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We love GlassWe love Glass

Trends in the Glass industryCase StudiesCooperation with Technology PartnersProducts and Solutions

Trends in the Glass industryCase StudiesCooperation with Technology PartnersProducts and Solutions

ideas for glass production and glass machinery

GlassFocusNovember 2004

English edition

GlassFocus 2004

16 ProductsSimatic WinCC flexible, Simatic IT, Profinet, Torque motors, Sinamics, Simatic PCS 7, process instrumentation, energy supply systems

Flat Glass22 Transparency and Reliability

Account Management Saint-GobainAutomation of a float glass line with Simatic PCS 7

Flat Glass24 Prepared for the Future

Cold repair of two lines at Saint-Gobain Germany

Glass Containers25 A Series of Successes

Simatic PCS 7 implemented in the glass container di-vision of Saint-Gobain

Glass Wool26 Multinational Teamwork

Experience and industry expertise convince Isover

Flat Glass28 Local Expertise

Glaverbel automates glass production with SimaticPCS 7

Flat Glass29 A Hot Project during Cold Repair

Modernization of a float line at Cardinal in the USA

Glass Market

4 New Challenges - New OpportunitiesInnovative solutions for the glass industry

Flat Glass

6 From the Cold-end to theWarehouseSuccessful cooperation of the cold-end experts Gren-zebach and Siemens

Hollow Glass8 Productive, Flexible and Integrated

Simotion increases productivity in the hollow glass in-dustry

Glass cutting10 Investing in the Future on the

BosporusProfessional glass cutting with Sinumerik 810D

Glass Grinding11 Everything Under Control

Glass grinding with Simatic S7-300 and SimaticMP270

Pre-Processing12 Uniform from Cutting to Washing

New pre-processing line for automobile glass panes

Laser Scribing14 Diamond and Metal are Passé

Laser scribing breaks glass with micrometer precision

Using integrated control ans automation technologyfrom Siemens, Benteler can process glass for automo-tive applications even more productively than before

SCHOTT has developed a laser scribingprocess that surpasses mechanical glasscutting

12 14 22

Optimized production:Simatic PCS 7 at Saint-Gobain

CONTENT2

GlassFocus 2004

Dear Readers!The market has changed a great deal in recentyears. New markets – especially in Asia andEastern Europe – with a rapidly increasingdemand for glass for automobiles, the buildingtrade, and the food and beverage industry aredictating the direction. International glass manu-facturers and machine builders are following thisdemand and are increasing their investments inthese markets.At the same time, the pressure of costs on glassproducers is increasing. Energy, one of the mostimportant driving forces behind costs in thisindustry, is becoming increasingly expensive. The business is becoming more and more global,and anyone who wishes to succeed will have toenter the market quickly and track down andconsistently exploit potential for rationalizationin production.We, the Siemens Glass Team, support ourcustomers – the glass manufacturers, proces-sors, and plant planners (EPCs), machine manu-facturers (OEMs), and consultant engineers –with an extensive and innovative product port-folio, tailor-made solutions, and experience andknow-how in the glass industry. We back ourcustomers from America to Asia, from Europe toAustralia and Africa. The Glass CompetenceCenter brings together our activities andexpertise so that our customers can benefit fromthe accumulated experience of more than 50years of international cooperation with the glassindustry. International account managementsupports machine manufacturers as well asglass-producing companies in the implementa-tion of international standards in automationtechnology, and a dense network of partnercompanies uses our products and solutions fortailor-made glass plants and machines thatoptimize production and processing.In this issue, we provide some select examples ofhow our customers benefit from collaborationwith Siemens and our partners – starting onpage 6 for glass machine manufacturing andpage 20 for glass production. We hope we cangive you a few valuable ideas.

Yours,

Bernhard SaftigSiemens Glass TeamHead of the Glass Competence Center

Ralph BurgstahlerSales/MarketingAutomation Glass Processing Machines

Glazing Systems30 Stepping into the Future

Simatic PCS 7 automates glazing system production

Flat Glass31 Several in a Row

Excellent cooperation with Guardian Industries Corp.

New Markets32 Success in China

34 Siemens Technology Partners

Support38 Good Advice is a Safe Bet

The right support for every phase

39 Dialogue

Success in China: Simatic technology at LG PhilipsDisplays ensures reliable operation in a crucialproduction step

32

3

GlassFocus 2004

4

Some of the best opportunities are inthe new markets. The heavy build-ing activity there but also the con-

stantly growing demand for mobility inthese countries are increasing the de-mand for flat glass enormously – this alsoapplies for hollow glass in the food andbeverages industry.But the building industry also is an impor-tant driving force for the glass industry inall other regions: not just float glass as animportant raw material for windows andfacade elements but also glass blocks as

rediscovered design materials as well asglass wool as an insulating material arejust some of the market segments that areshowing considerable growth.International competition and substituteproducts such as PET and Tetrapak inten-sify the price pressure in the traditionalglass industry markets which is having agreat effect especially for hollow glass.Here companies are being forced to be-come even better by optimum utilizationof their resources and plants.

With partners to success

The challenge to increase the productivitybut retain the same quality and flexibilityand at the same time reduce the costs can-not be met by the glass manufacturer alone.There is a great need for partners who areinternationally available, globally accept-ed and who use open standards, imple-ment integrated systems and develop in-novative techniques and concepts. Thegrowing demands of consumers can bestbe satisfied by all those involved in theproductivity chain.

Siemens’ competencies range from theproduct delivery to the electrotechnicalcomplete solution including the integra-tion of production and management or so-lutions for better exploitation of energy.Competencies which are equally impor-tant for glass production and glass pro-cessing. In partnership with customers,machine manufacturers and glass special-ists, Siemens develops intelligent solu-tions based on proven standard productswith which glass plants can be operatedmore efficiently and at state-of-the-artlevels.

Productivity, flexibility andtransparency

The main job of a glass plant is to producewhat the market needs as effectively aspossible and to bind less capital in rawmaterials, operating materials and fin-ished glass.

Innovative solutions for the glass industry

New Challenges – New OpportunitiesToday more than ever, low cost production in the glass industry means savingenergy, using resources more effectively, responding more flexibly to marketrequirements and binding less capital. But this is getting harder becausemarkets are growing closer together and competition is getting more fierce. But there are still opportunities, for example new markets in Eastern Europeand Asia or also new products such as ultra-thin glass for flat screens, PDAs ormobile phones. In order to successfully exploit these opportunities, all thoseinvolved must pull together – from the glass manufacturer through themachine manufacturer to the system supplier.

Glass Market

TRENDS

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For years, Simatic PCS 7 has proven it-self as an efficient process control systemin the glass industry. One of the most im-portant new features of Version 6 is theplant Asset Management. This alerts theglass producer’s attention to potential fail-ures in production in good time and there-fore considerably reduces production down-times or avoids them altogether.

Not only the quality of the raw materialbut also and quite particularly the preciseproportioning and exact observance of allthe process parameters is responsible forthe quality of the finished glass. Siemenshave consistently developed their productrange in this field or have expanded it bytheir acquisitions.

From the order to the finished glassplate

Of course the pressure of costs is also in-creasing in the area of the cold end, andtime-to-market is playing an increasinglyimportant role. Siemens respond to thenew requirements with their new float endconcept which serves as an example of a low-cost, homogeneous plant concept.The new drive concept with Simotion andSinamics is an integral part of TotallyIntegrated Automation and therefore fullycompatible with the Simatic world.Both in the cutting technique and the re-moval and transport of glass plates, mod-ularly structured plants and productionlines best satisfy today’s market require-ments. Modular plants with distributed

intelligence and simplified machine-ma-chine communication can be set up per-fectly with Component based Automation(CbA). The basis for this are mechatronicmodules which integrate mechanics, au-tomation technology and user program.The vision of “plug&work” of future pro-duction lines consisting of fully tested in-dividual machines which configure them-selves automatically in the network andcommunicate independently with each oth-er via standardized CbA interfaces are be-coming a more and more realistic prospect.

Due to the continually increasing eco-nomic demands, neither plant manufac-turers nor float glass producers can avoidintegrating the production level in an ex-isting order process any longer, becausethis is the only way to optimize the wholebusiness process. To keep waste as low aspossible, cutting should be done exactly atthe flawed position, e.g. occlusions in theglass. The dimensions of the plate then donot usually correspond to the dimensionsof the order currently being processed. Inthis case it is obviously useful to find asuitable order immediately and assign theplate to it. Simatic IT closes the gap be-tween the automation level and the orderprocess.

Standardized, homogeneous and global

With the standardized and homogeneoussolutions for the glass industry based onTotally Integrated Automation (TIA) andTotally Integrated Power (TIP), glass pro-

ducers and glass machine manufacturerscan effectively meet these challenges. Thehigh degree of standardization reduces theamount of time up to commissioning of aproduction or plant, simplifies mainte-nance and service and cuts implementa-tion costs.

The smooth integration between com-pany management, order managementand glass processing with Simatic IT re-leases a great potential for rationalizationespecially in the cold end.

In addition to innovative technologyand intelligent solutions for the wholeglass process, Siemens offers global sup-port and project handling as a partner tothe glass industry. The staff at the GlassCompetence Center coordinates activitiesfrom all over the world for the glass indus-try with a variety of solutions and theyregularly swap experience. ■

Find out more:www.siemens.com/glassE-mail: [email protected]

GlassFocus 2004

6

Successful cooperation of the cold-end experts Grenzebach and Siemens

From the Cold-end to the Warehouse

One of the specialists for the cold-end section of a flat glass plant is the Grenzebach Maschinenbau GmbH. The recipe for success of the globally active company is innovative mechanical engineering paired with intelligentcontrol and optimization technology. Grenzebach has relied for years on a homogeneous automation solutionbased on Totally Integrated Automation.

Flat Glass

CASE STUDY

The products of the Grenzebach Maschi-nenbau GmbH range from float glass andcutting lines through control technology

right up to stacking machines. With progressivedevelopment and new designs, the medium

sized company based in Southern Germanyhas become a world leader in the

glass industry. The company isnumber one on the market

for the constructionof float plants.

About 80

percent of the plants they produce are forexport.

Grenzebach also takes over the respon-sibility for the whole control and auto-mation technology in addition to the me-chanical engineering for the cold-endsection in flat glass production. A uniformplant concept is a decisive factor especiallyhere. Grenzebach has therefore chosenautomation based on Totally IntegratedAutomation with Simatic and Simotion.

The cutting technology – accurate, fast and ...

The nucleus of the plant is the cuttingline. Here a very high plant avail-

ability and extreme accuracyare demanded. Efficient

production also de-pends on an

opti-

Gre

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bach

Gre

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Flat glass production with Grenzebach plants

GlassFocus 2004

7

mized and job-related cutting of the glassweb. Precision, speed and maximum flexi-bility are essential aspects.

The Grenzebach float cutting techniqueconsists of two to three longitudinal and a maximum of six transverse cuttingbridges. On the longitudinal cutting bridgethe glass web gets one or two trimmingcuts on the left and right or two longitudi-nal dividing cuts before being divided onthe transverse cutting bridges.

The mechanical and electrical structureof the longitudinal cutting bridges is mod-ular and they can be equipped with up to16 cutting tools. A Simotion D435 takes careof the positioning of all the tools in everylongitudinal cutting bridge. In the up to sixtransverse cutting bridges per plant, thecutting head is pulled directly by a compactservo motor 1FK7 (by the flying saw prin-ciple). Here, one Simotion C230-2 perbridge controls the cut dependent on theglass feed. In this way an extremely accu-rate, straight and right-angled cut is made.The cutting section is rounded off by themarking system in which up to four mark-ing bridges also equipped with Simotion Dmark flaws reliably and accurately.

Hans Jenning, Deputy Design Managerat Grenzebach, is convinced by the newconcept with Simotion, "By using Simotion,the modularity of the system can also befully exploited on the control side. Thiskeeps availability very high because fail-ures on one of the bridges (longitudinal ortransverse bridge) have no influence on theother bridges and may even be compen-sated by them. In addition the commis-sioning is much easier and quicker becausethe individual modules can be started up

separately. An important advantage for usis that the delivery time is reduced

considerably by using standarddevices.

