astra body shop

Safety Integrated for the Automotive Industry

smoveupDistributed SafetyConcept at BMW

DaimlerChrysler:from Profibus to Profinet Safety

May 2004

Play it Safewith PROFIsafePlay it Safewith PROFIsafe

Distributed SafetyConcept at BMW

DaimlerChrysler:from Profibus to Profinet Safety

move up Safety Special May 2004

2

9 14 18

Industrial Ethernet and Profisafe are validatedfor the new automation standard integraMCG atDaimlerChrysler AG

The conveyor technology in the “New PaintshopStructure” (NLS) at BMWhad been extensivelymodernized with Profisafeand failsafe Simatic S7

CONTENTS

The first automation and safety project based onSafety integrated technology was recentlyimplemented at Opel Belgium

movePowertrain

12 A Fresh Way of Thinking …Safety Integrated in the steering knuckleassembly at Opel

Paintshop14 Seam Sealing Safe and Sound

Integrated safety technology: from Profisafe to Profinet Safety

Failsafe controllers16 A Safe Bet for Increasing Production

Toyota, Cambridge (Canada), with future-oriented safety technology

Failsafe controllers17 Toyota Mini-Van Production Failsafe

Simatic failsafe technology to becomecompany-wide standard in body shop

3 EDITORIAL

TRENDSSafety technology today

4 New Roads to SafetySafety Integrated: State of safetytechnology in automation

CASE STUDIESSimatic safety systems

6 New Safety Technology for FordBody Sub Assembly FacilitiesSix robot welding cell at Ford Geelongwith Simatic S7-400F safety systems

Simatic controller fail-safe9 Safety at Body Shop

Opel Belgium, Antwerp: Safetyintegrated technology forges ahead atOpel body shop

Cover:©Opel Antwerp

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22 The modern world of industry is becoming moreand more automated so that the protection fromdangers caused by malfunction or human error isgaining increasing significance.

The subject of safety has since become part ofevery technical discussion concerning theautomotive industry. The emphasis here is on theprocessing of safety-oriented signals, e.g. via fieldbuses like Profibus. The crux for many users is stillthe question of how the high safety standard canbe maintained when devices, components,systems and plants are networked. But separatesafety-oriented controls and bus systems are nolonger necessary. Safe programmable controllershave established themselves in recent years andSiemens has been offering standard controllerswith integrated safety functions for the last fouryears. Using the Profisafe profile, the same Profibuscan be used for transmitting safety data as for therest of the data transmission. The advantages areobvious: Integration of safety in the controltechnology which you need anyhow. All in all thistechnology allows technically and economicallyoptimized, fine scalable system solutions.

In the meantime the consistent use of Profisafehas established itself as the technical, economicaland of course safest solution with almost allautomotive companies. In this special issue ofmove up you can read how to be “on the safe side”with Safety integrated and Profisafe!

EDITORIAL

“On the Safe Side” with PROFIsafe!

The latest EMU plant in MAGNA-STEYR’spaintshop is equipped with failsafe Simatic S7-400F

eupDistributed safety solution in the paintshop

18 The Paint is “Safe”!Conveyor technology for the paintshop at theBMW factory Regensburg equipped with Profisafe

Failsafe automation22 F-Controller Goes it Alone

Failsafe Simatic controls complete emu plant at MAGNA STEYR

Rainer FrießCompetence Center AutomotiveSiemens AG

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4Safety technology today

TRENDS

Peter Weiß, TÜV Automotive GmbH,Automation, Software and Electronics,Munich and Howard T. Cox,Underwriters Laboratories Inc., USA:

“In September 2002, TÜV AutomotiveGmbH in Munich was commissioned bySiemens AG to test and certify the ‘S7 Dis-tributed Safety’ fail-safe automation sys-tem in accordance with the new 2002 edi-tion of NFPA 79 and other standards rele-vant to its use in the US and global markets(NFPA 85, UL 508, UL 1998, UL 991).

TÜV Automotive GmbH, part of TÜVSüddeutschland (TÜV = German Technical

Simatic S7 Distributed Safety certified by TÜV and UL in accordance with NFPA 79

“Fail-safe Automation System in Accordance with NFPA 79”

Simatic S7 Distributed Safety

The fail-safe Simatic S7 Distributed Safetysystem consists of F-capable centralprocessing units and fail-safe distributedand centralized I/O modules based onPROFIsafe Communication as well as the‘S7 Distributed Safety’ option package.

Supervisory Authority), and its Americancounterpart, Underwriters LaboratoriesInc. (UL), collaborate closely in this areaand have jointly developed an acceptanceinspection and testing procedure. Suc-cessfully completed certification in accor-dance with IEC 61508 is a basic prerequi-site for testing in accordance with NFPA79. The product documentation of themanufacturer serves as the basis for thetechnical briefing which ensures that Ger-man and American testers start off withthe same level of knowledge. After this, allthe requirements of NFPA 79 that are rele-


Safety Integrated: State of safety technology in automation

New Roads to SafetySafety Integrated: State of safety technology in automation

New Roads to SafetyTo effectively prevent accidents and the resulting injury and damage to man and machine due to technical malfunctions,reliable safety systems are urgently prescribed. Since the standards for electrical equipment of machines were modified,safety functions can now also be realized by programmable electronic systems and field buses which safely connect thesensors and actuators. A similar adaptation of the specifications for the world market is further promoting developmentsat all levels of safety technology. The latest state of affairs in safety technology is best reflected in the three followingexpert statements: Roman Wunschik on AS-Interface Safety at work, Herbert Barthel on Profisafe and Peter Weiß fromTÜV Automotive GmbH and Howard T. Cox of Underwriters Laboratories Inc., USA, on certification of the failsafe SimaticController.

Contact:[email protected]@us.ul.com

vant to programmable electronic systemsare checked against a detailed checklistand conformance with the standard isthen confirmed by means of a certificate.

