Using TIA Portal and the S7-1200 for Simplified, Distributed Control

Overview• Introductions

• Patco Machine and Fab, Inc.

• Project Challenges• The Traditional Solution• Distributed Control

Presenter Info

• B.S., M.S., Ph.D in Mechanical Engineering – University of Notre Dame

• CAD/CAM, Intelligent Systems @ ND• With DMC since 2010• Chicago, Boston, Houston

• PLC/HMI/SCADA, LabVIEW, C#/C++, .NET, • Proficient in Siemens (Step7, WinCC, Portal), AB, Beckhoff,

B&R, and more• Siemens Certified Professional

Jason MayesProject Director (Houston)

DMC Overview

Established in 1996, offices in Chicago, Boston, & Denver and customers

throughout the worldemployees &

growing

85+

Areas of Expertise

Manufacturing & Automation Certifications

DMC has the highest number of S7 certified engineers in the US.

• PLCs• HMIs• SIMOTION• WinAC• WinCC 7• WinCC OA• And more…

What We Do

Automotive Chemical & Food

Processing

Consumer Goods Defense Contracting Energy & Utilities Food

& Beverage Packaging Pharmaceutical Printing & Textiles

Semiconductor

Special Machinery Telecommunications Oil & Gas Test &

Measurement

Industries Served

Presenter InfoJohnny KilpatrickPresident, Patco Machine and Fab.

John R. KilpatrickFounder

• Founded in 1973 by Johnny R. Kilpatrick• Started as job shop/machine shop• Expanded to repairing/building hydraulic

cylinders for the oil field industry

Patco Machine & Fab, Inc.

• Services offerings now expanded to include Design and Manufacturing • Specializing in Production & Drilling Equipment

• Hydraulic Pump Skids• Hose and Cable Reels• Suction and Dump Valves for Mud Tanks• Much more….

• Pride, Quality and Commitment• Servicing Customer World Wide since 1973

Patco Machine & Fab, Inc.

Patco Machine & Fab, Inc.

Patco Machine and Fab

Cable & Hose Reel Systems

Cable & Hose Reel Systems

Challenges• Why automate?

• Looking to modernize the product to meet evolving industry requirements and standards

• Differentiate our products with first in the industry capabilities• Provide our customers with added value

• Potential challenges• Our expertise is in high quality mechanical/hydraulic design

and fabrication, not electronic controls• Limited experience in Zoned/Classified spaces

• ATEX/IECEx Class 1 space• Controls hardware selection/communication/software

• Extreme conditions of offshore drilling environment

Presenter InfoAdam TackerOutside Account Manager (AWC)

• 9 years at AWC• 6 years Applications Engineer/Field Service• 3 years on Account Management Team

• Expert in Siemens PLC and Drives, and Instrumentation• TI505/S5, Legacy Product Expert• Field service and startup experience• Certified Siemens Professional

• 50 years of serving our customers• Winning Together• Products and Services

• Siemens/P&F/Moxa/Phoenix Contact/Rittal• Project Management, System Design, 24/7

Tech Support• Over 400 engineers, 30 locations giving our

customers the best possible solution

AWC, Inc.

Building a Team

AWC – a Complete Solution• Electrical (Hazardous

Areas)• Controls• Project Management

Challenges • ATEX/IECEx Ratings

(dual)• Flexibility/Modularity• Hardware Selection

Challenges

Build a WINNING Team

AWC Project Management • R STAHL• DMC• Dynapar• Siemens

Traditional Solution

• Single Controller with Remote I/OTraditional Solution

Advantages

• Single controller• Initial setup• One copy of code to

manage• I/O local to remote racks• PN communication

Traditional Solution

Disadvantages

• Cost ($$)• 8 Remote Racks• More Complicated Panel

Design for Sheave (EX)• Need Ethernet in addition to

power to sheave• Not Flexible

• PLC program must be modified for different configs

• Reel HMI’s must look at unique tags

Traditional Solution

TIA Portal and the S7-1200

• Each Reel controlled locally• Sheaves all wired into central ET200SP (CPU)

• 4 encoders/load cells

Distributed Control

S7-1200

• Minimizing Cost• Built in I/O on 1200• Single ET200SP

(CPU) in remote panel for load cell/encoder

• Simple junction box on sheave

Leveraging the S7-1200

S7 Comm

CUSTOMER BENEFIT = lower cost per system

• Flexibility• Distributed control• More options

• Tension/payout• Multiple reel options

Leveraging the S7-1200

CUSTOMER BENEFIT = ‘custom’ options for Patco’s customer with no additional development

• Maintainability and Service• Fewer parts to

maintain• Easy to program via

MMC• Transfer Cards• Program Cards

Leveraging the S7-1200

CUSTOMER BENEFIT = easy system setup, service, and configuration without needing DMC

TIA Portal

Leveraging TIA Portal• Integrated Projects

• 5 PLCs + 5 HMIs = 1 Project• Drag & Drop Tags• Easy PLC to PLC

Communication• Easy to configure HMI

Connections

CUSTOMER BENEFIT = easier for Patco to maintain should features need to be added

Leveraging TIA Portal• Extended Diagnostics

• Integrated device level diagnostics

• Webserver/HMI• Improves ability to

remotely diagnose any issues

CUSTOMER BENEFIT = easier troubleshooting inthe field, remote support vs onsite

Leveraging TIA Portal• Library Functionality

• Typed Function Blocks• All reels share same

code• Changes only needed in

one place• Shared PLC/HMI Datatypes

• Easy Faceplate linkingCUSTOMER BENEFIT = minimize testing and

development time, save $$ and time

Leveraging TIA Portal• Configuration Control

• Define optional modules in ET200SP rack

• Can set hardware configuration from HMI

CUSTOMER BENEFIT = One project, multiple hardware configuration options

Conclusions

• TIA Portal and Siemens Factory Automation Products• Flexible/Modular• Expandable• Minimize Cost

Patented “Controlling Cable Spooling Systems,” #9,206,658

End Presentation