Another advan-tage is the im-

proved

troubleshooting; in such a plant concept wecan find errors and eliminate them muchfaster and more accurately. Moreover, in-novations in the individual modules can be made without feedback and thereforefaster. This means that the machine man-ufacturer and the plant operator can reactfaster to changing market requirementsand decisively reduce their time to market.”

The required homogeneity is naturallyguaranteed; Simotion is an integral part of Totally Integrated Automation and thusfully compatible with the Simatic world.Configuration, programming or parame-terization – these can all be combined inone system in Simotion and the flexibilityin terms of hardware is still retained.

... perfectly adapted to customers’wishes

The longitudinal cutting, transverse cut-ting and marking bridges are coordinatedby a redundantly designed Simatic indus-trial PC. A master control and optimizationcomputer knows the current status of theline and takes care of the quality and ca-pacity-dependent optimization of the cut.First all the flaws detected in the glass webare reported to the optimization computerwith position and classification. The com-puter then calculates the cutting coordi-nates based on the reported data and theexisting job data and sends them to theSimotion units of the individual bridges viaIndustrial Ethernet.

Distributed intelligence in the transport

Transport of the glass plates from the cut-ting section to the predetermined destina-tions (routing) is a perfect application forcomponent based automation (see alsopage 4 and 5). The slave transport systemsare restricted to just a few basic types (tech-nology modules) each equipped with theirown intelligence. Grenzebach’s solution atthe moment is to use pre-fabricated soft-ware modules – one module per basic type– which are available on the line computerand can be switched accordingly. To ensure

as high a fail safety of the cutting lineas possible, the line control is

designed redundantly witha high performance

Simatic S7-400H.The Profibus

DP field bus by which the periphery con-sisting of drives, actuators and sensors isconnected to the line control also has a re-dundant design. The visualization of theentire line is based on the Grenzebachvisualization system PC-Panel or theSCADA system Simatic WinCC and runs onSiemens industrial PCs (for example on thePanel PC 670).

Globally active partners

An export-oriented company like Grenze-bach appreciates, not only the innovativeautomation solutions of a partner such asSiemens, but also the optimum diagnosticpossibilities – such as the remote systemwhich enables telemaintenance of theplants. Equally important is the local sup-port from the automation provider. A flatglass plant needs to be in operation aroundthe clock for about 12 years. Problems haveto be eliminated quickly to avoid inter-rupting the process. The demands of theend customers on their plant suppliers areaccordingly high. Siemens can offer thenecessary automation know-how locallyworldwide. Grenzebach’s expansion intothe US market is helped greatly by the sup-port possibilities that Siemens is able toprovide there.

■

Find out more:www.siemens.com/glasse-mail: [email protected]

Automation has to deal with demand-ing tasks in the transportation ofglass containers: for example the

exact synchronization of the belts to themachine speed, the angled synchroniza-tion of belts and reversers and the move-ment of the feeder. The integration in anexisting environment also plays a majorrole in these factors. The Simotion motioncontrol system represents the ideal solu-tion for the complex tasks of glass manu-facture.

An essential factor in the qualitativelydemanding production of hollow glass isthe exact forming and cutting of the glassdrop and the loading of this drop into theproduction machine. A high-precision mo-tion control with absolute reproducibilityis necessary, which is provided by an elec-tronic cam disk. The slightest deviationsshow up by changes in the weight of theglass mass which in turn has a negative ef-fect on the productivity of the whole pro-duction line.

Simotion brings enormous advantages

Together with the Heye International GmbHin Oberkirchen, Germany, Siemens has de-veloped an innovative automation solutioninitially for belt drives. The globally situ-ated provider of technologies, machinesand plants for the container glass industryhad the drive-based variant Simotion D435installed for motion control and logic func-tions in which all motion control functionsare integrated directly in the control mod-

Simotion increases productivity in the hollow glassindustry

Productive, Flexible andIntegratedThe Heye International GmbH is using the drive-based variant Simotion D forthe first time as a belt drive for transporting glass containers. Simotion providesa motion control system which is practically made for optimum synchronizationof the axes and which can be easily integrated in existing plants.

8Hollow Glass

CASE STUDY

Simotion has a wide range of applicationpossibilities. Stretching from simplespeed control right up to complex multi-axis machines in which numerous singleaxes need to be commissioned. Motioncontrol, logic and technology functionsare integrated here homogeneously inone system. This dispenses with time-crit-ical interfaces between the individualcomponents and enables efficient engi-neering. As an integral part of TotallyIntegrated Automation, Simotion is fullycompatible with the Simatic world.Configuration, programming or parame-terization – all these engineering jobs canbe combined in one system with Simo-tion and the flexibility in terms of hard-ware is retained.

Simotion is made up of three differentcomponents: engineering system, runtimesoftware and various hardware platforms

as a target system. The engineering systemScout enables engineering of motion con-trol, logic and technology tasks in a ho-mogeneous system and provides all thetools from programming through para-meterization right up to commissioning.An application created with Scout runs onany hardware so that the user can choosethe hardware which best suits his machine.Scout also gives users graphic support increating the hardware and network con-figuration as well as a graphic program-ming language (Motion Control ChartMCC). Apart from MCC he also has thehigh-level Structured Texts (ST) languagefor programming Simotion and ContactPlans (KOP), and function plans (FUP) forlogic programming. The runtime softwareis flexible and scalable due to reloadabletechnology functions and enables motioncontrol, logic and technology functions to

be run on one controller. Its modularstructure allows the requirement profile tobe adapted exactly to the machine’s needs.

Simotion runs on three hardware vari-ants: the controller-based Simotion C in S7-300 design is modular and flexible. Simo-tion P on PC-basis unites motion controland HMI on a single platform and is there-fore open for other tasks. Already inte-grated in the drive, the compact drive-based variant Simotion D is ideal for dis-tributed automation structures. ■

Motion Control system for complex movements

GlassFocus 2004

TP 270operation/parameterization(selection of motion profile)

Profibus DP

ET 200M

Sinamics S120 withSimotion D435(logic + motion control+ technology)

Belts 1

Plunger

Shears

Drop distribution

IndustrialEthernet

rately. The system is also equally suitablefor all other plant sections for hollow glassproduction such as plunger, shears or dropdistributor. Previously, every plant sectionneeded its own control system – becauseof the scalability of Simotion with thehardware and software the machine man-ufacturer only needs one system. And thisis where the enormous advantages ofSimotion’s homogeneity come in: one en-gineering system – which reduces trainingexpenses and commissioning – and the ho-mogeneous communication via Profibus –this means not only less wiring work butalso fewer interfaces and therefore fewersources of error.

One engineering system for everything

Simotion Scout is an engineering programfor the configuration of typical logic func-tions as they arise in a belt drive solution– for example control panel button evalu-ation, locks, coolant controllers and auxil-iary drive controllers. The control providesthe necessary dynamic as well as can besynchronized in high resolution to an ex-ternal pulse.

The simple handling in case of servicemakes the system even more attractive. Allthe configuration data is stored on thememory card of the Simotion D435 headmodule so that you only have to change the

GlassFocus 2004


hardware module if a component of theplant operator fails. Then reconfigurationis not necessary because the new compo-nent gets its data sent automatically froma central station. In combination with theworldwide availability of Simotion D andthe possibility of teleservice, this helpskeep downtimes to a minimum.

Integration in existing automation

Easy operability is guaranteed by the lo-cally installed touch panel TP 270 based onWindows CE or a master visualization sys-tem. Almost unrestricted operation andmonitoring is possible thanks to installedinterfaces such as Ethernet and Profibus.Simotion D is connected to the main con-troller and the distributed Simatic ET 200Mdevices through the standard bus systemProfibus DP. Open interfaces and extensionpossibilities – such as the communicationmodules for ET 200M – allow simple inte-gration in the existing automation land-scape. The openness of the system has apositive effect on the operation becauseprocess data, messages or alarms are sentto a master control or the Simatic PCS 7process control system and where they canbe analyzed and archived. ■

9

ule of the new multi-axis drive SinamicsS120. The compact 1FK7 servo motors withtheir robust resolver transmitters ideallysupplement the drive range.

The decision in favor of Simotion wasnot a difficult one. A large number of axescan be controlled and synchronized accu-

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The CMS (Cam Makinalari SanayiLtd.) company founded in 1995 hasspecialized in a wide range of ma-

chines for the glass industry. CMS took animportant step in establishing an evenbetter position in the market with the in-troduction of CNC technology in a plate-cutting machine over two years ago.Whether windows, furniture glass or flatglass products for buildings, sanitary andautomotive industry; The standalone glasscutting table FCL 6032 cuts oversize platesinto the most accurate parts with CNCcontrol.

CNC controlled for a better cut

The desired cutting shape is transferred tothe Sinumerik 810D controller, which cutsthe glass with a cutting wheel along therail-controlled main axes X and Y. To obtaina perfect result, the cutting wheel, the Caxis, has to be guided tangentially. This is

achieved with the integrated tangentialcontrol of the Sinumerik 810D. At CMS, the“gantry function”, parallel drive in X direc-tion, compensates for the spindle pitcherror or reverse lots, which occur particu-larly on larger cutting tables. The cuttingpressure, cutting oil and cutting speed canbe set optimally using speed-dependentanalog outputs as well as the Simatic S7PLC integrated in the Sinumerik. The “lookahead” speed pre-control also guaranteesa high cutting speed in short travel sets.The Standard-PC PCU50 has many advan-tages; it not only enables operation andmonitoring (HMI) but it can also run third-party industry specific software, for exam-ple, for cutting optimization.

With Opty-Way, the optimization soft-ware from Optima, the glass industry hasan appropriate tool for efficient glass cut-ting management – starting from receivingan order right through to delivery. The user

can therefore largely avoid glass waste anduse the cutting surface on the glass platerationally.

Cutting plates more accurately andquickly

Since CMS has been using Sinumerik con-trols, they claim the quality of the cut glassplates has noticeably improved. Unlikepreviously used solutions, the dimensionscan now be corrected and entered as a cor-rection in the machine. The cutting speedhas also increased decisively to 150 metersper second.

The company is very pleased with thegrowing number of orders as a result.

“We have set the goal for ourselves ofbecoming a leading producer of plate cut-ting machines in this industry and are con-vinced that the cooperation with Siemenswill bring us further in this directionfaster.” The Istanbul glass machine manu-facturer has already set its sights on thenext development: a 5-axis edge-grindingmachine with the Sinumerik 840D CNCwith even more automation and accord-ingly less personnel involvement. ■

Glass plates in jumbo format can be cut exactly to the millimeter instraight or curved parts on the standalone glass cutting tables madeby the Turkish company CMS. Since being upgraded with the modern,compact CNC control Sinumerik, the machines now cut even moreaccurately and the cutting speed is three times as fast.


Glass cutting

CASE STUDY

CM

S

Sinumerik 810Dcombines high-precision axiscontrol with ease of use

Professional glass cutting with Sinumerik 810D

Investing in theFuture on theBosporus

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Glass grinding with Simatic S7-300 and Simatic MP270

EverythingUnderControl

CASE STUDY

The customers of the Italian companyZ.Bavelloni are benefiting from a newautomation concept which thecompany has developed specially forits grinding machines in cooperationwith Siemens. In addition to theimproved human-machine interfacethe machines are characterized byhigh dimensional accuracy in glassprocessing.

F lat glass processing ranks highly inthe wide range of machines of the Z.Bavelloni SpA., a subsidiary of the

Finnish Group Kyro. The strength of thedouble-sided grinding machine with cupgrinding discs of the VX series is in theprocessing of building glass. On a baseframe made up of two beams with onefixed and one moving cross beam theglass is transported by four individuallydriven high quality belts which are oper-ated by two maintenance-free compactsynchronous motors 1FK7. The Simodrive611U converters are used here as a drivesystem. The motors are electronically syn-chronized and guarantee higher qualityrunning and reliability with lower mainte-nance costs in comparison with conven-tional solutions with a drive shaft. Flexibleformat adjustment of the grinding discs isprovided by the distributed drive systemPosmo A which is ideally suited for adjust-ment jobs and communicates easily withthe controller via Profibus DP.

