INTRODUCTION
This report provides an overview of the TIA (Totally
Integrated Automation) Portal
software from Siemens. The TIA which stands for the “Totally Integrated
Automation” concept allows using uniformly all automation components and instrumentations which is using a
single system platform
and tools with simultaneous
operator interfaces.[3]
In the field of industrial automation and control, TIA
Portal Siemens software stands as the symbol of excellence. This integrated
development environment empowers engineers to seamlessly design,
program and manage industrial control and automation
projects.
What is Siemens TIA
Portal?
TIA Portal (Totally Integrated Automation Portal)
combines different automation components into a single platform and offers
automation engineers a wide range of functions. Before the release of the TIA
portal, the work of engineers was really difficult. Because they had to use
different types of applications. But today,
thanks to this program created
by Siemens engineers, it is possible to
perform several different tasks with just one program. As we can see the name of this program, TIA Portal is an integrated version of several
programs. Here are the main features of TIA Portal:
·
Project
Management: TIA Portal allows you to easily create, edit and
manage automation projects.
Project management includes
processes such as hardware configuration, programming
and simulation.
·
Modularity: TIA Portal
has a modular structure, which allows you to break down projects and manage them more
easily. This is especially useful for large and complex automation projects.
·
PLC
Programming: TIA Portal is used to program Siemens SIMATIC PLCs.
This is essential for creating and programming industrial control systems. For
instance, we can use Siemens S7-1200 PLC family for small and medium
application and Siemens S7-1500 PLC family for bigger applications. In addition
to that, as I mentioned before, TIA Portal also support different PLC Programming Languages. For example,
Ladder logic, Function Block
Diagram, Structured Text and etc.
Here is some examples
of this program:
 |
Fig.1 Project view and User Interface of TIA Portal
In this page PLCs, HMIs can be added. Also, users can be
program them inside the Main OB1 block. OB stands for Organization Block. All
of the programming things is happened here. Also, we can make communication
among the PLCs and HMIs in the Devices
& Networks field by using the different kind of
communication protocols where the protocols
are spread, among
them are PROFIBUS, Modbus,
AS-Interface, CAN, HART, IOLINK, PROFINET,
EtherCAT, EtherNet/IP and so on.[1]
 |
Fig.2 Portal view of TIA Portal
This section mostly
about the hardware
things and components. Here, we can save our project, Create new project, some visualization
things, make troubleshooting or online Diagnostics and so on.
·
HMI Design:
TIA Portal simplifies human-machine interface (HMI) design
with a user-friendly interface. You can create interfaces for operators to
monitor and control production processes.
If users want to add some HMI Screen they have to use this field called “Add New Device” :
Fig. 3 Interface
of adding new device
After that they supposed
to click the HMI Button :
 |
Fig. 4 Some HMI Products
of Siemens
Fig. 5 View of Simple
HMI Programming and Design screen
·
Data
Management and Communication: TIA Portal facilitates data
sharing and communication between different automation components. This ensures proper functioning of the
entire system.
 |
Fig. 6 Table of PLC tags for Data Management
Key components of TIA Portal
At the heart of the TIA Portal are various components,
each of which is designed for a specific function. In this section,
we will explore the main elements
that make up the TIA Portal and detail their respective roles. These components
include:
· Simatic Manager: The project
management tool that facilitates organization and configuration.
·
Step
7: The platform for PLC programming, enabling the creation of
automation logic. Generally, Siemens PLC S7-300, S7-1200, S7-1500 (SIMATIC
S7-1500 controllers has the capability to be scaled in terms of processing
speed and configuration limits. They also provide networking facilities via different communications standards [2]) and HMI KTP family called STEP 7 family.
·
WinCC:
A tool for designing Human-Machine Interfaces (HMIs) and
overseeing control systems.
In the simualtion of HMI and PLC mostly we can use the “WinCC Audit Runtime Advanced” software.
Here is how PLC/HMI
simulation looks like:
Fig. 7 HMI simulation screen with WinCC
RT (Run Time)
Blocks in TIA Portal
There are different kinds of blocks in TIA Portal. The main function
of these blocks is to make a
simple program for the industrial automation.
Fig. 8 Add New Block
section
Here we can see 4 different kinds of blocks,
which they have some
differences.
Organization block:
An "Organization Block" is a sort of block in
the Siemens TIA Portal that helps you arrange
and structure our program code. It serves
as a container for other program blocks and functions rather
than a block that holds logic or data directly. An organization block's
function is to give our program a higher level of structure and organization by
assisting us in managing and organizing our code in a more modular and
manageable manner.
