The supervision process

Thanks to the experience gained in various specific industrial sectors (engineering, automotive, rubber, plastics, food processing, cement, consumer goods, etc.) the ESEA Group and in particular ESEA Automation, are able to work with the customer in the most effective, finding a common language, by understanding the problems and identifying the most appropriate solution, always responding in a timely manner to all stimuli.

The supervision process refers to centralized systems which monitor entities ‘ranging from single machines or activities’ of industrial process, to the control of entire sites, or complexes of systems distributed over large areas. Most control actions are performed automatically.
ESEA Automation and in general the ESEA GROUP are companies that have grown constantly investing in research and technology in the quality of the software thanks to the great capacity of analysis and knowledge of needs and the demands from the market.
To achieve this goal the ESEA Group has chosen the platform Wincc.

WinCC is scalable process visualization system with powerful features for monitoring automated processes. WinCC provides complete SCADA functionality under Windows for all industries – from single-user systems up to multi-user systems with redundant servers and solutions for the entire production site with Web clients.

 

WinCC System Software

The WinCC system software is available in two basic variants:
WinCC complete package (RC: license for runtime and design)WinCC runtime package (RT: runtime license)Both packages are available with 128, 512, 2k, 8k, 64k, 100k, 150k or 256k PowerTags.
As PowerTags exclusively define the process variables that, through a communication channel WinCC, have a connection process with the PLC or other data sources. From a process variable are differentiable up to 32 messages and up to 256 analog alarms freely definable. The Powerpack allow you to increase the number of usable Power. In this way, if your application grows, WinCC also does. It can therefore start with the smallest variant and then, if necessary, add the Powerpack. With Powerpack the number of available archive tags can also be increases: 512 (basic equipment) to 1,500, 5,000, 10,000, 30,000 or 80,000, to 120,000.

 

WinCC Options

Functional software expansions specific per customer or industry are available in the form of WinCC options and WinCC Add-ons. WinCC options allow expansions of the WinCC basic system and can be combined as desired to suit your needs. Here follows a summary of the options available for SIMATIC WinCC V.7:

 

Scalable plant configurations


WinCC / Server – for the transformation of a single-user solution in a powerful (distributed) Client / Server with up to 12 redundant WinCC servers and 32 WinCC clients.

WinCC / Central Archive Server (CAS) – for the creation of a central data archiving process scalable and optionally redundant with up to 120,000 archive tags based on the MS-​​SQL Server.

WinCC / Web Navigator – offers the opportunity to control and monitor the system via the Internet / Intranet using MS Internet Explorer or the WinCC Web Viewer supplied, without the need to make changes to the WinCC project. Thin client solutions allow the use of PCs and even rugged devices and mobile PDAs under Windows CE.

Plant Intelligence and IT & Business Integration


A homogeneous and IT & Business Integration for optimizing production using Plant Intelligence is determined by the availability of standard interfaces and powerful tools for visualization, analysis and evaluation.

WinCC / DataMonitor – for viewing, analysis, evaluation and distribution of current process states and historical data (measured values​​, alarms, data) from the process database. As DataMonitor client any office PC may be used. The DataMonitor provides several tools for analysis or visualization.

WinCC / DowntimeMonitor – can detect and analyze downtimes of machines or systems and structured production lines and deduce specific parameters of the systems: the so-called Key Performance Indicators (KPI). The analysis of the causes of failure provide information about the frequency and duration of downtimes of machines and plants. WinCC Control can be easily integrated in WinCC process screens.

WinCC / ConnectivityPack – allows other applications to access the WinCC archives via OPC HDA or WinCC OLEDB or to current values ​​via OPC XML and transmits the current or historical reports via OPC (historical) A & E to higher-level systems. With WinCC / Connectivity Station, any Windows computer without installation of WinCC can be configured as an analysis station.

WinCC / IndustrialDataBridge – supports the connection of external databases, Office applications and IT systems and WinCC OLE-DB and OPC DA via standard and configurable software.

Increased availability

WinCC / Redundancy – increases system availability thanks to redundant WinCC stations or servers that monitor each other, ensures the operability of the plant and allow a comprehensive collection of data.

WinCC / ProAgent – allows targeted and quick process diagnostics for machines and plants … Thanks to full integration into the SIMATIC process diagnostics, ProAgent provides an integrated solution based on STEP 7, the engineering tools and SIMATIC S7 controllers.

SIMATIC Maintenance Station – displays information for the maintenance of the entire automation technology. The representative page of maintenance  is derived from the STEP 7 project.