High performance paired with easy operation

With the CPU Simatic S7-315 2DP, Z.Bavel-loni has considerably increased the per-formance capacity of its machines. The set-up times have been reduced above all: Theoperator not only has the possibility ofcreating and configuring 48 programs in

advance but also of defining and saving 40processing configurations. For exampleglass abrasion, feeding speed or grindingquality. An external PC can be linked seri-ally or via an Ethernet network. In thisway the solution also enables simple im-port and export of programs, data andalarms and therefore improves the datastorage for monitoring the machine. WhatZ.Bavelloni admires most about theSimatic S7 is the variety of possibilities foreasy integration of sensor systems. Glassmeasuring sensors which make it easy forthe operator to determine the exact dimen-sion of the glasses and therefore ensurethat the glasses are ground with high pre-cision can now be connected easily.

With the Simatic Multi Panel MP270 theoperator has full control over the whole

Glass Grinding

grinding line at all times. The Simatic ProTool/Pro visualization software also al-lows simple, fast, intuitive operation. Theoperation is also simplified by the ergonom-ic and multi-lingual user interface. In theevent of a faulty plant condition the opera-tor is immediately informed by an alarmin his own language on the screen. ■

The Simatic Multi Panel MP 270 features a clear user interface and intuitive operation: By entering and storing processing configurations,set up time is minimized (top).

The graphic display of defects allows for fast localization of problems (bottom)

For all sections of the modern plant for automotive glass panes Benteler now only needs a single Sinumerik 840D CNC

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Cost-effective, industrial production ofautomobile side windows requirescomplex systems which only a few

manufacturers can offer. One of these is theBenteler Maschinenbau GmbH & Co. KG in Bielefeld. According to the motto “tra-ditionally progressive”, the mechanical en-gineering division of the company pro-duces plants, machines and tools for theflat glass processing industry. Standardmachines and plants are just as much apart of the production range as customizedspecial solutions. A typical example of these

is a plant for cutting/breaking, grinding,drilling and washing automobile glasspanes, which was recently developed andbuilt for an Iranian customer.

Modern machines for newrequirements

The work processes, from cutting to wash-ing, are known as pre-processing becausethey are followed by further processes suchas bending or hardening. The heart ofevery pre-processing line is the combina-tion of a cutting/breaking table with a

grinding machine that can be arranged ad-jacently in any number and connected toother plant sections. In Iran there are threecutting/breaking tables and three grindingmachines including automatic robot feed-ing, the proven rotary table drilling machinefrom Benteler and a washing machine. Afteronly ten seconds the discs leave the machinecut to size, ground, drilled and washed.

The side windows of modern private au-tomobiles are becoming lighter and lighterand are therefore taking on increasinglycomplex shapes – this makes cutting a lotmore complicated and time-intensive. Atthe same time the grinding time is short-ened by the increased grinding speed. Tosynchronize the process Benteler has comeup with a very clever solution: the instal-lation of bridges in the plant shortens thecutting and breaking time because thepanes can be cut and broken simultane-ously. The response to model changes inthe automotive industry is also unprob-lematic: retooling on the cutting table isunnecessary because every pane shape canbe broken automatically on the soft base.

The maximum speed in the grindingmachine could be doubled because it hasbeen equipped with new vacuums that canbe arranged quickly to suit any pane shapeby vacuum fixing. Another advantage of themachine is its good accessibility and main-tenance friendliness. The new hood – madecompletely of diecast aluminum – requiresonly one touch to open for changing thegrinding tool or cleaning the nozzle ring.

Pre-Processing

CASE STUDY

New pre-processing line for automobile glasspanes

Uniform from Cutting to WashingSince the Benteler company revised their plant concept the auto-motive glass suppliers have become more productive than ever.The secret to their success lies in an integrated control and drivetechnology from Siemens.

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To ensure that all elements of the differentmachines interact perfectly, an efficientcontrol and drive technology is required.

One controller for all jobs

The heart of the automation is the Sinu-merik 840D machine tool controller withhigh-performance 32-bit microprocessor,up to 10 channels and up to 31 axes as wellas an integrated Simatic S7 PLC. It can beassembled from a few components and thespecific know-how of the machine manu-facturer added for different performancerequirements. This is an important aspectfor Andreas Lüdtke, Head of Electrical De-sign at Benteler: “The scalability of theSinumerik 840D is very good because wecan respond to many different automationtasks with just one uniform controller.”

The controller in the Benteler plant isequipped with 4 channels that run an NCprogram simultaneously and independ-ently. Where, in the past, cutting/breakingand grinding centers had to be equippedwith separate controllers there is now justone controller for both. “This brings a tech-nical simplification and a more favorablecost structure”, Andreas Lüdtke explains.With regard to dynamic and precision theSimodrives 611D in conjunction with the1FK7 compact servo motors meet all the re-quirements of a modern NC processing.Converters of the Micromaster type areused for transporting the panes that areconnected to the Sinumerik 840D orSimatic S7 controllers via Profibus DP. All

the components integrate smoothly intothe automation landscape thanks to TotallyIntegrated Automation (TIA), the uniformconfiguration and data storage.

Benteler is well known for its drillingstation with patented drilling spindle. Thecompact, fully enclosed unit, which is pro-tected by blocking air even against splashwater, is driven by a sliding rotor motor. Atorque-free power transmission guaran-tees a precise feed. A Simovert Master-drives MC converter controls the digitaldrive whilst the distributed Posmo A drivestake over the x and y movements of thedrilling table. Since the frequency con-verters and controller are directly on themotor in this case, distributed drives con-siderably reduce costs: they reduce the sizeof the switch cabinet, require less mainte-nance effort and are also more compact andmaintenance friendly.

Solution à la carte

Benteler relies on Siemens’ branch com-petence for such complex and tailor-madeconcepts. The joint development of a solu-tion gives the company the insurance thatall the components will fit together opti-mally and guarantees a cost-optimized re-sult. The support from Siemens in com-missioning the plant also receives a posi-tive echo: “We accept gladly because weneed less time, “ Andreas Lüdtke explains.

Benteler write the NC program for theplant themselves. The part currently re-quired for the job is transferred from a

server to the machine control via Ethernet.The program is selected on a Sinumerikpanel so that the operator can supply thenew program to all other machines fromone plant section. ■


Any model shapecan be cut andbroken on thesoft base withoutretooling

The patented Benteler drilling spindlewith Simovert Masterdrives MC andthe distributed drives Posmo A

With the vacuumfixing suckers thegrinding machinecan be adaptedquickly to anypane shape

All

pict

ure

s: B

ente

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GlassFocus 2004

14

The market for flat screens is growingconstantly. At the same time thecompetition in this segment of the

market is increasing and the innovationcycles are getting shorter and shorter. The“laser scribe & break” technique of SCHOTTAP, a division of the SCHOTT AG glass com-pany in Mainz, offers several solutions formore rational and flexible display produc-tion. In display manufacturing, the glasssurfaces to be cut are known as substratesand are usually coated with the electricallyactive components. Any waste thereforemeans not only the loss of a glass panel butalso of the finished display, which, in thecase of high quality and large screens,would mean considerable financial dam-age.

Since even the slightest contaminationof the coating could destroy the display, flatpanel production takes place under clean-room conditions. Cutting the glass surfacesto size by the conventional cutting methodinevitably produces glass dust.

Laser scribing on the other hand oper-ates without contact. A focussed CO2 laser

SCHOTT Advanced Processing (AP) has developed a lasercutting technique for display manufacturing which is superiorto mechanical glass cutting. Prerequisite for the splinter-freescribing which can be used directly in a clean-room environ-ment, is a highly flexible control and drive technology.

Laser Scribing

CASE STUDY

Laser scribing breaks glass with micrometer precision

Diamond and Metal are Passé

The SCHOTT lasercutting system cutsdisplay glasses underclean-room conditions

Sch

ott

AG

GlassFocus 2004

15

beam heats up the glass along the cuttingline, which is then cooled down almost in-stantly. No micro-tears occur on the surfacein embrittling and pre-tensioning andpractically no micro-particles in the subse-quent breaking of the substrate. The laserscribing method is therefore considereddust-free, and the edge produced is ex-tremely precise and stable.

Accurate adjustment to the micrometer

For optimum dynamic, maximum posi-tioning accuracy and minimum load on theclean room, SCHOTT AP uses a Sinumerik840D controller and the wear and mainte-nance-free linear motors 1FE3 and torquemotors 1FN3. The direct drives thereforemeet the requirements of clean room class1000 and interact optimally with theSimodrive 611D converter system. SCHOTTuses the high positioning accuracy andholding force achievable with this drivetechnology in its machines for micrometer-precise alignment of the substrate. A cam-era picks up the coordinates of threeprinted marks on the glass whereupon theSinumerik controller can then convert thecoordinates of the cutting contour to the in-dividual position of the glass plate.

The intensity of the laser beam is con-trolled dependent on the track speed for aneven cutting depth. A camera monitorswhether the intended scribing depth isreached – in case of errors the cutting linecan be retraced immediately with adaptedparameters. This reduces waste and im-proves the throughput.

The trend of display manufacturers toshift away from rectangular panels towardsmore complex shapes, places increasinglyhigh demands on the controller. When cut-ting narrow curve radii for example, thethermal conductivity of the material alsoneeds to be taken into account in additionto the track speed of the scribing head be-cause the inside of the curve is exposed toa greater heat than the outside. Because ofits flexibility and scalability the Sinumerik840D controller is also ideal for future tasksas far as the scope of functions and per-formance are concerned.

The clean room capability of the laserscribing method and the drive technologyused saves the display manufacturer sev-eral steps in the process chain such as in-termediate inspection, edge grinding andpolishing and subsequent washing. The in-vestment and operating costs and thespace required by a laser scribing systemare therefore less than a comparable me-chanical system. The laser scribing is alsofar superior to conventional methods as faras cutting accuracy is concerned. Edge con-tours with an accuracy of 50 micrometersare normal with laser scribing in compar-ison with 100 to 200 micrometers in me-chanical scribing.

Flexible conception

SCHOTT AP places great emphasis onfinding solutions that exactly meet the re-quirements of their respective customers.The flexibly designed machines DLC 600,800, 1200 and 2000 have a modular struc-ture and can therefore be put together inindividual line solutions or free-standingprocessing stations with little engineering

effort. Georg Geissler, Sales & MarketingDirector at SCHOTT AP stresses: “We ben-efit greatly from the openness and flexi-bility of the Siemens systems which enableus to individually adapt our basic machinesand standard solutions quickly and easilyto very special customer requirements.” Thehomogeneous Profibus architecture withits extensive diagnostic functions is just asimportant to SCHOTT as the compatibilitywith various HMI systems, for exampleWindows-based user interfaces. The com-pany especially exploits the possibility ofcreating user interfaces with Asian lan-guages.

The integration of the SCHOTT laserscribing machine in a Japanese productionline with about 100 machines was a chal-lenge. With installation and commission-ing deadlines of one to three weeks for thewhole production line – as is usual in thismarket segment – everything has to fit thefirst time. “One stop automation is there-fore very important for us. The opennessof the Siemens systems considerably sim-plifies integration in the whole system. Andthe fast commissioning of Sinumerik aswell as the self-optimizing Simodrives werea big help in meeting the tight dead-lines,“Geissler praises.

A homogeneous telemaintenance capa-bility of the control and drive technologyis indispensable to the display manufac-turers who are producing at full steam andis also offered by Siemens as a standard.Next to their own bases in Japan, China, Ko-rea and Taiwan, the dense service networkof their automation partner in Asia partic-ularly is very important to SCHOTT AP. Dr.Christoph Hermanns, General Manager ofSCHOTT AP, gives the reason that about 99percent of all TFT cells are produced inAsia, that is in Japan, Korea and Taiwan.■


The difference speaks for itself:Micro-tears are normal in the conven-tional cutting method (top) whilst theglass plate cut by laser (bottom) has notone single micro-tear

Sch

ott

AG

16

Numerous glass manufacturers andprocessors are now also using panels

for close-to-machine HMI for plant-wideprocess monitoring with SCADA systems(SCADA – Supervisory Control and DataAcquisition). Siemens previously offeredtwo different systems: Simatic ProTool orProTool/Pro for the configuration of close-to-machine HMI applications and SimaticWinCC for the process visualization.

