Application examples by function

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iba AG
Application examples
Bringing Transparency
to the World of Automation.
Measurement and Automation Systems
www.iba-ag.com
Application examples by function
Automation
Automation of video monitored fire test simulations
A complete solution; with iba-Software
4
Optimization of a non-online capable legacy system
ibaLogic as a Co-Processor
5
The automation of a tandem group in a rolling section mill
Automation with ibaLogic
6
Controlling complex solar installations
System control with ibaLogic
7
Process Monitoring
ibaPDA-S7-Analyzer: troubleshooting at a minesite
8
Monitoring and commissioning in open-cast coal mining
Monitoring of automation projects and commissioning of new drive
technology for major equipment in open-cast coal mines
9
Drive Optimization in a Railcar Dumper & Train Positioner for Mines
Data acquisition with ibaPDA,; ibaBM-DPM-S and EtherNet/IP
10
Bucket Wheel Reclaimer Reeler Tuning
Data acquisition with; ibaPDA and EtherNet/IP
11
Finding and correcting malfunctions in the hot rolling mill
Process analysis; with ibaCapture-CAM
12
Process analysis in plants for tube manufacturing
Capturing and analyzing process data with iba measuring systems
13
Optimizing the hydraulic actuator on a ship‘s drive
CAN-Bus Sniffer
14
Monitoring of over stage machinery functions on an opera stage
Signal capturing with PADUs
15
Transient Fault Recording in HVDC systems
Transient Fault Recording
16
The integration of a new thickness gauge in a legacy system
ibaLogic as a signal manager
17
System monitoring in a paper production facility
Process data acquisition; with ibaPDA
18
Process Monitoring
Plant monitoring of hot strip production
Sniffing on the Profibus
19
Equipment monitoring of medium hot strip mill
Database for maintenance; and quality control with ibaPDA
20
Quality Reporting
Length related data acquisition in strip processing lines
Quality data recording; with ibaQDR
21
Condition Monitoring
Optimization of wind energy systems
Condition Monitoring
22
Measurement and Testing Technology
Load tests for railroad ties
Data acquisition with; ibaPDA and ibaPADU-8
23
Data capture in a test bench for diesel drive systems
Integrated operator concept; with ibaQPanel
24
Modernization / Life Cycle
Gradually modernizing automation systems Soft-Revamp with ibaLogic
25
Optimization of an exhaust air treatment adsorber system Revamping with Soft-PLC
26
Hardware
Software
Training
Applikationen
Applikationen
Application
Automation of
video monitored fire test simulations
Advantages at a glance
■■A universal solution for the entire system.
■■Central documentation of experimental results and
values.
■■Relief personnel strain through fully automatic experimentation.
ibaLogic-V4
ibaPDA-V6
fire test furnace [factory photo Trox GmbH]
A complete solution
with iba-Software
The Project
At the heart of the most modern flammability test laboratory in Europe is a fire test furnace in which can be
tested even gigantic tunnel dampers that are used for
the extraction of smoke in subterranean traffic (tunnels).
A fire test furnace simulates a fire through standardized
temperature curves. This way, you can observe and measure elements such as temperature, deflection, etc., thus
simulating the behavior of components while they are
exposed to fire.
The requirement was a data capture system which was
easy to use while carrying out flexible test experiments.
All test data, experiment results and reports should be
stored in a centralized well organized way.
ibaCapture-CAM is a complete system, consisting of
hardware and software components, for the synchronized
recording of visual information and measured data in cooperation with ibaPDA-V6. It greatly facilitates tasks like
malfunction and process analysis, startup, training and
documentation of operational procedures.
ibaPDA-V6 is a PC based system for centralized capturing and recording of process data. The recording can be
chosen as time, length, batch or product related. Measurements are stored as so-called DAT-Files and can be
evaluated with the complimentary ibaAnalyzer.
ibaAnalyzer
The Technology
Control and automation of the test furnace is done with
ibaLogic. The experiments are run fully automatic. Results of the fire test such as pressure gradients, temperature gradients and object temperature are captured
and evaluated with ibaPDA as cyclic values. Two cameras
deliver real time images to the control room. The captured videos are stored synchronously with the recorded
data from the experiment. Inspection and evaluation of
the data and video sequences, including automatic report
generation, is done with the complementary ibaAnalyzer.
iba Products
ibaLogic combines the characteristics of a comfortable
signal manager with a powerful Soft-PLC. ibaLogic offers
an extensive function library as well as high transparence
with production and servicing of the application software.
Konfiguration
Configuration
Anlage / Prozess
Project information
system integrator for this project:
EAI
Elektro- und
Automatisierungstechnik GmbH
www.eai-net.de
Seite 4
Further information?
Do not hesitate to
contact us:
iba AG,
Koenigswarterstr. 44,
DE-90762 Fuerth
PHONE 0911 / 97282-0
MAIL [email protected]
www.iba-ag.com
Hardware
Software
Training
Applikationen
Applikationen
Application
Optimization of a
non-online capable legacy system
Advantages at a glance
■■Cost savings through the reduction of idle and dead
time.
■■Optimization of the software and the system during
continuous operations: no downtime.
■■Error free switching through the comparison of old
and new values.
ibaLogic
ibaPDA-V6
Coils [Werner Plass]
ibaLogic as a Co-Processor
The Project
As a part of a preliminary study, the optimization potential
of a rolling stand (slab deposit and reversing process) was
analyzed with ibaPADU.
The goal was to increase the material flow-rate by minimizing dead time and slab idle time.
Standards for the optimization phase were the error free
process optimization during ongoing operations and the
documentation of old and new conditions.
The ibaLink-SM-64-io board is an interface card adapted
to the SIMATIC S5 and the Simicro MMC 216 systems. The
card has a fiber optic sender/receiver pair on the front
side so that 64 analog and 64 digital signals can be transmitted. By using multiplexing techniques, more signals
can be transmitted.
ibaLink-SM-64-io
The Technology
Because the old system did not allow optimization during
operations (online), ibaLogic-System was deployed as a
“Co-Processor.” The communication with the old system
was accomplished with ibaLink-SM-64-io cards. All relevant data was collected, a new logic circuit was built and
introduced and thus, the stand subassemblies could be
controlled. The possibility to perform online programming
with ibaLogic, without time consuming compilations and
reloading, allowed rapid progress with the optimization.
Through the comparison of old and new values (ibaLogic dat-files), with the complimentary ibaAnalyzer, the
outcome of the optimization was quickly apparent. The
productivity rose by 30 to 60 percent.
iba Products
ibaAnalyzer
ibaLogic
ibaLogicas
alsaCo-Prozessor
Co-Processor
In this particular application, ibaLogic functions as a coprocessor.
What’s more, other modernization projects can be realized through the usage of methods such as the step by
step transfer of control functions of the “old” PLC to the
new ibaLogic automation.
Seite 5
Weitere information?
Further
Informationen?
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Sietouns
direkt: us:
contact
iba AG,
Königswarterstr. 44,
Koenigswarterstr.
44,
DE-90762 Fuerth
Fürth
TEL 0911
PHONE
0911
/ 97282-0
/ 97282-0
MAIL [email protected]
www.iba-ag.com
Hardware
Software
Training
Applikationen
Applikationen
Application
The automation of a tandem group
in a rolling section mill
Advantages at a glance
■■Higher plant availability through shorter product
change times.
■■Higher flexibility with process improvement through
online editing.
