自动化控制器发展的新趋势 现场设备的智能化提升控制系统的本地计算能力 PC机将更多参与自动化控制任务 智能型现场控制单元

Presentation on theme: "自动化控制器发展的新趋势 现场设备的智能化提升控制系统的本地计算能力 PC机将更多参与自动化控制任务 智能型现场控制单元"— Presentation transcript:

1 自动化控制器发展的新趋势 现场设备的智能化提升控制系统的本地计算能力 PC机将更多参与自动化控制任务 智能型现场控制单元 1990 2000
PLC PLC PLC PC 智能型现场控制单元 PC 1990 2000 2010 New SIMATIC S7-400 Firmware Version 4.0; Technical Information

2 自动化系统发展的新趋势 智能化采用分步式控制架构 Central previously Distributed today tomorrow
New SIMATIC S7-400 Firmware Version 4.0; Technical Information

3 自动化系统工程的新趋势 IT 技术越来越多融入自动化控制中 从ERP到现场级的纵向通讯集成 开放标准的使用 – 面向部件
Ethernet Automation system Field level ERP IT 技术越来越多融入自动化控制中 从ERP到现场级的纵向通讯集成 开放标准的使用 – 面向部件 – MS Office 应用 – XML, OPC, COM/DCOM, Active X技术 Interfaces New SIMATIC S7-400 Firmware Version 4.0; Technical Information

4 Horizontal and vertical Integration of + distributed intelligence
全集成自动化 – 西门子自动化的核心 ERP 企业资源规划 Architecture Business modelling factory MES 制造执行系统 200： TIA goes MES Enterprise asset management Industrial Framework open for all Plant maintenance management Dispatch Tracing and tracking 1998: T.I.A. incl.Drives and Low Voltage Control Systems 2000: UMC Universal Motion Control Automation 自动化 HMI Horizontal and vertical Integration of Networks - Communication - Data management - Config/Prog CNC, PLC, DCS TIA TIA Sensors, actuators + distributed intelligence Component based Automation Totally Integrated Automation is the core of our range of automation products and systems. And this system continues to develop. With “TIA goes MES” the automation level merges into the production control level. Vertical IT integration is the buzzword. The SIMOTION Motion Control system and the integration of drives and switchgear expand the range to cover a broad base. And with Component Based Automation, TIA takes a further consistent step towards the modularization of automation solutions. 过程自动化 工厂自动化 Machine automation 2001: T.I.A. with Distributed Intelligence 1996: T.I.A. for Discrete Manufacturing and Process Automation New SIMATIC S7-400 Firmware Version 4.0; Technical Information

5 新一代 S7-400 CPU 广泛适用于制造业和过程工业 功能最强大的PLC S7-400 即将于2004年8月推出 新一代！
新一代 S7－400 CPUs 全球市场占有率第一 中国市场占有率第一，高达35％ 制造业/过程工业通用自动化控制平台 全集成自动化先进理念的控制核心 西门子功能最强大的高端PLC In order that the S7-400 be able to fulfill the sophisticated demands placed on high-end automation equipment in future, it was completely revamped. In the process, the primary features and capabilities of the PLC were improved in the SIMATIC in such a way and to such a degree that our customers can continue to rely and depend on the S7-400 in the foreseeable future. New SIMATIC S7-400 Firmware Version 4.0; Technical Information