Here are some essential details
regarding to Organization Block:
Structural Organization: The program
is divided into many sections using the Organization Block, which facilitates
the management of complicated and large- scale
projects. Also we can write most of our programme in here by using Ladder Logic, Function Block Diagram and
other kind of programming language.
Block Storage: Within an Organization Block,
you can nest Program, Function, and Data blocks. This permits
us to group related objects and codes.
Block-to-Block Communication: Because
they are a part of the same organizational structure, blocks that are members of the same organizational block can
readily communicate with one another.
Your code may become more modular
and reusable as a result.
Enhanced readability: It's simpler to maintain and comprehend the structure of your project
when you use organization blocks to divide your software
into logical pieces.
Fig. 9 Some different organization blocks
Function and Function
Block:
The main aim of Function
and Function Block
approximately same. But there are same differences also:
Function:
Fundamental Logic: In the TIA Portal,
a function denotes
a fundamental logic unit. It is a set of commands and
procedures that carry out a certain job.
Not Modular: The modular
nature of functions
is not inherent. They don't
contain data; instead, they are stand-alone entities.
Single Instance: Functions are usually called
from the main application as stand-
alone procedures. A function can only be used once in your application; instances are not an intrinsic concept.
Absence of Internal
Memory: Internal memory is absent from functions. For input
and output, they make use of global variables or parameters.
Function Block:
Modular and Reusable: The modular and reusable
nature of Function
Blocks is built in. They
contain logic and data (internal memory) in one single unit.
Data Encapsulation: Because Function
Blocks have internal
memory, or instance data, they can include the data
and logic related to a particular functionality.
Several Instances: A Function
Block may be used in your application in several
instances, each of which may include a different set of data.
Function Blocks
can be parameterized, which enables you to build instances with various starting points or
behaviors.
Function
Blocks support an organized programming methodology,
which facilitates code management and comprehension, particularly in bigger projects.
Data Block:
A Data Block in the Siemens TIA Portal is a structure
for data management and organization in PLC (Programmable Logic Controller) projects.
As opposed to Function Blocks and Functions, Data
Blocks do not include logic; instead, their main functions are data kinds,
variable storage, and memory management.
Here are some key features:
Variable Storage: To define and
arrange variables, utilize data blocks. Process values, counters, timers, flags, and any other data that must be saved and retrieved while a program is running can
all be represented by these variables.
Memory Organization: You can arrange
the locations of variables in memory using Data Blocks.
For every variable,
this can involve
specifying the data type,
starting values, and addressing scheme.
Global Accessibility: Within a PLC program,
variables defined in a Data Block are usually globally accessible. This
implies that they can be applied to other program blocks, including FCs
(Function Blocks), FBs (Functions Blocks), and OBs (Organization Blocks).
Parameterization: Data Blocks are parameterizable, just like Function
Blocks are. This implies that
a Data Block can be created in several instances, each with a unique
combination of variables and memory allocation. When managing several instances
of the same machinery or procedure, this can be helpful.
Absence of Direct Logic: Data Blocks
lack programmable logic, in contrast to Function Blocks and Functions. Data management and organization are their main concerns.
Advantages and Challenges of TIA Portal
TIA Portal Siemens software offers a number of
advantages that make it an attractive choice for industrial automation projects. However, it is also important to recognize potential problems that
users may encounter during its implementation. Here is Advantages of TIA Portal;
·
Integration: TIA Portal's
greatest strength is its seamless
integration of various
automation components, making it a one-stop solution for automation projects.
This streamlines the engineering process, reduces compatibility issues, and
enhances overall efficiency.
·
Modularity: TIA Portal's
modular structure allows
engineers to break down
complex projects into manageable components. This modularity makes the system
easier to maintain and expand.
·
Efficiency: With a user-friendly interface and numerous built-in
features, TIA Portal accelerates project development. Engineers can save time and reduce errors during
configuration and programming.
·
Data
Management: TIA Portal offers robust data management and
communication capabilities, allowing
for real-time data exchange between different components of the
automation system.