■■Higher transparency of the automation system for
easier maintenance.
ibaLogic
ibaPDA-V6
two-high roll stand [Hoesch Schwerter Profile]
Automation with ibaLogic
The Project
A manufacturer of special steel profiles wanted an overall
modernization of the factory‘s rolling line. He wanted
all components to function fully automated. The goal of
this investion was an enhancement in productivity and a
broader and more flexible product portfolio. The commissioning of the whole tandem group as well as the drive
control have been realized by means of ibaLogic-V4.
These features make ibaLogic-V4 a great solution for modernizing existing heterogenous automation structures.
With iba connectivity, different generations of automation
worlds and systems of different manufacturers can be
interconnected and combined. Bidirectional data exchange enables the communication between controls that
normally would be incompatible.
ibaNET750
The Technology
At the core of the new automation configuration are
control PCs (industrial computers) with ibaLogic-V4.
These PCs control the whole plant and are connected to
the input and output peripherals (WAGO System 750) by
iba interface modules and fiber optic cables (FO). Several
PROFIBUS master systems connect the drives to the
Logic computers. All important measured values are
captured by ibaPDA and stored as data files. The data can
be analyzed on any computer in the plant with ibaAnalyzer
(free of charge). The computer work stations are linked
via Ethernet. The plant has three building lots and one
repair lot, where the rolling stands for the requested special profile can be pre-assembled and calibrated. On large
platforms, the rolling stands roll directly to the rolling line
for mounting. Changing the rolling line for a new product
only takes 20 minutes.
iba Products
ibaLogic is a system for signal processing and automation. With ibaNet fibre optic cables, bus couplers and
system interfaces can be connected. Moreover, linking
can be done via field bus, Ethernet and special protocols.
Konfiguration
Configuration
Project information
Further information?
Fest AG
www.fest-ag.net
Do not hesitate to
contact us:
iba AG,
Koenigswarterstr. 44,
DE-90762 Fuerth
PHONE 0911 / 97282-0
MAIL [email protected]
system integrator for this project:
Seite 6
www.iba-ag.com
Hardware
Software
Training
Applikationen
Applikationen
Application
Controlling complex solar installations
Advantages at a glance
■■Simple optimization.
■■Facilitation of measurement analysis.
■■Surplus solar energy is used for the heating and for
heating drinking water.
ibaLogic
Solar collector in Fuerth, Germany [Sven Hein]
System control with ibaLogic
The Project
Having gathered experience with high temperatures during the very hot summer months in 2003, iba AG Fuerth
had the idea for a concept of air-conditioning for all office
rooms. Room temperatures of over 104.0 °F exhausted
our employees. We even experienced PC breakdowns
caused by the high temperatures. Sustained by the spirit
of innovation, that has always been at the core of our
company and our products, iba was looking for a revolutionary solution to get its employees heads cool again.
Of course, we were looking for a solution that is environmentally friendly and energy-saving. We did not want to
generate cold by employing lots of primary energy.
The Technology
The main feature of this concept is the fact that the energy
needed for gernerating cold is given by the sun. There has
been a large reference project so far based on a similar
technogy - air-conditioning of the Berlin Federal Press
Office. iba AG wanted to show that air-conditioning only
based on solar energy can be done in a cost-efficient way
also for small and medium-sized builings. Flat collectors mounted on the roof of builings heat a solar liquid,
flowing in a closed circuit. This liquid transfers its energy
via a heat exchanger to a water circuit. The heated water
is lead to a 1000 gal buffer tank from where it can be used
for cooling and water heating.
iba Products
ibaLogic combines the features of signal management
with those of a high-performing PLC - or as we call it
today - a Programmable Automation Controller PAC.
plant
Anlagenschema
diagram of the
derpilot
Pilotanlage
plant forzur
thesolarautarken
solar autarkicKlimatisierung
air conditioning
ibaLogic is mainly used for fast and dynamic processes in
measurement and control technology. That is why short
program cycle times and a deterministic time response
are the main features of the system. As ibaLogic offers
not only a large function library but also a high tranparency in creating and maintaining the system software, it can
be used also for quite slow processes like temperature
controls as we find it in our example.
Seite 7
Further information?
Do not hesitate to
contact us:
iba AG,
Koenigswarterstr. 44,
DE-90762 Fuerth
PHONE 0911 / 97282-0
MAIL [email protected]
www.iba-ag.com
Hardware
Software
Training
Applikationen
Applikationen
Application
ibaPDA-S7-Analyzer
troubleshooting at a minesite
Advantages at a glance
■■Quick and easy ad-hoc setup for any S7 PLC related
troubleshooting and optimisation tasks incl. symbol
based selection of variables from the S7 program.
■■Ethernet based high speed acquisition, capturing,
trend display and analysis of analogue and digital
signals.
ibaPDA-S7-Analyzer
■■Long term continuous recording possible as well as
trigger/event based recording.
Open cut mine site - image author: bondgrunge/www.shutterstock.com
■■In this particular instance, the ROI (Return On Investment) was measured in minutes. It is estimated that
the usage of ibaPDA-S7-Analyzer saved many hours
of unscheduled downtime and associated production
loss.
The Challenge
After a scheduled maintenance shutdown in an ore processing plant, the start-up of a particular sequence came
to a grinding halt whenever a certain step in the sequence
was reached. The plant operators could not determine the
root cause of the problem, as their SCADA system was
flooded with seemingly unrelated alarm messages when
this sequence stop occurred.
A quick initial online monitoring of the S7 PLC logic by
the site engineer also yielded no meaningful clue to the
source of the problem.
ibaAnalyzer
cause was obvious and fixed a short time afterwards.
As it turns the digital output in question activated a
solenoid valve which had been immersed in water during
maintenance work. This now created a partial short circuit which drained the 24V supply.
All up, the identification of this rather simple problem
was made possible by the power of ibaPDA-S7-Analyzers
capability for high speed ethernet based data acquisition,
trending and analysis capability.
The Solution
As an iba user, the site engineer quickly realised that it
was time to get serious and to start up their ibaPDA-S7Analyzer. Thanks to symbol based S7 program integration, setup of the digital inputs and outputs that required
monitoring was a cinch.
The ethernet based acquisition times was then set to
10ms to get a high resolution capture of the seemingly
fleeting event. A short few minutes later, the plant operators were asked to attempt another sequence start.
As soon as the sequence crash occurred, the engineer
took one look at the live data on his ibaPDA trend screen
and immediately realised the root cause of the problem.
The trend clearly showed that all previously active 24V
digital inputs dropped to zero a mere 150ms after the
sequence program gave the command to activate a particular digital output.
This “loss” of all the 24V digital inputs led to the alarm
flooding on the SCADA system as well as the PLC program immediately aborting the sequence. Since this sequence stops also led to a deactivation of any associated
digital outputs (including the one that “drained” the 24V
supply), all inputs became healthy again some 50ms later.
As all of this happened in the blink of eye, it was impossible to observe it via traditional SCADA or S7 PLC online
monitoring means.
Based on the ibaPDA captured data though, the root
High speed ibaPDA fault capture trend of the S7 PLC’s digital I/O’s
iba Products
ibaPDA-S7-Analyzer
is a PC-based system
to record and analyse
data at high speed
from any S7 PLC via
ethernet or MPI/DP.
The recording can be
made to store data
continuously or event
based.
The data is filed as so-called DAT-files and can be
analysed, processed and archived with the ibaAnalyzer
software tool which is free of charge. An efficient report
generator allows for the creation of customized analytical
reports.
