Andreas Milbradt 05/12/2016
Flexible production is making far-reaching changes to the manufacturing industry. Low-cost manufacture of customized products enables manufacturers to respond quickly to customer wishes and requirements. The key to flexible production lies in digitalized machines and plant that transmit data during the planning, simulation and ongoing manufacturing processes, which both enables fast and efficient adjustments to the production itself and also permits constant monitoring for quality control purposes. This can be achieved with new machine and plant strategies that, when properly networked, make the benefits of digitalization available for practical use.
In our OEM Lounge at this year’s SPS we’ve highlighted the benefits of digitalization in machine building. We showed the complete product lifecycle, from design through manufacture as well as our service solutions. Machine design using the PLM software Mechatronics Concept Designer reduces development times by as much as 30 percent. The additional virtual commissioning function not only shortens the product introduction time, but this digital solution also saves the need for expensive prototyping. Integrated engineering makes use of the TIA Portal, which provides access to the complete digitalized automation process.
More flexibility with the right hardware
Digitalization in machine building means not only using software solutions that offer the right overview, but the hardware also has an important role to play. One of our transport solutions, the Multi-Carrier-System, provides flexibility for tasks in the fields of packaging or assembling. The industrial Ethernet standard Profinet is a perfect basis for the flawless integration of all machines.
Digitalized planning and engineering open up new opportunities for implementing the production process itself. In other words, data is not transmitted in just one direction. While the system is in operation, there is a bi-directional exchange between the digital representation and the real-life plant. This digital twin shows machine performance and status in real time. You thus have the opportunity to check throughput and efficiency, and at the same time an opportunity to identify errors at an early stage which could potentially lead to outages if not prevented by predictive maintenance. The connection to MindSphere – the cloud-based, open IoT operating system – from Siemens also provides many additional analysis functions that we are constantly expanding in collaboration with our partners.
Reduce downtimes with the service of the future
If repairs or maintenance are necessary, digitalization in machine building offers new and time-saving servicing options. One advanced approach is known as “Augmented Service.” In the OEM Lounge at SPS IPC Drives, we prepared a preview of the services of the future for you. With our partner Essert, we showed how “Augmented Support” via smart glasses can look. For repairs or outages, service employees can turn on the glasses and offer the mechanics on-site live, real-time, computer-supported, visual instructions to perform the maintenance work. This location-independent, time-saving approach will increase machine and plant availability by reducing downtimes.
This year’s SPS IPC Drives has been a complete success from our point of view. Not only did our innovative MindSphere Lounge attract a lot of visitors: at the “Expert Centers,” too, we provided a range of technical presentations to inspire many potential customers. For an overview of the whole exhibition program and event highlights, see our trade show page on SPS IPC Drives 2016 and our blog, Competitive Industry. A big thank-you to everyone who visited, and we look forward to seeing you again next year.
Andreas Milbradt 24/11/2016
The subject of industrial security is growing more and more important as the process of digitalization takes hold in industry and all the players become networked. In the lead-up to SPS IPC Drives, we reported in our blog about the multi-stage “Defense in Depth” security strategy. In today’s post we’ll look at what Siemens will be exhibiting in this area at its booth in hall 11.
You’ll find an arcade game machine in our Industrial Security area, where “Security Invaders” will give you the chance to experience industrial security in action. “This game shows just how important it is to have a varied and multi-level security strategy in place,” explains Oliver Narr, an expert in industrial security at Siemens. “We want to draw attention to the different types of threat in existence, but also the countermeasures that can be put in place. The goal of the game is the same as in real life: to take the right steps to respond to attacks, to fend them off and keep the plant secure.”
Defense against hackers, spies and saboteurs
The task facing players using the machine is to protect the plant. There are three different game modes in which spies, saboteurs and hackers try to gain access to the plant. It’s essential to stop intruders in order to prevent theft of intellectual property or malicious damage. Players use the joystick to coordinate three different protective measures to defend themselves against attacks on the plant, which is only safe once the right protective measure is put in place. The longer the game continues, the larger the number of attackers. This is designed to highlight the complexity of industrial security systems. At the end of the game, the screen shows the countermeasures that were used, such as discovering unauthorized network access or exposing social engineering.
