Reduce Downtime by Digitizing Mechanical Data...TIA Portal is required to configure the module • The lowest license, SIMATIC STEP 7 Basic, is sufficient for S7-1200 *) Not available

Unrestricted © Siemens 2020

www.siemens.com/siplus-cmsUnrestricted © Siemens 2020

Reduce Downtime by

Digitizing Mechanical

Data

Restricted © Siemens AG 20XX

XX.XX.20XXPage 2 Author / Department

Presenter

Luis Narvaez

Product Marketing Manager for Basic Automation Controllers

Siemens Industry, Inc.

• B.S. Electrical Engineering, University of Central Florida

• 10+ years experience in industry

• Worked in various roles in construction, entertainment/theme park

and manufacturing industries

• Primary objective is to focus on educating market on the SIMATIC

S7-1200 Basic Controller

• Started with Siemens as part of Engineering Leadership

Development Program

• Worked in various roles such as Systems Engineer, Applications

Engineer, Business Developer


Unplanned downtime

motivation for change

- $


What is predictive maintenance and why is it important?

• Drive higher asset uptime and utilization

• Reduce material and maintenance costs

• Increase production yields

Key capabilities

Predictive maintenance involves the continuous collection and analysis of real-time asset health and performance data

to better understand the root cause of quality and production issues. With this data, you can service assets at the right

time and frequency, before downtime occurs.


Existing maintenance approaches create challenges

Reactive vs. Predictive vs. Preventive

Cost

Maintenance Tasks

Predictive PreventiveReactive

Failure? Plan?Status?Total cost

Maintenance costs

(planned)

Loss of production

costs (unplanned)


Condition Monitoring

The machine under control

There is no machine without vibrations.

But when do vibrations cause damages?

And what kind of damages?

And will the machine suddenly break down?

Condition Monitoring Systems (CMS)

The answer to preventive maintenance

in industry


SIPLUS CMS

Possibilities of Condition Monitoring

Reaction time until breakdown

Minutes

Watch

Smoke

Days

Feel

Heat

Weeks

Hear

Noise

Months

SIPLUS CMS

Early detection

https://www.google.de/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwjm0JaRwcrYAhVN_aQKHcqXCRYQjRwIBw&url=http://freevector.co/vector-icons/weather/thermometer-with-high-temperature.html&psig=AOvVaw02isTLcpHFlTghewtwYtzQ&ust=1515574482463430


SIPLUC CMS

Data Collection

Shaft Coupler Gearbox Bearing FanDrive Motor


SIPLUS CMS - Real Example

Bearing failure gear box

Drawing Resulting damage at the inner ring

08.07.03 02.09.03 28.10.03 23.12.03 17.02.04 13.04.04 08.06.04 03.08.04 28.09.04 23.11.04 18.01.05 15.03.05 10.05.05date

0,2

0,4

0,6

0,8

1,0

1,2

1,4

1,6

1,8

2,0

a [m/s²]

Warning

08.07.12 02.09.12 28.10.12 23.12.12 17.02.13 13.04.13 08.06.13 03.08.13 28.09.13 23.11.13 18.01.14 15.03.14 10.05.14

Trend

Picture


CMS 1200

• Integrated with SIMATIC S7-1200 PLC for

additional monitoring or control of machines

• Flexible expansion up to 7 modules per station

• Analysis software on board

• Simple user interface

• Remote connectivity available

• Transparency across multiple levels

SIPLUS CMS

Condition Monitoring with SM 1281


SM 1281 Condition Monitoring Module

SIPLUS CMS1200: Condition Monitoring with SIMATIC S7-1200

SM1281 - Overview

Features

• Characteristic-based diagnostics

• Frequency-selective diagnostics

• Export of raw data

• SIMATIC and web-based

Connections

• Up to 4 vibration sensors (IEPE-sensors)

• 1 optional speed input (Bero)

• Ethernet (2 ports)

• Power supply 24VDC

Expansion option

Up to 7 modules can be connected;

depending on the S7-1200 CPU used

Operating principle

• Calculations are performed

continuously

• The 4 IEPE channels and

the speed sensor are read in and

processed simultaneously

Diagnosis

• Characteristic values

via SIMATIC S7-1200 and TIA Portal

• Frequency selective

via integrated Web Server

Advantages and Costumer benefits

No additional software for diagnosis and

visualizing needed

IEPE-sensors

BERO


Hardware requirements

SIPLUS CMS1200: Condition Monitoring with SIMATIC S7-1200

SM1281 – What is required?