Seite 8
Further information?
Do not hesitate to
contact us:
iba Oceania,
14 Laverick Avenue,
2322 Tomago NSW
Australia
TEL +61 (2) 49648548
[email protected]
www.iba-oceania.com
Hardware
Software
Training
Applikationen
Applikationen
Application
Monitoring and commissioning in
open-cast coal mining
Advantages at a glance
■■Efficient commissioning.
■■Cost savings due to targeted trouble shooting.
■■Monitoring for optimizing the drive and automation
technology.
ibaPDA-V6
Overview over partially automated projects.
ibaAnalyzer
Bucket-wheel excavator (Photo: RWE Power AG)
Monitoring of automation projects and commissioning of new drive
technology for major equipment in open-cast coal mines
The project
In the open-cast coal mines of RWE Power AG, major devices like bucket-wheel excavators and spreaders extract
more than 500 Mio t coal and overburden a year.
For increasing productivity and process quality, these major equipments are gradually partially automated, like e.g.
different steps of the excavation and the dumping process .
Moreover, in case of necessary replacements of system
components or economic advantages in the field of maintenance, drive technology is modernized.
are captured directly on the FM458 PROFIBUS interface
by means of the ibaBM-DPM-S module or on the Simolink-system bus via the ibaBM-SLM "Simolink monitor"
module. The measured values are then stored as a file on
the computer.
ibaBM-DPM-S
The technology
When partially automating major equipment, a wide variety of sensors is used. The raw data are prepared using
complex filter algorithms and provided to subsequent processes. A SIMATIC S7 control with the FM458 application
module assumes the control functions. The data recording
and the analysis of the process values from the automation devices provide the basis for optimizing the control
and the subsequent quality assurance.
As support for the commissioning of new drive technology
(e.g. for the 12x180kW DC-motors of the excavator chassis), the time-critical measured values of the control are
directly measured on the FM458 PROFIBUS interface.
ibaProducts
An ibaPDA-V6-system acquires the measured values in
the SIMATIC S7 control. Depending on the demands, either
a central measurement system or decentral systems are
implemented on the major equipment.
Time-critical measurement values of the drive controls
Supporting the commissioning of new drive technology
Using analysis regulations that are created just once,
characteristic values and graphs for an easy evaluation
can be generated automatically. This way, not only the
always recurring evaluation expense can be reduced, but
also an efficient trouble shooting is made possible. The
integration of the measurement system into the network
enables access directly from the office.
Seite 9
Weitere information?
Further
Informationen?
Do not hesitate
Kontaktieren
Sietouns
direkt: us:
contact
iba AG,
Königswarterstr. 44,
Koenigswarterstr.
44,
DE-90762 Fuerth
Fürth
TEL 0911
PHONE
0911
/ 97282-0
/ 97282-0
MAIL [email protected]
www.iba-ag.com
Hardware
Software
Training
Applikationen
Applikationen
Application
Drive Optimization in a Railcar Dumper
& Train Positioner for Mines
Advantages at a glance
■■Data from all drives trended synchronously in the
same window.
■■Data continuously recorded without the need for triggering. Acts like a “black box” for your drive system.
■■Effective trouble shooting, control system optimization and documentation of the results.
ibaPDA-V6
The Profibus network does not see any extra load as the
sniffer is passive and not part of the active bus. Data was
also captured from the Allen Bradley PLC via an EtherNet/IP interface. Any data available inside the PLC can
be marshalled and sent to the iba server and captured
synchronously with the Profibus data.
Multiple Motors on Car Positioner
ibaAnalyzer
Data acquisition with ibaPDA,
ibaBM-DPM-S and EtherNet/IP
The Project
iba Oceania designed a measuring system for a multiple
AC motor VVVF controlled car positioner in a mine. The
system was used to determine if load sharing issues
between the AC motors were occurring due to continual
clutch failures. The data captured provided a clear
illustration of the issues relating to the load sharing
mechanism between the motors.
Based on the recordings it then provided a clear path to
rectify the identified issues. Once the changes were
implemented the iba system was then used to verify that
the load sharing mechanism between the motors was
correct.
The iba system allowed for all VVVF drive data to be
trended synchronously in the same trend window. With
modern VVVF drive software this is not possible as each
drives data must be trended in separate windows.
The Technology
ibaAnalyzer Showing Load Sharing After
ibaBM-DPM-S
iba Products
ibaPDA-V6 is a PC-based system to centrally record data.
The recording can be made to store data continuously or
event based. The data is stored in so-called DAT-files and
can be analysed, processed and archived with the ibaAnalyzer software tool which is free of charge. An efficient
report generator allows for the creation of customized
analytical reports.
ibaBM-DPM-S is a fast interface device for Profibus DP.
The device has two modes of operation: sniffer mode and
active slave mode.
ibaPDA-Interface-Ethernet-IP allows for data to be
captured using the EtherNet/IP protocol over TCP/IP for
Rockwell PLCs.
ibaPDA-Interface
Ethernet IP
The VVVF drives are controlled via Profibus so an
ibaBM-DPM-S Profibus sniffer was used to capture the
drive data. With this bus module up to 512 analog and 512
digital signals can be read and recorded at 1ms sampling.
Further information?
ibaAnalyzer Showing Load Sharing Before
Configuration for VVVF Profibus Network
Seite 10
Do not hesitate to
contact us:
iba Oceania,
14 Laverick Avenue,
2322 Tomago NSW
Australia
TEL +61 (2) 49648548
[email protected]
www.iba-oceania.com
Hardware
Software
Training
Applikationen
Applikationen
Application
Bucket Wheel Reclaimer Reeler Tuning
Advantages at a glance
■■High speed data acquisition allows for fast and accurate control system analysis and tuning.
■■Data continuously recorded without the need for
triggering. Acts like a “black box” for your drive system.
ibaPDA-V6
Bucket Wheel Reclaimer - image author: Kodda/www.shutterstock.com
Data acquisition with
ibaPDA and EtherNet/IP
an EtherNet/IP interface which allows monitoring of all
the control system variables and drive control signals.
„Virtual“ signals were used within ibaPDA to apply further
processing algorithms to the raw PLC signals.
Convenient and powerful data analysis in ibaAnalyzer
helped to identify existing issues and to remove them.
ibaAnalyzer
The Project
iba Oceania designed and implemented a data logging and
analysis package to assist in fault finding and tuning of
a Reclaimer Reeler control scheme. The Reelers on this
machine had been historically problematic, causing
production delays and damage to the drive system clutches.
The data analysis allowed the engineering team to clearly
identify flaws in the existing control scheme. This allowed
control improvements to be developed offline, designed to
specifically target the issues identified in the data analysis.
The new control program was installed and the iba
system used to assist in commissioning and tuning the
new control improvements. It has resulted in a significant
improvement in machine reliablity and productivity. The
iba system has proved itself to be an invaluable tool for
both engineers and operators to monitor and maintain
their machine.
ibaPDA-Interface
Ethernet IP
ibaAnalyzer Showing Control Output After Tuning
iba Products
ibaPDA-V6 is a PC-based system to centrally record data.
The recording can be made to store data continuously or
event based. The data is stored in so-called DAT-files and
can be analysed, processed and archived with the ibaAna­­lyzer software tool which is free of charge. An efficient
report generator allows for the creation of customized
analytical reports.
ibaPDA-Interface-Ethernet-IP allows for data to be
captured using the EtherNet/IP protocol over TCP/IP for
Rockwell PLCs.