With Simatic WinCC flexible, uniformHMI software for all applications is avail-able for the first time. The compatible re-placement of ProTool and WinCC takesplace in two stages; since 2004, applica-tions for operating units under WindowsCE and PC systems under Windows 2000or XP Professional can be implementedwith WinCC flexible, while WinCC remainsthe Siemens process visualization system.With the second stage projects for theplant monitoring can also be implementedbased on WinCC flexible. The existing soft-ware products ProTool and WinCC are stillavailable.

WinCC flexible allows universal config-uration of all Windows CE-based SimaticHMI operating units – from the smallestMicro Panel right up to the PC solution –with one engineering software. ExistingProTool projects can be taken over com-patibly or converted.

The personnel only needs to learn oneengineering environment and can config-ure all visualization tasks with it. Projectparts created, for example, for a small panelcan be used in other panels or in the mas-ter process visualization. High configura-tion efficiency is ensured by the imagemodules and intelligent wizards providedas well as by full integration in TotallyIntegrated Automation by integration inSimatic Step 7, Simatic iMap and SimotionScout. A simple, intuitively operable inter-face has been developed with the aid ofnumerous usability tests in Europe and theUSA.

The support for foreign language con-figurations is of interest especially to ex-port-oriented machine manufacturers. Themost important terminology in the HMIfield is already available in 20 languagesand can easily be added to. Comfortabletext import and export functions allow ef-

ficient translation. The graphics of WinCCimages can be easily transferred to a WinCCflexible project. ■

Close-to-machine HMI and process visualization with one software

Find out more:www.siemens.com/wincc-flexible

PRODUCTS

Simatic IT optimizes production processes

The success story of Totally IntegratedAutomation continues with Simatic

IT. Full integration, extensive support ofall industrial standards and a compo-nent-based solution; that is Simatic IT.

With Framework and Simatic IT Com-ponents, Simatic IT provides a wide port-folio for successful E-manufacturing.

This integrates all production-rele-vant applications and activities whichenables company-wide communicationand coordination. By the exchange andcooperation of various factory plants ina Collaborative Manufacturing Execu-tion Exchange the supply chain re-quirements can be met efficiently andan increase in performance and pro-duction quality achieved.

Simatic IT Framework implements E-Manufacturing and takes care of system in-tegration in a factory, the standardizationof the production throughout the companyand the adaptation of the productionprocesses to the activities of the supplychain. With its various modules, the frame-work takes both production-oriented andIT-oriented perspectives into account andthus offers a complete production man-agement solution.

The production modeler is responsiblefor the entire management of an operation.

It synchronizes and coordinates people,machines and applications. An S95 plantmodel serves as a basis. The IT server takescare of component integration with eachother and in an existing IT environment.

WinCC flexible is the uniform visualization platform for every task whether inclose-to-machine applications (left) or control room solutions (right)

Siem

ens

GlassFocus 2004

Profinet sets new standards

17

The increasing importance of verticalintegration and the trend towards dis-

tributed automation structures both de-mand a new solution for industrial com-munication. Profinet, the innovative auto-mation standard of the Profibus UserOrganization for the implementation of acomplete and homogeneous automationsolution based on Industrial Ethernet, of-fers the most promising solution.

Profinet relies on established IT stan-dards and unrestrictedly supports TCP/IPsimultaneously for realtime communica-tion. Profinet consists of the solution forthe field area (Profinet IO) and the solutionfor distributed automation (Profinet CBA).Distributed field devices can be integrateddirectly on the Ethernet with Profinet IO.The master-slave method familiar fromProfibus becomes the provider-consumermodel. The usual IO view is retained, thatmeans the useful data of the field devicesare transferred cyclically to the processsimulation of the controller. This protectsthe investments of machine and plantmanufacturers and device manufacturersin changing over to Profinet. The heart of

Profinet CBA is a component model. It isused in distributed automation systemsand is ideally suitable for intelligent fieldand automation devices with programma-ble functions.

Solutions for realtime, Motion Control and safety

The realtime communication in Profinet isscalable according to requirements: RealTime for standard applications transfers re-altime data in response times which cor-respond to the performance of today’s fieldbuses. The Isochronous Real Time (IRT)with its extremely short response times issuitable for fast clock synchronous MotionControl applications. With IRT it is possi-ble to handle multi-axis machines such asthey occur for example in IS forming ma-chines with just one bus system. In this way150 drives can be operated at a cycle timeof one millisecond whereby a data rate ofsix Megabyte per second is even availablefor IT applications with TCP/IP protocol. TheProfisafe profile already proven in Profibuswill also provide for uninterrupted safetyof man and machine in the Profinet. ■

Find out more:www.siemens.com/profinetwww.profibus.com

Glass Focus 2004

With the Production Modeler, for exam-ple, it is possible to create a line configu-ration of a cutting line graphically from apre-fabricated library, parameterize therespective units automatically and gener-ate a configuration file. Changes in the con-figuration can be converted easily later inthe Production Modeler.

The standard products Simatic IT-Com-ponents provide a number of functions forexecuting production such as materialtracking and history, preventive mainte-nance, batch management and many othercomponents. ■

Find out more:www.siemens.com/simatic-it

More and more accuracy at high torqueand low speed – those are the de-

mands on high-tech machines in all in-dustries. So-called torque motors are ide-ally suited as direct drives for all rotationalaxes with high torque and low speed.

For example, torque motors are used inthe glass industry for driving rotary tables.

The drives work without mechanicaltransmission elements such as clutches orgears. They can be integrated directly in themachine structure. The advantage is an ex-tremely compact structure, in addition un-necessary elasticities and transmissionproblems are avoided. The minimizing oftotal mass and friction forces also in-creases the overall efficiency of the motorsas well as the machine dynamic. At thesame time the repetitive accuracy and po-sitioning accuracy are improved.

Torque motors are available in two ver-sions: as built-in or complete torque mo-tors. They have the water-cooled stator withthree-phase current coil and the rotor withpermanent magnet and hollow shaft incommon. In the case of the built-in torquemotor, the stator and rotor are deliveredseparately for installation in the machine.

The complete torque motor consists, as thename implies, of a ready-to-assemble unitwith its own mounting and integrated sen-sor system.

To suit various requirements, statorswith external diameters of 230 mm to 730mm are available. These cover a torquerange of 100 Nm to approx. 7,000 Nm. Thereference speeds are in a range from ap-prox. 250 to 500 rpm at low torques, up to

Cabinets from A to Z

The Chemnitzer Werk für Kombination-stechnik (WCK) offers tailor-made solu-

tions dealing with automation technology.The switch cabinet builder provides one-stop services – from consulting on hard-ware and software configuration right upto commissioning. Today about 420 peopleproduce more than 9,000 switch cabinets ayear in the factory, which was founded in1992. The recipe for success of the Chem-nitz company is their wide range of prod-ucts and services with which they can meetvarious customer requirements.

But the customer benefits from havinga single partner for the switch cabinet de-sign cycle even more than from the wide

product range. Configuration with the nec-essary products begins after customer-specific consulting. If necessary, customer-specific auxiliary modules can also be de-veloped and produced on the same site.The sophisticated material logistics andprocurements concepts specially adaptedto his requirements and the appropriatesupply chain management help the cus-tomer to save costs.

In production, every order is accompa-nied and executed completely by specialcustomer teams. Favorite suppliers ensureconsiderable price and logistics advan-tages. The machine manufacturer canchoose different service packages for theelectrical testing with which he can opti-mize his process costs. That means he getspre-tested total equipment on request. Thedelivery logistics are also adapted to thecustomer requirements. One example of

this are the ship-to-line concepts for dif-ferent customers. WKC fitters also providelocal support for assembly and commis-sioning on request. ■

A look at the switch cabinetproduction in Chemnitz

approx. 50 to 150 rpm at higher torquesand large external diameters.

Together with the proven converter se-ries Simovert Masterdrives Motion Controland Simodrive 611 the torque motors rep-resent another milestone in the Siemensdrive technology range. ■

Torque motors – new direct drives forthe glass industry

Find out more:www.siemens.com/drives

Torque motors get by totally withoutmechanical transmission elements

18 PRODUCTS

GlassFocus 2004

19

Sinamics: the new drive generation

W ith the Sinamics drive system inte-grated in Totally Integrated Automa-

tion all Siemens drives will have a commonsoftware and hardware platform in the fu-ture. Several Sinamics drives can be com-bined easily in individual drive solutionswithout any great engineering effort withthe common configuration and commis-sioning tools.

Based on typical reference data the usercan select the type and size of suitable drivewith the Sizer configuration tool. TheStarter tool provides optimum support inthe commissioning and testing of the drivesolution.

The Sinamics S120 is a modular drivewhich is particularly suitable for multi-axisapplications. Several axes are managed byone common control and supply module.The central control module of the Sinam-ics S120 performs the drive control for allconnected axes throughout and is respon-sible for the technological links betweenthe axes. Sinamics S120 contains bothservo and vector control. All componentsincluding the motors and the encoders areconnected with each other via a commoninterface, the Drive-Cliq. Transformer mod-ules for the conversion of conventional en-coder signals to Drive-Cliq are provided forOEM motors or retrofit applications.

To simplify clear identification of all themodules used in a machine, every compo-nent of the Sinamics S120 is equipped witha digital rating plate containing all the rele-vant technical and logistic data. These valuescan be called electronically locally and bytelediagnosis to greatly simplify drive serv-icing. The large mains voltage range of 380to 480 Volts allows worldwide utilization.

Sinamics G110, the smallest frequencyconverter for variable speed drives in theSinamics family, has been developed forsingle-phase mains at 200 to 240 V with apower range of 0.12 to 3 kW. It is availablein several versions with analog input orRS485 interface. Three digital inputs en-sure great flexibility. An integrated DIPswitch sets the drive to 50 or 60 Hz so thatSinamics G110 is ideally prepared forglobal application.

Finally, Sinamics G150 was developedfor pumps, fan and compressor drives. Itcontrols the speed of low voltage asyn-chronous motors with outputs between 75and 800 kW and is the world’s quietest andmost compact converter in the standardswitch cabinet at the moment. ■

Find out more:www.siemens.com/sinamics

Siem

ens

The first members of the newSinamics family: Sinamics S120(left), Sinamics G110 (right) and Sinamics G150 (in the back-ground)

Repair service

To ensure that costs are always withinthe planned scope and therefore re-

main calculable for the machine manu-facturer, Siemens offers a Repair ServiceAgreement (RSV). This agreement offersthe machine manufacturer worldwidetroubleshooting at a reasonable price– even at the plant operator’s.

The RSV contains the following serv-ices: provision of service personnel, er-ror diagnosis and troubleshooting onsite as well as certification of fault elim-ination.

The agreement runs for 12 or 24months.

Interested? Just get in touch withyour contact partner. You can find moreabout Siemens support solutions alsoon page 38. ■

Find out more:www.siemens.com/automation/support

GlassFocus 2004

availability. Usability and handling of allsystem components have been improved,and transmission and loading times havebeen reduced – in some cases by half.

Simatic PCS 7 version 6.1 still runs underMicrosoft Windows 2000 but also underWindows XP. ■

GlassFocus 2004

20

Simatic PCS 7 has been used successful-ly as an efficient process control system

within the scope of Totally Integrated Au-tomation for many years – in more than3,000 projects worldwide. The new version6.1, with numerous new functions and fea-tures, is now continuing this success story.

Thanks to the smooth integration ofplant asset management in Simatic PCS 7,plant operators are able to recognize po-tential problems in good time so that pro-duction failures can be effectively reducedor avoided altogether.