Software requirements Optional software

Important:

SM 1281 is supported as of

FW version V4.1 for S7-1200 CPU

• TIA Portal is required to configure the

module

• The lowest license, SIMATIC

STEP 7 Basic, is sufficient for

S7-1200

*) Not available for S7-1200

S7-1200 CPU Max. connectable SM1281

CPU 1211C None

CPU 1212C 2

CPU1214C / 1214FC 7

CPU 1215C / 1215FC 7

CPU 1217C 7

SIMATIC STEP 7

Programming languages

LAB, FBD, SCL, STL*, S7-GRAPH*

STEP 7 Safety option package

WinAC (incl. Failsafe**)

S7-300/400 (incl. Failsafe**)

S7-1500

S7-1200

Pro

fessio

nal

Basic

• If panels are used, optional use of the

corresponding WinCC version is

possible

→ Browser functionality for panels is

NOT supported by SM1281

SIMATIC WinCC

Machine-level operating and monitoring

SCADA applications

SCADA

PC (single user)

Comfort Panels + x77

(without Micro), Mobile

Basic Panels

Pro

fessio

nal

Ad

van

ced

Co

mfo

rt

Basic


Mechanical damages Electrical faults

Drive

Condition Monitoring with SIPLUS CMS

What sort of damage can be detected? An extract

Resonance

Resonance

Blade passing frequency

ImbalanceMeshing fault

Alignment fault

Bearing danage

Field faultBroken rotorbar

Imbalance

Bearing damage Meshing fault

Alignment fault Blade passing frequency

Pump / Fan Gear box

Condition Monitoring with SIPLUS CMS – more than just Motor Condition Monitoring

Field fault stator

Broken rotorbar


SIPLUS CMS1200: Analysis methods

SM1281 – Overview

Monitoring of machine vibration

based on characteristic values

• Simple representation, e.g. via traffic

light

• Trend analysis

Engineering in TIA Portal +

analysis via integrated software

Parameter-based analysis

Frequency-selective diagnostics of

machine vibration and bearing

• Spectrum view

via browser

• Integrated

message system

Engineering in TIA Portal / SM 1281

web-interface +

analysis via integrated software

Frequency-selective analysis

e.g. CMS X-Tools

Freely configurable analysis models,

e.g. for

• Detail analysis

• Gearbox diagnostics

• …

Engineering via separated analysis-

software e. g. CMS X-Tools

Expert analysis

Raw data analysis: on- or offlineMonitoring online in SM1281

Online Datastreaming /

Raw Data Export


Seite 15

Vorteil:

Einfach und schnell realisierbar

Geringe Condition Monitoring Kenntnisse erforderlich

Engineering and configuration

via SIMATIC S7-1200 CPU

or SM 1281 Web Interface

Characteristic value

vRMS frei projektierbar

vRMS acc. To ISO

10816-3

aRMS frei projektierbar

Monitoring of

vRMS:

Machine vibration

aRMS:

e.g. Bearing damages

Characteristic values

vRMS freely configurable

vRMS acc. to ISO 10816-3

Monitoring for

vRMS: machine vibration

Advantages:

Quick and easy to implement

Minor Condition Monitoring expertise required

aRMS / DKW:

e.g. bearing damage

aRMS freely configurable

Signal

Alarm

Warning

OK

• All monitoring parameters can be

set via the S7-1200 CPU

• Monitoring in the SM 1281

• Cyclic transfer to

S7-1200-CPU of:

• RMS value of vibration

velocity

• RMS value of vibration

acceleration

• Status messages

• Display trend on laptop, IPC,

panel, etc.