The Technology
The Reelers are driven by VVVF drives, controlled by a
Rockwell PLC. The iba system is connected to the PLC via
Further information?
ibaAnalyzer Showing Control Output Before Tuning
Configuration for iba Data Logging Network
Seite 11
Do not hesitate to
contact us:
iba Oceania,
14 Laverick Avenue,
2322 Tomago NSW
Australia
TEL +61 (2) 49648548
[email protected]
www.iba-oceania.com
Hardware
Software
Training
Applikationen
Applikationen
Application
Finding and correcting
malfunctions in the hot rolling mill
Advantages at a glance
■■Correlations between process malfunctions and
measurements are easier to recognize.
■■Cost savings through targeted malfunction searches.
ibaPDA-V6
ibaPDA
ibaPDA
mit Livebild
process monitoring in a hot rolling mill
Process analysis
with ibaCapture-CAM
The Project
Components in hot rolling mills, where there is the
potential for a malfunction, were to be better monitored
and analyzed through visually recorded images from
process events that are synchronized with corresponding
process data. This allowed a faster process analysis and a
reduction in cost through the removal of malfunctions in
production plant.
iba Products
ibaCapture-CAM is a complete system, consisting of
hardware and software components, for the synchronized recording of visual information and measured data
in cooperation with ibaPDA-V6. The intention is to focus
the video recording on process events of special interest
rather than using the system for general surveillance like
many other video systems. The precise linking of recorded
ibaAnalyzer
The Technology
Visual data from cameras is recorded by the ibaCaptureCAM video server and saved in a compressed form to
the hard drive. With continuous imaging, the fixed drive
storage is cyclically overwritten in a ring buffer. The so
called “video trigger” is configured to start and stop
imaging in specific procedure and sequence events. At
the same time, the storage domains are protected so that
the event triggered video recordings in the hard drive are
not overwritten by continuous imaging. Thus, important
process events are preserved for a long period of time and
available for later analysis.
The supervision of the continuous as well as the event
triggered imaging is taken over by ibaPDA-V6 which is in
constant contact with the ibaCapture-CAM video server
over the network.
The study and evaluation of measurement data and video
sequences takes place in the ibaAnalyzer with the help of
the data files. The video recordings of every camera module can be shown in a dockable window next to the usual
measurement signal curves. The marker position in the
measurement curve and the video image are accurately
synchronized.
Sample
Beispielkonfiguration
Configuration
data and visual information provides an unprecedented
process analysis of high quality because it enables the
user to look at visible process events in the machinery
and the corresponding historical data at the same time on
one screen. Tasks like malfunction and process analysis,
startup, training and documentation of operational procedures are better supported.
Seite 12
Further information?
Do not hesitate to
contact us:
iba AG,
Koenigswarterstr. 44,
DE-90762 Fuerth
PHONE 0911 / 97282-0
MAIL [email protected]
www.iba-ag.com
Hardware
Software
Training
Applikationen
Applikationen
Application
Process analysis
in plants for tube manufacturing
Advantages at a glance
■■More efficient commissioning.
■■Optimization of processes and manufacturing.
■■Guarantee of quality and enhancement of quality.
■■Rise in customer satisfaction.
ibaPDA-V6
iba Products
large-diameter pipes [press photo SMS Meer]
Capturing and analyzing process
data with iba measuring systems
The Project
ibaBM-DPM-S is an interface device for fast data exchange on PROFIBUS DP. The data received by PROFIBUS
are converted and transmitted to the ibaNet FO-cable
interface. Via an ibaFOB input card in the computer, the
data are available for ibaPDA-V6. The ibaFOB-D type input
cards are communication cards for ibaNet FO-cable connections. The cards are used for connecting a computer
to the following iba peripherals: ibaPADU A/D converter, ibaNET750-devices, ibaLink system couplings and
ibaBM-bus modules. ibaPDA-V6 is a Pc-based system for
centrally recording process data. Recording can be done
either with a time/length or batch/product reference. The
measured values are stored as so-called DAT files and
can be analyzed with the ibaAnalyzer (free of charge).
A leading supplier of tube manufacturing facilities wanted
to shorten the commissioning times for his facilities
and enhance product quality. For reaching this goal, he
wanted theoretic models for processes and machines to
be created. In course of a process analysis, we wanted
to gain a clear overview of the running processes and
analyze this actual state for detecting weaknesses and
savings potential. For gaining data that can be compared
to the process models, we needed a system for capturing
process data with a broad scale of analyzing possibilities.
ibaAnalyzer
ibaBM-DPM-S
The Technology
After first tests on an upsetting press, all key machines of
a big plant for tube manufacturing have been integrated.
The iba connectivity allows to interconnect the automation
worlds of different manufacturers. The PROFIBUS sniffer
ibaBM-DPM-S reads measured data from the SIMATIC-S7
and MAC-8 (Bosch-Rexrodt) controls. The computer for
data acquisition contaions an input card of the ibaFOB
family. The data are transmitted via FO-cables to the​
ibaPDA-V6 data capturing software. All important measured values are stored in data files and can be analyzed
with the ibaAnalyzer (free of charge). By comparing actual
and nominal values we can clearly see the optimization potential. With a powerful report generator, you can
create customized analysis reports concerning process
stability, velocities etc. By these improvement measures, satisfaction of the end customers was enhanced as
downtimes were minimized and machine damage could
be prevented.
Sample
Beispielkonfiguration
Configuration
Further information?
Project information
SMS Meer GmbH
www.sms-meer.com
Seite 13
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Applikationen
Application
Training
Optimizing the hydraulic actuator
on a ship‘s drive
Advantages at a glance
■■Detailed analysis of the operating behavior.
■■Precise fault finding by comparing the nominal values from the central ship‘s control.
■■The capturing of nautic signals gives reasons for the
change in nominal values.
ibaPDA-V6
inputs (ibaPADU-8 or ibaNet750). The ibaBM-CAN reads
via the bridge on the CAN-bus several status via the Simatic S7 over ibaPDA-S7-Analyzer (TCP-IP) and nominal
values.
ferry-boat [press photo TT-Line]
CAN-Bus Sniffer
ibaPDA-S7-Analyzer
iba Products
The Project
We faced a challenging task in the field of nautic engineering: optimizing the hydraulic circuit of a ferry ship‘s drive.
First, we had to measure the relevant system signals of
the position changer for the rudders.
The Technology
The positions of the rudders are changed by hydraulic
engines. Electrical motors with an adjustable hydraulic
pump supply these hydraulic engines. For optimizing the
hydraulic circuit, several pressures are read in via analog
The valve blocks are controlled by pulse-width-modulated
nominal values. This is why the ibaPADU-8-M is used. It
records at a rate of 25kHz the power-on and the power-off
cycle of the valves as raw values, which are subsequently
converted via virtual signals into analog signals. As the
communication of the hydraulic system and the control
system runs via a CAN-bus, we use ibaBM-CAN sniffers
for recording data transfer between the systems. Moreover an RS422-interface is used for receiving nautic signals
like position and direction of the ship and wind speed and
direction. These values are provided by an external tool to
the data capturing software ibaPDA-V6. Hence, we can not
only measure the nominal values of the hydraulic systems
but also find the reasons for changes in those values.
ibaBM-CAN
Further information?
