Siemens MediaService Industries 1

Steinach am Bodensee, Switzerland. The fishery in Steinach breeds fish species which are under threat so that they can be released into domestic waterways in the canton of St. Gallen. The quality and temperature of the water, light, and food all have a signifi-cant role to play in breeding - not to mention the requirements to be met for each fish species. To comply with these demands, the fishery relies on modern technology to monitor the breeding tanks. At the heart of the solution is a Siemens controller. End-to-end automation also secures the operation, even in the event of a power failure, and contributes to high survival rates amongst the breeding stock.

Around two thirds of fish and crab species native to Switzerland are threatened by extinction or no longer appear in the wild. The Amt für Natur, Jagd und Fischerei (Office for Nature, Hunting and Fishing) in the canton of St. Gallen has the task of maintaining and promoting biodiversity. The fish-

ery, which opened 12 months ago in Steinach, is making a significant contribution in this area. Approxi-mately 100 cubic meters of water are treated every hour in the fish breeding plants in order to meet the creatures’ requirements with respect to quality, oxygen content, and water tempera-ture. This process is controlled by a Siemens Simatic S7-1500 controller with two processors, CPU (Central Processing Unit) 1515-2 PN and CPU 1511-1 PN.

Comprehensive process managementThe water in the total of four tanks is drawn directly from Lake Constance and is extracted at a depth of 40 meters, then filtered, degassed and sterilized with UV radiation. Precise pressure control by the controller ensures that the pump motors are ramped up and down slowly. Were this not the case, pressure surges would occur in the pipework due to the sig-nificant difference in height when switching on and off due to the weight

Maintaining biodiversity

Fishery relies on Siemens process management system for successful breeding

Siemens MediaService Industries 2

Simatic www.siemens.com/simatic

Simatic ET 200SP www.siemens.com/et200sp

of the water column. This could dam-age the drives. It was important that the WinCC visualization software provided extremely easy and transpar-ent visualization and archiving of the process during operation. A redundant Simatic CPU 1211C monitors and controls the continuous power supply and notifies fishery employees by SMS in the event of a disruption. Project management of the whole plant takes place in the engineering framework TIA (Totally Inte grated Automation)

Portal and a distributed Simatic ET 200SP I/O system ensures quick data transfer into and away from the control cabinet.

High success rateThe end-to-end Siemens automation solution provides employees at the fishery with the necessary support to maintain biodiversity in Swiss waters. The survival rate of breeding stock in the center remains very high thanks to this reliable technology.

The fishery in Steinach breeds fish species which are under threat so that they can be released into domestic waterways in the canton of St. Gallen.

Water quality, temperature and light in the four huge breeding tanks are permanently moni-tored and adjusted as required.

The end-to-end Siemens automation solution and reliable monitoring of all processes ensures the survival rate for the breeding stock in the center is very high.

A redundant Simatic CPU 1211C monitors and controls the continuous power supply and notifies fishery employees by SMS in the event of a disruption.

The water in the four tanks is drawn directly from Lake Constance and is extracted at a depth of 40 meters, then filtered, degassed and sterilized with UV radiation.

A Simatic S7-1500 with around 800 inputs and outputs is connected to the two CPU 1515-2 PN and CPU 1511-1 PN processors and controls the processes in the fishery.

Siemens MediaService Industries 3

Flachau/Wagrain/St. Johann, Austria. At Snow Space, a winter sports resort near Salzburg, Bergbahnen AG Wa-grain operates the Sonntagskogel-bahn 2, a chair lift for taking skiing enthusiasts to the piste. To provide the most comfortable ride possible to the summit, for the skiers, the new chair lift has been fitted with efficient Sie-mens drive technology by the system integrator Frey Austria GmbH (Frey). The core element in the solution is ultra-modern frequency converter tech-nology in which the frequency conver-ters are optimally matched to the new synchronous servo motors. The redun-dant design of the system increases not only the availability of the chair lift but also the passenger safety.