Industrial security in practice
Right alongside the arcade game is our Industrial Security Wall, which shows how the multi-stage security strategy is implemented in real life. The TIA Portal is where the individual controls or network components are set up. These can be individually configured to maintain security. We’ll also be happy to tell you everything else you need to know about our “Defense in Depth” strategy as a part of our Totally Integrated Automation concept. We use Plant Security Services to evaluate the plant’s security status, so we can identify the best possible solution and constantly monitor the plant. And Siemens’ Industrial Security guarantees plant security, network security and system integrity at all times.
Take the challenge on our game machine. Crack the high score and protect the plant against attack for as long as possible. You can find “Security Invaders” and all other information on industrial security in hall 11.
Further information and free tickets to the trade show are available here: Siemens at SPS IPC Drives 2016
Andreas Milbradt 23/11/2016
Live from SPS IPC Drives 2016, we’re offering a view into the MindSphere Lounge, one of our highlights this year. In our first blog article on MindSphere – the cloud-based, open IoT operating system, we presented basic information about this powerful IoT operating system. Now it’s the turn of the partner companies who are helping expand MindSphere, and also presenting their innovations at the trade show.
MindSphere lives from collaboration with partner companies that not only make MindApps available but also add new functions to expand the system itself. At the individual stands and presentations in the MindSphere Lounge, experts from Siemens and our partners explain what the future of Cloud-based services will look like.
Rapid Solution Development gives quick access to MindApp
Tino Bombach from evosoft explains just how fast customers can use data analysis based on MindSphere: “We offer our customers easy access to an integrated solution in industrial data analytics. The key concept is Rapid Solution Development via Lean/Startup- und Design Thinking-methods. When realizing a project, it’s all about the time. Advantages in competition in the field of digital business models must be usable as soon as possible.”
Evosoft, a wholly owned subsidiary of Siemens AG, provides a full service solution for digitalizing industrial data on request - from consulting to creating the MindApp and the integration of machines or further systems like ERP, for example. As a first step, evosoft offers a quick assessment evaluating the current situation, which enables the potentials of the customer offered by intelligent analyses to be swiftly identified. During the next step, in the “Test and Application Center” in Nuremberg, Germany, evosoft’s inhouse model plant, the customer has the possibility to implement his individual use cases for getting a first impression and testing the specific system characteristics. This is followed by the actual project implementation, the challenge of generating knowledge from data. Evosoft is broadly positioned: The project team comprises experts from all the different areas involved, including advisers, automation specialists, experts in data integration and app developers, and will be there to assist you from the initial idea through to the ready-to-use MindApp.
In the MindSphere Lounge, evosoft demonstrates how MindApps help customers with the process of plant optimization. The MindApp independently contacts the customer as soon as it identifies available, unused potential. The customer can then decide whether the optimization proposal should be implemented. For this decision, also further information can be retrieved, e.g. what impacts the change would have on the production, and which forecasts can occur.
Public Cloud or “On-premise solution” for your data
A further partner is the French IT company Atos, with which we have worked as partners for many years now. Atos is also involved in MindSphere in the area of app development. As part of the overall process, Atos offers its customers advice, implementation in the form of ‘use cases,’ and subsequent MindApp development. In the best case, an app can be ready for use in just 12 weeks. The special feature lies in the integration of additional information, like MES or ERP data. In its first MindApp, “Manufacturing Sustainability,” Atos brings ERP and machine data together for the purpose of sustainable manufacturing. Linking data from machines and product orders means not only current plant energy consumption or order statuses can be displayed, but also a combined value. This gives manufacturers a picture of the current situation and consumption data, and also the CO2 emissions per unit produced. Before the end of this year, Atos intends to introduce more MindApps, for tasks such as quality assurance or uncomplicated plant monitoring.
In addition to developing new MindApps, Atos will also take over the task of hosting MindSphere in 2017. Where data is stored can be freely chosen, whether in the Cloud or as an ‘on-premise solution’ using the customer’s own resources.
New opportunities using Microsoft Azure
Microsoft is the third partner presenting its products and services in the MindSphere Lounge. It was revealed yesterday that the cloud-based, open IoT operating system will also be available on Microsoft’s Azure Cloud platform from next year, with an impressive result: using public Cloud services will save the installation and maintenance costs that setting up your own IT infrastructure would normally involve. .NET support also reduces programmer time and cost when developing new MindApps.