Validation and traceability

- WinCC / Audit (logging of operations, monitoring of project changes and traceability of the production process via audit trails)- WinCC / Change (project versioning and traceability of project changes) - SIMATIC Logon integrated in the user administration WinCC (central user administration, extended to the whole system) and related measures with regard to engineering, SIMATIC WinCC facilitates the fulfillment of the requirements of 21 CFR Part 11 in the pharmaceutical industry for the production of active ingredients and medicines, and of EU 178/2002 in the food and beverage industry.

SCADA expansions

WinCC / User Archives – supports the use of user archives in which data can be deposited in the form of data sets and exchanged recipes or data between WinCC and the controller.

System expansions

WinCC / IndustrialX – allows the configuration of user-specific objects in ActiveX technology. The objects can be standardized, used multiple times and modified centrally. WinCC / ODK – describes the open programming interfaces (C-API), which allow access to data and functions of the WinCC configuration and runtime, and even the creation of custom applications.

WinCC Add-ons

WinCC Add-ons are developed and sold by other Siemens departments and external suppliers. The support of WinCC add-ons is provided by the respective manufacturer of the product, that are also reference partners for the integration of the product into the automation solution.
Premium Add-ons
WinCC Premium Add-ons are quality products that are checked in the test center for SIMATIC products in relation to their interoperability with the basic WinCC system and are managed in the first instance by the central SIMATIC hotline. Currently the WinCC Premium Add-ons are available in the categories:
ConnectivityProcess ManagementDiagnostics and maintenanceSolutions for specific industries and technologiesDesign Tools

Universal use

The basic system is designed to be technology and application areas independent. This is shown by references from the most varied applications and from the most diverse sectors:  from construction of machines and plants, for the pharmaceutical industry for which, specific options of WinCC, comply with the requirements of 21 CFR Part 11.
All important communication channels for connecting to SIMATIC Controllers and Modbus Allen-Bradley Ethernet IP and TCP / IP and channels as cross-vendor PROFIBUS / PROFINET and OPC are included in WinCC. Open interfaces, multiplicity of options and the included Microsoft SQL Server for storing data as an information hub support the IT & Business Integration.

All HMI functions on board


HMI functions for industrial applications are part of the base system:
- Complete graphics display and sequences of the processes. - Operating the machine or plant via a customizable user interface with its own menus and toolbars - Signaling and acknowledgment of events - Storage of measured values ​​and messages in a process database - Recording of current process data and archive data acquired - Managing users and their access rights Transactions and events relevant to the quality are continually recorded and can be fully documented.

Configured easily and efficiently

Sophisticated design features drastically reduce the amount of engineering and training:

- Graphics editor, object-oriented - Comprehensive libraries - Efficient modular software - Fast changes due to design online - Configuration tool for the treatment of mass data - Transparency thanks to cross-reference list

Scalable – via the Web

To be able to meet growing requirements, the system needs to be expandable at any time, without causing technology incompatibilities or requiring completely new design. Investment protection is a top priority. WinCC provides the scalability to this need, from small single-user solution until the solution redundant client / server with Microsoft SQL-Server for central data storage and operator stations via the Web.

Open standards for easy integration

WinCC consistently builds on the highest possible openness and ability to integrate: ActiveX Controls and. NET controls for specific expansions and technology sector, multi-vendor process communication via OPC, standard interfaces for external access to the database (WinCC OLE-DB and OPC HDA) Integrated standard script languages ​​(VBScript and ANSI-C), access to data and system functions via the Application Programming Interface (API) with the Open Development Kit (WinCC / ODK), user-specific expansions of the graphical editor of WinCC via Visual Basic for Applications (VBA).

Microsoft SQL Server-integrated data storage as an information hub

SIMATIC WinCC has already integrated in the base system a powerful, scalable data archiving based on the Microsoft SQL Server. The user is therefore offered all the possibilities: archiving performance data and events of the current process, long-term archiving with high data compression and backup function, up to a central information hub consists of a Microsoft SQL- central server for data storage across the enterprise.

Increased production transparency through Plant Intelligence


Plant Intelligence allows production companies, thanks to the intelligent use of information within a plant, to reduce production costs, to reduce waste, to make the most of the manufacturing base and therefore obtain greater efficiency and economy. The high functionality of the system (eg. Statistical functions for measured values ​​and messages in the base system), unlimited openness, data store and a whole host of options ensure a new transparency in the production process and decisions.

Expandable using options and add-ons

The WinCC basic system forms the core of the most varied applications. Based on the open programming interfaces, WinCC options (from Siemens Industrial Automation) and WinCC Premium Add-ons (from internal and external partners to Siemens) have been developed. WinCC options can be used for scalable plant configurations for Plant Intelligence and IT & Business Integration, for increasing the availability, expanding the base system and the simplification of the validation or traceability.

