Manufacturing Solutions for the Power Industry Innovative CNC technology for higher productivity

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Answers for industry.

The global energy demand is continually on the rise, and at the same time, the requirements associated with generating elec-tric power are increasing. Power generation must be especially profitable, safe, reliable and environmentally friendly.

Wind turbines

Hydroelectric

turbines

Gas and steam

turbines

Innovative CNC technology for modern production facilitiesWhether wind or hydroelectric power, gas and steam power plants – the increasingly complex types of power generation demand automation and production techno- logies that are always more adaptable and have a higher performance. Our spectrum of solutions for the energy industry herolds a completely new era in the area of industrial automation technology.

For the first time ever, virtual as well as real production domains are completely addressed by one automation supplier. With our SINUMERIK CNC system, we are offering new production solutions with standard and seamless operation, adapted to address each and every requirement. Further, the CAD / CAM-CNC process chain can be seam- lessly integrated into the production environment. With experience, know-how and our spirit of innovation, we are working hard to develop automation solutions that give our customers the highest possible competitive advantages.

SINUMERIK Based on SINUMERIK control systems, state-of-the-art production facilities address new machining trends. This makes SINUMERIK the preferred CNC in industries of the future – such as energy generation.

ContentsProduction solutions for:

• Wind turbine systems 04

• Hydroelectric plants 05

• Gas and steam turbines 06

• Generators 07

Machining technologies 08

SINUMERIK 840D sl 10

CAD / CAM-CNC process chain 12

Service and support 14

Future-proof solutions 15

4

Quality defines the stabilityThe stability and load capability of the rotor blades essen-tially depends on the production quality when using com-posite fiber materials in the half-shell layering technique. Machining the flanges as well as grinding and painting the rotor blades demand automation systems that operate with high precision over enormous surface areas. This why precision, surface quality and flexibility are also espe-cially important for the gearwheel components that are used. These involve, for instance, gearboxes, rotor blade pitch adjustment and wind tracking systems.

The optimum CNC technology for every componentWhen machining hubs and drive shafts, which transfer the rotational energy of the rotor to the generator, precise turning-milling utilizing special tool retraction strategies is required. Milling the gearbox housing involves complex machining tasks – and at the same time, the user must be simply and reliably guided through the machining pro-cess. The complete system is subject to the most severe weather and to enormous forces on a daily basis – from the rotors, through the tower elements up to the outer shell of the nacelle. We have the optimum CNC technol-ogy when it comes to machining components for wind turbines. No matter whether it involves milling, turning, grinding or machining gearwheels.

Production solutions for wind turbines: Full speed ahead for wind energy

Wind turbine systems are not only becoming increasingly more efficient, but also larger. As a

consequence, they are subject to enormous loads and must fulfill high performance requirements.

When manufacturing components this means that the automated production of, for example,

rotor blades must be both efficient and extremely precise.

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High efficiency through precision productionFor instance, turbines used in tidal power plants operate when the water flows in both directions. The rotor blades must therefore be able to be reversed. The water flow is used to generate power by using free-standing turbines with underwater rotors. In order that the various turbine types achieve a high efficiency, the blades must be designed to take into account water compression and

angle of impact. To achieve this, high-precision milling or grinding is absolutely mandatory. However, when machining the turbine casings or the pressure pipes, high machining precision is also of utmost importance. Our CNC solutions support you when high-precision and high-speed machining is demanded, for example, when manu-facturing components for tidal and hydroelectric power plants.

High precision and machining speed: Fully utilize the force of water

Conventional hydroelectric power plants utilize the head of water in rivers or height differences

artificially created by dams. This water then drives various types of turbines. Innovative tech-

nologies such as these demand new production solutions.

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A high load capability is a real mustAll applications have one thing in common: In operation, turbines are subject to huge amounts of stress. For instance, the live steam in steam turbines can reach tem-peratures of 600 °C – and the pressure inside the casing up to 300 bar. This is compounded by the fact that depending on the particular design, extremely high speeds of up to 3600 revolutions per minute are involved. And the combustion chambers of gas turbines must be

able to withstand temperatures exceeding 1400 °C. This is the reason that precise and high-performance automa-tion, drive and monitoring systems for the various tech-nologies employed is necessary when machining turbine components that are subject to these high stress levels. Reliable and error-free automation is of prime importance when milling and grinding turbine blades and their non-destructive testing. The same is true when machining gearwheels for gearbox components.

Precisely manufactured for tough environ-mental conditions: Gas and steam turbines

Gas and steam turbines are used in many areas to generate power – whether in power stations or for

renewable energies, for instance, in thermal solar systems and in geothermal power plants. Precise

machining is demanded so that these components continue to reliably operate even under the highest

load levels.