Do not hesitate to
contact us:
iba AG,
Koenigswarterstr. 44,
DE-90762 Fuerth
PHONE 0911 / 97282-0
MAIL [email protected]
Konfiguration
Configuration
Seite 14
www.iba-ag.com
Hardware
Software
Training
Applikationen
Applikationen
Application
Monitoring of over stage
machinery functions on an opera stage
Advantages at a glance
■■Detailed Analysis of operational behaviour.
■■Advanced troubleshooting.
■■Remote diagnosis in the event of a malfunction.
ibaPDA-V6
iba Products
State Opera Vienna [press photo Waagner-Biro]
Signal capturing with PADUs
The Project
As global supplier of high-quality stage technology,
Waagner-Biro continuously works on improving their mechatronic systems. For reaching that goal, Waagner-Biro
entered into a working partnership with iba AG, two years
ago. Detailed analysis of stage mechanics in international
opera houses and theatres like the Seoul Arts Center, the
Vienna State Opera or the Darmstadt theatre (Germany)
mainly contributed to innovations in the Waagner-Biro
product range.
ibaPADU-8 is made up of 8 analog and 8 digital inputs.
Each channel is galvanically isolated (potential separation) and has an own a/d-converter. Hence, all channels
can be captured simultaneously. The main advantage is
the positioning of the channels in close proximity to the
sensors. This way, electromagnetic disturbances are
minimized.
ibaPDA-V6 is a PC based system for centralized capturing
and recording of process data. Recording can be done
either with a time/length or batch/product reference.
The measured values are stored as so-called DAT-Files
and can be analyzed by means of the ibaAnalyzer (free of
charge).
ibaAnalyzer
ibaPADU-8
The Technology
Mechanical stage technology comprises all movable parts
on a stage: Flying winches, lighting hoists, draperies for
machinery in the files, lifting podiums and understage
machinery that can be moved at random. The main requirements concerning stage technology are gentle and quiet
movements and a high degree of reliability. Developments
of the past years lead continuously to a more and more
complex stage technology, that has to conform to the
highest safety requirements (level SIL3).
Beispiel-Konfiguration
Sample Configuration
Project information
system integrator for this project:
Waagner-Biro Stage Systems
www.waagner-biro.at
Further information?
Do not hesitate to
contact us:
iba AG,
Koenigswarterstr. 44,
DE-90762 Fuerth
PHONE 0911 / 97282-0
MAIL [email protected]
Upper machinery [Waagner-Biro]
Seite 15
www.iba-ag.com
Hardware
Software
Applikationen
Applikationen
Application
Training
Transient Fault Recording
in HVDC systems
Advantages at a glance
■■Fast fault analysis.
■■Cost savings by precise fault finding.
■■Trend monitoring by database-supported long-time
analysis.
ibaPDA-V6
iba Products
The TFR function has been realized by combining the
following devices and components: industrial computers,
the data recording software ibaPDA with special converters for energy transmission (ibaPADU-16-M), fitted with
modules for current and voltage measuring, ibaNET750ibaAnalyzer
extra-high-voltage converter transformer [press photo Siemens AG]
Transient Fault Recording
ibaPADU16-M
The Project
HVDC (High voltage DC transmission) is the ideal solution
for transmitting high voltages over long distances, e.g. for
supplying Europe with solar energy from the Sahara desert or from underwater cables. The transmission losses
of this way of transmitting energy are much lower than
that of three-phase AC current.
modules for alarm and status reports and the interface
module ibaLink-SM-128V-i-2o for coupling the system
with SIMATIC TDC. Current transformers with an overload
factor of 1/100 at full resolution, developed especially
for the requirements of electrical engineering are worth
mentioning. For analyzing the recorded disturbances, you
can use ibaAnalyzer.
ibaLink-SM-128V-i-2o
Konfiguration
Configuration
The Technology
iba has delivered so-called TFR systems (Transient Fault
Recorders) for several HVDC plants in Asia, Europe and
Australia/New Zealand. In case of disturbances, the
TFR system records all important signals in HD (10-20
KSamples/s). By defining trigger values and events, the
recording can be started very precisely. Each recording
has its own signal selection and assignment of store
profiles.
Further information?
Project information
Siemens AG Energy Sector
www.siemens.de/energy
Seite 16
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iba AG,
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MAIL [email protected]
www.iba-ag.com
Hardware
Software
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Applikationen
Applikationen
Application
The integration of a new
thickness gauge in a legacy system
Advantages at a glance
■■No downtime through parallel operations.
■■Error free toggling through the comparison of old and
new values.
■■Risk-free modernization.
ibaLogic
ibaPDA-V6
hot strip mill [Werner Plass]
ibaLogic as a signal manager
The Project
A new thickness gauge (TMG) was to be put into operation, error free and in parallel to the old thickness gauge.
The old gauge had a serial interface (3964R) and the new
gauge communicates via TCP/IP and hardware connections.
The Technology
For the conversion phase, ibaLogic system was deployed
as a signal manager. All hardware signals were integrated
via ibaPADU modules.
The ibaLogic computer functioned as a toggle switch. In
the „OLD” position, the serial link of the old TMG as well
as hardware signals was connected to the legacy system.
In the „NEW” position, the TCP/IP data from the new TMG
was converted by ibaLogic and marshaled to the serial
interface of the legacy system. ibaLogic recorded the telegrams and signals in corresponding files. With so-called
DAT-files, one could see and compare the old/new values.
Through parallel operations and systematic observations/
comparisons, a commissioning without errors and production interruptions was possible.
iba Products
for integration into existing, heterogeneous automation
structures for modernization.
Because of iba’s interconnectivity, different generations
from different manufacturers can be interconnected. A
bi-directional data exchange enables the communication
between normally incompatible control systems.
ibaPADU (Parallel Analog Digital Unit) is the product
family which measures analog and digital signals of any
process.
ibaAnalyzer
ibaPADU-8
ibaLogic
ibaLogicas
alsa Signalmanager
signal manager
Further information?
ibaLogic is a system for signal processing and automation.
With ibaNet fiber optic cable, all modules from the
ibaPADU family, bus coupler and system interfaces can
be connected. In addition, coupling is available across
the field bus, Ethernet and special protocols. Because of
this characteristic, ibaLogic-V4 is particularly qualified
Do not hesitate to
contact us:
iba AG,
Koenigswarterstr. 44,
DE-90762 Fuerth
PHONE 0911 / 97282-0
MAIL [email protected]
Seite 17
www.iba-ag.com
Hardware
Software
Training
Applikationen
Applikationen
Application
System monitoring
in a paper production facility
Advantages at a glance
■■Improved quality through process optimization.
■■Consistent product quality through continuous quality
control.
■■High levels of system availability through prompt recognition of malfunctions.
ibaPDA-V6
ibaPADU-8
paper manufacture [© Semen Grinberg / PIXELIO]
Process data acquisition
with ibaPDA
The Project
The usage of different machine generations and product
lines from different manufacturers often make it difficult
to identify the source of a malfunction. In a facility which
yearly produces 555,000 tons of paper for newspapers and
magazines out of 100% recycled material, system transparence should be improved.
A measurement system was required to continuously
record process data from the control system and the
drives. It should take data from the drive system ABB and
from the controller Simatic S7. This process data should
be collected and evaluated along with laboratory data and
data from the paper quality analysis (Tapio®.)
iba Products
ibaPDA-V6 is a PC based system for centralized capturing of process data. The capture can be chosen as time,
length, batch or product related. Measurements are
stored as so-called DAT-Files and can be evaluated with
the complimentary ibaAnalyzer.