Easy access to Simatic PCS 7 via standardPCs is supported by the new OS-Web func-tion. For this a web server is installed on aPCS 7 client through which standard webclients can then monitor and supervise theprocess via intranet or Internet – from any-where in the world, using standard PC tech-nologies. Access can be protected by a pass-word, firewall technology, and also indi-vidual application concepts designed tomeet a plant’s specific safety requirements.

So-called floating licenses support aparallel user model – any number of in-stallations are allowed, but with restric-tions on the number of users who can workwith the software simultaneously. Enter-prise licenses are offered for large-scaleusers. With rental licenses, the softwareaccess expires after a certain number ofoperating hours – an attractive alternativefor projects with a time limit, which is typ-ical for engineering tasks. Finally, with atrial license the user is given access to thesoftware for demo, testing, and evaluationpurposes for a limited period.

The PCS 7 system bus can now also beoperated with transmission speeds in thegigabit range – an important aspect forvery large plants and when several plantsare networked on one site. Gigabit tech-nology is available both for optical andtwisted pair networks and can be designedin redundant and double redundant ringtechnology in order to considerably in-crease the network’s performance and

The story continues: New features in Simatic PCS 7

Find out more:www.siemens.com/pcs7E-mail: [email protected]

PRODUCTS

The choice of new sites for glass produc-tion depends not only on closeness to

the market but also on the availability ofappropriate high-voltage electrical net-works of sufficient quality.

Siemens is now offering products, sys-tems, and solutions for energy supply forglass production, including the associatedengineering services.

Utilities such as energy supply systemsshould be designed compactly to minimizefactory space requirements. SF6 switchingsystems on the high- and medium-voltage

level need only one-third the space of con-ventional switching systems. In addition,the 8DJ, 8DH, and NXPLUS C SF6 switchingsystems are climate independent andmaintenance free. Air-insulated switchingsystems in the NXAIR series are distin-guished by their modularity and perform-ance – a short-circuit rating of up to 50 kilo-amperes and a rated current of up to 4,000amperes.

The switching systems also meet a sec-ond basic requirement of the glass indus-try: availability and reliability of the energy

Full power: Integrated solutions for energy supply

For all situations: A wide range of processinstrumentation equipment

GlassFocus 2004

21

High availability, high reliability, andprecise results are the three basic re-

quirements of the glass industry forprocess instrumentation. Another impor-tant aspect is a high degree of standardi-zation to keep spare parts stocks andmaintenance expenses to a minimum. Theaim is to be able to cover the entire glassproduction process with just a few processinstrument types.

Due to the consistent development of itsproducts and the acquisition of well-known specialist companies, Siemens to-day offers a wide range of sensors andmeasuring instruments for almost all ap-plications.

With Siwarex in its portfolio, Siemens hasproducts for dynamic weighing as well asstatic weighing, including belt scales, pro-portioning belt scales, and deflector plates.The latest addition to the weighing systemsis the new Siwarex FTA weighing processor,with an integrated high-precision propor-tioning control and batch system.

For level measurements in silos andbunkers, Siemens offers, in addition toultrasonic sensors, radar instruments suchas the Sitrans LR 400, with which the levelcan be measured accurately to the millime-ter in silos with a height of up to 45 meters.

With its acquisition of the Danfoss FlowDivision, Siemens has added to its portfo-lio of instruments for pressure, flow, andtemperature measurements, as well as po-sition controllers, process controllers, andrecorders. New, for example, is the massflowmeter, using the Coriolis principle, forflows of 65 to 510,000 kilograms per hour.The 0.1 percent tolerance of the Sitrans FCMASSFLO and the repetitive accuracy guar-antee maximum quality and low waste.

The MicroSAM compact gas chromato-graph has a diameter of only 26 centime-ters and can be used directly in the process– for example, for determining the exactcalorific value in gas-fired ends. TheLDS 6 laser diode spectrometer that, for ex-ample, measures oxygen directly in the ex-

haust gas is a further step toward close-ness to the process. ■

Find out more:www.siemens.com/processinstrumentationE-mail: [email protected]

supply. The choice of transformer size for consumers should therefore also be-designed in accordance with the n-1 rulein order to avoid network problems in theevent of failures.

The standardized Totally IntegratedAutomation (TIA) and Totally IntegratedPower (TIP) system platforms enable theenergy supply and the process to be mon-itored continually. The continual recordingof consumption forms the basis for a sub-stantiated load forecast and optimization of energy consumption. All operating data

relating to the energy supply can also betransferred to the glass production processcontrol system so that the production man-ager can identify trends at an early stageand take appropriate action.

Siemens has created an open platformthat is also compatible with other systemsand therefore enables extensions and in-tegration of OEM systems. ■

Mehr zum Thema:www.siemens.com/ptdE-mail: [email protected]

GlassFocus 2004

22

The leading European glass manufac-turer Saint-Gobain was founded in1665 and has produced such famous

glass constructions as the Galerie desGlaces in the Palace of Versailles and thepyramid of the Louvre.

Transparent or colored glass is made ina float glass line in France and then, de-pending on the application, processed fur-ther in the building or automotive indus-try. The manufacture of colored glass re-quires a higher heat supply than normal

flat glass. Changeovers during produc-tion also cause heat shocks, which are of-ten the cause of material fatigue and re-duce the life of the furnace. Statisticallyspeaking, Saint-Gobain must renovateone and a half float units every year inits 26 float glass plants worldwide.

Uniform solution

In Chantereine the float lines were mod-ernized and the power distribution formedium and low voltage and the digitalcontrol system upgraded. The Teleperm Mcontrol technology was also migrated toSimatic PCS 7. The new control system nowcontrols the entire plant, from the compo-sition of the raw material mixture to theend of the cooling lehr. In the productioncontrol room the personnel can control andmonitor the processes in the batch section,on and in the melting furnace, in the floatbath, and in the cooling lehr, including theutilities from the operator stations.

The operator stations communicatewith each other via an optical Ethernet net-work. Two PCs serve as a server and man-age the database containing all the infor-mation collected from the automation sys-tems. Via a Fast Ethernet network, theservers communicate with the automationsystems for the furnace, the burners, thetop rollers, and the power distribution forthe factory.

Two Profibus DP bus systems connectthe process control system to the systemsin the process, where distributed SimaticET 200M and ET 200S devices are used asI/O. Profibus PA is used for connecting theprocess instrumentation.

Another unit of the float plant is alsoconnected to the process control system viaProfibus DP. The switchgear cabinets forthe power transmission and distributionsystems are equipped with Sentron WL

Automation of a float glass line with Simatic PCS 7 at Saint-Gobain in France

Transparency and ReliabilityThe Chantereine plant of Saint-Gobain Glass France primarily produces float glass for the automotiveindustry. The melting furnace of the plant in the French city of Thourotte was replaced during the coldrepair in 2001. By adopting the Simatic PCS 7 process control system, the company was able to secure its investment in the infrastructure.

Flat Glass

CASE STUDY

Saint-Gobain has been producing glass for300 years – and can therefore rightfullyclaim to be one of the oldest industrial en-terprises in the world. What began in asmall glass foundry in France is today an in-ternational group that is present in almostevery country in the world, producing – inaddition to glass – ceramic materials andmaterials for the building industry. Thecompany’s sales totaled 29 billion euros in2003.

Think global, act local – this strategy,which Saint-Gobain pursues consistentlywith its own production in 46 countries, isone of the company’s key strengths. "It isan important part of my job to help imple-ment this motto, both in Saint-Gobain andSiemens,” says Olivier Vincent, internation-al account manager for Saint-Gobain atSiemens.

"That means I work closely with the lo-cal teams on the projects and at the sametime keep an eye on the global aims of theSaint-Gobain Group. I am the one personresponsible for all questions regarding ourcollaboration with Saint-Gobain – regard-less of whether it is a project in Asia or a

strategic decision for a specific technology.Saint-Gobain is more than just a customerto us. We see our cooperation as a long-term partnership, and this is also how I amworking with the teams at Siemens and atSaint-Gobain – as a partner.”

This joint approach has proven itself inmore than 100 projects that Saint-Gobainand its subsidiaries have completed withSiemens since 1956. In the last few years,more than 15 projects used Simatic PCS 7as an automation solution, including plantsfor hollow glass, float glass, cast glass andglass wool.

Several of the plants are located in theworld’s emerging glass markets such asRussia and China, where technology andglass expertise has to be combined with lo-cal support. Siemens – a global player justlike Saint-Gobain – can offer just that, plusthe possibility of standardizing on provenand integrated solutions on a global scale,based on Totally Integrated Automationwith the process control system SimaticPCS 7. Together with Siemens, Saint-Gob-ain has all the means to face another 300years of successful business.

Global Partners: Saint-Gobain and Siemens

GlassFocus 2004

23

circuit breakers and the Simeas P low-volt-age monitoring systems. Other thyristorpower switches with a rating of 150 to 250kilowatts guarantee the additional electri-cal heating of the float bath.

The switches can be integrated easilywith the Totally Integrated Automationconcept and also communicate with the au-tomation system via Profibus DP. Around20 Siprotech 8DH10 protection devices areresponsible for the 20-kilovolt power sup-ply to the plant. These components are alsoconnected to the Simatic PCS 7 process con-trol system via Profibus DP.

Higher performance, lower costs

In the glass production process, 60 smartdigital Sitrans sensors were installed for the

first time to measure pressure, flow, andtemperature. These are connected directlyto the control system via Profibus DP. Jean-Paul Rischmann, head project engineer at Saint-Gobain, particularly admires thespeed at which the sensors can be com-missioned: They can be calibrated and pro-grammed through PCS 7, which “saves aconsiderable amount of commissioningtime.”

With the selection of Simatic PCS 7,Saint-Gobain Glass has chosen a future-safe process control system that can belinked to the IT level of the company – andall with comparable or even better per-formance than the previous system.Rischmann particularly stresses the eco-nomic advantages of the migration from

Teleperm M to PCS 7: “Up till now the plantwas controlled by a Teleperm M systemfrom Siemens. The installation of the PCS7 system meant that the majority of theolder peripheral devices could still beused, and thus the costs for the conversionwere kept low.” ■


The Float ProcessJust like every other type of glass,float glass is made of sand, soda, and lime, which are mixed, wet, and melted. What makes float glassspecial is the specific shapingprocess. The Float process was intro-duced to the public for the first timeon January 20, 1959, and has since,in a few variations, become by farthe most important glass producingprocess.

In the float process, the meltedglass flows from the end of themelting furnace at a temperature ofabout 1100 degrees Celsius into thefloat bath. There, the glass spreadsevenly on a surface of liquid tin. Thetop rollers and the speed at which theglass is drawn off determine the thick-ness of the continuous glass ribbon,that usually varies between 1.6 and19 millimeters.

The glass ribbon is cooled slowlyand evenly to room temperature inthe annealing lehr and then cut intoplates that match the requirementsof the current orders. Large lift-offdevices then store the plates onvertical racks.

GlassFocus 2004

24

The cold repair in the float plant at theStolberg factory was carried out inthe first half of 2002. With the con-

version of a standard float line into an ex-tra-wide float line, the plant in Stolberg –which has been producing float glass for 30years – has become one of the most mod-ern in the world. It is the fourth line at theSaint-Gobain site in Stolberg and producesfloat glass destined mainly for the auto-motive industry.

The cold repair of the float glass plantat the Cologne-Porz factory was performedin the second half of 2003. Increasing thevolume of the melting end has made theline in Cologne-Porz one of the largest floatglass plants in the world.

The melting furnace in Stolberg was of-ficially refired on May 21, 2002, and inCologne-Porz the melting furnace offi-cially began operation on October 21,2003. Saint-Gobain Germany also tookthe opportunity of the cold repair to bringthe electrical equipment up to date atboth sites. In modernizing the controlsystem, the company pursued clear goals.Great emphasis was placed on a moderncontrol concept with high availability,which also provides a platform for futureexpansion.

Uniform long-term solution

Saint-Gobain awarded both automationprojects to Siemens – not least due to thefact that Siemens had the necessary indus-try know-how to perform a general over-haul of the automation technology duringthe cold repair of the float line. The goodprice/performance ratio of the Siemens so-lution with Simatic PCS 7 and the goodsupport from account management werealso decisive factors.

