Dynamic and Scalable Systems Using WinCC OA
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This presentation shows how WinCC OA allows DMC to create a system that’s easy to use while retaining rich information for the user.
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Dynamic and Scalable Systems Using WinCC OA
- 1. Dynamic And Scalable Systems Using WinCC OA The REAPR project – a case study usa.siemens.com/summitUnrestricted © Siemens 2019
- 2. Unrestricted © Siemens Industry, Inc. 2019 Page 2 2019 Automation Summit • Title: Dynamic and Scalable Systems Using WinCC OA • Track: BPNA • Presenter: Leon Grossman • Company: DMC, Inc. • Session # (for your survey): 5.4
- 3. Unrestricted © Siemens Industry, Inc. 2019 Page 3 Presenter Info Leon Grossman Project Manager with DMC since 1998 DMC, Inc. B.S. in Chemical Engineering University of Oklahoma Professional Engineer SIMATIC Technical Certification WinCC OA Certified Consultant
- 4. Unrestricted © Siemens Industry, Inc. 2019 Page 4 DMC Overview Established in 1996, offices in Chicago, Boston, & Denver and customers throughout the world Established in 1996, DMC serves customers worldwide from offices in Chicago, Boston, Dallas, Denver, Houston, New York, Seattle, and St. Louis employees & growing 170+
- 5. Unrestricted © Siemens Industry, Inc. 2019 Page 5 DMC has the highest number of S7 certified engineers in the US. Siemens Expertise 35+
- 6. Unrestricted © Siemens Industry, Inc. 2019 Page 6 DMC Customers
- 7. Unrestricted © Siemens Industry, Inc. 2019 Page 7 Industries Served Energy & Utilities Printing Automotive Food & Beverage Semiconductor Chemical Oil & Gas Engineering Specialty Machinery Consumer Goods Packaging Machinery Programming Telecommunications Defense Contracting Pharmaceutical Test & Measurement
- 8. Unrestricted © Siemens Industry, Inc. 2019 Page 8 RATSCAT Facility • System originally built in 1963 • Was in use testing aircraft up until the mid 20-Teens • Primitive controls • Static pylon with a movable building to cover targets.
- 9. Unrestricted © Siemens Industry, Inc. 2019 Page 9 RAMS facility built for the B2 bomber • System originally built in 1984 for the B2 bomber • Movable pylon capable of being lowered to bring the target within the target support facility. • Control system was all manual controls and relays • Position feedback using WWII technology of resolvers and synchros. • Fun fact: these devices are incredibly robust and are still used in military applications today. The units we removed from this system have been in operation since 1984!
- 10. Unrestricted © Siemens Industry, Inc. 2019 Page 10 Yesterday’s technology in today’s world • Updated to Soft PLC system in 2000. • Any offline node takes down the entire system. • System increasingly unreliable after 17 years in operation and was no longer a supported platform. • System uses confusing “axis nomenclature” to represent everything. In many ways this does work but it prevents representing the system as a related set of devices. • System stopped working the day demolition started for the upgrade. • UGLY
- 11. Unrestricted © Siemens Industry, Inc. 2019 Page 11 Solution Requirements • Improved resolution • 10 KHz data collection synchronized to UTC time • Improved user experience • Improved diagnostics • Improved reliability • Also, one failed node can’t take down the entire system! • Emergency operation must be maintained without new control system operational WinCC OA Server 2 S7-1500 Driver Redundant Backup WinCC OA Server 1 S7-1500 Driver DAQ Server Redundant Master Pit2 / CP Switch Portable Target Mount (future) HTM Switch CF Switch RVUMS can be connected to only one of these locations at a time. TSF Switch RVUMS Switch at Pad RVUMS Switch at Range RCMS Switch Pit3 Switch (future) CF UI TSF UI RVUMS UI One server connects to all system PLCs at one time. The other server is on standby and constantly synchronized to the primary server.
- 12. Unrestricted © Siemens Industry, Inc. 2019 Page 12 Key Components • S7-1500 PLCs • Siemens Remote I/O • Siemens Drives • KP8 Panels
- 13. Unrestricted © Siemens Industry, Inc. 2019 Page 13 Key Components - Continued • National Instruments cRIO • Comfort Panels • Mobile Panels • SCADA Terminals • Copley Drives
- 14. Unrestricted © Siemens Industry, Inc. 2019 Page 14 All tied together by WinCC OA 3.16 Key features • Native Redundancy • Siemens native driver support • OPC UA server AND client support • Object Oriented (CTRL++) programming language for smart objects
- 15. Unrestricted © Siemens Industry, Inc. 2019 Page 15 Starting with the Hardware • Siemens IPC 547E rack mount servers • Siemens IPC 647D rack mount UI computers • High reliability • Robust design
- 16. Unrestricted © Siemens Industry, Inc. 2019 Page 16 Redundancy • System runs with either server active • Failover conditions are configurable • Automatic failover and recovery • Completely seamless to the user • Redundant setup only requires 3 config file changes!
- 17. Unrestricted © Siemens Industry, Inc. 2019 Page 17 Tag Structures • Para (tag database) supports structures. • Each element can have detailed metadata including • Address of tag on plc • Archive information • Units, display format, description Using this metadata allows the user interface to be automatically configured from the para database.
- 18. Unrestricted © Siemens Industry, Inc. 2019 Page 18 Tag Generation Tool • Creating all those structures is time-consuming! • We’ve made it easy. The DMC tool: • Is included with the WinCC OA Open Library • Generates the tag tree structure and associates metadata • Can pull format, unit, and description data from PLC comments • Automatically add alarm and warning properties • Turns hours/days of work into minutes!