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Power generation comes in many different forms. How-ever, no matter whether it involves wind turbine systems, hydroelectric power plants or conventional steam and gas turbines, kinetic energy is generated. Reliable and power-ful generators with different ratings are required to con-vert this kinetic energy into electric power, which can then be fed into the grid. This is the reason that precision and efficiency are of crucial importance in their production.

This is true when bending the elements for the windings, through milling the rotors, up to laser cutting the lami-nated sheet steel for the generator stators and the subse-quent robot-based stacking. State-of-the-art machine tools optimize the quality, cost-effectiveness and speed when machining all of the components used to generate power using wind, water, coal and gas etc. Based on its SINUMERIK CNC system, Siemens offers highly productive automation solutions to address the requirements of the energy generating sector.

Reliable generator production

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Siemens Machine Tool Systems is the only CNC manufac-turer in the marketplace that has a portfolio to address all of the important technologies in the machine tool market based on its SINUMERIK CNC system. At the same time, Siemens sets benchmarks when it comes to combining various technologies to create multitasking concepts. This provides the ideal prerequisites to address the increasing requirements regarding efficient CNC machining in the energy generation domain that helps to reduce the amount of valuable resources used.

We master the standards …Using preconfigured technology packages, SINUMERIK control systems are ideally suited for turning and milling machines. The associated multitasking concepts, i.e. turn-ing-milling and milling-turning, can also be addressed using predefined solutions. SINUMERIK also offers a mod-ular set of system functions. This allows other standard technologies to be covered, such as grinding, gearwheel machining, laser cutting and handling.

… and the specialitiesBased on the unique level of system openness, in addition to standard technologies, SINUMERIK also offers solutions for new machine concepts. For instance, when it comes to machining composite materials for applications in the power generation domain.

Unique features, such as the open architecture in the CNC kernel and the drive, form the basis. This makes SINUMERIK synonymous with maximum technological competence from a single source – to address standard up to special applications.

Technology cycles for all machining operationsSINUMERIK control systems offer a range of drilling, mill-ing and turning cycles that are absolutely unique in the market: From simple machining operations such as cen-tering, deep-hole drilling, milling circular pockets and turning grooves up to more complex operations such as engraving, deep-hole milling and trochoidal milling of hard metals. Thanks to intelligent kinematic trans- formations, these technology cycles are available at all ma- chining levels. For instance, on the face and peripheral surfaces of turned parts or in swiveled planes of milled workpieces.

High dynamic performance based on SINUMERIK Integrate Run MyRobotThe Run MyRobot technology package allows work- pieces and tools to be handled with a high dynamic per- formance. Operation, retraction, teach-in and diag- nostics can be realized from the CNC operator panel of the SINUMERIK 840D sl, therefore increasing the efficiency and flexibility of machine tools.

SINUMERIK – the optimum CNC for all machining technologies

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SINUMERIK MDynamics – premium millingThe SINUMERIK MDynamics milling technology package combines state-of-the-art operator control and unique technology cycles, outstanding workshop programming and high-quality CNC simulation – all complemented by premium motion control. Using Advanced Surface, state-of-the-art milling machines achieve maximum machining speeds with the highest surface quality and precision. Beyond this, user-friendly technology and measuring cycles support milling at the highest level. www.siemens.com/sinumerik-mdynamics

SINUMERIK Operate – one operating concept for all technologiesBased on the innovative SINUMERIK Operate concept, all machining technologies can be operated with a standard look & feel. For production facilities, this offers a high degree of flexibility when deploying their machine opera-tors. Beyond this, SINUMERIK supports all of the CNC pro-gramming methods specified worldwide – from single part production up to large series production. SINUMERIK Operate is the innovative basis for multitasking concepts, today and in the future. www.siemens.com/sinumerik-operate

SINUMERIK multitasking – consequential in all detailsWith just a few parameter entries, intelligent kinematic transformations transform milling machines into turning specialists and lathes into milling professionals. In conjunction with additional CNC highlights, such as cross-technology tool management and state-of-the-art velocity control, completely new CNC applications are opened up. These range from turning on milling machines up to machining free-form surfaces on lathes.

Turning Milling

Handling and CNC machining using robots

Machining composite materials

Machining housings Grinding

Multitasking Nibbling, waterjet cutting, laser- and plasma-based

machining

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SINUMERIK 840D sl – ultimate performance in the premium class

One CNC system for all possible technologies, such as

milling, turning, tape laying, grinding and many more.

It is certainly justified that SINUMERIK 840D sl is

considered the benchmark in the CNC premium class.

Maximum CNC performance as well as a degree of

flexibility and openness unknown up until now form

the basis for almost any machine concept.