Siemens delivered not only the compo-nents for the control system and devices forthe process instrumentation for both proj-ects but also managed the technical as-

sessment and compilation of the specifica-tion as well as the hardware and softwareengineering.

PCS 7 was able to demonstrate all itsstrengths, both in Stolberg and Cologne-Porz. In both cases, existing plant unitssuch as utilities were easily integrated intothe new control system. The field deviceswere also easily connected to PCS 7 viaProfibus DP and PA.

Within the scope of the standardizationand optimization of spare parts stocks,Saint-Gobain made sure that the drivesolutions were also standardized. After ex-tensive comparisons, Saint-Gobain choseSimovert Masterdrives for both Porz andStolberg. All the drive components wereconnected to the control system via

Profibus DP. Siemens was also contractedto design the respective control centersfrom which the individual plant sectionsare operated and monitored.

Double score

The two new lines have been in operationfor quite some time now, and Saint-GobainGermany has not regretted choosingSiemens. Both the implemented technol-ogy and the Siemens support lived up to allexpectations. ■

Cold repair of two float lines at Saint-Gobain Germany

Prepared for the FutureIn the past two years, two float lines at Saint-Gobain Germany have been modernized with the Simatic PCS 7process control system as an integral part of Totally Integrated Automation during scheduled cold repairs. Both sites benefit from the high level of integration the new solution offers.


Flat Glass

CASE STUDY

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CASE STUDYGlass Containers

S aint Gobain Oberland AG has beensynonymous with expertise in theglass industry for decades. As an in-

dependent subsidiary of the french Saint-Gobain Group, Saint-Gobain Oberland is aleader in glass container production. InGermany, Saint-Gobain Oberland runs fourfactories: in Bad Wurzach, Neuburg, Essen,and Wirges.

At the Wirges site, Saint-Gobain Ober-land replaced the existing automation of afurnace in 1999 with the Simatic PCS 7process control system. This made theWirges factory a pioneer in the Saint-Gobain Oberland company at that time.

The openness and high degree of inte-gration of Simatic PCS 7 was a particularlydecisive factor in the selection of theSiemens technology as well as the price/performance ratio and the long-term in-vestment security. PCS 7 relies on theproven components from the Simatic prod-uct line and therefore has a very soundtechnological basis.

The first in a series of successful projects

The pilot project in Wirges was so suc-cessful that Saint-Gobain Oberland soonbegan other projects with Siemens – alsoat other sites. At the Neuburg site, whereglass containers are produced for the foodand beverages industry, the company de-cided in 1999 to modernize the control sys-tem by implementing Simatic PCS 7 dur-ing the next scheduled cold repair of a fur-nace. The contract included the delivery ofthe hardware, the engineering, and thecommissioning, which was completed suc-cessfully and on time in February 2000.

After the successful conversion toSimatic PCS 7, it was only logical to im-plement PCS 7 for the other melting fur-naces in the following years.

Trend toward standardization

Additional projects have been completedsuccessfully in Wirges. In 2003, the deci-sion was taken to modernize another fur-nace with its corresponding feeders as well.Siemens received the order to convert theautomation in 2003 and will complete thework this year.

These projects for the glass containerdivision of Saint-Gobain continue the trendof using PCS 7 as a standard solution in theglass industry. ■


Simatic PCS 7 implementedin the glass containerdivision of Saint-Gobain

A Series ofSuccesses The production of glass containers forpackaging is without a doubt one ofthe most fiercely contested markets at present. A company wishing to besuccessful in this market must consis-tently optimize its plants, exploitsynergies, and use technical progressto its advantage – both in terms ofdevelopment of new products andoptimization of the plants. For thisreason, at Saint-Gobain Oberland AGthe automation technology has beenconsistently modernized with SimaticPCS 7 for several years.

Glass containers for the food and beverages industry arethe main market of Saint-Gobain Oberland

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Experience and industry expertise convince Isover

Multinational TeamworkDoing a big project in Russia with five companies in four different countries – still almost a routine job for Siemens,which took on the project management for a new glass wool plant for Isover under these conditions. A successfulproject for a similar plant in Poland, extensive experience in the Russian market, good relations with technology partners, and, last but not least, a cooperative customer all contributed to the successful completion of the project – which in turn prompted Isover to continue its partnership with Siemens.

Glass Wool

CASE STUDY

The TEL processThe raw material for glass wool is ordinary sand, which ismixed with melting agents and recycled glass and melted at1450 degrees Celsius. The glass melt is fiberized on a spinnerin the TEL machines. The fibers are treated with bindingagents (to give cohesion and mechanical properties to theglass wool) and formed into a fiber mat. The special TELSTARprocess used exclusively by Isover produces particularly longand soft fibers that have very good insulating properties.

The continuous fiber mat strand then passes through acuring oven, where it gets its final shape, strength, andstability. The finished fabric is then coated, cut, and packedeither as batts, slabs, or rolls.

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S tarting in 1996, Isover has been ac-tive in the Russian market for eightyears and is the second largest sup-

plier of insulating materials in Russia.Isover has benefited from the rapidly grow-ing demand for insulating materials in Rus-sia and neighboring states, and about twoyears ago the company decided to build itsown production site in Russia. The newplant was to be built on an old industrialsite in Yegorievsk, near Moscow. From thevery start, the project was geared towardfuture growth. Initially only one line witha capacity of 20,000 tons of glass wool wasto be built. However, the plant’s premisesare large enough to house further glasslines.

International project team underexperienced management

The new plant was built by Isover Oy of Fin-land, in cooperation with Isover Russia. Theplant uses state-of-the-art technology toensure efficient and reliable production.An energy-saving melting process, sophis-ticated TEL machines, and efficient and re-liable automation technology were plannedand implemented by an international proj-ect team.

Siemens was responsible for projectmanagement in the areas of automation,process instrumentation, and valve tech-nology, including the corresponding engi-neering and services. The fact that Siemenshad already proven its industry and proj-ect expertise in other Isover plants, forexample in Poland and Germany, was adecisive factor for Isover in placing thisorder.

The Siemens project management teamworked in close cooperation with Russianengineering consultants Sinetic, who tookover the responsibility for local installationof the systems. Siemens contracted itstechnology partner STG Cottbus GmbH tocreate the application software and super-vise the commissioning and installation ofthe systems on site. An Austrian companysupplied the valves, Siemens Germanyprovided the Simatic PCS 7 system and theentire field instrumentation, and SiemensFinland delivered the cabinets and opera-tor panels for the process control technol-ogy.

“Coordinating such a multinational proj-ect is always an immense challenge,” saysDirk Richter, Siemens project manager forthe plant in Yegorievsk. “We had to coor-

dinate all units that were in our responsi-bility along with the activities of the localRussian companies and our own subcon-tractors. In addition, the Russian markethas a number of peculiarities that demandspecial expertise.” Siemens has been ex-tremely active in the Russian market forseveral years and therefore possesses thenecessary licenses and permits – anotheradvantage of working with Siemens, asIsover confirms.

Uniform automation technology

The Simatic PCS 7 process control systemis used throughout the plant. The systemsin the process are connected to the controlsystem via Profibus DP – including SitransPS 2 positioners, which control the valvesin the plant, among other things.

The uniform system architecture offersIsover several advantages. The work in-volved in the commissioning and fine ad-justment of the individual units is reducedconsiderably, and maintenance and servic-ing of the plant are also simplified. At thesame time, Isover can be certain that boththe process control system and the processinstrumentation can be extended or modi-fied at any time – an important aspect, es-pecially in a plant that was geared towardgrowth from the very outset.

Project completed successfully

The whole project went off perfectly. Theplant went into operation in October 2003and was producing at full capacity within avery short time. This was due not least toSiemens’ international project expertise.Together with Isover, Siemens always man-aged to make the right decision when dif-ficulties arose or when modifications werenecessary.

In June of this year, Isover decided to ex-pand its activities in Russia even further. A second production line is presently un-der construction and has been designedfrom the start so that its capacity can eas-ily be doubled. With this new line operat-ing at maximum capacity, production inYegorievsk will be more than tripled. Forthe new project, Isover again put its trustin Siemens’ competence and appointed theproven team as project managers. ■

Isover: Experts in insulating materialsIsover is the primary global brand of the insula-tion division of the French glass manufacturerSaint-Gobain. With a market share of 30 per-cent in Europe and 20 percent in the UnitedStates, Isover is the world’s leading name in in-sulating material for building.

Isover is represented in 35 countries world-wide and produces glass and mineral wool andthermal and acoustical ceilings at 37 sites.Isover also produces insulating foams that aredeveloped in partnership with major chemicalcompanies.

Last year, the company, which currentlyemploys about 9,000 people, achieved sales ofapproximately 1.9 billion Euro.


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Glaverbel, as the European branch ofthe Asahi Glass Company, is a mem-ber of a leading global association

of glass-producing companies. By the mid-1990s, Glaverbel had identified the hugedevelopment opportunities offered by theRussian market and acquired a holding inthe country’s largest glass manufacturer,Bor Glassworks. Since then, the companyhas concentrated on massively expandingglass production in Russia in order to meetthe expected rapid increase in demand incoming years.

The company’s most recent project areproduction lines for float glass, coatedglass, and mirrors in Klin near Moscow, in-volving a total investment of 150 millioneuros. Siemens also has a significant rolein the project.

Know-how in Russia

Siemens was commissioned to handle theproject management because of its long-standing experience of co-operation withthe glass industry, and because of its ex-tensive knowledge of the applied processesin Russia. The size of the order comprisedthe complete engineering, installation andcommissioning of the plant. Siemens sup-plied all of the automation and drive engi-neering, the field instrumentation and theentire power supply infrastructure. In ad-dition, the responsibility for the integra-tion for the components of all of the sub-suppliers was handled by Siemens. Thecore component for the solution as part ofthe Totally Integrated Automation (TIA):Simatic PCS 7

Glaverbel and Siemens have alreadyworked together successfully on previousprojects, including the establishment ofglass plants in Iran and in Mol, Belgium.Philippe Mary of Siemens in Brussels says:“Siemens is an international partner ofGlaverbel. We were able to convince theGlaverbel experts of our qualifications by taking them to a few reference projects.

Glaverbel automates glass production with Simatic PCS 7

Local ExpertiseFor the automation of a new glass line in Russia, Siemens was able to win theclient’s trust with its extensive local experience and clear technology expertise.

Flat Glass

CASE STUDY

GlassFocus 2004

Siemens’ long presence in Russia alsoproved to be of considerable benefit.”

Another contributing factor in the deci-sion was the fact that Siemens works withpartners who have a very good reputationin their respective fields of expertise. Thesepartners include AEG as the supplier of theheating system for the float bath and STGas the provider of the process control forthe melting furnace.

“Glaverbel clearly valued our expertise inthe glass industry. Another crucial point inour favor was the Russian project manage-ment approach we use,” explains PhilippeMary. Guy André, manager of the Glaverbelproject, concurs. He also cites the efficientmethod of cabling and the outstanding rela-tionship between quality and costs. The ex-cellent on-site logistical support in Russia,facilitating the speedy implementation of the project, was also a deciding factor forGlaverbel. n


Modernization of a float line at Cardinal in the USA

A Hot Project during Cold Repair

The cold repair of a glass plant provides an opportunity to updateautomation technology. Cardinal Glass in the USA decided to installa consistent and redundant process automation solution based onSimatic PCS 7 at one of its float glass plants.

W ith more than 4,000employees, 18 pro-duction sites, and 2

in-house research centers,Cardinal Glass is one of theleading glass producers inthe USA. The company is con-sidered to be exceptionally in-novative and has made aname for itself in the field ofdouble-glazing for the con-struction industry.

As part of a cold repair car-ried out at its float glass plantin Menomonie, Wisconsin,Cardinal also wanted to up-date all the plant’s automa-tion technology. Specifically,Cardinal needed to imple-ment an integrated solutionfor the batch house, meltingfurnace and the cutting lineof this plant, which has anoutput of over 550 tons ofglass per day.