By implementing MindSphere in the Azure public Cloud, customers will be able to choose between different data centers in many locations around the world in the future. This maintains the benefits of the public Cloud, while simultaneously retaining the reviewing opportunities the data center offers. Sabine Bendiek, CEO of Microsoft Germany, summarizes the added value: “The integration of Siemens MindSphere and Microsoft Azure encourages business model innovations and will offer customers more flexibility and choices in the future.”
Find out firsthand about the new products and MindApps that our partners have on offer in the MindSphere Lounge in hall 11. For information about the booth, the presentations in the Lounge and in the mobile Expert Centers, and also free tickets to the trade show, see Siemens at SPS IPC Drives 2016.
Alexander Gloning 21/11/2016
Only one day left until SPS IPC Drives 2016 begins. Shortly before the start of the trade show, we have a final highlight, one that will enduringly change the future of industry. We are talking about MindSphere – the cloud-based, open IoT operating system – from Siemens, where the digital world merges with the real one. MindSphere plays a key role on the way to the digital enterprise and offers new service and business models. Seamless connectivity, a powerful IoT operating system as well as applications from Siemens, our partners and third-party providers create a basis for digital services that help to easily improve your company.
Cloud computing has been one of the key themes in the digital world for several years now. New business models arising through digitalization and cloud solutions are already well advanced, particularly in the private sphere. Pictures taken with smart phones are stored in the private cloud, while entire shelves of video and DVD collections are being exchanged for streaming services.
However, some business fields have not penetrated the digitalized world quite as far as private users have done. This is due primarily to the complexity of the various industries. In some sectors, the results of measurement and monitoring processes are so massive that they require complex operations to process and prepare them. With MindSphere, we are paving the way for the industrial use of cloud technology and making it easy to set up the cloud-based, open IoT operating system without problems. In an interview on the future of industry, digital change, and Industrie 4.0, Dr. Jan Mrosik, CEO of the Siemens Digital Factory Division, explains how fast it can be to connect to the operating system, it often takes less than an hour to connect machines to MindSphere.
The cloud itself lies at the heart of this extensive, competition-promoting nexus. It represents the IoT operating system for virtualized data management. A plant can also easily be connected. The MindConnect Nano plug & play solution makes it possible to connect machines and plants to MindSphere, regardless of the manufacturer. In the future, other ways to connect will be provided, for example through a software agent or through integration into Simatic and Sinumerik. The open interfaces support for example the OPC UA communication protocol. There is thus nothing to prevent the exchange of data across companies and manufacturers in the cloud-based, open IoT operating system MindSphere.
Analysis with MindApps
The ability to evaluate the collected data is what adds value. Depending on the requirements, this takes place in the various MindSphere applications, known as MindApps. We already some have MindApps in use today. One of the first in use is Fleet Manager for Machine Tools, our MindApp for machine tools. It processes the data of the machines in use – and it does so worldwide. The benefits and performance are transparent, thereby lowering the cost of service and maintenance and optimizing plant availability. The MindApp Visual Analyzer displays the collected data. It can show several collected values simultaneously, revealing interactions and including additional results to provide a clear overview of the plant data. These MindApps are only the beginning, and many more are implemented right now.
New business models develop through the IoT operating system
The powerful IoT operating system covers a wide range of functions, from data analysis to extensive connectivity, tools for developers, applications, and services. Based on MindSphere as a PaaS (Platform as a Service), you can thus also create your own applications, even including new business models. With strong partners, the portfolio is expanding constantly. Our alliance with Atos SE for example, which exists for years, was expanded in 2016. Atos offers services in the areas of integration, infrastructure, and security in order to provide customer-specific MindSphere applications. For this, Atos helps find the right hosting solution, either in the cloud or from the customer’s own resources. We also work with Accenture, another well-respected partner, who develops apps for MindSphere. The company’s focus is primarily on collaboration with OEMs to further promote the new digital business and service models. Other partners, such as Evosoft and Senseye, customers such as Mapal and Gehring, as well as industrial equipment providers and machine manufacturers can work more effectively by combining operation technology (OT) with information technology (IT). End customers can thus lower their energy and maintenance costs, while simultaneously shortening down times and prolonging the life of their machines. The wide range of analysis services also helps avoid problems such as production bottlenecks. Fact-based decisions make it easier to plan ahead with confidence.
