English KRONES Academy Automation Concept
Table of contents krones Automation Concept 5 krones filler simulation 29 On-site Training Center 8 krones filler/aseptic block simulator 31 krones S7 Rack 11 krones Automation Notebook 33 krones S7 Rack/TIA 13 krones Automation Engineer 34 krones Touch-Screen Rack 15 krones 36 krones Touch-Screen/S7 Rack 17 Line Documentation System (LDS) 39 krones AS-i Safety Rack 19 Line Performance Analyser (LPA) 41 krones B&R Rack 21 krones Asset Management (KAM) 43 krones frequency inverter rack for Danfoss 23 Line Management System (LMS) 45 krones LCT3 Rack 25 The krones course navigator 46 krones CLX Rack 27 2 3
KRONES 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: +49 9401 70-1503 Fax: +49 9401 70 91-1503 E-Mail: claudia.bruckbauer@krones.com 4 5
KRONES Automation Concept Our Automation Concept is the formula for your electronical and automation specialists for accurate diagnostics and optimisation of the entire automation technology. One concept, three components KRONES Automation Equipment Using different racks and machine simulation units, all staff members can learn and deepen the ideal use and expand their knowledge of handling the machines without any standstills during production. KRONES Automation Notebook It contains the required software as well as all adapters necessary for the diagnostics and data back-up of your line. KRONES 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. 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 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. Automation Concept Automation Engineer Automation Equipment Die magischen Dr Automation Rack Automation Noteb Automation Engin Automation Notebook You will find the digital version of the brochure under: http://www.krones.com > Academy > Automation Concept 6 7
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: providing us 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 established, your On-site Training Center can be used very versatile, 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 refer to the krones contact person if you have more questions about the Mechanical Training Units. Examplary planning of the room for 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
Krones S7 Rack Description With the S7 Rack, the user can make preliminary tests of the program changes made in the S7 controller and he learns how to use AS-Interface, Profi-Bus or network technology. The S7 Rack serves as a basis for the Touch-Screen rack and the AS-i Safety Rack. Accessories and expansions KRONES Touch-Screen rack, AS-i Safety Rack Transporting container (optional) Participation in the Basics course Siemens S7 for krones machines Training documentation (on request) Learning objectives Hardware and peripherals of a krones machine with communications to HMI and subsystems, understanding of data safety/diagnostics Structure of the user software, Profi-Bus/AS-i configuration structure Technical data, scope of supply KRONES S7 Rack Connection diagram and operating instruction Training documentation (optional) Realistic simulation of changes on the machine controller Development and testing of user programs and projects Exercise for replacement of components without affecting the current production Training for e.g. S7 control technology, Profi-Bus and AS-i Bus 10 11
Krones S7 Rack/TIA Description The S7 Rack/TIA is an ideal tool for testing S7 controller settings and programs you have configured yourself using the SIMATIC Step7 (TIA portal), as well as for learning how to handle AS-interface and Profinet. The S7 Rack/TIA, just like the S7 Rack, serves as a basis for the Touch- Screen Rack and the AS-i Safety Rack. Accessories and expansions KRONES Touch-Screen Rack, AS-i Safety Rack Transporting container (optional) Participation in the basic course Siemens S7/TIA for KRONES machines Training documentation (on request) Learning objectives Hardware and peripherals of a KRONES machine with communications to HMI and subsystems; understanding data security/diagnostics Configuration of the TIA-Portal and SIMATIC Step7 (TIA-Portal) user software Structure of the Profinet/AS-i configuration Technical data, scope of supply KRONES S7 Rack/TIA Connection diagram and operating instruction Training documentation (optional) Performing simulations of machine controller changes as realistically as possible Configuring and testing own programs and projects Exercising components replacement without affecting production Holding trainings with topics such as S7 control technology with SIMATIC Step7 (TIA portal), Profinet and AS-i bus 12 13
Krones Touch-Screen Rack Description The Touch-Screen Rack serves as expansion for the S7 rack with an integrated krones machine visualisation system where the user can exercise and call all functions known from the machine on the touch-screen. Accessories and expansions S7 Rack (requirement) Transporting container (optional) Participation in the course krones Visualisation Technology Zenon Touch-screen Training documentation (on request) Learning objectives KRONES emergency package solution, practical use of the Zenon tools Alarm handling, diagnostics and interpretation of faults Use of the type and user management, data back-up Technical data, scope of supply KRONES Touch-Screen Rack (incl. machine project) Connection diagram and operating instruction Customer transponder set Training documentation (optional) KRONES machine visualisation system with all included parameters visible Learn how to use the production machines in a reliable and targeted manner via the training with the Touch-Screen Rack Training for visualisation technology Quicker and more efficient use of the help tools 14 15