6 S7-400 概述 标准S7-400 S7-400 H 硬件冗余系统 S7-400 F/FH 系统 广泛适用于过程工业和制造业
新一代 S7－400 CPUs 标准S7-400 S7-400 H 硬件冗余系统 S7-400 F/FH 系统 广泛适用于过程工业和制造业 大数据量的处理能力 协调整个生产系统 支持等时模式 灵活，自由的系统扩展 支持带电热插拔 不停机添加/修改分布式I/O 尤其适用于过程工业 降低故障停机成本 双机热备，避免停机时间 无人职守运行 双CPU切换时间低于100 毫秒 先进的事件同步冗余机制 基于S7-400H冗余系统 实现对人身，机器和环境的最高安全性 符合EN 954 (高达安全等级4)安全规范 标准程序与故障安全程序在一块CPU中同时运行 The S7-400 is normally used to perform high-speed or data-intensive tasks. It's reproducibiity is excellent, i.e. there is little fluctuation. Irregular communication or test routines are executed without a measurable effect on the PLC cycle. In situations involving extremely complex applications, as many as four CPUs can be operated in parallel in the same subrack. The number of I/O channels is often in the thousands. As higher-order coordinating control unit and interface to the master computer, the S7-400 is normally equipped with one or more Ethernet cards. A high level of availability is guaranteed by even the standard system, in part through module replacement during operation (hot swapping). Based on standard controllers The S7-400H, as a high-availability (redundant) member of the S7-400 family, is a PLC which drastically reduces the risk of production downtimes. Thanks to its high-availability structure, the S7-400H is perfect for applications in which failures and downtimes must be largely avoided. High availability is achieved thanks to two parallel CPUs, redundant PROFIBUS DP lines, redundant I/O and redundant communication. In the event of a failure, switching is bumpless, i.e. the standby CPU takes over the control of the process at the point of interruption and without any loss of information. The CPU 414H and 417H CPUs are available for use in high-availability systems. Fail-safe SIMATIC S7-400F controllers assume or remain in a safe state the moment a fault occurs, thereby ensuring the highest level of safety for human, machine, environment and process. The safety functions are executed by the safety program in the CPU in conjunction with fail-safe I/O modules. Standard I/O and fail-safe I/O may be present in the same system. High-availability CPUs 414H/FH and 417H/FH are available for use in process automation, CPU 416F for use in production engineering. New SIMATIC S7-400 Firmware Version 4.0; Technical Information

7 显著增强的控制性能 OB1主程序循环时间降低 4倍以上 等时模式下显著的性能增强 OB 61-64 循环周期更快 412-1 0.1
0,4 bis 0.4 0.3 1.0 1,7-7,8 412-2 0,6 414-2 0.06 0,24 bis 0.24 0.18 0.6 1,0-4,6 414-3 0,36 1,0-4,7 416-2 0.04 0,16 bis 0.16 0.12 0,7-3,1 416-3 0,24 417-4 0.03 0.09 CPU 类型 最快指令执行时间 (µs) 定点数加法 浮点数乘法 浮点数除法 浮点数加法 浮点数数乘法 复杂算术功能 0.40 to 0.60 0.24 to 0.36 0.16 to 0.24 1.70 to 7.80 1.02 to 4.68 0.68 to 3.12 新一代 S7－400 CPUs OB1主程序循环时间降低 4倍以上 等时模式下显著的性能增强 OB 循环周期更快 New SIMATIC S7-400 Firmware Version 4.0; Technical Information

8 显著增强的控制性能 组合指令执行时间比较 （Load/Transfer/Add） 新一代 S7－400 CPUs
New SIMATIC S7-400 Firmware Version 4.0; Technical Information

9 显著增强的通讯性能 通讯性能提高体现在 网络响应时间大大缩短 数据吞吐量加倍 即使CPU已处于高负荷运行，通讯数据吞吐量也会显著提高
通讯对象 (类型及数目) 通讯接口 (MPI, DP 及背板总线) 通讯指令 通讯协议 新一代 S7－400 CPUs 网络响应时间大大缩短 数据吞吐量加倍 即使CPU已处于高负荷运行，通讯数据吞吐量也会显著提高 现场级通讯连接性能显著提高 等时模式下更短的循环周期 数据吞吐量更大，通讯响应时间大大缩短 与管理层/人机界面垂直集成 控制器间数据通讯 CP 高级通讯处理器集成 4个以太网接口 New SIMATIC S7-400 Firmware Version 4.0; Technical Information

10 通讯链接数目 新一代 S7－400 CPUs New SIMATIC S7-400 Firmware Version 4.0; Technical Information

11 显著增加的工作内存 工作内存(程序与数据内存) [K字节] 无需内存扩展 20,000 20,000 5,600 2,800 2,800
新一代 S7－400 CPUs 20,000 20,000 Previous + additional = new memory 5,600 2,800 2,800 144 256 512 1,400 1,400 无需内存扩展 New SIMATIC S7-400 Firmware Version 4.0; Technical Information

12 充足的定时器/计数器 新一代 S7－400 CPUs New SIMATIC S7-400 Firmware Version 4.0; Technical Information

13 其它 STEP 7 最新版本 新CPU需用STEP7 V5.2 SP1, Hotfix 3 及 Hardware Update 或更新版本 (STEP 7 V5.2 SP1 HF3 HSP) 许多功能只有STEP 7 V5.3 或更新版本支持 Trace functionality 简捷的CiR (Configuration in RUN) 定时器组态(timer configuration) 兼容性 新CPU完全替代旧CPU， 新老CPU保持零部件兼容 老CPU在与新CPU并存3个月后将淘汰 新一代 S7－400 CPUs New SIMATIC S7-400 Firmware Version 4.0; Technical Information