Since the 2018/2019 winter season, it has been possible to transport eight skiers to the summit in each gondola on the new high-tech Sonntagskogelbahn 2 chair lift instead of just four. This has been made possible by, amongst other things, the use of modern Siemens drive technology which has dispensed with a transmission between the elec-

tric motor and the pulley. Comfort is increased by precision speed control with encoder feedback. This is the first time this combination has been used: It makes transmission maintenance a thing of the past and offers optimum control options, and it also differentiates the Sonntagskogelbahn 2 from the other chair lifts.

Ultra-modern, new drive technologyThe gearless drive solution, consisting of a synchronous motor (90 pole) from Doppelmayr and two Sinamics S120 Cabinet Modules-2 redundant frequen-cy converter cabinets, form the techni-cal heart of the chair lift. The system comprises two Sinamics S120 Active-Line Modules and two recently deve-loped S120 Chassis-2 Motor Modules. The most significant benefits of these new devices are the smaller footprint, the sturdy overall design, and efficient operation combined with easier ser-vice. In addition to this, there is a considerable reduction in weight – ultimately each of the Sinamics S120 Chassis-2 has a reduced weight, from 450kg down to 160kg. The sturdy

overall construction of the frequency converters also significantly reduces the derating and the noise generated by the motors. The control is provided by a fail-safe Simatic S7-1500F con-troller combined with a distributed I/O Simatic ET 200S. Frey uses a TP-700B touch panel to operate the system. Frey is Siemens’ solutions partner from Innsbruck and is respon-sible for the electrical engineering solution for the drive, automation and visualization as well as the system engineering. The engineering for the whole solution is completed in the Siemens engineering framework TIA (Totally Integrated Automation) Portal.

Redundant system design for maximum safetyThe Sonntagskogelbahn 2 has two identical direct motors arranged con-centrically and vertically above each other; they are mechanically connec-ted to each other via a central shaft. Two Sinamics S120 power supplies and two Sinamics S120 Chassis-2 motor modules can be alternately connected to each other so that the

Future-proof chair lift system

Sonntagskogelbahn 2 in Salzburg benefits from modern Siemens drive technology

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Sinamics S120 www.siemens.com/sinamics-s120-innovation

required double redundancy is pro-vided not only for modular drive but also for drive control. “If a part fails, the operators are still able to run the system empty to ensure the safety of people in the lift,” explains Karl Pram-mer, CEO at Frey.

Project success launches future plans“The Sonntagskogelbahn 2 is cur-rently the most innovative chair lift

we operate here,” says Wolfgang Hettegger, CTO at Snow Space Salzburg. The chair lift transports approximately 3,600 people in 38 gondolas per hour up over 200 me-ters to the Sonntagskogel – around 25 percent more passengers than the previous arrangement. It is therefore understandable that the next two projects are already on the drawing board – the Sonntagskogel 3 and the Flying Mozart.

At the “new” Sonntagskogelbahn 2, part of the Snow Space Salzburg, new innovative drive technology guaranties the comfort and the safety of the customers.

At the heart of the drive for the new ski lift are redundant Sinamics S120 Cabinet Modules-2 from Siemens.

Synchronous motor (90 pole) from Doppel-mayr.

Redundant design improves operational safety.

Siemens MediaService Industries 5

Bochum, Germany. Klaus Union GmbH & Co. KG (Klaus Union) is one of the leading manufacturers of cen-trifugal and screw pumps for the oil and gas industry. In order to offer its customers maximum flexibility, fast delivery, and to maintain deadlines, the company operates pump test beds for both its own products and pumps from third parties. The latest test bed is designed to support flow volumes of up to 5,000 cubic meters per hour and is also suitable for complex tests. Klaus Union has taken Siemens on board for the electrical engineering. The end-to-end and transparent system technology makes the testing process significantly easier and pro-vides the pump test bed’s reliability and accuracy.

The test media in the new pump test bed are water and oil which are also mixed with air in multi-phase tests. One of the challenges for the new test bed was that Klaus Union did not want

to dig any new cable trenches in the current hall floor. The control panels therefore had to stand on plinths. In addition to this, it was also necessary to provide the medium-voltage trans-formers with an identical chassis and to arrange them in line on a track, despite the variation in their sizes. These special requests were only possible by having Siemens as a project partner.