Enter the MindSphere
Visit us at SPS to get an up-close look at the new possibilities that MindSphere has to offer. At our booth in Hall 11, you will find the MindSphere Lounge, which covers 400 m2 of space. Not only is the lounge a visual highlight, but we also present there, together with our partners, the latest applications for our IoT operating system. Presentations relating MindSphere by internal and external experts will also take place on the main stage. In addition, we will be demonstrating the first concrete application examples. Come learn about the many different MindSphere functions and discover how they can open up new business fields.
More information and a free ticket to the trade show can be found at Siemens at SPS IPC Drives 2016
Andreas Milbradt 16/11/2016
In our previous blog, we pointed out the importance of modern automation systems for the operators of tank storage systems and terminals in the age of digitalization and Industrie 4.0. This includes the very latest information and precise measured values. Intelligent field devices supply precise and transparent information about fill levels and pressure and give operators future-viable engineering practices.
Leaks or overfilled tanks can result in serious safety risks in tank storage systems and terminals, and can also result in government sanctions. After all, operators must comply with statutory safety regulations. To allow a facility to operate efficiently and safely, and thus also remain viable for the future, precision field and measuring instruments play a key role. With our comprehensive portfolio of devices, we assist the operators of tank storage facilities and terminals in measuring fill levels and displaying energy consumption, motor power, and the release of gas. Our portfolio offers a suitable solution to nearly every problem, one that facilitates field bus communication with HART/WirelessHart, PROFIBUS, and Foundation Field Bus.
Precise and reliable monitoring of fill levels
Point level switches are a cost-effective solution for applications related to practically all liquids and solids. They are available as ultrasonic, rotation, and vibration systems, and as inverse frequency shift capacitance devices. Our SITRANS and Pointek CLS capacitance measuring instruments measure a tank’s fill level reliably, accurately, and continuously. The SITRANS FUH1010 clamp-on ultrasonic flowmeter is ideally suited for interface detection in gasoline and crude oil lines. It can be used to easily identify products or detect accumulated water or gas – with wide-beam runtime technology. These flowmeters not only deliver extremely precise measurement results but also meet the strict OIML R117 and API requirements.
Our SITRANS FC430 Coriolis flowmeter offers the same high-precision performance. In addition to fast responses to changes in flow rate, it is particularly immune to process noise and can be set to a wide range of different flows. It not only can be used for liquids and gases but is also easy to install and is maintenance-friendly.
The flowmeter is pre-installed in skids, making it an end-to-end tank storage system management solution.
Solving problems quickly and safely
Thanks to their built-in measurement and diagnostic functions, SITRANS field devices can convert data and alarms into effective action. The SITRANS Library engineering tool, which has its own display, is easy to use and helps solve problems quickly.
Oxygen accumulation must be monitored constantly to prevent possible explosions. Our new measuring instruments have sensors that detect overpressure in tanks as soon as it occurs. If the measured values show a critical amount of gas, they initiate immediate preventive action, such as automatic flushing with nitrogen, activation of an alarm, or even triggering an emergency shutdown. The laser spectroscopy of our LDS6 analyzer for continuous in-situ gas analysis makes it possible to precisely monitor oxygen concentrations. It has an integrated reference cell and maintains stability throughout the system’s entire lifecycle.
Security management is becoming increasingly complex for the operators of tank storage systems. The security installations must meet precisely defined security standards, especially in terms of perimeter monitoring and fire safety. To protect personnel, assets, and the environment, we offer systems, services, technologies, products, and networks that meet high security standards.
However, motor and energy management as well as the use of equipment are also important topics. Our portfolio includes electrical components and systems for this purpose – including transformers, low-voltage and medium-voltage switchgear, and IEC- and NEMA-certified motors, governors, and variable-speed drives.
Alexander Gloning 15/11/2016
The German chemical industry produces approximately 30,000 products – and is the world’s largest exporter of chemical-pharmaceutical products. In order to efficiently manage the huge volume of fuels, lubricants, and solvents required, the operators of tank facilities and terminals need state-of-the-art automation systems. The Sitas TMS and Sitas IT management systems enable quick response to the requirements of operators and ensure a high level of transparency and availability.