Maximum CNC performanceSINUMERIK 840D sl offers an almost inexhaustible poten-tial when it comes to the CNC computational performance as a result of its drive-based, high-performance NCUs (Numerical Control Units), equipped with state-of-the-art multicore processor technology. Performance means a high number of axes in highly modular machine concepts, such as transfer lines or rotary indexing machines. Perfor-mance also means the highest degree of precision and machine dynamic response for high-speed cutting applica-tions in 5-axis milling centers for mold making. Irrespec-tive of which premium machine concept – SINUMERIK 840D sl always guarantees the highest degree of produc-tivity in the machining process.

Scalable CNC performanceSINUMERIK 840D sl supplies various machine concepts with the optimum CNC performance. To achieve this, it is available in various performance versions: SINUMERIK 840D sl BASIC, a combination of NCU710 and SINAMICS S120 Combi, is the perfect entry solution for compact pre-mium machines. Up to three NCU730s, coupled through the NCU link, provide the highest performance available. They can control up to 93 axes in 10 machining channels.

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Modular and scalableIn addition to scalable NCU performance, SINUMERIK 840D sl also has a high degree of modularity when it comes to the operating components. Based on the flexible M:N operating concept – for instance, the ability to com-bine any operator panels with the NCU – the SINUMERIK 840D sl ideally fits into the operating philosophy of mod-ern premium machine concepts. With our SINUMERIK 840D sl BASIC – the link with the compact SINAMICS S120 Combi converter – even compact machine concepts can be optimally addressed.

Benchmark in open architectureThe system openness of the SINUMERIK 840D sl is second to none. Thanks to SINUMERIK Integrate, the CNC can be optimally adapted to the particular machine technology; further, SINUMERIK Integrate ensures a high degree of flexibility in the production automation environment. For instance, operation can be supplemented and adapted, or even robots and handling systems can be integrated. With the openness in the CNC kernel and in the drive, unique mechanical concepts can be implemented; for example, using adapted control algorithms or specific kinematic transformations.

Can communicate at all levelsSINUMERIK 840D sl is perfectly embedded in the Siemens TIA environment using PROFINET, the leading Industrial Ethernet standard. Totally Integrated Automation stands for a unique level of integration and seamlessness. This extends from the field level through production up to the company supervisory level. The result: all components in the automation solution optimally interact with one another, therefore achieving a maximum degree of trans-parency and availability of the production process. www.siemens.com/sinumerik

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Highest degree of productivity through a perfectly coordinated process chain

To complement its CNC technology, Siemens also

offers a comprehensive portfolio for IT integration –

from standard data transfer using SINUMERIK

Operate up to PLM data management using

TEAMCENTER. The highest degree of productivity

in the production environment is achieved based

on the unique, perfectly harmonized process chain

comprising VNCK, NX CAD / CAM system and

SINUMERIK CNC.

Standard data transferThanks to LINUX and the Windows® operating system, SINUMERIK CNC controls can handle all of the usual data transfer techniques – such as USB, CF card and TCP/IP Ethernet – without requiring emulation and file con- version programs.

SINUMERIK IntegrateSINUMERIK Integrate perfectly integrates SINUMERIK con-trol systems into the IT landscape of modern production facilities. This is achieved using a powerful software suite:

• Manage MyPrograms – NC programs are organized and managed throughout the network

• Manage MyTools – tools are managed throughout the network

• Analyze MyCondition – machine states are evaluated for condition-oriented maintenance

• Analyze MyPerformance – machine data and operating states are acquired and visualized throughout the factory

• Access MyMachine – remote diagnostics – from peer-to-peer via LAN to the Internet

• Access MyBackup – interface to back up and assign versions to CNC data

• Create MyInterface – communication interface to connect to master computer applications

www.siemens.com/sinumerik-integrate

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IT integration with SINUMERIK and NX CAMUsing NX CAM, the well-proven solution for programming NC systems, companies can maximize the production throughput of their state-of-the-art machine tools. In addition to a wide range of flexible NC programming tech-niques, NX CAM also includes a part manufacturing solu-tion. This encompasses a library of clamping resources as well as options for data administration, data manage-ment, process planning and direct connection options to the workshop. Production workflows can be simulated and optimized using the integrated SINUMERIK Virtual NC kernel (VNCK) before parts are actually machined. Being closely coupled to the SINUMERIK CNC technology, results in an integrated and seamless CAD / CAM-CNC process chain – therefore ensuring maximum productivity when it comes to machining high-quality workpieces.

