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Automation and Drives

trends in distributed
control systems
SIMATIC PCS 7
Introduction

Dr. G.U. Spohr

Asset Management
Profibus PA
redundancy

Siemens A&D ST2

1 GB Ethernet
Wireless LAN
Web - Technology
MES

Automation & Drives


April 2005

A&D AS SM MP

PCS7_Overview_V6-1_E200502.ppt

Automation and Drives

Introduction
SIMATIC PCS 7
Introduction
Asset Management

Some major technological trends which will influence the design


of current and future decentralized control systems :

Profibus PA
redundancy
1 GB Ethernet

Intelligent Field-Devices and Asset Management

Wireless LAN
Web - Technology

Communication Technology
Redundant Profibus PA Fieldbus
Gigabit Ethernet
Wireless LAN

MES

Web Technology
Management Execution Systems MES

A&D AS SM MP

PCS7_Overview_V6-1_E200502.ppt

Automation and Drives

Intelligent sensor- and actor-systems


SIMATIC PCS 7
Introduction
Asset
Asset Management
Management

intelligent

sensor- and actor-systems


often provide additional
information

Profibus PA
redundancy

acoustic pump monitoring

1 GB Ethernet

valve diagnostics

Wireless LAN

internal self diagnosis

........

Web - Technology
MES

these

informations are transferred to


the control system using HART or a
fieldbus communication

....

but where do I evaluate these


informations ?

A&D AS SM MP

PCS7_Overview_V6-1_E200502.ppt

Automation and Drives

Integrated Plant Asset Management


SIMATIC PCS 7
Introduction
Asset
Management
Asset Management
Profibus PA
redundancy
1 GB Ethernet
Wireless LAN

Plant Asset Management Systems integrated in SIMATIC PCS 7


provides online, real time functions :

Monitoring of the components

Monitoring

Message at status change

Display of diagnostic information

Creation of maintenance request

Tracking of the maintenance activities

Diagnostics

Maintenance
Request

Maintenance

SIMATIC PCS 7 Plant Asset Management

Web - Technology
MES

Main benefits of the implementation :

Homogenous integration into the SIMATIC PCS 7 environment

Maintenance Station integrated into OS or as a dedicated station

Common visualization (symbols, faceplates) of all assets (unified assets)

Automatic generation of all Asset Management diagnostic pictures

Consequent implementation of NAMUR recommendations NA 64 & NE 91

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PCS7_Overview_V6-1_E200502.ppt

Automation and Drives

Asset Management Operating & Monitoring


SIMATIC PCS 7
Introduction

OS
MS

OS

OS
C1

Asset
Management
Asset Management

Cn

...

MS

(pictures, messages, faceplates)

Profibus PA
redundancy

AS 1

AS 2
...

AS n

AS 1

1 GB Ethernet
Wireless LAN

Web - Technology
MES

S1

Maintenance Station
integrated in
Operator Station

...
AS 2

...

Maintenance
Pictures

OS Clients with access


to maintenance area

Sn
AS n

Maintenance Station has


additionally direct online
access to PDM and
hardware engineering
AS
C
MS
OS
S

Automation System
Client
Maintenance Station
Operator Station
Server

All SIMATIC PCS 7 components with diagnostic functions included

Common and unified symbols for representing the status of all assets
Good

Announcement of request
for maintenance (low)

Request for maintenance


unknown/not activated

Simulation

Request for maintenance


(medium)

Request for maintenance


activated

Function
control/ local

Maintenance alert
(high)

Request for maintenance


in process

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PCS7_Overview_V6-1_E200502.ppt

Automation and Drives

Integrated Plant Asset Management


Hierarchical Structure
SIMATIC PCS 7

Fast and easy-to-use operator guidance through complete hierarchy


by unified symbols

Introduction
Asset
Management
Asset Management

SIMATIC S7-400
and PROFIBUS
Network

Profibus PA
redundancy
1 GB Ethernet

status and selection of


underlying hierarchy

Wireless LAN
Web - Technology
MES

ET 200M
Station

diagnosis symbol
of the component

Clear hierarchical structure

PROFIBUS
Assets

Plant overview

Overview all controllers

Controller (with sub-hierarchy)

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PROFIBUS Assets

DP station (e.g. ET 200M)

Intelligent field device

Faceplates
for intelligent
device
PCS7_Overview_V6-1_E200502.ppt

Automation and Drives

Integrated Plant Asset Management

Automatic generation of hierarchical diagnostic pictures


SIMATIC PCS 7
Introduction
Asset
Management
Asset Management
Profibus PA
redundancy
1 GB Ethernet

OS

OS
C1

S1
AS 1

Cn

...
AS 2

...

...