Krones Touch-Screen/S7 Rack Description The Touch-Screen/S7 rack is a combination of S7 and Touch-Screen Rack. The controller only works with integrated krones visualisation systems. Accessories and expansions Transporting container (optional) Participation in the course krones visualisation technology Zenon touch-screen Learning objectives KRONES emergency package solution, practical use of the Zenon tools Alarm handling, diagnostics and interpretation of faults Use of the type and user management, data back-up Technical data, scope of supply KRONES Touch-Screen Rack/ S7 Rack (incl. machine project) Connection diagram and operating instruction Customer transponder set Training documentation (optional) KRONES machine visualisation system with all included parameters visible Learn how to use the production machines in a reliable and targeted manner via the 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 S7 training contents are to be conveyed 16 17
Krones AS-i Safety Rack Description The AS-i Safety Rack can be used in training courses on the standard components of KRONES safety equipment. The rack allows you to exercise with these components and testing or replacing them. Accessories and expansions Replacement components of the safety equipment AS-i programming unit including adapter and programming cable Optional ASiMon software incl. connection/programming cable Participation in the course krones system technology Electrical components Learning objectives Replacing components Data back-up On-line functionality (ASiMon software) Technical data, scope of supply KRONES AS-i Safety Rack Connection diagram and operating instruction Training documentation (optional) 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 logics (in conjunction with the ASiMon software) 18 19
Krones B&R Rack Description The B&R Rack (filling technology) can be used in conjunction with the S7 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. The latter also applies to B&R Racks for labelling technology Accessories and expansions Optional service licence for B&R AS 3.0.9x Transporting container (optional) Participation in B&R Automation (electrical system) Workshop Optional B&R Acopos (24 V) incl. servo motor (24 V) 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 KRONES B&R Rack Connection diagram and operating instruction Training documentation (optional) Specific training with regard to Automation Studio Fault simulation for B&R controllers, it is also possible to replace components Hold training courses on the topics B&R Automation Workshop (create CF cards, use krones tools) 20 21
Krones frequency inverter rack for Danfoss Description With the frequency inverter rack for Danfoss, the parameterisation of motors and their parameters can be simulated in a realistic manner Accessories and expansions Transporting container (optional) Participation in the course krones system technology Electrical components Learning objectives Data transmission via Profi-Bus Data back-up and replacement of devices Structure, functions and connection options Parameterisation using the operator panel (LCP) Technical data, scope of supply KRONES frequency inverter rack for Danfoss Profi-Bus options card MCA101, Profi-Bus cable USB cable for communications and data back-up Connection diagram and operating instruction Training documentation (optional) Locating and fixing minor malfunctions Use of the MCT10 set-up software from Danfoss Back-up of parameter records 22 23
Krones LCT3 Rack Description The LCT3 Rack is a mobile training module which is suitable for KRONES AG machines built before the B&R controller was introduced into the control concept. Accessories and expansions Transporting container (optional) Programming cable (serial) Participation in the Filler electrical components (LCT3/KFS3) Learning objectives Use of the PD-Win, PD-exe software Data back-up Replacing components Diagnostics options (filling valves, sensors, etc.) Technical data, scope of supply KRONES LCT3 Rack Operating manual Optional training documentation Specific training with regard to parameterisation Training courses in the field of KFS3, Contiroll, Glideliner, block synchronisation etc. Use of the krones tools (PD- Win, PD-exe) 24 25
Krones CLX Rack Description The CLX Rack allows you to make preliminary tests of the program changes made in the ControlLogix controller. The CLX Rack can be operated in combination with the Touch-Screen Rack to make machine simulations. Accessories and expansions KRONES Touch-Screen Rack Transporting container (optional) Participation in the Control- Logix and DeviceNet control technology Learning objectives Hardware and peripherals of a krones machine with communication to HMI and subsystems Understanding of data back-up and diagnostics Structure of the user software Structure of the DeviceNet Technical data, scope of supply KRONES CLX Rack Connection diagram and operating instruction Realistic simulation of changes on the machine controller Development and testing of user programs and projects Replacement of components can be exercised without any effect on the production Holding training courses in the field of RSLogix (Rockwell software) 26 27
