Siemens Simatic s7-1200 User manual

Quality Assurance by

means of Weighing,

Controlling and

Logging (Set 6)

SIMATIC S7-1200 + SIWAREX WP231

https://support.industry.siemens.com/cs/ww/en/view/82454336

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Industry

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Support

Warranty and Liability

Weighing, Controlling and Logging (Set 6)

Entry ID: 82454336, V2.0, 10/2017

Warranty and Liability

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Table of Contents

Weighing, Controlling and Logging (Set 6)

Entry ID: 82454336, V2.0, 10/2017

Table of Contents

Warranty and Liability..............................................................................................2

1Task.................................................................................................................5

2Solution...........................................................................................................7

2.1 Overview...........................................................................................7

2.2 Hardware and software components..................................................9

2.2.1 Validity ..............................................................................................9

2.2.2 Components used .............................................................................9

3Basics ...........................................................................................................11

3.1 Recording weight as measured variable and providing as value.......11

3.2 Recipe management........................................................................12

3.3 Filling goods....................................................................................14

3.4 Logging the quality assurance .........................................................15

3.5 Automated archiving of the log data.................................................16

4Mode of Operation........................................................................................17

4.1 General overview.............................................................................17

4.2 SIWAREX blocks.............................................................................17

4.2.1 "WP231PR" function block...............................................................17

4.2.2 “WP231PR_DB” instance data block................................................19

4.3 Recipe blocks..................................................................................20

4.3.1 “Recipe_DB” data block...................................................................20

4.3.2 “Main_Recipe” organization block ....................................................21

4.3.3 “tags_Recipe” data block .................................................................23

4.4 User program blocks........................................................................23

4.4.1 “Filling” function block ......................................................................23

4.4.2 “HMI” function block.........................................................................26

4.4.3 “Tags” data block.............................................................................29

4.5 Data logging - blocks.......................................................................29

4.5.1 “Copy” function ................................................................................29

4.5.2 “DataLog” function block..................................................................31

4.5.3 “Time” function ................................................................................33

5Configuration and Settings..........................................................................35

5.1 Configuring SIMATIC Panel TP700 Comfort ....................................35

5.2 Network connections .......................................................................36

5.2.1 Setting PG/PC interface...................................................................38

5.3 Region and language options ..........................................................38

5.4 Configuring SIWAREX WP231 weighing module..............................39

6Installation and Commissioning..................................................................40

6.1 Installing the hardware.....................................................................40

6.2 Installing the software (download)....................................................42

6.3 Downloading the startup code..........................................................42

7Operating the Application............................................................................43

7.1 Overview.........................................................................................43

7.1.1 Toolbar (footer)................................................................................44

7.1.2 Header with scale status..................................................................44

7.2 Commissioning................................................................................45

7.2.1 Setting time.....................................................................................45

7.2.2 Quick Start ......................................................................................46

7.3 Live demo........................................................................................47

7.3.1 Recipe selection and individual weight determination.......................47

Table of Contents

Weighing, Controlling and Logging (Set 6)

Entry ID: 82454336, V2.0, 10/2017

7.3.2 Changing the recipe data via the web server....................................49

7.3.3 Filling process .................................................................................51

7.3.4 DataLog ..........................................................................................53

7.3.5 Reading out the DataLog file............................................................54

8Links & Literature.........................................................................................56

9History ..........................................................................................................56

1 Task

Weighing, Controlling and Logging (Set 6)

Entry ID: 82454336, V2.0, 10/2017

1 Task

Introduction

In the packaging industry, containers are to be filled with a specified number of

pieces (e.g. of wall anchors), calculated by weight control.

Before the actual filling, it can be selected via a recipe selection, what (which wall

anchor diameter) and how many are to be filled. Apart from the allowed weight

tolerance for the packaged goods, the recipe also includes the individual weight of

a wall anchor. This can be determined via a teach function, based on the arithmetic

average of a counted sample, and be saved in the recipe.

The packaging weight is tared to 0 before filling. The filling process opens two

sliders. One opens/closes the storage container with the goods to be packaged.

