Smarte Feldgeräte
Die Basis für Industrie 4.0
Vortragsreihe Automatisierungstechnik 2017
Unrestricted © Siemens AG 2017
siemens.com/digitalplant
From Industrie 1.0 to Industrie 4.0,
an initiative of the German industry sponsored by the German Government
Characteristics
First
Second
Third
Fourth
Industrial Revolution
Industrial Revolution
Industrial Revolution
Industrial (R)Evolution
… driven by Digitalization,
Integration and enhanced
Flexibility
• Humans, devices and systems are
connected along the entire value
chain
• All relevant information is available
in real-time – across suppliers,
manufacturers and customers
1784: First mechanical loom
1870: First conveyor belt,
Cincinnati slaughterhouse,
1908: Ford T-Model
• Parts of the value chain can
constantly be optimized with
respect to different criteria, e.g.,
cost, resources, customer needs
1969: First programmable
logic controller (PLC)
Modicon 084,
Time
1800
1900
2000
2025
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Digitalization is the next level to yield productivity within Process Industries
Process Industries
Electrification, Automation and Digitalization as levers to increase productivity
Technological driver
• Computing power
Digital Enterprise
• Communication
Integrated Engineering
and Integrated
Operations
• New sensors
Next level of
productivity
Digitalization
• Virtualization
• Cloud computing
• Simulation
• …
Automation
Electrification
Time
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Customer wishes are driving next level of productivity
“Advanced data analytics will be
key level to increase productivity”
“Modularization of production
is becoming key for higher
operational efficiency”
“Digital innovation power
speeds up chemical R&D”
“The efficiency of plant life cycle
processes will be significantly by a
seamless interoperable tool
landscape”
“Modelling and simulation
are reducing the need for
real world testing”
“Collecting data from fragmented
sources for efficient analytics”
“Information, not data, will be
the gold of the 21st century”
Unrestricted © Siemens AG 2017
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Customer wishes are driving next level of productivity
“Advanced data analytics will be
key level to increase productivity”
“Modularization of production
is becoming key for higher
operational efficiency”
“Modelling and simulation
are reducing the need for
real world testing”
“Digital innovation power
speeds up chemical R&D”
Smart Field Device
“Collecting data from fragmented
sources for efficient analytics”
Enabler for next level of productivity?
“The efficiency of plant life cycle
processes will be significantly by a
seamless interoperable tool
landscape”
“Information, not data, will be
the gold of the 21st century”
Unrestricted © Siemens AG 2017
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Smart Sensors – the basis for optimization of engineering, processes,
operation, maintenance and logistics
Scenarios for Sensoren 4.0 in process industries
Plant Asset
Management
Planning of revision
example control valve
•
Access to diagnostic data
e.g. motion profile
• Cross linking of information
for optimization of
diagnostics
=> Lifetime prediction
Flexibility
Multi purpose distillation
plant unit to increase plant
flexibility
• Information is basis for
decisions
• Matching: Process
requirements and
specification of the plant
unit
Device Integration
Smart functions simplify
sensor usage and enable
plug and play functionality
• Fast, secure
commissioning
Self-x
• Self diagnostics
• Self calibration
• Self configuration
Information for
optimization
Procurement of raw
materials and product sales
• Cross-linking of information
• Procurement, logistics,
order management, plant
availability
• Ubiquitous Information
Quelle: VDI/VDE Namur, Technologie-Roadmap “Prozesssensoren 4.0”
Unrestricted © Siemens AG 2017
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Smart Sensors: basis for plant asset management
Example control valve
Plant Asset
Management
Interactivity and connectivity
• Smart sensors provide measurement data and context information
• Linking with information out of the environment
Planning of revision
example control valve
•
Access to diagnostic data
e.g. motion profile
• Cross linking of information
for optimization of
diagnostics
=> Lifetime prediction
• Link Valve position with pressure and flow
• Turbidity and pH-Sensor
cavitation detection
abrasion and corrosion detection
Serviceability
• Data collective to derive valve state and predict remaining lifetime
Quelle: VDI/VDE Namur, Technologie-Roadmap “Prozesssensoren 4.0”
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Smart Sensors – Sensor information is basis for flexibility
Example plant availability
Flexibility
Virtual description / simulation
• Matching of engineering requirements with plant specifications, incl.