Cardinal selected theSimatic PCS 7 process controlsystem, a homogeneous andintegrated solution that isideal for the requirements ofglass production. Specifi-cally, the PCS 7 solution pro-vides the redundancy and re-liability necessary to sustaincontinuous glass production.

Redundancy from A to Z

The process control systemis redundantly configured inorder to provide maximum

availability – including the server andcontroller processors. Siemens is also pro-viding all the programming and installa-tion of the system, as well as supplying thefully integrated controllers for the heatingsystems and more than 30 transmittersfor the pressure and temperature values.

The project began in the summer of2003 with a comprehensive on-site analy-sis of the plant andwill conclude at thebeginning of 2005with in-depth train-ing of plant em-ployees.

Upon comple-tion of the project,Cardinal will haveat its disposal anintegrated, uniformtechnology thatbrings together theentire productionprocess in the hotend under a singleoperator interface,which will not inter-fere with produc-tion if individualcomponents break down. Cardinal is al-ready very satisfied with the project im-plementation and is convinced that bychoosing Simatic PCS 7 as a solution, it hasassured the cost-effective operation of theplant for many years to come. ■

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The Menomonieplant has anoutput of 550 tonsof glass per day

29CASE STUDYFlat Glass


A rchitects have long known Pilk-ington ProfilitTM as a product to beused for glass facades. Now, how-

ever, demand for the glass is increasing asits role expands to include more decorativefunctions. The ProfilitTM system consists ofself-supporting glass channels that are man-ufactured at Pilkington’s building glassplant in Schmelz, Germany, using a speciallydeveloped mechanical rolling process.

As part of a recent cold repair, Pilking-ton subjected the entire production site toa comprehensive refit before refiring the

new melting furnace in April 2004 and con-tinuing with the production of glass ele-ments.

Entering the 21st century

According to production managerChristoph Claesges, the technical upgradeof the plant has enabled profiled glass pro-duction to take a step into the 21st century,adapting Pilkington ProfilitTM to futuremarket requirements. A new control sys-tem for the melting furnace, shaping unit,

and utilities such as the compressor stationand hydrostation were a key part of theupgrade. Pilkington decided to work withSiemens on the implementation of the proj-ect and chose the Simatic PCS 7 process con-trol system.

The fully redundant system permits theuniform control and monitoring of the en-tire production process from one controlroom. It is accommodated in four standardcabinets and is expanded by processinstruments such as Sipart controllers,Siwarex weighing system, Sitrans P pres-sure transmitters, Sitrans FR flow meters,and Simovert Masterdrives.

Siemens was responsible for the imple-mentation of the entire project, includingthe development of the circuit diagrams,the cabling, the software configuration andparameterization, and the commissioningof the entire system. Simovert MasterdrivesVC control the transport of the raw glasswithin the shaping machine and in the an-nealing lehr. Their functions are also inte-grated into the PCS 7 interfaces.

Experienced project management

Pilkington was very satisfied with the ex-perienced project management providedby the Siemens team and was able to startoperations on time with no problems.From a technological viewpoint, the com-pany has now set a course for the success-ful manufacture of its unique product,which began life as purely industrial butwhich is now well on its way to becominga creative design element in modernarchitecture. ■

Find out More:www.siemens.com/glasswww.profilit.comE-mail: [email protected]

GlassFocus 2004

30Glazing Systems

CASE STUDY

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Simatic PCS 7 automates glazing system production

Stepping into the FutureThe ProfilitTM glazing system from Pilkington is rapidly moving beyond itsoriginal purely industrial function and becoming a design-oriented elementin modern architecture. This development has spurred a fundamentalmodernization of the company’s process control system.

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GlassFocus 2004

31CASE STUDYFlat Glass

Excellent cooperation with Guardian Industries Corp.

Several in a RowThe glass industry depends on extremely reliable production processes. Thismeans that the industry tends to use only proven innovative technology builtand commissioned by reliable partners – such as Siemens, who has imple-mented a sustainable, innovative automation solution for Guardian at severalsites in Europe and Saudi Arabia.

A s a rule, the glass industry relies onsolutions that have proven them-selves over decades. However, in

cooperation with the melting furnace spe-cialist STG from Cottbus, Siemens hasbeen able to introduce a range of innova-tions offering clear benefits in process con-trol, which have since become accepted asthe new industry standard. The trigger forthis change was a range of projects under-taken for Guardian in the UK, Poland,Spain, Luxembourg, Saudi Arabia, Ger-many and Hungary. Siemens implementeda new control concept in these applications.

One of these projects was the Guardianfloat glass plant at Goole in the UK. With acapacity of more than 600 tons per day, theplant produces all strengths of glass for theBritish construction industry. The projectincluded the automation of the entireprocess from the hot to the cold end. Notonly did Siemens supply and install the en-tire process control system for this project,but also all the sensor technology, as wellas the exhaust gas analysis system. The ex-pertise of Siemens’ long-term partner STGwas very beneficial, particularly with re-gards to the melting end and cooling chan-nel. The results were impressive: The plantdelivered perfect quality product – fromthe very first day of production.

Cooperation continues

The most recent project is the Guardianproduction line for float glass in Oroshaza,Hungary. This project involved the realiza-tion of the control technology for the melt-ing furnace and cooling channel. Work be-gan in July 2004. This project was also car-ried out with STG and utilizes SimaticS7-400 technology with comprehensivenetworking via Profibus DP in an approachvery similar to the innovative strategy al-ready implemented at Goole in the UK. Allparticipants are confident that this projectwill continue the series of successful proj-ects for Guardian and Siemens. ■


For Guardian in Mexico,Siemens supplied the medium voltageswitchgear

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First steps in theAmericasSiemens was able to secure anotherproject at the Guardian glass plant in El Marques, Mexico. This completelynew plant is the site of Guardian’sfirst flat glass production facility inMexico. It came online in August of2004 and is designed to produce adaily capacity of 700 tons.

Siemens supplied all the motorcontrol centers (MCCs), the gasanalysis system for the bath, mediumvoltage switchgear, distributionpanels and lighting panels, andessential parts of the electricalsystem. Siemens and its partnersplayed a crucial role in the project,with a team of Siemens experts fromMexico and the USA providingcomprehensive on-site support.

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Elam Engineering andSiemens began a new part-nership with a very largeand ambitious project: the automation of an impor-tant process step in a newproduction facility for LGPhilips Displays in Zhengzhou.Depending on the size of theproduced parts, the factoryhas a capacity of two tothree million glass screensand cones per year.

TV pressed glass is produced con-tinuously – 24 hours a day, sevendays a week. One of the most criti-

cal machines in the production processis the hydraulic press, which molds themelted and cut glass into its final shape.The press can exert a force of 700 kilo-newtons (70 tons) and has a maximumspeed of 1,000 millimeters per second.

The young Dutch company ElamEngineering was responsible for all theelectrical engineering and automation ofthe press and the machines that feed it,from portioning to placing the glass partson the conveyor belt. Elam Engineeringwas founded in mid-2001 by Huub Emontsand George Lam, who both came fromthe glass division of Philips and decided

TV Pressed Glass

CASE STUDY

Elam Engineering and Siemens: Automated Glass Production at LG Philips Displays

Perfect Premiere

to go independent withtheir own automationcompany.

Philips and LG PhilipsDisplays equip their plantswith Siemens automationtechnology as a standard.Simatic technology hastherefore already beenused successfully for sev-eral years in anotherproduction facility for LG Philips Displays inAachen, and the positiveresults gained from thisproject also benefited thework in Zhengzhou. HuubEmonts states, “Of coursewe worked closely withMartin Stofregen, theSiemens account man-ager for Philips. He coor-dinated all the Siemensactivities for us and in-troduced our team andthe LG Philips Displaysstaff to the Siemens so-lutions.”

The hardware for the press consists ofabout 30 control cabinets and 40 fieldcabinets, most of which are built andconfigured by Siemens. George Lam de-scribes the dimensions of the project:“The press is controlled by about 20Simatic S7-300 and S7-400 controllerswith the appropriate Simatic ET 200 dis-tributed systems, drives, and Siwarexweighing systems, which are linked viaProfibus and Ethernet.” The new plantbegan operation in March 2003 and hassince been running to the customer’scomplete satisfaction. ■

The mold press is the crucial unit of TV pressed glass production

Find out more:www.elam-engineering.nlwww.siemens.com/glassE-mail: [email protected]

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Stein Heurtey and Guangzhou CSG Float Glass rely on Siemens

New Project in China

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Shanghai Stein Heurtey MECC IndustryFurnace Co., Ltd. (SHMECC in brief) is

a Chinese joint venture of the renownedtechnology company Stein Heurtey, one ofthe World’s leading manufacturers of ther-mal systems for the glass industry. World-wide, more than 200 melting furnaces, in-cluding 15 for float glass lines, over 40 FloatBath, over 60 flat glass annealing lehrs andnow 7 hot ends for float glass lines havebeen supplied by the Stein Heurtey GlassGroup, including its subsidiary BelgiumGlass Equipment (BGE).

Two lines are under construction forGuangzhou CSG Float Glass Co., Ltd. SteinHeurtey, BGE and SHMECC are installingtwo new float glass lines with a productioncapacity of 550t/d and 700t/d respectively;both lines are equipped with the latest tech-nology and will produce high quality glassfor automobile and architecture industry.

In this project, Guangzhou CSG FloatGlass and Stein Heurtey /SHMECC are us-ing Siemens automation technology for thefirst time in China. The decisive factors inthe selection of the Siemens’s solution were

the smoothly integrated Totally IntegratedAutomation systems, the efficient Siglastechnology modules, Siemens long-termpresence in China, and the competent sup-port by industry experts on the Siemensglass team ■


From April 11 to April 14, BeijingInternational Exhibition Center was

home to the fifteenth International GlassExhibition. More than 2,100 companies at-tended the exhibition and 40 percent werefrom foreign companies, illustrating thegrowing global significance of the Chineseglass industry. China is becoming one ofthe most important glass-producing cen-ters with one of the most rapid growthrates worldwide. Siemens Ltd. Chinashowed the latest Simatic PCS7 technologyincluding the newly launched Simatic PCS7Box as well as motion control products, andSiemens Shanghai Industrial AutomationLtd. showed its solutions for the glassindustry.

During the exhibition, Siemens and theChina LuoYang Float Glass Group held anAdvanced System Integrator cooperatingsignature ceremony. China LuoYang FloatGlass Group was founded in 1956, and af-ter more than forty years development, ithas become a huge enterprise group con-taining technology development, produc-ing and marketing, import and export

signature, Siemens and China LuoYangFloat Glass Group will both venture into a fruitful cooperation that will provide agood platform for future projects. ■

LuoYang Float Glass and Siemens

Cooperation Agreement

LuoYang Float Glass and Siemens signing the cooperation agreement in Beijing


trade, finance and stock business. Thecompany has developed the LuoYang Floatprocess, one of the three main float glasstechniques, and is China’s top float glassmanufacturing company.

The president Mr. Liu Baoying and gen-eral manager Dr. Zhu Leibo of China Luo-Yang Float Glass Group expect that with the

Flat GlassCASE STUDIES

GlassFocus 2004

You will find more information about these and other companies in the glass portal at:

www.siemens.com/glass/partner

Better TogetherSiemens has been working successfully for many years with numerous machine manufacturers and plant plannersspecializing in the glass industry. This experience and collaboration guarantee glass manufacturers a uniform andstandardized automation solution based on Totally Integrated Automation (TIA) for all sections of the plant. Siemensalso supports its partners in the development of technological solutions that can, for example, save energy, ensurequality, or minimize nitric oxides. In this issue of GlassFocus we present some examples of companies that have beenrelying on innovative solutions from Siemens for years.