The second limits the filling speed (fast/slow). When reaching the specified

threshold (e.g. 90% of the weight setpoint), the filling speed is lowered by the

second slider. This prevents overfilling. When the calculated weight setpoint

(pieces x individual weight) is reached, the second slider is also closed and filling is

completed. Underfilling is not permissible.

Subsequently, a quality assessment is to take place. The packaged goods will pass

the quality control if the filling weight is within the tolerance specified, it not, it will

not pass.

In the course of this quality assurance measure, the goods are to be clearly

identified and all relevant data, including time stamp is to be logged.

It shall be possible to import the log data to Office Excel. The automation of the

logging process and the integration of the required components into the existing

infrastructure of the packaging system are to be possible.

It must be possible to apply the check for completeness of the packaged goods

also to other products with different content without extra work.

The packaging system is to be operated and maintained exclusively via an HMI

device. Operation is to be possible in German and English.

The recipe data is to be edited via remote access through a control station.

Accepting the changed data is then again to be done via the operator panel.

1 Task

Weighing, Controlling and Logging (Set 6)

Entry ID: 82454336, V2.0, 10/2017

Overview of the automation task

The figure below provides an overview of the automation task.

Figure 1-1

Recipe

Pieces

Filling

Quality

5029

124

125.6 g

Load cell

2 Solution

2.1 Overview

Weighing, Controlling and Logging (Set 6)

Entry ID: 82454336, V2.0, 10/2017

2 Solution

2.1 Overview

Schematic layout

The figure below shows a schematic overview of the most important components of

the solution:

Figure 2-1

1S7-1200 power suppy 3S7-1200 CPU

5SIWAREX WL 260

6TP 700 Comfort

4SIWAREX WP 231

2CSM 1277

1234

The automation solution uses an S7-1200 controller and the SIWAREX MS

weighing module WP231 with a WL260 load cell. The weight value of the

packaged goods is recorded and compared with a reference value. After filling, it is

checked whether all components are complete. The packaged goods can be

clearly identified by a batch number.

The DataLog function of the S7-1200 controller makes it possible to log the

currently measured weight values with a time stamp in the flash memory of the

CPU.

You can download your data log files with the help of an internet browser (e.g. the

integrated Internet Explorer on the TP 700 Comfort TouchPanel) via the integrated

PLC web server of the S7-1200 controller.

Connecting the S7-1200 controller to a Windows PC enables automatic read out

the log data and the evaluation with common spreadsheet applications such as

Excel.

The individual stations of the filling process are monitored via screens that can be

switched to German or English using a TP 700 Comfort touch panel.

The recipes to manage the reference data of different production series are saved

in the load memory of the S7-1200 controller.

The configuration of the SIWAREX WP231 weighing module is performed via the

SIMATIC S7-1200 by means of “write data record” as of firmware V1.1.

2 Solution

2.1 Overview

Weighing, Controlling and Logging (Set 6)

Entry ID: 82454336, V2.0, 10/2017

Application areas

Set 6 is suitable for many industrial applications in which cost-effective weight

measurements have to be performed with little engineering overhead. This set is

particularly suitable if additionally automated logging functions are required in the

framework of the measurements.

Set 6, for example, is particularly suitable for the following sectors and fields of

application:

Food industry

Packaging industry

Raw materials

Mechanical engineering

Advantages

The integration of the SIWAREX WP231 weighing module into the S7-1200

ensures that the technological functions of the weighing module are combined

with all advantages of the PLC world (expandability, flexibility, software, HMI,

drives, communication interfaces, etc.)

Cost-effective high-precision weighing by means of SIWAREX load cell

Fast and simple configuration via TIA Portal V14

Automated logging functions provides evidence for the customers

Easy integration into existing systems due to a connection via PROFINET

Topics not covered by this application

This application focuses on the filling process by means of weighing technology,

the recipe management and the data logging in the load memory of the controller.

The filling process is deliberately kept simple and is realized via the digital control

of two sliders. When controlling an analog valve, the program code has to be

adjusted accordingly.

This application does not include a description of:

Positioning of the filling container (delivery and forwarding)

Assumed knowledge

Basic knowledge of SIMATIC S7-1200 and the TIA Portal is assumed.