Mode of operation

Disadvantage:

Type of looming damage not discernable

➔ Troubleshooting required

DKW freely configurable

SIPLUS CMS 1200 Analysis Methods

Parameter-based analysis


Vibration velocity

v [rms]

10-1

000 H

z,

n >

600 1

/min

(2-1

000 H

z,

n >

120 1

/min

) mm/s inch/s

11 0,44

7,1 0,28

4,5 0,18

3,5 0,11

2,8 0,07

2,3 0,04

1,4 0,03

0,71 0,02

Rigid Soft Rigid Soft Rigid Soft Rigid Soft Foundation

Pumps > 15 kW Radial, axial, diagonal

Medium-sized Machines

15 kW < P ≤ 300 kW

Large Machines 300 kW < P < 50

MW Machine typ

Direct Drive Intermediate Shaft

Belt Drive

Motors 160 mm ≤ H < 315

mm

Motors 315 mm ≤ H

Group 4 Group 3 Group 2 Group 1 Group

A Newly commissioned C Short term operation

B Unlimited long term operation D Vibrations cause damage

Realizing the practical example with SM1281

Evaluation of limits for characteristic values

Basic Information to provide limit

values accordance with ISO10816-3

Motor Power: 20kW

Shaft height: 200mm

Foundation: rigid

Fan got newly commissioned

Limit values

Alarm threshold : 4,5 mm/s

Warning threshold: 2,8 mm/s


Benefits of frequency-selective diagnostics:

▪ Each type of mechanical damage has its own unique

frequency spectrum

▪ One glance at the frequency spectrum is sufficient to

determine the cause of damage to within a high degree

of accuracy

▪ The search for the actual cause of the damage is

reduced to a minimum

▪ The amplitude is a measure for the extent of damage,

which allows conclusions to be drawn about the

remaining lifespan. The experience of the operator plays

a decisive role here

SIPLUS CMS 1200 Analysis methods

Frequency-selective analysis: How does it work?


SIPLUS CMS1200: Analysis methods

SM1281 – Frequency-selective analysis

Monitoring for roller

bearing damage

Monitoring for machine

vibration

Signal

Advantages:

Quick and easy to implement

Type of damage identifiable→ less troubleshooting

Electrical faults detectable

Engineering and configuration via

SIMATIC S7-1200 CPU and SM 1281 Web interface • Settings for monitoring the spectra

are made in the SM 1281

• Monitoring in the SM 1281

• Cyclic transmission of

• Characteristic values

• Status messages

for S7-1200 CPU

• Display on PC, panel, etc.

• Access to Web interface

SM 1281 shows

• Spectra

• Trend analyses

How it works

Frequency-selective

analysis with

SM1281

Examples of detectable

mechanical damage

Detectable mechanical damage

Resonance

Imbalance

Misalignment

Coupling fault

Outer race

defect

Inner race

defect

Rolling element

damage

Cage damage


SIPLUS CMS: Condition Monitoring

Customer advantages at a glance

Lower costs

Goal-oriented repair

Shortened commissioning

Planned maintenance

Advantages

Simple design

Open standards

Easy Expandibility

Higher efficiency

Reference condition

Seamless knowledge

Easy error detection

Effective spare part inventories

Longer life cycles

Decision support

Longer service intervals

High availability

SIPLUS CMS – efficiency from the start

Investment protection


TIA

Portal

Controller HMI IPC

TIA

PortalEngineering

Framework

SCADA System

MES

Data Production

ERP

Distributed

I/O

CMS

Systems

Drive Systems

SIPLUS CMS

Mechanical condition data becomes digital added value

• Early detection of mechanical damage

• Consistent predictive maintenance

• Avoidance of unwanted downtimes

• Connection to cloud solutions

• Opens new business opportunities

Transparency of mechanical

components across all levels


The greater potential of the IIoT

Predictive maintenance

• Eliminate downtime

• Drive profitability by detecting and fixing machines before they

break

Process optimization

• More efficiently use and allocate resources within a process

• Increase production rates to limit waste and sunken costs

Analyze and predict


MindSphere Siemens’ cloud-based, open IoT operating system

ApplicationsMindSphere applications provide asset transparency

and analytical insights into machines, plants, fleets

and systems

Open PaaSMindSphere, the open PaaS, gives you scalable, global

IoT connectivity and application development with native

cloud accessibility

ConnectivityMindConnect connects products, plants, systems,

machines, enterprise applications and legacy

databases with a secured plug-and-play collection of

Siemens and third-party products and equipment


SIPLUS CMS 1200

The gateway to a digital enterprise

Automation

Field

Edge

Cloud


Condition Monitoring with Edge Analytics

MindSphere

MindApps

X-Tools Pro

Server

S7 PLC

Use Case

• The idea is to collect a huge amount of data (up to 50Khz) from a wide range

of data providers and calculate out of the mass data on the line (Edge) KPIs.