How can valuable substances be safely and efficiently transported and stored in a tank farm? How can deliveries be optimized and spills avoided? In light of the rapidly changing markets in the era of digitalization and Industrie 4.0, companies in the chemical industry are asking themselves these and other questions. With Sitas TMS and Sitas IT, Siemens offers solutions that enable these companies to transparently depict and optimize their processes and thus remain sustainable.
A modular system for maximum flexibility
Sitas TMS is particularly well-suited for tank farms and loading bays. The modular management system enables uniform automation and management of all processes – from the field device level to the automation level to integration into the enterprise resource planning (ERP) system. It can be used as a stand-alone system with an existing infrastructure or as an integrated part of a complete solution.
In plants with special IT requirements and when large volumes of data need to be recorded and converted into meaningful reports, Sitas IT with integrated manufacturing execution system (MES)enables additional data transparency and accessibility.
Sitas TMS provides comprehensive control features for inline and batch blending. Thanks to formulations that can be flexibly defined in the tank automation tool, the tool can take into account the quantity, quality, and costs of available raw materials, resulting in cost savings. In addition, this data can be entered and corrected online, ensuring precise compliance with standardized product specifications. Sitas TMS is based on Simatic PCS 7 and uses Industrial Ethernet and Profibus, two proven high-performance communication protocols.
It is possible to react in real time to actual developments in demand. The existing information networks are then immediately modified and expanded. The modular management system features an open software architecture and is compatible with products and systems from third-party manufacturers. It integrates features for tank farm balancing, ensures the secure and traceable management of all relevant master data, and provides a wide range of tried-and-tested reports to support process optimization.
Advanced digital solutions such as Simit Simulation, XHQ Operations Intelligence, and Comos Plant Design provide a common data platform for integrated operations management. Together with plant and security services, they are an important element of digitalization. Thanks to extensive monitoring and control features, the tank farms and terminals can react quickly to requirements based on sound information and flexibly adapt their processes accordingly. Sitas TMS ensures that the process data is transparent and accessible. It provides a clear graphical display of the operational workflows, which are synchronized, coordinated, analyzed, and optimized. This makes it possible to streamline processes, including supply and demand planning as well as order and inventory management and to meet the requirements of different operation managers.
Improved asset utilization, shorter waiting times, and fewer errors caused by manual processes ultimately result in greater efficiency. Centralized information and transparency provide for improved control of all terminal processes. This also results in better process security.
Alexander Gloning 10/11/2016
We already mentioned the importance of industrial security in our blog post about the process industry. It goes without saying that the protection of digitalized plants is important for the processing industry as well as for the manufacturing industry. As we progress down the path toward Industrie 4.0, the increased networking also leads to a greater need for security for industrial automation. The many benefits that can be achieved through a digitalized plant also involve certain risks. A comprehensive security concept counteracts those risks and protects the plant as well as the entire production network of a company.
In recent years, the number of attacks from the Internet has continued to grow. According to experts, in 2014 this resulted in damages estimated at $400 billion worldwide. In October 2016, the major attack on multiple online services in the United States made it clear how cyberattacks can impact everyday life in very concrete ways. In that case, the attacks affected services in the private sector. To avoid such incidents, cybersecurity is also the top priority for industry. The digitalization of automation has made plants more interesting targets for cyberattacks. To protect our customers from these dangers, we offer a holistic security concept throughout all levels, which is easy to integrate as part of Totally Integrated Automation: Industrial Security - Defense in Depth.
Securing plant access
The place to start is with plant security. Securing the physical access to a plant is the foundation for comprehensive protection. Cameras, fences, and access solutions, such as with a key card, can control critical areas. We additionally develop appropriate guidelines for everyone involved to ensure that productivity does not suffer despite the maximum level of security. We offer risk analyses to help develop a solution that will optimally meet your individual requirements. This approach makes it possible to quickly determine the current status as well as the measures necessary to tailor plant security to the individual challenges.
