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
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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
MES
 Communication Technology



Redundant Profibus PA Fieldbus
Gigabit Ethernet
Wireless LAN
 Web – Technology
 Management Execution Systems MES
A&D AS SM MP
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Automation and Drives
Intelligent sensor- and actor-systems
SIMATIC PCS 7
Introduction
 intelligent
sensor- and actor-systems
often provide additional information
Asset
Asset Management
Management
Profibus PA
redundancy

acoustic pump monitoring

valve diagnostics

internal self diagnosis

........
1 GB Ethernet
Wireless LAN
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
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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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Automation and Drives
Asset Management – Operating & Monitoring
SIMATIC PCS 7
OS
MS
Introduction
OS
OS
MS

...
C1
Asset
Management
Asset Management
(pictures, messages, faceplates)
Cn

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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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
ET 200M
Station
diagnosis symbol
of the component
Web - Technology
MES
Clear hierarchical structure

PROFIBUS
Assets
Plant overview

Overview all controllers

Controller (with sub-hierarchy)

A&D AS SM MP
PROFIBUS Assets

DP station (e.g. ET 200M)

Intelligent field device
Faceplates
for intelligent
device
PCS7_Overview_V6-1_E200502.ppt
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Automation and Drives
Integrated „Plant Asset Management“
Automatic generation of hierarchical diagnostic pictures
SIMATIC PCS 7
Introduction
OS
OS
MS
...
Asset
Management
Asset Management
Profibus PA
redundancy
1 GB Ethernet
C1
S1
AS 1
Cn
...
AS 2
...
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 !!!
Remote I/O
DP/PA - Link
Link Picture
CFC
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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
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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
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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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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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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
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Automation and Drives
Comparison of SCALANCE W / SCALANCE S
Secure
Secure
SIMATIC PCS 7
Introduction
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
EITHER ...
SIMATIC PCS 7
... 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
Security
mechanism
deactivated
VPN
Tunnel
SCALANCE S
SCALANCE
W-700
Ethernet
Ethernet
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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
Field PG with
CP 7515
PROFIBUS
MES
ET 200S
S7-300
Automated guided
vehicle systems
IE Client
Module
SCALANCE
W744-1PRO
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
Monitoring and Control via the Inter- / Intranet
Introduction
Asset Management
Profibus PA
redundancy
1 GB Ethernet
Wireless LAN
Web - Technology
Technology
MES
 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
A&D AS SM MP
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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
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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
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