Flexibility as a competitive edge“We were able to source everything we needed in terms of electrical, drive and automation technology from a single portfolio; from connecting to the power supply, including transformers, medium-voltage switchgear, and control center, control and drive tech-nology, to motors for pump drives, valve controls and lubrication,” ex-plains Oliver Hacker, responsible for the test rig at Klaus Union. The trans-formers are fitted with low-voltage Sinamics transformers and have an

Flexible pump testing

Pump manufacturer creates test bed with end-to-end Siemens system technology

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Sinamics www.siemens.com/sinamics

Simotics www.siemens.com/simotics

output range of five kilowatts to 2.7 megawatts at operating voltages of 230 Volt AC to 690 Volt 3AC. Param-eterization of the relevant combination of transformers and converters is completed from the control station via Profibus, the standard field bus com-munication system. Klaus Union uses Simotics motors for its own pump systems but the converters can also

be configured for other motors. “This flexibility of being able to easily oper-ate a very diverse range of motors is vital for us and was a further reason for deciding to work with Siemens systems,” says Klaus Union.

Focus on the actual workThe end-to-end system technology makes the test bed work significantly

easier, allowing the Klaus Union em-ployees to focus on the actual tests. The company also benefits from a close working relationship with Sie-mens customer service and technical sales support. “Even though the equip-ment was bought a long time ago, if we have any questions, we can still rely on the Siemens after-sales ser-vice,” Klaus Union is pleased to say.

Klaus Union GmbH & Co. KG carries out tests on its pump test bed with displacement volumes of up to 5,000 cubic meters per hour and pressures up to 100 bar.

In order to be able to test pumps which are ordered without motors as well as third-party units, the test bed is currently fitted with Siemens Simotics TN motors with an output range of up to 1.77 megawatts.

Measuring flanges with 0.5 to 1.0 percent accuracy measure the test bed performance.

End-to-end system technology from Siemens reduces the complexity of the system, making it easier to complete customer-specific tests.

Siemens MediaService Industries 7

Rottweil, Germany. Mikron GmbH develops automation and customized production systems used in the manu-facture of complex metal components. When working on the development of a prototype of the new Mikron 6x6 machine tool, the company opted to use solutions from the Siemens Mo-tion Control Services portfolio for the first time. This enables Mikron to generate a digital twin of the proto-type. The virtual image enables ad-vanced testing to prevent unwanted errors, and significantly reduces the commissioning time of the real ma-chine.

First of all, Siemens experts analyze project-specific commissioning re-quirements to determine the possibility of using virtual commissioning. So that the customer knows exactly what to expect in terms of work and financial outlay, an estimate of the cost and labor involved is also drawn up. The

experts from Siemens Industry Ser-vices then work with the Mechatronics Concept Designer software package (MCD) and the Simit simulation soft-ware to create a behavior model. Thisallows the customer to identify and fixany potential problems at an earlyjuncture using virtual commissioning,and enables kinematics and move-ment sequences to be visualized andoptimized. The early identification ofpotential design errors helps preventdamage to the physical machine. TheSiemens solution also allows the PLC(Programmable Logic Controller)project and the NC (Numerical Con-trol) archive to be commissioned inadvance. By linking up to the Simitsimulation software and MCD, com-missioning can be performed using areal Sinumerik 840D sl VC (VirtualCommissioning) test rack controller.This allows most of the project testingand optimization to be carried out inadvance and with minimized risk.

A faster start

Simulation solution and virtual commissioning services from Siemens speed up commissioning

Mikron GmbH develops automation and customized production systems for the manufacture of complex metal components.

When working on the development of a prototype of the new Mikron 6x6 machine tool, the company opted to use Sinumerik Virtual Commissioning Services to generate a digital twin of the plant for the first time.

The digital twin allows Mikron to simulate sequences such as different machine tool handling positions and identify potential design faults by virtual commissioning.

Motion Control Services www.siemens.com/motion controlservices

Simit www.siemens.com/simit

Siemens MediaService Industries 8

Nuremberg/Hannover, Germany. What does it take for Sweden, a country already playing in the top league of industrial nations, to improve even further? “Future technologies and cooperation are the keys to success in the digital age”, emphasized Digital Industries CEO Klaus Helmrich during a panel discussion at the Hannover Messe. The discussion with the CEOs of other world-renowned companies such as SKF, Scania, Electrolux, Sandvik and Northvolt – all Siemens customers – focused on the present and the future of digitalization in Sweden.