MS

Sn
AS n

Technologische Sicht PCS 7

Wireless LAN
Web - Technology
MES

Automatic generation of diagnostic area


Operating and monitoring
hierarchical pictures
asset symbols with faceplates
alarm linking
Engineering
CFC charts with diagnostic blocks

Plant

Plant view in
SIMATIC PCS 7
engineering

Unit 1
Unit 2
Boiler 21
Diagnosis
Diagnosis
AS - Station

CP1 - Field bus


CP2 - Field bus

No engineering overhead !!!


All Asset Management related information is generated automatically !!!
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Remote I/O
DP/PA - Link
Link Picture
CFC
PCS7_Overview_V6-1_E200502.ppt

Automation and Drives

PROFIBUS PA- Redundancy


SIMATIC PCS 7

Possible Failures in a PA- Segment

Introduction
Asset Management
Profibus
PA
Profibus PA
Redundancy
redundancy
1 GB Ethernet
Wireless LAN
Web - Technology
MES

A&D AS SM MP

PCS7_Overview_V6-1_E200502.ppt

Automation and Drives

PROFIBUS PA- Redundancy


SIMATIC PCS 7

Basic Concept

Introduction
Asset Management
Profibus
PA
Profibus PA
Redundancy
redundancy
1 GB Ethernet
Wireless LAN
Web - Technology
MES

A&D AS SM MP

PCS7_Overview_V6-1_E200502.ppt

Automation and Drives

SIMATIC PCS 7 system bus:


flexibility in communication
SIMATIC PCS 7
Introduction

1 Gbps, ring topology:


Double ring topology for
Plant bus (double redundant)
Fiber optic or twisted pair
Switching technology

High performance variant:


Industrial Fast Ethernet
(100 Mbit/s, redundant)

Normal requirement:
Industrial Ethernet
(10Mbits/s, redundant)

Introductory solution:
Basic Communication Ethernet
via normal LAN connection

Asset Management
Profibus PA
redundancy
1 GB Ethernet
Ethernet
Wireless LAN
Web - Technology
MES

High communication capacity


even for "XXL applications
providing total system
stability and high availability !

Gigabit Plant Backbone

SCALANCE X208

SCALANCE Serie X400


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Automation and Drives

Wireless LAN
These are the most important requirements
SIMATIC PCS 7
Introduction
Asset Management
Profibus PA
redundancy
1 GB Ethernet
Wireless
LAN
Wireless LAN
Web - Technology
MES

Metal housing with


high degree of protection

Robust

Protection against
vibration and shock
Extended temperature
range

Cyclic data traffic


(deterministics)
Redundancy

Reliable
Monitoring of the radio
connection
Stable radio connection

Easy
configuration

Secure
Access control
(authentication)
Encoding of
the data

WIRELESS AS RELIABLE AS WIRE!


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PCS7_Overview_V6-1_E200502.ppt

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Automation and Drives

Cyclic data traffic


Reliable

SIMATIC PCS 7

Data
rates
reserv.

Introduction
Asset Management
Profibus PA
redundancy
1 GB Ethernet
Wireless
LAN
Wireless LAN
Web - Technology
MES

802.11

Data
rates
reserv.

802.11

Data
rates
reserv.

802.11

T1
T2
T3
T4
T5
T6

Time

Nodes 1, 2 and 3 may access


predictably the radio channel,
controlled through Robust
Access Point

Node 4 is allowed access to


the radio channel only in
the 3rd cycle

Conform with 802.11, SCALANCE W guaranteed data


reservation
Any client devices applicable (non-SIMATIC as well)

Cyclic data traffic, well known from fieldbusses


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PCS7_Overview_V6-1_E200502.ppt

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Automation and Drives

Redundancy Mode
Reliable

SIMATIC PCS 7
Introduction
Asset Management
Profibus PA
redundancy
1 GB Ethernet
Wireless
LAN
Wireless LAN
Web - Technology
MES

Transmission of the data via two different radio channels


e.g. by disturbance switching from 2,4 GHz at 5 GHz or vice
versa.

Redundancy increases the availability and


reduces the sensitivity to interference
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Automation and Drives

Security settings
Secure

SIMATIC PCS 7
Introduction

Security
levels:

Asset Management
Profibus PA
redundancy
1 GB Ethernet
Wireless
LAN
Wireless LAN

When choosing
none no
security level is
activated!

Web - Technology
MES

The required security level is achieved by one


software setting
A&D AS SM MP

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Automation and Drives

Comparison of SCALANCE W / SCALANCE S


Secure

SIMATIC PCS 7
Introduction

Secure
SCALANCE W-700 with
WPA, TKIP, MIC and AES
Authentication (Who am I?)
Coding

Asset Management
Profibus PA
redundancy
1 GB Ethernet

SCALANCE S-600 with


IPsec VPN tunneling and Firewall
Authentication (Who am I?)
Authorisation (What may I?)
Coding

SCALANCE W-700

Secure

Wireless
LAN
Wireless LAN
Web - Technology

SCALANCE S-600

MES

Multiple protection against unauthorised access and


bugging
on automation components or cells.
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Automation and Drives

SCALANCE W or SCALANCE S
SIMATIC PCS 7

EITHER ...