Horn Glass Industries AG produces plants that are distinguished bymaximum reliability and transparency. The company relies on TotallyIntegrated Automation with the Simatic PCS 7 process control system.

www.horn-glas.de

In the Glass Academy in Zwiesel, UAS Messtechnik GmbH installed a newglass melting end – a highly available solution with a universal backupfunction – without interrupting ongoing operation. A Simatic PCS 7process control system monitors and stores all plant data.

www.uas.de

The non-contacting, wear-free thyristor power actuators from AEG SVS PowerSupply Systems, in connection with Profibus and Simatic PCS 7, guarantee100 percent quality in glass manufacturing – reliably, reproducibly andperfectly documented.

www.aegsvs.de

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In just six months, AST Automation completed a total turnkey projectincluding Batching, Furnace, Forming and Packaging of a glass bottleproduction line for Nampak Roodekop South Africa. This included all HT,LT and Automation systems. One of the factors that contributed to theproblem-free implementation of the new plant that also features a MESsystem were Simatic S7 and Simatic WinCC.

www.ast.co.za

As the market leader in zirconium oxide probes for online control of effectivecombustion in industrial furnaces, STG GmbH Cottbus combines automationexpertise with technological know-how and measurable cost advantages fromNOx reduction and energy saving, providing the basis for more than 20successful projects with Simatic S7 and Simatic PCS 7 systems in the fields ofinsulating, container, and float glass.

www.stg-cottbus.de

Raute Precision is one of the leading suppliers for weighing and dosingsystems and implements cost-effective and innovative solutions for theglass industry. One example are standardizes WinCC operator interfacesthat can be used in both Simatic WinCC and Simatic PCS 7 environments.

www.rauteprecision.fi

In close cooperation with Siemens, AAC produces complete process solutionsfor hollow and flat glass plants – for both new plants and migration fromTeleperm M. The company relies on Totally Integrated Automation withSimatic PCS 7 and Totally Integrated Power for greater effectiveness, flexibility,and quality in glass production.

www.aac-st.de

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You will find these and other interesting applications described in detail at:

www.siemens.com/glass/partner

The Sorg Group combines plant and machine manufacturing and servicesfor the glass industry in three companies. Nikolaus Sorg GmbH & Co. KGsupplied a fully electrically heated glass-melting end of the VSM type forthe Beijing Glass Instrument Factory in China. The melting end can meltup to 35 tons of borosilicate glass. EME Maschinenfabrik Clasen GmbH,which also belongs to the Sorg Group, has developed a system with whichproportioning and weighing units can be controlled in a decentralizedmanner. Both solutions use Simatic technology.

www.sorg.dewww.eme.de

G-E-N, a cooperatively organized network of small and medium-sized suppliersto the glass industry, combines expertise from various technical fields. Whetherthe project is an efficient individual solution or the automation of an entireprocess section, G-E-N produces first-class solutions based on Totally IntegratedAutomation.

www.glasnetzwerk.de

Schlemmer Prozess Systeme GmbH (SPS) relies on Totally IntegratedAutomation for the implementation of individually tailored automationsolutions. This pays off all along the line, with drastically reducedproduction costs per unit as well as the minimization of expenses relatingto spare parts storage, maintenance, and training.

www.sps-gmbh.de

Glashüttentechnik Grob GmbH planned and produced a low-cost, fullyautomatic booster control for a discontinuous glass melting and conditioningprocess with a Simatic S7-300 controller for one of its customers. Grob alsodeveloped a system with which the process can be monitored and controlledboth manually at the local level and from the central control room and at themanagement level.

www.grob-glass.de

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In order to be able to meet the constantly growing demand for low-emission (Low-E) glass from its own production, BAMO-FLOAT GLASSSolnetschogorsk chose a completely new inline sputter plant made by VonArdenne Anlagentechnik GmbH. The plant, controlled by a Simatic S7controller, went into operation after just 10 months. GlasinvestEngineering und Anlagenbau was heavily involved in the project.

www.glasinvest.com

Zippe-Technologie is an expert partner to the glass industry, for new plantsand plant modernizations alike. For the modernized float-glass mixing plantfor Hunguard in Hungary, the company relied on Siemens components thatare all networked via Profibus or Ethernet.

www.zippe.de

Pyro-Contrôle, part of the Chauvin Arnoux Group, offers a comprehensivetemperature sensor portfolio – tailor-made to suit the extremerequirements of the glass and ceramics industries. The high-performance,high-quality devices are being used as an integral part of Simatic PCS 7 inmany of Siemens’ turn-key projects.

www.pyro-controle.com

Where quality control and company-wide information management areconcerned, the ilis GmbH in Erlangen offers first-class solutions for the glassindustry. One of the highlights from the company’s wide range of services:Glasdata, a Web-based information system for company-wide datamanagement (for the fields of used glass, laboratory, mixing, and melting),which can easily be linked to Simatic PCS 7.

www.ilis.de

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M achine and plant manufacturers,for example, can ask for earlysupport for large projects abroad.

The regional Siemens branch on locationwill then make the right preparations forthe machine or plant and offer the rightservice and support locally. That way, ma-chine manufacturers or OEMs often evendo not have to have a spare parts stock ontheir own.

Always prepared: The Automation Value Card

More than 140,000 cases per year are reg-istered alone at the Siemens DispatchCenter in Germany. The Technical Support

center for Siemens automation technology,which handles specific product and systemrelated technical inquiries, takes about800 calls a day. The appropriate expert callsback in an average time of two hours. Basiccases which take up to approx. one hour isone of Siemens' free services.

However, if a company requires emer-gency assistance – for example, within thecommissioning phase of a plant or in a caseof system or product failure- Siemens of-fers to its customers and partners addi-tional services with the Automation Valuecard (AVC). This AVC is charged with a num-ber of credits which can then be used up –similar to a telephone card – easily with the

card and PIN number. With the AutomationValue Card (AVC, the customer can requestin urgent cases a priority or a 24-hours sup-port as well as support for products whichare no longer available and called Matureproducts. Additional software tools can alsobe downloaded with the card. The creditsare then simply deducted online from theAutomation Value Card.

More time for core activities

Franz Nolte, head of customer support at Zippe Industrieanlagen GmbH, is im-pressed by the advantages and benefits ofthe networked services offering. "Ourproject engineers’ concentration on cur-rent projects was always being disturbedby inquiries about our plants,” he says."Today Siemens Support & Services takescare of these inquiries for more than 350Zippe plants worldwide, and that, ofcourse, saves us a great deal of time.” Con-tact with technical support has long be-come part of the daily routine at Zippe,and experience has shown that the glob-ally active Siemens specialists who are fa-miliar with the entire product range canalways be relied on. For Nolte, at any rate,the relationship with Siemens ensures asmooth daily routine in the industrialplants: "The Siemens experts are alwaysthere when you need them.” ■

The right support for every phase

Good Advice is a Safe BetSiemens supports its customers at every stage – from online and technicalsupport to extensive consulting and engineering services to rapid field serviceand maintenance and optimization of machines and plants – around the clockand (almost) everywhere in the world.

SERVICE


GlassFocus 2004

Technical Consulting

Design andSoftware Engineering

Field Service

Repairs andSpare Parts

Optimization andModernization

Planning & Design Project Engineering & Installation & Operation & ModernizationDevelopment Commissioning Maintenance

The right support in every phase

➔ ➔ ➔ ➔

Online Support

Technical Support

39

GlassFocus2004

HerausgeberSiemens Aktiengesellschaft,Bereich Automation and Drives (A&D), Gleiwitzer Str. 555, 90475 Nürnberg

www.siemens.com/glass

Bereichsvorstand Helmut Gierse, Anton S. Huber, Alfred Ötsch

Presserechtliche VerantwortungPeter Miodek

Verantwortlich für den fachlichen InhaltRalph Burgstahler, Cornelia Dürrfeld, Bernd Lehmann

VerlagPublicis KommunikationsAgentur GmbH, GWACorporate Publishing ZeitschriftenPostfach 3240, 91050 ErlangenTel.: (0 91 31) 91 92-5 01Fax: (0 91 31) 91 92-5 [email protected]

Redaktion: Dr. Beate Bellinghausen (ChR), Kerstin Purucker, Gaby Stadlbauer

Layout: Jürgen Streitenberger, Alexandra Graf

Projektmanagement: Regina Severing, Daisy Kraus

DTP: Doess, Nürnberg

Druck: Wünsch Offsetdruck GmbH

Auflage: 20.000

© 2004 by Siemens Aktiengesellschaft München und Berlin. Alle Rechte vorbehalten.

Diese Ausgabe wurde auf Papier aus umwelt-freundlich chlorfrei gebleichtem Zellstoffgedruckt.

Die folgenden Produkte sind eingetragene Markender Siemens AG:ET 200, MP270, PCS 7, POSMO, ProTool,ProTool/Pro, S7-300, S7-400, SENTRON, SIMATIC,SIMEAS, SIMODRIVE, SIMOTION, SIMOVERT,SINAMICS, SINUMERIK, SIPART, SIPROTECH,SITRANS, SIWAREX, STEP, TELEPERM, TOTALLYINTEGRATED AUTOMATION (TIA), TOTALLYINTEGRATED POWER (TIP), WinCC.

Wenn Markenzeichen, Handelsnamen, technischeLösungen oder dergleichen nicht besonderserwähnt sind, bedeutet dies nicht, dass sie keinenSchutz genießen.

Die Informationen in diesem Magazin enthaltenlediglich allgemeine Beschreibungen bzw. Leistungs-merkmale, welche im konkreten Anwendungsfallnicht immer in der beschriebenen Form zutreffenbzw. welche sich durch Weiterentwicklung derProdukte ändern können. Die gewünschtenLeistungsmerkmale sind nur dann verbindlich,wenn sie bei Vertragsschluss ausdrücklichvereinbart werden.

Bestellnummer E20001-A370-P620-X-7600

onlineonline

DIALOGUE

Custom-made suit off the rack:The Glass Industry SuiteWith the Industry Suites, Siemens has grouped its wide range of productsfor automation, drive technology, process instrumentation, and energy sup-ply systems into industry-specific suites. There is a special Industry Suitefor the glass industry, which covers the entire glass-production process,from mixture preparation through special solutions for the hot end to fur-ther processing and conditioning of the finished glass in the cold end.

The basis of the Industry Suites is the open, standardized, and uniformTotally Integrated Automation (TIA) and Totally Integrated Power (TIP) plat-forms, as well as a thorough understanding of the production and busi-ness processes in the glass industry – including the products, the indus-try-specific process expertise, and specific MES solutions and services forthe industry.

Of course, solutions from third-party technology partners are also anintegral part of the Glass Industry Suite. A lambda-controlled melting end,which makes an effective contribution toward minimizing NOx and opti-mizing energy consumption, is just as much a part of the Industry Suiteas are special add-ons for process control.

With the Industry Suite, all those involved – the end customer, systemsintegrator, and OEM – can save time and reduce costs. The industry-spe-cific layout of products, systems, and solutions accelerates bidding proce-dures, simplifies the integrated planning of all units, and minimizes thenumber of interfaces. A visitor to the Internet portal of the Glass IndustrySuite will find the right solution for every process step, along with quick,clear information about the range of products and services available forthe glass industry.

www.siemens.com/[email protected]

teamteamThe Siemens Glass Team:Global knowledgeThe Siemens Glass Team is a network of committed employees with a keeninterest in the glass industry. They support the glass industry worldwidewith products, systems, and solutions for optimizing the economy and ef-ficiency of production and ensuring product quality. Teamwork and an un-derstanding of the problems in glass production are just as essential asthe intensive consulting provided to customers in the design phase.You can find your contact partner on the Internet or by e-mail:

www.siemens.com/glass/[email protected]

GlassFocus 2004

Maximize …

… your Profit

Our top priority? Keeping productivity curves on the upswing for the glass industry.

The Siemens Glass team, backed by innovative technologies and years of experience

in the glass industry, is expert in creating profitable solutions that remain viable into

the future. Our approach integrates all levels of your enterprise from the field to

management, and all processes from raw materials to finished glass products. Whether

you’re installing a new facility or upgrading an existing one, we’ll integrate your field

instrumentation, IT and automation and energy technologies to create a complete,

comprehensive solution. For you, Totally Integrated Automation means increasing

flexibility, higher quality, minimized costs – and a clear competitive advantage for

your company. You can contact us directly at [email protected]

www.siemens.com/glass

Greater productivity –with more flexibility at lower cost

totally integrated

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