sensors. Digital specification and information availabiltiy is basis for decision
Interactivity, connectivity
Multi purpose distillation
plant unit to increase plant
flexibility
• Information is basis for
decisions
• Matching: Process
requirements and
specification of the plant
unit
• Necessary, optimized application parameters can be accessed from the net
Traceability, serviceability / condition
• Data collective is basis for plant unit status and prediction of condition
Quelle: VDI/VDE Namur, Technologie-Roadmap “Prozesssensoren 4.0”
Unrestricted © Siemens AG 2017
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Pre condition for new automation structures
Smart Sensors as enabler
Connectivity
Serviceability
Traceability
Virtuality
Interactivity
Quelle: VDI/VDE Namur, Technologie-Roadmap “Prozesssensoren 4.0”
Expectation for a smart sensor
• Plug and Play, automated integration in plant
structure
• Self calibration, diagnosis, prediction
• Communication (sensor-sensor/sensor-DCS)
• Multi Sensor / multi variable
Source: Survey Smart Sensors Namur Hauptversammlung 2015
Drivers
• Less skilled and less people available for plant
operation and maintenance
• Central operation of plants
• Maintenance and service is outsourced
• More information of process state, trend and quality
• Central optimization of logistic processes
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Virtual Description
Virtuality
Technical specification
• Digital, harmonized description of functionalities and attributes
• Basis for seamless engineering and commissioning
Integration in simulation and
planning tools
Digital models
Engineering
• 3D models, virtual functional description for engineering, commissioning,
operation and training as well as for maintenance and service.
Maintenance
• Models for plant and automation simulation
Training
Automation
Service
Quelle: VDI/VDE Namur, Technologie-Roadmap “Prozesssensoren 4.0”
Unrestricted © Siemens AG 2017
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Virtual description
Data and information consistency of virtual and real world
Next level of
productivity
Virtual description
• Simulation models
• Technical data for
engineering
• Properties
• Approvals
Quelle: VDI/VDE Namur, Technologie-Roadmap “Prozesssensoren 4.0”
Unrestricted © Siemens AG 2017
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Example: Seamless integration of Smart Field Devices in Digital Engineering
Tools
Virtuality
Customer Challenges and Potential
?
• Which device fits to my
measuring requirement
• Automated purchasing
process increases
• Purchasing efficiency required
• High effort for selection
fitting devices for measuring • More and complex product
information at high quality
points
required
• High effort for integration
of device data into planning
tool
Smart Sensor Solution
Engineering
Interface from virtual field device to digital
engineering tools
• Product configuration, comparison, and selection
• Seamless integrated inside the engineering environment
• Consistent and up-to-date data in all planning stages
Significant effort reduction and quality increase in the
engineering phase
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Example: Specific simulation models for field devices allow detailed plant
simulation
Virtuality
Customer Challenges and Potential
Smart Sensor Solution
Simulation models of virtual field devices
• Efficient use of
automation equipment
• High test effort of Smart
Sensor functions
• First testing of automation
behavior with final HW –
high risk of reengineering
Basic functionalities for
digitalization
• Virtual Commissioning: test
original automation software and
smart field device functionality
• Operator training: train the
interaction with original software
• Faster commissioning: automation engineering tested early
w/o final hardware; including specific field device functions
• Higher engineering quality: early detection of errors and
more comprehensive automation checks
• Lower costs: avoiding re-engineering and shorter
commissioning time
Reliable automation set-up will prevent errors and will
safe time and money
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Connectivity
Smart sensors are the major data source
Connectivity
Context information
• Different user groups have the need for different kind of information, context
information are the basis to convert sensor data into information
User interface to standard hardware
Digital connection of smart
sensors to the environment
