dt media newsletter february 2011 division drive technologies · simatic pcs7 is the central system...
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DT Media NewsletterDivision Drive Technologies
February 2011
• Modernization of rolling mills for Böhler Edelstahl in Austria• Achieving greater success with maintenance data • Siemens modernizes the drives in three copper ore crushing mills for Rio Tinto• CNC training partner certifi ed by Siemens• Switch to high-effi ciency motors• Dates
Division Drive Technologies
DT Media Newsletter February 2011
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The Siemens Industry Solutions Division starts into
the New Year with an extensive modernization pro-
ject. Until end of 2011 the company will install new
drive and automation equipment on the continuous
rolling mill in the multiline rolling mill and the plate
rolling stand of the blooming mill. The goals of the
modernization project are to reduce energy and
media consumption, widen the range of products,
and improve their quality still further.
Böhler Edelstahl‘s multiline rolling mill in Kapfenberg
has been in operation since 1988, at which time it was
one of the world‘s most modern plants. Siemens will
install a digital control system with Simatic S7-400
programmable logic controllers to bring the automation
in the plant up to the state of the art. A “RollMaster”
specially developed for long product rolling mills will
handle the generation and management of the pass
schedules. This software is the link between the pro-
duction planning system and the plant automation.
The existing hydraulic drive trains will be replaced by
controlled, water-cooled three-phase asynchronous
motors, including gearboxes, couplings and cardan
shafts. The drives will be fed by frequency converters
from the Sinamics product family, configured as
multi-motor drives. This will facilitate precise, highly
dynamic control of the rolling stands and enable Böhler
Edelstahl to extend its range of products and further
improve their quality. The elimination of the hydraulic
systems will reduce the cost of maintenance and incre-
ase plant availability which, in turn, will also increase
the productivity of the rolling lines. The energy requi-
rement will fall by many thousands of megawatt hours
per annum, and the consumption of hydraulic oil and
cooling water.
Siemens will also renew the auxiliary drives on the
continuous rolling mill, and the uninterruptible power
supply (UPS). The scope of the modernization project
also includes equipping the plate rolling stand of the
blooming mill with a new 3.3 megawatt main drive.
Siemens will also be responsible for the installation of
all the electrical systems and the commissioning of the
rolling lines.
Böhler Edelstahl GmbH & Co KG is one of the world‘s
most important producers of high-speed steel, tool
steel and special materials. The multiline rolling mill
produces bar, round and flat steels, as well as wire.
Further information about solutions for steel works,
rolling mills and processing lines is available at:
http://www.siemens.com/metals
Siemens to modernize rolling mills for Böhler Edelstahl in Austria
Division Drive Technologies
DT Media Newsletter February 2011
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Achieving greater success with maintenance data
Efficient condition monitoring of machine tools is
an indispensable part of a fully streamlined produc-
tion system today. The ePS Network Services from
Siemens offer a high-performance condition moni-
toring system, whose core functions are now also
available during operation without online connec-
tion to locally hosted servers.
Machine tool maintenance is becoming increasingly
important for a cost-effective production process in
terms of productivity, supply capability and competi-
tiveness. Downtimes must be minimized, while a high
level of availability and manufacturing precision must
be guaranteed over long operating periods. For the
maintenance team this presents a major challenge that
can, however, be met by means of efficient condition
monitoring.
Continuous condition monitoring is useful for gaining
reliable information on the current condition of the
machine. It helps to determine maintenance and spare
parts requirements at an early stage, which prevents
prolonged downtimes, particularly in the case of un-
scheduled outages. In normal operation too, condition
monitoring can provide detailed verification of manu-
facturing precision, enabling conclusions to be drawn
about the ageing behavior of the plant and supplies
information on special design requirements placed on
new machinery. This enables hidden potential for im-
provement to be discovered and integrated accordingly
into the design proces.