The Simatic S7 Distributed Safety sys-tem has successfully completed all thetests and is thus the world’s first fail-safeautomation system that can be used world-wide for purposes of machine safety.” ■

The fail-safe ‘Simatic S7 DistributedSafety’ system is the first system of itskind in the world to be certified accordingto IEC 61508 and NFPA 79


5

move up Safety Special 2004PublisherSiemens Aktiengesellschaft, Bereich Automation and Drives (A&D), Gleiwitzer Str. 555, 90475 Nuremberg, Germany

www.siemens.de/automation

Group Executive ManagementHelmut Gierse, Anton. S. Huber, Alfred Ötsch

Editorial Responsibility in Accordance with the German Press LawPeter Miodek

Responsible for Technical ContentsThomas Schott

Internal editors:Kathrin Brä[email protected]ürgen [email protected]

ConceptChristian Leifels

Publishing HousePublicis KommunikationsAgentur GmbH, GWA Corporate Publishing ZeitschriftenP. O. Box 3240, 91050 ErlangenTelephone +49 (0) 9131 / 91 92-5 27Telefax +49 (0) 9131 / 91 92-5 [email protected]

Editorial staff:Dr. Beate Bellinghausen (editor in chief), Robert Engelhardt, Christoph Manegold,Kerstin Purucker

Layout: Axel Kornemann, Reinhard Sorger, Jürgen Streitenberger, Werner Völkl

Copy editors: Regina Severing, Olaf Wolff (copy chief),Irmgard Wagner, Sabine Zingelmann

DTP: Döss Prepress, Nürnberg

Printed by: Stürtz AG, Würzburg

Circulation: 3,000

© 2004 by Siemens Aktiengesellschaft Munich and Berlin. All rights reserved by the publisher

This edition was printed on environmentally-friendly chlorine-free paper.

The following products are registered trademarks of Siemens AG:MOBY, SICALIS, SIMATIC (S7-200, S7-300, S7-400, ET 200), SIMATIC HMI, STEP, TIA, Touch Panel 270

If trademarks, technical solutions or similar are not included in the list, it does not imply that they are not protected.

The information provided in this magazine containsmerely general descriptions or characteristics ofperformance which in case of actual use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristicsshall only exist if expressly agreed in the terms ofcontract.

Order No.: E20001-M4504-B100-X-7600

Printed in Germany

“The official launch, i.e. the presentationof products and systems for the Profisafeprofile, came at the Hanover trade fair in2002. At the Profibus users organization(PNO) booth, we were able to present acomprehensive range of safe devices, withwhich decentralized automation solutionscan be realized without a separate safetybus.

The range of products that use theProfisafe profile is increasing steadily asa result, and there are now also numer-ous applications, in which Profisafe hasproven the readiness to use. Such diversesystems as laser scanners, programma-ble logic controllers and safe I/O systemsare all using Profisafe – also integratedmotor starters are available, which up un-til a few years ago would have been total-ly inconceivable without a safety bus.

Last fall, the PNO then presented ver-sion 1.20 of Profisafe, which includes a more detailed specification of theProfisafe controller’s software interface.Recently, the PNO’s Profisafe workinggroup has also drawn up standards andguidelines for important issues such as

electromagnetic compatibility and thejoint operation of ‘standard’ Profibussubscribers and Profisafe devices.

Meanwhile, in terms of configuration,commissioning, diagnostics and mainte-nance, Profisafe has reached the samelevels of convenience and functionality as the ‘standard’ Profibus. At the 2004Hanover trade fair, we will be presentingthe latest expansions and options to theaudience.” ■

Profibus user organization believes Profisafe is heading in the right direction

“We Will Expand theFunctionality evenFurther”

More information:www.siemens.com/safetywww.as-interface.comwww.profibus.com

Contact:[email protected]

Herbert Barthel, Siemens AG, Nuremberg

and Chairman of the PNO Profisafe working group

6Simatic safety systems

CASE STUDY

Six robot welding cells at Ford Geelong with Simatic S7-400F safety systems

New SafetyTechnology for FordBody Sub AssemblyFacilities

The safety systems for the recent Body Sub Assembly robotwelding cells at the Ford plant in Geelong are implementedusing Simatic Failsafe PLC technology and PROFIsafe. Effectiveuse of Profibus distributed components has resulted in cellswith a minimum of discrete components, a minimum of fieldwiring and excellent diagnostics. New cells under constructionare taking advantage of the recently released DistributedSafety CPU with safety logic configuration in Ladder.

Made down-under: The Falcon is totally Australiandesigned for the local market

7

neers to the selection of the SiemensSimatic product range. The selection ofsafety system technology was then thenext consideration. Having traditionallyutilised a combination of hardwired tradi-tional safety relays to implement the cellsafety, Ford investigated concepts for useof the then newly released S7-400F Fail-safe PLC as an alternative to the relativelycomplex safety relay circuits traditionallyemployed. This concept design was assist-ed by Industrial Control Technology PtyLtd (ICT) (the local Siemens SolutionProvider), in conjunction with SiemensAustralia, and a specialist from theSiemens Automotive Competency Centrein Germany.

The result was an elegant design con-cept which could be applied uniformlyacross the 6 new cells which were to bebuilt, and which eliminated a large per-centage of the contactors, relays and com-plex interconnecting wiring which werepreviously required. Safety functionalitywas also able to be improved relative toearlier cells, plus more safety facilities and

automatic checks added. These facilitiesin particular make maintenance and setup operations easier and safer. Detaileddiagnostics from the touch panels stream-line troubleshooting operations.

Robot welding cells

The Body Sub Assembly cells are primari-ly for robot welding. Pressed metal partsare typically loaded at operator stationswhere they are spot welded and in somecases transferred by the robot to other fix-tures for further operations. Ford engi-neers have utilised the Simatic HMI andProfibus distributed I/O technologies tomaximum advantage in the design ofthese cells. Robots are interfaced via directProfibus Interfaces, providing fast andconvenient data exchange. Solenoidvalves and proximity switches associatedwith the fixtures are connected via Festovalve blocks on Profibus. Operator sta-tions typically utilise the PP17 operatorpanel for clear and robust operator inter-action, whilst a touch panel provides ac-cess to production statistics and diagnos-

Ford Australia is enjoying broadpraise, industry awards and ahealthy order book for its recently

released new model Falcon. The BA Falconreleased in October 2002 is a large 6 cylin-der family car and is totally Australiandesigned and manufactured at the Fordplants in Victoria.

