Project Knjaz Milos

Published on Monday, 05 May 2014 22:56

The project realized in the "Knjaz Miloš" factory included the development of detailed design for migration of PLC system from S5 to S7 on the complete PET bottle filling line. The line consisted of the following segments:

  • air transport empty bottles
  • transport of filled bottles
  • transport of packages
  • charger
  • palletizer
  • mixer

The project was implemented in phases, by the mentioned segments. In the project the following tasks were completed:

  • Supply and installation of PLC control system components
  • Software works on PLC system migration from S5 to S7 controllers
  • Implementation of new software for improving the efficiency of the entire system
  • Software works on HMI application migration from "Lauer PCS" to "Zenon" and "WinCC flexible"
  • Dismantling S5 100U and 115U PLC systems, marking wires and
  • Testing parameter setup and commissioning of machinery at work

For migration from S5 to S7 controllers, VIPA IM306 DP interface card was used, which allows connecting the existing DI/DO and AI/AO modules of S5 control system with the new Simatic CPU S7-300 or S7-400 systems. During migration, CPU module in S5 controller was replaced with IM306 DP module. Communication between S5 and S7 systems was realized through IM306 DP using PROFIBUS network. Connection between S5 digital and analogue modules and S7 system is enabled in such way, which allows simple and fast preparation of new S7 software for testing without significant hardware changes (replacement of S5/S7 peripherals) and simple fallback to previous control system (S5). After testing S7 software using S5 peripherals, if the software performs by specifications and the system meets the set-points, the migration proceeds with replacing S5 peripherals with S7 cards.

Technological processes covered by the project are the following:

  • Detailed analysis of the existing S5 system (hardware and software)
  • Choice of a suitable replacement S7 hardware configuration of the system
  • S5/S7 converter software
  • Analysis of converted software, refactoring/modifications/code improvements
  • Software testing in workshop conditions
  • Replacement S5 CPU units with corresponding S7 CPU units
  • Embedding VIPA IM306 DP modules in S5 rack system and connecting via PROFIBUS network with S7 CPU units
  • Testing the manufacturing software
  • Changes / update / upgrade the S7 software during testing
  • Replacement of peripheral modules of S5 system with the corresponding S7 modules
  • Testing the complete S7 system

The modernization of the control system creates new opportunities for improving the production process:

  • Increase Productivity
  • Raising the quality of production and products
  • Reduction of maintenance costs
  • Increase in system flexibility
  • Expandable system (adding I / O modules, function modules, communication modules...)
  • Expandable system functionality (visualization, data archiving...)

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