• Access to all data via standard tools and hardware
Engineering
• Ensure compatibility to existing IT infrastructure
Maintenance
Data security and availability
Logistic
• Communication has to be standardized and secure
Automation
• Any kind of information must be accessible from any place at any time for
every authorized person
Service
Quelle: VDI/VDE Namur, Technologie-Roadmap “Prozesssensoren 4.0”
Unrestricted © Siemens AG 2017
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Example: Connection to additional information and functions of a smart field
device
Connectivity
Customer Challenges and Potential
Smart Sensor Solution
Specific faceplates for efficient use of connectivity
• Generic faceplates
support only standard
device functions
• Efficient engineering
• Access to additional device
functions
• High integration effort for • Avoid inconsistency for device
specific device functions
parameters
• Risk of data
inconsistencies
• Simplified checks due to easy access to special functions in
the device e.g. partial stroke tests
• Analysis of status via integrated diagnostics
• Improved plant operation due to one single view with all
necessary parameters
Significant reduction in engineering, commissioning,
cost for testing, and increased performance
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Example: Description of functionality by use of integration standards
Connectivity
Customer Challenges and Potential
Smart Sensor Solution
?
EDD
DTM
Different tools and
systems for
• Parameterization
• Diagnostics
• Commissioning
• Maintenance, Service
Higher efficiency required for
• commissioning and overview of
plant wide diagnosis
• Field device access
• Mobile accessibility in the field
• Smart functionality
FDI
Field device description via EDD, DTM, FDI
• Support of all standard field device integration technologies
• Support of the common device integration technology FDI
• Tested interoperability for all integration packages
Smart Sensor capabilities require harmonized and
powerful field device descriptions
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Example: Interoperability ensures smooth integration
Connectivity
Customer Challenges and Potential
Smart Sensor Solution
?
!
Big variety of
• Field devices
• DCS
• Infrastructure components
• Integration tools
• Smart Sensor functionalities
Today even further
• Increase of the
communication types
• Increase of product variants
• Increase of communication
protocol versions and types
• Customer frustration about
integration
!
!
Pretested Interoperability
• Substantial interoperability test to ensure perfect integration
into standard DCS systems
• Assured and optimized compatibility of infrastructures
components
Guaranteed interoperability reduces effort and cost
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Smart Sensors – enabler to merge business processes
Horizontal and vertical integration
Planning
Operation and Maintenance
Engineering
Maintenance
Logistic
Automation
Service
Training
Field – Smart Sensors
Connectivity
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Serviceability
Traceability
Virtuality
Interactivity
Quelle: VDI/VDE Namur, Technologie-Roadmap “Prozesssensoren 4.0”
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Traditional sensors provides measurement data
Traditional field device
4 .. 20mA
Measurement
Data
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Smart Sensors the information broker and basis for digitalization
Traditional field device
Smart Sensor
4 .. 20mA
Information broker
Measurement
Data
Measurement
Data
+
Context data
Tech Data
3D Models
Trace data
Certificates
Digital
Communication
Smart
functions
Remote access
Remote HMI
Self-x
Simulation
Documentation
Security
Condition
Monitoring
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Siemens realizes Digital Enterprise for Process Industries
through Integrated Engineering and Integrated Operations
Digital Enterprise
Breadcrumb
Topic
for Process Industries
Focus of Siemens
Integrated Engineering optimizes engineering and life cycle management …
Integrated engineering tools
Digital Twin
Simulation
Common data model
Thanks for your attention!
Cloud-enabled services and analytics
Next generation of Control
Questions?
Digitalization of field level
Reliable connectivity
… Integrated Operations improves productivity and flexibility
Product design
Process & plant design
Engineering & commissioning Operation
Service
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