2 Solution

2.2 Hardware and software components

Weighing, Controlling and Logging (Set 6)

Entry ID: 82454336, V2.0, 10/2017

2.2 Hardware and software components

2.2.1 Validity

This application is valid for

STEP 7 V14 (\9\) Update 2 (\11\)

WinCC Comfort V14 (\10\) Update 2 (\11\)

CPU 1214C Firmware V4.2.1 (\12\)

SIWAREX WP231 Firmware V3.1.1 (\5\)

2.2.2 Components used

The application was created using the following components:

Hardware components

Table 2-1

Component

Qty.

Article number

Note

PM 1207 power supply

6EP1332-1SH71

Supplies the

components with 24V

CSM 1277

6GK7277-1AA10-0AA0

Ethernet switch

CPU 1214C DC/DC/DC

6ES7214-1AG40-0XB0

S7-1200 controller

Firmware: V4.2.1

SIWAREX WP 231

7MH4960-2AA01

Weighing module

Firmware: V3.1.1

SIWAREXWL 260 load cell

7MH5102-1KD00

Rated load: 3 kg

SIMATIC HMI TP700

Comfort

6AV2124-0GC01-0AX0

Operator panel

Accessories

Table 2-2

Component

Qty.

Article number

Note

SIMATIC NET, INDUSTRIAL

ETHERNET TP CORD

RJ45/RJ45, CAT 6, TP CABLE

4X2, PREPARED WITH 2

RJ45 CONNECTORS, …

0.5M

10M

6XV1870-3Q…

…E50

…H10

…H20

…H60

…N10

Ethernet cable

Standard mounting rail 35mm

6ES5 710-8MA11

483 mm

2 Solution

2.2 Hardware and software components

Weighing, Controlling and Logging (Set 6)

Entry ID: 82454336, V2.0, 10/2017

Software components

Table 2-3

Component

Qty.

Article number

Note

STEP 7 Basic V14

6ES7822-0AA04-0YA5

Configuration and

programming of the SIMATIC

S7-1200

WinCC Comfort V14

6AV2101-0AA04-0AA5

Configuration and

programming of the TP 700

Comfort

SIWATOOL V7

Configuration

package

7MH4960-2AK01

PC configuration software for

the SIWAREX WP 231

weighing module

- optional: only required for

firmware updates.

Example files and projects

The following list includes all files and projects that are used in this example.

Table 2-4

Component

Note

82454336_S7-

1200_SIWAREX_Set6_PROJ_v2d0.zip

This zip file contains the TIA Portal

project.

82454336_S7-

1200_SIWAREX_Set6_DOC_v2d0_en.pdf

This document.

3 Basics

3.1 Recording weight as measured variable and providing as value

Weighing, Controlling and Logging (Set 6)

Entry ID: 82454336, V2.0, 10/2017

3 Basics

3.1 Recording weight as measured variable and providing

as value

Table 3-1

No.

Function

Comment

The SIWAREX WL260 load cell is used to

convert a mechanical force into an electrical

signal.

Four expansion measuring strips (EMS)

interconnected to a Wheatstone bridge, are

attached to the spring rod of the load cell.

If a force acts upon the spring rod and

compresses or stretches the expansion

measuring strips attached to it, an overall

misalignment of the spring rod can be

determined from the positive and negative

changes in resistance. (Measurement voltage,

proportional to change in resistance)

With the aid of the analog-digital converter

integrated in the SIWAREXWP231 weighing

module, a weight value is continuously

calculated from the measurement voltage.

Measuring signal

10 ms

Weight

value 2300 g

The S7-1200 controller accesses this weight

value via the backplane bus in the analog input

address area of the WP231 weighing module.

The transferred value is a 16-bit integer value.

The “WP231PR” function block is used for the

conversion into the respective weight value as

floating point number.

The weight value to be used is stored in the

“WP231PR_DB” instance data block.