Tech giants from StockholmDid you know that the tech giants such as the music streaming service Spotify, the mobile payment provider iZettle and the payment provider Klarna all come from the Swedish capital of Stockholm? Sweden is a leader in numerous innovative fields - including digitalization. Year after year, the country ranks among the three most innovative nations world-wide and has been the undisputed

number ONE in Europe for four years now. Of course, the country relies on digitalization to maintain its leading position. “Thanks to close collabora-tion and co-creation we leverage the opportunities of digitalization to create added value and make Sweden a global leader in cutting-edge, sustain-able industrial production”, explains Ulf Troedsson, CEO of Siemens Sweden.

Siemens and Sweden have a long tradition of successful partnership dating back to 1853. They kept in touch throughout the years – and became even closer in recent times. This is clearly demonstrated by the successful cooperation between Siemens and Northvolt (battery pro-duction), Sandvik (a long-standing PLM software customer) and Scania (eHighways). “These cooperations will be intensified. And thanks to the integration of future technologies such as Artificial Intelligence, Blockchain and Edge Computing, we will continue to support Swedish industry in pro-gressing to the next level of digital

transformation”, Helmrich empha-sized.

Which future technologies are of particular relevance to Swedish CEOs? For Klas Forsström, CEO Sandvik Machining Solutions, Additive Manufacturing clearly plays the key role – because many young people have a strong interest in this topic and Additive Manufacturing enhances the attractiveness of the industrial busi-ness. Jan Brockman, Chief Operations Officer at Electrolux, emphasized: “The most important future technology is the one that is most useful to con-sumers and provides added value within a short time.” He also advo-cated the introduction of uniform standards and appealed to politicians to make this happen.

Setting benchmarks for the future: MindSphereSKF Group CEO Alrik Danielson is convinced that “what Siemens has in mind with MindSphere will set future trends.” In fact, for a technology to be disruptive and trend-setting, it must be put into practice – which is actually the case with MindSphere. Scania CEO Henrik Henriksson stressed that autonomous driving is of prime impor-tance to Scania – and is likely to fundamentally change the company’s business. It is quite possible that Scania will develop more and more into a transport logistics provider.

For Peter Carlsson, CEO of Northvolt AB, the most important change is how software and hardware interact with each other in today’s modern world: ”When you deliver hardware to a

Industry is cool !

Opportunities and challenges in the digital transformation of Swedish industry: Panel discussion with Klaus Helmrich, Ulf Troedsson and the CEOs of SKF, Scania, Electrolux, Sandvik and Northvolt.

Siemens MediaService Industries 9

Siemens Sweden https://new.siemens.com/se/sv.html

Siemens Digital Industries https://new.siemens.com/global/en/company/about/businesses/digital-industries.html

customer it’s just the start of a jour-ney. With connectivity and machine learning you can analyze user behav-ior, i.e. how your product is actually used in practice. This is a major change and it also requires industry to learn from its consumers’ applica-tions.”

All the panel discussion participants agreed that industry underwent fundamental change in recent years, thus representing a highly interesting field of activity. ”It’s clean, it’s bright and it’s the future”: Alrik Danielson and Ulf Troedsson got straight to the point with their statement ”Industry is cool”.

Infobox

Electrolux AB is a Swedish multi-national home appliance manufac-turer, headquartered in Stockholm.

Northvolt was founded in 2016 with the mission to build the world’s greenest battery, with a minimal carbon footprint and the highest targets for recycling, to enable the European transition to renewable energy.

Sandvik is one of Sweden’s largest global industrial groups. Founded in Sandviken, Sweden, in 1862, the com-pany is a major player in the special steel industry worldwide.

Scania AB is a major Swedish manu-facturer of commercial vehicles and buses, and is also a leading provider of industrial and marine engines. With headquarters in the Swedish city of Södertälje, it is one of the most profit-able vehicle makers in the world.