Here is the some data types in PLC Programming world:
|
Data Type |
Bits |
Range of Values |
Adress Example in PLC |
|
Bool |
1 |
0-1 |
I0.0, Q0.0, M0.0, Q6.1 |
|
BYTE |
8 |
0-255 |
MB0,MB4,MB6 |
|
WORD |
16 |
0-65535 |
MW0,MW4,MW8 |
|
Tab. 1 Data types in the TIA Portal software Disadvantages of TIA Portal:
·
Learning
Curve: For new users, TIA Portal may have a steep learning
curve due to its feature-rich environment. Adequate training or courses may be
necessary to unlock its full potential.
·
Hardware
Compatibility: While TIA Portal is designed for Siemens hardware, it
may pose compatibility challenges with hardware from other manufacturers, potentially limiting options for users.
But it is useful for all
manufacturers soon.
·
Cost: Overall, TIA Portal program
package is more expensive than the other companies. Licensing and initial
setup costs can be significant, particularly for smaller companies or projects
with budget constraints.
·
System Resources: This program contains
a lot of other things
by itself and as a result program need more powerful
computer system for running properly. Complex automation projects may demand
substantial system resources, which can affect performance and necessitate powerful hardware.
·
Maintenance
and Support: Like any software, TIA Portal may require updates,
maintenance, and ongoing technical support. Ensuring access to these resources is crucial for the smooth
operation of automation systems.
In summary, TIA Portal Siemens
software offers a lots
of advantages that streamline industrial automation projects,
but users should be aware of potential
challenges. A comparative analysis with alternative automation solutions can help
in determining whether TIA Portal aligns with the specific requirements and
constraints of a given project.
Conclusion and Recommendations
To wrap up this report,
I will summarize the key takeaways and provide
some useful information, shedding light on why TIA Portal Siemens is a
formidable asset in the world of industrial automation.
In Siemens TIA Portal there are some steps that need to be done to connect the PLC to Factory I/O. It is
important to make sure that in the general configuration of the device, in
“Protection” tab, the “no protection” option is the one selected and check the option
“Permit access with PUD/GET communication from remote partner (PLC,
HMI, OPC…)”.[4]
I think that
the best way to learn how to
use the TIA Portal is using different kind of simulation programs. PLC SIM, WinCC and of course
FACTORY IO. This way of
learning also highly recommended by professionals. Factory IO is really useful
not only for beginners but also for professional PLC Programmers. Users can
simulate real work environment with this software.
Fig. 10 Real environment simulation with Factory IO
In this application, I simulated control
of Filling and Draining valves with TIA Portal and WinCC runtime
HMI KTP-400.
Fig. 11 Sorting
of boxes by its size and counting
them
In this project,
I counted the large and small boxes using a counter and sensors.
The conveyor stops when the number of both small and large boxes reaches 5.
Conclusion
In conclusion, TIA Portal Siemens software enables
automation professionals to implement industrial control and automation
projects with efficiency and reliability. As we continue
to witness advancements in automation, TIA Portal remains a symbol of excellence in
simplifying complex automation tasks and ensuring seamless operation of
industrial systems. Nowadays, Siemens TIA Portal is the best PLC Programming software
in the world.
Variables for Lab 1,2 and 3
LAB1
Configuration PLC
I utilized a PLC setup with 140
CPU 434 12A/U 03.20 to complete the aforementioned method. Figure 1 displays
the arrangement.
Since I have two outputs and four
inputs in my simulation, DDM390 00 fits my demands. The fact that these inputs
are digital is crucial to understand. Additionally, I used CPS 211 00 as the
power source.
Figure1: Configuration PLC
Inventory of Function Blocks and Used Variables, Together with
Their Types
The variables that are used are
listed in Figure 1.2. BOOLEAN type variables are all that I used in the
application. EBOOLEAN-type program sections are used.
Algorithm
Initialization:
Set initial conditions, reset any
memory bits.
Define variables for inputs (START
button, STOP button, EMERGENCY button, FUSE) and outputs (Alarm, Contactor).
Figure2: PLC components
Main Program:
Step 1 (Alarm):
If the START button is pressed and
the EMERGENCY button is not pressed:
Turn ON the Alarm output.
Set a timer for 10 seconds.
If the timer is done (10 seconds
passed):
Turn OFF the Alarm output.
Move to the next step.
Step 2 (Delay):
If the START button is still
pressed and the EMERGENCY button is not pressed:
Set a timer for the desired delay
(if any).
If the timer is done:
Move to the next step.
Step 3 (Contactor/Motor Start):
If the START button is still
pressed and the EMERGENCY button is not pressed:
Turn ON the Contactor/Motor
output.