• Send the calculated KPIs and preprocessed data into the MindSphere for

further calculations and analysis.

Solution

• These use cases can be done on a Windows system with the extreme open /

flexible CMS X-Tools Professional system.

• On the other hand is can be also done with a very user and price friendly

MindConnect Edge Analytics system.

Benefits

• Select the necessary footprint of your solution (price & performance). Use the

MindConnect hardware platform or Windows platform.

• Use the wide range of available data providers in the complete offering

• Offer an easy entry with a web based solution to non expert users – MCEA

• Offer an open, scalable, windows based analytics product to experts – CMS

X-Tools

• Work with very flexible amount of data (up to 50Khz)

• Do advanced analytics on MindSphere data with X-Tools professional and

MCEA

• Store and work with complex data in MindSphere (Spectra, Orbit, …)

• Easy to use user experience

• Build your analysis per drag & drop

Edge

Automation

X-Tools Pro

ClientMindConnect Edge Analytics

on MindConnect Nano box

MindConnect Edge

Analytics


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Edge analytics with CMS X-Tools

Integration in Mindsphere

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SIMATIC S7-300, 400, 1200 and 1500

SIMATIC WinCC / PCS7 (OPC UA)

SIPLUS CMS SM1281

Third-party sensors

OPC UA SERVER / CLIENT

Modbus TCP / RTU

Device development kit ?

Data processed and sent to

MindSphere

Low to high frequency data from various

sources collected

Data ready for visualization and

analytics

SIMOTION (OPC UA)

MindSphere –

The cloud-based,

open IoT operating

systemX-Tools server hosted

on Microbox PC


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Edge analytics with MindConnect Nano

Integration in Mindsphere

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SIMATIC S7-300, 400, 1200 and 1500

SIMATIC WinCC / PCS7 (OPC UA)

SIPLUS CMS SM1281

OPC UA SERVER / CLIENT

Modbus TCP / RTU

Data processed and sent to

MindSphere

Low to high frequency data from various

sources collected

Data ready for visualization and

analytics

SIMOTION (OPC UA)

MindSphere –

The cloud-based,

open IoT operating

system

MindConnect

EdgeAnalytics on

MindConnect Nano IPC


Analyze and predict • Aggregate and analyze big data from multiple enterprise

systems

• Analytics reveal insights from the data

• New insights create processes to react proactively

• Multi-model-based machine learning predictive analytics

• Prescriptive solutions enhance processes, reduce costs and

increase productivity

Digitize and transform• Interconnection across systems,

devices, applications and services

• Heterogeneous ensemble deep learning modelling

• Business transformation

• New products, apps, new

markets, product as servicesConnect and monitor• Connect assets for remote transparency

• Collect data for use in apps or processes

• Reduce downtime, improve customer

experience

Valu

e c

reation

Prescriptive

Energy Product

Production

Performance

System

of Systems

Deep Learning

EDI and Integrated

Data Lake

Artificial

Intelligence (AI)

Self-

Optimizing

Systems

Intelligent /

Expert Systems

Artificial

Intelligence (AI)

Asset

Performance

ManagementAsset Mgmnt

Condition

MonitoringPredictive

Digital Twin

Augmented Reality

Virtual Reality

Preventative

Maintenance Consumption

OptimizationUsage

Transparency

Closed Loop (CLx)

.

MindSphere Digital Transformation Journey

Unrestricted

Solution Scope


Thank you for your attention

Luis Narvaez

Technical Product & Marketing Manager, S7-1200

Siemens Digital Industries, USA

www.siemens.com/siplus-cms

Subject to changes and errors. The information given in this document only contains general descriptions and/or performance features which may

not always specifically reflect those described, or which may undergo modification in the course of further development of the products. The requested

performance features are binding only when they are expressly agreed upon in the concluded contract.

All product designations, product names, etc. may contain trademarks or other rights of Siemens AG, its affiliated companies or third parties.

Their unauthorized use may infringe the rights of the respective owner.

www.linkedin.com/in/narvaezl/

Documents

Reduce Downtime by Digitizing Mechanical Data...TIA Portal is required to configure the module • The lowest license, SIMATIC STEP 7 Basic, is sufficient for S7-1200 *) Not available