Solutions for all sectors and all technologies

The WinCC basic system is independent of technologies and sectors, modular and flexibly expandable. It allows both single-user applications in the field of machine building, as well as complex multi-station solutions or even distributed systems with multiple redundant servers and clients in the field of plant construction. Countless references covering all applications and all sectors demonstrate the versatility and performance capability:

 

  • Automotive industry and its subcontractors,
  • Chemical and pharmaceutical industry
  • Industry of food and beverages
  • Manufacture of machinery and equipment
  • Energy production and distribution
  • Field of trade and services
  • Plastic and Rubber Industry
  • Metalworking industry and steel industry
  • Production and processing of paper, printing industry
  • Industrial transportation, traffic and logistics
  • Water treatment and purification of waste water
  • Building Automation and management of real estate
  • Integrated in all automation solutions and any company

All important communication channels for connecting to SIMATIC S5 / S7 / 505 (ex. Using the S7 Protocol Suite), as well as for Allen-Bradley Ethernet IP and Modbus TCP / IP and channels as cross-vendor PROFIBUS / PROFINET and OPC are included i WinCC. Since each controller manufacturer also provides for the hardware related OPC server, the possibilities of WinCC are almost limitless.

SIMATIC WinCC integrates in the base system a powerful, scalable data archiving based on Microsoft SQL Server, which can be used as a central information hub.

Open interfaces and options form the basis for effective IT & Business Integration, therefore a connection with the Manufacturing Execution Systems (MES) and Enterprise Resource Planning Systems (ERP) is also guaranteed.

Integrated user management
Access rights of users in the design and the runtime software with the WinCC User Administrator are assigned and controlled in the design and the runtime software. The administrator can configure at any time, even during the financial year, up to 128 user groups with respectively 128 individual users and assign them access rights to the functions of WinCC. A total of up to 999 different permissions.

Graphic system

The graphics system of WinCC processes all inputs and outputs on the screen during runtime. The pages that are used for displaying and controlling plant are created with the support of the WinCC Graphics Designer. Whether it is a small, simple or complex HMI control tasks, user interfaces tailored to the safe handling of the process and to optimize the entire productio can be realized with the standard WinCC.  Through central settings of design and color palettes as well as their menus and toolbars, you can create a specific look and feel for the project.

Command …

All the controls of the system of the WinCC archive and can be locked and protected from unauthorized access. WinCC can record tag – with date, time, username, and a comparison between the old and new value.
And monitoring …

To create a user interface attractive and appropriate to the process, the system provides various elements, such as graphical objects, menus, toolbars, buttons and controls as well as the faceplate personalized and modified centrally. The designer dynamically manages the appearance of the graphics and can access the values ​​of variables or detect them directly from programs. WinCC supports the display of images with up to 10,000 x 10,000 pixels, whereas the resolution is always adjusted to the necessary screen. This allows for investment protection in the case of successive enlargements of the plant.

Reporting system

Minimize downtimes – through alarms and messages

SIMATIC WinCC acquire process messages and local events in archives and, if necessary, makes them available to filtered or sorted. The reports may be the derivation of the individual bits of a process variable (max. 32,) as a result of a message frame directly from the automation system, as a result of analog alarms for any number of violations of limit values ​​or on the basis a command (-> post operative). Reports can be designed so that the operator has to acknowledge it.

Structure of reports are definable with no limitations

Since the structure of a message is completely definable, it can be adapted to the specific needs of the plant. The division into max. 10 text blocks (plant, fault location, text, etc..) improves visibility and, in combination with filtering functions or classification, it allows targeted analysis. The classification into max. 16 alarm classes allows for simple status and fault as well as the separate management of alarms, warnings, faults and errors for several different plant areas. Within a class of signals, (ex. Alarm) can be up to 16 distinct priorities.

Comfortable viewing of reports

The message display on the screen via the WinCC Alarm Control is completely configurable. Here, for example. it is possible to precisely adapt the display of information to the operator needs. The settings made can be saved in user-specific or global templates. Based on the contents of the individual message blocks, the view can be filtered, selected and classified, for example. according to chronology, priority or fault location. The contents can then be directly exported as a CSV file or printed as a report. A function of completely customizable toolbar also provides a high degree of flexibility. it is thus possible to integrate the project-specific functions. To maintain a clear view even in the presence of numerous reports coming in, the operator can hide less relevant reports on the screen by means of Alarm Hiding. The messages are still stored in the background.

Archiving and logging of alarms

Microsoft SQL Server  it is used for archiving messages. It ensures a complete record of all events. Messages are archived at the same time (the so-called signaling events  when there is an alarm or change of value of the message).