14 Sufficient digital and analog inputs/outputs possible
S7-400 CPU 技术指标 新一代 S7－400 CPUs 性能升级 价格不变! 类型 内存 指令处理 通讯接口 I/O 计数器/定时器 PLC 144KB KB from 100ns MPI/DP PROFIBUS-DP PLC 512KB MB from 60ns MPI/DP PROFIBUS-DP PLC 2.8MB MB from 40ns MPI/DP PROFIBUS-DP PLC 417-4 20MB from 30ns MPI/DP PROFIBUS-DP The slide shows the new line of CPUs. The new CPUs will have the exact same list prices as the old CPUs, greatly improving the price-performance ratio. Sufficient digital and analog inputs/outputs possible 2048 / 2048 2048 / 2048 2048 / 2048 2048 / 2048 New SIMATIC S7-400 Firmware Version 4.0; Technical Information

15 轻松简单的模板安装 鲁棒、可靠的模板插接 前连接器机械自锁定连接技术（Self-coding） 全部模板统一使用48针前连接器
TOP 连接技术 防止仪表极性接反 通过预制电缆 模板的全部参数均通过软件设定， 没有DIP/DIL开关 带电热插拔 机架 /电源 – 对全部CPU通用，即使配置多CPU工作，减少配件 扩展机架价格低廉 模板无插槽规则限制 高密度模板配置，节约空间 标准S7－400也可以选用冗余电源 机架接地方便 单槽宽、双槽宽均适用 安装 A universal subrack for Central controller Expansion unit suitable for 19“ cabinets The self-coding front connector is available in the following versions: Universal terminal in screw-type technology Fast and easy in spring-mounted technology In Crimp technology for series New SIMATIC S7-400 Firmware Version 4.0; Technical Information

16 新功能(CiR) 尤其适用于过程工业 运行中修改组态（CiR） 运行时自由修改分布式I/O 的 系统硬件配置（增加删除从站） 应用于
生产不能停机的过程工业 启动成本很高的生产线 用户利益 节约时间，低成本的生产线改进 无需特殊的启动程序 高度的柔性生产线 新功能 Prerequisites: S7-400 FW V3.1, STEP7 V5.2 Applications for CiR – Configuration in Run – are industrial plants with non-stop requirements, continuous processes which must not be halted or interrupted, and production plants with high restart costs. CiR enables non-reacting expansion and optimization of plants with distributed I/O while the plant is in operation. Plant modifications can thus be completed quickly and cost-effectively. Modifications in RUN mode permit an extremely flexible response to changes in and optimization of industrial processes. Even plants which have no non-stop requirements can shorten the time otherwise needed for modification and reconfiguration, since plants modified in RUN mode need not be reinitialized or resynchronized because of changes in the hardware configuration. The following changes can be made to a plant's hardware configuration during operation: Addition or removal of PROFIBUS DP-/PA slaves. Addition, removal, reparameterization or I/O modules in the ET200M I/O system. CiR is possible only for distributed I/O. All S7-400 standard CPUs as well as standalone high-availability S7-400H CPUs can be used. H-CiR is available for redundant H systems. CiR is possible using the following DP masters: CPU via integrated interfaces, CP443-5 ext (beginning version V5.0), module IF964-DP. 不停机系统改进 车间和过程优化 New SIMATIC S7-400 Firmware Version 4.0; Technical Information

17 CiR的应用条件 CiR S7-400 PLCs 414-4-1H 417-4-1H ET 200M DP-Slave F-Module
CiR 支持分布式I/O 模块的 重新参数化: CiR S7-400 PLCs H H 新功能 CPU 41x 的MPI/DP-集成接口 CPU41x-2集成DP接口 IF 964-DP 接口模块 CP443-5 扩展的外部 DP 接口 ET 200M DP-Slave F-Module PA-Slave 可添加、移走的模块范围 General condition: CPU handles a DP line via integrated interfaces or CP443-5 ext (V5.0) or IF. CiR can be used with all DP masters. However, these must already exist in the initial configuration! Reparameterization works for all modules that receive data blocks over the C1 channel, i.e. all S7(V1) slaves (e.g. ET200M). New SIMATIC S7-400 Firmware Version 4.0; Technical Information