Krones filler simulation Description The B&R-FVC Rack in conjunction with the S7 Rack and the Touch- Screen Rack or the Touch-Screen/ S7 Rack can be used to simulate the visualisation system of the krones filler in a realistic manner. This way it is possible to visualise operating and diagnostics processes that relate to the control of krones filling technology. Accessories and expansions AS-i Safety Rack Transporting container (optional) Optionally with SDC (Servo Drive Control) Learning objectives Quick and more 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 B&R-FVC-Rack Operating manual Training documentation (optional) KRONES machine visualisation system with all included parameters visible Simulation and understanding of the filling process or the filling program Holding training courses on the topics Filler electrical system and B&R Automation Workshop 28 29
Krones filler/aseptic block with WinMod/ SIMBA pro Emulator Description Process sequences during production, cleaning, sterilisation of a filler or aseptic block including beverage mixing and product treatment system (CIP, mixer, flash pasteuriser) can be displayed using Touch- Screen/S7 Racks. Moreover, processrelevant malfunction scenarios (e.g. deviations in temperature, pressure or flow) can be activated via a field bus emulator and a simulation software. Accessories and expansions Transporting container (optional) Participation in process technology seminars Learning objectives Theoretical training: Explanation of the process sequences and correlations, step sequences and machine communication, signal transmission (medium: Process description, P&ID) Practical training: Exercise of operating routines, malfunction analysis, troubleshooting (medium: simulator) Technical data, scope of supply 5 Touch-Screen/S7 Racks, 1 krones filler/aseptic block simulation with WinMod/ SIMBApro emulator Realistic exercise of operating routines in a calm classroom atmosphere Quick and efficient process troubleshooting No line standstill during training Increase of the line efficiency and process reliability 30 31
Krones Automation Notebook Description Regardless if for training support in automation training or diagnostics and troubleshooting in 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 can be obtained. 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) KRONES 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 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
KRONES Automation Engineer Your own expert KRONES 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 way to the krones Automation Engineer Level 0 Technology Basic knowledge Electrotechnology Basic knowledge Electrical components Electronics engineer Mechatronics engineer Step 7 KRONES basics CLX Controllogix Krones system technology Electrical components Krones/ Zenon visualisation system Krones/ Zenon emergency package Preventative maintenance Maintenance Troubleshooting Electrical components Step 7 Krones Advanced B&R workshop hardware/ tools Krones system technology Workshop Krones MES Krones Data/Backup KRONES Automation Engineer (KAE) Administration Diagnostics Certificate KAE Continuous Improvement KRONES line efficiency Line Management IT consultant On-site Training Center: Automation Notebook and Automation Rack with introduction 34 35
Quality Infrastructure Processing Filling and Packaging Logistics Execution Planning Maintenance Business Intelligence Manufacturing Intelligence KRONES : 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 Engineers 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. 36 37
Line Documentation System (LDS) Filling and Packaging Logistics Execution 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 Analysis of production data Processing Maintenance Automatic recording of all available production data and losses Web reporting: reports on Freely selectable query period Display of machine states across operating status, malfunction all lines analyses, programs, production, Identification of root causes of product lists or customer-specific faults on the lead machine and information assigned stations Representation of trends Graphical representation of trend values, e.g., by means of scalable curve generation 38 39
Filling and Packaging Logistics Execution Infrastructure Quality Processing Maintenance Manufacturing Intelligence Line Performance Analyser (LPA) 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 40 41
Filling and Packaging Logistics Execution Infrastructure Processing KRONES Asset Management (KAM) Maintenance Manufacturing Intelligence 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 42 43
Line Management System (LMS) Filling and Packaging Logistics Execution 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 Lower production costs thanks to Greater efficiency, lower costs Processing Maintenance Start, change and deletion of all bottle or tank-level precision in production jobs production Order-dependent parameterisation of the machinery involved ing times because jobs can be Shorter change-over and clean- in production, including printers bundled and dating units High line availability with on-thefly order and batch changes Prompt, automatic material call requests via connection to the High process reliability thanks to warehouse management system operator guidance Parts lists management Feedback on actual production data and consumption 44 45
The KRONES 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 KRONES course navigator under: http://www.krones.com > Academy > Automation Concept 46 47
Subject to technical changes 0 900 22 849 6 PDF_en 05/15 krones ag Academy Böhmerwaldstraße 5 93073 Neutraubling Germany Phone +49 9401 70-6414 Fax +49 9401 70-3913 E-Mail info@krones.com Internet www.krones.com