In practice a great number of demands are made on
high-performance condition monitoring. On the one
hand, the tests required for maintenance must not af-
fect the production procedures. On the other hand, the
flood of data must be edited and compressed in such a
way that it is of value to and can be utilized by the com-
pany. The products available on the market differ from
each other in this respect.
The ePS Network Services from Siemens are the gate-
way to efficient and practical condition monitoring. The
system guarantees a comprehensive functionality and
a fully integrated approach. Condition-based preven-
tive maintenance is linked to the provision of up-to-
date operational metrics, thereby improving planning
reliability and cost control for the production facility.
Whereas the system could previously only be used as
an online service, Siemens has only recently made it
available as a purely local installation for the machi-
ne operator: eP-Satellite offers the option of hosting
data and functions locally and is primarily intended for
manufacturing facilities that require no online con-
nection of their production resources. The integration
of both versions of the ePS Network Services in the
CNC is always seamless, because even controllers from
third-party suppliers as well as external sensors can be
integrated into the condition monitoring system thanks
to the vendor-independent OPC interface. In this way,
Siemens ensures that a single, uniform software system
offers maximum inter-compatibility for the monitoring
and maintenance of all relevant machines in a produc-
tion plant.
Division Drive Technologies
DT Media Newsletter February 2011
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Siemens modernizes the drives in three copper ore crushing mills for Rio Tinto
The mining company Rio Tinto has commissioned
Siemens Industry, Inc., to modernize three SAG
mills in its Kennecott copper mine in Utah, USA. The
DC drives will be equipped with new control and
automation technology. Together with enhanced
diagnostic features, the modernization ensures
operational reliability and availability of the plant
while at the same time the maintenance costs can
be reduced. Retaining the power section of the
rectifier is the key feature of the modernization con-
cept developed by Siemens, leading to significantly
reduced investment cost for the modernization. The
modernization project will start in early 2011 and
will be finished in the beginning of 2012.
The three mills equipped with Twin Pinion DC motor
systems installed in the Kennecott Mine in 1998 will
be equipped with a new control system. The system is
based on Simatic S7 for the general control of the mill
and a Sinamics DCM converter for the drive specific
control of the rectifier. Thanks to the modularized
concept of Sinamics DCM to implement control and
power section separately, a modernization concept
was designed where the power section of the existing
rectifier remains in operation. Together with the
possibility to also retain transformer and motor, in-
vestment cost for the modernization can be reduced
significantly and the length of the shutdown period is
minimized.
Simatic PCS7 is the central system for all visualization
and diagnostic tasks for all three mills. The scope of
supply also includes an additional diagnostic system
for enhanced diagnostics, as well as operating data
acquisition and remote service features: This will
enable unplanned shutdowns to be largely avoided
and maintenance costs to be reduced. Siemens is
responsible for the hardware and software engineering
including installation and commissioning at site.
The Kennecott Bingham Canyon Mine run in Utah by
Rio Tinto is one of the world‘s largest copper mines.
In addition to copper, it also extracts gold, silver and
molybdenum. There are four SAG mills with Siemens
drives working in the mine.
Further information about solutions for the mining
industry can be found at:
http://www.siemens.de/mining
Division Drive Technologies
DT Media Newsletter February 2011
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The Institute for Economic Advancement of the Upper
Austrian Chamber of Commerce (WIFI OÖ) in Linz is
now an official „Siemens CNC Training Partner“ for
the training courses Operation and Programming of
ShopMill, Operation and Programming of ShopTurn
and Programming of Sinumerik DIN/ISO – making
it the first CNC Training Partner in Europe outside
Germany to be certified by Siemens. On January 12,
2011 Erich Döberl, Head of Training for CNC technology
at WIFI OÖ, accepted the certificate from Austrian
Sinumerik Training Adviser Andreas Göstl. In order
to extend the certification on a regular basis, the
instructors in Erich Döberl‘s department will have
to attend an annual refresher course at the Siemens
Technology and Application Center (TAC) in Erlangen.