The facilities for manufacture of theBody Sub Assembly components are atGeelong, south west of Melbourne. TheGeelong plant has used a variety of PLCsin the past, and the commencement of de-sign of facilities for the new model saw areview of available automation technolo-gies to select an automation platform forthe future. Ford were looking for a plat-form which would be flexible, simple fortheir electricians to program and trou-bleshoot, and which would integrate read-ily on a “Field Bus” with third party com-ponents such as robots and valve blocks.

Siemens Simatic selected

Detailed investigation and review ulti-mately led the Body Sub Assembly engi-

PP 17

RobotET 200 M

PP 17

S7-400

Profibus DP

TP 27TP 27

Festovalve blocks

Festovalve blocks

Configuration of a robotwelding cell with failsafeSimatic S7-400F

8 CASE STUDY

tic information. On the larger cells, anMP370 touch panel provides productionstatistics and diagnostic information ad-ditionally at a central location. The excel-lent quality graphics on these panels hasalso allowed the recent introduction ofphoto images of the fixtures with thedynamic status of clamps and proximityswitches superimposed. This promises tobe an excellent method of clearly pre-senting diagnostic information to an op-erator.

Menu screen from MP370 Touch Panelon robot welding facility

The automation of the cells is controlledby Standard (non fail safe) Ladder code inthe S7-400F which interacts closely withthe programs in the robots. Ford person-nel program the robots according to theprocess requirements and to interface tothe supervisory PLC. Development ofstandard code for the PLC has been donein most cases by ICT in close collabora-

tion with Ford. Ford personnel have im-plemented later cells in-house.

Safety systems

The safety systems of course represent acritical component of these cells. As pernormal practice, a perimeter safety fencesurrounds each of the cells. Light guardsprotect operator stations where parts aremanually loaded, while a Two Hand Con-trol facility allows a part to be pre-clamped while the operator remains in-side the area protected by the light guard.Robot base switches monitor the orienta-tion of the robot to allow access to one fix-ture while the robot is working at the oth-er. Light guards also protect forklift accesspoints where finished parts on pallets areunloaded via forklifts.

Safety interlocks act on the Robot, fix-ture solenoid valves, servo turntabledrives and an overall air dump solenoidvalve, according to signals including lightguards, access gate and Emergency Stop.

More information:www.siemens.com/safety

Intuitive operatingscreens on theSimatic TP 27Touch Panels

The highresolutiongraphics of theTP 27 TouchPanel showsreal-life photosof the fixtures

Simatic safety systems

The electric lock on the access gate is alsocontrolled by the safety PLC.

All of these safety functions are imple-mented via the S7-400F Failsafe PLC. Theirimplementation in software has led to adramatic simplification of the cabinetwiring, and a more satisfactory imple-mentation of the required safeguardinglogic. New maintenance functions havealso been added which would have beenimpractical in the previous hardwired sys-tem. Diagnostic functions at the touchpanels provide detailed information re-garding the safety system status as well asfault diagnostic information to the pointlevel. This aims to simplify maintenanceby avoiding the need for personnel to ac-cess the PLC for troubleshooting. Failsafecode for these PLCs has been implement-ed and tested by ICT, although Ford re-tains a close involvement in system con-figuration and overall software structure.

A key consideration for Ford was to beable to “lock away” the safety functions,while retaining free access to the Standardcode. This is important as changes and ad-ditions to the process occur from time totime, whilst the safety functions typicallyremain fixed. This was readily achievedwith the S7-400F, allowing the Ford elec-tricians to modify the Standard code with-out affecting the Failsafe code.

Distributed safety

The recent release of the Distributed Safe-ty system programmed in Ladder hasbeen well received by Ford personnel. Theprogramming of Failsafe logic in Ladder isseen as a simpler alternative to the CFCused by the earlier S7-400F system andwill be adopted for all future systems.Ford have in fact commented that theS7315F PLC is an extremely cost effectiveand powerful CPU and indicate that theyare likely to use it with safety I/O even forsmall machines which would have re-quired even only one or two safety relays.Five new cells have recently been com-menced for a new vehicle which is cur-rently under development. These cells willuse the S7-315F Distributed Safety PLC forall automation and safety tasks. ■


9CASE STUDYSimatic controller fail-safe

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Opel Belgium, Antwerp: Safety integrated technology forges ahead at Opel body shop

Safety at Body ShopOpel Belgium N.V., the major Opel site at the Port of Antwerp and one of thejewels in the crown of the Belgian car assembly plants with a reputation for highquality, currently produces different versions of the Opel Astra model. The endproduct finds its way to more than a hundred international destinations from the Port of Antwerp. The observant visitor will notice that quite a few Astra carbodies on the production line have a dashboard with the cavity for the steeringmechanism on the right hand side … B

The first automation and safety proj-ect based on safety integration tech-nology was recently implemented

at Opel Belgium. This consisted of closecooperation between the local Opel engi-neering team, safety consultants CardoenIndustries, system integrator Imtech Bel-gium Projects, and Siemens Automation &Drives who, as system supplier, also im-plemented the first system and acted asconsultants.

Francis Luyckx, responsible for engi-neering at the Opel Belgium body shop,sketched the scene. In the body shop, po-tentially dangerous machines and con-veyance systems comprising robots andconveyors are made safe by cages, light cur-tains, safety switches and emergency stops,but are still controlled by old-fashioned re-lay connections.

Francis Luyckx says: “This was a doubleproject: a new robot welding line that need-ed a control and safety system, and an exist-ing “traditional” control and safety systemthat needed to be replaced. This old installa-tion based on relay technology had already

been upgraded quite a few times, and couldno longer accommodate the latest safetymechanisms and the required additionalsafety functions.”