The bus monitor ibaBM-DDCS captures the system bus
signals from the ABB drives.
ibaBM-DDCS
The Technology
An ibaPDA system was installed. The data from the drive
system was read in with the ibaBM-DDCSM and the
process data was read with ibaPADUs. A specialty of the
PADUs is the fast capture of incremental encoder signals
from all drives in the press and drying sections. Eccentricities and roller abrasions were easily recognized through
a frequency analysis in the ibaPDA. At the control level,
an online surveillance of parameter scenarios render the
automatic generation of warnings and alarms. All vital
information was stored in data files and could be evaluated with the complimentary ibaAnalyzer. A powerful report
generator allows for the creation of custom-made analysis reports (process stability, speed, etc.). For a continued
quality assurance, the ibaDAT-Coodinator can take data
from different systems, process, evaluate and store this
information.
Beispiel-Konfiguration
Sample Configuration
ibaPADU is a product family for measuring analog and
digital signals from any process with sampling rates up to
1kHz. The main advantage lies in its ability to be placed in
the near vicinity of the sensors.
Seite 18
Further information?
Do not hesitate to
contact us:
iba AG,
Koenigswarterstr. 44,
DE-90762 Fuerth
PHONE 0911 / 97282-0
MAIL [email protected]
www.iba-ag.com
Hardware
Software
Training
Applikationen
Applikationen
Application
Plant monitoring
of hot strip production
Advantages at a glance
■■Accessibility of the measurement data throughout the
entire mill.
■■Minimization of machine downtime due to quick error
detection.
■■Trend observations made by means of long-term data
base analysis .
ibaPDA-V6
ibaAnalyzer
hot strip finishing train [Salzgitter AG]
Sniffing on the Profibus
The Project
iba Products
In a hot strip mill, several different measurement systems
were used within plant production areas. A unified measurement system, which enabled the analysis of complex
relationships, was requested. The data obtained was to
be accessible throughout the rolling mill and saved for
long-term analysis and quality evaluations. The control
systems used were Siemens S7 and SMS Xpact.
ibaBM-DPM-S is a fast interface device for Profibus DP.
The device has two modes of operation: sniffer mode and
active slave mode.
ibaLink-SM-128V connects VME bus systems with iba
measurement systems as well as ibaLogic. It has 64
analog plus 64 binary channels over two fiber optic
cables sender links. An additional receiver link with 64 +
64 channels supports communication functions as well
The Technology
Because of the high number of measurement signals,
an analog measuring method was ruled out. With the
Profibus Sniffer ibaBM-DPM-S, up to 512 analog and 512
digital signals can be read per milli-second. Neither the
Profibus nor the S7-CPUs must bear an additional load
because the sniffer module is not an active part of the
bus. It merely listens to the communication between the
automation modules and drive units such as distributed I/
Os. The Profibus data is transformed and sent through the
fiber optic link to a data acquisition computer containing
input cards from the ibaFOB card family along with the
acquisition software, ibaPDA-V6. Data acquisition from
VME bus-based system is carried out via interface board,
ibaLink-SM-128V-i-2o. All relevant data is placed in data
files in their entirety and can be examined and evaluated
with the complimentary ibaAnalyzer. Also, the data can
be archived in an external database for long-term content
analysis.
ibaBM-DPM-S
ibaLink-SM-128V-i-2o
Konfiguration
Configuration für
for Simatic S7
as the expansion of VME systems with iba peripheral
devices. The refresh rate of all signals on the fiber optic
bus is 1ms.
ibaPDA-V6 is a PC based system for centralized capturing and recording of process data. The recording can be
chosen as time, length, batch or product related. Measurements are stored as so-called DAT-Files and can be
evaluated with the complimentary ibaAnalyzer.
Seite 19
Further information?
Do not hesitate to
contact us:
iba AG,
Koenigswarterstr. 44,
DE-90762 Fuerth
PHONE 0911 / 97282-0
MAIL [email protected]
www.iba-ag.com
Hardware
Software
Training
Applikationen
Applikationen
Application
Equipment monitoring
of medium hot strip mill
Advantages at a glance
■■Accessibility of the measurement data in the entire
company.
■■Consistent product quality through continuous quality
control.
■■Optimization of work flow and production processes.
middle strip mill [press photo Siemens]
Database for maintenance
and quality control with ibaPDA
The Project
A manufacturer of steel strip for high dynamic stresses
used a wide variety of data acquisition systems. This
meant an abundance of non-transparent and incomplete
data. 4400 analog and 6600 binary signals were captured
and processed from a total of 140 control systems. A
unified data acquisition system was desired to create a
reliable database for maintenance and quality control.
ibaPDA-V6
ibaPDA-V6.
The ibaLink-SM-64-SD16 module serves as a direct
optical interface of the automation system, SIMADYN, to
the process data acquisition system, ibaPDA. The ibaLinkSM-64-SD16 possesses an optical bidirectional channel
in which 64 analog and 64 binary signals can be sent or
received within 1 ms.
ibaPADU (Parallel Analog Digital Unit) is the product
family which measures analog and digital signals of any
process. The main advantage of ibaPADUs is that they can
be installed in direct sensor vicinity. This reduces the influence of electromagnetic interference to a great extent.
The cards of the ibaFOB family are communication boards
for ibaNet fiber optic cable connections. The ibaFOB-4i-S
board is used to connect a computer running iba software
applications and peripheral devices such as ibaPADU
ibaBM-DPM-S
ibaFOB-4i-D
The Technology
A broad range of interfaces guarantee the connection to
the automation systems from different vendors:
The data from SIMATIC-S7 is read with the ProfibusSniffer ibaBM-DPM-S and the process data from the
roughing and finishing trains are read in with ibaPADUs.
As an interface to the SIMADYN automation systems,
ibaLink-SM-64-SD16 is used. (Cards of this type can be
directly plugged into a Simadyn D rack and behave like
a standard Simadyn D card.) The data is transferred via
fiber optic cable to a data acquisition computer containing
input cards from the ibaFOB card family along with the
acquisition software, ibaPDA-V6. All data is stored in data
files and evaluated with the complimentary ibaAnalyzer.
The ibaAnalyzer-DB-Extractor compresses the DAT-Files
into a database. The result is a central product data information system which covers plant wide networking, from
single machines to cross-plant operations.
iba Products
ibaBM-DPM-S is an interface device which is designed for
high speed data acquisition on a Profibus DP drop. With
input cards from the ibaFOB family, data is transferred to
Konfiguration
Configuration
Further information?
analog to digital converter, ibaNET750 devices, ibaLink
system interfaces and ibaBM bus modules.
ibaPDA-V6 is a PC based system for centralized capturing and recording of process data. The recording can
be chosen as time, length, batch or product related.
Measurements are stored as so-called DAT-Files and can
be evaluated with the complimentary ibaAnalyzer.
Seite 20
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contact us:
iba AG,
Koenigswarterstr. 44,
DE-90762 Fuerth
PHONE 0911 / 97282-0
MAIL [email protected]
www.iba-ag.com
Hardware
Software
Training
Applikationen
Applikationen
Application
Length related data acquisition
in strip processing lines
Advantages at a glance
■■Automatic reporting (e.g. for the end customer).
■■Quality data management for superimposed systems
(MES, DataWarehouse).