Step 4 (STOP Button):
If the STOP button is pressed:
Turn OFF the Contactor/Motor
output.
Step 5 (EMERGENCY Button):
If the EMERGENCY button is
pressed:
Turn OFF the Alarm output.
Turn OFF the Contactor/Motor
output.
Reset all timers.
Go back to Step 1.
Step 6 (FUSE):
If the FUSE input is active
(similar to EMERGENCY):
Turn OFF the Alarm output.
Turn OFF the Contactor/Motor
output.
Reset all timers.
Go back to Step 1.
LAB1 LD
LAB1 FBD
LAB1 ST LAB1 IL
LAB2
Configuration PLC
I have two digital inputs and one
output in this software. I thus utilized the PLC configuration 140 CPU 434
12A/U 03.20. The power and input/output combinations are chosen in accordance
with Figure 3.
Figure3: Configuration PLC
Algorithm
Figure4: PLC Components
1. Understand the Motor Direction:
Imagine there are two special
buttons called "x0" and "x1" that tell us about the motor
direction. We want to check if both x0 and x1 are OFF (LOW) or both are ON
(HIGH). I created two special signs, "DoubleDark" and "DoubleLight
to remember these conditions.
2. Detect Motor Direction:
If both x0 and x1 are OFF (LOW),
set " DoubleDark " to remember it's one way.
If both x0 and x1 are ON (HIGH),
set " DoubleLight " to remember it's the other way.
The next time we check, we will
know the motor's direction based on the remembered conditions.
3. Show Motor Direction with Lamp:
Imagine there's a lamp that shows
if the motor is turning right or left.
If " DoubleDark " is
remembered (meaning the motor is turning right), make the lamp blink.
If " DoubleLight " is
remembered (meaning the motor is turning left), keep the lamp constantly ON.
Putting it Together:
Check x0 and x1 to see their
values.
If both are OFF, set "DoubleDark."
If both are ON, set " DoubleLight "
If " DoubleDark " is
set, make the lamp blink (motor turning right). If " DoubleLight " is
set, keep the lamp ON (motor turning left).
Repeat:
Keep checking x0 and x1 to see if
the motor's direction changes.
If it changes, update " DoubleDark
" or " DoubleLight " accordingly.
Adjust the lamp based on the
updated condition.
LAB2 LD
LAB2 FBD
LAB2 ST
LAB2 IL
LAB3
140 CPU 434 12A/U 03.20 is what I
chose. I have two digital inputs (J1, J2) and one output (LAMP) in this
application. As a result, Figure 2.1's input/output and power configurations
are chosen. I am able to have 8 inputs and 4 outputs in this arrangement.
Figure 5 displays the arrangement.
Algorithm
Figure6: PLC Algorithm
Initialize Variables:
Set counters for J1 and J2 to
zero.
Create a variable to store the
difference between J1 and J2 (diff).
Main Loop:
Enter a continuous loop to repeat
the process.
Counting Pulses:
Increment counters for J1 and J2
every time a pulse is detected.
Compare Every 100 Pulses:
If the counters for J1 and J2
reach 100 pulses:
Calculate the difference: diff =
|J1 - J2|.
Reset counters for J1 and J2 to
zero.
Determine Operation Mode:
If diff is less than or equal to
2:
Set the mode to NO SLIP.
Set the status to TOGGLING.
If diff is greater than 2:
Set the mode to SLIP.
Set the status to ON.
Perform Operations Based on Mode:
If the mode is NO SLIP:
Execute operations as if the
machine is toggling.
If the mode is SLIP:
Execute operations as if the
machine is on.
Repeat the Process:
Go back to the main loop and keep
counting pulses, comparing, and performing operations.
AB3 LD
LAB3 FBD
LAB3 ST
LAB3 IL
LAB6
PLC Configuration
In Figure 7, the setup is displayed.
Figure7: PLC Configuration
Algorithm
Figure8: PLC Algorithm
Initialize Variables:
Set variables to track conveyor
status (moving or not moving).
Set variables to track the
direction of conveyor movement (right, left, or none).
Start the System:
Upon starting the program, the
conveyor is assumed to be not moving.
Place/Remove Items:
Items can be placed on or removed
from the conveyor only when it's not moving.
Move Conveyor to the Right (Ein
Rechts - E3/E4):
If Ein Rechts (E3 or E4) is pressed:
Check if the conveyor is not
moving.
If true, activate A1 (right
movement output) and set a timer for a 1.5-second delay.
