have maximum priority with this enormous volume. Advantages Downtimes have been virtually eliminated since malfunctions in the system only require a partial shutdown of the conveyor technology. That means it is possible to achieve and maintain the high output required. The integrated control and visualization concept also plays an important role. If required, it sends a radio signal to notify the service technician and provides concrete information about the cause of the error, ensuring a speedy response. Another compelling advantage are the lowmaintenance motor starters, which also reliably output a warning in the event of conveyor motor intolerances. 16 Our solution The SIMATIC S7-400 automation system with STEP 7 V5.2 is used for the open-loop control system and for HMI in the conveyor plant, combined with SIMATIC Panel PCs with WinCC V6. The standard and High Feature SIRIUS motor starters ET 200S are installed for optimum protection, switching and monitoring of the geared motors. In addition, the SIMATIC Mobile Panel 170 ensures flexible and targeted maintenance. Automotive industry Conveyor technology modernization optimizes truck production at IVECO Magirus in Ulm AS-i repeaters per line. Furthermore, DP/AS-i links establish the connection to the higher-level PROFIBUS. The challenge While modernizing both of their truck assembly lines at the IVECO plant in Ulm, Germany, the company wanted to upgrade the outdated contactor controls and drive system. Both of the production lines for 14-ton trucks and larger are roughly 500 meters long and divided into three segments. The conveyor must be able to run at a variable speeds between 0.5 m/min and 1.4 m/min. Our solution Our Siemens/Flender spur wheel and bevel helical geared motors with 5,100 Nm and 3,000 Nm respectively are operated via MICROMASTER 440 frequency inverters with vector control. These are linked to the SIMATIC S7-400 automation system via PROFIBUS DP. All of the sensor signals are bundled via several stations of the distributed SIMATIC ET 200S I/Os and also forwarded to the controllers or to the higher-level SIMATIC WinCC process control system via PROFIBUS. The 56 EMERGENCY STOP switches distributed widely throughout the plant are connected to ASIsafe via safe and reliable AS-i I/O modules K45. The four AS-i lines each cover a distance of about 300 meters each. This was achieved through the use of two Advantages The comprehensive modernization of the drive and controller systems resulted in a drastic increase in plant availability and, of course, a jump in productivity. In addition to the production area, the benefits primarily extend to the maintenance of the assembly line networks. Whereas operators would previously have to contend with 30 to 40 malfunctions a day, they now only need to deal with five to six. And since this small handful of incidents is now consistently and automatically logged in the control system, it is now possible to isolate and eliminate any recurring problems. IVECO Magirus

17 Conveyor technology references: Airports Integrated drive and automation technology for airport logistics The challenge With continuously increasing airport traffic and a flood of new airlines, the rapid growth of the aerospace industry places extreme demands on infrastructure and logistics and on all the technologies they entail. Major hubs typically have a large number of gates, high passenger volume and a high transfer quota. Whether short or long transfer times the solution must include fast and powerful baggage handling and conveying plants with a high capacity and precise sorting capabilities. Our solution Covering 9,000 m 2, the innovation and testing center in Fürth, Germany, demonstrates how a variety of different individual systems can be combined into a functional overall concept for an ultramodern international airport. Our integrated drive systems ensure reliable transport. After a piece of luggage is checked in and a corresponding bar code is attached, it is forwarded on an RFID-supported conveyor belt plant to the HBS system (hold-baggage-screening). The baggage is screened there according to the specified safety regulations. Then, it is forwarded to the tray conveyor technology. The tray protects the baggage from undue wear during transport at especially high speeds up to 10 m/s. Finally, the baggage is fed to the airplane loading station via the sorter and slides. Advantages The innovation and testing center in Fürth proves how a modern airport can be efficiently implemented using integrated overall concepts, and how power consumption can be minimized while increasing capacity at the same time. This is just the solution major airports need to handle further increases in passenger volume. Whether you are more interested in products, special plant sections or an overall solution, you can rely on our 20 years of experience and expertise in planning and implementing airport equipment. There s a reason why five of the ten of the best airports in the world are equipped with our baggage handling systems: the global leader Hong Kong International Airport along with the airports in Dubai, Munich, Seoul and Sydney. As a comprehensive and innovative partner, we know what s important both today and in the future. References 17 With this configuration, the luggage conveying system places high demands on the drives. To meet these demands, our powerful drive solutions combine low-noise, high-torque Siemens/Flender geared motors with attuned frequency converters and intelligent motor starters with starting frequencies of up to 3,000 units/h. The motors are linked to the centralized control system of the luggage conveying system via the communications system AS-Interface and PROFIBUS. The conveying segments only run when needed, thanks to quickresponse drives synchronized according to the respective sensor signals. Finally, intelligent power supply and management systems supply the drives with the necessary power at the appropriate time. Innovation and testing center for airports