- 19. Unrestricted © Siemens Industry, Inc. 2019 Page 19 Reusable Objects • Self configuring objects • Labels, units, format come from tags • Objects made from complex structures only require the root tag to be configured! • Security enabled objects enable/disable based on logged in user level. • Limit switch object (right) has the ability to force and disable channels as needed.
- 20. Unrestricted © Siemens Industry, Inc. 2019 Page 20 Named Colors and Color Schemes are Awesome • Consistent color across the application • Ability to change schemes on the fly
- 21. Unrestricted © Siemens Industry, Inc. 2019 Page 21 Animated Objects • Shows test article position and orientation • Weather status • Door position • Etc… Everything needed to know how the system is operating is available at a glance.
- 22. Unrestricted © Siemens Industry, Inc. 2019 Page 22 Auto Generation of System Settings Screens • System settings automatically generated from Config struct • Stored in archives so that changes can be recovered • Displayed hierarchically • Inherit format/units/description from Para tag database
- 23. Unrestricted © Siemens Industry, Inc. 2019 Page 23 Benefits • We got the improved resolution, reliability and modernization we were looking for. And • Trending has dramatically improved diagnostics • Visualization gives true, at a glance, understanding of what’s going on • Test setup now dramatically faster than before • Ability to operate many components independently and simultaneously in ways that weren’t possible before
- 24. Unrestricted © Siemens Industry, Inc. 2019 Page 24 Lessons Learned • You can’t prevent acts of god.
- 25. Unrestricted © Siemens Industry, Inc. 2019 Page 25 Lessons Learned • You can’t prevent acts of god. • Division of responsibilities between partners is critical.
- 26. Unrestricted © Siemens Industry, Inc. 2019 Page 26 Lessons Learned • You can’t prevent acts of god. • Division of responsibilities between partners is critical. • When you’re this remote, the wildlife owns the land!
- 27. Unrestricted © Siemens Industry, Inc. 2019 Page 27 Lessons Learned • You can’t prevent acts of god. • Division of responsibilities between partners is critical. • When you’re this remote, the wildlife owns the land! • … • We’ve become way to accustomed to our “internet access” and our “cellular telephones” and our “slack”.
- 28. Unrestricted © Siemens Industry, Inc. 2019 Page 28 WinCC OA Open Library • Over 2.5 years in the making. • Used it to refine our best OO CTRL++ best practices. • Contains: • screen objects for most of the PLC Open Library. • Tag importer tool for TIA Portal projects. • Open Source! • Available at: https://openplclibrary.com/
- 29. Unrestricted © Siemens Industry, Inc. 2019 Page 29 Dynamic and Scalable Systems Using WinCC OA Name: Leon Grossman Company: DMC, Inc. Email: [email protected] Phone: 312-500-9137 Session # (for your survey): 5.4
Editor's Notes
- #3: Session # will be provided with the June scheduling email.
- #4: I’ve been with DMC for 20+ years
- #7: Here are some of DMC’s 1,200 customers
- #8: Our diverse experience in technology, industry and processes allows us to bring best practices from many areas. We deliver solutions not available from singularly focused organizations. Our experience is broad and deep. We have a proven track record in a wide range of industries.
- #9: This slide should describe the business challenge or business requirements What major challenges was your business facing? Include overview diagrams and drill down deeper into the situation.
- #10: This slide should describe the business challenge or business requirements What major challenges was your business facing? Include overview diagrams and drill down deeper into the situation.
- #11: This slide should describe the business challenge or business requirements What major challenges was your business facing? Include overview diagrams and drill down deeper into the situation.
- #12: This slide should describe the solution Start conceptually (block diagram) and drill down
- #13: Hardware pictures from “Controls Hardware Specification”
- #14: Hardware pictures from “Controls Hardware Specification” and the Internet.
- #15: I could spend hours talking about all the pieces of this system. The way that we married PLCs, SCADA, comfort panels, and mobile panels into a unified whole that created a powerful but still easy to use system! We’re here to talk about WinCC OA, though!
- #16: We could have chosen any computer but this is a remote location and reliability is key. Fun fact, we needed 4K video in the 647D computers. I was able to make a gaming card fit by slightly modifying an internal bracket…
- #17: • WinCC OA Failover is a native feature. It’s easy to configure and operates seamlessly • One nice feature is that you can perform server maintenance without taking down the system
- #18: The “para” tag database is both a powerful and frustrating part of WinCC OA. By utilizing the powerful scripting of objects, we’re able to inherit our display characteristics from para.
- #19: This slide should describe the solution Start conceptually (block diagram) and drill down
- #20: • As mentioned in the previous slide, objects can be self configuring. • Objects can be made from objects. • More objects can be made from those objects.
- #21: WinCC OA’s color schemes allows for global tweaking of color without having to dig into each object. On top of that, you can create schemes that can be switched between based on buttons or even more clever scripting! Imagine having a critical condition and being able to change the entire display based on that event!
- #22: I know this is a bit obvious. Well-duh, you have animated objects. Doesn’t everyone? The beauty here is the complexity we can bring and the ability for the UI to convey complex information easily. (Describe the rotator object)
- #23: This slide should describe the solution Start conceptually (block diagram) and drill down
- #24: Bring up the diagnostics What were the actual benefits of the project? Return On Investment (ROI) Improvements in cycle time Reduced start-up time Cost reductions (e.g., for engineering changes, operations, and maintenance) Energy savings Unexpected benefits? “Quotes” from stakeholders (operators, management)
- #29: Bring up the diagnostics What were the actual benefits of the project? Return On Investment (ROI) Improvements in cycle time Reduced start-up time Cost reductions (e.g., for engineering changes, operations, and maintenance) Energy savings Unexpected benefits? “Quotes” from stakeholders (operators, management)