Stop Conveyor (AUS - E1/E2):
If AUS (E1 or E2) is pressed:
Deactivate A1 and A2 (stop
movement outputs).
Automatic Stop by Light Barriers
(B1/B2):
If light barriers B1 or B2 detect an obstacle:
Deactivate A1 and A2 (stop
movement outputs).
Move Conveyor to the Left (Ein
Links - E5/E6):
If Ein Links (E5 or E6) is pressed:
Check if the conveyor is not moving.
If true, activate A2 (left
movement output) and set a timer for a 1.5-second delay.
Start Continuous Right Movement
(E7/E8):
If E7 or E8 is pressed:
Check if the conveyor is not
moving.
If true, activate A1 and set the
conveyor to continuously move to the right as long as E7 or E8 is pressed.
Automatic stop by B1 or B2.
Deactivate Manual Control (E7/E8):
If E7 or E8 is pressed:
Deactivate Ein Rechts (E3/E4) and
Ein Links (E5/E6) buttons.
Enable E7/E8 Only at Conveyor Halt:
E7/E8 can only be activated if the
conveyor is not moving.
Outputs A1 and A2:
A1 and A2 control the movements to
the right and left, respectively.
Repeat the Process:
The system continuously repeats
the conveyor control process based on user inputs and sensor feedback.
Putting it Together:
Users can place or remove items
only when the conveyor is not moving.
Buttons control movements: E3/E4
for right, E5/E6 for left, and E7/E8 for continuous right.
Conveyor stops automatically if
AUS is pressed or light barriers detect obstacles.
Manual control buttons (Ein
Rechts, Ein Links) are deactivated when continuous right movement is initiated.
E7/E8 can only be pressed when the
conveyor is at a halt.
LAB6 ST
LAB7
Configuration PLC
In Figure 9, the setup is
displayed.
Figure9: PLC Configuration
Algorithm
Figure10: PLC Algorithm
Initiation:
Press the "Freigabe"
button to start the process.
Box Placement and Bottle Transportation:
Upon pressing
"Freigabe," position the box and transport bottles to the filling
location.
Filling Process:
If the bottle reaches the filling
position:
Stop the conveyor immediately.
Lower the dosing head to the
appropriate level.
Valve Activation:
Activate the filling valve for a
specific duration (5 seconds) to fill the bottle.
Completion of Filling:
After the set time, the dosing
head ascends, indicating the completion of the filling process.
Bottle Transfer to the Box:
Move the filled bottle to the
designated box.
Cycle Reiteration:
Repeat the entire cycle with a
1-second delay before starting the next cycle.
Cycle Counting:
Keep track of the number of
cycles.
If 12 cycles are completed (12
filled bottles), proceed to the box replacement step.
Box Replacement:
Press the "Freigabe" button
again to initiate the box replacement process.
End of Algorithm:
The algorithm concludes, and the
system is ready for the next set of cycles.
LAB7 FBD
LAB8
In Figure 11, the setup is
displayed.
Figure11: PLC Configuration
Algorithm
Figure12: PLC Algorithm
Initialize Variables:
Set a variable to track the
current mode (Manual or Semi-automatic).
Initialize variables for log sizes
(small, medium, long).
Start the System:
Upon starting the program, logs
begin to move through three light barriers.
Log Sorting Process:
Logs are transported through the
light barriers for detection.
If a log is small, it goes to Box
1. If medium, it goes to Box 2. If long, it needs processing elsewhere.
Ensure Sequential Sorting:
The next log can only be taken if
the current log is sorted. Detection is performed by the light barriers.
Manual Mode:
If the system is in Manual Mode:
Logs are sorted when the start
button is manually pressed.
Long logs cannot be sorted even if
the button is pressed.
Semi-automatic Mode:
If the system is in Semi-automatic
Mode:
Short and medium logs are
automatically sorted after the start button is pressed.
Long logs are automatically
sorted.
Change Log Size Processing:
If a change is needed in log size
processing (e.g., different processing for long logs), the system should be
configured accordingly.
Repeat the Process:
The system continually repeats the
log sorting process, ensuring sequential sorting and adherence to the selected
mode.
Putting it Together:
Logs move through light barriers
for detection.
Based on the mode (Manual or
Semi-automatic), logs are sorted accordingly.
Long logs are processed elsewhere.
The system continuously repeats
the sorting process based on the selected mode.
LAB8 LD
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