Statistical Analysis

A variety of integrated statistics functions allow the comprehensive analysis of process states. The hit list of the reports shows the average duration and total specific alarms as well as the average and total recognition. Reports can also be filtered according to the relevant events, places of origin of the reports and the intervals of time. In this way the critical points and bottlenecks in the production are immediately highlighted. To classify the messages in its visualization for analysis, you can simply select the column header and select the desired sorting criteria (ex. “Descending by frequency”).

High-performance archive for messages and measured values

Historical values ​​or trend of the values ​​are stored in the archives of the process values. WinCC archives in addition to process values ​​also reports and user data. The files are stored in files in the high performance Microsoft SQL Server database: for a central archive server it is in fact achievable, without problems, a continuous load of 10,000 measured values ​​and 100 messages per second (with a peak even 15,000 alarms within 10 seconds), The memory requirement is very low thanks to powerful compression without loss of data.

Tailored size and segmentation

The storage of measured values ​​or alarms are configured in an archive. The maximum amount of time of storage can be set according to practical needs, such as a month or a year or a maximum volume of data by default. The archive itself can be segmented. The individual logs can be transferred regularly on the storage server in the long term and, if necessary, can be read by WinCC and analyzed with the tools available. The swap ensured that even in case of long-term storage there is no data loss.

Representation of measured values

The representation of process values ​takes place via the WinCC Online Table Controls and Online Trend Controls, which represent data in the form of table or curve (trend). In addition, the WinCC Trend Ruler Control provides the ability to represent the integrated statistics functions independently of the trend display. The representation is freely selectable, ex.:

  • Online trend, curves archive trends, F (x)
  • Curve of reference values
  • Different writing directions, display of areas and limit values, interpolation, curves steps, curves staggered tables
  • Read line, zooming, scale switching, start / stop, scroll

For better display and analysis capabilities, you can design the thickness of the trend lines. By activating the right mouse button on the line of the curve, a tooltip shows detailed information about the measuring point: archive, archive tag, date / time, value and connection status. The operator can not only change the representation, but can save the changes in the configuration and, moreover, configure a trend for any process variable. Current values ​​(online trend), the values ​​of historical process and curves of reference values ​​can be displayed in the same curves. The axis of the times and the range of values ​​can be scaled individually (eg. Scaling percentage). The axes of time and the values ​​of the individual curves can be moved online by moving the mouse. This function can be used, for example, to batch comparisons.

To improve visibility, you can choose to represent only the Y-axis of the selected curve to the left and / or right of the display of the curve. The choice of the curve can be established in the design or online using the buttons on the Trend Control. The settings made can be saved in the template user-specific or global. Using the freely definable toolbar function can be integrated its project-specific functions. You will reach a high degree of flexibility. The process values ​​represented in the display of curves and statistical data can be exported with key commands from a CSV file and then analyzed with standard tools.

Statistical analysis of measured values

Numerous integrated statistics functions allow a comprehensive analysis of process states, which can be positioned anywhere in the WinCC Trend Ruler Control. The acquired process values ​​can be determined and displayed for a defined period of time, the minimum, maximum, average, standard deviation and the integral. To simplify data analysis is also possible to use a second read line. it is also possible a logarithmic representation of the trends of the curves and export values ​​displayed in Excel format.

Reporting and logging system

WinCC has an integrated logging system with which you can print data from WinCC or from other applications. It prints in a programmable layout the data acquired in the runtime of different types of protocols, the protocols of sequential signals and those of system messages. Reports can also be saved as a file and displayed on the screen in a preview. Of course, these protocols can be designed in multiple languages.

Individually configurable layouts

The report output can be initiated at a specific time and event or on direct command from the operator. In a dialog box, you can select the printer online. The contents of a log can be determined dynamically at runtime.

Opening and integrability

WinCC logs can contain data from the database and external data in CSV format as a table or curve. For the visualization of data from other applications in the form of tables or graphs you can also develop your own report provider.

Control functions (Basic Process Control)

In the basic WinCC system are also contained functions that make WinCC stations suitable for applications in process control. Additional objects and configuration tools (eg. Picture Tree Manager) in Basic Process Control provide for a easy implementation of typical technique of process control.
Group displays

  • Fixed split screen
  • Hierarchy of pages,
  • navigation pages
  • monitoring
  • Activating external signal transmitters (eg. Acoustic)
  • Time synchronization via PROFIBUS or Ethernet

Ensure the flow of information in the process, in real time, the sensor system to the management, is the solution “real” to manage the production of any modern system, improve efficiency and increase business.

Sorry, this entry is only available in Italiano.

Sorry, this entry is only available in Italiano.

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