... OR

SCALANCE
W-700

Introduction

SCALANCE
W-700
SCALANCE S

Asset Management
Profibus PA
redundancy

Secure

Ethernet

Ethernet

1 GB Ethernet
Wireless
LAN
Wireless LAN
Web - Technology

WPA/AES
(Software
included in
AP)

User- defined
Firewall setting

MES
SCALANCE
W-700

Ethernet

VPN
Tunnel

Security
mechanism
deactivated

SCALANCE
SCALANCE S W-700

Ethernet

Ethernet

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PCS7_Overview_V6-1_E200502.ppt

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Automation and Drives

IWLAN and mobile diagnosis


SIMATIC PCS 7
Introduction

IE

Access Point
SCALANCE
W788-2PRO

Access Point
SCALANCE
W788-1PRO

Access Point
SCALANCE
W788-2PRO

IE

Asset Management
Profibus PA
redundancy
1 GB Ethernet
Wireless
LAN
Wireless LAN

IE Client
Module
SCALANCE
W744-1PRO

S7-200
S7-400

Web - Technology
PROFIBUS

MES
ET 200S

S7-300
Automated guided
vehicle systems

IE Client
Module
SCALANCE
W744-1PRO

Field PG with
CP 7515

ET 200S

Mobile diagnosis and service

Wireless PLC
Separate radio
network

Components for IWLAN for mobile data access.


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Automation and Drives

Monitoring and Control


via SIMATIC PCS 7 Web Client
SIMATIC PCS 7
Introduction
Asset Management
Profibus PA
redundancy
1 GB Ethernet
Wireless LAN
Web - Technology
Technology
MES

Monitoring and Control via the Internet / Intranet


Web Client as thin client
Complete plant overview
Remote diagnostics and asset management
Advanced security is ensured by
User-specific password
Firewall technology
Individual application concepts

SIMATIC PCS 7
Web-Client
Modem

LAN Intranet

Minimal installation at the Web Client


OCX file via net download or CD

Internet
Explorer

Direct conversion of process screens for the web


Superior performance by
Compressed process
pictures for the Web
Report by exception based
runtime communication

Worldwide and safe access


to the plant based on stateof-the-art web technology !
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SIMATIC PCS 7
Web-Client

LAN Intranet
Terminal Bus

Web-Server within a
SIMATIC PCS 7 Client

Plant Bus

PCS7_Overview_V6-1_E200502.ppt

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Automation and Drives

PCS 7 OS Web Client


SIMATIC PCS 7
Introduction
Asset Management
Profibus PA
redundancy
1 GB Ethernet
Wireless LAN
Web - Technology
Technology
MES

Monitoring and Control via the Inter- / Intranet


Web Client as Thin Client
Manager node
Remote diagnostics and asset management

Advanced security is ensured by


user-specific password
Firewall technology
Individual applications concepts

Minimal installation at the client (OCX via net)


Direct conversion of process screens for the web
Superior performance by
Compressed PCS 7 screens
Report by exception based runtime communication

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PCS7_Overview_V6-1_E200502.ppt

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Automation and Drives

MES interface to the IT world with SIMATIC IT


SIMATIC PCS 7
Introduction
Asset Management
Profibus PA
redundancy

Information technology (IT),


process data management and
production planning systems

Connects the control level with the


MIS/MES level

Comprehensive basic packages available

Integration of vendor-neutral IT products

1 GB Ethernet
Wireless LAN
Web - Technology
MES

play an increasingly important role in


production optimization and cost reduction

To the ISA S95 standard; integration


of heterogeneous (as well as host) applications
Short response times, more transparency,
more reliable decision-making

Integration & synchronization of all business processes


with the SIMATIC IT technology platform
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Automation and Drives

SIMATIC IT Integration
SIMATIC PCS 7
Introduction
Asset Management
Profibus PA
redundancy

Browsing of MES- relevant Objects

1 GB Ethernet
Wireless LAN
Web - Technology
MES

A&D AS SM MP

PCS7_Overview_V6-1_E200502.ppt

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Automation and Drives

SIMATIC PCS 7
Introduction

SIMATIC PCS 7

Asset Management
Profibus PA
redundancy
1 GB Ethernet
Wireless LAN
Web - Technology
MES

A&D AS SM MP

PCS7_Overview_V6-1_E200502.ppt

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