Weight

value

WP231PR_DB

WP231PR

Prinzipdarstellung

einer

Wheatstone-Bridge

DMS (gestreckt) DMS (gestaucht)

DMS

(gestreckt)

DMS

(gestaucht)

Prinzipdarstellung

einer

Wheatstone-Bridge

Prinzipdarstellung

einer

Wheatstone-Bridge

DMS (gestreckt) DMS (gestaucht)

DMS

(gestreckt)

DMS

(gestaucht)

belasteter Biegestab

gestauchter

DMS

gestreckter

DMS

gestreckter

DMS gestauchter

DMS

belasteter Biegestab

gestauchter

DMS

gestreckter

DMS

gestreckter

DMS gestauchter

DMS

3 Basics

3.2 Recipe management

Weighing, Controlling and Logging (Set 6)

Entry ID: 82454336, V2.0, 10/2017

Note

The real addressing can be read out via the device view of the SIWAREX

WP231 weighing module in the “I/O addresses” and “Hardware identifier” menu

item in STEP 7 V14 Basic.

3.2 Recipe management

The recipes are saved in the load memory of the controller (internally or on the

memory card) to relieve the main memory.

In the main memory, only a data structure of the recipe elements has to be defined

as a wild card.

A certain recipe data record is copied from the load memory to the wild card in the

main memory via the “READ_DBL” function.

Recipe information of the wild card in the main memory is copied in a certain recipe

data record via the “WRIT_DBL” function.

Figure 3-1

Load memory Main memory

Web server

READ_DBL

WRIT_DBL

RECIPE_DB

SIMATIC

Memory

Card

Internal

load memory

RecipeImport

RecipeExport

Upload

Download

As of CPU firmware V4, the recipe data in the load memory can be copied as csv

file onto the integrated web server of the S7-1200 controller via the “RecipeExport”

function.

Via a web browser on your PG you can download this csv file from the web server,

edit it, save it and upload it again onto the web server (after previously deleting the

original file).

The changed recipe data from the csv file on the web server can then be copied

into the load memory of the controller via the “RecipeImport” function.

3 Basics

3.2 Recipe management

Weighing, Controlling and Logging (Set 6)

Entry ID: 82454336, V2.0, 10/2017

Table 3-2

No.

Function

Comment

Within the framework of the configuration, the

packaged goods are selected with the help of

the recipe management.

In the example project a recipe has been

created as PLC data type

“UDT_Wall_anchors”.

The recipe consists of 5 elements:

Name of the product

Diameter of the wall anchors to be

packaged

Individual weight of a wall anchor

Quantity (number of the wall anchor to be

packaged)

Tolerance in gram

3 recipe data records are predefined in the

“RECIPE_DB” recipe data block under the

name “Products” as array of

“UDT_Wall_anchors” with respective start

values.

200 wall anchors with a diameter of 6mm

100 wall anchors with a diameter of 8mm

50 wall anchors with a diameter of 10mm

Set the “Only store in load memory” option in

the properties of the “RECIPE_DB” data block

under “Attributes”.

The recipe for filling can be selected via the

data record no.

In addition, there is the option to weigh a

counted sample of wall anchors via the

“Teach” function. The detected weight is

divided by the pieces specified and thus the

arithmetic average is calculated and written

into the recipe data record as new individual

weight of a wall anchor.

The weight to be filled can be calculated via

the pieces and the individual weight. The

tolerance is decisive for the later quality

assessment of the packaged product.

3 Basics

3.3 Filling goods

Weighing, Controlling and Logging (Set 6)

Entry ID: 82454336, V2.0, 10/2017

3.3 Filling goods

Table 3-3

No.

Function

Comment

Once the product to be packaged is selected

via the recipe data record, the setpoint weight

is calculated in the CPU and filling is started

via the digital control of the two sliders.

During the filling process the actual weight is

compared with the setpoint weight, with the

help of the load cell and the weighing module.

When a specified threshold has been reached

(e.g. 90% of the setpoint weight), the filling

speed is reduced via the slider control. When

the setpoint has been reached, the sliders are

closed.