■■System optimization through trend analysis.
ibaQDR
ibaAnalyzer
Quality data recording
Quality data recording
with ibaQDR
The Project
Today, quality control is an indispensible component of
the production process. The end customers demand proof
about product quality. The production planning system
requires data for optimum loading and the engineer
needs the data for process optimization. For example,
indications of quality for treated cold strip would be strip
thickness, the plating thickness of the zinc coating, strip
tension, or the course of the temperature during the
annealing process. These quality indications depend upon
the characteristics of the incoming strip and the corresponding process effects of the treatment line.
inspection plants in the metal industry but can be used in
other industry fields as well. Besides the online display
of measured signals, a status window provides detailed
information about which product is at which point and the
data file name.
Measurements are stored as so-called DAT-Files and can
The Technology
With strip processing lines, all quality relevant parameters, which are measured at various points in the
facility, are recorded and assigned to the corresponding
one-meter segment of the finished product. The length
and product related data can then be analyzed with the
complimentary ibaAnalyzer.
With the ibaDat-Coordinator, it is possible to control
further automatic data processing. For example, it can
initiate database extraction with the ibaDat-Extractor or
create reports with the help of the report generator. Naturally, everything is fully automatic.
Example for mapping of measured data to product position (length) in a processing line
Further information?
iba Products
The quality data recording system ibaQDR is a PC based
technology and offers a transparent quality data acquisition with comfortable operation, a wide range of
interfaces and efficient data management. The system
has been optimized for rolling mills, processing lines and
be evaluated with the complimentary ibaAnalyzer.
The ibaDat-Coordinator is an auxiliary program for an
automatic post processing of Dat files.
To date, circa 50 strip processing lines worldwide are
equipped with ibaQDR.
Seite 21
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contact us:
iba AG,
Koenigswarterstr. 44,
DE-90762 Fuerth
PHONE 0911 / 97282-0
MAIL [email protected]
www.iba-ag.com
Hardware
Software
Training
Applikationen
Applikationen
Application
Optimization of wind energy systems
Advantages at a glance
■■Remote control diagnosis upon malfunctions.
■■Possible damage can be prediagnosed.
■■Security and efficiency through the observation of
trends.
ibaAnalyzer
ibaDat-Coordinator
Remote control diagnosis image author: Michal Bednarek / www.shutterstock.com
Condition Monitoring
The Project
Normally, operators of wind parks only have access to
current system data and parameter values. In order to
optimize the system and to diagnose system deviations
and damage, it is useful to consider system data over a
long period of time.
The Technology
ring, chatter monitoring and eccentricity analysis and
control. A synchronization channel on the backplane bus
guarantees that all I/O modules precisely and accurately
function.
The modular concept is based on a component rack with
a backplane bus for the ibaPADU-S-IT processor unit and
For exact information about the current status of a wind
turbine, relevant mechanical (rotational speed, bearing
temperature, main bearing oscillation, etc.) and electrical parameters of the generators (electrical voltages
and currents) are taken. Also of great importance for the
optimal usage of the system is knowledge about the outer
conditions (wind strength and direction) and orientation
of the tower in relationship to the wind. Implementation is
realized through the reading in and saving of (solid state
disk) relevant raw data direct from the tower from pertinent sensors with the help of an ibaPADU-S-IT system.
With the use of a data interface, additional information
from the system controls can be time synchronously
recorded. From the data won forms the basis for special
analysis (order analysis, trend analysis…) calculations.
The data is daily stored on a central data base (server) via
UMTS Router.
iba Products
ibaPADU-S-IT is a powerful CPU designed for fast measurement, signal processing and control. When equipped
with the appropriate I/O modules, the ibaPADU-S-IT is
well suited for a wide variety of applications: for example,
fast drive and position control, machine status monito-
ibaPADU-S-IT
Sample
Beispielkonfiguration
Configuration
Further information?
up to four other input or output modules. I/O modules
for analog and digital input/output, as well as SSI and
pulse generators, are at your disposal. The I/O modules
are available for different signal levels, for voltage and
current signals and for sampling rates at the frequencies
of 1 kHz or 20 kHz.
Seite 22
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contact us:
iba AG,
Koenigswarterstr. 44,
DE-90762 Fuerth
PHONE 0911 / 97282-0
MAIL [email protected]
www.iba-ag.com
Hardware
Software
Training
Applikationen
Applikationen
Application
Load tests for railroad ties
Advantages at a glance
■■Central documentation of the test results and data.
■■Customized analytical reports as proof for the compliance with norms.
evaluation and the representation of the generated data
file is carried out by the free software ibaAnalyzer. With the
report generator, a customized analytical report is made
for every test run. This report also serves to prove the
compliance with norms and specifications.
ibaPDA-V6
iba Products
ibaPDA-V6 is a PC-based system to centrally record process data. The recording can be made referring to either
the time/length or the batch/product. The data is filed as
so-called DAT-files and can be analyzed, processed and
archived with the ibaAnalyzer free of charge. An efficient
report generator allows for the creation of customized
analytical reports.
ibaPADU-8 has 8 analog and 8 digital input channels.
ibaAnalyzer
Test stand for load tests
ibaPADU-8
Data acquisition with
ibaPDA and ibaPADU-8
The Project
iba designed a measuring system for a modern test laboratory with test stands for new rail types, new railroad ties
and rail fastening systems.
Railroad ties have to fulfill various requirements; thus,
they have to withstand the weather, distribute loading, be
sufficiently dimensionally stable and not least affordable
concerning their maintenance.
The Technology
For cyclic flexural and load tests, an oscillating force is
put on the tie by means of a hydraulic cylinder. The force
and position is measured continuously with ibaPADU-8
devices. The devices are connected to an ibaFOB card
which is installed in a PC by means of an optical fiber
cable. The ibaPDA software can collect and process the
data in its own measurement cycle.
Per 1000 test cycles, an average value is generated from
10 measurement cycles. The force and position values
are clearly represented in a coordinate system. Also
statistical information, such as the maximum, minimum,
average value and standard deviation as well as the rate
of change of the flexural force are available by one mouse
click. The values are always calculated for a part of the
curve quickly and freely adjustable with the cursor. The
Measurement report
Further information?
Each channel is galvanically insulated (digital potential
isolation) and has its own A-D converter to simultaneously capture all channels. The main benefit is the extensive
placement in close vicinity to the sensors. Thereby,
troubles caused by electromagnetic radiation can be minimized to the greatest extent.
Seite 23
Do not hesitate to
contact us:
iba Benelux BVBA,
Rivierstraat 64,
BE-9080 Lochristi
TEL +32 (9) 2262304
MAIL roeland.struye
@iba-benelux.com
www.iba-ag.com
Hardware
Software
Training
Applikationen
Applikationen
Application
Data capture in a test bench
for diesel drive systems
Advantages at a glance
■■One system for the entire signal path from capture to
report generation.
■■Individually configurable.
■■User friendly display and input screens.
ibaPDA-V6
iba Products
MTU-Motor [press photo Tognum AG]
Integrated operator concept
with ibaQPanel
The Project
iba supplied to a leader in the diesel motor and drive system industry the measurement and analysis equipment
for a test bench for decentralized energy systems (DieselGen-Set). Besides data capture, the system should
also provide the operator interface for automated tests,
carrying out various analyses and creating test reports.
Above all it should also be easy to use. The purpose of
this implementation was to optimize the complete system
consisting of diesel motor, alternator and closed loop
control and to document defined transients in a report
which would be used later for required certification.
ibaQPanel is a freely configurable visualization program
for the live representation of process and quality data.
For rendering, a choice of display objects is available.