IT in

tegr

atio

n

Ethernet, CF card, USB

SINUMERIK Integrate

SINUMERIK & NX CAM

TEAMCENTER

SINUMERIK

Plant

Company network

TEAMCENTERTEAMCENTER, a product from Siemens PLM Software, is the central information source for product and process know-how in companies. Based on the comprehensive PLM (Product Lifecycle Management) solution portfolio, TEAMCENTER links all of the stations of the product life- cycle to this central source. The portfolio encompasses requirement and engineering process management, simu-lation process management as well as production process management. The latter is a unique, scalable reliable and secure source for production data, which supports life- cycle processes extending from development up through to production. www.siemens.com/plm

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SINUMERIK Manufacturing Excellence – service and support at the highest level

Field service, spare part supply, hotline support and train-ing form the basis of our services and support. Beyond this, SINUMERIK Manufacturing Excellence covers all of the requirements relating to machine tools in the form of intelligent services.

Field serviceAs company active around the world, Siemens Machine Tool Systems also has a global service team. They provide fast and competent repair, inspection and maintenance services in more than 60 regions around the world.

Technical support (hotline)In more than 25 regions around the world, our competent hotline experts answer all of your questions relating to SINUMERIK – and naturally in the local time and local language! www.siemens.com/industry/onlinesupport

Spare parts and repairsA closely meshed, flexible and understanding spare parts and repair service network ensures that spare parts are quickly available at reasonable prices in more than 70 regions around the world.

SINUMERIK trainingSITRAIN offers professional training courses for operation, programming, commissioning and maintenance of SINUMERIK control systems in more than 30 countries around the globe. www.siemens.com/sitrain

Supplementary services – how we inspire our customersWith a wide range of additional, intelligent services, SINUMERIK Manufacturing Excellence boosts machine productivity – from the initial design through use up to retrofits and modernization.

• Siemens Financial Services – financial solutions that perfectly fit requirements and situations www.siemens.com/sfs

• Manufacturing IT – process optimization by imple- menting the SINUMERIK Integrate product suite

• Extended Machine Contracts – service contracts tailored specifically to customer requirements

• Spares Plus – preventive spare part management• Productivity Improvement – reducing cycle times of

existing machines• Machine Retrofit – general overhaul of machine tools www.siemens.com/sinumerik/manufacturingexcellence

Procurement Machine in use Machine modernization

SINUMERIK Manufacturing Excellence

Basic services – what you can expect from us …

Field Service Spare Parts Repairs

Technical Support (Hotline) Training

Supplementary services – what our customers find attractive …

Siemens Financial Services

Manufacturing IT

Extended Machine Contracts

Spares Plus Productivity Improvement

Machine Retrofit

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A strong partner for the machine tool environmentSINUMERIK CNC controls have been influencing the machine tool market for over 50 years. Siemens Machine Tool Systems is present in the market with the innovative force of a unique and experienced development team, so that also in the future, highly productive machines can be implemented with SINUMERIK. In addition to innovation, Siemens places the highest emphasis on quality.

Global organizationWith its tightly meshed global network of sales, service and training centers, as well as international production facilities, Siemens Machine Tool Systems is optimally organized to globally market machine tools. Several Tech-nology and Application Centers demonstrate our techno-logical competence and secure the ergonomics of our CNC software in practical use. Further, Siemens is the pioneer when it comes to sustainability and energy efficiency as Siemens Machine Tool Systems plays a leadership role when it comes to energy-efficient equipment for machine tools.

Leading-edge solutions for every sector

Aerospace

Medical

Automotive

Electronics

Power Generation

Siemens Machine Tool Systems – a strong partner for machine tools

The optimum solution for every sectorGlobal trends such as rapid population growth coupled with the rising demand for energy, transport solutions as well as communication equipment, are placing new demands on sectors such as power generation, aerospace, automotive, electronics and the medical industry. Siemens Machine Tool Systems has direct contact with these users of machine tools. This ensures that SINUMERIK systems represent the optimum product fit.

Premium IT integration and servicesBeyond this, we offer leading-edge IT integration and sim-ulation solutions for optimally networking production and IT landscapes. This is complemented by a sector-specific support and service portfolio to ensure maximum produc-tivity in the production environment as well as efficient service and maintenance. This is reflected in the fact that you can find SINUMERIK sector solutions around the globe.

Subject to change without prior notice Article No.: E20001-A1770-P610-X-7600 Dispo 06311 WÜ/51077 V1.MKPOWE.WES WS 05143.0 Printed in Germany © Siemens AG 2014

The information provided in this brochure contains me re ly general descriptions or characteristics of per for m ance which in case of ac tual use do not al-ways ap ply as described or which may change as a result of fur ther de ve lopment of the products. An obligation to provide the respective characteristics shall only exist if ex pressly agreed in the terms of contract

All product designations may be trademarks or product na mes of Siemens AG or supplier compa-nies whose use by third parties for their own pur-poses could violate the rights of the owners.

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