18 Conveyor technology references: Food & Beverage Automation of the storage and transport system at Sachsenmilch in Dresden The challenge With one of the most modern and largest dairy factories in Europe, Sachsenmilch Dresden produces one billion liters of milk each year. To streamline production processes as much as possible, the company wanted to install an integrated automation solution for all relevant transport and logistic processes. The focus was on assuring quality and hygiene. Advantages In general, Sachsenmilch Dresden now benefits from optimum system availability, efficient, bidirectional transport and dynamic, factory-wide processes. The flow of goods through the plant is quick and effectively regulated. The storage and retrieval of goods in the warehouse has also been greatly improved thanks to SIMATIC. Finally, the solution reliably meets all government requirements for hygiene. 18 Our solution We were able to plan, configure and implement a powerful and highly automated storage and transport system based on SIMATIC within just 14 days from start to finish including a complete steel shelving system, mechanical components, controllers and user software. The core element of the plant is the dual-level monorail overhead conveyor which handles all transporting tasks to and from the high-bay warehouse. Pallets are used to manage transport for fully automated operations without the need for stackers. Sachsenmilch Packaging control for Hochwald in Polling The challenge The Hochwald food processing factory in Polling produces a wide range of products which naturally involves a wide range of different types of packaging. There are roughly 100 different package types in 18 sizes transported to the boxing station through five production lines at a rate of 40 units per minute. They all need to be reliably identified and sent along the right path. Advantages Thanks to precise color coding, none of the packages in the logistics processes will ever be sent the wrong way. Since the installed color area sensors can be taught to recognize up to 16 set patterns at a time, Hochwald can still be flexible in its selection of products and packaging. What s best, the work and expenses involved are kept to a minimum: the plant is easy to start up and no programming is required. Our solution Our SIMATIC MV220 color area sensors proved to be the ideal solution here. The sensor identifies the package according to a unique color pattern and relays the result to the higher-level S7-300 controller, which in turn determines the corresponding destination. The system is linked through PROFIBUS to the SIMATIC controller via the digital I/Os of the vision sensor and distributed SIMATIC ET200 I/Os on site. A SIMATIC TP 170B Touch Panel is used for HMI at the boxing station. Hochwald food processing factory

19 Conveyor technology references: Logistics & Warehouse SIMATIC controls logistics and production at Universal Manufacturing & Logistics in Langenleben The challenge Universal Manufacturing & Logistics (UML) produces CDs and DVDs in small batches. With a SIMATIC control system in place, they can now be delivered to customers in 80 countries from the company s own distribution center within 24 hours. UML itself has a maximum storage capacity of 28 million data carriers. An enormous volume that requires an integrated and reliable automation concept to ensure precise handling. Our solution After the CDs and DVDs are produced on more than 22 ultramodern carousel sets at UML, each disc receives its own unique label with up to 6 different colors in a screen printer. Our SIMATIC S7-300 process control system is responsible for controlling this process and for the subsequent complex process through nine packing lines. SIMOVERT MASTERDRIVE converters are used for the drive and like the distributed SIMATIC ET 200 I/O modules are linked to the controller via PROFIBUS DP. The individual storage bays are integrated into the automation solution and linked to one another via SIMATIC, PROFIBUS and AS-Interface using Siemens technology. Advantages Our solutions have proven a worthwhile investment for UML. Thanks to the maximum transparency in relation to the technical production and logistical processes, 95 percent of the catalog items are available for delivery at any one time and UML can act more quickly to refill production gaps. What s more, thanks to especially short processing times, UML is now able to process up to 90,000 order lines per day for distribution. UML References Flexible and functional: Storage and retrieval machines by Dematic Dematic has decades of experience in building storage and retrieval machines. Its comprehensive product range with fieldtested, modularly designed components has the perfect storage and retrieval machine for any warehouse solution. They all feature a cost-effective, rugged and durable design that meets the most extreme demands for performance and availability. The powerful and field-tested control system behind Dematic storage and retrieval machines is based on the SIMATIC industrial PC or the SIMATIC S7 controller. As for drive technology, Dematic relies on the modular SINAMICS S120 drive system with the integrated SIMOTION D Motion Controller. Based on this flexible, modular system, it is possible to design optimally tuned drive units with the necessary drive performances to ensure the required level of dynamics for each and every application. drive axes can also be flexibly adjusted to the respective circumstances. The harmonious interaction between the SINAMICS S120 drives and the SIMOTION Motion Control system results in a high throughput rate while minimizing operating costs. Operator panels with comprehensive operating and diagnostic options, including the display of utilization and wear data, greatly facilitate servicing of the plant. The flexible drive and automation technology based on SINAMICS S120 used in Dematic is another reason why it is the right solution for any storage and retrieval application easy, fast and reliable. The controllers and the SINAMICS S120 drive system communicate via PROFIBUS which is powerful enough to enable effective interaction for positioning and synchronizing the drive axes. Depending on the dynamic requirements, they are equipped with standard asynchronous motors or servomotors and operated by SINAMICS S120 in servo or vector control. The number of Dematic