SKF Group: Svenska Kullagerfabriken (SKF) is a Swedish corporate group offering a wide range of products and services focusing on bearings, seals, lubrication, mechatronics (linear sys-tems, actuators, tensioners) and related services. From 1929 to 1953, SKF in Germany operated under the name of Vereinigte Kugellagerfabriken AG (VKF), with headquarters in Schweinfurt.

Group photo after the panel discussion at the Siemens stand at the Hannover Messe 2019 (from left): Ulf Troedsson (Siemens), Klas Forsström (Sandvik Machining Solutions), Henrik Henriksson (Scania), Alrik Danielsson (SKF Group), Peter Carlsson (Northvolt), Jan Brockmann (Electrolux) and Klaus Helmrich.

On the Open Space stage at the Hannover Messe 2019: Digital Industries CEO Klaus Helmrich (right) and moderator Chris Brow (2nd f. r.) with their Swedish guests

Ulf Troedsson (Siemens) and Peter Carlsson (Northvolt)

Siemens MediaService Industries 10

Nuremberg, Germany. Ensuring ser-vice engineers can handle the compo-nents they encounter in the field to the best of their ability and carry out their work with optimum efficiency requires professional design management. This user-friendly design of devices such as controllers or network components assumes a team has experience in design, use and production as well as a step-by-step development process. At Siemens, the design process is linked to product management, devel-opment and design at an early stage. And the results justify this process: Apart from having satisfied customers, Siemens is also pleased to have received many design awards on a regular basis such as the Red Dot Award.

It all starts with a detailed briefing: How will the customer use the device, what are its most important features? From this, the Siemens team assesses the initial design proposals using digital models or 3D-printed proto-types. An example of a particularly

service-friendly device is the Scalance XP-200 switch family. Industrial-grade and with high IP65 protection, these switches are also intended for space-saving installation outside a control cabinet. An enclosure concept only a few centimeters deep was devised for this design with angled connectors to keep cabling flat. The connections were arranged in two offset rows to facilitate easy fitting of the cables. The offset control panel provides quick diagnosis as the LED displays can be easily read, even with full cabling.

Part of the family but still independentService specialists must be able to handle a variety of devices, so consis-tency of design is therefore extremely important to Siemens. At the same time, specific requirements must not be overlooked. For example, the Scalance XM-400 switches are closely based on the design of the Simatic S7-1500 controller family – from the labeling of the operating elements to the configuration of top-hat rail mount-

ing. A major difference, though, is the layout of the Ethernet jacks. While they are hidden under the display on the S7-1500 CPU, they were executed without a cover on the Scalance XM-400. The reason: While the communi-cation plug on the CPU is usually only pulled when a device is replaced, maintenance technicians often have to hook up new devices to the switch or connect their laptop for diagnostic purposes – a cover would be very annoying here.

Operation via softwareA significant change in the way these devices are handled is in their opera-tion – this has shifted heavily towards software. As a result, the device de-sign must also take this user interface into account to make the operation easy to learn and yet productive. Visual structuring, simplification, orientation on specific work processes, and consistency are important guiding principles when it comes to the design. For example, Siemens pays attention to a consistent labeling and arrange-

Appearance counts!

Carefully thought-through device design makes handling easier in the field

Siemens MediaService Industries 11

Industrial Communication www.siemens.com/industrial-communication

RFID www.siemens.com/rfid

ment of the menu items – as was the case with the Simatic RF600 RFID (Radio Frequency Identification) reader, where a team of experts from design, marketing, technical customer support and development analyzed in detail the individual operating steps involved in setting up an RFID reading point and developed an innovative user interface from that. The result: Users can now put a reading point into operation in just a few minutes.

To ensure the consistency of the products, Siemens early on develops a “stage set”, which shows how the components visually interact.

The special layout of the connections on the Scalance XP-200 does not follow aesthetic aspects, but quite practically simplifies the commissioning.

Thanks to the hierarchical structure of the operating elements, the individual function groups are clearly delineated and prioritized.

Since the user experience is strongly shaped by the software, this user interface is created by means of a detailed development process. The example shows the diagnostic view of the Simatic RF600 RFID reader.