Security for network and system
Another key aspect is the security of the network. Firewalls and network segmentations can be utilized to protect production networks. In industrial networks, encrypted communication is used, particularly when remote maintenance and remote access is performed via public networks. With the Scalance S security modules, which are designed for this purpose, we supply products that are specially designed for automation technology. With additional network components that are equipped with integrated security functions, such as the Scalance M routers and modems, we ensure a secure infrastructure.
The control level is another area of potential danger. Our measures for these components protect against unauthorized access. Devices such as controllers and HMIs have multi-level access and copy protection. Even drives and motion control systems offer integrated functions for know-how and access protection. This ensures that corporate knowledge and data remain secure, and that the integrity of the system is safeguarded.
Identifying risks at an early stage
When it comes to attacks and growing cybercrime threats, a rapid response can often prevent extensive damage. In order to implement such responses, we have established a Cyber Security Operation Center (CSOC) in Europe as well as in the USA. In the CSOCs, the continuous monitoring and analysis of security-relevant data identify risks at an early stage. Our CSOC employees work with customers to implement effective countermeasures.
The most important factor for security is keeping the system fully up-to-date. Experts estimate that approximately 95 percent of attacks have no impact if the system is completely up-to-date. When developing new products for our automation portfolio, we always observe the latest security guidelines. We remain in close contact with our suppliers to ensure that the highest standards are met. Alerts and updates provide the latest information. At the same time, we can draw upon a network of more than 200 security experts to exploit their full potential in an emergency and respond quickly. This approach enables us to keep the system up-to-date and safeguard your plant.
Beating the high score
Visit us at SPS IPC Drives 2016 and experience our holistic industrial security concept in the “Industrial Security” and “Digital Enterprise for discrete industries” focus areas. In addition to the presentation of our products and integrated solutions, including an example implemented at Schunk GmbH & Co. KG, we have another highlight ready for you: At the trade fair you can try your hand at “Security Invaders,” an industrial security arcade game. Get involved in the action and try to set a new high score in the game! We look forward to your visit at SPS. Our booth is located in Hall 11.
More information and a free ticket to the trade show can be found at: Siemens at SPS IPC Drives 2016
Andrea Kerber 08/11/2016
Not only is it one of the oldest production facilities still in operation, it is also one of Berlin’s heritage buildings – Siemens has been manufacturing electric drives, motors, and generators in its dynamo factory in Siemensstadt for more than one hundred years. That’s why we are celebrating 110 years of innovation and inventive talent – Ingenuity for life!
Built by Karl Jahnisch and Carl Dihlmann in 1906, the dynamo factory on Nonnendammallee is one of the central buildings of Siemensstadt. The neighborhood, which is named after company founder Werner von Siemens, is located on the eastern edge of the Spandau district in western Berlin. The dynamo factory, constructed of characteristic red bricks, was expanded in two phases between 1909 and 1942 and is one of the oldest buildings in Siemensstadt. For 110 years now, the company has been producing components here that drive ships, elevators, and locomotives, among other things – an excellent reason to celebrate!
Industry and ingenuity
Siemensstadt, a neighborhood steeped in tradition, is one of the oldest and best known industrial estates in Germany. Construction of its characteristic residential and commercial buildings began in the Nonnenwiesen area of Spandau in 1904. Today, some of the ten- to 15-story buildings are under historic preservation – and the Siemensstadt Housing Estate has even been a UNESCO World Heritage Site since 2008!
However, the story of the neighborhood has its origins in Charlottenburg, where in 1872 Siemens relocated its production program, which had been in Kreuzberg previously. Due to growth in telecommunications and electrical engineering, the founder’s successors subsequently went looking for opportunities to expand by adding more production plants. They chose the Nonnenwiesen area and thus laid the foundation for Siemensstadt. Once a railway connection with tracks and stops as well as a bridge had been built, the dynamo factory was one of the first buildings to be constructed on the future industrial estate, starting in 1906.
Production gets in gear
Impressive single-phase generators were installed in the dynamo factory, for example for the Walchensee power plant – the biggest storage power plant of the day – which went into operation in 1924. Three years later, in 1927, the dynamo factory produced two 40 MVA generators with rotational speeds of 300 revolutions per minutes for the world’s first pumped-storage power plant in Herdecke. Other historic achievements of the developers and engineers include the E 44, the world’s first multipurpose electric locomotive with its welded design (1930), the generator of the 60 MW turbo set, which had the biggest steam turbine at the time (1935), the first hydroelectric power generator with a capacity of more than 100 MW (1938), and much more.