The combination of new standards andfunctionality, particularly in terms of de-tailed and reliable fault reporting, wouldalso have to comply with modern economiccriteria: easy expandability in future andreasonable life cycle costs.

According to Francis Luyckx: “The com-parison between a system with separatePLC for control and relays for safety on theone hand and a real “failsafe” PLC on theother, was soon made: the latter system ismore flexible and reports on faults rightdown to the last wire! What’s more, it’sbound to be more cost-effective.”

The almost obvious choice …

“We selected the Siemens solution in par-ticular based on very clear motives. Forone thing, Opel engineering is alreadyextensively tailored to the Profibus fieldbus. Besides positive experience, we also

CASE STUDYSimatic controller fail-safe

10

Assembly ofthe trunk lid

Rework in the metal finish department


11

form tests. Francis Luyckx, says: “Every-thing at that level that can be performedoff-line and therefore beforehand, is toour benefit.”

Further refining

Now there is even more extensive integra-tion of safety functions on the wish list.Fault reporting is the most prominent.The intention is to generate fault reportson the operating consoles (HMI panels)simply by using standard parametricSiemens software. Another benefit is thatthe Opel engineers can now also imple-ment other forms of safety intelligence,for example controlling the muting func-tions (programmed and safe suppressionof safety functions, required for the nor-mal run of production) when using safetylight curtains.

Erik Moons, Opel Engineering, alsopointed out the e-mail card that is in thefailsafe PLCs: “The central Opel safetyservices now have – as required – a newoption to monitor the safety software. Ifthe latter changes, an e-mail message isautomatically generated and sent to thesafety service.”

Siemens Automation & Drives saw tothe commissioning and programming ofthe first failsafe PLC installation. Systemintegrator, Imtech, was responsible forthe second one – independently and with-out problems. Wim Van Goethem, projectengineer at Imtech Belgium Projects, said:“A course presented by Siemens providedthe basic knowledge needed for the over-all programming and implementation torun smoothly. We had a permanent fall-back solution by means of a continuouspurging and back-up procedure in ourplanning. That proved to be a luxury evenin the period at the end of the year andwith a tight implementation schedule …”

The findings of the Opel team after twomonths' use speak for themselves. FrancisLuyckx says: “The system was started upand we just about immediately forgotabout it, because it was working well. Wedid not experience any problems. Al-though we have to get used to the newphilosophy: safety is actually integrated

Simatic S7-416F

into this system. Before, the safety func-tions were build up with hardware. Nowthey are incorporated and although weknow that, there is sometimes still the re-flex to want to see everything separately.We actually want to see the separate hard-ware functions in the software.”

On the shop floor

Both failsafe PLC systems are installed inthe metal finishing department where fin-ishing work is carried out on the basicbodywork. One unit provides the func-tions for stud welding and the conveyorsystem where assembly of the trunk lid or tailgate takes place, depending on thetype of vehicle.

The second PLC assists with finishing,careful polishing and visual checking ofsurface quality, as well as the fitting. Thatincludes fitting the doors into the dooropenings and opening the trunk lid be-fore the car body glides into the paint tun-nels. Both systems require extensive andcomplicated conveyance, and a lot of spe-cialized human work also takes place inthe area, resulting in many potentiallydangerous movements having to bescreened off.

Francis Luyckx says: “Physical safetymeasures consist of emergency stopchords, emergency stop buttons, lightcurtains with or without muting func-tions, screens for lift apertures, classicalsafety cages with safety catches, etc. It is a complex scenario, but the failsafe PLCcontrols it all and communicates with theordinary control systems via Profibus-DP/DP couplers. We hope to take it onestep further later this year; complete inte-gration of both the failsafe and the stan-dard control system in one PLC.” ■

Safety: before …

… after

gained a huge amount of internal know-how. Now that we have access to recentsafety integrated technology via Siemens,the choice is obvious: the failsafe PLC, acontrol unit with completely integratedsafety functions. Open for all future au-tomation developments.”

Opel Belgium of course sees the bene-fit of the Totally Integrated Automationconcept because of the specific character-istics of this enormous assembly plant.Endless preparation cells and typical sup-ply systems for the assembly line of theOpel Astra demand smaller, decentral-ized automation units. There are numer-ous practical benefits: flexibility, shortercables, extensive network possibilitiesand integration on Profibus, and – just asimportantly – the necessary time to per-

More Information:www.siemens.com/safety


12Powertrain

CASE STUDY

… for enhanced safety. According tothis slightly modified company motto,steering knuckles will be assembledmore safely than ever before at Opelin Bochum. Operators, maintenancetechnicians and owners will soon benext to benefit from the first use of afailsafe Simatic Controller and theProfisafe technology after the auto-maters. From improved safety, morecomfortable diagnostics and conse-quently higher availability andincreased productivity.

P lant 2 at Opel Bochum is the compo-nent plant of the automobile manu-facturer and specializes in engine,

gearbox and axle construction for theEuropean factories. From the summer of2004 they will be producing up to 120,000steering knuckles per year for the newAstra Diesel there semi-automatically intwo different versions and delivering them“just-in-time” to the production line forshock absorbers.

In a 40-second cycle, a robot takes abrake disc delivered on a pallet and placesit on the conveyor belt. It is automaticallypositioned correctly and the angular ballbearing, steering knuckle and cover plateare mounted at two manual workstations.Two screwing stations screw the individ-ual parts to the “sub-assembly” and thetorques are measured without contact bythe Moby I identification system. A secondrobot then takes over the finished assem-bly and places it back on a pallet.

State-of-the-art safety technology in use

Extensive safety precautions have beentaken to protect operating personnel fromdanger and injury. Sturdy protective grat-ings and several safety doors with lockswhich can only be opened in safe condi-tions are fitted round both robots and the

screwing stations for example. Two lightgrids protect the danger zone on the sup-ply side. Twenty emergency stop switchesare also installed around the plant. Amongother places on four Simatic Operator Pan-els OP 17 which supply the workers with in-formation and on the robot control units.The dead-man switches on two of the firstportable manual operator units SicalisPMC Mobile HMI to be used in practice are also integrated in the emergency stopconcept.