18 新功能—等时模式 尤其适用于生产加工业 将 SIMATIC自动化解决方案连接到 等时的 PROFIBUS网络 用户程序I/O访问同步
一致的输入和数据传输 过程映像全部数据具有逻辑上 和时间上的关系 应用： 运动控制、回路调节 新功能 Prerequisites: S7-400 FW V3.1, STEP7 V5.2 Because they entail lower costs – less cabling, easier installation - distributed automation solutions are assuming increasing significance. Production processes and machining processes are getting faster and faster, and demands for precision are growing. Applications for isochrone mode: motion control, synchronous operation, closed-loop control, software-based cam control, multipoint measurement, rotational speed and flow measurement The user program is synchronized with the I/O, i.e. all procedures are chronologically coordinated. All input data are acquired at a defined point in time, and output data become effective at a defined point in time as well. The processing of all input and output data is equidistant, i.e. input data are always read in at specific intervals, and output data are always output at specific intervals. All input and output data are transferred in consistent form, i.e. all data in the process image belong together both logically and chronologically. High-speed time-based procedures in which reproducibility plays a decisive role can also be automated with distributed I/O. 高速处理又能安全控制 具有可重复性，定义的分布式 I/O过程响应时间 连续操作机械显著提高了控制和定位精度 大大提高了生产力 New SIMATIC S7-400 Firmware Version 4.0; Technical Information

19 新功能 等时模式 Ti To System cycle ET 200S ET 200M CPU
Many cycles non-coordinated T1: Read input signal T2: ET 200 backplane bus T3: PROFIBUS-DP T4: CPU program scan cycle T5: PROFIBUS-DP T6: ET 200 backplane bus T7: Issue output signal New SIMATIC S7-400 Firmware Version 4.0; Technical Information

20 等时模式循环周期 新功能 New SIMATIC S7-400 Firmware Version 4.0; Technical Information

21 TIA 完全的冗余解决方案 Management level Process level Field level S7-400的冗余方案
Clients Parallel redundancy Server Parallel redundancy With archive-matching PC network/terminal bus Fault-tolerant communication Ethernet Media redundancy Process level H CPUs Hot stand-by SW redundancy Warm stand-by Redundant power supply ET 200M Field level Redundant PROFIBUS Redundant IM 153 New SIMATIC S7-400 Firmware Version 4.0; Technical Information

22 Introduction Industries for H Systems
Energy Generation and Distribution (Oil, Gas, Electricity) Power plants Pipeline Offshore District heating Chemical/ Electrochemical/ Petrochemical/ Pharmaceutical Mining Environmental technology Water processing Garbage incineration Cellulose, Paper, Printing

23 Introduction Industries of H Systems
Steel and metal industry Food, beverages, and tobacco Industry Glass industry Wafer production Transportation Tunnel ventilation Ship automation Airport automation Maneuvering area lighting Luggage transportation

24 S7–400H 硬件冗余 Hidden redundancy
Transparent programming (programming same as for non- redundant systems) Standard system parameterization Standard handling All SIMATIC programming languages can be used without restriction Platform for F and FH systems S7-400的冗余方案 New SIMATIC S7-400 Firmware Version 4.0; Technical Information

25 无缝的CPU主备切换时间 切换时间 何时切换 < 100ms，通常20ms 切换期间输出保持 没有信息、报警或中断的损失
Master 失效 电源 机架 同步模块 同步电缆 CPU DP string or DP slave 接口模块失效，不必切换 New SIMATIC S7-400 Firmware Version 4.0; Technical Information

26 自动事件同步——最先进的冗余机制 Synchronization procedure Event synchronization No
Cycle synchronization Time synchronization Command synchronization Subcontroller A Subcontroller B Subcontroller A Subcontroller B Subcontroller A Subcontroller B Subcontroller A Subcontroller B New SIMATIC S7-400 Firmware Version 4.0; Technical Information

27 Redundant communication Principle
Redundant communication is attained through redundant connections, which are then used when a problem occurs. Redundant connections can be created from H stations to Other H stations (one- or two-channel) HMI PCs (software Redconnect required) Active connection Stand-by connection Communication New SIMATIC S7-400 Firmware Version 4.0; Technical Information