Powerful and diverse
To this day, the dynamo factory continues to produce technology that is redefining the limits of feasibility. The Berlin plant has been setting standards in the development and production of large drives for the past 110 years, including customized motors with a power output between three and 100 MW, rotational speeds between 10 and 15,000 revolutions per minute, and weights up to 500 metric tons! Drives for dragline excavators and cruise ships, gearless wind power generators, integrated drives for shaft winding engines, rolling mill main drives, and ring motors for grinding mills are also part of the factory’s extensive portfolio. Thus, the world’s biggest electric drive for an LNG compressor, with an output of 78 MW, was produced in the red brick building in Berlin in 2012, while the biggest hyper compressor drive, with an output of 24 MW, followed in 2013.
With approximately 12,000 people employed in the areas of development, planning, sales, and management, Berlin is one of our most important locations and the world’s biggest production facility. Around 800 employees work in the dynamo factory. They develop and produce primarily high-capacity special-purpose drives and generators for a wide range of industries in an area covering 50,000 square meters. Their motto is: “We reliably develop and construct THE motor for our customers: now and in the future.”
Alexander Gloning 06/12/2016
Distinguished innovator Bradley Allen Fiske was impressed. The heavily moustachioed inventor – who would go on to become a Rear Admiral and command the United States’ Atlantic Fleet – sat down with pen and paper, dated his report April 24, 1884 and wrote:
“The first to conceive … the idea of an electric railway [was] Dr. Werner Siemens, of the celebrated firm of Siemens & Halske, which has been more identified with the practical development of electrical science than any other firm in the world...”
Five years earlier, Siemens & Halske had presented the world’s first electric train; a small locomotive which pulled three carriages – each holding six passengers – around a 300-meter-long circular track, powered by a 150-volt direct current flowing through two rails.
The exhibition generated wild publicity – and the 1,000 passengers per day paying 20 pfennigs a ride, a welcome sum for local charities.
But Werner von Siemens was not a man to rest on his laurels: within two years, he had personally funded and built a 2.5-kilometre-long electric tramway in Berlin, following this world-first with electric trolleybuses, mine locomotives and an underground railway.
By the time Fiske sat down to write his contribution to Popular Science Monthly, Siemens & Halske electric railways were in widespread commercial use; the longest being a six-mile track in Ireland, running from Portrush to Bushmills.
The Foundation of Electric Transport
Electric trains were made possible by Werner von Siemens’ revelation exactly 150 years ago that dynamos could be self-excited – their heavy permanent steel magnets replaced by electromagnets and their drive units rendered 85 percent lighter, 35 percent more efficient and 75 percent less expensive to produce than their conventional counterparts.
For the first time electric power could be generated inexpensively and used at much higher capacities. The foundation had been laid for today’s use of electric energy in all areas of life, including on the railways over which Fiske waxed lyrical.
A century and a half later, Siemens is still a world-leader in electric rail technology – ranging from high speed and intercity trains, to rail automation, traction systems and complete rail solutions that have been delivered to a wide range of clients worldwide.
Siemens’ Velaro, for example, is one of the fastest high-speed trains in service in the world today, having reached a speed of 403 km/h without modifications. It covers the 625 kilometre route from Madrid to Barcelona in less than 2½ hours, traveling well over 500,000 kilometers a year, with a punctuality rate exceeding 99%.
From its aerodynamic optimisation to its precision welding, the train has been engineered with the same spirit of innovation that drove Werner von Siemens to lay laid the foundation for the electrical age 150 years ago and rapidly follow this achievement with the world’s first electric railway. And now, a century and a half later, Siemens is laying the foundation for a new age of electrical transport. This time, no rails will be required and the sky is the limit.
The Future: Electric Flight
In June 2016, a modified version of the German-built Walter Extra 300L tandem two-seater aeroplane took to the skies from Schwarze Heide Airport near Dinslaken, Germany. Spectators cheered, but other than that it was eerily quiet; the normal roar from the Extra’s standard Lycoming IO-540 piston engine entirely absent.