The automater Com-Tec Communica-tionstechnic in Leonberg has implementeda distributed concept and installed fail-

safe peripheral modules of the ET 200SProfisafe series in 11 small local junctionboxes. Various peripheral ET 200X mod-ules apart from the robots and screwingstations are connected to this. They arepowered by the power modules of the ET200S and therefore satisfy safety category3 in accordance with EN 954-1. The robotcells themselves comply with safety cate-gory 3. Failsafe motor starters of the ET200S series which are switched off redun-dantly in the event of a fault by an inte-grated power switch and without an exter-nal power contactor are also the new stan-dard.

Safety Integrated in the steering knuckle assembly at Opel

A Fresh Way of Thinking …

13

The heart of the control for both the“normal” and safety-oriented part of theplant is a Simatic Controller S7-400F withCPU 416F, a first for automaters and users.The Profibus DP which is ideal for safecommunication with its Profisafe profileprovides the link to the distributed pe-ripheral units. The failsafe PLC and field-bus technology from Siemens is graduallyinfiltrating the whole factory and replacingpermanently wired hardware connections.This preference originates from the Opel

headquarters in Rüsselsheim where worksstandards are defined. The employees atthe Bochum plant who have had only pos-itive experience of Siemens products are ofthe same opinion.

Easier configuration, installation anddiagnostics

The advantages of the integrated solutionare obvious for Hans-Joachim Meyer, Man-aging Director of the automater Com-Tec:“Once we get used to the new technology

we will save at least 10 to 15 percent onengineering and commissioning costs forfuture applications.” The Profibus technol-ogy reduces the wiring effort considerablyand the switch cabinets can be designedsmaller and cheaper. The configurationand programming of the safety technologyis fully embedded in the Step 7 environ-ment and there is no need to re-learn it. Itwas therefore easy to generate an individ-ual safety program from the existing com-mands of the software options package FSystems. With pre-fabricated componentsfrom the F-library and your own compo-nents, for example for moving the insidesafety door before loading. A programwhich is easy to change and therefore a lot more flexible than permanently wiredsystems.

The automaters and the people respon-sible at Opel envisage further saving po-tential in later assembly. The production,information and plant monitoring systemSicalis PMC will provide the same valuableservices it did during commissioning. Anoperator unit with protection class IP65 ispermanently installed in a central position.Two portable Sicalis Mobile HMI units withdead-man switch are provided for set-upand maintenance technicians with whichthe emergency stop circuit can be by-passed simply and safely when the safetydoor is open. Faults and bottlenecks in theproduction process and on safety devicescan be detected and eliminated morequickly in the immediate vicinity. This, weare convinced, will have a direct effect onthe availability and productivity of thesteering knuckle assembly. ■


120,000 steering knuckles a year areassembled semi-automatically and safelyfor the Astra Diesel models

Connected to Simatic S7-400F via SimaticET 200S Profisafe and protected by lightgrids: Robot cell at the inlet to thesteering knuckle assembly

SICALIS PMC7mobile HMI

ET200S-F +failsafemotor starter

OP17

Robot



OP17 ET200S-F +failsafemotor starter

OP17



Robot

OP17Screwingstation


Screwingstation


SIMATIC S7-416F SICALIS PMC7 HMI

Profisafe

Integrated safety by Simatic PLC and Profisafe: Distributed automation concept of the assembly plant

Further projects:Bodyshop and Conveyer: Antwerp(Belgium)Paintshop: Bochum, Rüsselsheim(Germany), Saragossa (Spain)Powertrain: Bochum (Germany)

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Simatic CPU 416F-2 which controls boththe conventional and the safety-orientedplant parts side by side. This solution com-pletely does away with the need for a sep-arate safety control and the installation ofa separate safety bus. The connection to allthe field components is made throughoutby a common bus system, Profibus withProfisafe profile. In the field level, conven-tional and failsafe distributed IP20 pe-ripheral devices and motor starters of theSimatic ET 200S have established them-selves, the IP65/67 periphery scopes arecovered both by conventional and failsafeSimatic ET 200eco peripheral devices. ASiemens frequency inverter available fromthe mid-year is already being subjected tointensive field tests in prototype versions.

Profisafe – open to partners

One of the decisive factors in Daimler-Chrysler AG’s choice of the Profisafe tech-nology was the extensive integration pos-sibility for the products of other partners.For total implementation of the plant func-tions, the robot controls, the vision system,

DaimlerChrysler AG has developed anew kind of fully automatic applica-tion process for body seam sealing ina pilot project. Potential innovationsfor the company-wide automationstandard integraMCG are to be vali-dated and ensured simultaneously forthe control-technical implementationof the process.

The aim of the seam sealing robottower pilot plant at the Daimler-Chrysler AG works in Sindelfingen

was to demonstrate a production processfor fully automatic, smear-free sealing ofthe up to 80 meter long jointing seams ofthe vehicle bodies. A two-tier tower archi-tecture was developed for this which en-ables application robots to work on the topand bottom body halves at the same time.

A look ahead: Profinet Safety

Basic problems in the control-technical im-plementation of the project were to work

out a basis for the planned mid-term useof the Ethernet technology (Profinet) forconventional and failsafe automation tech-nology in the production. The ambitiousschedule for implementing the plant auto-matically demanded a split-level imple-mentation strategy for the control-techni-cal equipping of the plant.

