Automation engineering enhances efficiency in process and manufacturing industries

With its new Sirius Modular System for industrial controls, Siemens has succeeded not only in cutting down on the amount of wiring work but also in reducing space requirement in the control panel. At the same time, lower power dissipation means increasing the energy efficiency of industrial controls. In addition, the new Simatic S7-1200 microcontroller and innovative Profienergy solutions are also playing a role in reducing energy consumption and so enhancing efficiency in production. And finally, innovations in the Sinamics drive family not only suppress disturbing feedback by inverters into the grid but also help to save energy, particularly in conjunction with pumps and compressors.

The efficient use of resources such as energy and raw materials and the achievement of efficient production sequences are among the most challenging issues faced by today’s process and manufacturing industries. At this year’s SPS/IPC/Drives, the Siemens IA and DT Divisions will be showcasing systems, applications and components designed to address these challenges by making a major contribution to increased efficiency for OEMs and end users. In the words of the Control Components and Systems Engineering Business Unit CEO Karlheinz Kaul: “Energy efficiency is a main focus of this year’s fair, and is an issue which comes as second nature to the Drives Technologies and Industry Automation Divisions. Our Modular System Sirius, for instance, offers energy-efficient products which help us reduce control panel-related power dissipation by as much as ten per cent.“ The innovated Sirius Modular System featured as a highlight at the Siemens booth is all about increasing the efficiency of industrial controls across the board: Higher power ratings using the same external dimensions mean space savings in the control panel, and by integrating functions into components and simplifying the connection method, wiring work can be reduced. Controls and switchgear in plants can be simply connected via IO link and AS-Interface, and integrated application monitoring complete with monitoring relay helps improve plant availability.

The new System Module also substantially reduces the work involved in planning and configuration, for example through the provision of CAx data. According to Eckard Eberle, Head of Control Components: “Our new Sirius generation allows us to sharpen the competitive edge of our customers: For machine and control panel manufacturers, Sirius will mean not only greater speed and efficiency in terms of control panel assembly and handling, but also simplified planning and configuration. Automation engineers will now be able to simply link the industrial controls to the automation level, and for end users these new developments help us prevent sources of error and also enhance plant availability – while at the same time reducing operating costs.”

Integral energy management for plants and machines has a central contribution to make here. What this means in practice is that the complete drive train is taken equally into consideration alongside plant automation. Because energy-efficient drive systems, integrated analytical tools and intelligent automation engineering address the issues of both energy efficiency and environmental protection, Siemens has pledged its support for the Profienergy initiative launched by the Profibus User Organization PNO. Profienergy is a Profinet-based data interface which allows unnecessary loads to be switched off during production rest periods. This ensures that dynamic energy management is implemented right across productive periods as well as non-productive periods of different lengths. An energy saving profile permits the energy saving modes of connected devices to be simply addressed on a standardized basis and their respective feedback evaluated. Using this information, a plant control system is able to optimize energy consumption during both production and standstill periods. Head of Factory Automation Thomas Schott explains: “Studies have shown that almost as much energy is consumed during production rest periods as during actual production itself. Profienergy now provides machine manufacturers with a standard which allows major loads to be switched off during rest periods or at least their power consumption reduced. The gains to be made in terms of energy efficiency are enormous.”

Siemens will also be featuring additional innovations to the Simatic S7-1200 which was unveiled in April: Analogue signal modules, digital signal boards and a signal module expansion cable. The two new signal modules offer high density analogue channels in compact 45 millimeter wide modules. A signal board can also be plugged onto each S7-1200-CPU to extend the number of I/O channels without changing the controller’s dimensions. Six new high speed digital signal boards in 24 or 5 Volt DC provide even greater flexibility to meet specific customer requirements. The new signal module expansion cable provides additional flexibility when configuring and installing the Simatic S7-1200. Where required, it allow for the installation of the CPU and signal modules on two separate rows. As Thomas Schott comments: “Although it has only been on the market for a short time, our customers are already recognizing the added value potential of our new, coordinated offering, which is comprised of the Simatic S7-1200 controller, Simatic HMI Basic Panels and the Simatic Step 7 Basic Engineering System. Our customers from across different sectors of industry have praised the practical interaction between Step 7 Basic and WinCC Basic as well the intuitive operation, which enables engineering without referring to manuals or calling on support”.

Siemens is also featuring a number of innovations on the drive level with its Sinamics G150 Clean Power and Sinamics G120P. The Sinamics G150 Clean Power inverter reduces low-frequency disturbing feedback into the grid, so complying with the stringent demands made on the current and voltage quality of power grids. The modular frequency inverter Sinamics G120P is designed specifically for pump, fan and compressor applications to permit the energy-efficient operation of continuous flow machines in building automation applications, the process industry and water management. The frequency inverters are part of Siemens’ Environmental Portfolio. In fiscal 2009, revenue from the Portfolio totalled about €23 billion, making Siemens the world’s largest supplier of ecofriendly technologies.

In case of questions, please quote reference “IA2402”:
Siemens Industry Automation, Infoservice, Postfach 23 48, D-90713 Fürth
Fax: ++49 911 978-3321 or E-Mail: infoservice@siemens.com
The Siemens Industry Sector (Erlangen, Germany) is the worldwide leading supplier of production, transportation, building and lighting technologies. With integrated automation technologies as well as comprehensive industry-specific solutions, Siemens increases the productivity, efficiency and flexibility of its customers in the fields of industry and infrastructure. The Sector consists of six Divisions: Building Technologies, Drive Technologies, Industry Automation, Industry Solutions, Mobility and Osram. With around 222,000 employees worldwide Siemens Industry posted in fiscal year 2008 a profit of EUR3.86 billion with revenues totalling EUR38 billion.

The Siemens Drive Technologies Division (Nuremberg) is the world's leading supplier of products and services for production machinery and machine tools. Drive Technologies offers integrated technologies that cover the entire drive train with electrical and mechanical components. This includes standard products but also encompasses industry-specific control and drive solutions for metal forming, printing and electronic manufacturing as well as solutions for glass, wood, plastic, ceramic, textile and packaging equipment and crane systems. The services provided by the Division include mechatronics support in addition to online services for web-based fault management and preventive maintenance. With around 39,900 employees worldwide, Siemens Drive Technologies Division posted a profit of EUR 8.9 billion with revenues totalling EUR 39,900 billion in fiscal year 2008.

The Siemens Industry Automation Division (Nuremberg, Germany) is a worldwide leader in the fields of automation systems, low-voltage switchgear and industrial software. Its portfolio ranges from standard products for the manufacturing and process industries to solutions for whole industrial sectors that encompass the automation of entire automobile production facilities and chemical plants. As a leading software supplier, Industry Automation optimizes the entire value added chain of manufacturers – from product design and development to production, sales and a wide range of maintenance services. With around 42,900 employees worldwide Siemens Industry Automation achieved in fiscal year 2008 total sales of EUR8.7 billion.

Reference Number: IIA2009112402e