WIFI OÖ is one of the largest professional training centers
in Europe, offering over 7,000 courses to more than
75,000 participants each year. These include more than
30 apprenticeship and adult training courses for CNC
machining technicians each year. The CNC workshop in
Linz has numerous machine tools, including two CNC
horizontal machining centers (Emco MaxxTurn 45), for
the efficient production of complex turned and milled
components with the maximum thermal stability,
machining accuracy and rapid traverse velocity. Both
machines are equipped with SINUMERIK 840D sl
(Solution Line) controllers and the fully graphical ShopMill
and ShopTurn programming software. Programming
with ShopMill or ShopTurn ensures maximum efficiency
with extremely short programming times, especially
when manufacturing individual parts and small batch
sizes.
WIFI OÖ has about 20 PC training terminals at which
the Sinutrain training software is used for accurate
control simulation. This means that programs can
be written on standard PCs without additional CNC
hardware, then transferred directly to the machine
and processed.
First CNC training partner outside Germany: Siemens certifies the Institute for Economic Advancement of the Upper Austrian Chamber of Commerce
Sinumerik Training Adviser Andreas Göstl (right) presents the certificate to Erich Döberl, Head of Training for CNC Technology at WIFI OÖ
Division Drive Technologies
DT Media Newsletter February 2011
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As from June 16, 2011, minimum efficiency class IE2
will become mandatory in the European Economic
Area. After this date, manufacturers are only per-
mitted to ship high-efficiency motors. The EU Direc-
tive 640/2009 applies to low-voltage asynchronous
motors between 0.75 kW and 375 kW. From January
2015, efficiency class IE3 will become mandatory
for the power range between 7.5 kW and 375 kW.
Alternatively, an IE2 motor with a frequency converter
can be used.
For further information, go to:
http://www.siemens.com/press/de/index.php?id=68316
1. 3. - 4. 3. 2011
Intec, trade fair for manufacturing, machine tools
and special-purpose machine manufacturing, Leipzig
http://www.messe-intec.de
15. 3. - 19. 3. 2011
ish, the world‘s leading trade fair for bathroom
design, building systems, energy and air-conditioning
systems and renewable energies, Frankfurt/Main
http://www.ish.messefrankfurt.com
About 100 days to go: switch to high-efficiency motors
DATES
Division Drive Technologies
DT Media Newsletter February 2011
Media Contact:
The Siemens Industry Sector (Erlangen) is the world’s
leading supplier of environmentally friendly produc-
tion, transportation, building and lighting technolo-
gies. With integrated automation technologies and
comprehensive industry-specific solutions, Siemens in-
creases the productivity, efficiency and flexibility of its
customers in the fields of industry and infrastructure.
The Sector consists of six divisions: Building Technolo-
gies, Drive Technologies, Industry Automation, Industry
Solutions, Mobility und Osram. With around 204,000
employees worldwide(September 30), Siemens Indust-
ry achieved total sales of approximately €34.9 billion in
fiscal 2010.
www.siemens.com/industry
The Siemens Drive Technologies Division (Nurem-
berg) is the world‘s leading supplier of products, sys-
tems, applications and services for the entire drive train
with electrical and mechanical components and motion
control systems for production machinery as well as
machine tools. Drive Technologies serves all segments
in manufacturing industry, process industry and ener-
gy/infrastructure. The Division addresses key customer
requirements in terms of productivity, energy efficiency
and reliability. With around 36,000 employees of the
Division (September 30), achieved total sales of €7.0
billion in fiscal 2010.
www.siemens.com/drivetechnologies
Siemens Industry Sector
Drive Technologies
Julia Kauppert
Phone +49 (0)911 - 895 7952
Siemens Industry Sector
Drive Technologies
Franz-Ferdinand Friese
Phone +49 (0)911 - 895 7946
The Industry Sector and Drive Technologies Division in brief