Profisafe – a safe bet

To enable the project team comprising thegeneral manager KUKA welding systems,the control technology supplier Siemensand the DaimlerChrysler designers of PWT-VAS to get off to a quick, trouble-free start,a technological basis was required with ahigh innovation and future potential butwhich at the same time promises a high de-gree of real production capabilities. It wasdecided to implement an initial architec-ture based on Profibus with Profisafe tech-nology – but at the same time to take thenecessary measures to be able to easilyconvert to Profinet or Profinet Safety later.The core of the initial architecture is thesystem and safety control based on a

Integrated safety technology: from Profisafe to Profinet Safety

Seam Sealing Safe and Sound


14Paintshop

CASE STUDY

the first implementation stage, all devel-opment goals including the integration ofthe components of third party providerswere achieved in just five months andwithin the budget. The transfer of the newtechnologies to the planners, operators andmaintenance people also worked thanks tothe great commitment of those involved inthe project. The implemented architectureoffers both plant manufacturers and endusers a modular system which leaves themfreedom of choice between a central or dis-tributed plant structure and leads to prov-able savings after internal cost analysis. ■

the safe servo drives, light grids and laserscanner, wireless safety systems and theprocess diagnostics system are linked tothe Profibus with Profisafe profile. The con-ventional bus also failsafe linking to neigh-boring plants is done simply, safely andflexibly with conventional DP-DP couplers.

Profisafe – one diagnostics for all

By using the Profibus diagnostics repeaterthe Profibus with Profisafe profile field-bus system can play out another of itsstrengths; homogeneous bus diagnosticsfor all field devices and conventional andfailsafe peripheral devices. For this a newkind of Profibus diagnostic software wasdeveloped in close cooperation with the de-velopers and maintenance people at theDaimlerChrysler AG which will soon be-come part of the Siemens product land-scape.

Industrial Ethernet for verticalintegration

A terminal server/thin client principle is be-ing relied on for the first time for opera-tion and monitoring of the whole system.The programs integrated on the serversuch as Step 7/Graph 7 and other HMI soft-ware communicate with their target sys-tems such as the system and safety control,the robot controls and slave technologycontrols via Industrial Ethernet. The cost-optimized, “zero-administration” thin-client systems integrated locally in the op-erator stations only send the mouse andkeyboard information to the terminalserver and receive the screen informationfrom the terminal server via the networkfor display.

A fireworks display of innovations – in time, in budget

The experience in the implementationphase was exclusively positive according tothe coordinating staff at DaimlerChrysler.Despite the large number of innovations in


Terminal Server FarmHMISiemens Step 7, other

Robotcontrols

Visionsystem

Operator panel

Technologycontrols

Safe fieldbus(PROFIBUS DP with ProfiSafe-Profil)

Network infrastructure location(Ethernet / TCP/IP)

Plant network(Ethernet / TCP/IP)

Robot field bus

Safedrives

Siemens ET 200ecoStandard and/orF periphery (IP65 / IP67)

Thin clientopeator systems

Systems switch

System and safety controlSimatic S7-416F-2DP

Diagnoticsrepeater V2.x

Siemens ET 200SStandard and/orF periphery (IP20)


15

For the first time robots can work auto-matically on the top and bottom bodyhalves simultaneously in the two-tierapplication tower

Industrial Ethernet and Profisafe are validated for the new automation standard integraMCG at DaimlerChrysler AG

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16Failsafe controllers

CASE STUDY

Not only is it consistently rated inthe top 10 by JD Power and Associ-ates,the southern Ontario facility

was honoured by the parent company,when it became the first Lexus plant out-side Japan. Toyota Motor ManufacturingCambridge (TMMC) along with partnersSiemens Canada, and consulting engi-neers Stantec further demonstrated its ex-pertise by installing top-notch, ControlReliable safety solutions that have beencost effectively applied to both the newLexus RX330 plant, and in a retrofit of the

existing Corolla plant. Besides maximumsafety, the new system boosts productionthrough increased diagnostic capability.Siemens machine safety program manag-er Ondrej Benjik recalls planning theretrofit strategy with TMMC project man-ager Scott Bartlett. Bartlett identified anumber of essential criteria for the retro-fit, including the integration of the newsafety solution with the existing controlsplatform,the replacement of existing fielddevices andwiring,the ability to executethe retrofit with no, or limited scheduled

down time, and effective use of the newsystems,such as the quick recovery fromfault conditions.

All safety regulations met

“The Siemens Actuator-Sensor Interfaceproducts haveproved themselves wellsuited to the challenge and fully satisfiedthe requirements of OHSA by passing PSRunder Sec. 7 of Reg. 851. The easy transi-tion was accomplishedwith no resistance,”recalls Bartlett, “and a ready acceptance by

Toyota team members that understoodthe concept and value of the installa-tion.” Performed on weekends and dur-ing the holiday’s shutdown, the retrofit tothe Corolla paint plant’s robot cells oc-curred without production downtime.The “anti-chip” booth which applies pro-tective coating to a vehicle’s rocker pan-els), and the “black out” booth (whichpaints under-body components), wereupgraded with the new Control Reliablesafety systems with minimal changes to the existing PLC control system.

Toyota, Cambridge (Canada), with future-orientedsafety technology

A Safe Bet forIncreasing ProductionToyota Canada chose a safety solution with Siemens AS-Interface at Work and Simatic S7-300F for their new Lexus factory and a plantretrofit. In addition to the enhanced safety, the automobilemanufacturer also profits from the higher availability and thusincreases productivity.

1 The new RX 330 luxury SUV

7 Lexus RX 330 body-in-whitePh

otos

: Toy

ota


17

Simatic failsafe technology to becomecompany-wide standard in body shop

Toyota Mini-VanProduction Failsafe

PLC forrobot control

CPU315F-2DP

ProfiSafe

Fiber optic

ET 200M & F-SM (DI, DO)

OBT

FailsafeI/O modules• Emergency Off• Light Curtain• Safety Switches

The control architecture:Safety-related functionsare controlled by SimaticS7-300F. Both controlscommunicate viaProfibus DP

Siemens’ non-propri-etary AS-i safety net-work was an easy fit,since it can be easilyintegrated into virtu-ally any PLC. The AS-inetwork easily inte-grates light curtains,laser scanners, safetyinterlocks and E-stopswith direct connectionto a single cable; meet-ing the Category 4safety level. As well,the AS-i systems’unique direct-connec-tion technology ofsafety devices and/orsafety input modules,eliminates the needfor distributed I/Ostations; which re-duces hardwiringdown to nearly zero.This ease of installa-tion greatly reducesthe commissioningcost and site time re-quired for a retrofit,and allows for fullfunctional testing pri-or to commissioning.