Beside the usual trend curves, bar graphs, 2D false colour
topview charts, FFT analysis and alpha numeric status
indications and others are all available to the user. Thanks
to the possibility to use graphics as backgrounds HMI-like
monitor images can be realized.
ibaPDA-V6 is a PC based system for centralized capturing and recording of process data. The recording can be
chosen as time, length, batch or product related. Measurements are stored as so-called DAT-Files and can be
evaluated with the complimentary ibaAnalyzer.
ibaPADU-S is a powerful modular system designed for
fast measurement, signal processing and control. The
modular concept of this family allows users to combine an
intelligent I/O unit for virtually every task. It is based off of
a component rack with a backplane bus for the ibaPADUS-IT processor unit and up to four other input or output
ibaAnalyzer
ibaQPanel
ibaPADU-S-IT
The Technology
In order to fulfill the project requirements, an integrated control concept compatible with the bench test was
realized with ibaPDA-V6, ibaQPanel and ibaAnalyzer. As
to the optimization, several test cycles are to be run with
varying parameters. If, after some testing, the optimal
behaviour of the system is found this state is documented
in a report which is also used as acceptance protocol. The
data files from the earlier failed attempts can then be
deleted.
The measurement data is captured with a decentralized
measurement unit from the modular family ibaPADU-S
which among other things is equipped with input modules
for high voltages and currents. With the help from the
software ibaQPanel, which is a visualization add-on to
ibaPDA, a user friendly graphic interface and data display
were realized. The electrical values were computed with a
special online function in ibaPDA.
Beispiel
Sample
einerof
Versuchsmessung
an experimental measuring
zur Optimierung
modules. I/O modules for analog and digital input/output,
for different signal levels, for voltage and current signals
as well as SSI and pulse generators, are at your disposal.
Sampling rates of up to 20 ksamples/s are standard.
Seite 24
Further information?
Do not hesitate to
contact us:
iba AG,
Koenigswarterstr. 44,
DE-90762 Fuerth
PHONE 0911 / 97282-0
MAIL [email protected]
www.iba-ag.com
Hardware
Software
Training
Applikationen
Applikationen
Application
Gradually modernizing
automation systems
Advantages at a glance
■■Cost savings by revamping during production without
a line stand-still.
■■Existing software can be transferred, while functionality and response of the plant or line remain the
same.
■■Switching without faults by comparing old and new
values.
ibaLogic-V4
ibaPADU-8
Modernization - now more than ever!
Soft-Revamp with ibaLogic
iba Products
The Project
Especially in times when money is tight, companies
have to ponder carefully which risk they want to take: a
decaying plant that constantly has to fight with system
availability issues or a complete reconstruction with
recommissioning.
Fortunately, there is a golden mean: The so-called SoftRevamp. With this solution, you can take out step by step
single automation functions and realize them subsequently with a new system.
The Technology
As iba designs all system controls to operate bidirectionally, we can not just read values out of an automation
system but also write values in an active way. This is
the main feature used for soft-revamping. The data of
the old system are analyzed by one or more iba system
modules. Meanwhile, the new system gradually takes
more and more of the tasks until the old system is
superfluous.
In older systems, the decentral peripherals can not
be integrated by a field bus. Instead, they use central
input and output groups integrated into the automation
system. Often, these groups when they have been used
for a certain time, cause problems as they show more
and more failures. In this case, we offer a solution: we
establish a direct connection between the iba system
groups integrated in the old system and ibaPADUs or
ibaNet750-heads with intelligent WAGO/Beckhoff cage
clamps.
ibaLogic is a system for signal processing and automation that allows connecting ibaNet fibre optic cables,
bus couplers and other interface connections. Moreover,
linking can be done via field bus, Ethernet and special
protocols. These features make that ibaLogic-V4 is a
great solution for modernizing existing heterogenous
automation structures. With iba connectivity, different generations of automation worlds and systems
of different manufacturers can be interconnected and
combined. Bidirectional data exchange enables the
communication between controls that normally would be
incompatible.
ibaPADU (Parallel Analog Digital Unit) is a device family
for measuring analog and digital signals of any process.
ibaLink-SM-64 and -128V are interface cards:
The ibaLink-SM-64-io module is an interface card adapted to the SIMATIC S5 and Simicro MMC 216 systems.
With this interface card, measuring data are transferred
from a Simatic S5 or Simicro MMC 216-system to
ibaPDA or ibaLogic. The card can also be used for realizing a so-called frame-linking. On its front side, the card
has a pair of FO sender and receiver.
The ibaLink-SM-128V card connects VME bus systems
to iba measuring systems and ibaLogic. It offers two FOcable sending links to 64 analog and 64 binary channels.
With a surplus receiving link with 64+64 channels, the
card offers communication functions. Moreover, VME
systems can be expanded by adding iba peripherals. All
signals in the FO-cable bus have an update rate of 1ms.
The card can be used without initialization. Data (signals)
are directly written into the dualport RAM of the module
and read from there. Hence, you do not need complex
driver interfaces within the VME-bus.
Seite 25
ibaNET750
ibaLink-SM-128V-i-2o
ibaLink-SM-64-io
Further information?
Do not hesitate to
contact us:
iba AG,
Koenigswarterstr. 44,
DE-90762 Fuerth
PHONE 0911 / 97282-0
MAIL [email protected]
www.iba-ag.com
Hardware
Software
Training
Applikationen
Applikationen
Application
Optimization of an exhaust
air treatment adsorber system
Advantages at a glance
■■Simplified start up through on-line changes without
production interruptions.
■■Quick error analysis through integrated data recording.
■■Long term storage in customer’s central databank.
ibaLogic
■■Automatic reporting, for example emission balances .
ibaAnalyzer
adsorber
Revamping with Soft-PLC
The Project
Environmental protection requires special attention in
regard to pollutants. Therefore a modern exhaust gas
cleaning system with the greatest amount of security is a
must; especially in respect to the burden of proof required
by public authorities. Also another economic aspect is
material recovery.
The existing plant had an human-machine-interface
based on an out-dated DOS interface which was afflicted
with errors and often crashed. As to the process controls,
several different PLC systems were used (more than 15
years old). After an analysis of the systems, the operator
came to the conclusion that it made sense to replace the
control system as well as the user interface.
All important data values are stored in data files and can
be evaluated with the complementary ibaAnalyzer. The
ibaDat-Coordinator extracts the data files in an Oracle
databank.
ibaNET750
The Technology
In order to fulfill customer requirements, an existing
exhaust gas cleaning system was to be modernized and
adapted to the flexible and easy to use Soft-PLC ibaLogic
which has an integrated data capture system and long
term archivability.
iba Products
Konfiguration
Configuration
At the heart of the new automation configuration is the
control PC with ibaLogic. This PC takes over the complete
system control and is connected to I/O periphery (WAGO
System 750) through iba interface modules and fiber optic
cables. Modules for digital and analog input/output and
PT100 elements are deployed. Connection over a long distance is not a problem because of fiber optic connection.
The interface with two gas photometers with six channels
is implemented with ibaLogic.
Further information?
Do not hesitate to
contact us:
iba AG,
Koenigswarterstr. 44,
DE-90762 Fuerth
PHONE 0911 / 97282-0
MAIL [email protected]
Seite 26
www.iba-ag.com
Automatisierungswelten
werden transparent
.
iba AG
Koenigswarterstrasse 44
DE-90762 Fuerth
PHONE +49 (0)911 / 97282-0
FAX +49 (0)911 / 97282-33
www.iba-ag.com
[email protected]
Measurement and Automation Systems
www.iba-ag.com
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