28 Redundant communication Configuration with redundant bus (1)
Ethernet H-CPU in single mode Equivalent circuit diagram: Communication PS CPU CP Bus CP CPU PS PS CPU CP Bus CP CPU PS New SIMATIC S7-400 Firmware Version 4.0; Technical Information

29 Redundant communication Configuration with redundant bus (2)
Ethernet H-CPU in single mode Equivalent circuit diagram: Communication CP CP PS CPU CPU PS Bus CP CP CP CP Bus PS CPU CPU PS CP CP New SIMATIC S7-400 Firmware Version 4.0; Technical Information

30 Redundant communication Configuration with single bus
Ethernet H-CPU in single mode Equivalent circuit diagram: Communication PS CPU CP CP CPU PS Bus PS CPU CP CP CPU PS New SIMATIC S7-400 Firmware Version 4.0; Technical Information

31 Redundant communication Configuration with ring bus
S7-400H S7-400H H-CPU in single mode Equivalent circuit diagram: Communication PS CPU CP Bus CP CPU PS PS CPU CP Bus CP CPU PS New SIMATIC S7-400 Firmware Version 4.0; Technical Information

32 S7-400的软件冗余 定位 应用 低成本的冗余解决方案 适合全部S7-31x-2DP CPUs
从CPU 313C-2DP 或更新 到CPU 417-4 包括混合 应用 适合于主站与备用站切换秒级允许时间的过程应用 示例应用: 水处理过程 冷却水循环过程 许多行业中控制与监控 温度和液位 运输流量控制 (例如. 隧道) 采集测量数据 New SIMATIC S7-400 Firmware Version 4.0; Technical Information

33 软件冗余的工作机理 Stand-by Master 接收并评估主机的状态数据 执行非冗余用户程序 冗余用户程序未被执行 读入输入信息
送出冗余和非冗余输出信息 Master 读取并评估备用机的状态数据 执行冗余部分用户程序 发送状态数据到主机 发送冗余数据到备用机 S7-400的冗余方案 New SIMATIC S7-400 Firmware Version 4.0; Technical Information

34 Connection to redundant components
MPI, PROFIBUS DP, Ethernet S7-400的冗余方案 Connection to redundant components Master controller Back-up controller Non-redundant area Non-redundant area ET 200M with 2 x IM 153-2 Redundancy area Active bus Passive bus New SIMATIC S7-400 Firmware Version 4.0; Technical Information

35 I/O冗余 New: redundant I/O S7-400的冗余方案 Redundant communication
Redundant controller New: redundant I/O PROFIBUS DP Redundant PROFIBUS Sensor/control element Redundant IM New SIMATIC S7-400 Firmware Version 4.0; Technical Information

36 SIMATIC ET 200 在防爆区的定位 ProfiBus 通讯
New SIMATIC S7-400 Firmware Version 4.0; Technical Information

37 产品推出计划 2004年8月 2004下半年 2005 新CPU与现有CPU是零部件兼容的 无需改动程序或设计文档即可享受增强的性能
集成PROFInet接口的 S7-400 CPU PROFInet – CP 带 PROFInet I/O 新一代S7-400 CPU CP 高级通讯处理器开始供货 The new CPUs have compatible spare parts. The existing CPUs will therefore be phased out after a short overlap period of about three months. In June of 2004, CbA, and most importantly PROFInet I/O, will be possible with the S This is made possible by an update of the CP Advanced firmware. By the end of 2004, in all probability, there will be two new CPUs in the S S7-400 CPUs with PROFInet interface represent an expansion of the CPU product line! Probable communication protocols: PROFInet and PROFInet I/O; S7-communication; PG/OP services; The following versions will be available: CPU 414-2/1 (2xDP / 1xPN) Same quantity framework as –2 CPU (512kB main memory) CPU 416-2/1 (2xDP / 1xPN) Same quantity framework as –2 CPU (2.8MB main memory) The list price has not yet been set. The innovated F-CPUs will be launched at the same time as the standard CPUs in March The new H-CPUs will be coming in April 2004. Background: The new CPUs have spare parts compatible with the current S7-400 CPUs. However, a new hardware concept poses the restriction that the DP modules will not be replaced with modules whose spre parts are compatible. No program modifications are required to convert to the new CPUs. As was successfully introduced some time ago for the S7-300, the new CPUs will be equipped with a toggle switch (instead of a keylock switch). 2004年8月 2004下半年 2005 New SIMATIC S7-400 Firmware Version 4.0; Technical Information