Simatic S7-300F for the Lexus

The new Lexus RX330 plant will featureSiemens safety solutions that meetEN954-1 and IEC 61508 standards. TheAS-i will be in service in the new paintshop, while the body and weld shops willbe enhanced by the Siemens S7 ‘F’ safetyPLC on Profibus. “Toyota has shown thatthe best in class safety solutions can notonly ensure enhanced operator safety,”concludes Siemens’ Benjik, “but maintainbusiness goals like high availability andquick mean time to recovery.” ■


ToyotaMotorCorporation

Toyota Motor Corporation is theworld’s third largest automaker,producing a full range of models,from minivehicles to large trucks.Global sales of its Toyota and Lexusbrands, combined with those ofDaihatsu and Hino, totaled 5.94million units in 2001. As of March2002, besides its 12 own plants inJapan, Toyota has 54 manufacturingcompanies in 27 countries/locations,which produce Lexus- and Toyota-brand vehicles and components,employs 246,700 people worldwide(on a consolidated basis), andmarkets vehicles in more than 160countries and regions. Automotivebusiness, including sales finance,accounts for more than 90 percentof the company’s total sales,Diversified operations includetelecommunications, prefabricatedhousing and leisure boats.

A fter a long and intensive evaluation, Toyota decided to usethe new failsafe technology based on Siemens S7 PLCs andProfiSafe to be used in the safety installation within the

bodyshop of the new “Sienna” mini van. Since a production linegets continuously modified due to model changes, the use of aSafety PLC with distributed system allows a fast, easy and cost effective adaptation. Toyota rated the Siemens Safety PLC as themost reasonable one concerned with functionality and reliabilityin an automation line among other several other safety PLCsuppliers evaluated. Currently three projects are on the way inToyota plants around the world: Tahara (Japan), Indiana (US)Cambridge (Canada). The overall content of Safety PLCs used inall 3 plants is around 170 PLCs with about 2000 safe I/O modulesin use. ■

Further projects:Bodyshop and paintshop: Tahara(Japan); Indiana and Kentucky (USA);Cambridge (Canada)Press-shop: Kentucky (USA); Cambridge (Canada); NUMMI (Joint venture GM and Toyota),California (USA)


18Distributed safety solution in the paintshop

CASE STUDY

Conveyor technology for the paintshop at the BMW factory Regensburg equipped with Profisafe

The Paint is “Safe”!


19

BMW uses Profisafe in the field ofconveyor technology in the “NewPaintshop Structure” (NLS) at theirRegensburg factory. The new controlconcept using the failsafe Simatic S7controller with distributed “safe”periphery enables optimum switch-off zones to be set up flexibly forpersonal and machine protection withProfisafe.

S ince the spring of 2002 the paint-shop at the BMW factory in Regens-burg is being extensively modern-

ized. New technology standards in paint-ing techniques for automobiles, capacitybottlenecks and the necessity to replaceexisting systems prompted the companyto undertake the “New Paintshop Struc-ture” (NLS) project with a total investmentvolume of 225 million Euro.

With the final commissioning of thelast new installations in March 2004 (firststage) and March 2005 (second stage), thenew installations and conversions in thepaintshop at the BMW factory in Regens-burg will be completed.

New solution for the conveyortechnology

In the course of modernization of the paint-shop, the entire conveyor system automa-tion was renewed. BMW decided to useProfisafe for all conveyor systems. Thiscorresponds to a scope of more than 1,850single conveyor elements with a length ofapproximately seven kilometers.

In order to be able to control this enor-mous scope optimally, 36 failsafe con-trollers of the Simatic S7 416-2F type areused.

These control the approximately 850distributed peripheral stations equippedwith safety technology in terms of bothcontrol and safety: “Our criteria for select-ing this safety solution were on the onePh

oto:

W. G

eyer

B

+LS-01 +ES-01

+UV-01

ET 200S

Conveyor direction

Failsafe power module

ET 200S ET 200S

DP/DP coupler

S7-416-2F

+EA-01

Emergency stop section 1 Emergency stop section 2Assembly to be conveyed

ET 200SProfisafe Profisafe

Powersupply

“Safe” signalexchange withother controllers


20Distributed safety solution in the paintshop

CASE STUDY

The project team BMW/Siemens. From left to right: Jens Rutenberg (Siemens), Karl-Heinz Fischer (Siemens), Norbert Schottenheim (BMW), Christian Weitl (BMW)

Schematic plant concept of the distributed safetytechnology in the paintshop of the BMW factoryin Regensburg

N

N

Only a distributed, freely programma-ble safety technology allows a flexible andfinely graduated safety concept in thepaintshop which enables individual zonesin a cell to be shut down. This modularstructure allows a very limited area to beshut down without affecting the overallproduction.

Narrow time windows

Numerous individual measures such asthe mounting of lifting stations or linkingconveyors were installed at the weekendand during the Christmas, Easter andSpring breaks. Certain conversion andnew installations had to be made duringongoing production however.


21


A three-week production shutdown inAugust 2003 was planned by the “NewPaintshop Structure” team down to thevery last detail. During this time, 20 of thetotal of 36 new conveyor installations wereextended or installed and commissionedwith the “safe” control technology. Anoth-er 20 existing conveyor systems were con-verted. A Siemens service engineer was onsite during all phases of the project, suchas compiling the specifications, writingprograms, commissioning and trainingBMW staff.

Distributed safety technology withmany advantages

Several plant sections could be commis-sioned separately with all the necessarysafety functions using island solutionswith temporary PLC cabinets and distrib-uted technology during production. Onlythe individual program modules of theisland solutions had to be joined up in ageneral program (standard and safetyprogram) and the networking completedwith Profisafe to complete the control tech-nology of a system.

The safety technology linked decentral-ly to the PLC reduces installation times dueto the shorter cable distances. The space re-quirements for the total system is also re-duced due to the omitted switch cabinet.