0,4

Selection

of recipe

data set

Digital control

After filling, the filled weight is evaluated for

quality assurance. The weight value for a

positive evaluation has be within the following

limits:

Setpoint weight + resolution of the load

cell

Setpoint weight + resolution of the load

cell + tolerance

If the real weight value of the product is in the

tolerance range of the requirements, the

quality of the current product is assessed as

good.

Underfilling is therefore not possible.

(a) Setpoint weight: e.g. 200 g

(b) Resolution: 0,2 g

(d) Real weight: 205 g

195 200 205 210 215

205

200,2

Tolerance range (good quality)

a+b d

a+b+c=210,2

Each filled product is counted. The continuous

numbering, for example, can be linked with the

product via a labeling machine. This is how the

product (e.g. via barcode scanner) can be

tracked. The product can later also be clearly

identified in the log data via this ID.

205 g

After completing the quality assurance, the

result of the quality assurance is assigned to

the product ID.

Quality status:

0 (poor)

1 (good)

3 Basics

3.4 Logging the quality assurance

Weighing, Controlling and Logging (Set 6)

Entry ID: 82454336, V2.0, 10/2017

3.4 Logging the quality assurance

Table 3-4

No.

Function

Comment

Within the framework of the configuration,

logging is executed with the help of the “Data

Log” functionality in the flash memory of the

S7-1200.

Each data log entry includes the following

data:

Recipe ID

Diameter of the wall anchors to be

packaged

Individual weight of a wall anchor

Quantity (number of the wall anchor to be

packaged)

Tolerance in gram

Total weight measured

Quality of the filling (good/poor)

Product ID (packet no.)

Logging is performed with the help of the

“DataLog” function block, once packaging and

quality check of the product has been

completed.

DataLog

205 g

When the logging process is started, the FB

“DataLog” writes the current values into the

flash memory of the CPU 1214C. With every

call, a new data record is added to the already

existing log data. The size of the log file is

specified with 1000 data records before the

oldest is overwritten. (Ring buffer)

When creating the log file (first call of FB

“DataLog”) its size can be determined

(memory capacity of the flash memory is

assumed).

In addition, a date and time stamp is

stored for each data record

3 Basics

3.5 Automated archiving of the log data

Weighing, Controlling and Logging (Set 6)

Entry ID: 82454336, V2.0, 10/2017

3.5 Automated archiving of the log data

Archiving the log data

Table 3-5

No.

Function

Comment

The log data can be exported from the flash

memory onto the local hard disk of a Window

PC with the help of an internet browser via the

integrated web server of the S7-1200 and can

be saved as CSV file1.

In addition, the SIMATIC Automation Tool

(SAT) as of V3.0, provides access to csv files

(saved on a plugged memory card) of S7-

1200.

The SIMATIC Automation Tool as of V3.0

additionally provides an API that enables you

to, for example, remotely execute SAT

functions via Visual Studio.

With the help of the “Scheduled Tasks”

standard function in MS Windows and the

SIMATIC Automation Tool as of V3.0, you can

automate the archiving of the log data at user-

definable intervals.

SIMATIC

Automation Tool

V3.0

Note

For more information on the SIMATIC Automation Tool V3.0, as well as further

links, please refer to the Sales and delivery release (\16\).

A CSV file is an ASCII file for saving or exchanging simple structured data. The abbreviation CSV stands for

Character Separated Values, since the individual values are separated by a special separator. There is no general

standard for the file format. In the application on hand, the line end is respectively characterized by CR, LF and the

individual data is separated by semicolon.

4 Mode of Operation

4.1 General overview

Weighing, Controlling and Logging (Set 6)

Entry ID: 82454336, V2.0, 10/2017

4 Mode of Operation

Below, the blocks used are introduced and the most important interface parameters

are described.

4.1 General overview

Figure 4-1

User program

DataLog blocks SIWAREX block Data blocks

Main

[OB 1]

WP231PR

[FB 231]

Filling

[FB 12]

HMI

[FB 13]

copy

[FC 142]

DataLog

[FB 143]

time

[FC 144]

Main_Recipe

[OB 123]

tags_Recipe

[DB 3]

RecipeExport

[SFB 1003]

RecipeImport

[SFB 1004] RECIPE_DB

[DB 1]

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