20 Conveyor technology references: Other sectors Comprehensive automation solutions for the Ingolstadt Hospital The challenge Serving more than 1,000 patients a meal on time three times a day. The logistics at Ingolstadt Hospital place high demands especially since the solution also needs to provide for a reliable supply of medications, sterile utensils, laundry and detergents. In addition, used items and material must be disposed of, with a strict separation between supply and disposal to prevent any contamination. Advantages The modernization of the automation system has markedly improved the workflow and increased the level of satisfaction among patients, employees and operators. For example, containers can now be returned without any extra operational work. Since the centralized control program only allows transports from the kitchen, when necessary, and all other transports are automatically blocked, it is now possible to deliver meals to all patients without a delay. 20 Our solution Within the scope of comprehensive modernization of the automation system, the hospital chose SIMATIC. The core elements in the chassis frame and loading cart are now SIMATIC controllers S7-300 CPU 313C. They are combined with MICROMASTER 440-series frequency inverters as well as two powerful asynchronous motors. Easy operator control and monitoring for the individual chassis is provided by a SIMATIC OP3 Operator Panel. The RF identification system Moby D is used to localize them along the 500-meter track. Furthermore, all the level controllers exchange information via standardized SIMATIC CP communications processors and through high-speed PROFIBUS communications. Ingolstadt Hospital Innovative configuration and visualization in glass production at Rexam in Nienburg The challenge Rexam Glass Germany produces more than 300,000 tons of glass annually at its Nienburg location. During continuous production operations, the glass bottles are transported after the coating to buffer sections and tables which can buffer the running production up to 20 minutes in the event of an interruption. However, Rexam does not want to have to use this option too often. After all, a company s profitability rises and falls with the availability of its production facilities. Our solution One crucial element of the comprehensive modernization measures on six production lines at the cold end is a conveyor technology approximately 1,000 meters in length with 220 frequency-controlled single drives. This solution was developed by the German company Miprotek and features especially userfriendly operator control based on the dust-proof and heatresistant SIMATIC Panel PC 670 with degree of protection IP65. A PLC-based conveyor concept developed by Miprotek ensures smooth processes. There is a SIMATIC S DP controller installed on each line: it sets the speed and individual setpoint values for the individual drives, reads out the updated current values, monitors limits and compiles important process data. Furthermore, intelligent configuration and visualization software ensures maximum transparency in all process steps. The software is based on individual Visual Basic scripts which were implemented in ProTool/Pro. Advantages While the SIMATIC Panel PC 670 ensure trouble-free visualization, ProTool/Pro considerably facilitates programming of the installed drives. The drives are largely preconfigured, meaning the ProTool/Pro user interface was easy to transmit to all six production lines at the cold end. This reduced the engineering overhead by roughly 20%. Rexam Glass

21 The right solution for any conveyor technology application Whether airports, automotive, food & beverage or warehouse & logistics, we offer customized solutions for any industry where conveyor technology applications are used. In addition to automation and drives, we can supply the right products and systems for many other sectors and industries. Our network of products and services features everything you need for more mobility in your conveyor technology. We d be glad to consult you personally on your individual potential. range Anytime, anywhere service without borders Whether you need your drive sent to you just-in-time or you require delivery, assembly, commissioning or maintenance, our experts are always there to serve you. All over the world, directly on site and in over 130 countries. You benefit from shorter delivery times. Thanks to our optimized logistics and production processes, each and every component reaches you as quickly as possible. 21 You can even place your orders over the Internet. At you can find a clear overview of all our products. And with EDIFACT, you can complete the entire ordering process online. But we are also glad to provide the personal assistance you need. If you want support from a service specialist, or want to order spare parts, or just have a question, through our hotline you ll obtain optimum consulting services. Service Helpline for Service & Support: Technical support: Sales partner info helpline:

22 Fax Reply +49 (0) Want more information? We d be happy to help! Please check the information packages you re interested in: Geared motors Converters/Inverters Motor starters Controllers Communication Human Machine Interfaces (HMI) Sensors Safety Integrated Power distribution Company / Department Name Street Postal code, City Phone / Fax You can find up-to-date information on our products and solutions for conveyor technology applications on the Internet at: AD/Z 1272 Subject to change without prior notice 04/06 Order No. E80001-A260-P210-X-7600 DISPO C9266 MK.SD.FT.XXXX WS Printed in Germany Siemens AG 2006 Siemens AG Automation and Drives The information provided in this brochure contains merely general descriptions or characteristics of performance which in case of actual 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.