“With Profisafe, standard and safetyfunctions run on one PLC. This gives us aflexible and innovative safety technologyfor the price of the standard technology,”Christian Weitl explains. Where specialknowledge used to be necessary for pro-gramming, standard and safety functionscan be programmed today by the same ed-itor. This reduces planning and commis-sioning times per plant. In addition, boththe complicated hardware planning andthe “inflexible” switch cabinet wiring forthe conveyor system safety technology areomitted.

“The safety cut-outs no longer need tobe wired “rigidly” but are freely program-mable according to the respective require-ments. This makes safe shutdown zoneseasy to change,” Weitl describes other ad-vantages of the new safety technology. ■

hand maximum safety at minimum shut-down and on the other hand low influenceon production in the event of an emer-gency stop,” Christian Weitl, responsiblefor control technology/conveyor technolo-gy in the “New Paintshop Structure” proj-ect explains.

The demand: flexible safety

A very high safety standard is demandedin the paintshop at the workstations withfully automated production plants. Manand machine work right next to the con-veyor systems. Safety components such aslight curtains, switches and emergencystop buttons ensure safety of the person-nel and trouble-free machines.

The Remains of the Switch Cabinet – the distributed safety conceptwith Profisafe only needs about a quarter of the previously necessaryswitch cabinet volumeN

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Further projects:Final assembly: Munich, Regensburg,Leipzig (Germany)Conveyer bodyshop and centralbuilding: Leipzig (Germany)

Advantages which the MAGNA STEYRFahrzeugtechnik AG & Co. KG in Graz-Thondorf has learned to appreciate. TheAustrian company paint and assemble ve-hicles of different manufacturers and inSummer 2003 they fully modernized anexisting emu plant. Since then one failsafeSimatic S7-400F has been controlling thenormal cleaning process and the safety-relevant devices of the plant all on its own.This saves the safety PLC which alwaysused to be used additionally and the asso-ciated costs.

The “normal” jobs of the F-controllerincludes saving and managing the bodydata and the coordination of roof, in-


22Failsafe automation

CASE STUDY

B efore car bodies can be painted, theymust be freed from dust and dirtparticles. Every paintshop has an

emu plant for this job. The plant which re-sembles a carwash is so called because the

rollers which pick up the dust areequipped with emu feathers. The finefeathered coat of the Australian runningbird picks up dust particles very well andis also easy to neutralize electrostatically.

Failsafe Simatic controls complete emu plant at MAGNA STEYR

F-Controller Goes it AloneThe feathers of the Australian emu are still an irreplaceable means ofremoving dust and other contamination before painting auto bodies. AtMAGNA STEYR too where, just recently, an almost completely new “emu plant”was installed and brought up to the latest state of the art automation-wise.The separate safety PLC was one of the things to be replaced, namely by a failsafe Simatic S7-400F which controls both the “normal” process and thesafety-relevant functions.

plant which is easily achieved with theSimatic F-controller (satisfies SIL3).

New roads to safety

For the S7-400F series there are no inputand output modules which can be pluggeddirectly into the rack but only distributedperipheral modules ET200M. These are con-nected to the controller by conventionalProfibus DP-lines. The Profisafe telegramwhich contains the checksum for error de-tection, a consecutive number and a statusbyte in addition to the normal Profibus use-ful data is used for communicating withthe failsafe modules. Unlike other failsafecontrollers the fail safety in the Simatic S7-400F is not guaranteed by two or moreprocessors. The failsafe CPU S7-416F-2 isbased on a standard CPU, the operating sys-tem and hardware components of whichhave been extended by various safety mech-anisms. It has only one processor and there-fore executes every command additionallywith negated variables complementary andthen checks the results. ■

clined and vertical rollers and post-ion-ization which neutralizes electrostaticcharges.

Another emphasis is on the communi-cation to the conveyor technology, to visu-alization and to the central control tech-nology. Added to this are various safety-relevant functions for the first time on anemu plant such as monitoring of all emer-gency stop circuits and the light curtainsfor the access protection. Emergency stopswitches are mounted on both sides of thecabin entrance and exit, another one onthe control panel. Cabin entrance and exitare protected against unauthorized accessby light curtains whereby the mutingfunction prevents the bodies triggeringan emergency stop.

All emergency stop functions are de-signed as 2-channel version, that meanstwo separate lines are laid for sensor sup-ply and feedback. If the transmitted sig-nals differ (apart from a discrepancy timeof a few milliseconds) this is registered inthe failsafe input module and reported to

the F-controller. MAGNA STEYR also picksup emergency stop signals from otherplant parts or controllers through the in-put modules and evaluates these.

These include safety-relevant signalsfrom the fire alarm center, the conveyortechnology and the process technology.

Exactly defined safety requirements

There are various ways of estimating therisk potential on machines and plants in-cluding the risk estimate (danger analy-sis) according to DIN V 19250, EN 954-1 orIEC 61508. The rulebooks are very similarand differ only slightly in the division andemphasis. The DIN norm defines require-ment classes (RQ), the EN norm categories(cat.) and the IEC norm Safety IntegrityLevels (SIL). According to the risk esti-mate plants can be classified in an exactlydefined safety class whereby it basicallyapplies: The higher the safety class, thegreater the demands on the safety conceptof the plant. Safety Integrity Level 2 wasdetermined for the MAGNA STEYR emu


23

A failsafe SimaticS7-400F controlsboth the “normal”and the safety-relevant functionsof the emu plant at MAGNA STEYRand saves theadditional safety PLC

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totally integrated

www.siemens.com/automation

Something holding you back?

Feel like you’re stuck in traffic lately? Like you want to move forward, but

can’t seem to get anywhere? That’s when you really need maximum flexi-

bility, so you can make the right changes. And with Siemens automation

technology, you’re ready to handle whatever changes are needed – like

installing new setups, expanding, or converting production. And because

Totally Integrated Automation is as comprehensive as it is open, it gives

you all the flexibility you need – so you can start moving forward again.

astra body shop

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