The aerobatic plane was powered by a radical new type of electric motor developed by Siemens researchers. Despite weighing just 50 kilograms, the motor delivers a continuous output of about 260 kilowatts – five times more than comparable drive systems.
The success of the test flight means that hybrid-electric aircraft with four or more seats are now possible. As Siemens’ Chief Technology Officer Siegfried Russwurm puts it: "This is a milestone on the road to the electrification of aviation. Disruptive ideas and the courage to take risks are crucial to innovation. That's why the development of electric propulsion systems for aircraft is also the first project for our new start-up organization, next47."
Electric drives are scalable and Siemens is also contributing this pioneering technology to a cooperative project with Airbus that was agreed in April 2016. The joint venture is aimed at further developing electrically powered flight; the partners plan to jointly develop prototypes for various propulsion systems, with power classes ranging from a few 100 kilowatts up to 10 and more megawatts.
A great future”, Fiske wrote in Volume 24 of the periodical after seeing the future of electric rail, “is prophesied for electric engines.” At Siemens, we continue to concur.
Read more on innovation of electric planes over here.
If you want to learn more on 150 years of innovation on electric drives visit us also here: Siemens at SPS IPC Drives 2016
Alexander Gloning 31/10/2016
Over the past week, our blog on the SPS IPC Drives 2016 trade show has focused on Totally Integrated Automation. We also offer comprehensive energy management solutions, which build on our integrated automation solutions. These solutions cover every aspect of manufacturing, every conveyor belt, every individual sensor. But it is the energy-intensive parts of plants, which are common to many industries, that can truly benefit from these solutions. After all, they offer enormous savings potential. A complete overview of the plant reveals this potential. The result is not only a more cost-effective production process but also one that is more environmentally friendly, due to lower energy consumption.
Transparent energy consumption requires integrated energy metering systems in the plant. Thanks to our universal product portfolio, which covers everything from the field level (with the SIMATIC, SENTRON, SIMOCODE, SINAMICS, and SIRIUS product families) to the SIMATIC Energy Suite and SIMATIC Energy Manager Pro software systems, energy data can be easily and transparently collected and visualized on the production and management levels. 7KM PAC measuring instruments and 3VA molded case circuit breakers with measurement capability from the SENTRON portfolio make energy flows transparent and thus establish the best technical basis for a company’s energy management system according to ISO 50001. Open interfaces also allow other devices from third-party suppliers to be integrated. On the plant level, Simatic Powerrate enables the collection of energy consumption data. The system visualizes and archives the data for Simatic PCS 7 and Simatic WinCC.
TÜV-tested energy management system
The integrated energy management system offers even more benefits by linking energy and production data and thereby facilitating an energy efficiency management system. This makes it possible to determine the energy costs per machine or even per unit. Simatic Energy Manager Pro, the successor to SIMATIC B.Data, can be used to efficiently and economically regulate consumption. Installed in one or multiple plants, the system also allows you to work across locations, due to its scalability.
However, it can also be connected directly to production with PCS 7 or WinCC in Energy Manager Pro. Alternatively, the energy data can be processed in a cloud-based solution. Energy Analytics provides easy and intelligent analysis capabilities that reveal the savings potential of your plant.
The primary benefits of the energy management system are improved efficiency and the cost savings that go along with this. However, Energy Manager Pro also provides support when it comes to purchasing energy – by choosing the optimum supplier, based on a consumption forecast. As a result, we deliver a TÜV-tested energy data acquisition system according to ISO 500001.
Energy Suite live at SPS
At SPS IPC Drives, we will present our complete portfolio of industrial energy management solutions in the “Energy Efficiency” and “Totally Integrated Power” theme areas. Simatic Energy Manager Pro and the 7KT PAC1200 multichannel current measuring system are our highlighted products at the trade show. And our exhibit also includes the new Simatic Energy Suite. At SPS, we will use a model to present the functionality of our integrated energy management solution. Several stakeholders configured in the TIA Portal supply data to the Energy Suite, which makes the current energy consumption clear at all times. Visit our booth in Hall 11 at SPS 2016 to learn more about our integrated energy management system.
More information and a free ticket to the trade show can be found at: Siemens at SPS IPC Drives 2016